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YK-XG Series I/M English

1. Orange Blue Violet Grey O White Base side User signal line lO Brown Red Arm side O O O C1 AJOJN c Oo O C1 BR Wy PP e e Orange n5 N k CD k CD 5 AL Q o 3 A A al al Flame Ground Robots models with non standard specifications may have different wiring colors The following describes how to make the wiring to the connector supplied with the robot Solder the user signal wires to the connector as shown in Fig below and assemble the connector Then connect it to the user wiring connector Tighten each connector screw to its specified torque If the outer diameter of the cable is small use tape or an equivalent item to thicken the cable clamp Otherwise moisture and dust may penetrate inside the robot Wiring Setscrew B User wiring Setscrew A 7 Clamp nut End hood 23207 HM 00 e Screw tightening torque Position Torque value kgf cm End hood 10 to 15 Clamp nut 15 to 20 Setscrews A and B 2t0 3 e Cable outer diameter Model Cable outer diameter mm YK250XGC P YK350XGC P YK400XGC P YK500XGLC P YK600XGLC P 613 1 to 15 0
2. Robot model YK250XGC P YK350XGC P YK400XGC P YK500XGLC P Arm length 100mm 200mm 250mm 250mm 350mm X axis Rotation angle 129 Axi Arm length 150mm 250mm re Y axis speeilcallens Rotation angle 134 144 Z axis Stroke 150mm R axis Rotation angle 360 X axis 200W Y axis 150W Motor Z axis 50W R axis 100W XY resultant 4 5m s 5 6m s 6 1m s 5 1m s 4 9m s Maximum speed Z axis 1 1m s R axis 1020 s XY axes 0 01mm Repeatability 1 Z axis 0 01mm R axis 0 004 Payload 4kg R axis tolerable moment of inertia 2 0 05kgm 0 5kgfcms User wiring 10 cables User tubing 4x4 Travel limit 1 Soft limit 2 Mechanical stopper XYZ axes Robot cable 3 5m option 5m 10m Weight 22kg 22 5kg 25kg Degree of cleanliness YK XG L C Class ISO 3 ISO14644 1 Suction air flow 30N2 min 3 Dust drip proof protection rating YK XG L P IP65 IEC60529 or its equivalent 4 1 At constant ambient temperature XY 2 There are limits to acceleration coefficient settings 3 Class 10 0 1um FED STD 209D or its equivalent The required suction air flow may vary depending on the operating conditions or environment 4 Do not splash the jet flow onto the bellows directly For details about drip proof performance for fluid other than water contact your distributor The Z axis spline may vibrate in a Z axis operation speed range of 2096 to 4096 depending on the arm position or Z axis positio
3. 90 AAA e User tubing 1 64 black If the user tubing is not used attach the plug supplied with the robot User tubing 2 04 red 290 fi m a WZ gt SF Y AS gt JA 101153 130 M8 bolt for installation 4 bolts used 13 4 Since this tapped hole is used for the wiring or tubing clamp do not apply a large load 7 8 12 1183 Dimensions of base installation part 250 117 Maximum 160 during arm rotation 852 822 150 702 6 4 y 627 296 2 4 247 186 146 133 Mi 67 5 2 Aj m 150 IN 82 5 L1 ial Z axis upper end mechanical stopper position Z axis rises by 4mm during return to origin Z axis lower end mechanical stopper position 675 10 Maximum 730 during arm rotation 1523 1441 User tubing 3 04 blue User tubing 4 64 white 1256 221 3202 1167 93 1 58 H 127m 0 0 M4 ground terminal Standard clean room model dust drip proof model Tapped hole for user 4 M3x0 5 Depth 6 Width across flat 15 Cross section A A The weight of the tool attached here should be added to the tip mass 5 8 Scale 1 1 View of F Scale 1 1 User tubing 1 64 black User tubing 2 64 red I
4. 2 1 lt step ll Y Turn off the controller Disconnecting the connector for the user wiring gt Step 12 andremoving the plate seal and seal washer step 12 Remove the mounting bracket disconnect the connector for the Connector for user wiring ox Mounting bracket user wiring and remove the plate seal 4 5 and seal washer 3 23221 HM 00 Hex socket head bolt M3 length 6 stainless 2 pcs YAMAHA s part No 91380 03006 Y axis arm cover clamping bolt Hex socket head bolt M3 length 18 stainless 4 pcs YAMAHA s part No 91380 03018 step 1 3 Remove the cover seal 6 and seal 7 Since the seal 7 is affixed to the Y axis arm peel off the adhesive agent completely 23222 HM 00 dA em Plate 23223 HM 00 E d A Seal 4 N E DM Seal 5 When detaching or attaching the cover it may be E in contact with the boss inside the cover or the stay So install the cover while widening it slightly gt Step 13 Removing the cover and seal or shifting it 5 u Q o 3 Boss inside Stay Nen Cover A m Em ung NS Ji AR gt pem Og Seal 6 1L 1 Y axis arm amp ME i 1 I Be Adhesion surface AH ee is located at the SSF omer portion Y axis arm cover clamping screw Binding head screw M3 length 12 4 pcs Seal washer 8 YAMAHA s part No 98980 0301 2 gt Ste
5. 4 M3x0 5 Depth 5 There is no phase relationship with the R axis origin Since this tapped hole is used for the wiring or tubing clamp do not apply a large load 12 View of F User tubing 2 44 red 183 Dimensions of base installation part Scale 1 1 VE 117 56 150 u 250 N Maximum 190 during arm rotation 839 8091 AH 8 689 661 SES 632 10 6141 Maximum 660 during arm rotation User tubing 1 64 black an 1910 If the user tubing is not used attach the plug supplied with the robot 1428 User tubing 2 64 red Suction air joint 12 YK400XGC Since this joint is not used attach the plug supplied with the robot to User tubing 3 the joint YK400XGP 04 blue 946 User tubing 4 Connector for user wiring i No 1 to 10 usable Cable clamp size LL oo Ame LA 134 to 15 If not used cover the connectors with me h 167 the caps supplied with the robot Ze HN salts DEN j 98 an BE Sn poOO A 2440012 D cS Z axis upper end mechanical stopper position M4 ground terminal 6 22 5 I Z axis rises by 4mm during return to origin 26 31 jn Z axis lower end mechanical stopper position 95 5 Standard clean room model dust drip proof model Tapped hole for user 6 M3x0 5 Depth 6 Width across flat 15
6. 23208 HM 00 Bolt Use the bolt shown in the Fig on the left Cap Mounting bracket Stainless gt 9 o Bolt M3 x 6 Ss PA u A Q ES T E d IN o 5 ni Daly JL we EN Z 2 TEN as YD ae gt D SS EWN 33 J ys Folk Plug Connector for user wiring 23209 HM 00 Connector for user wiring supplied with the robot at shipment Robot Model Connector for user wiring on arm side Connector for user wiring on base side YK250XGC P YK350XGC P YK400XGC P YK500XGLC P NJW 24 16 PM 15 NJW 24 16 PF 15 YK600XGLC P Manufacturer MISUMI or NANABOSHI ELECTRIC MFG 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 5 1 Trial Operation in Chapter Safety Instructions of this manual 2 8 4 Limiting the movement range with X and Y axis mechanical stoppers ALWAYS TURN OFF THE CONTROLLER BEFORE CHANGING THE MOVEMENT RANGE WITH MECHANICAL STOPPERS When the mechanical stopper positions are changed the soft limits must be set to a point inside the mechanical stopper positions For details about soft limits see 3 Setting the soft limits in Chapter 3 of the Installation Manual for YK XG standard model If the working envelope during robot work is smaller than the maximum working envelope range or if the robot interferes with periphe
