yamaha scara robot yk-xr series - yrg, inc. · ver. 1.09 ewfk155120 ver. 1.20 e66 yamaha scara...

Ver. 1.09

EWFK155120

E66Ver. 1.20

YAMAHA SCARA ROBOT

Installation ManualYK-XR SeriesYK400XR

CONTENTS YK-XRInstallation Manual

T-1

Safety Instructions

1. Safety Information S-1

2. Signal words used in this manual S-2

3. Warning labels S-3

3.1 Warning labels S-3

3.1.1 Warning label messages on robot and controller S-3

3.1.2 Supplied warning labels S-8

3.2 Warning symbols S-9

4. Important precautions for each stage of the robot life cycle S-10

4.1 Precautions for using robots and controllers S-10

4.2 Essential precautions for the linear conveyor module S-11

4.3 Design S-12

4.3.1 Precautions for robots S-12

4.3.2 Precautions for robot controllers S-12

4.4 Moving and installation S-13



4.5 Safety measures S-16

4.5.1 Safety measures S-16

4.5.2 Installing a safety enclosure S-17

4.6 Operation S-18

4.6.1 Trial operation S-18

4.6.2 Automatic operation S-20

4.6.3 Precautions during operation S-20

4.7 Inspection and maintenance S-22

4.7.1 Before inspection and maintenance work S-22

4.7.2 Precautions during service work S-23

4.8 Disposal S-24

5. Emergency action when a person is caught by robot S-25

6.Cautionsregardingstrongmagneticfields S-25

7. Using the robot safely S-26

7.1 Movement range S-26

7.2 Robot protective functions S-27

7.3 Residual risk S-28

7.4 Special training for industrial robot operation S-28


T-2 T-3

Warranty

Introduction

Before using the robot (Be sure to read the following notes.) i

Introduction iv

Chapter 1 Functions

1. Robot manipulator 1-1

1.1 Manipulator movement 1-1

1.2 Part names 1-2

2. Robot controller 1-3

3. Robot initialization number list 1-4

Chapter 2 Installation

1. Robot installation conditions 2-1

1.1 Installation environments 2-1

1.2 Installation base 2-2

2. Installation 2-3

2.1 Unpacking 2-3

2.2 Checking the product 2-4

2.3 Moving the robot 2-5

2.4 Installing the robot 2-6

3. Protective bonding 2-7

4. Robot cable connection 2-8

5. User wiring and user tubing 2-9

6. Attaching the end effector 2-11

6.1 Accelerationcoefficientvs.momentofinertia 2-11

6.1.1 R-axis tolerable moment of inertia and acceleration coefficient 2-11

6.1.2 Parameter setting according to R-axis moment of inertial of load 2-11

6.2 Equation for moment of inertia calculation 2-12

6.3 Example of moment of inertia calculation 2-15

6.4 Attaching the end effector 2-17

6.5 Gripping force of end effector 2-19

T-2


T-3

7. Limiting the movement range with X-axis and Y-axis mechanical stoppers 2-20

7.1 Installing the X-axis/Y-axis additional mechanical stoppers 2-21

7.2 Robot overrun during impacts with X-axis or Y-axis mechanical stopper 2-23

8. Working envelope 2-24

9. Stopping time and stopping distance at emergency stop 2-27

10. Installing the user wiring and tubing newly 2-30

11. Passing the wiring and tubing in the user wiring/tubing through spline type 2-31

12. Detaching or attaching the covers 2-32

Chapter 3 Robot settings

1. Overview 3-1

2. Adjusting the origin 3-2

2.1 Return-to-origin method 3-3

2.1.1 Stroke end method 3-3

2.1.2 Mark method 3-4

2.1.3 Sensor method (X-axis, Y-axis) 3-4

2.2 Machine reference 3-5

2.3 Return-to-origin procedures 3-6



2.4 Adjusting the machine reference value 3-9



2.4.2.1 Absolute reset in servo on state (re-reset) 3-14

2.4.2.2 Absolute reset in servo off state (re-reset) 3-16

2.4.2.3 Absolute reset in servo on state (new reset) 3-19

2.4.2.4 Absolute reset in servo off state (new reset) 3-21


3. Setting the soft limits 3-27

3.1 Setting the X-axis and Y-axis soft limits 3-27

3.2 Setting the Z-axis soft limits 3-28

3.3 Setting the R-axis soft limits 3-28

3.4 Relation between the X, Y, and R-axis movement angle, the Z-axis movement distance and the number of pulses 3-28

4. Setting the standard coordinates 3-29

4.1 Standard coordinate setting using a standard coordinate setup jig 3-30


T-4

5.Affixingthestickersfororiginpositions,movementdirections,andaxisnames 3-32

Chapter 4 Periodic inspecition

1. Overview 4-1

2. List of inspection items 4-2

Chapter 5 Harmonic drive replacement period

1. Overview 5-1

2. Replacement period 5-2

Chapter 6 Increasing the robot operating speed

1. Increasing the robot operating speed 6-1

1.1 Increasing speed by arch motion 6-1

1.2 Increasing the speed with the WEIGHT statement 6-3

1.3 Increasing the speed by the tolerance parameter 6-4

1.4 Increasing the speed by the OUT effective position parameter 6-5

Chapter 7 Torque limit designated Z-axis pushing action

1. Torque limit designated Z-axis pushing action 7-1

Chapter 8 Specifications

1. Manipulator 8-1

1.1 Basicspecification 8-1

1.2 External view and dimensions 8-2

1.3 Robot inner wiring diagram 8-4

1.4 Wiring table 8-5

Contents

1. Safety Information S-1

2. Signal words used in this manual S-2

3. Warning labels S-3

3.1 Warning labels S-3

3.1.1 Warning label messages on robot and controller S-3

3.1.2 Supplied warning labels S-8

3.2 Warning symbols S-9

4. Important precautions for each stage of the robot life cycle S-10

4.1 Precautions for using robots and controllers S-10

4.2 Essential precautions for the linear conveyor module S-11

4.3 Design S-12



4.4 Moving and installation S-13



4.5 Safety measures S-16

4.5.1 Safety measures S-16

4.5.2 Installing a safety enclosure S-17

4.6 Operation S-18

4.6.1 Trial operation S-18

4.6.2 Automatic operation S-20

4.6.3 Precautions during operation S-20

4.7 Inspection and maintenance S-22

4.7.1 Before inspection and maintenance work S-22

4.7.2 Precautions during service work S-23

4.8 Disposal S-24

5. Emergency action when a person is caught by robot S-25

6. Cautions regarding strong magnetic fields S-25

7. Using the robot safely S-26

7.1 Movement range S-26

7.2 Robot protective functions S-27

7.3 Residual risk S-28

7.4 Special training for industrial robot operation S-28

Safety Instructions

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1. Safety InformationIndustrial robots are highly programmable, mechanical devices that provide a large degree of freedom when performing various manipulative tasks. To ensure safe and correct use of YAMAHA industrial robots and con-trollers*, carefully read and comply with the safety instructions and precautions in this "Safety Instructions" guide. Failure to take necessary safety measures or incorrect handling may result in trouble or damage to the robot and controller, and also may cause personal injury (to installation personnel, robot operator or service personnel) including fatal accidents. * The descriptions about the controller stated in this manual also include the contents of the robot driver.

Before using this product, read this manual and related manuals and take safety precautions to ensure cor-rect handling. The precautions listed in this manual relate to this product. To ensure safety of the user’s final system that in-cludes YAMAHA robots, please take appropriate safety measures as required by the user’s individual system.

To use YAMAHA robots and controllers safely and correctly, always comply with the safety rules and instruc-tions.

• Forspecificsafetyinformationandstandards,refertotheapplicablelocalregulationsandcomplywith the instructions.

• WarninglabelsattachedtotherobotsarewritteninEnglish,Japanese,ChineseandKorean.Thismanual isavailableinEnglishorJapanese(orsomepartsinChinese).Unlesstherobotoperatorsorservice personnel understand these languages, do not permit them to handle the robot.

• CautionsregardingtheofficiallanguageofEUcountries ForequipmentthatwillbeinstalledinEUcountries,thelanguageusedforthemanuals,warninglabels, operationscreencharacters,andCEdeclarationsisEnglishonly. WarninglabelsonlyhavepictogramsorelseincludewarningmessagesinEnglish.Inthelattercase, messagesinJapaneseorotherlanguagesmightbeadded.

It is not possible to list all safety items in detail within the limited space of this manual. So please note that it is essential that the user have a full knowledge of safety and also make correct judgments on safety proce-dures.

Refer to the manual by any of the following methods when installing, operating or adjusting the robot and controller.

1. Install, operate or adjust the robot and controller while referring to the printed version of the manual (available for an additional fee).

2. Install, operate or adjust the robot and controller while viewing the disc version of the manual on your computer screen.

3. Install, operate or adjust the robot and controller while referring to a printout of the necessary pages from the disc version of the manual.

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2. Signal words used in this manualThis manual uses the following safety alert symbols and signal words to provide safety instructions that must be observed and to describe handling precautions, prohibited actions, and compulsory actions. Make sure you understand the meaning of each symbol and signal word and then read this manual.

w DANGER This indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.

w WARNING This indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

c CAUTION This indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury, or damage to the equipment.

n NOTE Explains the key point in the operation in a simple and clear manner.

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3. Warning labelsWarninglabelsshownbelowareattachedtotherobotbodyandcontrollertoalerttheoperatortopotentialhazards. To ensure correct use, read the warning labels and comply with the instructions.

3.1 Warning labels

w WARNING If warning labels are removed or difficult to see, then the necessary precautions may not be taken, resulting in an accident. • Donotremove,alterorstainthewarninglabelsontherobotbody. • Donotallowwarninglabelstobehiddenbydevicesinstalledontherobotbytheuser. • Provideproperlightingsothatthesymbolsandinstructionsonthewarninglabelscanbeclearlyseenfrom outside the safety enclosure.

3.1.1 Warning label messages on robot and controllerWord messages on the danger, warning and caution labels are concise and brief instructions. For more specific instructions, read and follow the "Instructions on this label" described on the right of each label shown below. See “7.1 Movement range” in “Safety instructions” for details on the robot’s movement range.

Warning label 1 (SCARA robots, Cartesian robots) ■

w DANGER Serious injury may result from contact with a moving robot. • Keepoutsideoftherobotsafetyenclosureduringoperation. • Presstheemergencystopbuttonbeforeenteringthesafetyenclosure.

Instructions on this label

• Alwaysinstallasafetyenclosuretokeepallpersonsawayfromtherobotmovementrangeandpreventinjuryfromcontactingthemovingpartoftherobot.

• Installaninterlockthattriggersemergencystopwhenthedoororgateofthesafetyenclosureisopened.

• Thesafetyenclosureshouldbedesignedsothatnoonecanenterinsideexceptfromthedoororgateequippedwithaninterlockdevice.

• Warninglabel1thatcomessuppliedwitharobotshouldbeaffixedtoaneasy-to-seelocationonthedoororgateofthesafetyenclosure.

Potential hazard to human body Seriousinjurymayresultfromcontactwithamovingrobot.

To avoid hazard•Keepoutsideoftherobotsafetyenclosureduringoperation.

•Presstheemergencystopbuttonbeforeenteringthesafetyenclosure.

90K41-001470

Warning label 2 (SCARA robots, Cartesian robots, single-axis robots*) ■

* Warning label 2 is not attached to some small single-axis robots, but is supplied with the robots.

w WARNING Moving parts can pinch or crush hands. Keephandsawayfromthemovablepartsoftherobot.


Usecautiontopreventhandsandfingersfrombeing

pinchedorcrushedbythemovablepartsoftherobot

whentransportingormovingtherobotorduring

teaching.

Potential hazard to human body Movingpartscanpinchorcrushhands.

To avoid hazard Keephandsawayfromthemovablepartsoftherobot.

90K41-001460

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Warning label 3 (SCARA robots, Cartesian robots, controllers*) ■

* Some models

w WARNING Improper installation or operation may cause serious injury. Before installing or operating the robot, read the manual and instructions on the warning labels and understand the contents.


• Besuretoreadthewarninglabelandthismanualcarefullytomakeyoucompletelyunderstandthecontentsbeforeattemptinginstallationandoperationoftherobot.

• Beforestartingtherobotoperation,evenafteryouhavereadthroughthismanual,readagainthecorrespondingproceduresand"Safetyinstructions"inthismanual.

• Neverinstall,adjust,inspectorservicetherobotinanymannerthatdoesnotcomplywiththeinstructionsinthismanual.

Potential hazard to human body Improperinstallationoroperationmaycauseseriousinjury.

To avoid hazardBeforeinstallingoroperatingtherobot,readthemanualandinstructionsonthe

warninglabelsandunderstandthecontents.

90K41-001290

Warning label 4 (SCARA robots*) ■

* This label is not attached to omnidirectional type SCARA robots.

c CAUTION Do not remove the parts on which Warning label 4 is attached. Doing so may damage the ball screw.


TheZ-axisballscrewwillbedamagediftheupperend

mechanicalstopperontheZ-axissplineisremovedor

moved.Neverattempttoremoveormoveit.

90K41-001520

Warning label 5 (Cartesian robots*, single-axis robots*) ■

* Some robot models

w WARNING Ground the controller to prevent electrical shock. Ground terminal is located inside this cover. Read the manual for details.


• Highvoltagesectioninside

• Topreventelectricalshock,besuretogroundtherobotusingthegroundterminal.

Potential hazard to human body Electricalshock

To avoid hazard Groundthecontroller.

90K41-001480

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Warming label 6 (Robot drivers RDV-X/RDV-P) ■

w WARNING • Beforetouchingtheterminalsorconnectorsontheoutsideoftherobotdriver,turnoffthepowerandwaitfor 10 minutes or longer to prevent electrical shock. Otherwise, burn or electrical shock may result. • Beforeusingtherobotdriver,besuretothroughlyreadthismanual. • Besuretogroundthegroundterminal. • Usenonflammablemetalplatesforthematerialoftheinstallationwallsurface.


• Thisindicatesahighvoltageispresent.Touchingtheterminalblockorconnectormaycauseelectricalshock.

• Thisindicatesimportantinformationthatyoumustknowisdescribedinthemanual.Beforeusingtherobotdriver,besuretoreadthemanualthoroughly.

• Besuretogroundthegroundterminaltoavoidelectricalshock.

• Usenonflammablemetalplatesforthematerialoftheinstallationwallsurface.Otherwise,firemayresult.

Potential hazard to human body To avoid hazard

Electricalshock Donottouchtheterminalsectionfor10minutesafterpower-off.

Improperinstallationoroperationmaycause

seriousinjury.

Beforeinstallingoroperatingtherobot,readthemanualandinstructions

onthewarninglabelsandunderstandthecontents.

Electricalshock Besuretogroundthegroundterminal.

3T034156-1/NE63012

Warming label 7 (controllers TS-X/TS-P) ■

w WARNING • Beforetouchingtheterminalsorconnectorsontheoutsideofthecontroller,turnoffthepowerandwaitatleast 10 minutes to avoid burns or electrical shock. • Motorsandheatsinksbecomehotduringandshortlyafteroperation,sodonottouchthem.

c CAUTION • Beforeusingthecontroller,besuretoreadthemanualthoroughly. • Besuretogroundthegroundterminal.


• Thisindicatesahighvoltageispresent.Touchingtheterminalblockorconnectormaycauseelectricalshock.

• Thisindicatestheareaaroundthissymbolmaybecomeveryhot.Motorsandheatsinksbecomehotduringandshortlyafteroperation.Donottouchthemtoavoidburns.

• Thisindicatesimportantinformationthatyoumustknowisdescribedinthemanual.Beforeusingthecontroller,besuretoreadthemanualthoroughly.Whenaddingexternalsafetycircuitsorconnectingapowersupplytothecontroller,readthemanualcarefullyandmakechecksbeforebeginningthework.

• Besuretogroundthegroundterminaltoavoidelectricalshock.

Potential hazard to human body To avoid hazard

Electricalshock Donottouchtheterminalsectionfor10minutesafterpower-off.

Donottouchthemtoavoidburns. Donottouchthemotorsandheatsinksduringpower-on.

Improperinstallationoroperationmaycause

seriousinjury.

Beforeinstallingoroperatingtherobot,readthemanualandinstructions

onthewarninglabelsandunderstandthecontents.

Electricalshock Besuretogroundthegroundterminal.

90K41-000950

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Warming label 8 (controllers RCX240, controllers RCX340) ■

w WARNING These are precautions for YAMAHA and distributors' service personnel. Customers must not attempt to open the covers.

w WARNING Wait at least 100 seconds after power-off before opening the covers.


• Waitatleast100secondsafterpower-off

beforeopeningthecovers(*).

• Somepartsinthecontrollerstillretainahigh

voltageevenafterpower-off,soelectrical

shockmayoccurifthosepartsaretouched.

Potential hazard to human body Electricalshock

To avoid hazard Waitatleast100secondsafterpower-offbeforeopeningthecovers(*).

* These are precautions for YAMAHA and distributors' service personnel. Customers must not attempt to open the covers.

90K41-001390

Warning label 9 (single-axis linear motor robots) ■

c CAUTION A magnetic scale is located inside this cover. Bringing a magnet close to it may cause malfunction.


• Topreventtherobotfromoperatingimproperlyduetomagneticscalemalfunction,donotbringastrongmagnettothecover.

• Donotbringtoolsclosetothemagneticscale.

90K41-001510

Warning label 10 (single-axis linear motor robots) ■

c CAUTION Powerful magnets are installed in the robot. Do not attempt to disassemble the robot to avoid possible injury. Do not bring any device that may malfunction due to magnetic fields close to the robot.


Besuretoread"6.Cautionsregardingstrongmagnetic

fields"in"Safetyinstructions"andmakesureyoufully

understanditscontentsbeforehandlingoroperating

therobot.

Potential hazard to human body Injuryordeathmayresultinsomecases.

To avoid hazard Makeyouunderstandtheprecautionsregardingstrongmagneticfields.

90K41-001500

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Warning label 11 (Controller)* ■

* This label is attached to the front panel.

c CAUTION Refer to the manual.

取扱説明書参照

READ INSTRUCTIONMANUAL


Thisindicatesimportantinformationthatyoumust

knowandisdescribedinthemanual.

Beforeusingthecontroller,besuretoreadthemanual

thoroughly.

Whenaddingexternalsafetycircuitsorconnectinga

powersupplytothecontroller,readthemanual

carefullyandmakechecksbeforebeginningthework.

Connectorshaveanorientation.Inserteachconnector

inthecorrectdirection.

93005-X0-00

Warning label 12 (single-axis robots, Cartesian robots*) ■

* Some robot models

w WARNING If a load is applied to the motor cover, this may cause breakage. The robot may drop at installation, causing personal injury.


• Donottransporttherobotbyholdingthemotorcover.

Potential hazard to human body Personalinjurymayresult.

To avoid hazard Donotholdthemotorcover.

90K41-001850

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3.1.2 Supplied warning labelsSome warning labels are not affixed to robots but included in the packing box. These warning labels should be affixed to an easy-to-see location.

Warning label is attached to the robot body.

Warning label comes supplied with the robot and should be affixed to an easy-to-see location on the door or gate of the

safety enclosure.

Warning label comes supplied with the robot and should be affixed to an easy-to-see location.

SCARA robots

Cartesian robots

Single-axis robots

Warning label 1

*1

Warning label 2 *1 *2

Warning label 3 *1

*1: See "Part names" in each SCARA robot manual for label positions.

*2: This label is not attached to some small single-axis robots, but is supplied with the robots.

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3.2 Warning symbols

Warningsymbolsshownbelowareindicatedontherobotsandcontrollerstoalerttheoperatortopotentialhazards. To use the YAMAHA robot safely and correctly always follow the instructions and cautions indicated by the symbols.

Electrical shock hazard symbol1.

w WARNING Touching the terminal block or connector may cause electrical shock, so use caution.

Instructions by this symbol

Thisindicatesahighvoltageispresent.Touchingtheterminalblockorconnectormaycauseelectricalshock.

93006-X0-00

High temperature hazard symbol2.

w WARNING Motors, heatsinks, and regenerative units become hot, so do not touch them.


Thisindicatestheareaaroundthissymbolmaybecomeveryhot.Motors,heatsinks,andregenerativeunitsbecomehotduringandshortlyafteroperation.Toavoidburnsbecarefulnottotouchthosesections.

93008-X0-00

Caution symbol3.

c CAUTION Always read the manual carefully before using the controller.

!


Thisindicatesimportantinformationthatyoumustknowandisdescribedinthemanual.Beforeusingthecontroller,besuretoreadthemanualthoroughly.Whenaddingexternalsafetycircuitsorconnectingapowersupplytothecontroller,readthemanualcarefullyandmakechecksbeforebeginningthework.Connectorsmustbeattachedwhilefacingacertaindirection,soinserteachconnectorinthecorrectdirection.

93007-X0-00

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4. Important precautions for each stage of the robot life cycleThis section describes major precautions that must be observed when using robots and controllers. Be sure to carefully read and comply with all of these precautions even if there is no alert symbol shown.

4.1 Precautions for using robots and controllers

General precautions for using robots and controllers are described below.

Applications where robots cannot be used1.

YAMAHA robots and robot controllers are designed as general-purpose industrial equipment and cannot be used for the

following applications.

w DANGER YAMAHA robot controllers and robots are designed as general-purpose industrial equipment and cannot be used for the following applications. • Inmedicalequipmentsystemswhicharecriticaltohumanlife • Insystemsthatsignificantlyaffectsocietyandthegeneralpublic • Inequipmentintendedtocarryortransportpeople • Inenvironmentswhicharesubjecttovibrationsuchasonboardshipsandvehicles.

Qualification of operators/workers2.

Operators or persons who perform tasks for industrial robots (such as teaching, programming, movement check, inspec-

tion, adjustment, and repair) must receive appropriate training and also have the skills needed to perform the tasks

correctly and safely.

Those tasks must be performed by qualified persons who meet requirements established by local regulations and

standards for industrial robots. They must also read the manual carefully and understand its contents before attempting

the robot operation or maintenance.

w WARNING • Itisextremelyhazardousforpersonswhodonothavetheabovequalificationstoperformtasksforindustrial robots. • Adjustmentandmaintenancethatrequireremovingacovermustbeperformedbypersonswhohavethe above qualifications. Any attempt to perform such tasks by an unqualified person may cause an accident resulting in serious injury or death.

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4.2 Essential precautions for the linear conveyor moduleThe linear conveyor module is a YAMAHA robot so safety measures must be followed and safety equipment must be installed just as required for other YAMAHA robots.This section describes essential precautions for handling the linear conveyor module. Precautions for each stage in the robot life cycle are listed from the next section, so be sure to read the whole section of “Safety Instruction” in this manual.

Slider ejection1.

w DANGER The slider and workpieces ejected at high SPEED from the linear conveyor module may strike persons, causing serious and POSSIBLY fatal injuries. Please comply with the following points. • Donotenterorallowthefaceandhandstointrudeanywherealongthelinewherethelinearconveyor guide railmayextend(notonlyejectionsideoftheconveyorbutalsotheinsertionside). • Ifejectingtheslideronthelinearconveyor,theninstallasuitableejectionmechanism(devicetocatchand stoptheejectedslider). • Installastructureandamechanismtocatchandretaintheslideronthesidewherethesliderisinserted. • Installasafetyenclosureoutsidethelinearconveyormovementrange.Designthesafetyenclosuresothatthe slider and workpieces from the linear conveyor are not ejected outside of the enclosure.

Preventing electrical shock2.

w DANGER Always comply with the instructions in this manual when installing, operating and inspecting the linear conveyor module. Failure to do so may lead to electrical shock, serious injury or even death. Please comply with the following items: • ReadandFOLLOWtheinstructionsinthismanualwhengroundingthelinearconveyormoduleandinstalling the termination module. • Donottouchthemotorofthelinearconveyormodulewhenitison. • Alwayscomplywiththeinstructionsinthemanualwhenperformingmaintenanceandbesuretoturnoffthe power before starting maintenance tasks. • Ifcrackedorbrokenplasticmotorpartsarefound,stopusingthelinearconveyormoduleimmediatelyand turn off the power.

Strong magnetic field3.

w WARNING The linear conveyor module contains powerful permanent magnets and electromagnets that generate strong magnetic fields. Always comply with the precautions listed in this manual when using the linear conveyor module. Those persons wearing medical electronic devices such as cardiac pacemakers or hearing aids are at particular risk of major injury or even death. • Alwaysattachthemagnetprotectivecover(supplied)whenhandling,shippingorstoringthesliderwhen removing it from the linear conveyor module’s guide rails. • Donotapproachthemotorofthelinearconveyormodulewhilethepowerison.(Stayatleast100mmaway.) • Donotattempttodisassemblethelinearconveyormodule(includingsurroundingcovers). • Do not place any tools near the slider magnets and the linear conveyor motor while the power is on.

High temperature hazard4.

w WARNING The motor for the linear conveyor module is mounted on the module, and so it is easy to come into contact with. To allow heat generated during operation to DISSIPATE, install the module on a base made from good heat conducting material such as metal. The motor reaches high temperatures during and IMMEDIATELY after operation, so touching it at those times may cause burns. Before touching the motor, first turn off the controller power, then wait a while and check that the temperature has DROPPED sufficiently.

