NXY User`s Manual
Contents
1. Ball screw linear guide ball bushing chapter CAUTION Using grease other than those recommended by YAMAHA might shorten the service life of the ball screw linear guide and linear bushing shaft SNOILDIdSNI OIAOINdd 2 Periodic inspection 2 3 Six month inspection Check the following points every 6 months and adjust or replace parts if needed Checkpoints Check items Major bolts and screws Check for looseness Tighten if on robot loose Check the ball screw and linear guide for backlash Tighten if necessary Consult us if problem cannot be solved or there is backlash due to wear Check for vibration during operation Tighten bolts if necessary to secure drive unit and or shaft Ball screw linear guide Check for backlash due to wear Check if terminals are loose Controller Chapter Check if connectors are loose Apply grease every 6 months to ball screw nut and linear guide Recommended grease Albania No 2 Shell Daphne Eponex No 2 Idemitsu 6 Greasing to ball screw nut section and linear guide See 4 3 in this chapter On long stroke robots check the Slider slider inside the top cover for wear or damage every 6 months CAUTION Using grease other than those recommended by YAMAHA might shorten the service life of the ball screw and linear guide 2 A Three year inspection SNOILLO3dSNI OIAOINdd Check the following points ev2. ALWAYS USE THE DESIGNATED BOLT AND SECURELY TIGHTEN IT WITH THE CORRECT TORQUE FAILURE TO OBSERVE THIS COULD CAUSE THE ROBOT POSITION TO DEVIATE AND COULD ALSO LEAD TO SERIOUS ACCIDENTS NOILVTIVISNI B Method A 1 Open a 6 5 through hole on the installation base s robot installation surface For machining positions refer to the external view and dimensions in the catalog or website www yamaha motor co jp global industrial robot 2 Set the robot on the installation base and fix with M6 bolts from below 2 2 m Method B 1 Tap M6 coarse screw thread holes into the installation base where the robot is to be installed For machining positions refer to the external view and dimensions in the catalog or website www yamaha motor co jp global industrial robot 2 Remove the end cover 1 upper end cover from each end of the robot Then remove the screws 4 pcs holding the top cover and remove the top cover 2 Chapter End cover 1 Top cover NOILVTIVISNI 3 Secure the robot to the base with the specified bolts utilizing the mounting holes in the bottom of the robot frame While moving the table slider secure the robot to the base using all the mounting holes in the bottom of the robot frame M6 hex wrench A WARNING M TIGHTEN THE BOLTS SECURELY TO THE CORRECT TORQUE FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE POSITIONING ERRORS AND SERIOUS ACCIDE
3. AXIS MOVING SECTIONS IF THERE ARE ANY INTERFERENCES IN THE Z AXIS UPWARD TRAVEL PATH REEVALUATE THE ROBOT POSITION EXCEPT FOR EMERGENCIES 1 4 9 Pay attention to interference of Z axis with peripheral devices for ZAS AK WARNING AAA A A AA AA AAA AAA Ch pter IF THE Z AXIS INTERFERES WITH A PERIPHERAL DEVICE AND STOPS THERE IS A RISK OF PINCHING HANDS ETC WHEN THE INTERFERING OBJECT IS REMOVED AS THE Z AXIS WILL SUDDENLY MOVE TURN THE CONTROLLER POWER OFF AND STOP THE AIR SUPPLY BEFORE REMOVING THE INTERFERING OBJECT THE Z AXIS WILL NATURALLY DROP SO PROP IT UP WITH A SUPPORT STAND ETC BEFORE STOPPING THE AIR SUPPLY 10 Z axis movement when air supply is stopped A WARNING THE Z AXIS WILL DROP WHEN THE AIR SUPPLY IS STOPPED CREATING A HAZARDOUS SITUATION PROP UP THE Z AXIS WITH A SUPPORT STAND ETC BEFORE TURNING THE CONTROLLER POWER OFF AND STOPPING THE AIR SUPPLY E Z O L m A Y O un gt M rm ps e 11 Use caution when disassembling and replacing the pneumatic devices A WARNING IF THE PNEUMATIC DEVICES ARE DISASSEMBLED OR REPLACED WHILE THE AIR IS SUPPLIED THE PARTS OR AIR COULD SCATTER TURN THE CONTROLLER POWER OFF STOP THE AIR SUPPLY AND RELEASE ALL RESIDUAL PRESSURE FROM THE PNEUMATIC DEVICES BEFORE STARTING WORK THE Z AXIS WILL NATURALLY DROP SO PROP IT UP WITH A SUPPORT STAND ETC BEFORE STOPPING THE AIR SUPPLY 12 Use cau
4. D No one is within the safeguard enclosure 2 The programming unit or tools etc are in their specified location 3 The alarm or error lamps etc on the robot and peripheral devices do not flash 4 The safeguard enclosure is securely installed with safety interlocks etc actuated 2 Observe the following during automatic operation or in cases where an error occurs 1 After automatic operation has started check the operation status and warning lamps to ensure that the robot is in automatic operation 2 Never enter the safeguard enclosure during automatic operation 3 If an error occurs in the robot or peripheral devices observe the following procedures before entering the safeguard enclosure D Press the emergency stop button to set the robot to emergency stop 2 Place a sign on the start switch indicating that the robot is being inspected in order to keep any other person from touching the start switch and restarting the robot 1 11 9 Adjustment and Inspection pS A WARNING DO NOT ATTEMPT ANY INSTALLATION ADJUSTMENT INSPECTION OR MAINTENANCE UNLESS DESCRIBED IN THIS MANUAL UNEXPECTED ACCIDENTS OR TROUBLES MAY OTHERWISE RESULT 10 Repair and Modification AK WARNING DO NOT ATTEMPT ANY REPAIR PART REPLACEMENT OR MODIFICATION UNLESS DESCRIBED IN THIS MANUAL THESE MATTERS REQUIRE TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE WORK HAZARDS AT3dJVS LOJON