7. Safety Instructions Contents 1 Safety Information S 2 Signal words used in this manual S 2 3 Warning labels S 3 3 3 1 Warning labels S 3 1 1 Warning label messages 9 9 3 1 2 Supplied warning labels 9 0 3 2 Warning symbols S 6 4 Major precautions for each stage of use 4 1 Precautions for using robots and controllers S 7 4 2 Design S 8 4 2 1 Precautions for robots 9 8 4 2 2 Precautions for robot controllers 9 8 4 3 Moving and installation S 9 4 3 1 Precautions for robots S 9 4 3 2 Precautions for robot controllers S 10 4 4 Safety measures S 12 4 4 1 Safety measures S 12 4 4 2 Installing a safety enclosure 9 13 4 5 Operation S 14 4 5 1 Trial operation S 14 4 5 2 Automatic operation S 16 4 5 3 Precautions during operation S 16 4 6 Inspection and maintenance S 18 4 6 1 Before inspection and maintenance work S 18 4 6 2 Precautions during service work S 19 4 7 Disposal S 20 5 Emergency action when a person is caught by robot S 21 6 Using the robot safely S 22 6 1 Robot safety functions S 22 6 2 Special training for industrial robot operation S 23 1 Safety Information Industrial 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 controllers carefully read and comply with the safety instructions and precautions in this Safety In
8. 2 lt e SECURE THE CONNECTOR FOR THE USER WIRING SUPPLIED FIRMLY WITH THE MOUNTING BRACKET SUPPLIED IF THIS CONNECTOR COMES OFF THIS MAY CAUSE THE ROBOT TO MALFUNCTION SEE THE FIG BELOW e TAKE APPROPRIATE MEASURES SO THAT THE WIRING OR TUBING PREPARED BY THE USER THAT HAS BEEN INSTALLED USING THE CONNECTOR FOR THE USER WIRING OR THE JOINT FOR THE USER TUBING DOES NOT INTERFERE WITH THE ROBOT ENTANGLE AROUND THE ROBOT OR FLAP AROUND DURING ROBOT OPERATION OTHERWISE THE WIRING OR TUBING IS DAMAGED CAUSING MALFUNCTION e LAY OUT THE WIRING OR TUBING PREPARED BY THE USER THAT HAS BEEN INSTALLED USING THE CONNECTOR FOR THE USER WIRING OR THE JOINT FOR THE USER TUBING SO THAT IT DOES NOT HINDER THE MOVEMENT OF WORK PERSONNEL OTHERWISE WORK PERSONNEL MAY STUMBLE OVER THE WIRING OR TUBING CAUSING FALLING OR PERSONAL INJURY For the connector for the user wiring supplied with the robot pin contacts are connected to the connector on the arm side while socket contacts are connected to the connector on the base side Pay special attention to this instruction when performing the soldering Be sure to use the connector for the user wiring supplied with the robot If other connector is used contact fault may occur 5 u Q o 3 Connector for user wiring Y axis arm side 7 Connector for user wiring Bolt Use the bolt shown in the Fig on the left Mounting bracket Bolt M3 x 6 Stainless
9. 2 14 8 Passing the user wiring and tubing through the spline In the YK250XGC P YK350XGC P YKAOOXGC P YKSOOXGLC P and YK600XGLC P the user wiring and tubing can be passed through 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 speed reduction unit or R axis motor Use an appropriate connector that passes through the spline with an inside diameter of 11 Example of how to pass the wiring and tubing Clamp using nylon clamp etc f J Clamp using nylon clamp etc pw ia Stay MU User wiring UONDIIDISUI Mt ll User tubing Junkosha s mechatro flat tube MF1 06 working length cm 10 x 0 1 0 1sq wire materials 10 pcs are included in the air tube outside diameter 66 x inside diameter 64 air tube M j ENE f y 7 ES Outside diameter 4 x inside diameter 2 5 Air tube e LCD Clamp on the hand side Z axis moves up Z axis moves down c M3 bolt 23216 HM 00 2 15 lt 9 Detaching or attaching the covers To detach the covers remove the bolts and screws It is recommended to replace the O rings and seals shown below with new ones Part name Part number O ring 90200 01J350 O ring 90990 17J025 Seal washer 90990 36J008 Seal
10. 9 6 The weight of the tool attached here should be added to the tip mass Scale 1 1 Cross section A A 16 h7 Qoia Z axis tip shape 23507 HM 00 YK400XGC YK400XGP Tool flange mount type 99 5 630h7 8 021 C o D O zh Q Q O o 4H7 6 through hole Detailed drawing D Scale 1 1 View of E 23508 HM 00 YK400XGC YK400XGP Working envelope Option X axis additional stopper X axis mechanical stopper position can be changed to 119 position working envelope 117 Y axis additional stopper Y axis mechanical stopper position can be changed to 108 position working envelope 116 Oo Other option Standard coordinate setting jig 307 Note that the robot cannot be used at a position where the base flange robot cable spline bellows and tool flange interfere with each other in the working envelope shown above e X axis mechanical stopper position 131 Y axis mechanical stopper position 146 23509 HM 00 5 lt C o D O zh Q Q O o 1 2 4 YK500XGLCIP Connector for user wiring No 1 to 10 usable Cable clamp size 013 1 to 15 If not used cover the connectors with the caps supplied with the robot User tubing 3 64 blue User tubing 4 64 white 4 M3x0 5 Depth 5 There is no phase relationship with the R axis origin
11. e Tightening torque 3 5Nm 3 kgfcm Set screw 3 Apply Loctite 262 Henkel Japan to the set screw gt Step7 Installing the tool flange step Y Affix the warning label 4 SSSA step Go out of the safety enclosure Degrease this portion and affix the warning label 4 2 21 lt 5 a Q o 3 e Robot settings Contents 1 Overview 3 1 2 Adjusting the origin 3 2 3 Standard coordinate setting using a standard coordinate setup jig 3 3 1 Overview Various settings have been completely made at the factory or by your distributor before shipment including the 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 e Read and understand the contents of this chapter completely before attempting to set the robot e Place a conspicuous sign indicating the robot is being adjusted to prevent others from touching the controller switch programming box or operation panel If a safety enclosure has not yet been provided right after installation of the robot rope off or chain off the movement area 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 visi
12. 4 Allow a waiting time after power is shut off Allow time for temperature and voltage to drop e WHEN PERFORMING MAINTENANCE OR INSPECTION OF THE ROBOT CONTROLLER UNDER YOUR DISTRIBUTOR S INSTRUCTIONS WAIT AT LEAST 30 MINUTES FOR THE RCX SERIES OR 5 MINUTES FOR THE SR1 SERIES AFTER TURNING THE POWER OFF SOME COMPONENTS IN THE ROBOT 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 THE MOTOR AND SPEED REDUCTION GEAR CASING ARE VERY HOT SHORTLY AFTER OPERATION SO BURNS MAY OCCUR IF THEY ARE TOUCHED BEFORE TOUCHING THOSE PARTS FOR INSPECTIONS OR SERVICING TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THE TEMPERATURE HAS COOLED 5 Precautions during inspection of controller e WHEN YOU NEED TO TOUCH THE TERMINALS OR CONNECTORS ON THE OUTSIDE OF THE CONTROLLER DURING INSPECTION ALWAYS FIRST TURN OFF THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER TO PREVENT POSSIBLE ELECTRICAL SHOCK e DO NOT DISASSEMBLE THE CONTROLLER NEVER TOUCH ANY INTERNAL PARTS OF THE CONTROLLER DOING SO MAY CAUSE BREAKDOWN MALFUNCTION INJURY OR FIRE gt S 18 4 6 2 Precautions during service work 1 Precautions when removing a motor Cartesian robots and vertical mount single axis robots THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE MOTOR IS REMOVED CAUSING A HAZARDOUS SITUATION e TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER TH