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4.3 Design

4.3.1 Precautions for robots

Restricting the robot moving speed1.

w WARNING Restriction on the robot moving speed is not a safety-related function. To reduce the risk of collision between the robot and workers, the user must take the necessary protective measures such as enable devices according to risk assessment by the user.

Restricting the movement range2.

See “7.1 Movement range” in “Safety instructions” for details on the robot’s movement range.

w WARNING Soft limit function is not a safety-related function intended to protect the human body. To restrict the robot movement range to protect the human body, use the mechanical stoppers installed in the robot(oravailableasoptions).

c CAUTION Iftherobotmovingathighspeedcollideswithamechanicalstopperinstalledintherobot(oravailableasoption),therobotmaybedamaged.

Provide safety measures for end effector (gripper, etc.)3.

w WARNING • Endeffectorsmustbedesignedandmanufacturedsothattheycausenohazards(suchasalooseworkpiece orload)evenifpower(electricity,airpressure,etc.)isshutofforpowerfluctuationsoccur. • Iftheobjectgrippedbytheendeffectormightpossiblyflyoffordrop,thenprovideappropriatesafety protection taking into account the object size, weight, temperature, and chemical properties.

Provide adequate lighting4.

Provide enough lighting to ensure safety during work.

Install an operation status light5.

w WARNING Installasignallight(signaltower)ataneasy-to-seepositionsothattheoperatorwillbeawareoftherobotstopstatus(temporarilystopped,emergencystop,errorstop,etc.).

4.3.2 Precautions for robot controllers

Emergency stop input terminal1.

w DANGER Each robot controller has an emergency stop input terminal to trigger emergency stop. Using this terminal, install a safety circuit so that the system including the robot controller will work safely. For the robot driver without emergency stop input terminal, construct a safety circuit including the emergency stopfunctionusinganexternalcircuit.

Maintain clearance2.

c CAUTION Do not bundle control lines or communication cables together or in close to the main power supply or power lines. Usually separate these by at least 100mm. Failure to follow this instruction may cause malfunction due to noise.

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4.4 Moving and installation

4.4.1 Precautions for robots

Installation environment ■

Do not use in strong magnetic fields1.

w WARNING Donotusetherobotnearequipmentorinlocationsthatgeneratestrongmagneticfields.TherobotmayBREAKDOWN or malfunction if used in such locations.

Do not use in locations subject to possible electromagnetic interference, etc.2.

w WARNING Do not use the robot in locations subject to electromagnetic interference, electrostatic discharge or radio frequency interference. The robot may malfunction if used in such locations creating hazardous situations.

Do not use in locations exposed to flammable gases3.

w WARNING • YAMAHArobotsarenotdesignedtobeexplosion-proof. • Donotusetherobotsinlocationsexposedtoexplosiveorinflammablegases,dustparticlesorliquid.Failureto follow this instruction may cause serious accidents involving injury or death, or lead to fire.

Moving ■

Use caution to prevent pinching or crushing of hands or fingers1.

w WARNING Moving parts can pinch or crush hands or fingers. Keephandsawayfromthemovablepartsoftherobot.

As instructed in Warning label 2, use caution to prevent hands or fingers from being pinched or crushed by movable

parts when transporting or moving the robot. For details on warning labels, see "3. Warning labels" in "Safety instruc-

tions."

Take safety measures when moving robots2.

To ensure safety when moving a SCARA robot with an arm length of 500mm or more, use the eyebolts that come

supplied with the robot. Always refer to the robot user’s manual for details.

When moving other robots, please comply with the transport methods described in their respective user’s manuals.

Take measures to prevent the robot from falling3.

When moving the robot by lifting it with equipment such as a hoist or crane, wear personal protective gear and be

careful not to move the robot at higher than the required height.

Make sure that there are no persons on paths used for moving the robot.

w WARNING A robot falling from a high place and striking a worker may cause death or serious injury. When moving the robot, wear personal protective gear such as helmets and make sure that no one is within the surrounding area.

Installation ■

Protect electrical wiring and hydraulic/pneumatic hoses1.

Install a cover or similar item to protect the electrical wiring and hydraulic/pneumatic hoses from possible damage.

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Wiring ■

Protective measures against electrical shock1.

w WARNING Always ground the robot to prevent electrical shock.

Adjustment ■

Adjustment that requires removing a cover1.

w WARNING Adjustment by removing a cover require specialized technical knowledge and skills, and may also involve hazards if attempted by an unskilled person. This adjustment must be performed only by persons who have the required qualifications described in “2. Qualification of operators/workers” in section 4.1 of this “Safety instruc-tions”.

4.4.2 Precautions for robot controllers

Installation environment ■

Installation environment1.

w WARNING YAMAHArobotsarenotdesignedtobeexplosion-proof.Donotusetherobotsandcontrollersinlocationsexposedtoexplosiveorinflammablegases,dustparticlesorliquidsuchasgasolineandsolvents.Failuretofollow this instruction may cause serious accidents involving injury or death, and lead to fire.

w WARNING • Usetherobotcontrollerinlocationsthatsupporttheenvironmentalconditionsspecifiedinthismanual. Operation outside the specified environmental range may cause electrical shock, fire, malfunction or product damage or deterioration. • Therobotcontrollerandprogrammingboxmustbeinstalledatalocationthatisoutsidetherobotsafety enclosure yet where it is easy to operate and view robot movement. • Installtherobotcontrollerinlocationswithenoughspacetoperformwork(teaching,inspection,etc.)safely. Limited space not only makes it difficult to perform work but can also cause injury. • Installtherobotcontrollerinastable,levellocationandsecureitfirmly.Avoidinstallingthecontrollerupside down or in a tilted position. • Providesufficientclearancearoundtherobotcontrollerforgoodventilation.Insufficientclearancemaycause malfunction, breakdown or fire.

Installation ■

To install the robot controller, observe the installation conditions and method described in the manual.

Installation1.

w WARNING Securely tighten the screws to install the robot controller. If not securely tightened, the screws may come loose causing the controller to drop.

Connections2.

w WARNING • Alwaysshutoffallphasesofthepowersupplyexternallybeforestartinginstallationorwiringwork.Failuretodo this may cause electrical shock or product damage. • Neverdirectlytouchconductivesectionsandelectronicpartsotherthantheconnectors,rotaryswitches,and DIP switches on the outside panel of the robot controller. Touching them may cause electrical shock or breakdown. • Securelyinstalleachcableconnectorintothereceptaclesorsockets.Poorconnectionsmaycausethe controller or robot to malfunction.

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Wiring ■

Connection to robot controller1.

The controller parameters are preset at the factory before shipping to match the robot model. Check the specified robot

and controller combination, and connect them in the correct combination.

Since the software detects abnormal operation such as motor overloads, the controller parameters must be set correctly

to match the motor type used in the robot connected to the controller.

Wiring safety points2.

w WARNING Alwaysshutoffallphasesofthepowersupplyexternallybeforestartinginstallationorwiringwork.Failuretodothis may cause electrical shock or product damage.

c CAUTION • Makesurethatnoforeignmattersuchascuttingchipsorwirescrapsgetintotherobotcontroller.Malfunction, breakdown or fire may result if these penetrate inside. • Donotapplyexcessiveimpactsorloadstotheconnectorswhenmakingcableconnections.Thismightbend the connector pins or damage the internal PC board. • Whenusingferritecoresfornoiseelimination,besuretofitthemontothepowercableasclosetotherobot controller and/or the robot as possible, to prevent malfunction caused by noise.

Wiring method3.

w WARNING Securely install the connectors into the robot controller and, when wiring the connectors, make the crimp, press-contact or solder connections correctly using the tool specified by the connector manufacturer.

c CAUTION When disconnecting the cable from the robot controller, detach by gripping the connector itself and not by tuggingonthecable.Loosenthescrewsontheconnector(iffastenedwiththescrews),andthendisconnectthecable. Trying to detach by pulling on the cable itself may damage the connector or cables, and poor cable contact will cause the controller or robot to malfunction.

Precautions for cable routing and installation4.

c CAUTION • Alwaysstorethecablesconnectedtotherobotcontrollerinaconduitorclampthemsecurelyinplace.Ifthe cablesarenotstoredinaconduitorproperlyclamped,excessiveplayormovementormistakenlypullingon the cable may damage the connector or cables, and poor cable contact will cause the controller or robot to malfunction. • Donotmodifythecablesanddonotplaceanyheavyobjectsonthem.Handlethemcarefullytoavoid damage. Damaged cables may cause malfunction or electrical shock. • Ifthecablesconnectedtotherobotcontrollermaypossiblybecomedamaged,thenprotectthemwitha cover, etc. • Checkthatthecontrollinesandcommunicationcablesareroutedatagapsufficientlyawayfrommainpower supply circuits and power lines, etc. Bundling them together with power lines or close to power lines may cause faulty operation due to noise.

Protective measures against electrical shock5.

w WARNING Be sure to ground the ground terminals of the robot and controller. Poor grounding may cause electrical shock.

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4.5 Safety measures

4.5.1 Safety measures

Referring to warning labels and manual1.

w WARNING • Beforestartinginstallationoroperationoftherobot,besuretoreadthewarninglabelsandthismanual,and comply with the instructions. • Neverattemptanyrepair,partsreplacementandmodificationunlessdescribedinthismanual.These tasks require specialized technical knowledge and skills and may also involve hazards. Please contact your distributor for advice.

n NOTE For details on warning labels, see "3. Warning labels" in "Safety instructions."

Draw up "work instructions" and make the operators/workers understand them2.

w WARNING Decide on "work instructions" in cases where personnel must work within the robot safety enclosure to perform startup or maintenance work. Make sure the workers completely understand these "work instructions".

Decide on "work instructions" for the following items in cases where personnel must work within the robot safety

enclosure to perform teaching, maintenance or inspection tasks. Make sure the workers completely understand these

"work instructions".

1. Robot operating procedures needed for tasks such as startup procedures and handling switches

2. Robot speeds used during tasks such as teaching

3. Methods for workers to signal each other when two or more workers perform tasks

4. Steps that the worker should take when a problem or emergency occurs

5. Steps to take after the robot has come to a stop when the emergency stop device was triggered, including checks for cancelling the problem or error state and safety checks in order to restart the robot.

6. In cases other than above, the following actions should be taken as needed to prevent hazardous situations due to sudden or unexpected robot operation or faulty robot operation as listed below.

•Placeadisplaysignontheoperatorpanel

• Ensurethesafetyofworkersperformingtaskswithintherobotsafetyenclosure

•Clearlyspecifypositionandpostureduringwork Specify a position and posture where worker can constantly check robot movements and immediately move to avoid trouble if an error/problem occurs

•Takenoisepreventionmeasures

•Usemethodsforsignalingoperatorsofrelatedequipment

•Usemethodstodecidethatanerrorhasoccurredandidentifythetypeoferror

Implement the "work instructions" according to the type of robot, installation location, and type of work task.

When drawing up the "work instructions", make an effort to include opinions from the workers involved, equipment

manufacturer technicians, and workplace safety consultants, etc.

Take safety measures3.

w DANGER • Neverentertherobotmovementrangewhiletherobotisoperatingorthemainpoweristurnedon.Failureto follow this warning may cause serious accidents involving injury or death. Install a safety enclosure or a gate interlock with an area sensor to keep all persons away from the robot movement range. • Whenitisnecessarytooperatetherobotwhileyouarewithintherobotmovementrangesuchasforteaching ormaintenance/inspectiontasks,alwayscarrytheprogrammingboxwithyousothatyoucanimmediately stop the robot operation in case of an abnormal or hazardous condition. Install an enable device in the externalsafetycircuitasneeded.Alsosettherobotmovingspeedto3%orless.Failuretofollowthese instructions may cause serious accidents involving injury or death.


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w WARNING • Duringstartupormaintenancetasks,displayasign"WORKINPROGRESS"ontheprogrammingboxand operation panel in order to prevent anyone other than the person for that task from mistakenly operating the start or selector switch. If needed, take other measures such as locking the cover on the operation panel. • Alwaysconnecttherobotandrobotcontrollerinthecorrectcombination.Usingtheminanincorrect combination may cause fire or breakdown.

Install system4.

When configuring an automated system using a robot, hazardous situations are more likely to occur from the automated

system than the robot itself. So the system manufacturer should install the necessary safety measures required for the

individual system. The system manufacturer should provide a proper manual for safe, correct operation and servicing of

the system.

w WARNING To check the robot controller operating status, refer to this manual and to related manuals. Design and install the system including the robot controller so that it will always work safely.

Precautions for operation5.

w WARNING • Donottouchanyelectricalterminal.Directlytouchingtheseterminalsmaycauseelectricalshock,equipment damage, and malfunction. • Donottouchoroperatetherobotcontrollerorprogrammingboxwithwethands.Touchingoroperatingthem with wet hands may result in electrical shock or breakdown.

Do not disassemble and modify6.

w WARNING Neverdisassembleandmodifyanypartintherobot,controller,andprogrammingbox.Donotopenanycover.Doing so may cause electrical shock, breakdown, malfunction, injury, or fire.

4.5.2 Installing a safety enclosureBe sure to install a safety enclosure to keep anyone from entering within the movement range of the robot. The safety enclosure will prevent the operator and other persons from coming in contact with moving parts of the robot and suffering injury. See “7.1 Movement range” in “Safety instructions” for details on the robot’s movement range.

w DANGER Serious injury may result from contact with a moving robot. •Keepoutsideoftherobotsafetyenclosureduringoperation. •Presstheemergencystopbuttonbeforeenteringthesafetyenclosure.

w WARNING • Installaninterlockthattriggersemergencystopwhenthedoororgateofthesafetyenclosureisopened. • Thesafetyenclosureshouldbedesignedsothatnoonecanenterinsideexceptfromthedoororgate equipped with an interlock device. • Warninglabel1(See"3.Warninglabels"in"Safetyinstructions")thatcomessuppliedwitharobotshouldbe affixedtoaneasy-to-seelocationonthedoororgateofthesafetyenclosure.

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4.6 OperationWhen operating a robot, ignoring safety measures and checks may lead to serious accidents. Always take the following safety measures and checks to ensure safe operation.

w DANGER Check the following points before starting robot operation. •Nooneiswithintherobotsafetyenclosure. •Theprogrammingunitisinthespecifiedlocation. •Therobotandperipheralequipmentareingoodcondition.

4.6.1 Trial operationAfter installing, adjusting, inspecting, maintaining or repairing the robot, perform trial operation using the following procedures.

If a safety enclosure has not yet been provided right after installing the robot:1.

Then rope off or chain off the movement range around the robot in place of the safety enclosure and observe the

following points.


w DANGER Placea"Robotismoving-KEEPAWAY!"signtokeeptheoperatororotherpersonnelfromenteringwithinthemovement range of the robot.

w WARNING • Usesturdy,stablepostswhichwillnotfallovereasily. • Theropeorchainshouldbeeasilyvisibletoeveryonearoundtherobot.

Check the following points before turning on the controller.2.

• Istherobotsecurelyandcorrectlyinstalled?

•Aretheelectricalconnectionstotherobotwiredcorrectly?

•Areitemssuchasairpressurecorrectlysupplied?

• Istherobotcorrectlyconnectedtoperipheralequipment?

•Havesafetymeasures(safetyenclosure,etc.)beentaken?

•Doestheinstallationenvironmentmeetthespecifiedstandards?

After the controller is turned on, check the following points from outside the safety enclosure.3.

•Doestherobotstart,stopandentertheselectedoperationmodeasintended?

•Doeseachaxismoveasintendedwithinthesoftlimits?

•Doestheendeffectormoveasintended?

•Arethecorrectsignalsbeingsenttotheendeffectorandperipheralequipment?

•Doesemergencystopfunction?

•Areteachingandplaybackfunctionsnormal?

•Arethesafetyenclosureandinterlocksfunctioningasintended?

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Working inside safety enclosures4.

Before starting work within the safety enclosure, always confirm from outside the enclosure that each protective

function is operating correctly (see the previous section 2.3).

w DANGER Never enter within the movement range while within the safety enclosure.


w WARNING When work is required within the safety enclosure, place a sign "Work in progress" in order to keep other persons from operating the controller switch or operation panel.

w WARNING Whenworkwithinthesafetyenclosureisrequired,alwaysturnoffthecontrollerpowerexceptforthefollowingcases:

Exception Work with power turned on, but robot in emergency stop

Origin position setting SCARA robotsFollowtheprecautionsandproceduredescribedin"Adjustingthe

origin".

Standard coordinate setting SCARA robotsFollowtheprecautionsandproceduredescribedin"Settingthe

standardcoordinates".

Soft limit settings

SCARA robotsFollowtheprecautionsandproceduredescribedin"Settingthesoft

limits".

Cartesian robots

Single-axis robots

Followtheprecautionsandproceduredescribedin"Softlimit"in

eachcontrollermanual.

Work with power turned on

Teaching

SCARA robots

Cartesian robots

Single-axis robots

Referto"5.Teachingwithinsafetyenclosure"describedbelow.

Teaching within the safety enclosure5.

When performing teaching within the safety enclosure, check or perform the following points from outside the safety

enclosure.

w DANGER Never enter within the movement range while within the safety enclosure.


w WARNING • Makeavisualchecktoensurethatnohazardsarepresentwithinthesafetyenclosure. • Checkthattheprogrammingboxorhandyterminaloperatescorrectly. • Checkthatnofailuresarefoundintherobot. • Checkthatemergencystopworkscorrectly. • Selectteachingmodeanddisableautomaticoperation.

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4.6.2 Automatic operationCheckthefollowingpointswhenoperatingtherobotinAUTOmode.Observetheinstructionsbelowincaseswhere an error occurs during automatic operation. Automatic operation described here includes all operations inAUTOmode.

Checkpoints before starting automatic operation1.

Check the following points before starting automatic operation

w DANGER • Checkthatnooneiswithinthesafetyenclosure. • Checkthesafetyenclosureissecurelyinstalledwithinterlocksfunctional.

w WARNING • Checkthattheprogrammingbox/handyterminalandtoolsareintheirspecifiedlocations. • Checkthatthesignaltowerlampsorotheralarmdisplaysinstalledforthesystemarenotlitorflashing, indicating no error is occurring on the robot and peripheral devices.

During automatic operation and when errors occur2.

After automatic operation starts, check the operation status and the signal tower to ensure that the robot is in automatic

operation.

w DANGER Never enter the safety enclosure during automatic operation.

w WARNING If an error occurs in the robot or peripheral equipment, observe the following procedure before entering the safety enclosure. 1)Presstheemergencystopbuttontosettherobottoemergencystop. 2)Placeasignonthestartswitch,indicatingthattherobotisbeinginspectedinordertokeepotherpersonsfrom restarting the robot.

4.6.3 Precautions during operation

When the robot is damaged or an abnormal condition occurs1.

w WARNING • Ifunusualodors,noiseorsmokeoccurduringoperation,immediatelyturnoffpowertopreventpossible electrical shock, fire or breakdown. Stop using the robot and contact your distributor. • Ifanyofthefollowingdamageorabnormalconditionsoccurstherobot,thencontinuingtooperatetherobot is dangerous. Immediately stop using the robot and contact your distributor.

Damage or abnormal condition Type of danger

Damagetomachineharnessorrobotcable Electricalshock,robotmalfunction

Damagetorobotexterior Damagedpartsflyoffduringrobotoperation

Abnormalrobotoperation(positiondeviation,vibration,etc.) Robotmalfunction

Z-axis(verticalaxis)orbrakemalfunction Z-axisunitfallsoff

High temperature hazard2.

w WARNING • Donottouchtherobotcontrollerandrobotduringoperation.Therobotcontrollerandrobotbodyareveryhot during operation, so burns may occur if these sections are touched. • Themotorandspeedreductiongearcasingareveryhotshortlyafteroperation,soburnsmayoccurifthese are touched. Before touching those parts for inspections or servicing, turn off the controller, wait for a while and check that their temperature has cooled.

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Use caution when releasing the Z-axis (vertical axis) brake3.

w WARNING Theverticalaxiswillslidedownwardwhenthebrakeisreleased,causingahazardoussituation.Takeadequatesafety measures in consideration by taking the weight and shape into account. • Beforereleasingthebrakeafterpressingtheemergencystopbutton,placeasupportundertheverticalaxisso that it will not slide down. • Becarefulnottoletyourbodygetcaughtbetweentheverticalaxisandtheinstallationbasewhenperforming tasks(directteaching,etc.)withthebrakereleased.

Be careful of Z-axis movement when the controller is turned off or emergency stop is triggered 4. (air-driven Z-axis)

w WARNING TheZ-axisstartsmovingupwardwhenpowertothecontrollerorPLCisturnedoff,theprogramisreset,emergen-cystopistriggered,orairissuppliedtothesolenoidvalvefortheZ-axisaircylinder. • DonotlethandsorfingersgetcaughtandsqueezedbyrobotpartsmovingalongtheZ-axis. • KeeptheusualrobotpositioninmindsoastopreventtheZ-axisfromhanginguporbindingonobstacles duringraisingoftheZ-axisexceptincaseofemergencystop.

Take protective measures when the Z-axis interferes with peripheral equipment (air-driven Z-axis)5.

w WARNING WhentheZ-axiscomestoastopduetoobstructionfromperipheralequipment,theZ-axismaymovesuddenlyafter the obstruction is removed, causing injury such as pinched or crushed hands. • Turnoffthecontrollerandreducetheairpressurebeforeattemptingtoremovetheobstruction. • Beforereducingtheairpressure,placeasupportundertheZ-axisbecausetheZ-axiswilldropunderitsown weight.

Be careful of Z-axis movement when air supply is stopped (air-driven Z-axis)6.

w WARNING TheZ-axiswillslidedownwardwhentheairpressuretotheZ-axisaircylindersolenoidvalveisreduced,creatinga hazardous situation. TurnoffthecontrollerandplaceasupportundertheZ-axisbeforecuttingofftheairsupply.

Make correct parameter settings7.

c CAUTION The robot must be operated with the correct tolerable moment of inertia and acceleration coefficients that match the manipulator tip mass and moment of inertia. Failure to follow this instruction will lead to a premature end to the drive unit service life, damage to robot parts, or cause residual vibration during positioning.

If the X-axis, Y-axis or R-axis rotation angle is small8.

c CAUTION IftheX-axis,Y-axisorR-axisrotationangleissetsmallerthan5degrees,thenitwillalwaysmovewithinthesameposition. This restricted position makes it difficult for an oil film to form on the joint support bearing, and so may possibly damage the bearing. In this type of operation, add a range of motion so that the joint moves through 90 degrees or more, about 5 times a day.

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4.7 Inspection and maintenanceAlways perform daily and periodic inspections and make a pre-operation check to ensure there are no prob-lems with the robot and related equipment. If a problem or abnormality is found, then promptly repair it or take other measures as necessary.Keep a record of periodic inspections or repairs and store this record for at least 3 years.

4.7.1 Before inspection and maintenance work

Do not attempt any work or operation unless described in this manual.1.

Never attempt any work or operation unless described in this manual.

If an abnormal condition occurs, please be sure to contact your distributor. Our service personnel will take appropriate

action.

w WARNING Never attempt inspection, maintenance, repair, and part replacement unless described in this manual. These tasks require specialized technical knowledge and skills and may also involve hazards. Please be sure to contact your distributor for advice.

Precautions during repair and parts replacement2.

w WARNING When it is necessary to repair or replace parts of the robot or controller, please be sure to contact your distributor and follow the instructions they provide. Inspection and maintenance of the robot or controller by an unskilled, untrainedpersonisextremelyhazardous.

Adjustment, maintenance and parts replacement require specialized technical knowledge and skills, and also may

involve hazards. These tasks must be performed only by persons who have enough ability and qualifications required by

local laws and regulations.

w WARNING Adjustment and maintenance by removing a cover require specialized technical knowledge and skills, and may also involve hazards if attempted by an unskilled person. This adjustment must be performed only by persons who have the required qualifications described in “2. Qualification of operators/workers” in section 4.1 of this “Safety instructions”.

Shut off all phases of power supply3.

w WARNING Alwaysshutoffallphasesofthepowersupplyexternallybeforecleaningtherobotandcontrollerorsecurelytightening the terminal screws etc. Failure to do this may cause electrical shock or product damage or malfunc-tion.

Allow a waiting time after power is shut off (Allow time for temperature and voltage to drop)4.

w WARNING • Whenperformingmaintenanceorinspectionoftherobotcontrollerunderyourdistributor'sinstructions,waitat leastthetime(*)specifiedforeachcontrollerafterturningthepoweroff.Somecomponentsintherobot controller are very hot or still retain a high voltage shortly after operation, so burns or electrical shock may occur if those parts are touched. • Themotorandspeedreductiongearcasingareveryhotshortlyafteroperation,soburnsmayoccuriftheyare touched. Before touching those parts for inspections or servicing, turn off the controller, wait for a while and check that the temperature has cooled.

* For information on how long you should wait after turning the power off, see the user’s manual for each controller.

Precautions during inspection of controller5.

w WARNING • Whenyouneedtotouchtheterminalsorconnectorsontheoutsideofthecontrollerduringinspection,always first turn off the controller power switch and also the power source in order to prevent possible electrical shock. • Donotdisassemblethecontroller.Nevertouchanyinternalpartsofthecontroller.Doingsomaycause breakdown, malfunction, injury, or fire.