5. Depth 9 2 05H7 Depth 8 gt z E gt E s O z I 3 al fs z ee Ec E yo y 70 Tolerance between knock 0 02 CAUTION If the bolt fitting length is 9mm or more from the installation surface the bolt will contact the bottom 4 2 3 ZFL single arm type double arm type When using the 3rd axis model with ZFL for the 3rd axis install the workpiece onto the ZFL slider by using six M5 coarse thread tap holes and a 65 reamer hole opened on the slider s workpiece installation surface Use six M5 coarse thread tap holes on the side of slider to fix light loads other than the tool such as a wiring retainer There is a step on the top of the slider Select the nominal length of the tool fixing bolt so that the fitting length of the screw fixing the tool is 8mm or more 12mm or less Mg Chapter _ 100 4 Tolerance between knock 0 02 TOOL AHL DNITIVISNI OC SE If the bolt fitting length is 12mm or more from the installation surface the bolt will contact the bottom 4 3 MEMO 4 4 USER WIRING AND USER PIPING A WARNING ALWAYS TURN OFF THE CONTROLLER BEFORE WIRING AND PIPING TO PREVENT ELECTRICAL SHOCKS 1 Cable carrier type A cable carrier is mounted as a standard between the X and Y axes When 3rd axis are used a cable carrier is also provided between the Y and Z axes and when using
6. ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE MALFUNCTIONS MIGHT OTHERWISE OCCUR 6 Use caution when releasing the brake for the Z axis vertical axis A WARNING THE Z AXIS WILL DROP WHEN THE BRAKE IS RELEASED CREATING A HAZARDOUS SITUATION PRESS THE EMERGENCY STOP BUTTON AND PROP UP THE Z AXIS WITH A SUPPORT STAND ETC BEFORE RELEASING THE BRAKE BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE Z AXIS AND INSTALLATION BASE ETC WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACHING Al4ddVS LOJON JHL DNISN 7 Provide safety measures for end effector gripper etc A WARNING END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY CREATE NO HAZARDS FOR EXAMPLE A WORKPIECE THAT COMES LOOSE EVEN IF POWER ELECTRICITY AIR PRESSURE ETC IS SHUT OFF OR A POWER FLUCTUATION OCCURS IF THERE IS A POSSIBLE DANGER THAT THE OBJECT GRIPPED BY THE END EFFECTOR MAY FLY OFF OR DROP THEN PROVIDE APPROPRIATE SAFETY PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE WEIGHT TEMPERATURE AND CHEMICAL PROPERTIES 8 Movement of Z axis at controller power shut off and emergency stop for ZAS A WARNING THE Z AXIS WILL START TO RISE WHEN THE CONTROLLER POWER IS SHUT OFF THE PLC POWER IS SHUT OFF THE PROGRAM IS RESET EMERGENCY STOP IS APPLIED AND WHEN THE SUPPLY OF AIR TO THE Z AXIS AIR CYLINDER S SOLENOID VALVE IS STARTED TAKE CARE NOT TO PINCH OR CRUSH HANDS ETC IN THE Z
7. JHL DNISN 1 12 11 Warranty 11 Warranty For information on the warranty period and terms please contact our distributor where you purchased the product B 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 Usage that exceeded the specifications or standard performance shown in the YAMAHA manual 3 Product usage other than intended by YAMAHA A manual Damage due to improper shipping or shipping methods Accident or collision damage Installation of other than genuine YAMAHA parts and or accessories oO N O Ui 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 E 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 o
8. OIAOINdd 2 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 3 Remove the axis stroke cover when replenishing grease Refer to section 2 Installation for details on removing the X axis cover 6 5 4 Replenishing grease to the ball screw Po 4 Using a grease gun replenish grease from the grease nipple installed on the linear guide bearings Sufficient grease has been replenished when new grease starts to seep out from the clearance between the linear guide bearings and rail 6 Chapter Grease nipple X axis Y axis The X axis and Y axis each have four linear guide bearings Replenish grease to all four bearings Wipe off any excessive grease that has seeped out to the rail Z axis ZFL Two linear guide bearings are attached A grease nipple is attached to the counter motor side of the slider so move the slider to the motor side and then start the work 5 Install the stroke cover SNOILIIdSNI OIAOINdd 6 Confirm the surrounding safety and then turn the controller power ON 4 Replenishing grease to the ball screw The X axis Y axis and Z axis use a ball screw Grease must be replenished to this ball screw periodically Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION gt A eee When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robo