13. 5 u Q o 3 Seal 9 Base front cover clamping bolt Hex socket head bolt M4 length 12 stainless 4 pcs YAMAHA s part No 91380 04012 23226 HM 00 Base rear cover E E Base rear cover clamping bolt Hex socket head bolt M4 length 18 stainless 4 pcs YAMAHA s part No 91380 04018 23227 HM 00 2 20 10 Installing the tool flange The tool flange can be retrofitted The following option parts are needed Part No Remarks KCY M1790 000 Tool flange 91312 05014 Bolt 92A08 05308 Set screw 90K41 001490 Warning label step Y Turn off the controller step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller and operation panel step Enter the safety enclosure step Install the tool flange gt Step 4 6 i Installing the tool flange Align the orientation of the tapped hole for the tool flange set screw with that of the width across flat part of the spline and then insert the tool flange all the way inside 23228 HM 00 step Install the tool flange with the bolt 2 Secure the tool flange after it has been inserted all the way inside e Tightening torque 9Nm 92kgfcm Degrease these portions Apply the grease to the bolt thinly to make the tightening torque stable Tool flange 1 23229 HM 00 stepO Tighten the set screw 3
14. YAMAHA SCARA ROBOT Y K XG Series Clean room models YK250XGC YK350XGC YK400XGC YK500XGLC YK600XGLC Dust drip proof models YK250XGP YK350XGP YK400XGP YK500XGLP YK600XGLP Ver 1 00 CONTENTS Installation Manual 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 S 3 3 1 2 Supplied warning labels S 5 3 2 Warning symbols S 6 4 Major precautions for each stage of use S 7 4 1 Precautions for using robots and controllers S 7 4 2 Design S 8 4 21 Precautions for robots S 8 4 2 2 Precautions for robot controllers S 8 4 3 Moving and installation S 9 4 31 Precautions for robots o 9 4 3 2 Precautions for robot controllers S 10 4 4 Safety measures S 12 4 4 1 Safety measures S 12 4 4 2 Installing a safety enclosure S 13 4 5 Operation S 14 4 5 1 Trial operation S 14 4 5 2 Automatic operation S 16 4 5 3 Precautions during operation S 16 4 6 Inspection and maintenance S 18 4 6 1 Before inspection and maintenance work S 18 4 6 2 Precautions during service work S 19 4 7 Disposal S 20 5 Emergency action when a person is caught by robot S 21 6 Using the robot safely S 22 6 1 Robot safety functions S 22 6 2 Special training for industrial robot operation S 23 Warranty T4 CONTENTS YK XG Installation Manual Introduction Before using the robot Be sure to read the following notes Introduction
15. zh Q Q O o Detailed drawing D Scale 1 1 View of E 23502 HM 00 YK250XGC YK250XGP Working envelope Option X axis additional stopper X axis mechanical stopper position can be changed to 119 position working envelope 117 Y axis additional stopper Y axis mechanical stopper position can be changed to 108 position working envelope 106 Other option Standard coordinate setting jig Note that the robot cannot be used at a position where the base flange robot cable spline bellows and tool flange interfere with each other in the working envelope shown above e X axis mechanical stopper position 131 Y axis mechanical stopper position 136 23503 HM 00 5 3 1 2 2 YK350XGC P User tubing 3 64 blue Connector for user wiring User tubing 4 44 white 4 M3x0 5 Depth 5 es usable Cable clamp size 212 There is no phase relationship with the R axis origin 1 to r 7 Since this tapped hole is used for the wiring or tubing If not used cover the connectors with 5 i clamp do not apply a large load the caps supplied with the robot E e 7 3 do 3 res E User tubing 1 64 black Y ET If the user tubing is not used 2 ri attach the plug supplied with the robot 30 x 8 ae gt bolt for installation 4 bolts used 134 134 s View o
16. Chapter 1 Functions 1 Robot manipulator 1 1 Manipulator movement 1 2 Part names 2 Robot initialization number list Chapter 2 Installation 1 Robot installation conditions 11 Sucking from the base rear side of the clean room model 1 2 Protection ratings for moisture and dust on dust drip proof models 2 Installation 2 1 Checking the product 2 2 Moving the robot 3 User wiring and user tubing 4 Limiting the movement range with X and Y axis mechanical stoppers 4 1 Installing the X axis Y axis additional mechanical stoppers 5 Limiting the movement range with Z axis mechanical stopper 6 Working envelope and mechanical stopper positions for maximum working envelope T Installing the user wiring and tubing newly 8 Passing the user wiring and tubing through the spline 9 Detaching or attaching the covers 10 Installing the tool flange Chapter 3 Robot settings 1 Overview 1 1 1 1 12 2 1 2 1 2 2 2 3 2 4 2 6 2 9 2 10 2 13 2 13 2 14 2 21 3 1 CONTENTS Hair Installation Manual 2 Adjusting the origin 3 2 3 Standard coordinate setting using a standard coordinate setup jig 3 3 Chapter 4 Periodic inspecition 1 List of inspection items 4 1 Chapter 5 Specifications 1 Manipulator 5 1 1 1 Basic specification 5 1 1 2 External view and dimensions 5 2 1 24 YK250XGC P 5 2 1 2 YK350XGC P 5 4 1 2 8 YK400XGCIP 5 6 1 2 4 YK500XGLC P 5 8 1 2 5 YK600XGLC P 5 10
17. Check that the fan rotates o l e Check for object blocking the fan e Air cooling fan on the rear of the controller Check for noise during rotation 5 o Check the fan cover for contamination o 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 switch is pressed outside the safeguard enclosure or when the controller power is turned off visually inspect the Z axis brake 5 f any object is found through the visual inspection remove it If noise is heard even when no object is found contact your distributor 4 1 lt O a Iloedsur 5 UOI a Ioedsur 5 UOI 4 2 Bolt tightening torque Bolt size M3 button head bolt Tightening torque kgfcm Tightening torque Nm M4 set screw M3 M4 M5 M6 M8 dry Specifications Contents 1 Manipulator 1 1 1 2 2 22 1725 LAA s Basic specification External view and dimensions YK250XGC P YK350XGC P YKA400XGC P YK500XGLC P YK600XGLC P 5 1 5 2 5 2 5 4 5 6 5 8 5 10 l 1 1 Manipulator Basic specification