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4.7.2 Precautions during service work

Precautions when removing a motor (Cartesian robots and vertical mount single-axis robots)1.

w WARNING Theverticalaxiswillslidedownwhenthemotorisremoved,causingahazardoussituation. • Turnoffthecontrollerandplaceasupportundertheverticalaxisbeforeremovingthemotor. • Becarefulnottoletyourbodygetcaughtbythedrivingunitoftheverticalaxisorbetweentheverticalaxis and the installation base.

Be careful when removing the Z-axis motor (SCARA robots)2.

w WARNING TheZ-axiswillslidedownwardwhentheZ-axismotorisremoved,causingahazardoussituation. • TurnoffthecontrollerandPlaceasupportundertheZ-axisbeforeremovingtheZ-axismotor. • BecarefulnottoletyourbodygetcaughtbythedrivingunitoftheZ-axisorbetweentheZ-axisdriveunitand the installation base.

Do not remove the Z-axis upper limit mechanical stopper3.

c CAUTION Warninglabel4isattachedtoeachSCARArobot.(Fordetailsonwarninglabels,see"3.Warninglabels"in"Safetyinstructions.") RemovingtheupperlimitmechanicalstopperinstalledtotheZ-axissplineorshiftingitspositionwilldamagetheZ-axisballscrew.Neverattempttoremoveit.

Use caution when handling a robot that contains powerful magnets4.

w WARNING Powerful magnets are installed inside the robot. Do not disassemble the robot since this may cause injury. Devices that may malfunction due to magnetic fields must be kept away from this robot.

See "6. Cautions regarding strong magnetic fields" in "Safety instructions" for detailed information on strong magnetic fields.

Use the following caution items when disassembling or replacing the pneumatic equipment.5.

w WARNING Airorpartsmayflyoutwardifpneumaticequipmentisdisassembledorpartsreplacedwhileairisstillsupplied. • Doserviceworkafterturningoffthecontroller,reducingtheairpressure,andexhaustingtheresidualairfrom the pneumatic equipment. • Beforereducingtheairpressure,placeasupportstandundertheZ-axis(2-axisrobotswithairdrivenZ-axis) since it will drop under its own weight.

Use caution to avoid contact with the controller cooling fan6.

w WARNING • Touchingtherotatingfanmaycauseinjury. • Ifremovingthefancover,firstturnoffthecontrollerandmakesurethefanhasstopped.

Precautions for robot controllers7.

c CAUTION • Backuptherobotcontrollerinternaldataonanexternalstoragedevice.Therobotcontrollerinternaldata (programs,pointdata,etc.)maybelostordeletedforunexpectedreasons.Alwaysmakeabackupofthisdata. • Donotusethinner,benzene,oralcoholtowipeoffthesurfaceoftheprogrammingbox.Thesurfacesheetmay be damaged or printed letters or marks erased. Use a soft, dry cloth and gently wipe the surface. • Donotuseahardorpointedobjecttopressthekeysontheprogrammingbox.Malfunctionorbreakdown may result if the keys are damaged. Use your fingers to operate the keys.

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4.8 DisposalWhendisposingofrobotsandrelateditems,handlethemcarefullyasindustrialwastes.Usethecorrectdisposal method in compliance with your local regulations, or entrust disposal to a licensed industrial waste disposal company.

Disposal of lithium batteries1.

When disposing of lithium batteries, use the correct disposal method in compliance with your local regulations, or

entrust disposal to a licensed industrial waste disposal company. We do not collect and dispose of the used batteries.

Disposal of packing boxes and materials2.

When disposing of packing boxes and materials, use the correct disposal method in compliance with your local regula-

tions. We do not collect and dispose of the used packing boxes and materials.

Strong magnet3.

w WARNING Strong magnets are installed in the robot. Be careful when disposing of the robot.

See "6. Cautions regarding strong magnetic fields" in "Safety instructions" for detailed information on strong magnetic

fields.

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5. Emergency action when a person is caught by robotIf a person should get caught between the robot and a mechanical part such as the installation base, then release the axis.

Emergency action ■

Release the axis while referring to the following section in the manual for the robot controller.

Controller Refer to:

RCX240Section1,"Emergencyactionwhenapersoniscaughtbyrobot"inChapter1

RCX340

n NOTE Make a printout of the relevant page in the manual and post it a conspicuous location near the controller.

6. Cautions regarding strong magnetic fieldsSome YAMAHA robots contain parts generating strong magnetic fields which may cause bodily injury, death, or device malfunction. Always comply with the following instructions.

•Personswearingmedicalelectronicdevicessuchascardiacpacemakersorhearingaidsmustkeepawayfrom the linear single-axis robot and linear conveyor. (Stay at least 100mm away.)

•PersonswearingIDcards,purses,and/orwristwatchesmustkeepawayfromthelinearsingle-axisrobotandlinear conveyor.

•Donotattempttodisassemblethelinearsingle-axisrobotandlinearconveyor(includingsurroundingcovers).

•Donotbringtoolsclosetotheinternalpartsoftherobotandthelinearconveyormagnets.•Alwaysattachthemagnetprotectivecover(supplied)whenhandling,shippingorstoringthelinearconvey-

or’s slider when removing it from the module.

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7. Using the robot safely7.1 Movement rangeWhen a tool or workpiece is attached to the robot manipulator tip, the actual movement range enlarges from the movement range of the robot itself (Figure A) to include the areas taken up by movement of the tool and workpiece attached to the manipulator tip (Figure B). The actual movement range expands even further if the tool or workpiece is offset from the manipulator tip. The movement range here is defined as the range of robot motion including all areas through which the robot arms, the tool and workpiece attached to the manipulator tip, and the solenoid valves attached to the robot arms move. To make the robot motion easier to understand, the figures below only show the movement ranges of the tool attachment section, tool, and workpiece. Please note that during actual operation, the movement range includes all areas where the robot arms and any other parts move along with the robot.

Movement range

Figure A: Movement range of robot itself Figure B: Movement range when tool and workpiece are attached to manipulator tip

93009-X0-00

c CAUTION To make the robot motion easier to understand, the above figures only show the movement ranges of the tool attachment section, tool, and workpiece. In actual operation, the movement range includes all areas where the robot arms and any other parts move along with the robot.

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7.2 Robot protective functionsProtective functions for YAMAHA robots are described below.

Overload detection1. This function detects an overload applied to the motor and turns off the servo.

If an overload error occurs, take the following measures to avoid such errors:

1. Insert a timer in the program.

2. Reduce the acceleration.

Overheat detection2. This function detects an abnormal temperature rise in the driver inside the controller and turns off the servo.

If an overheat error occurs, take the following measures to avoid the error:

1. Insert a timer in the program.

2. Reduce the acceleration.

Soft limits3. Soft limits can be set on each axis to limit the working envelope in manual (jog) operation and automatic operation after

return-to-origin. The working envelope is the area limited by soft limits.

w WARNING Soft limit function is not a safety-related function intended to protect the human body. To restrict the robot movement range to protect the human body, use the mechanical stoppers installed in the robot(oravailableasoptions).

Mechanical stoppers4. If the servo is turned off by emergency stop operation or protective function while the robot is moving, then these

mechanical stoppers prevent the axis from exceeding the movement range. The movement range is the area limited by

the mechanical stoppers.

SCARA robots

• TheXandYaxeshavemechanicalstoppersthatareinstalledatbothendsofthemaximummovementrange.Somerobotmodelshaveastandardfeaturethatallowschangingthemechanicalstopperpositions.Onsomeothermodels,themechanicalstopperpositionscanalsobechangedbyusingoptionparts.

• TheZ-axishasamechanicalstopperattheupperendandlowerend.Thestopperpositionscanbechangedbyusingoptionparts.

• NomechanicalstopperisprovidedontheR-axis.

YK-TWseriesrobotsdonothavemechanicalstoppersintendedtoprotectthehumanbody,duetotheproductcharacteristicoftheorbitmovement.Whenitisnecessarytorestrictthearmrotationanglesoastoensurethesafety,installadditionalstopperseparately.

Single-axis robots

Cartesian robots

• Thelinearmovementaxishasamechanicalstopperatbothendsofthemaximummovementrange.Thepositionsofthesemechanicalstopperscannotbechanged.

• Nomechanicalstopperisprovidedontherotationalaxis.

w WARNING Axismovementdoesnotstopimmediatelyaftertheservoisturnedoffbyemergencystoporotherprotectivefunctions, so use caution.

c CAUTION Iftherobotmovingathighspeedcollideswithamechanicalstopperinstalledintherobot(oravailableasoption),therobotmaybedamaged.

w DANGER When the linear conveyor module is used to insert or eject the slider, mechanical stoppers cannot be attached to the module body due to the structural limits. So install a device to catch and stop the slider being ejected at high speed from the module, as well as other necessary safety measures.

Z-axis (vertical axis) brake5. An electromagnetic brake is installed on the Z-axis to prevent the Z-axis from sliding downward when the servo is OFF.

This brake is working when the controller is OFF or the Z-axis servo power is OFF even when the controller is ON. The

Z-axis brake can be released by the programming unit / handy terminal or by a command in the program when the

controller is ON.

w WARNING Theverticalaxiswillslidedownwardwhenthebrakeisreleased,causingahazardoussituation.Takeadequatesafety measures in consideration by taking the weight and shape into account. • Beforereleasingthebrakeafterpressingtheemergencystopbutton,placeasupportundertheverticalaxisso that it will not slide down. • Becarefulnottoletyourbodygetcaughtbetweentheverticalaxisandtheinstallationbasewhenperforming tasks(directteaching,etc.)withthebrakereleased.

Safe

ty Instructio

ns

S-28

7.3 Residual riskTo ensure safe and correct use of YAMAHA robots and controllers, System integrators and/or end users imple-ment machinery safety design that conforms to ISO12100.ResidualrisksforYAMAHArobotsandcontrollersaredescribedintheDANGERorWARNINGinstructionsprovided in each chapter and section. Read them carefully.

7.4 Special training for industrial robot operationOperators or persons who handle the robot for tasks such as for teaching, programming, movement checks, inspections, adjustments, and repairs must receive appropriate training and also have the skills needed to perform the job correctly and safely. They must also read the manual carefully to understand its contents before attempting the robot operation or maintenance.

Tasks related to industrial robots (teaching, programming, movement check, inspection, adjustment, repair, etc.) must be performed by qualified persons who meet requirements established by local regulations and safety standards for industrial robots.

Comparison of terms used in this manual with ISO

This manual ISO 10218-1 Note

Maximum movement range maximumspace Arealimitedbymechanicalstoppers.

Movement range restrictedspace Arealimitedbymovablemechanicalstoppers.

Working envelope operationalspace Arealimitedbysoftwarelimits.

Within safety enclosure safeguardedspace


YAMAHA MOTOR CO., LTD. IM Operations

All rights reserved. No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO., LTD.Information furnished by YAMAHA in this manual is believed to be reliable. However, no responsibility is assumed for possible inaccuracies or omissions. If you find any part unclear in this manual, please contact your distributor.

Safety InstructionsFeb.2015Ver.1.20

Revision record

Manual version Issue date Description

Ver.1.00 May2012 Firstedition

Ver.1.01 Jun.2012 Descriptionof"Emergencyactionwhenapersoniscaughtbyrobot"wasadded,theworksequenceforworkingwithinthesafetyenclosurechanged,typingerrorscorrected,etc.

Ver.1.02 Sep.2012 Descriptionofwarninglabelswasadded;descriptionsof"softlimits","mechanicalstoppers"andworkperformedwithverticalaxisbrakereleasedwerechanged;andresidualriskdescriptionwasadded.

Ver.1.03 Dec.2012 Warningonrestrictingtherobotmovingspeedwasaddedanddescriptionofwarninglabellanguagewaschanged.

Ver.1.04 Jun.2013 Descriptionof“Movementrange”wasadded.

Ver.1.05 Sep.2013 Descriptionoflinearconveyormodulewasadded.

Ver.1.06 Apr.2014 Descriptionofwarninglabelswasaddedanddescriptionof

“Qualificationofoperators/workers”waschanged,etc.

Ver.1.10 Dec.2014 Descriptionofwarninglabelswasadded,etc.

Ver.1.20 Feb.2015 Descriptionof"mechanicalstoppers"wasadded,etc.

Wa

rranty

Ver.1.01_201209

WarrantyFor information on the warranty period and terms, please contact our distributor where you purchased the product.

This warranty does not cover any failure caused by: ■

1. Installation, wiring, connection to other control devices, operating methods, inspection or maintenance that does not comply with industry standards or instructions specified in the YAMAHA manual;

2.UsagethatexceededthespecificationsorstandardperformanceshownintheYAMAHAmanual;

3. Product usage other than intended by YAMAHA;

4. Storage, operating conditions and utilities that are outside the range specified in the manual;

5. Damage due to improper shipping or shipping methods;

6. Accident or collision damage;

7. Installation of other than genuine YAMAHA parts and/or accessories;

8. Modification to original parts or modifications not conforming to standard specifications designated by YAMAHA, including customizing performed by YAMAHA in compliance with distributor or customer requests;

9. Pollution, salt damage, condensation;

10. Fires or natural disasters such as earthquakes, tsunamis, lightning strikes, wind and flood damage, etc;

11. Breakdown due to causes other than the above that are not the fault or responsibility of YAMAHA;

The following cases are not covered under the warranty: ■

1. Products whose serial number or production date (month & year) cannot be verified.

2. Changes in software or internal data such as programs or points that were created or changed by the customer.

3. Products whose trouble cannot be reproduced or identified by YAMAHA.

4. Products utilized, for example, in radiological equipment, biological test equipment applications or for other purposes whose warranty repairs are judged as hazardous by YAMAHA.

THEWARRANTYSTATEDHEREINPROVIDEDBYYAMAHAONLYCOVERSDEFECTSINPRODUCTSANDPARTSSOLDBYYAMAHATODISTRIBUTORSUNDERTHISAGREEMENT.ANYANDALLOTHERWARRANTIESORLIABILITIES,EXPRESSORIMPLIED,INCLUDINGBUTNOTLIMITEDTOANYIMPLIEDWARRANTIESOFMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEAREHEREBYEXPRESSLYDISCLAIMEDBYYAMAHA.MOREOVER,YAMAHASHALLNOTBEHELDRESPONSIBLEFORCONSEQUENTORINDIRECTDAMAGESINANYMANNERRELATINGTOTHEPRODUCT.

This manual does not serve as a guarantee of any industrial property rights or any other rights and does not grant a license in any form. Please acknowledge that we bear no liability whatsoever for any problems involving industrial property rights which may arise from the contents of this manual.

Warranty

Contents

Beforeusingtherobot(Besuretoreadthefollowingnotes.) i

Introduction iv

Introduction

Introd

uctio

n

i

Before using the robot (Be sure to read the following notes.)Atthistime,ourthanksforyourpurchaseofthisYAMAHAYK-XRseriesSCARArobot.

n NOTE In the RCX340 controller, axis names are called using numeric values, like axis-1, axis-2, axis-3, and so on. In this manual, axis names are called using alphabetic characters, like X-axis, Y-axis, Z-axis, and so on. So, read this manual while referring to the robot external view and axis name correspondence table shown below.

External view of robot and axis name correspondence table

X-axis arm(arm -1)

Y-axis arm(arm -2)

R-axis(axis -4)

Z-axis(axis -3)

X-axis(axis -1)

Y-axis(axis -2)Y-axis

(axis -2)

(+)

(+)

(+)

(+)

(-)

(-)

(-)

(-)

23002-FK-00

RCX340 controller axis name Axis name in this manual

Axis1 X-axis

Axis2 Y-axis

Axis3 Z-axis

Axis4 R-axis

Introd

uctio

n

ii

Please be sure to perform the following tasks before using the robot.1. Failing to perform the tasks below will require re-teaching of the robot since the origin position cannot be set to the same

previous position. Robot malfunctions (vibration, noise) may also occur.

The origin position of the YK-XR series robots is adjusted to the position as shown below, so the reference or standard

coordinates are temporarily set. The customer should set the origin position before any other job. There are 2 types of

origin position settings as shown below.

[1]Setting the origin position adjusted at the factory prior to shipment as the origin position (When setting the origin position with the robot arm extended, you must check that there will not be any interference from any peripheral equipment during the next return-to-origin.)

[2]Setting a position OTHER than the origin position adjusted at the factory prior to shipment as the origin position

Default origin position

Sensor type

Standard type

129°+/-3°

147°+/-3°

23313-FK-00

[1]To set the origin position adjusted at the factory prior to shipment as the origin position

Return-to-origin

The YK-XR series robots only require the return-to-origin to be performed once when the robot is introduced. Once the

return-to-origin is performed, you do not need to reperform it when the power is turned on next time. Set the origin

position while referring to return-to-origin methods in "2. Adjusting the origin" in Chapter 3 of this manual and in

"Return-to-origin"ofthe"YAMAHARobotControllerUser'sManual".Settingofstandardcoordinatesisnotrequiredin

the above case. To set the standard coordinates with high accuracy, refer to "4. Setting the standard coordinates" in

Chapter3ofthismanualand"SettingtheStandardCoordinates"inthe"YAMAHARobotControllerUser'sManual".If

the standard coordinate settings are incorrect, robot malfunctions (vibration, excessive noise) may occur.

c CAUTION Neverentertherobotmovementrangeoncetherobotservoisturnedonasthisisextremelyhazardous.

[2]To set a position OTHER than the origin position adjusted at the factory prior to shipment as the origin position

1.Return-to-origin

The YK-XR series robots only require the return-to-origin to be performed once when the robot is introduced. Once

the return-to-origin is performed, you do not need to reperform it when the power is turned on next time. Set the

origin position while referring to return-to-origin methods in "2. Adjusting the origin" in Chapter 3 of this manual and

in"Return-to-origin"ofthe"YAMAHARobotControllerUser'sManual".Settheoriginpositionwiththereturn-to-

origin.

c CAUTION Neverentertherobotmovementrangeoncetherobotservoisturnedonasthisisextremelyhazardous.

2.Affixing the origin position sticker

Set in emergency stop when return-to-origin is complete, and immediately affix the origin point sticker according to

instructions in "5. Affixing stickers for origin positions, movement directions and axis names" in Chapter 3 of this manual.

Introd

uctio

n

iii

3.Setting the standard coordinates

Set the standard coordinates while referring to instructions in "4. Setting the standard coordinates" in Chapter 3 of

thismanualandalsoto"SettingtheStandardcoordinates"inthe"YAMAHARobotControllerUser'sManual".Robot

malfunctions (vibration, noise) may occur if the standard coordinates are not set correctly.

Eventhoughthereisnoproblemwiththerobot,theerrormessagesareissuedwhentherobotandcontrollerare

connected and power first turned on. (Actual error messages may differ according to how the robot and controller are

connected.)

Example of error messages issued when robot & controller are connected Example

17.410: ABS. battery error

17.411: ABS. encoder error

17.412: ABS. count error

17.413: ABS. overflow error

17.414: ABS. mixing error 1

etc.

Repetitive positioning accuracy2.

"Repetitive positioning accuracy" is not guaranteed under the following conditions.

[1] Factors related to absolute accuracy

• Iftheaccuracybetweenthecoordinatepositions(commandpositions)insidetherobotcontrollerandthereal

space positions (moving positions) is required.

[2] Motion pattern factors

• Ifamotionapproachingtotheteachingpointfromadifferentdirectionisincludedduringrepetitiveoperation.

• Ifthepoweristurnedoffortherobotisstoppedbeforecompletingthemotionorthemovingspeedischanged

even when approaching to the teaching point from the same direction.

• Iftherobotismovedtotheteachingpointusingahandsystemdifferentfromthehandsystem(right-handedor

left-handed system) used for the teaching.

[3] Temperature factors

• Iftheambienttemperatureenvironmentchangessignificantly.

• Ifthetemperatureoftherobotmainbodychanges.

[4] Load variation factors

• If load conditions vary during operation (the load varies depending on whether or not the workpiece is present, etc.).

If the X-axis, Y-axis or R-axis rotation angle is small.3.

If the X-axis, Y-axis or R-axis rotation angle is smaller than 5° so that it moves in almost the same position, an oil film is

difficult to be formed on the joint support bearing, possibly leading to damage to the bearing. In this type of operation,

add a movement so that the joint moves through 90° or more, about 5 times a day.

Do not remove the Z-axis upper-end mechanical stopper4.

Removing or moving the upper-end mechanical stopper attached to the Z-axis spline can damage the Z-axis ball screw.

Never remove or move it.

Introd

uctio

n

iv

IntroductionTheYAMAHAYK-XRseriesrobotsareSCARAtypeindustrialrobotsdevelopedbasedonyearsofYAMAHA experience and achievements in the automation field as well as efforts to streamline our in-house manufacturing systems. TheYK-XRseriesrobotshaveatwo-jointmanipulatorconsistingofanX-axisarmandaY-axisarm,andarefurtherequippedwithaverticalaxis(Z-axis)andarotatingaxis(R-axis)atthetipofthemanipulator.TheYK-XRseriesrobotscanbeusedforawiderangeofassemblyapplicationssuchasinstallationandinsertionofvarious parts, application of sealant, and packing operations.

Thisuser'smanualdescribesthesafetymeasures,handling,adjustmentandmaintenanceofYK-XRseriesrobots for correct, safe and effective use. Be sure to read this manual carefully before installing the robot. Evenafteryouhavereadthismanual,keepitinasafeandconvenientplaceforfuturereference.Thisuser'smanualshouldbeusedwiththerobotandconsideredanintegralpartofit.Whentherobotismoved,transferred or sold, send this manual to the new user along with the robot. Be sure to explain to the new user the need to read through this manual.

Fordetailsaboutactualrobotoperationandprogramming,refertothe"YAMAHARobotControllerUser'sManual".

w WARNING THEADjUSTMENTANDMAINTENANCEWORKWITHTHECOvERREMOvEDNEEDSTHESPECIALKNOWLEDGEANDSKILL.IFUNSKILLEDWORKPERSONPERFORMSSUCHWORK,THISMAYINvOLvERISK. READ"2.QUALIFICATIONOFOPERATORS/WORKERS"INSECTION4.1OFTHESAFETYGUIDEANDALLOWONLYQUALIFIEDENGINEERSTOPERFORMTHISWORKWHILEREFERRINGTOTHESEPARATEMAINTENANCEMANUAL.

"Harmonic" and "Harmonic drive" are the registered trademarks of Harmonic Drive Systems Inc.

NOTES

• Thecontentsofthismanualaresubjecttochangewithoutpriornotice.

• InformationfurnishedbyYAMAHAinthismanualisbelievedtobereliable.

However,ifyoufindanypartunclearorinaccurateinthismanual,pleasecontactyourdistributor.


Chapter 1 Functions

Contents

1. Robot manipulator 1-1

1.1 Manipulator movement 1-1

1.2 Part names 1-2

2. Robot controller 1-3

3. Robot initialization number list 1-4

1-1

1

Functio

ns

1. Robot manipulator1.1 Manipulator movementThe YK-XR series robots are available in 4-axis models having an X/Y-axis arm (equivalent to human arm) and a Z/R-axis (equivalent to human wrist). With these 4 axes, the YK-XR series robots can move as shown in the Fig. below. By attaching different types of end effector (gripper) to the end of the arm, a wide range of tasks can be performed with high precision at high speeds. The (+) and (-) signs show the direction of axis movement when the jog keys on the programming box are pressed (standard setting at the factory).

Manipulator movement

X-axis arm

Y-axis arm

R-axis

Z-axis

X-axis

Y-axisY-axis

(+)

(+)

(+)

(+)

(-)

(-)

(-)

(-)

23101-FK-00

1-2

1

Functio

ns

1.2 Part names

Part names

Standard type

User wiring connector(Numbers 1 to 10 are usable.)


Warning label 4*Serial label

Y-axis mechanical stopper

X-axis mechanical stopper

X-axis motor

X-axis speed reduction gearX-axis arm

Y-axis arm

Y-axis speed reduction gear

Y-axis motor

Z-axis motor

R-axis motor

Ball screw Machine harness

Z-axis splineWarning label 1*Warning label 2*

Warning label 3*


M4 ground terminal

User tubing 1 (φ4 black)User tubing 2 (φ4 red)User tubing 3 (φ4 blue)

User tubing 1 (φ4 black)User tubing 2 (φ4 red)User tubing 3 (φ4 blue)

Tapped hole for user

User wiring/tubing through spline type

Extension shaft for user wiring and tubing

23102-FK-00

*YAMAHAPartNos.

Warninglabel1 90K41-001470




1-3

1

Functio

ns

2. Robot controllerTheYK-XRseriesrobotcomessuppliedwitharobotcontrollerRCX340.Formoredetails,refertotheseparate"YAMAHARobotControllerUser'sManual".

Robot controller

RCX340

23103-FK-00

1-4

1

Functio

ns

3. Robot initialization number listTheYK-XRseriesrobotsareinitializedforoptimumsetting(defaultsetting)accordingtotherobotmodelpriorto shipping. The robot controllers do not have to be reinitialized during normal operation. However, if for some reason the controller must be reinitialized, proceed while referring to the robot number shown below.