9. PERIODIC INSPECTIONS 1 Before beginning work 6 1 2 Periodic inspection 6 3 2 1 Daily inspection 6 3 2 2 Three month inspection 6 3 2 3 Six month inspection 6 4 2 4 Three year inspection 6 4 3 Replenishing grease to the linear guide 6 5 4 Replenishing grease to the ball screw 6 6 USING THE ROBOT SAFELY 1 Safety Information Industrial robots are highly programmable machines that provide a large degree of freedom in movement To ensure correct and safe use of YAMAHA robots carefully read this manual to make yourself well acquainted with the contents FOLLOW THE WARNINGS CAUTIONS AND INSTRUCTIONS INCLUDED IN THIS MANUAL Failure to take necessary safety measures or mishandling due to not observing the instructions in this manual may result in trouble or damage to the robot and injury to personnel robot installer operator or service personnel including fatal accidents Chapter h Warning information in this manual is classified into the following items A DANGER FAILURE TO FOLLOW DANGER INSTRUCTIONS WILL RESULT IN SEVERE INJURY OR DEATH TO THE ROBOT OPERATOR BYSTANDERS OR PERSONS SERVICING THE ROBOT A WARNING FAILURE TO FOLLOW WARNING INSTRUCTIONS COULD RESULT IN SEVERE INJURY OR DEATH TO THE ROBOT OPERATOR BYSTANDERS OR PERSONS SERVICING THE ROBOT A134VS LOJON JHL DNISN CAUTION Failure to follow CAUTION instructions may result in injury to the robot operator bystanders or persons se
10. 2 YAMAHA YAMAHA MOTOR CO LTD YAMAHA CARTESIAN ROBOT XY X series User s Manual TETE YAMAHA MOTOR CO LTD IM Operations 882 Soude Naka ku Hamamatsu Shizuoka 435 0054 Japan URL http www yamaha motor jp robot index html E40 Ver 1 06 Chapter 1 USING THE ROBOT SAFELY 1 PPrTPPP PP Pp LL 12 General Contents Safety Information Essential Caution Items Special Training for Industrial Robot Operation Robot Safety Functions Safety Measures for the System Trial Run Work Within the Safeguard Enclosure Automatic Operation Adjustment and Inspection Repair and Modification Warranty CE Marking Chapter 2 INSTALLATION 1 PPP Chapter 3 PROTECTIVE CONNECTIONS L Installation bolt types Installation bolt nominal length Tightening torque Installation methods Ground terminal Ground wire Wiring methods Grounding to the single arm robot Grounding to the double arm robot 1 1 1 2 1 8 1 9 1 10 1 10 2 1 2 1 2 2 2 2 3 1 3 2 3 2 3 2 3 3 SINA31NOO TIVAINI9 SINA31NOO TVAINI9 Chapter 4 INSTALLING THE TOOL 1l Single arm type double arm type 2 axis model 4 1 2 ZFH single arm type double arm type 4 2 3 ZFL single arm type double arm type 4 3 Chapter 5 USER WIRING AND USER PIPING 1 Cable carrier type 5 1 1 1 Wiring piping to the single arm robot 5 1 1 2 Wiring piping to the double arm robot 5 3 1 3 Cable carrier specifications 5 6 Chapter 6
11. 4th axis a cable carrier is also provided between the Z and R axes Lay the wiring and piping to the tool using these ducts A 0 3sq 10 core flexible cable is wired from the X axis wiring box to the final axis wiring box and can be used freely The wiring and piping methods for a 2 axis arm type are explained below as an example Chapter 1 1 Wiring piping to the single arm robot al CAUTION Wiring layout must be designed in the unoccupied area Secure the wiring and piping so that they can move freely within their bending radius range Make sure that the wiring has an adequate space that is about one finger as a guide when the axis moves See the figure below 1 Remove the outer lids on the cable carrier by using a flat tip screwdriver The outer lids do not have to be removed if the connectors are not attached to the wiring materials NidId 4ISN GNV DNIAIM 335N 5 1 2 Set the outer lids back in the original position after finishing the wiring layout al Chapter 3 Fix the wiring materials with Insulock ties as necessary Insulock base must be attached See the photograph below for the machining position NidId 4ISN ANV DNIAIM AISAN Make sure that the clamp part does not move by the wiring tension during axis operation 5 2 1 Cable carrier type 1 2 Wiring piping to the double arm robot CAUTION Wiring layout must be designed in the unoccupied area 1 Remove the outer l
12. HT NOT BE TAKEN RESULTING IN ACCIDENTS DO NOT REMOVE ALTER OR STAIN THE WARNING LABELS ON THE ROBOT DO NOT ALLOW THE WARNING LABELS TO BE HIDDEN BY DEVICES INSTALLED ONTO THE ROBOT BY THE USER PROVIDE PROPER LIGHTING SO THAT THE SYMBOLS AND INSTRUCTIONS ON THE WARNING LABELS CAN BE CLEARLY SEEN EVEN FROM OUTSIDE THE SAFEGUARD ENCLOSURE Chapter h 19 Protective connections A WARNING BE SURE TO GROUND THE ROBOT AND CONTROLLER TO PREVENT ELECTRICAL SHOCK A13J4VS LOJON AHL DNISN 20 Be sure to make correct parameter settings Part 1 CAUTION 0000000000002 Always input the correct parameters matching the payload and stroke working envelope before operating the robot 21 Be sure to make correct parameter settings Part 2 CAUTION When using a rotary axis RF RH etc the robot must be operated with the tolerable moment of inertia and correct acceleration coefficients according to the tip mass and moment of inertia If these are not correct the drive unit service life may end prematurely and damage to robot parts or residual vibration during positioning may result 22 Do not use the robot for tasks requiring motor thrust CAUTION Avoid using the belt driven type robots for tasks that utilize motor thrust press fitting burr removal etc These tasks may cause malfunctions in the robot 1 7 3 Special Training for Industrial Robot Operation Fo o 3 Special Training