18. Y A label 4 VR RE ZORE ERZ Eo easy to see location SCARA robots Cartesian robots 1 For the label positions see the SCARA robot user s manual 1 2 Part names in Chapter 1 2 This label is not attached to some small single axis robots but is supplied with the robots Single axis robots o 5 4 suouyonjjsu AJoJoOS suouyonjjsu AJoJoOS 3 2 Warning symbols Warning symbols shown below are printed on the robot and controller to alert the operator to potential hazards To use the YAMAHA robot safely and correctly always follow the instructions and cautions indicated by the symbols l Electrical shock hazard symbol TOUCHING THE TERMINAL BLOCK OR CONNECTOR MAY CAUSE ELECTRICAL SHOCK SO USE CAUTION Instructions by this symbol This indicates a high voltage is present Touching the terminal block or connector may cause electrical shock 93006 X0 00 2 High temperature hazard symbol MOTORS HEATSINKS AND REGENERATIVE UNITS BECOME HOT SO DO NOT TOUCH THEM Instructions by this symbol This indicates the area around this symbol may become very hot Motors heatsinks and regenerative units become hot during and shortly after operation To avoid burns be careful not to touch those sections 93008 X0 00 3 Caution symbol CAUTION Always read the manual carefully before using the controller Instructions by this symbol This indicates im
19. YOUR DISTRIBUTOR e IFANY OF THE FOLLOWING DAMAGE OR ABNORMAL CONDITIONS OCCURS THE ROBOT THEN CONTINUING TO OPERATE THE ROBOT IS DANGEROUS IMMEDIATELY STOP USING THE ROBOT AND CONTACT YOUR DISTRIBUTOR Damage or abnormal condition Type of danger Damage to machine harness or robot cable Electrical shock robot malfunction Damage to robot exterior Damaged parts fly off during robot operation Abnormal robot operation position deviation vibration etc Robot malfunction Z axis vertical axis or brake malfunction Loads fall off 2 High temperature hazard e DO NOT TOUCH THE ROBOT CONTROLLER AND ROBOT DURING OPERATION THE ROBOT CONTROLLER AND ROBOT BODY ARE VERY HOT DURING OPERATION SO BURNS MAY OCCUR IF THESE SECTIONS ARE TOUCHED THE MOTOR AND SPEED REDUCTION GEAR CASING ARE VERY HOT SHORTLY AFTER OPERATION SO BURNS MAY OCCUR IF THESE 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 gt S 16 3 Use caution when releasing the Z axis vertical axis brake THE VERTICAL AXIS WILL SLIDE DOWNWARD WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION e PRESS THE EMERGENCY STOP BUTTON AND PLACE A SUPPORT UNDER THE VERTICAL AXIS BEFORE RELEASING THE BRAKE e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS AND THE INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACH 4 Be
20. careful of Z axis movement when the controller is turned off or emergency stop is triggered air driven Z axis THE Z AXIS STARTS MOVING UPWARD WHEN POWER TO THE CONTROLLER OR PLC IS TURNED OFF THE PROGRAM IS RESET EMERGENCY STOP IS TRIGGERED OR AIR IS SUPPLIED TO THE SOLENOID VALVE FOR THE Z AXIS AIR CYLINDER e DO NOT LET HANDS OR FINGERS GET CAUGHT AND SQUEEZED BY ROBOT PARTS MOVING ALONG THE Z AXIS e KEEP THE USUAL ROBOT POSITION IN MIND SO AS TO PREVENT THE Z AXIS FROM HANGING UP OR BINDING ON OBSTACLES DURING RAISING OF THE Z AXIS EXCEPT IN CASE OF EMERGENCY STOP 5 Take protective measures when the Z axis interferes with peripheral equipment air driven Z axis WHEN THE Z AXIS COMES TO A STOP DUE TO OBSTRUCTION FROM PERIPHERAL EQUIPMENT THE Z AXIS MAY MOVE SUDDENLY AFTER THE OBSTRUCTION IS REMOVED CAUSING INJURY SUCH AS PINCHED OR CRUSHED HANDS e TURN OFF THE CONTROLLER AND REDUCE THE AIR PRESSURE BEFORE ATTEMPTING TO REMOVE THE OBSTRUCTION e BEFORE REDUCING THE AIR PRESSURE PLACE A SUPPORT UNDER THE Z AXIS BECAUSE THE Z AXIS WILL DROP UNDER ITS OWN WEIGHT 6 Be careful of Z axis movement when air supply is stopped air driven Z axis THE Z AXIS WILL SLIDE DOWNWARD WHEN THE AIR PRESSURE TO THE Z AXIS AIR CYLINDER SOLENOID VALVE IS REDUCED CREATING A HAZARDOUS SITUATION TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER THE Z AXIS BEFORE CUTTING OFF THE AIR SUPPLY 7 Make correct parameter settings The robot must be op
21. movement range and prevent injury from contacting the moving part of the robot IE BR 3 i Install an interlock that triggers emergency stop mE when the door or gate of the safety enclosure is Stay clear of moving machine Can cause serious injury p opened e The safety enclosure should be designed so that no 1 S is one can enter inside except from the door or gate EB SLBKETHES SENS equipped with an interlock device 90K41 001470 e Warning label 1 that comes supplied with a robot should be affixed to an easy to see location on the door or gate of the safety enclosure 90K41 001470 2 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 MOVING PARTS CAN PINCH OR CRUSH HANDS KEEP HANDS AWAY FROM THE MOVABLE PARTS OF THE ROBOT Instructions on this label Use caution to prevent hands and fingers from being pinched or crushed by the movable parts of the robot when transporting or moving the robot or during teaching Pinch or crush hazard bhta atnda 90K41 001460 90K41 001460 S 3 4 SUOHONILSU AJoJoS suouyonjjsu AJoJoOS 3 Warning label 3 SCARA robots Cartesian robots IMPROPER INSTALLATION OR OPERATION MAY CAUSE SERIOUS INJURY BEFORE INSTALLING OR OPERATING THE ROBOT READ THE MANU
22. tubing 3 94 blue There is no phase relationship with the R axis origin 13 1 to 15 i i i eee angen aL Since this tapped hole is used for the wiring or tubing If not used cover the connectors with ee eae the caps supplied with 7 robot clamp do not apply a large load Ol Me TY ZA les User tubing 1 64 LS If the user tubing is not used attach the plug supplied with the robot User tubing 2 04 red 4 09 M8 bolt for installation 4 bolts used 13 4 13 4 10 53 130 12 Maus H 4 Scale 1 1 183 Dimensions of base installation part 117 Maximum 170 during arm rotation 675 10 1 Maximum 740 during arm rotation User tubing 1 4 black User tubing 2 04 red If the user tubing is not used attach the plug supplied with the robot Suction air joint 612 YK600XGLC Since this joint is not used attach the plug supplied with the robot to t523 444 User tubing 3 the joint YK600XGLP 04 blue O User tubing 4 Connector for user wiring 04 white Vo 1 to 10 usable Cable clamp size D i 613 1 to 15 O 5 If not used cover the connectors with a the caps supplied with the robot p 1167 O 11 O a n HA H 12 O 3 A Z axis upper end mechanical stopper position M
23. 2 External view and dimensions in Chapter 5 For details about cautions see the Installation Manual for YK XG standard models For the YK250XGC P YK350XGC P YKAOOXGC P YK500XGLC P and YK6OOXGLC P operate the robot carefully since there are positions where the base flange or robot cable interferes with the spline bellows or tool flange even within the working envelope UONDIIDISUI 2 13 5 n Q o 3 7 Installing the user wiring and tubing newly Use the user wiring and tubing in the machine harness as much as possible by considering the durability of the machine harness If the user wiring and tubing incorporated into the machine are insufficient add new user wiring and tubing using cable ties 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 cable tie 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 Cable tie Machine harness Signal line SF m N AN U 9 y 23215 HM 00 Signal line outside diameter Tube outside diameter o D mm x quantity d mm x quantity Robot model YK250XGC P YK350XGC P YK400XGC P 6 x 1 pc 4 x 3 pcs YK500XGLC P YK600XGLC P Dep 4x 3p