YK400XR Robot number:

Robotinitialization

number

Modelname Remarks

2140 YK400XR Standardtype

2146 YK400XR Sensortype(optional)

c CAUTION • Return-to-originmustbeperformedafterreinitializingthecontroller.Beforereinitializingthecontroller,readthe descriptions in " 2. Adjusting the origin" in Chapter 3 and make sure you thoroughly understand the procedure. • Whenthecontrollerisinitialized,the"ARMLENGTH"and"OFFSETPULSE"settingsintheaxisparameterswillbe erased,makingthestandardcoordinatesettingsinvalid.(Fordetailsonstandardcoordinates,see"4.Setting thestandardcoordinates"inChapter3.)Ifyoudonotwanttochangetheoriginpositionbyinitializing,makea note of the "ARM LENGTH" and "OFFSET PULSE" settings before initializing, and re-enter their settings after initialization is complete.

Chapter 2 Installation

Contents

1. Robot installation conditions 2-1

1.1 Installation environments 2-1

1.2 Installation base 2-2

2. Installation 2-3

2.1 Unpacking 2-3

2.2 Checking the product 2-4

2.3 Moving the robot 2-5

2.4 Installing the robot 2-6

3. Protective bonding 2-7

4. Robot cable connection 2-8

5. User wiring and user tubing 2-9

6. Attaching the end effector 2-11

6.1 Acceleration coefficient vs. moment of inertia 2-11

6.1.1 R-axis tolerable moment of inertia and acceleration coefficient 2-11

6.1.2 Parameter setting according to R-axis moment of inertial of load 2-11

6.2 Equation for moment of inertia calculation 2-12

6.3 Exampleofmomentofinertiacalculation 2-15

6.4 Attaching the end effector 2-17

6.5 Gripping force of end effector 2-19

7. Limiting the movement range with X-axisandY-axis mechanical stoppers 2-20

7.1 InstallingtheX-axis/Y-axisadditionalmechanicalstoppers 2-21

7.2 RobotoverrunduringimpactswithX-axisorY-axismechanicalstopper 2-23

8. Working envelope 2-24

9. Stopping time and stopping distance at emergency stop 2-27

10. Installing the user wiring and tubing newly 2-30

11. Passing the wiring and tubing in the user wiring/tubing through spline type 2-31

12. Detaching or attaching the covers 2-32

2

Installa

tion

2-1

1. Robot installation conditions1.1 Installation environmentsBe sure to install the robot in the following environments.

Setting environments Specifications

Allowableambienttemperature 0to40°C

Allowableambienthumidity 35to85%RH(noncondensation)

Altitude 0to1000metersabovesealevel

Ambientenvironments Avoidinstallingnearwater,cuttingwater,oil,dust,metallicchipsandorganicsolvent.

Avoidinstallationnearcorrosivegasandcorrosivematerials.

Avoidinstallationinatmospherecontaininginflammablegas,dustorliquid.

Avoidinstallationnearobjectscausingelectromagneticinterference,electrostatic

dischargeorradiofrequencyinterference.

Vibration Donotsubjecttoimpactsorvibrations.

Airsupplypressure,etc.Below0.58MPa(6.0kgf/cm2);cleandryairnotcontainingdeterioratedcompressoroil;

filtration40μmorless

Workingspace Allowsufficientspacemargintoperformjobs(teaching,inspection,repair,etc.)

For detailed information on how to install the robot controller, refer to the separate "YAMAHA Robot Controller User'sManual".

w WARNING • AvOIDINSTALLINGTHEROBOTINLOCATIONSWHERETHEAMBIENTCONDITIONSMAYEXCEEDTHEALLOWABLE TEMPERATUREORHUMIDITY,ORINENvIRONMENTSWHEREWATER,CORROSIvEGASES,METALLICPOWDEROR DUST ARE GENERATED. MALFUNCTION, FAILURE OR SHORT CIRCUITS MAY OTHERWISE RESULT. • THISROBOTWASNOTDESIGNEDFOROPERATIONINENvIRONMENTSWHEREINFLAMMABLEOREXPLOSIvE SUBSTANCES ARE PRESENT. • DONOTUSETHEROBOTINENvIRONMENTSCONTAININGINFLAMMABLEGAS,DUSTORLIQUIDS.EXPLOSIONSOR FIRE COULD OTHERWISE RESULT. • AvOIDUSINGTHEROBOTINLOCATIONSSUBjECTTOELECTROMAGNETICINTERFERENCE,ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE. MALFUNCTION MAY OTHERWISE OCCUR. • DONOTUSETHEROBOTINLOCATIONSSUBjECTTOEXCESSIvEvIBRATION.ROBOTINSTALLATIONBOLTSMAY OTHERWISEBECOMELOOSECAUSINGTHEMANIPULATORTOFALLOvER.

2

Installa

tion

2-2

1.2 Installation basePrepare a sufficiently rigid and stable installation base, taking account of the robot weight including the end effector (gripper), workpiece and reaction force while the robot is operating.

w WARNING • BESURETOINSTALLTHEROBOTONAHORIZONTALSURFACEWITHTHEBASEMOUNTSECTIONFACINGDOWN. INSTALLTHEWALL-MOUNTORWALL-MOUNTINvERSEMODELROBOTWITHTHEBASEMOUNTSECTIONFACING SIDEWARD.IFTHEORIENTATIONOFTHEBASEMOUNTSECTIONISNOTOBSERvEDWHENINSTALLINGTHEROBOT, THEGREASEOFTHESPEEDREDUCTIONUNITMAYLEAK. • DONOTPLACETHEROBOTONAMOvINGINSTALLATIONBASE.EXCESSIvELOADSWILLBEAPPLIEDTOTHEROBOT ARMBYMOvEMENTOFTHEINSTALLATIONBASE,RESULTINGINDAMAGETOTHEROBOT.

c CAUTION • Themanipulatorpositioningmightdecreaseiftheinstallationsurfaceprecisionisinsufficient. • Iftheinstallationbaseisnotsufficientlyrigidandstableorathinmetallicplateisattachedtotheinstallation base,vibration(resonance)duringoperation,causingdetrimentaleffectsonthemanipulatorwork.

1 Prepare a robot installation base.The maximum reaction force applied to the X-axis and Z-axis of each robot during operation is shown in the Table below. These values are instantaneous force values applied to the robot during operation and do not indicate the load resistant values.

Maximum reaction force during robot operation

Fxmax

Fzmax

Mxmax

Load

23201-F6-00

The flatness of the robot installation base surface must be machined within a precision of ± 0.05mm/500mm.

2 Tap holes into the installation surface of the base.

n NOTE For details about machining dimensions and positions, see "1.2 External view and dimensions" in Chapter 8.

3 Securely fix the installation base on the floor.Securely fix the installation base with the anchor bolts so that it does not move.

Robot ModelFxmax Mxmax Fzmax

N kgf Nm kgfm N kgf

YK400XR 176 18 226 24 75 8

2

Installa

tion

2-3

2. Installation2.1 Unpacking

w WARNING THEROBOTANDCONTROLLERAREHEAvY.TAKESUFFICIENTCARENOTTODROPTHEMDURINGMOvINGORUNPACKINGASTHISMAYDAMAGETHEEQUIPMENTORCAUSEBODILYINjURY.

c CAUTION When moving the robot or controller by equipment such as a folklift that require a license, only properly qualified personnel may operate it. The equipment and tools used for moving the robot should be serviced daily.

The YK-XR series robot comes packed with a robot controller and accessories, according to the order specifications.Usingacarryingcart(dolly)orforklift,movethepackagetoneartheinstallationbase.Takesufficient care not to apply shocks to the equipment when unpacking it.

Packed state

Robot manipulator

Robot manipulator

Case

Pallet

Robot controller and accessories

Transportation using case

Transportation using pallet

23201-FK-00

2

Installa

tion

2-4

2.2 Checking the productAfter unpacking, check the product configuration and conditions.

c CAUTION If there is any damage due to transportation or insufficient parts, please notify your distributor immediately.

● Controller : RCX340 Robot : YK-XR series

A BX YZ R

Product configurations

PBX programming box, etc.

Robot manipulatorDisc version of the User’s Manual

orUser's Manual

RCX340 controller

Warning label (×1)

X-axis additional stopper(option)

Y-axis additional stopper(option)

Origin position stickers

User wiring connector kit(Connector, 2 pcs. Pin, 30 pcs.)

Standard

Option

Y-axis standard coordinate setup jig(Option)

X-axis standard coordinate setup jig(Option)

23202-FK-00

2

Installa

tion

2-5

2.3 Moving the robot

w WARNING SERIOUS INjURY MAY OCCUR IF THE ROBOT FALLS AND PINS SOMEONE UNDER IT. • DONOTALLOWANYPARTOFYOURBODYTOENTERTHEAREABENEATHTHEROBOTDURINGWORK. • ALWAYSWEARAHELMET,SAFETYSHOESANDGLOvESDURINGWORK.

To check the mass of robot, refer to "1.1 Basic specification" in Chapter 8.

1 Fold the arms.Take out the robot from the case or remove it from the pallet. Fold the arms while referring to the Fig. below.

Moving the robot

Support

Robot cable

Robot main body

Support

23219-FK-00

2 Place the robot on the base.One work person holds the support of the robot main body with both hands and other work person holds the robot cable to place the robot on the base.

3 Temporarily secure the robot by tightening the bolts.

n NOTE For details about tightening torque to secure the robot firmly, see "2.4 Installing the robot".

2

Installa

tion

2-6

2.4 Installing the robotInstall the robot securely with the four hex socket head bolts as shown in the Fig. below.The robot can be secured from the upper portion.

w WARNING WHEN INSTALLING THE ROBOT, BE SURE TO USE THE SPECIFIED SIzE AND QUANTITY OF BOLTS THAT MATCH THE DEPTH OF TAPPED HOLES IN THE INSTALLATION BASE, AND SECURELY TIGHTEN THE BOLTS TO THE CORRECT TORQUE. IF THE BOLTS ARENOTTIGHTENEDCORRECTLY,THEROBOTMIGHTFALLOvERDURINGOPERATIONCAUSINGASERIOUSACCIDENT.

Tightening torque

Robot Model Bolts Used Tightening torque

YK400XR M8 37Nm(380kgfcm)

Depth of tapped holes in installation base:Iron installation base : Bolt diameter × 1.5 or moreAluminum installation base Bolt diameter × 3 or more

Recommended bolt : JIS B 1176 hex socket head bolt, or equivalent Strength class JIS B 1051 12.9, or equivalent

Installing the robot

Installation base

Hex socket head bolt

23203-FK-00

n NOTE Knock holes for the positioning pins are provided on the base surface of the robot main body. When driving the positioning pins, the positional deviation due to attachment/detachment or vibration of the robot main body during maintenance work can be suppressed to the minimal level. For details about knock hole shape and dimensions, refer to "1.2 External view and dimensions" in Chapter 8.

2

Installa

tion

2-7

3. Protective bonding

w WARNING • BESURETOGROUNDTHEROBOTANDCONTROLLERTOPREvENTELECTRICALSHOCK. • TURNOFFTHECONTROLLERBEFOREGROUNDINGTHEROBOT.

Provideaterminalmarked"PE"fortheprotectiveconductoroftheentiresystemand connect it to an external protective conductor. In addition, securely connect the ground terminal on the robot pedestal to the same protective conductor. (See the Fig. below.)

(Symbol　417-IEC-5019）

23201-F0-00Example of grounding

Ground symbol

M4 Ground terminal

23204-FK-00

Useagroundcablewithaconductorwirecrosssectionofatleast2.0mm2 and a length within 1 meter.

c CAUTION When the end effector uses an electrical device which, if it malfunctions, might make contact with the power supply,theusermustprovidepropergroundingonhisownresponsibility.TheYK-XRseriesrobotsdonothaveaground terminal for this purpose.

n NOTE For details on protective bonding on the robot body to comply with CE Marking, follow the instructions on protective bonding explained in the "YAMAHA Robot Controller User's Manual".

2

Installa

tion

2-8

4. Robot cable connectionTherobotcableispre-connectedtotheYK-XRseriesrobot.Fordetailsonconnectionstotherobotcontroller,refertotheFig.belowandthe"YAMAHARobotControllerUser'sManual".Aftermakingconnections,checktheoperationwhilereferringtothesection"4.6.1TrialOperation"inChapter“SafetyInstructions”ofthismanual.

w WARNING • BEFORECONNECTINGTHECABLES,CHECKTHATTHEREARENOBENDSORBREAKSINTHECONNECTORPINSOF THEROBOTCABLEANDTHATTHECABLESARENOTDAMAGED.BENTORBROKENPINSORCABLEDAMAGEMAY CAUSE MALFUNCTION OF THE ROBOT. • ENSURETHATTHECONTROLLERISOFFBEFORECONNECTINGTHEROBOTCABLETOTHECONTROLLER. • INTHERCX340CONTROLLER,THEMOTORCONNECTORSXMANDZM,ANDYMANDRMEACHHAvEIDENTICAL SHAPES.INADDITION,THEPICONNECTORSXYANDZRHAvEIDENTICALSHAPES.DONOTCONFUSETHESE CONNECTORSWHENMAKINGCONNECTIONS.WRONGCONNECTIONSMAYRESULTINMALFUNCTIONAND HAzARDOUS SITUATIONS. • IFTHECONNECTORINSTALLATIONISINADEQUATEORIFTHEREARECONTACTFAILURESINTHEPINS,THEROBOT MAY MALFUNCTION CAUSING A HAzARDOUS SITUATION. RECONFIRM THAT EACH CONNECTOR IS SECURELY INSTALLED BEFORE TURNING ON THE CONTROLLER. • TOATTACHTHEPICONNECTORSECURELY,TIGHTENTHESCREWSSUPPLIEDWITHTHEROBOT. • TAKECAUTIONNOTTOAPPLYANEXCESSIvELOADTOTHECONNECTORSDUETOSTRESSORTENSIONONTHE CABLES. • LAYOUTTHECABLESSOTHATTHEYDONOTOBSTRUCTTHEMOvEMENTOFTHEMANIPULATOR.DETERMINETHE ROBOTWORKAREAINWHICHTHEROBOTCABLESWILLNOTINTERFEREWITHTHELOADORWORKPIECEPICKEDUP BYTHEMANIPULATOR.IFTHEROBOTCABLESINTERFEREWITHTHEMOvABLEPARTSOFTHEROBOT,THECABLESMAY BEDAMAGEDCAUSINGMALFUNCTIONANDHAZARDOUSSITUATIONS.REFERTO"1.2EXTERNALvIEWAND DIMENSIONS" IN CHAPTER 8. • LAYOUTTHEROBOTCABLESSOASTOKEEPTHEOPERATORORANYOTHERPERSONFROMTRIPPINGONTHEM. BODILY INjURY MAY RESULT IF SOMEONE TRIPS ON THE CABLES.

Robot cable connections

Robot cable

Robot side connector

XM

YM

ZM

RM

XY

ZR

Controller side connector

RCX340

XM

YM

ZM

RM

ROB I/O

XY

ROB I/O

ZR

23205-FK-00

2

Installa

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2-9

5. User wiring and user tubing

w WARNING ALWAYSTURNOFFTHECONTROLLERANDSHUTOFFAIRSUPPLYBEFOREATTEMPTINGWIRINGANDTUBINGWORK.IFAIRORPOWERISSUPPLIEDDURINGTHISWORK,THEMANIPULATORMAYMOvEERRONEOUSLYCAUSINGAHAzARDOUS SITUATION.

The YK-XR series robots are equipped with user wires and air tubes in the machine harness. The table below shows the number of wires and air tubes available for each robot model.

Robot Model User wiring User tubing

YK400XR 10wires φ4,3tubes(Base-Y-arm)

*Robotmodelsforcustomspecificationsmayhavedifferentwiringortubing.

The specifications of the user wires and air tubes are shown below. Always observe the specifications.

User Wiring

Rated voltage 30V

Allowable current 1.0A

Nominal cross-section area of conductor 0.15mm2

Shield Yes

User Tubing

Maximum pressure 0.58MPa(6Kgf/cm2)

Outer diameter × inner diameter φ4mm×φ2.5mm

FluidDrycleanairnotcontainingdeterioratedcompressoroil;

filtration40μmorless

A connector for user wiring and a bulkhead union for user tubing are provided one each on the arm side and pedestalside.Forthelocations,referto"1.2Externalviewanddimensions"inChapter8.

2

Installa

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2-10

Signal wiring connections in the machine harness ■

Connector pins 1 to 10 can be used. Pin 11 is connected to a shield wire and cannot be used as a signal wire.

Signal Connector No. Connection No. Connector Color

Usersignalline IO

(Armside)

1 1

IO

(Baseside)

Brown

2 2 Red

3 3 Orange

4 4 Blue

5 5 Violet

6 6 Grey

7 7 White

8 8 Brown

9 9 Red

10 10 Orange

FlameGround 11 11 Green

FlameGround 1 FG Grey

As shown in the Fig below, either use a crimping tool (J.S.T. Mfg Co., Ltd. YC12) to crimp the connector for the user-prepared wiring, or solder it.

Connecting the connector

Robot side connector

Connector (supplied)

Lock mechanism

pin

Cable to be prepared by user

23209-FG-00

w WARNING • SECURELYFIXTHECONNECTOR(SUPPLIED)TOTHEROBOT'SCONNECTORUSINGTHELOCKMECHANISM ATTACHEDWITHTHEHOUSING(SEEFIG.ABOvE).THEOPERATIONCOULDMALFUNCTIONIFTHECONNECTOR DISLOCATES. • DONOTUTILIZETHEMACHINEHARNESS,USERSIGNALWIRESORAIRTUBESOFTHEROBOTTOFASTENANYCABLE ORTUBEPREPAREDBYTHEUSER,ASTHISMAYBREAKTHEROBOTHARNESSORUSERSIGNALWIRESCAUSING MALFUNCTION OF THE ROBOT. THIS WILL ALSO RESULT IN POOR POSITIONING ACCURACY. • MAKESURETHATUSERWIRINGANDTUBINGCONNECTEDWITHTHEUSERWIRINGCONNECTORANDUSERTUBING jOINT DO NOT INTERFERE WITH THE ROBOT, GET WOUND AROUND THE ROBOT OR LED AROUND WHEN THE ROBOT MOvES.THEWIRINGANDTUBINGCOULDBEDAMAGEDANDRESULTINMALFUNCTIONING. • ARRANGETHEUSERWIRINGANDTUBINGINSTALLEDWITHTHEUSERWIRINGCONNECTORANDUSERTUBINGjOINT NOT TO POSE HAzARDS FOR THE OPERATORS. THE OPERATORS COULD TRIP ON THESE PARTS AND BE INjURED.

c CAUTION Always use the supplied connectors and pins. Contact faults could occur if other types are used.

• Connector supplied at shipmentYAMAHA’s model number Part name Model number Q’ty

KDS-M4870-000

Connector

(Usedforboththearmandbase.)

SMR-11V-B

(J.S.T.Connector)2

PincontactSYM-001T-P0.6orBYM-001T-P0.6

(J.S.T.Connector)30

To check the operation and signal transmission between the end effector and the controller or peripheral equipment after making connections, refer to the section "4.6.1 Trial Operation" in Chapter “Safety Instructions” of this manual.

2

Installa

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2-11

6. Attaching the end effector6.1 Acceleration coefficient vs. moment of inertia

6.1.1 R-axis tolerable moment of inertia and acceleration coefficientThe moment of inertia of a load (end effector and workpiece) that can be attached to the R-axis is limited by the strength of the robot drive unit and residual vibration during positioning. It is therefore necessary to reduce the acceleration coefficient in accordance with the moment of inertia.

The acceleration coefficient corresponding to the R-axis tolerable moment of inertia and the moment of inertia has the relationship shown in the graph below. The RCX340 holds different data by model or load weight inside the controller. (Y-axis: Acceleration coefficient, X-axis: Moment of inertia around R-axis)

0.010.1

0.020.2

0.030.3

0.040.4

0.050.5

0

100

80

60

40

20

Ir (kgm2)Jr (kgfcmsec2)0

23207-FM-00

Therefore, optimal acceleration coefficient is automatically determined by entering only the load weight and the moment of inertia.

c CAUTION The“tipweight”parameterisapplicableonlytointegerentry.Forexample,evenwhentheloadweightis"1.1kg", round up the digits after the decimal point and set "2kg".

6.1.2 Parameter setting according to R-axis moment of inertial of loadIn the YK-XG series robots, it is necessary to set the parameter according to the moment of inertia of the load around the R-axis. Set the moment of inertia around the R-axis of the load for the “SCARA R axis inertia [kgm2 x 10-4]” robot parameter in kgm2 x 10-4 steps.

c CAUTION • Whentheinputvaluetothe“SCARARaxisinertia[kgm2x10-4]” parameter is small when compared to the actual load, the warning is given from the controller. Whentheloadshapeislarge,setalargervalueforthe"SCARARaxisinertia[kgm2x10-4]" parameter. • vibrationsmayoccurintheR-axisdependingontheloadstatusoroperationpattern.Inthiscase,makethe inputvalueofthe"SCARARaxisinertia[kgm2x10-4]" parameter larger to make the adjustment. • Donotchangearobotparameterotherthan“SCARARaxisinertia[kgm2x10-4]". If changed, the Cartesian coordinate accuracy may lower or the robot may malfunction.

Methodsforcalculatingthemomentofinertiaoftheloadareshownin"6.2Equationformomentofinertiacalculation"and"6.3Exampleofmomentofinertiacalculation"inthisChapter.However,itisnoteasytoprecisely figure out these values. If a calculated value smaller than the actual moment of inertia is set, residual vibrations may occur. In this case, decrease the SCARA R-axis moment of inertia further.

c CAUTION • EnterthecorrectpayloadandSCARAR-axismomentofinertiaandstrictlyobservethetolerablemomentof inertia to operate the robot in a correct and safe manner. If not observed, the service life of the drive part may lower, breakage or residual vibrations during positioning may occur. • DependingontheZ-axisposition,vibrationmayoccurwhentheX,YorR-axismoves.Ifthishappens,reduce theX,YorR-axisaccelerationtoanappropriatelevel. • Ifthemomentofinertiaistoolarge,vibrationmayoccurontheZ-axisdependingonitsoperationposition.If thishappens,reducetheZ-axisaccelerationtoanappropriatelevel.

2

Installa

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2-12

6.2 Equation for moment of inertia calculationUsuallytheRaxisloadisnotasimpleform,andthecalculationofthemomentofinertiaisnoteasy.Asamethod, the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated. The total of the moment of inertia for these factors is then obtained.The objects and equations often used for the calculation of the moment of inertia are shown below. Incidentally, there is the following relation: J (kgfcmsec2) = I (kgm2) × 10.2.

1) Moment of inertia for material particle The equation for the moment of inertia for a material particle that has a rotation center such as shown in the Fig. below is as follows: This is used as an approximate equation when x is larger than the object size.

Moment of inertia for material particle

x

J=Wx2

g(kgfcmsec2)

g : Gravitational acceleration (cm/sec2)

m : Mass of material particle (kg)

... (1)

I= mx2 (kgm2)

W : Weight of material particle (kgf)

23203-F0-00

2) Moment of inertia for cylinder (part 1) The equation for the moment of inertia for a cylinder that has a rotation center such as shown in the Fig. below is given as follows.

Moment of inertia for cylinder (part 1)

D

h

J=ρπD4h

32g

WD2

8g= (kgfcmsec2)

... (2)

I=ρπD4h

32

mD2

8= (kgm2)

ρ : Density (kg/m3, kg/cm3)


m : Mass of cylinder (kg)

W : Weight of cylinder (kgf)

23204-F0-00

2

Installa

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2-13

3) Moment of inertia for cylinder (part 2) The equation for the moment of inertia for a cylinder that has a rotation center such as shown in the Fig. below is given as follows.

Moment of inertia for cylinder (part 2)

h

D

2h

... (3)

J=ρπ D2h

16g

W

4g=

D2

4

h2

3( + )

D2

4

h2

3( + )

I=ρπ D2h

16

m

4=

D2

4

h2

3( + )

D2

4

h2

3( + )





(kgfcmsec2)

(kgm2)

23205-F0-00

4) Moment of inertia for prism The equation for the moment of inertia for a prism that has a rotation center as shown in the Fig. below is given as follows.

Moment of inertia for prism

a

c

b

1/2aJ=

ρabc(a2+b2)

12g

W(a2+b2)

12g=

... (4)

I=ρabc(a2+b2)

12

m(a2+b2)

12=

(kgfcmsec2)

(kgm2)



m : Mass of prism (kg)

W : Weight of prism (kgf)

23206-F0-00

5) When the object's center line is offset from the rotation center. The equation for the moment of inertia, when the center of the cylinder is offset by the distance "x" from the rotation center as shown in the Fig. below is given as follows.

When the object’s center line is offset from the rotation center.