13. MOVING ROBOT e KEEP OUTSIDE SAFEGUARD ENCLOSURE DURING AUTOMATIC OPERATION e PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFEGUARD ENCLOSURE The warning label 1 is attached to the robot Install a safeguard enclosure to keep all personnel from entering within the movable range of the robot and suffering injury due to being struck by moving parts Al4ddVS LOJON JHL DNISN Install a safety interlock that triggers emergency stop when the door or panel is opened Install safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks The warning label 1 are supplied with the robot and should be affixed to conspicuous places on doors or panels equipped with safety interlocks A DANGER Serious injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power before approaching robot Warning label 1 2 Use caution to prevent hands or fingers from being pinched or crushed A WARNING MOVING PARTS CAN PINCH OR CRUSH KEEP HANDS AWAY FROM ROBOT ARMS 1 2 Warning label 2 is affixed to the robot Use caution to prevent hands or fingers from being pinched or crushed in the robot s moving parts during transporting the robot or teaching etc Chapter h A WARNING Moving parts can A pinch or crush Keep hands away from robot arms Warning label 2 3 Follow the instructions li
14. NTS 4 After installing the robot reattach the top cover and end covers 1 upper end covers CAUTION Take care not to catch the wiring when assembling the stroke cover 2 3 MEMO 2 4 PROTECTIVE CONNECTIONS Connect the robot side ground terminal with the external protective conductor s ground terminal using a ground wire WARNING _ _ _ _ _A _ A _ _ _ AA ALWAYS GROUND THE ROBOT AND CONTROLLER TO PREVENT ELECTRICAL SHOCKS ALWAYS TURN THE CONTROLLER POWER OFF BEFORE CONNECTING THE GROUND TO PREVENT ELECTRICAL SHOCKS WHEN USING A TOOL OR WORKPIECE HAVING POWER WHICH COULD CONTACT an THE ROBOT DUE TO A FAILURE OR THE SPECIFICATIONS THE USER MUST PROVIDE PROPER GROUNDING SINCE THE ROBOT DOES NOT HAVE A GROUND TERMINAL FOR THOSE DEVICES Q 1 Ground terminal E Single arm robot Grounding terminal is on the external face of the X axis wiring box X axis wiring box SNOILDANNOD JAILDILOAd Ground terminal E Double arm robot Grounding terminal is inside the X axis wiring box Ground terminal X axis wiring box 3 1 2 Ground wire Use an AWG14 2 0mm or larger ground wire with a total length of 1m or less Crimp an M4 ring tongue terminal on the end of the wire connected to the robot 3 Wiring methods UA An M4 small screw with spring washer and lock washer are attached to the ground terminal Arrange the parts in the o
15. PENING THE GREASE CONTAINER SO USE PROTECTIVE GLOVES e KEEP OUT OF THE REACH OF CHILDREN DO NOT HEAT THE GREASE OR PLACE NEAR AN OPEN FLAME SINCE THIS COULD LEAD TO SPARKS AND FIRES EMERGENCY TREATMENT e IF GREASE GETS IN THE EYES WASH LIBERALLY WITH PURE WATER FOR ABOUT 15 MINUTES AND CONSULT A PHYSICIAN FOR TREATMENT e IF GREASE COMES IN CONTACT WITH THE SKIN WASH AWAY COMPLETELY WITH SOAP AND WATER e IF TAKEN INTERNALLY DO NOT INDUCE VOMITING BUT PROMPTLY CONSULT A PHYSICIAN FOR PROPER TREATMENT 6 Chapter SNOILDIdSNI OIAOINdd 6 2 2 Periodic inspection 2 1 Daily inspection Check the following points on a daily basis before and after robot operation Checkpoints Check items Check for damage dent and Cables excessively tight bends Replace if needed Check for unusual vibration Ball screw bearing and noise Check for unusual vibration Motor and noise and for abnormal temperature rise 2 2 Three month inspection Chapter Check the following points every 3 months and apply grease if needed 6 Checkpoints Check items Check for dust buildup or debris Clean if necessary Apply grease after cleaning Check to see if the ball screw linear guide and ball bushing are lubricated See 4 3 in this not dry Apply grease if necessary Standard robots Albania No 2 Shell Daphne Eponex No 2 Idemitsu Clean room robots LG 2 NSK
16. TIONS AND REQUIRING NO MECHANICAL MOVEMENT OF THE ROBOT KEEP THE EMERGENCY STOP BUTTON PRESSED USE ONLY LUBRICANT AND GREASES SPECIFIED BY YAMAHA SALES OFFICE OR REPRESENTATIVE USE ONLY PARTS SPECIFIED BY YAMAHA SALES OFFICE OR REPRESENTATIVE TAKE SUFFICIENT CARE NOT TO ALLOW ANY FOREIGN MATTER TO CONTAMINATE THEM DURING ADJUSTMENT PARTS REPLACEMENT OR REASSEMBLY DO NOT MODIFY ANY PARTS ON THE ROBOT OR CONTROLLER MODIFICATION MAY RESULT IN UNSATISFACTORY SPECIFICATIONS OR THREATEN OPERATOR SAFETY WHEN ADJUSTMENT OR MAINTENANCE IS COMPLETE RETIGHTEN THE BOLTS AND SCREWS SECURELY DURING ROBOT ADJUSTMENT OR MAINTENANCE PLACE A SIGN INDICATING THAT THE ROBOT IS BEING ADJUSTED OR SERVICED TO PREVENT OTHERS FROM TOUCHING THE CONTROL KEYS OR SWITCHES PROVIDE A LOCK ON THE SWITCH KEYS OR ASK SOMEONE TO KEEP WATCH AS NEEDED 6 Chapter SNOILDIdSNI OIAOINdd 6 1 When applying grease to the ball screw and linear guide take the following precautions A WARNING PRECAUTIONS WHEN HANDLING GREASE e INFLAMMATION MAY OCCUR IF THIS GETS IN THE EYES BEFORE HANDLING THE GREASE WEAR YOUR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES INFLAMMATION MAY OCCUR IF THE GREASE COMES INTO CONTACT WITH SKIN BE SURE TO WEAR PROTECTIVE GLOVES TO PREVENT CONTACT WITH SKIN DO NOT TAKE ORALLY OR EAT EATING WILL CAUSE DIARRHEA AND VOMITING HANDS AND FINGERS MIGHT BE CUT WHEN O