24. 4 ground terminal ij Z axis rises by 4mm during return to origin 82 5 1 u o E Z axis lower end mechanical stopper position Standard clean room model dust drip proof model User tool installation range Width across flat 15 Cross section A A Z axis tip shape Tapped hole for user 4 M3x0 5 Depth 6 Scale 1 1 The weight of the tool attached here should be added to the tip mass 23513 HM 00 5 10 YK600XGLC YK600XGLP Tool flange mount type 64H7 9 through hole Detailed drawing D Scale 1 1 View of E C o D O zh Q Q O o 23514 HM 00 YK600XGLC YK600XGLP Working envelope 7 7 T II Option e X axis additional stopper X axis mechanical stopper position can be changed to 119 position working envelope 117 Y axis additional stopper Y axis mechanical stopper position can be changed to 108 position working envelope 116 e Other option Standard coordinate setting jig Note that the robot cannot be used at a position where the base flange robot cable spline bellows and tool flange interfere with each other in the working envelope shown above X axis mechanical stopper position 131 Y axis mechanical stopper position 146 23515 HM 00 5 11 4 Revision record Manual version Issue date Description Ver 1 00 Jul 2012 First edition Installatio
25. 500mm or more use the eyebolts that come supplied with the robot Refer to the robot manual for details B Installation 1 Protect electrical wiring and hydraulic pneumatic hoses Install a cover or similar item to protect the electrical wiring and hydraulic pneumatic hoses from possible damage B Wiring 1 Protective measures against electrical shock ALWAYS GROUND THE ROBOT TO PREVENT ELECTRICAL SHOCK o 9 4 suouyonisu AJoJoS suouyonijsu AJoJoS B Adjustment 1 Adjustment that requires removing a cover YAMAHA ROBOT CONTROLLERS ARE NOT DESIGNED TO BE EXPLOSION PROOF DO NOT USE THEM IN LOCATIONS EXPOSED TO EXPLOSIVE OR INFLAMMABLE GASES GASOLINE OR SOLVENT FAI LURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH OR LEAD TO FIRE FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT 4 3 2 Precautions for robot controllers B installation environment 1 Installation environment YAMAHA ROBOTS AND ROBOT CONTROLLERS ARE NOT DESIGNED TO BE EXPLOSION PROOF DO NOT USE THEM IN LOCATIONS EXPOSED TO EXPLOSIVE OR INFLAMMABLE GASES GASOLINE OR SOLVENT FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH AND LEAD TO FIRE USE THE ROBOT CONTROLLER IN LOCATIONS THAT SUPPORT THE ENVIRONMENTAL CONDITIONS SPECIFIED IN THIS MANUAL OPERATION OUTSIDE THE SPECIFIED ENVIRONMENTAL RANGE MAY CAUSE ELECTRICAL SHOCK FIRE MALFUN
26. 60 during arm rotation 614 010 User tubing 1 64 black If the user tubing is not used m 408 attach the plug supplied with the robot O User tubing 2 64 red O e Suction air joint 412 YK250XGC O Since this joint is not used attach Sum the plug supplied with the robot to h User tubing 3 64 blue the joint YK250XGP O 264 User tubing 4 I LEBER Connector for user wiring 246 1 Fi No 1 to 10 usable Cable clamp size O 234 dj enne EA 0131t015 2 202 If not used cover the connectors with O 173 1167 the caps supplied with the robot 133 120 93 a o ii wi 01 0 0 dim 0 Z axis upper end mechanical stopper position M4 ground terminal 22 9 Z axis rises by 4mm during return to origin 126 95 5 2 ____ Z axis lower end mechanical stopper position t Standard clean room model dust drip proof model User tool installation range al oO a c9 Width across flat 15 0 016 h7 0 018 39 39 Cross section A A Z axis tip shape Tapped hole for user 6 M3x0 5 Depth 6 Scale 1 1 The weight of the tool attached here should be added to the tip mass 23501 HM 00 gt 5 2 YK250XGC YK250XGP Tool flange mount type 65 50 5 2 99 5 E 2 Clean room model dust drip proof model with tool flange C o D O
27. AL AND INSTRUCTIONS ON THE WARNING LABELS 4 5 AND UNDERSTAND THE CONTENTS Read and understand manuals before operation TO MUS AA EA MURS SAMICVIAPIVERATHRT EZ 90K41 001290 _ Warning label 4 SCARA robots Instructions on this label Be sure to read the warning label and this manual carefully to make you completely understand the contents before attempting installation and operation of the robot Before starting the robot operation even after you have read through this manual read again the corresponding procedures and Safety instructions in this manual Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual 90K41 001290 Do not remove the parts on which Warning label 4 is attached Doing so may damage the ball screw Do not remove the parts UDR Read instruction manual label Controller Refer to the manual AES CAUTION ENGE E READ INSTRUCTION MANUAL Instructions on this label The Z axis ball screw will be damaged if the upper end mechanical stopper on the Z axis spline is removed or moved Never attempt to remove or move it 90K41 001520 Instructions on this label This indicates important information that you must know and is described in the manual Before using the co
28. BELS IN SAFETY INSTRUCTIONS THAT COMES SUPPLIED WITH A ROBOT SHOULD BE AFFIXED TO AN EASY TO SEE LOCATION ON THE DOOR OR GATE OF THE SAFETY ENCLOSURE o 13 suouyonijsu AJoJoS SUOHONIALSU AJoJoS 4 5 Operation When 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 A DANGER CHECK THE FOLLOWING POINTS BEFORE STARTING ROBOT OPERATION NO ONE IS WITHIN THE ROBOT MOVEMENT RANGE THE PROGRAMMING UNIT IS IN THE SPECIFIED LOCATION THE ROBOT AND PERIPHERAL EQUIPMENT ARE IN GOOD CONDITION 4 5 1 Trial operation After installing adjusting inspecting maintaining or repairing the robot perform trial operation using the following procedures l If a safety enclosure has not yet been provided right after installing the robot then rope off or chain off the movement range around the robot in place of the safety enclosure and observe the following points DANGER PLACE A ROBOT IS MOVING KEEP AWAY SIGN TO KEEP THE OPERATOR OR OTHER PERSONNEL FROM ENTERING WITHIN THE MOVEMENT RANGE OF THE ROBOT e USE STURDY STABLE POSTS WHICH WILL NOT FALL OVER EASILY e THE ROPE OR CHAIN SHOULD BE EASILY VISIBLE TO EVERYONE AROUND THE ROBOT 2 Check the following points before turning on the controller e Is the robot securely and correctly installed Are the electrical connections to the robot wired correct
29. BLE CONNECTOR INTO THE RECEPTACLES OR SOCKETS POOR CONNECTIONS MAY gt S 10 CAUSE THE CONTROLLER OR ROBOT TO MALFUNCTION B Wiring 1 Connection to robot controller 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 2 Wiring safety points ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE STARTING INSTALLATION OR WIRING WORK FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE Make sure that no foreign matter such as cutting chips or wire scraps get into the robot controller Malfunction breakdown or fire may result if these penetrate inside Do not apply excessive impacts or loads to the connectors when making cable connections This might bend the connector pins or damage the internal PC board e When using ferrite cores for noise elimination be sure to fit them onto the power cable as close to the robot controller and or the robot as possible to prevent malfunction caused by noise 3 Wiring method 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 SPECIFI