D

h

x

Center line

Rotationcenter

J=ρπD4h

32g

WD2

8g=

... (5)

+ρπD2hx2

4g

+Wx2

g

I=ρπD4h

32+

ρπD2hx2

4

mD2

8= mx2+





(kgfcmsec2)

(kgm2)

23207-F0-00

2

Installa

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2-14

In the same manner, the moment of inertia of a cylinder as shown in the Fig. below is given by

Moment of inertia of a cylinder

h

D

x

Center line

W

4g=

... (6)

D2

4

h2

3( + )

J=ρπD2h

16g+

D2

4

h2

3( + )

ρπD2h x2

4g

+Wx2

g

I=ρπD2h

16+

D2

4

h2

3( + )

ρπD2h x2

4

=

(kgfcmsec2)

m

4

D2

4

h2

3( + ) + mx2 (kgm2)

23208-F0-00

In the same manner, the moment of inertia of a prism as shown in the Fig. below is given by

Moment of inertia of a prism

a

c

bx

Center line

J=ρabc(a2+ b2)

12g

W(a2+ b2)

12g=

... (7)

+ρabcx2

g

Wx2

g+

I=ρabc(a2+ b2)

12+ ρabcx2=

m(a2+b2)

12

m : Mass of prism (kg)

W : Weight of prism (kgf)

(kgfcmsec2)

+ mx2 (kgm2)

23209-F0-00

2

Installa

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2-15

6.3 Example of moment of inertia calculationLet's discuss an example in which the chuck and workpiece are at a position offset by 10cm from the R-axis by the stay, as shown in the Fig. below. The moment of inertia is calculated with the following three factors, assuming that the load material is steel and its density ρ is 0.0078kg/cm3.

Example of moment of inertia calculation

(The chuck and workpiece are at a position offset by 10 cm from the R-axis by the stay.)

10cm

2cm

2cm

R-axis

1cm

1cm

2cm

2cm

4cm

6cm

4cm

Stay

Chuck

Workpiece

23210-F0-00

1. Moment of inertia of the stay

Moment of inertia of the stay

12cm

2cm

2cm

Center line

5cm

R-axis

The weight of the stay (Ws) is given as follows:

Ws = ρabc = 0.0078 × 12 × 2 × 2

= 0.37 (kgf)

The moment of inertia of the stay (Js) is then calculated from Eq. (7).

Js =0.37 × (122+22)

+0.37 × 52

= 0.014 (kgfcmsec2)12 × 980 980

23211-F0-00

2

Installa

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2-16

2. Moment of inertia of the chuck

Moment of inertia of the chuck

10cm2cm

6cm

4cm

R-axis

When the chuck form resembles

that shown in figure, the weight

of the chuck (Wc) is

Wc = 0.0078 × 2 × 4 × 6

= 0.37 (kgf)

The moment of inertia of the

chuck (Jc) is then calculated

from Eq. (7).

Jc =0.37 × (22+42)

12 × 980

0.37 × 102 +

980

= 0.038 (kgfcmsec2)

23212-F0-00

3. Moment of inertia of workpiece

Moment of inertia of workpiece

10cm

4cm

R-axis

2cm

Ww =ρπD2h

= 0.0078π × 22 × 4

4 4

= 0.098 (kgf)

The moment of inertia of the

workpiece (Jw) is then calculated

from Eq. (5).

When the workpiece form

resembles that shown in figure, the weight of the

workpiece (Ww) is

Jw =0.097 × 22

+ 0.097 × 102

8 × 980 980

= 0.010 (kgfcmsec2)

23213-F0-00

4. Total weight The total weight (W) is calculated as follows: W = Ws + Wc + Ww = 0.84 (kgf)

5. Total moment of inertia The total moment of inertia (J) is then obtained as follows: J = Js + Jc + Jw = 0.062 (kgfcmsec2)

2

Installa

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2-17

6.4 Attaching the end effectorIt is necessary to prepare the user's end effector attaching part to the robot that has adequate strength and rigidity, as well as gripping force to prevent positioning errors.

w WARNING • BEFOREATTACHINGTHEENDEFFECTOR,BESURETOTURNOFFTHECONTROLLER. • WHENTHEENDEFFECTORISATTACHEDUSINGTHESLOTCLAMPING,ALWAYSOBSERvETHECONDITIONSLISTEDIN THE TABLE, "MAxIMUM LOAD APPLIED TO END EFFECTOR ATTACHMENT". IF THESE ARE IGNORED, THE END EFFECTOR MAY COME LOOSE AND FLY OFF DURING ROBOT OPERATION, RESULTING IN AN ACCIDENT OR INjURY. • INCASESWHEREOTHERATTACHMENTMETHODSAREUSED,BESURETHATTHEENDEFFECTORWILLNOTCOMEOFF EvENWHENTHELOADSLISTEDINTHETABLE,"MAXIMUMLOADAPPLIEDTOENDEFFECTORATTACHMENT"ARE APPLIED.

n NOTE When checking end effector operation, refer to the section "4.6.1 Trial Operation" in Chapter “Safety Instructions” of this manual.

The following shows the maximum load that can be applied to the end effector attachment of each robot model.

w WARNING • THEENDEFFECTORATTACHMENTMUSTHAvEADEQUATESTRENGTHTOWITHSTANDTHELOADSLISTEDINTHETABLE BELOW.IFTHESTRENGTHISINSUFFICIENT,THEATTACHMENTMAYBREAKDURINGROBOTOPERATIONAND FRAGMENTS FLY OFF, CAUSING ACCIDENTS OR INjURIES. • THEENDEFFECTORATTACHMENTMUSTHAvESUFFICIENTRIGIDITYTOTHELOADSLISTEDINTHETABLEBELOW.IF THISRIGIDITYISINADEQUATE,THEENDEFFECTORMAYvIBRATEDURINGROBOTOPERATION,CAUSINGADvERSE EFFECTSONTHEWORK.

Maximum load applied to end effector attachment

Robot ModelFXYmax FZmax FRmax MRmax Mmax

N kgf N kgf N kgf Nm kgfm Nm kgfm

YK400XR 256 27 75 8 63 7 2 0.2 1 0.1

Maximum load applied to end effector attachment

FRmax

End effector

Stay

FxYmax

Fzmax

MRmax

Mmax

23210-F6-00

2

Installa

tion

2-18

Next, the following shows the recommended end effector attaching method.

Attaching the end effector

Hole diameter

Bolt

Slot

Spline shaft

End effector or stay

23214-F0-00

Robot Model Bolts used Number of boltsTightening torque

Hole diameter (mm)Nm kgfcm

YK400XR M5ormore 2ormore 9 92 16 +0.0180

The following shows the details of the end effector attachment of each robot.

Details of end effector attachment

30

16 h7 -0.0180

Never loosen this bolt.

23209-FK-00

For details about the depth of the tapped hole and recommended bolt, see the Table below.

Depth of tapped holeIronmaterialbase Boltdiameter×1.5ormore

Aluminummaterialbase Boltdiameter×3.0ormore

Recommended boltJISB1176Hexsocketheadbolt,orequivalent

(Strengthclass:JISB105112.9,orequivalent)

2

Installa

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2-19

6.5 Gripping force of end effectorThe gripping force of the end effector must have a sufficient extra margin of strength versus the workpiece weight and reaction force applied to the workpiece during robot operation. The reaction force applied to the workpiece during operation can be calculated from the acceleration applied to the end effector attachment. The maximum acceleration on the end effector attachment of each robot model is listed in the table below. When the workpiece position is offset to the end effector attachment, the accelerations Amax and AXYmax become larger by an amount equal to the offset versus the arm length. When the R-axis rotates during operation, this acceleration ARmax must be taken into account.

w WARNING THEGRIPPINGFORCEOFTHEENDEFFECTORMUSTHAvEASUFFICIENTEXTRAMARGINOFSTRENGTHTOPREvENTTHEWORKPIECEFROMCOMINGLOOSEANDFLYINGOFFDURINGROBOTOPERATION.IFTHEGRIPPINGFORCEISTOOWEAK,THEWORKPIECEMAYCOMELOOSEANDFLYOFFCAUSINGACCIDENTSORINjURIES.

Maximum acceleration during robot operation

Amax(m/sec2) AXYmax(m/sec2) AZmax(m/sec2) ARmax(rad/sec2)

21 87 25 1000

Maximum acceleration on end effector attachment

ARmax

Azmax

Amax AXYmax

(centrifugal acceleration) (Tangential acceleration)

23213-F6-00

2

Installa

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2-20

7. Limiting the movement range with X-axis and Y-axis mechanical stoppers

w WARNING ALWAYSTURNOFFTHECONTROLLERBEFORECHANGINGTHEMOvEMENTRANGEWITHMECHANICALSTOPPERS.

c CAUTION When the mechanical stopper positions are changed, the soft limits must be set to a point inside the mechanical stopperpositions.(Referto"3.Settingthesoftlimits"inChapter3.)

If the working envelope during robot work is smaller than the maximum working envelope range or if the robotinterfereswithperipheralunits,themovementrangeislimited.(Whentherobotisshippedfromfactory, the movement range is set to the maximum level.) ThemovementrangecanbelimitedbyshiftingtheX-axisandY-axismechanicalstopperpositions.Followthesteps below to limit the movement range.

The following shows the mechanical stopper positions and movement range.

Mechanical stopper position and maximum movement position

150°

Y-axis standard stopper position

116°

Y-axis additional stopper

104°

X-axis additional stopper

132°

X-axis standard stopper position

23211-FK-00

As option parts are ordered, and then they are installed, the movement ranges of the X-axis and Y-axis can be narrowed.

n NOTE Note that the stopper position may slightly deviate due to the part machining accuracy and mounting position.

2

Installa

tion

2-21

After changing the mechanical stopper positions, set the soft limits to the values shown below.

Soft limits ■

Standard stopper Additional stopper

StopperpositioninX-axisplusorminusdirection 134° 106°

MaximummovementpositioninX-axisplusorminusdirection 132° 104°

StopperpositioninY-axisplusorminusdirection 154° 120°

MaximummovementpositioninY-axisplusorminusdirection 150° 116°

Soft limits after setting additional stopper ■

X-axis Soft limit (pulses) Working envelope

WorkingenvelopeinX-axisplusdirection 295822 104°

WorkingenvelopeinX-axisminusdirection -295822 -104°

Y-axis Soft limit (pulses) Working envelope

WorkingenvelopeinY-axisplusdirection 329955 116°

WorkingenvelopeinY-axisminusdirection -329955 -116°

7.1 Installing the X-axis/Y-axis additional mechanical stoppersFollow the steps below to install the X-axis/Y-axis additional mechanical stoppers.Usetheboltslistedbelowtoinstalloptionalmechanicalstoppers.

No. Part No. Q'ty Remarks

Additionalmechanicalstopperpartsineitherone

directionofX-axisplusorminusdirection(*1)1 91312-08016 1 Stopperbolt

Additionalmechanicalstopperpartsineitherone

directionofY-axisplusorminusdirection(*1)2 91312-08012 1 Stopperbolt

*1: Torestricttheworkingenvelopeintheplusandminusdirectionsatthesame,twostopperpartsareneeded.

The X-axis and Y-axis mechanical stoppers can be individually installed in the X-axis and Y-axis plus and minus directions. The following describes how to install the mechanical stopper using the stopper in the X-axis and Y-axis plus direction as an example. (The stopper in the minus direction can also be installed in the same manner.) Prepare a hex wrench set.

2

Installa

tion

2-22

1 Turn off the controller.

2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being adjusted, to keep others from touching the controller switch.

3 Enter the safety enclosure.

4 Secure the bolt. Installing to the standard stopperStep 4

Y-axis standard stopper

X-axis standard stopper

X-axis plus direction additional stopper

Y-axis plus direction additional stopper

Minus direction

Plus direction

23213-FK-00

5 Check that the movement range is limited.

6 Go out of the safety enclosure.

7 Turn on the controller.Check that no one is inside the safety enclosure, and then turn on the controller.

8 Set the X-axis soft limits in the plus direction.When the stopper is installed in the minus direction, set the soft limits in the minus direction.

c CAUTION WhetherornottheX-axisstopsatapositionbeforethe stopper limited by the soft limit must be checked from the outside of the safety enclosure.

9 Check that the X-axis stops firmly.Whether or not the X-axis stops at a position before the stopper limited by the maximum soft limit must be checked from the outside of the safety enclosure.

n NOTE The X-axis may not stop at a position before the stopper due to the stopper part accuracy or position. If this happens, decrease the value while referring to the Table "■ Soft limits" described previously.

2

Installa

tion

2-23

7.2 Robot overrun during impacts with X-axis or Y-axis mechanical stopperThe robot may overrun from the mechanical stopper position for some reason, such as deformation of the mechanical stopper during impacts with mechanical stopper. Be aware that the end effector may interfere with the robot main body and peripheral unit or the robot main body may interfere with the peripheral unit due to overrun during impacts with mechanical stopper.Maximum overrun amounts are listed below (for normal operation, maximum payload, maximum speed).

X-axis Y-axis

2° 1°

Note:Here,°(deg.)istheoverrunangleattheX-axisandY-axisjoints.

c CAUTION • IftheX-axisorY-axismechanicalstopperisdeformedordamagedduetoanimpactonthestopper,please contact your distributor. Continued use of the deformed or damaged stopper is very dangerous, and so it must be replaced. • WhentherobotstrikestheX-axisorY-axismechanicalstopperoranotherobject,orwhentheR-axiscollides with an object, the speed reduction gears are locked while being meshed if the collision impact is large. If this happens, please contact your distributor.

2

Installa

tion

2-24

8. Working envelopeTheworkingenvelopeofeachrobotisshownin“1.2Externalviewanddimensions”ofChapter8.

X and Y axes ■

Do not use an area other than the working envelope for the work.

The working envelope described in this manual shows the robot working envelope in the no-load state based on the robot

front.

Working envelope

150°13

2°

132°

74° 74°

90 90

R115

150°

23215-FK-00

2

Installa

tion

2-25

Z-axis ■

Do not attempt work outside the working envelope. In particular, do not attempt work in the area between the working

envelope and mechanical stopper position. Mechanical stoppers are installed at both the upper and lower ends of the

movement range.

w WARNING THE ROBOT CABLE, USER WIRING OR TUBING MAY BE DAMAGED IF THE ROBOT LOAD INTERFERES WITH THEM RESULTING IN HAzARDOUS ROBOT MALFUNCTIONS. DO NOT OPERATE AT POINTS WHERE THE LOAD MAY INTERFERE WITH THE ROBOT CABLE, USER WIRING OR TUBING.

Z-axis mechanical stopper position

0

493

150

(7)

(10)

0

124.7±2

Z-axis lower end mechanical stopper position

Z-axis upper end mechanical stopper positionZ-axis rises 10mm during return-to-origin.

23216-FK-00

2

Installa

tion

2-26

R-axis ■

The R-axis has no mechanical stoppers.

c CAUTION SincetheR-axishasnomechanicalstoppers,makecertainthattheendeffectorwiringandtubingdonotbecome entangled during operation.

Robot overrun during impacts with mechanical stopper ■

The robot may overrun from the mechanical stopper position for some reason, such as deformation of the mechanical stopper during impacts with mechanical stopper. Be aware that the end effector may interfere with the robot main body and peripheral unit or the robot main body may interfere with the peripheral unit due to overrun during impacts with mechanical stopper. Maximum overrun amounts are listed below (for normal operation, maximum payload, maximum speed).

X-axis Y-axisZ-axis

Upper end Lower end

4° 1° 2mm 3mm

Note:Here,°(deg.)istheoverrunangleattheX-axisandY-axisjoints.

c CAUTION • If an impact occurs with the mechanical stopper and the stopper is deformed or broken, contact your distributor. If the deformed or broken mechanical stopper is used continuously, this is hazardous. So, the defective mechanical stopper needs to be replaced. • AftertherobotstrikestheZ-axismechanicalstopper,thestopperpositionmayshift,andsocheckthestopper position. If shifted, move the stopper to the correct position and refasten it securely by following the assembly procedure.

2

Installa

tion

2-27

9. Stopping time and stopping distance at emergency stopWhentheemergencystopbuttonispressedduringrobotoperationorthepowersupplytothecontrolleristurned off, the stopping time and stopping distance or angle of the main 3 axes change depending on the operation speed as shown below. The following figures show typical time and distance or angle needed for each axis to come to a stop after a stop signal is initiated when the robot arms are fully extended while 3 typesoftipmass(33%,66%and100%ofmaximumpayload)areloaded.

10 30 50 70 90

XY-axis stopping time

(Emergency stop is activated while the XY-axis operates in the plus direction.)

1kg XY-axis2kg XY-axis

3kg XY-axis

0 20 40 60 80 1000.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

XY-

axis

sto

ppin

g tim

e (s

ec.)

Operation speed (%)

23220-FK-00

10 30 50 70 90

XY-axis stopping angle

(Emergency stop is activated while the XY-axis operates in the plus direction.)

0

20

40

60

80

100

120

0 20 40 60 80 100

1kg X-axis

2kg X-axis2kg Y-axis

3kg Y-axis

1kg Y-axis

3kg X-axis

XY-

axis

sto

ppin

g ro

tatio

n an

gle

(°)

Operation speed (%)

23221-FK-00

2

Installa

tion

2-28

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

0 10 20 30 40 50 60 70 80 90 100

Z-axis stopping time

(Emergency stop is activated while the Z-axis operates in the plus direction.)

Operation speed (%)

Z-a

xis

stop

ping

tim

e (s

ec.)

1kg Z-axis2kg Z-axis

3kg Z-axis

23222-FK-01

0

2

4

6

8

10

12

14

16

18

20

0 10 20 30 40 50 60 70 80 90 100

Z-axis stopping distance

(Emergency stop is activated while the Z-axis operates in the plus direction.)

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

1kg Z-axis2kg Z-axis

3kg Z-axis

23223-FK-01

2

Installa

tion

2-29

R-axis stopping time

(Emergency stop is activated while the R-axis operates in the plus direction.)

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0 10 20 30 40 50 60 70 80 90 100

1kg 0.0166kgm2 R-axis


3kg 0.05kgm2 R-axis

Operation speed (%)

R-a

xis

stop

ping

tim

e (s

ec.)

23224-FK-00

R-arm stopping angle

(Emergency stop is activated while the R-axis operates in the plus direction.)



3kg 0.05kgm2 R-axis

0

50

100

150

200

250

300

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

R-a

xis

stop

ping

rot

atio

n an

gle

(°)

23225-FK-00

2

Installa

tion

2-30

10. Installing the user wiring and tubing newlyUsetheuserwiringandtubinginthemachineharnessasmuchaspossiblebyconsideringthedurabilityofthe machine harness. If the user wiring and tubing incorporated into the machine are insufficient, add new user wiring and tubing using tie bands. The following shows the outside diameters and quantities that can be added by considering the durability of the machine harness.

Installing the user wiring and tubing newly

Clamp the user wiring and tubing with minimal tie band quantity so that the additional signal lines and tubes do not deviate.If the clamp is too strong, the machine harness may have faulty wiring.

φ D

φ d

Machine harness

Signal line

Air tube

Tie band

23223-F6-00

Robot modelSignal line outside diameter

φ D (mm) × quantity

Tube outside diameter

φ d (mm) × quantity

YK400XR φ6×1pc. φ4×3pcs.

2

Installa

tion

2-31

11. Passing the wiring and tubing in the user wiring/tubing through spline type

IntheYK-XRserieswiththeuserwiring/tubingthroughsplinetype,theuserwiringandtubingcanbepassedthrough the spline. The following Fig. shows a reference example. The wiring at the top end of the spline can be detached or attached easily when replacing the spline, R-axis speedreductionunit,orR-axismotor.Useanappropriateconnectorthatpassesthroughthesplinewithaninside diameter of φ11.

Example of how to pass the wiring and tubing

Clamp using nylon clamp, etc.

Stay

Extension shaft

Clamp using nylon clamp, etc.

Stay

Junkosha’s mechatro flat tubeMF1-06-working length (cm)-10 × 0.10.1sq wire materials (10 pcs.) are included in the air tube (outside diameter �φ6 × �φ4 air tube)

Outside diameter �φ4 × inside diameter �φ2.5Air tube

Clamp on the hand side.

User wiring

User tubing

φ11

Z-axis moves up Z-axis moves down

M3 bolt

23224-F6-00

2

Installa

tion

2-32

12. Detaching or attaching the coversTo detach or attach the covers, remove the bolts and screws shown in the Fig. below.

w WARNING • WHENTHECOvERSHAvEBEENREMOvEDFORTHEMAINTENANCEWORK,BESURETORETURNTHECOvERSTO THEIRORIGINALPOSITIONSUSINGTHESCREWSANDBOLTSTHATHAvESECUREDTHEM. • IFANYSCREWORBOLTISLOST,BESURETOSECURETHECOvERSWITHTHESPECIFIEDNUMBEROFSPECIFIEDSCREWS AND BOLTS WHILE REFERRING TO THE FIG. BELOW. • IFTHECOvERSARENOTSECUREDFIRMLY,NOISEMAYOCCUR,THECOvERMAYDROPANDFLYOUT,YOURHAND MAYBEENTANGLEDINTHEDRIvEUNITDURINGTEACHING,ORYOURHANDMAYBEINCONTACTTHEHOTDRIvE UNIT,CAUSINGBURN.TOPREvENTSUCHTROUBLES,STRICTLYOBSERvETHISCAUTION.

YK400XR

Base rear cover mounting boltHex socket head bolt M4×8, 4 pcs.(YAMAHA’s part No.: 91312-04008)

Y-axis arm cover(YAMAHA’s part No.: KDS-M1314-000)

Harness cover(YAMAHA’s part No.: KDS-M1312-000)

Harness cover mounting boltHex socket head bolt M4×10, 4 pcs.(YAMAHA’s part No.: 91312-04010)

Y-axis arm cover mounting screwBinding head screw M3×20, 6 pcs.(YAMAHA’s part No.: 91312-03020)

Base rear cover(YAMAHA’s part No.: KDS-M1310-000)

23217-FK-00

Chapter 3 Robot settings

Contents

1. Overview 3-1

2. Adjusting the origin 3-2

2.1 Return-to-origin method 3-3




2.2 Machine reference 3-5

2.3 Return-to-origin procedures 3-6



2.4 Adjusting the machine reference value 3-9


2.4.2 Mark method 3-132.4.2.1 Absolute reset in servo on state (re-reset) 3-14

2.4.2.2 Absolute reset in servo off state (re-reset) 3-16

2.4.2.3 Absolute reset in servo on state (new reset) 3-19

2.4.2.4 Absolute reset in servo off state (new reset) 3-21


3. Setting the soft limits 3-27

3.1 SettingtheX-axisandY-axissoftlimits 3-27

3.2 SettingtheZ-axissoftlimits 3-28

3.3 SettingtheR-axissoftlimits 3-28

3.4 RelationbetweentheX,Y,andR-axismovementangle, theZ-axismovementdistanceandthenumberofpulses 3-28

4. Setting the standard coordinates 3-29

4.1 Standard coordinate setting using a standard coordinate setup jig 3-30

5. Af fixingthestickersfororiginpositions, movementdirections,andaxisnames 3-32

3

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3-1

1. OverviewVarioussettingshavebeencompletelymadeatthefactoryorbyyourdistributorbeforeshipment,includingthe origin position setting. If the operating conditions are changed and the robot needs to be set again, then follow the procedures described in this chapter.

The following describes the safety precautions to be observed when making various settings.

c CAUTION • Readandunderstandthecontentsofthischaptercompletelybeforeattemptingtosettherobot. • Placeaconspicuoussignindicatingtherobotisbeingadjusted,topreventothersfromtouchingthecontroller switch,programmingbox(PBX)oroperationpanel. • Ifasafetyenclosurehasnotyetbeenprovidedrightafterinstallationoftherobot,ropeofforchainoffthe movement range around the manipulator in place of a safety enclosure, and observe the following points. 1. Use stable posts which will not fall over easily. 2. The rope or chain should be easily visible by everyone around the robot. 3. Place a conspicuous sign prohibiting the operator or other personnel from entering the movement range of the manipulator. • Tochecktheoperationafterthesettingshavebeenmade,refertothesection"4.6.1TrialOperation"inChapter “Safety Instructions” of this manual.

3

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3-2

2. Adjusting the originTheYK-XRseriesrobotsuseanabsolutetypepositiondetector.Theoriginposition(zeropulsepoint)canbedeterminedbyreturn-to-origin.Oncereturn-to-originisperformed,youdonothavetorepeatreturn-to-originwhen turning the power on next time. However, return-to-origin is required if any of the following cases occur. The robot is shipped from the factory in condition "3." (below), so please perform return-to-origin after installing the robot. For more details on return-to-origin, refer to "Return-to-origin" in the "YAMAHA Robot ControllerUser'sManual".

1. Absolute-related error occurred on the axis.

2. Power drop was detected in the absolute battery for the driver installed inside the robot controller.

3. Cable connecting the robot unit to the controller was disconnected. (This is the status when shipped from the factory.)

4. Robot generation was performed.

5. Parameters were initialized.

6. Axis parameters "Origin shift", "Return-to-origin method", "Return-to-origin direction" or "Motor axis polarity" were changed.

7. Motor was replaced. (Motor wiring connector was removed.)

8. Data in the ALL data file (extension: ALL) or parameter file (extension: PRM) was written into the controller by way of the Online command.