17. arm type 2 axis model Eight M6 coarse thread tap holes and two 6 reamer holes are opened on the Y axis slider Install the user tool onto the Y axis slider using these holes M5 coarse thread tap holes are also opened on the slider side Use these to fix light loads other than the tool such as a wiring retainer There is a step on the top of the slider The actual tool installation surface is the shaded section shown in the drawing Select the nominal length of the tool fixing bolt so that the fitting length of the screw fixing the tool is 6mm or more 8mm or less 90 2 06H7 Depth8 70 8 Allowable screw depth 6 Thread insert depth 8 M6x1 0 Depth8 TOOL AHL DNITIVISNI S 0 02 135 110 Tolerance between knock E CAUTION If the fitting length is less than 6mm the threads could be damaged during tightening If the fitting length exceeds 8mm the bolt end could contact the bottom 4 1 2 ZFH single arm type double arm type When using the 3rd axis model with ZFH for the 3rd axis install the workpiece onto the ZFH slider by using four M5 coarse thread tap holes and a 5 reamer hole opened on the slider s workpiece installation surface The tap depth is 9mm There is a step on the top of the slider The actual tool installation surface is the shaded section shown in the drawing 4 M5x0 8
18. bot cable domain When setting the harness and air tube into the cable carrier make sure that the total cross sectional area of all wires and pipes including the YAMAHA cable inside the cable carrier does not exceed 30 of the cable carrier s cross sectional area When many harnesses and air tubes with different diameters and materials are stored into the cable carrier they may intertwine with each other in spiral form causing faulty wiring 5 6 PERIODIC INSPECTIONS 1 Before beginning work Periodic inspection and maintenance are essential to ensure safe and efficient operation of YAMAHA robots This chapter describes periodic inspection items and procedures for the NXY Before beginning work read the precautions below and also in Chapter 1 Using the Robot Safely and follow the instructions A DANGER IF THE INSPECTION OR MAINTENANCE PROCEDURE CALLS FOR OPERATION OF THE ROBOT STAY OUT OF THE WORKING AREA OF THE ROBOT DURING OPERATION DO NOT TOUCH ANY PARTS INSIDE THE CONTROLLER KEEP WATCHING THE ROBOT MOVEMENT AND SURROUNDING AREA SO THAT THE OPERATOR CAN PRESS THE EMERGENCY STOP BUTTON IF ANY DANGER OCCURS A WARNING WHEN THE ROBOT DOES NOT NEED TO BE OPERATED DURING ADJUSTMENT OR MAINTENANCE ALWAYS TURN OFF THE CONTROLLER AND THE EXTERNAL SWITCH BOARD DO NOT TOUCH INTERNAL PARTS OF THE CONTROLLER FOR 5 SECONDS AFTER THE CONTROLLER HAS BEEN TURNED OFF WHEN ONLY MAKING ELECTRICAL INSPEC
19. ery 3 years or more often if the robot is used frequently Checkpoints Check items Ball screw nut section Check ball screw nut and linear Consult us if abnormal and linear guide guide for backlash due to wear condition is found DENN LZ 3 Replenishing grease to the linear guide A WARNING ALWAYS TURN THE CONTROLLER POWER OFF BEFORE STARTING PERIODIC INSPECTIONS SERIOUS ACCIDENTS COULD OCCUR IF THE ROBOT STARTS MOVING DURING THE PERIODIC INSPECTION THE MOTOR AND SPEED REDUCTION GEAR CASING ARE EXTREMELY HOT AFTER AUTOMATIC OPERATION SO BURNS MAY OCCUR IF THESE ARE TOUCHED BEFORE HANDLING THESE PARTS TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THE PART HAS COOLED 3 Replenishing grease to the linear guide Grease must be replenished to this linear guide periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu 6 Chapter CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc 1 Turn the controller power OFF When the ZFL unit is attached for the 3rd axis the replenishment work can be carried out easier by moving the Z axis slider to near the motor near the origin and turning the controller power OFF SNOILDIdSNI
20. f during high speed operation by emergency stop or safety functions these mechanical stoppers prevent the axis from exceeding the movable range Note that the movable range is the area limited by the mechanical stoppers No mechanical stopper is provided on the R axis 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from dropping when the servo power is shut off This brake is working when the controller power is OFF or if the Z axis servo is OFF even when the controller power is ON The Z axis brake can be released by means of the programming unit or by a command in the program when the controller power is ON A WARNING THE Z AXIS WILL DROP WHEN THE BRAKES ARE RELEASED CREATING A HAZARDOUS SITUATION PRESS THE EMERGENCY STOP BUTTON AND PROP UP THE Z AXIS WITH A SUPPORT STAND ETC BEFORE RELEASING THE BRAKE BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE Z AXIS AND INSTALLATION BASE ETC WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACHING 1 9 A Al4ddVS LOJON JHL DNISN Chapter 5 Safety Measures for the System When the robot is commonly used in conjunction with an automated system dangerous situations are more likely to occur from the automated system than from the robot itself Appropriate safety measures must be taken on the part of the system manufacturer according to the individual system The system manufacture should provide a pr