30. CARA robots Follow the precautions and procedure described in origin position in Chapter 3 2 Adjusting the Reference coordinate setting SCARA robots Follow the precautions and procedure described in reference coordinates in Chapter 3 4 Setting the SCARA robots Soft limit settings Cartesian robots Single axis robots Work with power turned on SCARA robots Teaching Cartesian robots Single axis robots Follow the precautions and procedure described in soft limits in Chapter 3 Follow the precautions and procedure described in each controller manual 3 Setting the Soft limit in Refer to 5 Teaching within safety enclosure described below 5 Teaching within the safety enclosure When performing teaching within the safety enclosure check or perform the following points from outside the safety enclosure DANGER NEVER ENTER WITHIN THE MOVEMENT RANGE WHILE WITHIN THE SAFETY ENCLOSURE MAKE A VISUAL CHECK TO ENSURE THAT NO HAZARDS ARE PRESENT WITHIN THE SAFETY ENCLOSURE e CHECK THAT THE PROGRAMMING BOX OR HANDY TERMINAL OPERATES CORRECTLY e CHECK THAT NO FAILURES ARE FOUND IN THE ROBOT e CHECK THAT EMERGENCY STOP WORKS CORRECTLY e SELECT TEACHING MODE AND DISABLE AUTOMATIC OPERATION o 15 4 SUOHONIALSU AJoJoS suouyonijsu AJoJoS 4 5 2 Automatic operation Check the following points when operating the robot in AUTO mode Observe the instructions below in
31. CTION OR PRODUCT DAMAGE OR DETERIORATION THE ROBOT CONTROLLER AND PROGRAMMING BOX SHOULD BE INSTALLED AT A LOCATION THAT IS OUTSIDE THE ROBOT MOVEMENT RANGE YET WHERE IT IS EASY TO OPERATE AND VIEW ROBOT MOVEMENT INSTALL THE ROBOT CONTROLLER IN LOCATIONS WITH ENOUGH SPACE TO PERFORM WORK TEACHING INSPECTION ETC SAFELY LIMITED SPACE NOT ONLY MAKES IT DIFFICULT TO PERFORM WORK BUT CAN ALSO CAUSE INJURY INSTALL THE ROBOT CONTROLLER IN A STABLE LEVEL LOCATION AND SECURE IT FIRMLY AVOID INSTALLING THE CONTROLLER UPSIDE DOWN OR IN A TILTED POSITION PROVIDE SUFFICIENT CLEARANCE AROUND THE ROBOT CONTROLLER FOR GOOD VENTILATION INSUFFICIENT CLEARANCE MAY CAUSE MALFUNCTION BREAKDOWN OR FIRE B installation To install the robot controller observe the installation conditions and method described in the manual 1 Installation SECURELY TIGHTEN THE SCREWS FOR THE L SHAPED BRACKETS USED TO INSTALL THE ROBOT CONTROLLER IF NOT SECURELY TIGHTENED THE SCREWS MAY COME LOOSE CAUSING THE CONTROLLER TO DROP 2 Connections e ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE STARTING INSTALLATION OR WIRING WORK FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE e NEVER DIRECTLY TOUCH CONDUCTIVE SECTIONS AND ELECTRONIC PARTS OTHER THAN THE CONNECTORS ROTARY SWITCHES AND DIP SWITCHES ON THE OUTSIDE PANEL OF THE ROBOT CONTROLLER TOUCHING THEM MAY CAUSE ELECTRICAL SHOCK OR BREAKDOWN e SECURELY INSTALL EACH CA
32. E VERTICAL AXIS BEFORE REMOVING THE MOTOR e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BY THE DRIVING UNIT OF THE VERTICAL AXIS OR BETWEEN THE VERTICAL AXIS AND THE INSTALLATION BASE 2 Be careful when removing the Z axis motor SCARA robots THE Z AXIS WILL SLIDE DOWNWARD WHEN THE Z AXIS MOTOR IS REMOVED CAUSING A HAZARDOUS SITUATION e TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER THE Z AXIS BEFORE REMOVING THE Z AXIS MOTOR e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BY THE DRIVING UNIT OF THE Z AXIS OR BETWEEN THE Z AXIS DRIVE UNIT AND THE INSTALLATION BASE 3 Do not remove the Z axis upper limit mechanical stopper Warning label 4 is attached to each SCARA robot For details on warning labels see 3 Warning labels in Safety instructions Removing the upper limit mechanical stopper installed to the Z axis spline or shifting its position will damage the Z axis ball screw Never attempt to remove it 4 Use caution when handling a robot that contains powerful magnets 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 5 Use the following caution items when disassembling or replacing the pneumatic equipment AIR OR PARTS MAY FLY OUTWARD IF PNEUMATIC EQUIPMENT IS DISASSEMBLED OR PARTS REPLACED WHILE AIR IS STILL SUPPLIED e DO SERVICE WORK AFTER TURNING OFF THE CONTROLLER REDUCIN
33. ED BY THE CONNECTOR MANUFACTURER When disconnecting the cable from the robot controller detach by gripping the connector itself and not by tugging on the cable Loosen the screws on the connector if fastened with the screws and then disconnect the cable 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 4 Precautions for cable routing and installation Always store the cables connected to the robot controller in a conduit or clamp them securely in place If the cables are not stored in a conduit or properly clamped excessive play or movement or mistakenly pulling on the cable may damage the connector or cables and poor cable contact will cause the controller or robot to malfunction Do not modify the cables and do not place any heavy objects on them Handle them carefully to avoid damage Damaged cables may cause malfunction or electrical shock If the cables connected to the robot controller may possibly become damaged then protect them with a cover etc e Check that the control lines and communication cables are routed at a gap sufficiently away from main power supply circuits and power lines etc Bundling them together with power lines or close to power lines may cause faulty operation due to noise 5 Protective measures against electrical shock BE SURE TO GROUND THE CONTROLLER USING THE GROUND TERMINAL ON THE POWER TE
34. G THE AIR PRESSURE AND EXHAUSTING THE RESIDUAL AIR FROM THE PNEUMATIC EQUIPMENT BEFORE REDUCING THE AIR PRESSURE PLACE A SUPPORT STAND UNDER THE Z AXIS 2 AXIS ROBOTS WITH AIR DRIVEN Z AXIS SINCE IT WILL DROP UNDER ITS OWN WEIGHT 6 Use caution to avoid contact with the controller cooling fan e TOUCHING THE ROTATING FAN MAY CAUSE INJURY e IF REMOVING THE FAN COVER FIRST TURN OFF THE CONTROLLER AND MAKE SURE THE FAN HAS STOPPED 7 Precautions for robot controllers e Back up the robot controller internal data on an external storage device The robot controller internal data programs point data etc may be lost or deleted for unexpected reasons Always make a backup of this data Do not use thinner benzene or alcohol to wipe off the surface of the programming box The surface sheet may be damaged or printed letters or marks erased Use a soft dry cloth and gently wipe the surface e Do not use a hard or pointed object to press the keys on the programming box Malfunction or breakdown may result if the keys are damaged Use your fingers to operate the keys e Do not insert any SD memory card other than specified into the SD memory card slot in the programming box Malfunction or breakdown may result if the wrong memory card is inserted o 19 4 suouyonijsu AJoJoS suouyonjjsu AJoJoOS 4 7 Disposal When disposing of robots and related items handle them carefully as industrial wastes Use the correct disposal method i