The following sections explain how to perform return-to-origin.

c CAUTION • Ifanyoftheabovecasesoccurafterinstallingtherobot,return-to-originmustbeperformedagain.Toperform return-to-origin, move the robot arms back to their origin positions where the robot does not interfere with peripheral equipment after the setup is complete. • Afterperformingreturn-to-origin,movetherobottoaknownpointtocheckwhethertheoriginpositionis correctly set. When doing this check, move the robot at the slowest possible speed. • Thestandardcoordinateandpointdatamustberesetwhentheoriginpositionischanged. • Makepointdatasettingafterchangingtheoriginposition.Afterchangingtheoriginposition,donotusethe previous point data.

3

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2.1 Return-to-origin methodTwo kinds of return-to-origin methods, stroke end method and mark method are available for the YK-XR series as standard methods. The sensor method is optional.

2.1.1 Stroke end methodIn the stroke end method, return-to-origin is performed at a position slightly backed off from the stroke end, after the axis whose return-to-origin is performed contacts the mechanical stopper and stroke end is detected.

w WARNING SERIOUSINjURYMIGHTOCCURFROMPHYSICALCONTACTWITHTHEROBOTDURINGOPERATION.NEvERENTERWITHINTHEROBOTMOvEMENTRANGEDURINGRETURN-TO-ORIGIN.

c CAUTION • Beforestartingreturn-to-originoperation,movetheX-axistoapositionontheplussidefromtheoriginposition (SeeFig.Below),andtheY-axistoapositionontheminusside,sothattherobotispositionedinaright-handed systemasshowninFig.below.Whenthereturn-to-originoperationstarts,theX-axiswillmovetotheminusside andtheY-axiswillmovetotheplusside.Afterpushingagainstthemechanicalstopper,theaxeswillreturn slightly, and the return-to-origin will be completed. • Whenperformingthereturn-to-originoftheZ-axisorR-axis,thereturn-to-originoperationsoftheZ-axisand R-axisareautomatically performed continuously. So, pay special attention to the interference between the tip tool and robot or peripheral unit.

Default origin position

129°±3°

147°±3°147°±3°

Plus side

Plus side

Minus sideMinus side

23001-FK-00

c CAUTION TheXandY-axeswillmovetothepositionsshowninFig.belowduringreturn-to-origin,somakesurethatthetoolontheend,therobotandtheperipheraldevicesdonotinterfere.Themaximumtolerableloadradius(whenloadiscylindricalobject)isshowninFig.below.Ifreturn-to-originisperformedwithaloadlargerthanthisradiusinstalledontheR-axis,thebaseandloadcouldinterfere.

X and Y-axis maximum movement position during detecting origin position by mechanical stroke end

Maximum tolerable load radius

*1*1

最大許容負荷半径※1R24

106°

154°

Y-axis additional stopperX-axis additional stopper

R24

134°

154°

134°

R126

120°

When the additional stopper is installed and the return-to-origin in the stroke end method is performed, it is necessary to change the origin shift amount of the axis, on which the additional stopper is installed.

*1 Load is a cylindrical object.

Maximum tolerable load radius*1Maximum tolerable load radius*1

最大許容負荷半径※1Maximum tolerable load radius*1Maximum tolerable load radius*1

R126

Maximum tolerable load radius

23314-FK-00

3

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3-4

2.1.2 Mark methodIn the mark method, the robot is moved to a position beforehand where the return-to-origin is performed and this position is determined to the return-to-origin position.There are two kinds of methods to move the robot to a position where the return-to-origin is performed as described below. (See also "■ Absolute reset flowchart" in "2.4.2 Mark method".)

Move the robot using the step operation in the servo on state.1.

When the mark (sticker) that shows the origin position is seen from a position beyond the robot movement range, select

this step.

The origin position reset by means of the mark method is called “absolute reset”.

Move the robot by hand in the servo off state.2.

When the mark (sticker) that shows the origin position is not seen from a position beyond the robot movement range,

select this step.

c CAUTION Theabsoluteresetbymeansofthemarkmethodcanbeexecutedusingtheprogrammingbox(PBX)oronlinecommand.However,notethattheabsoluteresetcannotbeexecutedusingthededicatedinput.

c CAUTION When performing the absolute reset again at the previous absolute reset position, the deviation between the originpositionmarksneedstobeputinacertainrange(repeatabilityallowablevalue) (Seetheillustrationshowingthepositionalrelationshipbetweenoriginpositionstickersstatedin"2.4.2Markmethod"ofthisChapter.) Iftheabsoluteresetisperformedatapositionexceedingtherepeatabilityallowablevalueoratapositiondifferent from the previous absolute reset position, the position deviation may occur. Use the origin position stickers supplied with the product so that the origin position can be reproduced correctly within the allowable value. Insection"2.4.2.2Absoluteresetinservooffstate(re-reset)"ofthischapter,the"originpositionrepeatabilityallowablevalue"indicatestheoriginpositionrepeatabilityallowablevalueforeachaxisoftherobot.

2.1.3 Sensor method (X-axis, Y-axis)In the sensor method, the target axis is automatically operated for the return-to-origin, and the return-to-origin is performed at the position where the proximity sensor provided on the target axis detects the detection area (dog). The return-to-origin in the sensor method can be executed with the programming box (PBX), online command, and dedicated input.


c CAUTION Theorigincannotbedetectedinanyaxiswhichisnotpositionedontheplussidefromtheorigin(seetheFig.statedinstep5of"2.3.2Sensormethod(X-axis,Y-axis)"inthisChapter)beforestartingthereturn-to-origin

operation. In this case, press the keytointerruptthereturn-to-originoperation,movethetargetaxistothe

plus side of the origin, and reperform the origin return operation. If the return-to-origin operation is not interrupted, the robot will continue the operation and may collide with the mechanical stopper or a peripheral device.

3

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3-5

2.2 Machine referenceThe position detector of the YK-XR series uses a resolver that has five positions where the return-to-origin can be performed per motor revolution.The machine reference means the position relationship of the position where the robot detects the origin signal to the position where the reset can be performed soon after detection (see the Fig. below). The machine reference is expressed with the ratio of the minimum interval (A) between the positions where the return-to-origin can be performed to the interval (B) between the positions where the return-to-origin can be performed soon after the origin signal detection.The machine reference value is displayed on the optional PBX screen (unit: %).

Machine reference value = B/A × 100(%)

c CAUTION The machine reference must be adjusted within a specified range to keep the repeatability precision of the return-to-originposition(Themachinereferenceisfactory-adjustedpriortoshipping).Iftheoriginpositionischanged, the machine reference must be readjusted. For information on how to adjust the machine reference, refer to "2. Adjusting the origin” in this Chapter. When the temperature of the robot joint sections is high immediately after the robot has been operated, the machine referencevaluemightbeoutsidethespecifiedrange(25to75%).Whencheckingoradjustingthemachinereference value, always make sure that the temperature of the robot joint sections has returned to room temperature. Recommendedmachinereferencevalue:25to75%

Machine referenceOrigin signal detection

Origin signal

Resolver

Positions where return-to-origin can be performed

One motor revolution

BA

ON

OFF

23301-F0-00

Machine reference display on PBX screen

24301-F0-00

3

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2.3 Return-to-origin procedures

2.3.1 Stroke end method

w WARNING SERIOUSINjURYMAYOCCURFROMPHYSICALCONTACTWITHTHEROBOTDURINGOPERATION.NEvERENTERWITHINTHEROBOTMOvEMENTRANGEDURINGRETURN-TO-ORIGIN.

The Z-axis and R-axis perform the return-to-origin in the stroke end method at the same time.

The operation procedure using the PBX is described below.

n NOTE

• When pressing the key on the execution confirmation screen, the execution of the return-to-origin is canceled.

• Fordetailsabouthowtooperatetherobotcontroller,seethe"YAMAHARobotControllerUser'sManual".


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being adjusted, to keep others from operating the controller or operation panel.

3 Display the "ORIGIN RTN (TRQ/SENS)" screen on the PBX (operation → return-to-origin).

24304-F0-00

Return-to-origin mode screenStep 3-4

4 Select an axis whose return-to-origin is performed.Use the cursor keys ( / ) to select an axis number whose return-to-origin is performed.

n NOTE As the return-to-origin operations of the Z-axis and R-axis are performed simultaneously, you can select either axis number 3 or 4.

The execution confirmation screen will pop up.

Return-to-origin Step 5

5 Perform the return-to-origin.The return-to-origin execution confirmation screen pops up. Check that there are no obstacles within the

movement range, and then press . To

cancel the return-to-origin, press . After

the return-to-origin has been completed,

press to return to the "ORIGIN RTN (TRQ/SENS)" screen.

24304-F0-00

Machine reference valueStep 6

6 Check the status and machine reference value.“Status” and “Ref.” (machine reference) are displayed on the "ORIGIN RTN (TRQ/SENS)" screen. Check that the status is "OK" and that the machine reference value is within the return-to-origin tolerable range (25 to 75%).

24305-F0-00

3

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Machine reference value checking procedure ■

1. Use the cursor keys ( / ) on the initial screen to select Operation and press to display the operation menu.

2. Select Origin Return and press to display the “ORIGIN RTN (TRQ/SENS)" screen. The return-to- origin completion status and machine reference are then displayed.

If the machine reference value is beyond the return-to-origin tolerable range, the next return-to-origin may not be performed correctly. In this case, make the adjustment while referring to "2. Adjusting the origin" in this Chapter.

2.3.2 Sensor method (X-axis, Y-axis)



n NOTE

• When pressing the key on the execution confirmation screen, the execution of the return-to-origin is canceled.

• Fordetailsabouthowtooperatetherobotcontroller,seethe"YAMAHARobotControllerUser'sManual".




Return-to-origin mode screenStep 3-4

24302-F0-00

4 Select an axis whose return-to-origin is performed.Use the cursor keys ( / ) to select an axis number whose return-to-origin is performed. The execution confirmation screen will pop up.

c CAUTION

Whenabsoluteresetforallaxesisperformed,thestrokeendmethodZ-axiswillrisefirst(defaultsetting),sotakecarethatyourhanddoes not get pinched.

5 Check the axis position.

Return-to-origin possible rangeStep 5

Origin position at shipment

Return-to-origin cannot be performed from this area.

Minus direction

Plus direction

Return-to-origin direction

Check that the axis whose return-to-origin is performed is located at a position on the plus side from the origin. (See also the figure on the right.) If not located on the plus side, move the target axis to the plus side using the JOG operation beforehand.

23306-FK-00

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3-8

6 Perform the return-to-origin.The return-to-origin execution confirmation screen pops up. Check that there are no obstacles within the

movement range, and then press . To

cancel the return-to-origin, press . After

the return-to-origin has been completed,

press to return to the "ORIGIN RTN (TRQ/

SENS)" screen.

24303-F0-00

Return-to-origin Step 6

7 Check the machine reference value.“Status” and “Ref.” (machine reference) are displayed on the "ORIGIN RTN (TRQ/SENS)" screen. Check that the status is "OK" and that the machine reference value is within the return-to-origin tolerable range (25 to 75%).

24303-F0-00

Machine reference value checking procedure ■

1. Use the cursor keys ( / ) on the initial screen to select Operation and press to display the

operation menu.

2. Select Origin Return and press to display the “ORIGIN RTN (TRQ/SENS)" screen. The return-to-

origin completion status and machine reference are then displayed.

If the machine reference value is beyond the return-to-origin tolerable range, the next return-to-origin may not be performed correctly. In this case, make the adjustment while referring to "2. Adjusting the origin" in this Chapter.

3

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3-9

2.4 Adjusting the machine reference valueThe X- and Y-axis origin positions of the YK-XR series are fixed and cannot be changed. Additionally, the machine reference value was correctly adjusted at shipment. The readjustment is not needed during normal operation. However, if the machine reference value exceeds the return-to-origin tolerance range for some reason, follow the steps below to readjust the machine reference value.

w WARNING BEFORESTARTINGTHEWORK,THOROUGHLYREAD"12.DETACHINGORATTACHINGTHECOvERS"INCHAPTER2.

c CAUTION If any machine reference is adjusted, the origin position may change. Before the adjustment, mark off the reference mark at the current origin position on the main body of the robot. After the machine reference is adjusted, be sure to check that the origin position has not deviated. If the origin position changes after the machine reference has been adjusted, then the standard coordinate and point data must be reset.

2.4.1 Stroke end methodThe return-to-origin of the YK-XR series uses the stroke end method. The machine reference value was adjusted correctly at shipment. So, the readjustment is not needed during normal operation. However, if the machine reference value exceeds the return-to-origin tolerance range (25 to 75%) for some reason, follow the steps below to readjust the machine reference value.

c CAUTION The origin position may change due to machine reference adjustment. If it occurs, you must set point data again.



3 Perform the return-to-origin.

n NOTE For details about how to perform the return-to-origin, refer to "2.3 Return-to-origin procedures" in this Chapter.

4 Record the machine reference value.

5 Turn off the controller.The Z-axis motor brake is now working at the origin position.


3

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3-10

Changing the X-axis reference value ■

7 Loosen the bolts that secure the speed reduction gear.At this time, it is enough to loosen the bolts. Do not pull out the bolts. A rattle is produced. Utilize this rattle to turn the arm. To increase the reference value, turn the X-axis arm clockwise when viewed from the top of the robot. Conversely, to decrease the reference value, turn the X-axis arm counterclockwise when viewed from the top of the robot.

8 Secure the speed reduction gear temporarily.Tighten the bolts while applying an appropriate torque so that the speed reduction gear and arm do not deviate.

9 Remove the temporarily secured bolts, and then secure the speed reduction gear temporarily with new bolts.Replace the bolts one-by-one and take great care so that the speed reduction gear and arm do not deviate. Bolt M3 x 35, (YAMAHA’s part No.: 91312-03035) 12 pcs.

0 Secure the speed reduction gear.Secure the speed reduction gear while referring to “2.1 Replacing the X-axis harmonic drive” in Chapter 5 of the Maintenance Manual.

Changing the Y-axis reference value ■

7 Loosen the bolts that secure the speed reduction gear.At this time, it is enough to loosen the bolts. Do not pull out the bolts. A rattle is produced. Utilize this rattle to turn the arm. To increase the reference value, turn the Y-axis arm counterclockwise when viewed from the top of the robot. Conversely, to decrease the reference value, turn the Y-axis arm clockwise when viewed from the top of the robot.

8 Secure the speed reduction gear temporarily.Tighten the bolts while applying an appropriate torque so that the speed reduction gear and arm do not deviate.

9 Remove the temporarily secured bolts, and then secure the speed reduction gear temporarily with new bolts.Replace the bolts one-by-one and take great care so that the speed reduction gear and arm do not deviate. Bolt M3 x 30, (YAMAHA’s part No.: 91312-03030) 12 pcs.

0 Secure the speed reduction gear.Secure the speed reduction gear while referring to “2.2 Replacing the Y-axis harmonic drive” in Chapter 5 of the Maintenance Manual.

Step 10 Changing the reference value

Turning the speed reduction gear clockwise will increase the reference value.

Turning the speed reduction gear counterclockwise will decrease the reference value.

Reference value decreases.Reference value increases.

23309-FK-00

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Changing the Z-axis and R-axis reference ■

values

9 Remove the cover.Remove the cover while referring to "12. Detaching or attaching the covers" in Chapter 2.

Cover

Z-axis motor

R-axis motor

Step 9 Removing the cover

23301-FK-00

w WARNING IF THE PULLEY COMES OFF FROM THE BELT, THE z-AxIS MAY DROP. BE SURE TO PROP THE z-AxIS WITH A SUPPORT STAND. BE CAREFUL NOT TO DROP THE z-AxIS AND ENTANGLE THE BELT DURING ADjUSTMENT.

0 Prop the spline or end effector with a support stand to prevent from dropping.

q Loosen the bolts that secure the motor installation plate.

Step 11 Removing the plate

To adjust the R-axis reference value, loosen the bolts at 3 locations.

Z-axis motor

R-axis motor

R-axis fixing plate

Z-axis fixing plateTo adjust the Z-axis reference value, loosen the bolts at 3 locations.

23302-FK-00

w Shift the engagement between the motor pulley and belt tooth.Shifting the belt engagement one tooth will change the machine reference value approximately 25%. When shifting the pulley clockwise with the belt teeth left as they are, the reference value will increase. Conversely, when shifting the pulley counterclockwise, the reference value will decrease. Shift the engagement between the pulley and belt so that the Z-axis machine reference value enters a range of 25 to 75% when compared to that confirmed in Step 4.

e Tighten the plate mounting bolts.At this time, tighten the bolts while applying an appropriate tension to the belt. The appropriate tension can be checked as the vibration frequency is measured when the belt is stretched. (Appropriate frequency: 50 to 53 Hz)

• Z-axis belt tension (Appropriate frequency): 259 to 333Hz

•R-axis belt tension (Appropriate frequency): 308 to 398Hz

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3-12

r Go out of the safety enclosure.

t Turn on the controller.Check that no one is inside the safety enclosure, and then turn on the controller.

y Perform the return-to-origin of the Z-axis.

n NOTE For details about how to perform the return-to-origin, refer to "2.3 Return-to-origin procedures" in this Chapter.

u Check the Z-axis machine reference value.After the return-to-origin has been completed, check that the machine reference value is within the return-to-origin tolerance range (25 to 75%). If the adjustment machine reference value is outside the tolerance range (25 to 75%), then repeat the procedure from step 9 again to readjust it.

i Turn off the controller.

o Enter the safety enclosure.

p Reattach the cover.

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2.4.2 Mark methodThe absolute reset in the mark method is classified into four groups according to the conditions as shown in the flowchart below. Since each operating procedure varies, refer to relevant portion.

Absolute reset flowchart ■

(*)

The origin is performed at the same position as the previous absolute reset position.

The origin is performed at a position different from the previous absolute reset position.

Theoriginpositionmarkcanbeseenfromapositionbeyondtherobotmovementrange.

Theoriginpositionmarkcannotbeseenfromapositionbeyondtherobotmovementrange.

Therobotcanbeguidedtotheneworiginpositionbytheservodrivefromapositionbeyondtherobotmovementrange.

Therobotcannotbeguidedtotheneworiginpositionbytheservodrivefromapositionbeyondtherobotmovementrange.

To“2.4.2.1absoluteresetinservoonstate(re-reset)”

To“2.4.2.2absoluteresetinservooffstate(re-reset)”

To“2.4.2.3absoluteresetinservoonstate(newreset)”

To“2.4.2.4absoluteresetinservooffstate(newreset)”

(*) To perform the absolute reset for the first time, refer to this portion.

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2.4.2.1 Absolute reset in servo on state (re-reset)

w WARNING SERIOUSINjURYMIGHTOCCURFROMPHYSICALCONTACTWITHTHEROBOTDURINGOPERATION.NEvERENTERWITHINTHEROBOTMOvEMENTRANGEDURINGABSOLUTERESET.


n NOTE

• When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled.

•Fordetailsabouthowtooperatetherobotcontroller,seethe"YAMAHA Robot Controller User's Manual".



3 Move to a position where the origin position sticker can be seen.Move to a position where the origin position sticker can be seen while holding the PBX. At this time, never enter the robot movement range.


5 Display the "ORIGIN RTN (MARK)" screen.Press (MARK) on the "ORIGIN RTN (TRQ/SENS)" screen.

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6 Select an axis whose absolute reset is performed.Use the cursor keys ( / ) to select an axis number whose absolute reset is performed, and then

press . The execution confirmation screen will pop up.

7 Perform the step movement.Press the jog key to perform the step movement of the robot until the origin position marks are matched with each other.

c CAUTION Multipleabsoluteresettablepositionsexistdiscretely. When moving the robot by pressing the jog key, all robot stop positions become absolute resettable positions. Beforeperformingtheabsolutereset,pressthejogkeyagaintomovetheaxisleftorrighttocheckthattheoriginposition marks are matched with each other correctly. (Seethefigurebelow.) When performing the absolute reset again at the previous absolute reset position, the deviation between the originpositionmarksneedstobeputinacertainrange(repeatabilityallowablevalue).(Seethefigurebelow.) Iftheabsoluteresetisperformedatapositionexceedingtherepeatabilityallowablevalueoratapositiondifferent from the previous absolute reset position, the position deviation may occur. When performing the absolute reset, take appropriate measures so that the deviation between the origin position marks is put in the repeatability allowable value range correctly. Theoriginpositionrepeatabilityallowablevalueofeachaxisisshownbelow.

Origin position repeatability allowable value.

axis Origin position repeatability allowable value(° )

X ±0.72

Y ±0.72

R ±3.00

Positional relationship between origin position stickers

Repeatability allowable value

Origin position sticker




NG




NG

OK

OKArm side ........................

End effector side ........................

23306-FH-00

8 Perform the absolute reset.Press on the "ORIGIN RTN (MARK)" pop-up screen to complete the absolute reset. After the absolute reset has been completed, the axis moves to the “0” pulse position.

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2.4.2.2 Absolute reset in servo off state (re-reset)

w WARNING BESURETOPRESSTHEEMERGENCYSTOPBUTTONANDMOvETHEROBOTINTHESTATEWHERETHESERvOONCANNOT BE OPERATED FROM THE OUTSIDE.


n NOTE


• Fordetailsabouthowtooperatethe robot controller, see the "YAMAHA Robot Controller User's Manual".



3 Enter the safety enclosure.Enter the safety enclosure while holding the PBX.



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6 Move the arm to the position where the origin position marks are matched with each other.Press the emergency stop button on the PBX to put the robot in the emergency stop state.


Manually move the robot to a position where the origin position marks are aligned with each other.

c CAUTION To perform the absolute reset again at the same position as the previous absolute reset position, it is necessary to putthedeviationbetweentheoriginpositionmarkswithinacertainrange(repeatabilityallowablevalue).(SeetheFig.below.) Iftheabsoluteresetisperformedatapositionexceedingtherepeatabilityallowablevalueorapositiondifferentfrom the previous absolute reset position, the positional deviation may occur. When performing the absolute reset, take appropriate measures so that the deviation between the origin position marks is put in the repeatability allowable value range correctly. Theoriginpositionrepeatabilityallowablevalueofeachaxisisshownbelow.



X ±0.72

Y ±0.72

R ±3.00







NG




NG

OK

OKArm side ........................


23307-FH-00

7 Check the machine reference value.When the robot is moved to a position where the absolute reset is performed, check that the value of the selected axis is in the range between 26 and 74 on the PBX screen. (Normally, this value is 50.)

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press .

The execution confirmation screen will pop up.

c CAUTION • Therearemultiplediscretepositionswheretheabsoluteresetcanbeperformed.Movetherobotstep-by-step while referring to the PBx screen. When the robot comes to a position near the return-to-origin position where

thevalueoftheselectedaxisonthePBXscreenenterstherangebetween26and74,pressthe key.

• Ifthevalueoftheselectedaxisisnotintherangebetween26and74,themessage,“Positionresetmalposition”, appearsinthenextoperationandtheabsoluteresetcannotbecompleted.

9 Perform the absolute reset.Press on the "ORIGIN RTN (MARK)" pop-up screen to complete the absolute reset.

0 Go out of the safety enclosure.

q Release the emergency stop of the controller.After checking that no one is inside the safety enclosure, release the emergency stop of the controller.

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2.4.2.3 Absolute reset in servo on state (new reset)

w WARNING SERIOUSINjURYMIGHTOCCURFROMPHYSICALCONTACTWITHTHEROBOTDURINGOPERATION.NEvERENTERWITHINTHEROBOTMOvEMENTRANGEDURINGABSOLUTERESET.


n NOTE


• Fordetailsabouthowtooperate the robot controller, see the "YAMAHA Robot Controller User's Manual".



3 Move to a position where the joint can be seen.Move the robot to an arm position where the absolute reset is performed newly, and then move to a position where the joint can be seen while holding the PBX. At this time, never enter the robot movement range.




press .

7 Perform the step movement.Press the jog key to perform the step movement of the robot until the absolute reset position are matched with each other.

c CAUTION There are multiple discrete positions where the absolute reset can be performed. When moving the robot by pressing the jog key, all robot stop positions become absolute resettable positions.

8 Perform the absolute reset.Press on the "ORIGIN RTN (MARK)" pop-up screen to complete the absolute reset.

After the absolute reset has been completed, the axis moves to the “0” pulse position.

9 Move to the all-axis 0 pulse position.When the absolute reset has been completed, move the robot to the all-axis 0 pulse position. For details about how to move to the 0 pulse position, refer to the "YAMAHA Robot Controller User's Manual".

c CAUTION Beforeaffixingtheoriginpositionstickers,besuretomovetherobottotheallaxes"0"pulseposition.Iftherobotisnotmovedtothisposition,thenextabsoluteresetmaynotbeperformedcorrectly.

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0 Affix the origin position stickers.After the robot has been moved to the all axes "0" pulse position, press the emergency stop button and affix the origin position stickers to legible positions. After that, these origin position stickers are used to perform the absolute reset again at the same position. Degrease the origin position sticker affixing surface with alcohol, etc. After the surface has been dried, affix the sticker.

c CAUTION Whenthenextabsoluteresetisperformedatthesameposition,itisnecessarytoputthedeviationbetweentheoriginpositionstickersinacertainrange(repeatabilityallowablevalue).(SeetheFig.below.) Whenaffixingtheoriginpositionstickers,eliminatethedeviationbetweentheupperandlowerstickersasmuchaspossiblesothattheresetpositioncanbeunderstoodsecurelyduringnextabsolutereset. Theoriginpositionrepeatabilityallowablevalueofeachaxisisshownbelow.