21. for Industrial Robot Operation Companies or factories using industrial robots must make sure that every person who handles the robot such as for teaching programming movement check inspection adjustment and repair has received appropriate training and also has the skills needed to perform the job correctly and safely Since YAMAHA Cartesian robot XY series falls under the industrial robot category the user must observe local regulations and safety standards for industrial robots and provide special training for every person involved in robot related tasks teaching programming movement check inspection adjustment repair eta Chapter rem A13JVS LOJON AHL DNISN 1 8 4 Robot Safety Functions 1 Overload detection This function detects an overload applied to the motor and shuts off the servo power Chapter h 2 Overheat detection This detects an abnormal rise in the controller driver temperature and shuts off the servo power If an overload or overheat error occurs take the following measuring Insert a timer in the program 2 Reduce the acceleration coefficient 3 Soft limits Soft limits can be set on each axis to limit the working envelope in manual operation after return to origin and during automatic operation Note that the working envelope is the area limited by soft limits ATJdYS LOJON JHL DNISN 4 Mechanical stoppers If the servo power is suddenly shut of
22. hapter 2 Method A Open through holes on the installation base and install with M6 bolts from below M6 tap holes are opened on the bottom of the robot Method B Tap holes into the installation base and secure the robot with M6 bolts from the inside of the robot 1 Installation bolt types NOILVTIVISNI Use the installation bolt with a hexagon socket head cap screw M6 strength 8 8T 2 Installation bolt nominal length CAUTION Do not use washers or spring washers with the tightening bolt The bolt head could interfere with the linear guide s bearings and be damaged e When using method A determine the nominal length so that the length of the screw from the robot bottom is 9mm or more 27mm or less Refer to the drawing below e When using method B if the installation base is made of steel secure 1D or more 6mm or more for M6 for the installation base s screw fitting length When made of aluminum secure 1 5D or more 9mm or more for M6 Refer to the drawing below 11 Nominal length of the bolt 2 1 3 Tightening torque The accurate tightening torque will differ according to the seating face frictional coefficient and the female screw material etc The recommended tightening torque is between 9 8N m to 12 7N m 100kgf cm to 130kgf cm Chapter 4 Installation methods A WARNING
23. ids on the cable carrier by using a flat tip screwdriver The outer lids do not have to be removed if the connectors are not attached to the wiring materials NidId 4ISN GNV DNIAIM 335N 5 3 2 Set the outer lids back in the original position after finishing the wiring layout al Chapter 3 Fix the wiring materials with Insulock ties as necessary Insulock base must be attached See the photograph below for the machining position Nidld 4ISN ANV DNIAIM AISAN Make sure that the clamp part does not move by the wiring tension during axis operation 4 A bundle of wires can be set either left or right of the robot Chapter al Nidld 4ISN ANY DNIAIM 43SN 5 5 1 3 Cable carrier specifications The cross sectional shape of the cable carrier and the shape of the cable mounted initially by YAMAHA are shown below 2 axis specifications X Y cable carrier User wiring area Signal wire 610 1 Power wire 49 8 Chapter L 120 al UN rm A Y Z cable carrier 3 axis specifications X Y cable carrier A User wiring area Signal wire 98 2 User wiring area Power wire 97 6 Signal wire 610 1 Z Power wire 7 6 Signal wire 8 2 Power wire 9 8 O gt AP e g Dd z 50 i c 80 100 120 Un 100 gt rm A CAUTION LLL Harness and air tube must be laid in the unoccupied area Do not set the user Z wiring piping in the YAMAHA ro
24. on Ver 1 03 Jun 2011 The manual s version number was changed to match that for the Japanese manual Ver 1 06 Jul 2012 The description regarding Warranty was changed User s Manual XY X series n NX Y Jul 2012 Ver 1 06 This manual is based on Ver 1 06 of Japanese manual 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
25. oper user s manual for safe correct operation and servicing of the system 6 Trial Run After making installations adjustments inspections maintenance or repairs to the robot carry out trial run using the following procedures 1 If a safeguard enclosure has not yet been provided right after installation of the robot rope off or chain off the movable range in place of the safeguard enclosure and observe the following points CD Use sturdy stable posts that will not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 8 Place a sign to keep the operator or other personnel from entering the movable range 2 Check the following points before turning the controller ON DIs the robot securely and correctly installed 2 Are the electrical connections to the robot correct 8 Are items such as air pressure correctly supplied 4 Is the robot correctly connected to peripheral devices 5 Have safety measures safeguard enclosure etc been taken 6 Does the installation environment meet the specified standards 3 After the controller power is turned ON check the following points from outside the safeguard enclosure D Does the robot start and stop as intended Can the operation mode be selected correctly 2 Does each axis move as intended within the soft limits 3 Does the end effector move as intended 4 Are the signal transmissions to the end effector and periphe