35. IS MANUAL AND TO RELATED MANUALS DESIGN AND INSTALL THE SYSTEM INCLUDING THE ROBOT CONTROLLER SO THAT IT WILL ALWAYS WORK SAFELY 5 Precautions for operation e DO NOT TOUCH ANY ELECTRICAL TERMINAL DIRECTLY TOUCHING THESE TERMINALS MAY CAUSE ELECTRICAL SHOCK EQUIPMENT DAMAGE AND MALFUNCTION e DO NOT TOUCH OR OPERATE THE ROBOT CONTROLLER OR PROGRAMMING BOX WITH WET HANDS TOUCHING OR OPERATING THEM WITH WET HANDS MAY RESULT IN ELECTRICAL SHOCK OR BREAKDOWN 6 Do not disassemble and modify NEVER DISASSEMBLE AND MODIFY ANY PART IN THE ROBOT CONTROLLER AND PROGRAMMING BOX DO NOT OPEN ANY COVER DOING SO MAY CAUSE ELECTRICAL SHOCK BREAKDOWN MALFUNCTION INJURY OR FIRE 4 4 2 Installing a safety enclosure Be 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 A DANGER SERIOUS INJURY MAY RESULT FROM CONTACT WITH A MOVING ROBOT e KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION e PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE INSTALL AN INTERLOCK THAT TRIGGERS EMERGENCY STOP WHEN THE DOOR OR GATE OF THE SAFETY ENCLOSURE IS OPENED e THE SAFETY ENCLOSURE SHOULD BE DESIGNED SO THAT NO ONE CAN ENTER INSIDE EXCEPT FROM THE DOOR OR GATE EQUIPPED WITH AN INTERLOCK DEVICE e WARNING LABEL 1 SEE 3 WARNING LA
36. K600XGLP This manual describes the safety measures handling adjustment and maintenance of XGC P series robots for correct safe and effective use Be sure to read this manual carefully before installing the robot Even after you have read this manual keep it in a safe and convenient place for future reference This manual should be used with the robot and considered an integral part of it When the robot is moved 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 For explanations not described in this manual see the Installation Manual and Maintenance Manual for YK XG series Additionally for details about safety instructions see also these manuals If you have any questions contact your distributor UOIINPOHU For details about actual robot operation and programming refer to the YAMAHA Robot Controller User s Manual THE ADJUSTMENT AND MAINTENANCE WORK WITH THE COVER REMOVED NEEDS THE SPECIAL KNOWLEDGE AND SKILL IF UNSKILLED WORK PERSON PERFORMS SUCH WORK THIS MAY INVOLVE RISK THESE TASKS MUST BE PERFORMED ONLY BY PERSONS WHO HAVE ENOUGH ABILITY AND QUALIFICATIONS IN ACCORDANCE WITH LOCAL LAWS AND REGULATIONS BY REFERRING TO THE SEPARATE MAINTENANCE MANUAL FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT e The contents of this manual are subject to change without prior notice e Infor
37. KDM M1328 000 Seal KDM M1329 000 KDM M1567 000 YK250XGC P YK350XGC P YK400XGC P KDM M1567 100 YK500XGLC P YK600XGLC P 5 2 Q o 5 KDM M1568 000 YK250XGC P YK350XGC P YK400XGC P KDM M1568 100 YK500XGLC P YK600XGLC P Seal washer 90990 36J008 Seal KDM M1315 000 WHEN THE COVERS HAVE BEEN REMOVED FOR THE MAINTENANCE WORK BE SURE TO RETURN THE COVERS TO THEIR ORIGINAL POSITIONS USING THE SCREWS AND BOLTS THAT HAVE SECURED THEM IF ANY SCREW IS LOST BE SURE TO SECURE THE COVERS USING THE SPECIFIED SCREWS AND QUANTITIES WHILE REFERRING TO THE FIG BELOW IF THE COVERS ARE NOT SECURED FIRMLY NOISE MAY OCCUR THE COVER MAY DROP AND FLY OUT YOUR HAND MAY BE ENTANGLED IN THE DRIVE UNIT DURING TEACHING OR YOUR HAND MAY BE IN CONTACT THE HOT DRIVE UNIT CAUSING BURN TO PREVENT SUCH TROUBLES STRICTLY OBSERVE THIS INSTRUCTION The Y axis arm cover cannot be detached or attached unless the Z axis is moved down to its lower end e If any seal loses its strength when detaching the cover it is recommended to replace it with a new one If not replaced with a new one the dust drip proof performance or the degree of cleanliness may lower Some seals are affixed When removing such seal peel off the adhesive agent and replace the seal with a new one B Y axis arm cover step Y Turn on the controller Check that no one is inside the safety enclosure and then turn on the cont
38. MI and M2 for 11 Arm length mm of axis parameters M1 X axis arm length M2 Y axis arm length YK250XGC P YK350XGC P P AJ O O e o Y E O o YK400XGC P YK500XGLC P YK600XGLC P step 1 1 Enter the 12 Offset pulse values gt Step 11 Entering the 12 Offset pulse values Enter the values shown on the right in 12 Offset pulse of axis parameters M1 X axis position pulse value you have made a note of in step 9 23304 HM 00 Y axis position pulse value you have Y axis position pulse value you have M2 made a note of in step 8 clockwise made a note of in step 8 counterclockwise step 12 Reattach the plug bolt and seal 2 washer Note Round off the decimal part of the M2 value 1 Remove the pin and bolt 2 Reattach the plug bolt and seal washer 3 4 ANA Periodic inspecition Contents 1 List of inspection items l List of inspection items ONLY QUALIFIED ENGINEERS WHO HAVE RECEIVED THE ROBOT TRAINING COURSE CONDUCTED BY YOUR DISTRIBUTOR ARE ALLOWED TO INSPECT THE ITEMS NEEDING THE COVER REMOVAL WORK WHILE REFERRING TO THE SEPARATE MAINTENANCE MANUAL FOR YK XG SERIES O Conduct O Conduct if trouble is found as a result of inspection A Contact your distributor B Inspection with the controller turned off e Check for scratch dent or excessive be
39. RMINAL BLOCK POOR GROUNDING MAY CAUSE ELECTRICAL SHOCK S 11 4 suouyonjjsu AJoJoOS 4 4 Safety measures 4 4 1 Safety measures 1 Referring to warning labels and manual e BEFORE STARTING INSTALLATION OR OPERATION OF THE ROBOT BE SURE TO READ THE WARNING LABELS AND THIS MANUAL AND COMPLY WITH THE INSTRUCTIONS NEVER ATTEMPT ANY WORK OR OPERATION UNLESS DESCRIBED IN THIS MANUAL NEVER ATTEMPT ANY REPAIR PARTS REPLACEMENT AND MODIFICATION UNLESS DESCRIBED IN THIS MANUAL THESE TASKS REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS PLEASE CONTACT YOUR DISTRIBUTOR FOR ADVICE For details on warning labels see 3 Warning labels in Safety instructions SUOHONAISU AJoJoS 2 Draw up work instructions and make the operators workers understand them DECIDE ON WORK INSTRUCTIONS IN CASES WHERE PERSONNEL MUST WORK WITHIN THE ROBOT MOVEMENT RANGE 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 movement range 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