X ±0.72

Y ±0.72

R ±3.00







NG




NG

OK

OKArm side ........................


23309-FH-00

c CAUTION Whenaffixingtheoriginpositionstickers,becarefulnottomovethejointoftherobot.Whentheservoisturnedoff, the joint may move due to the harness reaction force depending on the arm position. If this symptom is predicted, determine other position where the joint does not move to the origin position.

q Go out of the safety enclosure.

w Release the emergency stop of the controller.After checking that no one is inside the safety enclosure, release the emergency stop of the controller.

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2.4.2.4 Absolute reset in servo off state (new reset)


n NOTE


• Fordetailsabout how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual".



3 Enter the safety enclosure.Enter the safety enclosure while holding the PBX.



6 Move the arm to the position where the origin position marks are matched with each other.Press the emergency stop button on the PBX to put the robot in the emergency stop state.


Manually move the robot to a position where the return-to-origin is performed.

7 Check the machine reference value.When the robot is moved to a position where the absolute reset is performed, check that the value of the selected axis is in the range between 26 and 74 on the PBX screen. (Normally, this value is 50.)


press . The execution confirmation screen will pop up.

c CAUTION • Therearemultiplediscretepositionswheretheabsoluteresetcanbeperformed.Movetherobotstep-by-step while referring to the PBx screen. When the robot comes to a position near the absolute reset position where

thevalueoftheselectedaxisonthePBXscreenenterstherangebetween26and74,pressthe key. • Ifthevalueoftheselectedaxisisnotintherangebetween26and74,themessage,“Positionresetmalposition”, appearsinthenextoperationandthereturn-to-origincannotbecompleted.

9 Perform the absolute reset.Press on the "ORIGIN RTN (MARK)" pop-up screen to complete the absolute reset. After the absolute reset has been completed, the axis moves to the “0” pulse position.

0 Move the robot to the all-axis 0 pulse position.When the absolute reset has been completed, move the robot to the all-axis 0 pulse position. For details about how to move to the 0 pulse position, refer to the "YAMAHA Robot Controller User's Manual".

c CAUTION Beforeaffixingtheoriginpositionstickers,besuretomovetherobottotheallaxes"0"pulseposition.Iftherobotisnotmovedtothisposition,thenextabsoluteresetmaynotbeperformedcorrectly.

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q Affix the origin position stickers.After the robot has been moved to the all-axis 0 pulse position, press the emergency stop switch and affix the origin position stickers supplied with the robot to easy-to-identify positions near the R-axis rotation part so that they can be used when the absolute reset is performed again at the same position. Degrease the origin position sticker affixing surfaces with alcohol. After the surfaces have been dried, affix the origin position stickers.

c CAUTION Whenthenextabsoluteresetisperformedatthesameposition,itisnecessarytoputthedeviationbetweentheoriginpositionstickersinacertainrange(repeatabilityallowablevalue).(SeetheFig.below.) Whenaffixingtheoriginpositionstickers,eliminatethedeviationbetweentheupperandlowerstickersasmuchaspossiblesothattheresetpositioncanbeunderstoodsecurelyduringnextabsolutereset. Theoriginpositionrepeatabilityallowablevalueofeachaxisisshownbelow.



X ±0.72

Y ±0.72

R ±3.00







NG




NG

OK

OKArm side ........................


23311-FH-00

c CAUTION Whenaffixingtheoriginpositionstickers,becarefulnottomovethejointoftherobot.Whentheservoisturnedoff, the joint may move due to the harness reaction force depending on the arm position. If this symptom is predicted, determine other position where the joint does not move to the origin position.

w Go out of the safety enclosure.

e Release the emergency stop of the controller.After checking that no one is inside the safety enclosure, release the emergency stop of the controller.

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2.4.3 Sensor method (X-axis, Y-axis)

Adjusting the X-axis machine reference ■

c CAUTION • Theoriginpositionmaychangeduetomachinereferenceadjustment.Ifitoccurs,youmustsetpointdata again. • Whenthereturn-to-origindirectionisreversed,theoriginpositionmaynotbethebasefront.Whenusingthe standardsoftlimit,theaxismaycollidewiththemechanicalstopper.Atthistime,setthesoftlimit2°ormore inward from the mechanical stopper while referring to "3. Setting the soft limits".

Follow the steps below to adjust the X-axis machine reference value.Prepare a wrench for a width across flat of 13 mm.


2 Perform the return-to-origin.Perform the return-to-origin from outside the safety enclosure. For details about how to perform the return-to-origin, refer to "2.3 Return-to-origin procedures" in this Chapter.

3 Check the machine reference value.If the machine reference value displayed on the PBX is not in the range between 25 and 75 (recommended range) after the return-to-origin has been completed, follow the steps below to adjust the machine reference value.




7 Put a mark at the origin position.Scribe a mark at the current origin position on the X-axis joint area of the robot. At this time, be careful to prevent the origin position from deviating since the X-axis arm is touched.

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8 Loosen the hex nut.Using the wrench, loosen the hex nut that secures the X-axis origin sensor.

Adjusting the X-axis machine reference valueStep 8-10

Hex nut

X-axis origin sensor23307-FK-00

c CAUTION It is enough to loosen the nut. Do not remove the nut completely.

9 Move the X-axis origin sensor.Move the X-axis origin sensor as follows. Determine the distance between the sensor and dog to 0.2 to 0.8 mm so that the sensor does not collide with the dog.

To decrease the X-axis machine

reference value, move the sensor away

from the dog.

To increase the X-axis machine reference

value, put the sensor close the dog.

0 Secure the X-axis origin sensor with the hex nut.Secure the X-axis origin sensor with the hex nut.

Tightening torque 5Nm(50kgfcm)

Tool KANON(NakamuraMfg.Co.,Ltd.)

Torque wrench N190SPK13

q Turn on the controller.Check that no one is inside the safety enclosure, and then turn on the controller.

w Perform the return-to-origin.Perform the return-to-origin from outside the safety enclosure.

e Check the machine reference value.1. After the return-to-origin has been

completed, read the machine reference

value displayed on the PBX.

2. If the machine reference value is in the

range between 25 and 75 (recommended

range), the adjustment of the machine

reference value is then completed.

3. If it is outside the recommended range,

then repeat the procedure from step 9

again to readjust it.

r Turn off the controller.

t Enter the safety enclosure.

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Adjusting the Y-axis machine reference ■

c CAUTION The origin position may change due to machine reference adjustment. If it occurs, you must set point data again.

Follow the steps below to adjust the Y-axis machine reference value.Prepare a wrench for a width across flat of 13 mm.


2 Perform the return-to-origin.Perform the return-to-origin from outside the safety enclosure. For details about how to perform the return-to-origin, refer to "2.3 Return-to-origin procedures" in this Chapter.

3 Check the machine reference value.If the machine reference value displayed on the PBX is not in the range between 25 and 75 (recommended range) after the return-to-origin has been completed, follow the steps below to adjust the machine reference value.




7 Put a mark at the origin position.Scribe a mark at the current origin position on the Y-axis joint area of the robot. At this time, be careful to prevent the origin position from deviating since the Y-axis arm is touched.

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8 Loosen the hex nut.Using the wrench, loosen the hex nut that secures the Y-axis origin sensor.

Adjusting the Y-axis machine reference valueStep 8-10

Hex nut

Y-axis origin sensor

23308-FK-00

c CAUTION It is enough to loosen the nut. Do not remove the nut completely.

9 Move the Y-axis origin sensor as follows.Move the Y-axis origin sensor as follows. Determine the distance between the sensor and dog to 0.2 to 0.8mm.

To decrease the Y-axis machine

reference value, move the sensor away

from the dog.

To increase the Y-axis machine reference

value, put the sensor close the dog.

c CAUTION Pay special attention so that the sensor does not collide with the dog.

0 Secure the Y-axis origin sensor with the hex nut.Secure the Y-axis origin sensor with the hex nut.

Tightening torque 5Nm(50kgfcm)

Tool KANON(NakamuraMfg.Co.,Ltd.)

Torque wrench N190SPK13

q Turn on the controller.Check that no one is inside the safety enclosure, and then turn on the controller.

w Perform the return-to-origin.Perform the return-to-origin from outside the safety enclosure.

e Check the machine reference value.1. After the return-to-origin has been

completed, read the machine reference

value displayed on the PBX.

2. If the machine reference value is in the

range between 25 and 75 (recommended

range), the adjustment of the machine

reference value is then completed.

3. If it is outside the recommended range,

then repeat the procedure from step 9

again to readjust it.

r Turn off the controller.

t Enter the safety enclosure.

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3. Setting the soft limitsOntheYK-XRseries,theworkingenvelopeduringjogmovementandautomaticoperationcanbelimitedbyspecifyinga"+"softlimit[pulse]anda"-"softlimit[pulse].Theoriginpoint(0[pulse])isusedasthereference to set the soft limits. The working envelope can be limited by specifying the number of pulses from the0pulseposition.

c CAUTION If you want to check the soft limits by operating the robot, perform jog operation from outside the safety enclosure.

n NOTE Refer to the "YAMAHA Robot Controller User's Manual" for further details. Also refer to "1.2 External view and dimensions" in Chapter 8 for the working envelope area.

3.1 Setting the X-axis and Y-axis soft limitsThe X-axis and Y-axis have mechanical stoppers for protection of internal wiring outside their movement ranges. The soft limits must be set within the working envelope or the inside of the interference position with peripheral equipment (this must be within the working envelope). If the working envelope during robot work is small or if the robot interferes with the peripheral equipment, narrow the working envelope. Follow the steps below to set the soft limits.


2 Press the emergency stop button.Press the emergency stop button on the PBX to put the robot in the emergency stop status.

n NOTE For details about emergency stop and how to cancel the emergency stop, see the "YAMAHA Robot Controller User's Manual".


4 Enter the safety enclosure while holding the PBX.

5 Move the X-axis and Y-axis arms by hand.Move the X-axis and Y-axis to the mechanical stopper positions or to the point where interference with the peripheral equipment occurs.

6 Note the pulse values.Read the X-axis and Y-axis plus (+) and minus (-) direction pulses displayed on the PBX in step 6 and note them.

c CAUTION • Beforecancellingtheemergencystop,checkfromoutsidethesafetyenclosurethatnooneisinsidethesafety enclosure. • Setthesoftlimitsfromoutsidethesafetyenclosure.

7 Set the soft limits.Set the soft limits to within the figure for the X-axis and Y-axis encoder pulses that you have noted in step 7.

n NOTE For details about how to set the soft limits, see the "YAMAHA Robot Controller User's Manual".

c CAUTION • The origin position factory-adjusted at shipment is not completely aligned with the front face position of the robot. When installing the robot, be sure to set the soft limits with the number of pulses from the origin position (0pulseposition). • Overloads may occur if the soft limit is almost near the encoder pulse at the mechanical stopper and the operating point is used at the edge of the movement range. Set the soft limit to the inner side of the mechanical stopper with an ample safety margin.

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3.2 Setting the Z-axis soft limits

c CAUTION SettheZ-axissoftlimitsfromoutsidethesafetyenclosure.

The Z-axis has mechanical stoppers fixed at the upper and lower ends of the Z-axis movement range. When the actual working range of the robot is smaller than the maximum working envelope or the manipulator interferes with the peripheral equipment, reduce the Z-axis plus (+) soft limit [pulses] to narrow the working envelope.

c CAUTION Overloads may occur if the soft limit is almost near the encoder pulse at the mechanical stopper and the operating point is used at the edge of the movement range. Set the soft limit to the inner side of the mechanical stopper with an ample safety margin.

3.3 Setting the R-axis soft limits

c CAUTION SettheR-axissoftlimitsfromoutsidethesafetyenclosureoraftertheemergencystopbuttonhasbeenpressedinthesamemannerastheX-axisandY-axissoftlimits.

The R-axis has no mechanical stoppers. When the actual working range of the R-axis is small or it interferes with the peripheral equipment, reduce the R axis plus (+) soft limit [pulse] and minus (-) soft limit [pulses] to narrow the working envelope.

3.4 Relation between the X, Y, and R-axis movement angle, the Z-axis movement distance and the number of pulsesThe tables below are for calculating resolver pulses with respect to the X, Y and R-axis movement angles and totheZ-axismovementdistanceforeachrobot.Usethesefiguresasaguidetosetthesoftlimits.

X, Y and R-axis speed reduction ratio and Z-axis ball screw lead for each robot

X-axis Y-axis Z-axis R-axis

50 50 12mm 12

Operation angle/distance vs. number of resolver pulses X, Y and R-axis speed reduction ratio

Speed ratio Number of resolver pulses per turn (360 degrees)

12 245760

50 1024000

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4. Setting the standard coordinates

c CAUTION If the standard coordinate settings are incorrect, the acceleration cannot be optimized to match the arm position. This results in too short a service life, damage to the drive unit, or residual vibration during positioning. In addition, the cartesian coordinate accuracy will be impaired.

Setting the standard coordinates enables the following operations and functions.

1. Optimizes acceleration according to arm position during automatic operation.

2. Allows moving robot arm tip at right angles.

3. Allows using shift coordinates.

4.Enablescommandssuchaslinearinterpolationandarmswitching.

The procedure for setting standard coordinates and cautions are shown below.


2 Check that the soft limits are correctly set.If not correctly set, adjust the soft limits while referring to "3. Setting the soft limits".


4 Enter the safety enclosure while holding the PBX.At this time, stay outside the robot movement range.

c CAUTION Never enter the robot movement range.

5 Set the standard coordinates.See "Setting the standard coordinates" stated in the "YAMAHA Robot Controller User's Manual".

n NOTE The next section, "4.1 Standard coordinate setting using a standard coordinate setup jig (option)", describes how to set the standard coordinates more accurately using an optional setup jig.

6 Check that the standard coordinates are set correctly.1. Does jog operation (millimeter coordinate system) move the robot arm tip at right angles?

2. Check that the values nearly equal to the X-axis and Y-axis arm lengths are entered in "Arm length"

of the axis parameters.

If points 1 and 2 shown above are not satisfied, the standard coordinate settings are incorrect. So, make the standard coordinate settings again.

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4.1 Standard coordinate setting using a standard coordinate setup jigUseastandardcoordinatesetupjig(option)tosetthestandardcoordinatesmoreaccurately. The following describes how to set the standard coordinates using the standard coordinate setup jig.

Standard coordinate setup jig (option)

Part No. Name Q'ty

99480-06018 Pin 1

KCY-M1577-000 Shaft 1

91312-04065 Bolt 1


2 Put the robot in the emergency stop status.Press the emergency stop button on the PBX to put the robot in the emergency stop status.

n NOTE For details about emergency stop and how to cancel the emergency stop, see the "YAMAHA Robot Controller User's Manual".


4 Enter the safety enclosure while holding the PBX.

5 Insert the shaft.1. Make the adjustment so that the X-axis

arm and Y-axis arm are aligned on an

almost straight line.

2. Adjust the arm positions so that the shaft

enters the slot in the Y-axis arm and the

hole in the X-axis arm without prying, and

then insert the shaft.

Installing the Y-axis standard coordinate jigStep 5-6

Shaft

Bolt

HoleSlot

23311-FK-00

6 Secure the shaft with the bolts.Tighten the bolts so that the shaft does not move.

7 Insert the pin.Insert the pin into the hole in the base as shown in the Fig.

Installing the X-axis standard coordinate jigStep 7

Pin

23312-FH-00

8 Make a note of the Y-axis position pulse value.1. Access the "Jog" screen.

2. Lightly apply a clockwise torque to the

Y-axis while holding the X-axis.

3. Make a note of the Y-axis position pulse

value displayed on [CURRENT] when the

torque is unloaded.

4. Lightly apply a counterclockwise torque

to the Y-axis while holding the X-axis.

5. Make a note of the Y-axis position pulse

value displayed on [CURRENT] when the

torque is unloaded.

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9 Put the X-axis arm in contact with the X-axis standard coordinate setting jig.Put the X-axis arm in contact with the standard coordinate setup jig as shown in the figure. At this time, make a note of the X-axis position pulse value displayed on [CURRENT].

Putting the X-axis arm in contact with the X-axis standard coordinate setting jigStep 9

23310-FK-00

0 Enter the axis parameter "ARM LENGTH".Enter the following values (arm length values) in the axis parameter "ARM LENGTH" A1 and A2.

A1 (X-axis arm length) A2 (Y-axis arm length)

225 175

q Enter the axis parameter "OFFSET PULSE".Enter the values shown on the right in the axis parameter "OFFSET PULSE".

Entering the “Offset pulse” valuesStep 11

Note) Round off the decimal part of the A2 value.

A1= X-axis position pulse value you have made a note of in step 9

2A2=

+Y-axis position pulse value you have made a note of in step 8 (clockwise)

Y-axis position pulse value you have made a note of in step 8 (counterclockwise)

23304-FK-00

w Remove the standard coordinate jig.

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5. Affixing the stickers for origin positions, movement directions, and axis names

Therobotcomespackedwithstickersshowingoriginpositions,movementdirectionsandaxisnames.Usingthe following procedure, attach these stickers in conspicuous points on the robot after changing the origin position and installing peripheral equipment.

A BX YZ R

Origin position stickers, direction of movement and axis name stickers

Direction of movement andaxis name stickers

Origin position stickers

23305-F6-00

w WARNING AFFIXTHEORIGINPOSITIONSTICKERSPRECISELYONTHEORIGINPOSITIONS.ALIGNTHEDIRECTIONOFMOvEMENTSTICKERSWITHTHEjOGDIRECTIONANDAFFIXTHEMCORRECTLY.AFFIXEACHAXISNAMESTICKERONTHECORRECTAXIS.AFFIXINGTHESTICKERATAWRONGLOCATIONMAYCAUSEFAULTYOPERATIONANDHAZARDOUSSITUATIONS.


2 Move the robot to the 0 pulse position.

n NOTE For details about how to move the robot to the 0 pulse position, see “8. Point trace function” in Chapter 3 of the "RCX340 User's Manual".




6 Affix the stickers.Being careful not to move the origin positions, affix the stickers at legible points on matching sides of components such as the robot arm of each axis, base, and end effector. Affix stickers nearby showing the axis name and movement direction. Use a cloth moistened with alcohol to remove grease from the surface where you will affix the stickers. After the surface is dry, affix the stickers securely.

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Sticker affixing positions (example)

XX

YYYYYY

Z

+

+

+

-

-

-

R +-

23305-FK-00

Chapter 4 Periodic inspecition

Contents

1. Overview 4-1

2. List of inspection items 4-2

4

Perio

dic

inspe

citio

n

4-1

1. OverviewDailyandperiodicinspectionoftheYAMAHArobotisessentialinordertoensuresafeandefficientoperation. TheperiodicinspectionforYK-XRseriesconsistsofdailyinspectionand6-monthinspection. Be sure to perform the daily inspection before starting the robot and after completion of the day’s work. Fordetailsaboutinspectionitems,see"2.Listofinspectionitems"inthenextsection. Fordetailsabouthowtoperformtheperiodicinspection,seetheseparateMaintenanceManualforYK-XRseries.

Before starting the maintenance work, thoroughly read the following cautions and Safety Instructions to strictly observe the instructions.

w WARNING • WHENYOUNEEDTOTOUCHTHETERMINALSORCONNECTORSONTHEOUTSIDEOFTHECONTROLLERDURING INSPECTION, ALWAYS FIRST TURN OFF THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER TOPREvENTPOSSIBLEELECTRICALSHOCK. • NEvERTOUCHANYINTERNALPARTSOFTHECONTROLLER.

Cautions on daily inspection ■

c CAUTION • Read "2. Qualification of operators/workers" in section 4.1 of the Safety Guide and allow only qualified engineers to perform the periodic inspection while referring to the separate Maintenance Manual. Or, perform the periodic inspection with engineers having the qualification of operators/workers attended. • Donotattemptanyinspection,adjustment,repairandpartsreplacementnotdescribedinthismanual.This work requires specialized technical knowledge and skill, and may also involve work hazards. • Wheninspectionisrequiredinsidethesafetyenclosure,alwaysturnoffthecontrollerandalsotheexternal switch board. • Iftheinspectionormaintenanceprocedurecallsforoperationoftherobot,stayoutsidethesafetyenclosure. • Placeasignindicatingtherobotisbeinginspected,tokeepothersfromoperatingthecontrollerswitch, programmingbox(PBX)oroperationpanel. • Useonlythelubricantsspecifiedbyyourdistributor. • To check the operation after inspection, refer to "4.6.1 Trial Operation" in Chapter “Safety Instructions” of this manual.

n NOTE For precautions on handling the controller, refer to the "YAMAHA Robot Controller User's Manual".

Cautions on 6-month inspection ■

w WARNING THEZ-AXISWILLSLIDEDOWNWHENTHEZ-AXISBRAKEISRELEASED,CAUSINGAHAZARDOUSSITUATION.DONOTRELEASETHEBRAKEWHENLUBRICATINGTHEZ-AXISPARTS.

When lubricating the ball screw and spline shaft, observe the following precautions.

w WARNING PRECAUTIONS WHEN HANDLING GREASE: • INFLAMMATIONMAYOCCURIFTHISGETSINTHEEYES. BEFORE HANDLING THE GREASE, WEAR YOUR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES. • INFLAMMATIONMAYOCCURIFTHEGREASECOMESINTOCONTACTWITHSKIN.BESURETOWEARPROTECTIvE GLOvESTOPREvENTCONTACTWITHSKIN. • DONOTTAKEORALLYOREAT.(EATINGWILLCAUSEDIARRHEAANDvOMITING.) • HANDSANDFINGERSMIGHTBECUTWHENOPENINGTHECONTAINER,SOUSEPROTECTIvEGLOvES. • KEEPOUTOFTHEREACHOFCHILDREN. • DONOTHEATTHEGREASEORPLACENEARANOPENFLAMESINCETHISCOULDLEADTOSPARKSANDFIRES. EMERGENCY TREATMENT: • IFTHISGREASEGETSINTHEEYES,WASHLIBERALLYWITHPUREWATERFORABOUT15MINUTESANDCONSULTA PHYSICIAN FOR TREATMENT. • IFTHISGREASECOMESINCONTACTWITHTHESKIN,WASHAWAYCOMPLETELYWITHSOAPANDWATER. • IFTAKENINTERNALLY,DONOTINDUCEvOMITINGBUTPROMPTLYCONSULTAPHYSICIANFORTREATMENT. DISPOSING OF GREASE AND THE CONTAINER: • PROPERDISPOSALISCOMPULSORYUNDERFEDERAL,STATEANDLOCALREGULATIONS.TAKEAPPROPRIATE MEASURES IN COMPLIANCE WITH LEGAL REGULATIONS. • DONOTPRESSURIZETHEEMPTYCONTAINER.PRESSURIZINGMAYCAUSETHECONTAINERTORUPTURE. • DONOTATTEMPTTOWELD,HEATUP,DRILLHOLESORCUTTHISCONTAINER.THISMIGHTCAUSETHECONTAINERTO ExPLODE AND THE REMAINING MATERIALS INSIDE IT TO IGNITE.

c CAUTION Unless grease specified by YAMAHA is used, the service life of the ball screw and ball spline will shorten.

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2. List of inspection items

w WARNING ENGINEERSWHOHAvETHEQUALIFICATIONINCONFORMITYWITH"2.QUALIFICATIONOFOPERATORS/WORKERS"INSECTION4.1OFTHESAFETYGUIDEMUSTPERFORMTHEINSPECTIONITEMSREQUIRINGTHECOvERREMOvALWHILEREFERRINGTOTHESEPARATEYK-XRSERIESMAINTENANCEMANUAL.

: Conduct. : Conduct if trouble is found as a result of inspection. : Contact your distributor.

Location Contents Daily 6-month Cleaning Adjustment Replacement

■ Inspection with the controller turned off

MachineharnessRobotcable

•Checkforscratch,dent,orexcessivebend.

•Checkfordamage.

Cablespreparedbyuser •Checkforscratch,dent,orexcessivebend.

RegulatorJointAirtubeSolenoidvalveAircylinder

•Checkthattheairpressureleveliscorrect.

•Checkforairleak.

•Checkthatthedrainisdischarged.

•Checktheairfilterforcontaminationordamage.

Exteriorofrobot •Checkfordamage.

Majorboltsandscrewsofrobotmainbody(thoseexposedtotheoutside)

•Checkforlooseness.(*1)

Belt •Checkthatthebelttensionisappropriate.

DetectionpartsofX-axisandY-axisoriginsensors •Checkforcontamination.

Controller

•Checktheterminalontheoutsideofthecontrollerforlooseness.

•Checktheconnectionconnectorforlooseness.(*2)

ApplicationofgreasetoZ-axissplineandZ-axisballscrew(*3)

•RemovetheoldgreasewithaclothragandapplyLG2(NSK).

Z-axisballscrewandballspline •Checkforplay.

■ Inspection with the controller turned on

Safeguardenclosure

•Checkthatthesafeguardenclosureislocatedatitsspecifiedposition.

•Checkthattheemergencystopturnsonwhenthesafeguardenclosureisopen.

•Checkthatthewarninglabelisaffixedtotheentrance.

Emergencystopbutton •Checkthattheemergencystopturnsonwhenpressed.