26. r 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 THE WARRANTY STATED HEREIN PROVIDED BY YAMAHA ONLY COVERS DEFECTS IN PRODUCTS AND PARTS SOLD BY YAMAHA TO DISTRIBUTORS UNDER THIS AGREEMENT ANY AND ALL OTHER WARRANTIES OR LIABILITIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXPRESSLY DISCLAIMED BY YAMAHA MOREOVER YAMAHA SHALL NOT BE HELD RESPONSIBLE FOR CONSEQUENT OR INDIRECT DAMAGES IN ANY MANNER RELATING TO THE PRODUCT Ver 1 00_201205 Storage operating conditions and utilities that are outside the range specified in the Chapter mh Al4ddVS 104909 JHL DNISN 1 13 12 CE Marking Refer to the following YAMAHA robot controller user s manuals for details on the related CE Marking for export to or use in EU regions Chapter zul e CE marking supplement manual for RCX series Al4ddVS LOJON JHL DNISN 1 14 INSTALLATION A WARNING Always turn the controller power OFF before installing the robot Serious accidents might occur if the robot starts to operate during installation The NXY is installed with one of the following two methods C
27. ral devices correct 5 Does emergency stop work 6 Are the teaching and playback functions normal Are the safeguard enclosure and interlock working as intended Does the robot move correctly during automatic operation 1 10 A 7 Work Within the Safeguard Enclosure 7 Work Within the Safeguard Enclosure When work is required in the safeguard enclosure always turn the controller power OFF and place a sign indicating that the robot is being adjusted or serviced in order to keep any other personnel from touching the controller power switch or operation panel except for the time during soft limit setting and teaching operation Follow the applicable parts of cautions and procedures in the user s manual for soft limit setting Read the below for teaching operation Chapter 1 ll Teaching operation within a safety enclosure 1 Check or perform the following points from outside the safeguard enclosure D Make sure that no hazards are present within the safeguard enclosure by a visual check 2 Check that the programming unit MPB or RPB operates correctly 3 Check that no failures are found in the robot 4 Check that emergency stop works correctly 5 Select teaching mode and prohibit automatic operation Al4ddVS LOJON JHL DNISN 2 Never enter the movable range of the robot while within the safeguard enclosure 8 Automatic Operation 1 Check the following before starting automatic operation
28. rder of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten OO M4 small screw with spring washer Ring tongue terminal Lock washer CAUTION auai Accurately insert the lock washer between the ring tongue terminal and robot Proper continuity may not be secured if the lock washer is dislocated Take care not to catch the harness and ground wire from the X axis with the cover of X axis wiring box when installing the cover SNOILDANNOD JAILIALOUd 3 1 Grounding to the single arm robot Connect the ground wire to the ground terminal on the external face of X axis wiring box 3 2 Grounding to the double arm robot 1 Remove the M4 bolts 2 pcs on the top of the X wiring box and open the cover by sliding toward the robot Chapter Q Ground terminal SNOILDANNOD JAIL9I1104d Ground wire 3 3 MEMO 3 4 INSTALLING THE TOOL BEEN Single arm type double arm type 2 axis model A WARNING ALWAYS TURN THE CONTROLLER POWER OFF BEFORE INSTALLING A TOOL TO PREVENT AN ACCIDENT BEFORE INSTALLING A TOOL CHECK THAT THE ROBOT IS SECURELY FIXED TO THE BASE THE USER IS RESPONSIBLE FOR DETERMINING THE REQUIRED BOLT TYPE AND TIGHTENING TORQUE AND ACCURATELY INSTALLING THE TOOL IMPROPER INSTALLATION CAN CAUSE THE TOOL TO DISLOCATE DURING OPERATION AND LEAD TO SERIOUS ACCIDENTS Ja Chapter Single arm type double
29. rvicing the robot or damage to the robot and or robot controller Nul 7 NOTE Explains the keypoint in the operation in a simple and clear manner Refer to the user s manual by any of the following methods to operate or adjust the robot safely and correctly 1 Operate or adjust the robot while referring to the printed version of the user s manual available for an additional fee 2 Operate or adjust the robot while viewing the CD ROM version of the user s manual on your computer screen 3 Operate or adjust the robot while referring to a printout of the necessary pages from the CD ROM version of the user s manual It is not possible to list all safety items in detail within the limited space of this manual Thus it is essential that the user have full knowledge of basic safety rules and that the operator makes correct judgments on safety procedures during operation When exporting this robot the warning labels and user s manuals must be changed to export specifications 1 1 2 Essential Caution ltems Particularly important cautions for handling or operating the robot are described below In addition safety information about installation operation inspection and maintenance is provided in each chapter Be sure to comply with these instructions to ensure safe use of the robot Chapter 1 Observe the following cautions during automatic operation A DANGER SERIOUS INJURY WILL RESULT FROM IMPACT WITH