Robotoperation •Checkforunusualoperation,vibration,ornoise.

FunctionalcheckofZ-axisbrake(*4)

•DropamountfromtheZ-axisreststateis3mmorless.

Aircoolingfanontherearofthecontroller

•Checkthatthefanrotates.

•Checkforobjectblockingthefan.

•Checkfornoiseduringrotation.(*5)

•Checkthefancoverforcontamination.

*1: If any bolt or screw is loose, retighten it. (For details about tightening torque, see the table below.)*2: For details, see "4. Robot cable connection" in Chapter 2.*3: For detail about how to apply the grease, see the separate Maintenance Manual.*4: When the emergency stop button is pressed outside the safeguard enclosure or when the controller power is turned

off, visually inspect the Z-axis brake.*5: If any object is found through the visual inspection, remove it. If noise is heard even when no object is found,

contact your distributor.

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Bolt tightening torque

Bolt size Tightening torque (kgfcm) Tightening torque (Nm)

M3setscrew 7 0.69

M4setscrew 17 1.7

M3 20 2.0

M4 46 4.5

M5 92 9.0

M6 156 15.3

M8 380 37

M10 459 45.0

Chapter 5 Harmonic drive replacement period

Contents

1. Overview 5-1

2. Replacement period 5-2

5

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1. OverviewTheYK-XRseriesrobotsusesaharmonicdriveasthespeedreductiongearfortheXandYaxes.Harmonicdrivesneedtobereplacedafterspecifiedoperationhourshaveelapsed.Usetheguidelineexplainedbelowtodeterminethereplacementperiodandreplacetheharmonicdriveperiodically.SincetheYK-XRseriesrobots listed below use long-life harmonic grease, it is not necessary to replace the harmonic grease.

w WARNING ENGINEERSWHOHAvETHEQUALIFICATIONINCONFORMITYWITH"2.QUALIFICATIONOFOPERATORS/WORKERS"INSECTION4.1OFTHESAFETYGUIDEMUSTPERFORMTHEHARMONICDRIvEREPLACEMENTWHILEREFERRINGTOTHESEPARATEYK-XRSERIESMAINTENANCEMANUAL.

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2. Replacement periodThe harmonic drive replacement period is determined by the total number of turns of the wave generator used in the harmonic drive. It is recommended to replace the harmonic drive when the total number of turns hasreached8.4×108(atambientoperatingtemperaturesof0°Cto+40°C).Thismeansthatthereplacementperiod will differ depending on the following operating conditions. If the robot operation duty ratio is high or the robot is operated in environments at higher temperatures, the harmonic drive should be replaced earlier.

Replacement period = 8.4×108/(n×60×h×D×N×θ) years where n : Number of axis movements per minute θ : Average turn per axis movement N : Speed reduction ratio h : Operation time per day D : Operation days per year

For example, when the robot is used under the following conditions, the replacement period for the X-axis harmonic drive of the YK-XR series robots can be calculated as follows.

n : 10

θ : 0.25

N : 50

h : 24 hours per day

D : 240 days per year

Replacement period = 8.4×108/(n×60×h×D×N×θ) = 8.4×108/(10×60×24×240×50×0.25) = 19.4 years

Harmonic drive speed reduction ratio

Robot model X-axis Y-axis

YK400XR 50 50

Chapter 6 Increasing the robot operating speed

Contents

1. Increasing the robot operating speed 6-1

1.1 Increasing speed by arch motion 6-1

1.2 Increasing the speed with the WEIGHT statement 6-3

1.3 Increasing the speed by the tolerance parameter 6-4

1.4 Increasing the speed by the OUT effective position parameter 6-5

6

Increasing the robot operating speed

6-1

1. Increasing the robot operating speedTherobotoperatingspeedcanbeincreasedbythefollowingmethods.Usethesemethodsasneededwhenprogramming.

1.1 Increasing speed by arch motion[Also refer to:]Robot controller user’s manual ("Controller system settings" in Chapter 7) (11.5 Axis parameters Arch pulse) Programming manual ("Robot Language Lists" in Chapter 8) (ARCHP1/ARCHP2)

Gate motion1.

From point P1 to P4 via P2 and P3:

MOVEP,P2

MOVEP,P3

MOVEP,P4

Gate motion

Z=0P2

P1

P3

P4

23601-F0

Arch motion2.

From point P1 to P2:

MOVEP,P2,Z=0

Axis parameter arch pulse 1, arch pulse 2 (ARCHP1, ARCHP2)

ARCHP1 = 102400 pulses

ARCHP2 = 102400 pulses

* The default arch pulse value is 9999999 pulses.

ARCHP1 ARCHP2 Obstacles Obstacles

Arch motion:

Z=0

P1 P2

23602-F0

After the Z-axis has moved up 102400 pulses from P1, the X-, Y-, and R-axis start operating. This operation is performed

so that the remaining Z-axis movement distance becomes 102400 pulses when the movements of the X-, Y-, and R-axis

have been completed.

As the tracking draws an arc, the cycle time is shortened when compared to the gate motion stated in 1 above.

6


6-2

Arch motion: Making the arch position value smaller3.

In "2. Arch motion", as the arch pulse value is made further smaller, the tracking arc becomes large to further shorten the

cycle time. Since the tracking draws an arc, use caution to avoid obstacles if they are located on the arm movement

path.

Arch motion: changing the arch positions in the program4.

[Example]

From point P1

ARCHP1 = 140000 ... Arch pulse1


MOVEP,P2,Z=0



MOVEP,P3,Z=102400

Since the arch positions can be changed in the program, optimizing the arch positions can further shorten the cycle time.

Arch motion

Z=0

P1 P2 P3

Z=102400

Large arch pulse

Small arch pulse

23603-F0

[Example2]Archpulsedesignationusingoption

From point P1

MOVEP,P2,Z=0.00{90.00,90.00}

MOVEP,P3,Z=60.00{40.00,40.00}

Z=0.00

P1 P2 P3

Z=60.00

Large arch pulse

Small arch pulse

Arch motion

21607-F0

Arch position can be set for each axis.

6


6-3

1.2 Increasing the speed with the WEIGHT statement[Also refer to:]Robot controller user’s manual ("Controller system settings" in Chapter 7) (11.4 Robot parameters Tip weight) Programming manual ("RobotLanguageLists"inChapter8)(WEIGHT)

[Example]

From P1 when chuck is open:

WEIGHT5 ...............Changes the tip weight parameter to 5kg (no workpiece).

MOVEP,P2,Z=0

DO3 (0) = 1 ............Chuck closes.

WEIGHT10 .............Changes the tip weight parameter to 10kg (with workpiece).

MOVEP,P3,Z=0

In the above program, the acceleration can be set to a higher level by reducing the tip weight parameter to 5kg while the

chuck does not grip any workpiece, and then set to a lower level by changing the tip weight parameter to 10kg while the

chuck grips a workpiece. Compared to programs using a tip weight parameter left set at 10kg, this method shortens the

cycle time since the acceleration is increased.

Increasing the speed with the WEIGHT statement

P1

Z=0

Chuck opens.

Chuck 5kg

Workpiece 5kg

P3P2

Chuck closes.

No workpiece Chuck is gripping workpiece.

23604-F0

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6-4

1.3 Increasing the speed by the tolerance parameter[Also refer to:]Robot controller user’s manual ("Controller system settings" in Chapter 7) (11.5 Axis parameters Tolerance) Programming manual ("RobotLanguageLists"inChapter8)(TOLE)

Increasing the speed by the tolerance parameter

P1

P2

P3

23605-F0

[Example]

From P1 to P3 via P2

TOLE(1)=2048...X-axistolerance(pulses):Increasesthetolerance.

TOLE(2)=2048...Y-axistolerance(pulses)

TOLE(3)=2048...Z-axistolerance(pulses)

TOLE(4)=2048...R-axistolerance(pulses)

MOVEP,P2

TOLE(1)=80.......DecreasesthetoleranceatP3.

TOLE(2)=80

TOLE(3)=80

TOLE(4)=80

MOVE,P,P3

If P2 is a transit point whose location does not need to be specified precisely, speed can be increased by increasing the

tolerance of positioning at P2.

Specifying a greater tolerance will produce increased sound and vibration when the robot is operating, and will make the

movement path irregular, so pay attention to the sound, vibration, and movement path as you increase the tolerance little

by little from the default value. In general, you should consider 2048 for each axis to be the maximum value.

Tolerance can be set for each axis. If the same tolerance is used for all axes,youcanwriteas"TOLE2048".

If the same tolerance is used for all axes,youcanwriteas"TOLE80".

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6-5

1.4 Increasing the speed by the OUT effective position parameter[Also refer to:]Robot controller user’s manual ("Controller system settings" in Chapter 7) (11.5 Axis parameters Out valid position) Programming manual ("RobotLanguageLists"inChapter8)(OUTPOS)

[Example]

From P1 when chuck is open:

OUTPOS(1)=10000...X-axisOUTeffectiveposition(pulses):IncreasestheOUTeffectiveposition.

OUTPOS(2)=10000...Y-axisOUTeffectiveposition(pulses)

OUTPOS(3)=10000...Z-axisOUTeffectiveposition(pulses)

OUTPOS(4)=10000...R-axisOUTeffectiveposition(pulses)

MOVEP,P2,Z=0

DO3 (0) = 1 ................ Chuck closes.

OUTPOS(1)=2000.....ReturnstheOUTeffectivepositiontothedefaultvalue.

OUTPOS(2)=2000

OUTPOS(3)=2000

OUTPOS(4)=2000

Increasing the speed by the OUT effective position parameter

P1 P2

Chuck closed.

Chuck starts closing.

OUT effective position

23606-F0

WhenalloftheX,Y,Z,andRaxesentertheOUTeffectiveposition(10000pulsespriortoP2),thechuckstartsclosing.

BysettingtheOUTeffectivepositionlarger,thechuckstartsclosingwhiletherobotarmisstillmovingatanearlier

point,sothatthechuckcangriptheworkpiecemorequickly.ThedefaultvalueoftheOUTeffectivepositionis2000

(pulses).

[Reference]

Relation between X, Y, R-axis movement angle, Z-axis movement distance and pulse values

Thearchposition,toleranceandOUTeffectivepositionparametersaresetinpulses.FortherelationbetweenX,Y,

R-axis movement angle, Z-axis movement distance and pulse values, refer to "3.4 Relation between the X, Y, and R-axis

movement angle, the Z-axis movement distance and the number of pulses" in Chapter 3.

TheOUTeffectivepositioncanbe set for each axis. IfthesameOUTeffectiveposition is used for all axes, you canwriteas"OUTPOS10000".

IfthesameOUTeffectiveposition is used for all axes, youcanwriteas"OUTPOS2000".

Chapter 7 Torque limit designated Z-axis pushing action

Contents

1. TorquelimitdesignatedZ-axispushingaction 7-1

7

TorquelimitdesignatedZ-axispushingaction

7-1

1. Torque limit designated Z-axis pushing actionYoucanusethePUSHstatementinaprogramtoapplyaZ-axispushingaction(inthedirectionofgravity). The table below shows the torque limit value (%) and speed limit value (%) for the motor rated torque at the tip load weights. Stay within these limit values while operating the robot. Failure to observe these limits may shorten the life of the Z-axis drive unit and the arm joint section. Thepushingforce(N)showninthetableisthepushingforcewhenadownwardpushingactionisappliedatthe torque limit value (%). The actual pushing force will differ due to individual variance and sliding friction of the robot model. Thespeedlimitvalue(%)showninthetableisoneoftheoptionsofthePUSHstatement,andisthevaluetobeenteredasthemovementspeedDSoftheaxis. Ifthespeedlimitvalue(%)is100%,themovementspeedwillbe10%ofthemaximumspeed. Forspecificprogramming,refertotheseparate"RCX340ProgrammingManual."

Tip Load Weight (kg) Torque Limit Value (%) Pushing Force (N) Speed Limit Value (%)

3kg 10%to100% 40Nto150N 20%

2kg 10%to100% 35Nto145N 20%

1kg 10%to100% 20Nto130N 20%

0kg 10%to100% 10Nto115N 20%

* Inthecaseofoptionalspecifications(toolflangemountspecifications),thetiploadweightmustnotexceed2kg.Theloadoftheoptionalspecificationpartitselfmustbeaddedtothetiploadweightandtothepushingforce.Toolflangeweight0.3kg,pushingforce2.9N

Chapter 8 Specifications

Contents

1. Manipulator 8-1

1.1 Basic specification 8-1

1.2 Externalviewanddimensions 8-2

1.3 Robot inner wiring diagram 8-4

1.4 Wiring table 8-5

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1. Manipulator1.1 Basic specification

Axis

specifications

X-axisArm length 225mm

Rotation angle ±132°

Y-axisArm length 175mm

Rotation angle ±150°

Z-axis Stroke 150mm

R-axis Rotation angle ±360°

Motor

X-axis 200W

Y-axis 100W

Z-axis 100W

R-axis 100W

Maximum speed

XY resultant 6m/s

Z-axis 1.1m/s

R-axis 2600°/s

Repeatability (*1)

X-, Y-axis ±0.01mm

Z-axis ±0.01mm

R-axis ±0.01°

Payload (*2) 3kg

Standard cycle time (*3) 0.45s

R-axis tolerable moment of inertia (*4) 0.05kgm2(withoutoffset)

User wiring 0.2sq×10

User tubing (Outer diameter) φ4×3

Travel limit 1.Softlimit2.Mechanicalstopper(X,Y,Z-axis)

Robot cable Standard:3.5mOption:5m,10m

Weight 17kg

*1. Thisisthevalueataconstantambienttemperature.

*2. Intheuserwiring/tubingthroughsplinetype(option),thisvaluebecomes2kg.

*3. Whenmovinga2kgloadbackandforth300mmhorizontallyand25mmvertically(roughpositioningarchmotion).

*4. Limitsmustbeplacedonparameterssuchasaccelerationaccordingtothemomentofinertiabeingused.

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1.2 External view and dimensions

3939

12 2051 4-φ9

124.7±2

174186201

150

(7)

3010

(10)

φ35φ16 h7

A A

0

136140147181

261281

347

493

580

175 225 120.5 1948

120

65

131

15

φ6 H7+0.012

0

9030

166-φ9

156

8

100

(120.5)

140

6060

16

6 H7+0.012

0

45.5

0

0.0180

-

10

R

User wiring connector (Numbers 1 to 10 are usable.)

J.S.T. ConnectorSM connector: SMR-11V-BPin: SYM-001T-P0.6 is attached.Use AP-K2N for the crimping machine.

User tubing 1 (ϕ4 black)

User tubing 2 (ϕ4 red)

User tubing 3 (ϕ4 blue)

166 (Base size) XY-axis origin position(Sensor type)When performing return-to-origin, move both the X-axis and Y-axis counterclockwise in advance from the position shown above.

M8 bolt for installation, 4 bolts used

Maximum 370 during arm rotation

Maximum 600 during arm rotation

Z-axis lower end mechanical stopper position

Keep enough space for the maintenancework at the rear of the base.

R27 (Min. cable bending radius)Do not move the cable.

(Z-axis origin position)

Z-axis upper end mechanical stopper position10mm rise during return-to-origin

Z ax

is st

roke

(Width across flats)

User tool installation range

Standard type

Cross section A-A

Wid

th a

cros

s fla

t 15

Hollow diameter ϕ11

The weight of the tool attached here should be added to the tip mass.

Tapped hole for user wiring 4-M3 × 0.5 Depth 6

23801-FK-00

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YK400XR

XY-axis origin position(Stroke end type)When performing return-to-origin, move the X-axis and Y-axis counterclockwise and clockwise, respectively in advance from the position shown above.

20 19.4

73 73

150°

150°

132°

132°

74°

R115

90 90

150

653

5

φ27↓F

7.8

7.8

7.8 7.8

74°

OptionUser wiring and tubing routed through spline shaft.

4-M3 × 0.5 through-hole (No phase relation to R-axis origin.)

As this hole is intended for the wiring/tubing clamp, do notattach a large load to it.

View of F

X-axis mechanical stopper position : 134°Y-axis mechanical stopper position : 154°

Working envelope

User tubing 1 (ϕ4 black)User tubing 2 (ϕ4 red)User tubing 3 (ϕ4 blue)

M4 ground terminal

User wiring connector (Numbers 1 to 10 are usable.)

J.S.T. ConnectorSM connector: SMR-11V-BPin: SYM-001T-P0.6 is attached.Use AP-K2N for the crimping machine.

129°+/-3°

147°+/-3°

23802-FK-00

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1.3 Robot inner wiring diagram

Robot inner wiring diagram

User tubing

Machine harness

User IO connector

Y-axis arm

X-axis arm

M4 ground terminal

Robot cable

Round terminal

Round terminal

User tubing

User IO connector

XM

YM

XY

ZM

RM

ZR

XORG

XORG

Y-axis origin sensor

FG

RORGRORG

YM

ZMZM

RMRM

XMXM

YPYP

ZP

RPRP

YORG YORG

ZBK ZBK

XPXP

RM

RP RP

RM ZM

ZBK

YORG YORG

RORG

ZBK

ZP ZP

ZM YM

YP YP

YM

FG

YM

ZP

X-axis motorX-axis resolver

R-axis motorR-axis resolver

Z-axis motorZ-axis resolver

Y-axis motorY-axis resolver

Z-axis brake

I/O

I/O

X-axis origin sensor

23803-FK-00

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1.4 Wiring table

Robot cable wiring table

Signal Connector No. Connection No. Connector Color/Number Wire

Resolver S2

XP

1 1

XY

Orange-1-Red 0.15sq

S4 2 2 Orange-1-Black Twistedpair

S1 3 3 Gray-1-Red 0.15sq

S3 4 4 Gray-1-Black Twistedpair

R1 5 5 Skyblue-2-Red 0.15sq

R2 6 6 Skyblue-2-Black Twistedpair

DG 7 7 Gray 0.3sq

Resolver S2

YP

1 19 Orange-2-Red 0.15sq


S1 3 21 Brightgreen-2-Red 0.15sq

S3 4 22 Brightgreen-2-Black Twistedpair

R1 5 23 Pink-2-Red 0.15sq

R2 6 24 Pink-2-Black Twistedpair

DG 7 25 Gray 0.3sq

FG

FG

1 18 Gray-2-Red 0.15sq

36 Gray-2-Black 0.15sq

HLIM 10 Gray 0.3sq

GND24 11

HLIM 28 Gray 0.3sq

GND24 29

OriginSensor GND

XORG

3 13 Skyblue-3-Red 0.15sq

ORG 2 12 Skyblue-3-Black Twistedpair

24V 1 9 Pink-3-Red 0.15sq

OriginSensor 24V

YORG

1 27 Pink-3-Black Twistedpair

ORG 2 30 Brightgreen-1-Red 0.15sq

GND 3 31 Brightgreen-1-Black Twistedpair

U

XM

1 2

XM

Black 0.75sq

V 2 3 Red 0.75sq

W 3 4 White 0.75sq

FG Roundterminal 1 Gray 0.75sq

U

YM

1 2

YM

Yellow 0.75sq

V 2 3 Brown 0.75sq

W 3 4 Blue 0.75sq

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Signal Connector No. Connection No. Connector Color/Number Wire

Resolver S2

ZP

1 1

ZR

Orange-1-Red 0.15sq


S1 3 3 Gray-1-Red 0.15sq

S3 4 4 Gray-1-Black Twistedpair

R1 5 5 Skyblue-2-Red 0.15sq

R2 6 6 Skyblue-2-Black Twistedpair

DG 7 7 Gray 0.3sq

Brake MB+

ZBK

1 14 Pink-1-Red 0.15sq

MB– 2 16 Pink-1-Black Twistedpair

15 Skyblue-1-Red 0.15sq

17 Skyblue-1-Black Twistedpair

Resolver S2

RP

1 19 Orange-2-Red 0.15sq


S1 3 21 Brightgreen-2-Red 0.15sq

S3 4 22 Brightgreen-2-Black Twistedpair

R1 5 23 Pink-2-Red 0.15sq

R2 6 24 Pink-2-Black Twistedpair

DG 7 25 Gray 0.3sq

FG

FG

1 18 Gray-2-Red 0.15sq

36 Gray-2-Black 0.15sq

HLIM 10 Gray 0.3sq

GND24 11

HLIM 28 Gray 0.3sq

GND24 29

OriginSensor 24V

ZORG

3 13 Skyblue-3-Red 0.15sq

ORG 2 12 Skyblue-3-Black Twistedpair

GND 1 9 Pink-3-Red 0.15sq

OriginSensor 24V

RORG

1 27 Pink-3-Black Twistedpair

ORG 2 30 Brightgreen-1-Red 0.15sq

GND 3 31 Brightgreen-1-Black Twistedpair

U

ZM

1 2

ZM

Black 0.75sq

V 2 3 Red 0.75sq

W 3 4 White 0.75sq

FG Roundterminal 1 Gray 0.75sq

U

RM

1 2

RM

Yellow 0.75sq

V 2 3 Brown 0.75sq

W 3 4 Blue 0.75sq

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Machine harness wiring table

Signal Connector No. Connection No. Connector Color Wire

Y-axisResolver S2

YP

1 1

YP

Brown 0.2mm2

TwistedpairS4 2 2 White

S1 3 3 Red 0.2mm2

TwistedpairS3 4 4 White

R1 5 5 Orange 0.2mm2

TwistedpairR2 6 6 White

DG 7 7 Gray Shield

Z-axisResolver S2

ZP

1 1

ZP

Brown 0.2mm2

TwistedpairS4 2 2 Black

S1 3 3 Red 0.2mm2

TwistedpairS3 4 4 Black


TwistedpairR2 6 6 Black

DG 7 7 Gray Shield

R-axisResolver S2

RP

1 1

RP

Brown 0.2mm2

TwistedpairS4 2 2 Gray

S1 3 3 Red 0.2mm2

TwistedpairS3 4 4 Gray


TwistedpairR2 6 6 Gray

DG 7 7 Gray Shield

Y-axismotor U

YM

1 1

YM

Brown

0.75mmW 2 2 Red

V 3 3 Orange

Z-axismotor U

ZM

1 1

ZM

Blue

0.75mmW 2 2 Purple

V 3 3 Gray

R-axismotor U

RM

1 1

RM

Black

0.75mmW 2 2 Blue

V 3 3 Red

Z-axisbrake 1ZBK

1 1ZBK

Purple 0.3mm

Z-axisbrake 2 2 2 Gray 0.3mm

UsersignallineIO

1 1

IO

Brown

0.2mm2

2 2 Red

3 3 Orange

4 4 Blue

5 5 Purple

6 6 Gray

7 7 White

8 8 Brown

0.2mm29 9 Red

10 10 Orange

Frameground 11 11 Gray Shield

Frameground 1 FG Gray Shield

OriginSensor 24V

YORG

1 1

YORG

White

0.2mm2ORG 2 2 Purple

GND 3 3 Gray

OriginSensor 24V

RORG

1 1

RORG

White

0.2mm2ORG 2 2 Blue

GND 3 3 Gray

Roundterminal Roundterminal Yellow/Green 0.75sq

Roundterminal Roundterminal White 0.75sq

8

Spe

cific

atio

ns

8-8

Motor wiring table

Signal Color P Connection P Remarks

U Red Motor CN3 1 U

V White 2 V

W Black 3 W

PEGreen/

YellowMotor Roundterminal PE

Cable wiring table (Motor Robot cable)

Signal No Connection No Wire

S2 1 4 0.3sq Blue

S4 2 6 Orange

S1 3 3 Brightgreen

S3 4 5 Brown

R1 5 1 Gray

R2 6 2 Red

FG 7 Drainwire

Origin sensor wiring table

Signal Color Connection No. Connector

+24V Brown 1

XORG,YORGORG Black 2

0V Blue 3

All rights reserved. No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO., LTD. Information furnished by YAMAHA in this manual is believed to be reliable. However, no responsibility is assumed for possible inaccuracies or omissions. If you find any part unclear in this manual, please contact your distributor.

SCARA Robots

Installation Manual


YK-XR Series

Revision record

Manual version Issue date Description

Ver.1.00 Jul.2014 Firstedition

Ver.1.01 Sep.2014 Clericalerrorcorrections,etc.

Ver.1.10 Nov.2014 InChapter2"9.Stoppingtimeandstoppingdistanceatemergencystop,"thegraphsofZ-axiswerechanged.

Ver.1.20 May2015 InChapter2,"6.Attachingtheendeffector"waschanged.InChapter3"2.3.2Sensormethod(X-axis,Y-axis),"acautionstatementwasaddedtoStep4.InChapter6"Increasingtherobotoperatingspeed,"contentswerechanged.InChapter7"1.TorquelimitdesignatedZ-axispushingaction,"theleadtextandtablewerechanged.Clericalerrorcorrections,etc.

May2015Ver.1.20

http://global.yamaha-motor.com/business/robot/

Robot manuals can be downloaded from our company website. Please use the following for more detailed information.

YAMAHA MOTOR CO., LTD.

IM Operations

882 Soude, Nakaku, Hamamatsu, Shizuoka, 435-0054, JapanTel. 81-53-460-6103 Fax. 81-53-460-6811

yamaha scara robot yk-xr series - yrg, inc. · ver. 1.09 ewfk155120 ver. 1.20 e66 yamaha scara...

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