30. sted on warning labels and in this manual A WARNING IMPROPER INSTALLATION OR OPERATION CAN RESULT IN SERIOUS INJURY READ THE USER S MANUAL AND ALL WARNING LABELS BEFORE OPERATION AlddVS LOJON AHL DNISN The warning label 3 is attached to the robot e Be sure to read the warning labels and this manual carefully and make sure to thoroughly understand the contents before attempting installation and operation of the robot Before starting robot operation be sure to reread the procedures and cautions related to the work as well as the descriptions in this chapter Chapter 1 Using the Robot Safely Never install adjust inspect service or operate the robot in any manner that does not comply with the instructions in this manual A WARNING Improper installation or operation can result in serious injury or death Read user s manual and all warning labels before operation Warning label 3 4 Do not use the robot in environments containing inflammable gas etc A WARNIG THIS ROBOT IS NOT DESIGNED FOR OPERATION IN ENVIRONMENTS WHERE INFLAMMABLE OF EXPLOSIVE SUBSTANCES ARE PRESENT DO NOT USE THE ROBOT IN ENVIRONMENTS CONTAINING INFLAMMABLE GAS DUST OR LIQUIDS EXPLOSIONS OR FIRE MIGHT OTHERWISE RESULT 1 3 5 Do not use the robot in locations possible subject to electromagnetic interference etc ae AX WARNING 4 AVOID USING THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC INTERFERENCE
31. t is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc Always remove the grease nipple after completing the work Damage or positional deviation could occur if the robot is operated with the grease nipple installed 6 6 DENN LLL 4 Replenishing grease to the ball screw 1 Use the recommended grease nipple A M6X1 JIS B1575 2 Turn the controller power OFF When the ZF unit is attached for the 3rd axis the replenishment work can be carried out easier by moving the Z axis slider to near the motor near the origin and turning the controller power OFF 3 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 4 Remove the stroke cover of the axis to which grease is to be replenished Refer to section 1 Installation for details on removing the X axis cover 5 Install the grease nipple onto the ball screw flange 6 Using a grease gun replenish grease from the grease nipple Chapter O SNOILOAdSNI 310014 3d Sufficient grease has been replenished when new grease starts to seep out from the clearance between the ball screw nut and screw Wipe off any excessive grease Recommended grease f Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu Recommended grease gun MG70 THK N type nozzle 7 Remove the grease nipple 6 7 Revision record Manual version Issue date Descripti
32. tion when disassembling and replacing the motor A WARNING WHEN DISASSEMBLING OR ASSEMBLING THE MOTOR FOR A BALL SCREW DRIVE TYPE ROBOT A STRONG MAGNETIC ATTRACTION FORCE WILL BE PRESENT BETWEEN THE MOTOR STATOR FIXED COIL AND ROTOR ROTATING MAGNET CAUSING A RISK OF PINCHING HANDS ETC A YAMAHA TRAINED OPERATOR MUST CARRY OUT THIS WORK USING THE YAMAHA RECOMMENDED JIGS 13 Use caution when removing the Z axis brake A WARNING THE Z AXIS WILL NATURALLY DROP WHEN THE BRAKE IS REMOVED CAUSING A HAZARDOUS SITUATION PROP UP THE Z AXIS WITH A SUPPORT STAND ETC BEFORE TURNING THE CONTROL POWER OFF AND REMOVING THE BRAKE BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE Z AXIS DRIVE SECTION AND Z AXIS INSTALLATION BASE ETC 1 5 14 Take the following safety precautions during inspection of the controller AK WARNING __ _ M IF THE TERMINALS OR CONNECTORS ON THE OUTSIDE OF THE CONTROLLER MUST BE TOUCHED DURING INSPECTION ETC ALWAYS FIRST TURN THE CONTROLLER POWER OFF AND THE POWER SOURCE TO PREVENT POSSIBLE ELECTRICAL SHOCK REFER TO THE YAMAHA ROBOT CONTROLLER USER S MANUAL FOR PRECAUTIONS ON HANDLING THE CONTROLLER NEVER TOUCH ANY INTERNAL PARTS OF THE CONTROLLER 15 Consult YAMAHA for corrective action
33. when the robot is damaged or malfunctions occur A WARNING IF ANY PART OF THE ROBOT IS DAMAGED OR ANY MALFUNCTION OCCURS CONTINUING THE OPERATION MAY BE VERY DANGEROUS PLEASE CONSULT YOUR YAMAHA SALES OFFICE OR DEALER FOR CORRECTIVE ACTION Al4ddVS LOJON AHL DNISN Damage or Trouble Possible Danger Damage to machine harness or robot cable Electrical shock malfunction of robot Flying outward of damaged parts during robot Damage to exterior of robot operation Abnormal operation of robot positioning error Malfunction of robot excessive vibration etc Z axis brake trouble Dropping of load 16 Use caution not to touch the controller rear panel cooling fan A WARNING e INJURY MAY OCCUR FROM COMING INTO CONTACT WITH THE COOLING FAN WHILE IT IS ROTATING e WHEN REMOVING THE FAN COVER FOR INSPECTION FIRST TURN OFF THE CONTROLLER AND MAKE SURE THAT THE FAN HAS STOPPED 17 Be careful not to touch the motor or speed reduction gear casing when hot THE MOTOR AND SPEED REDUCTION GEAR CASING ARE EXTREMELY HOT AFTER AUTOMATIC OPERATION SO BURNS MAY OCCUR IF THESE ARE TOUCHED BEFORE HANDLING THESE PARTS DURING INSPECTION OR SERVICING TURN THE CONTROLLER POWER OFF WAIT FOR A WHILE AND CHECK THAT THE PART HAS COOLED 1 6 18 Do not remove alter or stain the warning labels A WARNING IF THE WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE THEN ESSENTIAL PRECAUTIONS MIG
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