40. S SHUT OFF OR POWER FLUCTUATIONS OCCUR e F THE OBJECT GRIPPED BY THE END EFFECTOR MIGHT POSSIBLY FLY OFF OR DROP THEN PROVIDE APPROPRIATE SAFETY PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE WEIGHT TEMPERATURE AND CHEMICAL PROPERTIES 2 Provide adequate lighting Provide enough lighting to ensure safety during work 3 Install an operation status light INSTALL A SIGNAL LIGHT SIGNAL TOWER AT AN EASY TO SEE POSITION SO THAT THE OPERATOR WILL BE AWARE OF THE ROBOT STOP STATUS TEMPORARILY STOPPED EMERGENCY STOP ERROR STOP ETC 4 Do not use robots for tasks requiring motor thrust Avoid using the belt driven robots for tasks which make use of motor thrust press fitting burr removal etc These tasks may cause the robot to malfunction 5 Clean work tools Work tools such as welding guns and paint nozzles mounted on the robot manipulator tip should preferably be cleaned automatically when needed 4 2 2 Precautions for robot controllers 1 Emergency stop input terminal 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 2 Maintain clearance 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 noi
41. SE THE ROBOT OR ANY PART OF THE ROBOT IN WATER OTHERWISE WATER MAY PENETRATE INSIDE THE ROBCT e DO NOT USE THE ROBOT IN AN ENVIRONMENT EXCEEDING THE LISTED LEVELS OF PROTECTION FOR DUST AND MOISTURE OTHERWISE WATER OR DUST MAY PENETRATE INSIDE THE ROBCT e DO NOT SPLASH THE JET FLOW ONTO THE BELLOWS DIRECTLY FOR DETAILS ABOUT DRIP PROOF PERFORMANCE FOR FLUID OTHER THAN WATER CONTACT YOUR DISTRIBUTOR IP 65 L Degree of protection versus water penetration 5 At level 5 water injected from an optional angle does not exert a harmful effect Water injection pressure per the standards is 30kPa 30kN m O 3kgf cm Injection speed is 12 5 liters per minute at a time interval of 3 minutes Water may penetrate inside the robot if the water pressure is higher than this level 5 n Q o 3 Degree of protection versus solid debris 6 At level 6 there is no dust penetration CAUTION For dust drip proof models attach the plug supplied with the robot to 12 joint on the base rear side If the plug is not attached dust etc may penetrate inside the robot See also the Fig below Attaching the plug Dust drip proof model Attach the plug supplied with the robot 23203 HM 00 gt 2 2 2 Installation 2 1 Checking the product After unpacking check the product configuration and conditions The following configurations are typical examples so please check that the product is as specified in your or
42. US 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 e WHEN IT IS NECESSARY TO OPERATE THE ROBOT WHILE YOU ARE WITHIN THE ROBOT MOVEMENT RANGE SUCH AS FOR TEACHING OR MAINTENANCE INSPECTION TASKS ALWAYS CARRY THE PROGRAMMING BOX WITH YOU SO THAT YOU CAN IMMEDIATELY STOP THE ROBOT OPERATION IN CASE OF AN ABNORMAL OR HAZARDOUS CONDITION FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH gt S 12 DURING STARTUP OR MAINTENANCE TASKS DISPLAY A SIGN WORK IN PROGRESS ON THE PROGRAMMING BOX AND 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 e ALWAYS CONNECT THE ROBOT AND ROBOT CONTROLLER IN THE CORRECT COMBINATION USING THEM IN AN INCORRECT COMBINATION MAY CAUSE FIRE OR BREAKDOWN 4 Install system safeguards 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 TO CHECK THE ROBOT CONTROLLER OPERATING STATUS REFER TO TH
43. ace uononpoyul uonuonpollu 3 Put timer during Z axis operation If the tip load attached to the spline tip of the YK250XGC P YK350XGC P YK400XGC P YK500XGLC P or YK600XGLC P exceeds 2kg the Z axis may be overloaded depending on the operation pattern In this case put a timer during operation as shown in the Fig below to prevent overload of the Z axis The reference timer values are shown below Furthermore the maximum payload is 4kg If the tip load exceeds this maximum payload the Z axis may be overloaded easily So do not operate the robot with a tip load exceeding 4kg Putting timer during Z axis operation S_ gt 5 C C e e e Cv 3 e Cv 2 e Y y ce Upper end Timer 0 5 sec Lower end Total timer 1 0 sec Timer 0 5 sec Only Z axis operates All axes operate 23002 HM 00 4 Z axis additional mechanical stopper The Z axis additional mechanical stopper cannot be installed in the YK250XGC P YK350XGC P YK400XGC P YK500XGLC P and YK600XGLC P as they are equipped with bellows 5 Detach or attach the Y axis arm cover The Y axis arm cover cannot be detached or attached unless the Z axis is moved down to its lower end For details see 9 Detaching or attaching the covers in Chapter 2 Introduction This manual describes YAMAHA industrial robots YK XGC series clean room models YK250XGC to YK600XGLC and YK XGP series dust drip proof models YK250XGP to Y
44. ad applied to the motor and shuts off the servo power If an overload error occurs take the following measures to avoid such errors 1 Insert a timer in the program 2 Reduce the acceleration coefficient 2 Overheat detection This function detects an abnormal temperature rise in the driver inside the controller and shuts off the servo power If an overheat error occurs take the following measures to avoid the error 1 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 The working envelope is the area limited by soft limits SOFT LIMITS MUST BE SET WITHIN THE MOVEMENT RANGE MECHANICAL STOPPER IF THE SOFT LIMIT IS SET OUTSIDE THE MOVEMENT RANGE THEN THE ROBOT AXIS MAY COLLIDE WITH THE MECHANICAL STOPPER AT HIGH SPEED CAUSING THE OBJECT GRIPPED BY THE END EFFECTOR TO FLY OUTWARD OR DROP AND THE ROBOT TO MALFUNCTION 4 Mechanical stoppers If the servo power is shut off by emergency stop operation or safety function while the robot is moving then these mechanical stoppers prevent the axis from exceeding the movement range No mechanical stopper is provided on the rotational axis The movement range is the area limited by the mechanical stoppers e The X and Y axes have mechanical stoppers that are installed at both ends of the maximum movement range Some ro
45. axis plus or 134 YK250XGC P YK350XGC P minus direction 144 YK400XGC P YK500XGLC P YK600XGLC P Stopper position in Y axis plus or minus direction 5 u Q o 5 E Soft limits after setting additional stopper Soft limit pulses Movement range Working envelope in X axis plus direction 425984 Working envelope in X axis minus direction 425984 Working envelope in Y axis plus direction 385934 Working envelope in Y axis minus direction 385934 4 1 Installing the X axis Y axis additional mechanical stoppers Follow the steps below to install the X axis Y axis additional mechanical stoppers Install the X axis additional mechanical stopper by moving only the existing stopper Use the optional bolts and nuts listed below to install the Y axis additional mechanical stopper Part No Remarks KCY M2197 000 Stopper damper Additional mechanical stopper parts in either one 90990 01067 Bolt direction of Y axis plus or minus direction or both directions 1 90189 00J106 Nut 90990 36J010 Seal washer 1 Only one set of parts shown above is used even when the stopper is added in either plus or minus direction or both directions When adding the stopper in both directions the existing stopper is also used after moving it 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
46. bing 4 64 white O O User tubing 1 64 black Bellows a gt LL a x d n L IL e L gl Ball screw O O User tubing 2 64 red gt gt Machine harness vaie molor Suction air joint YK XGC E Warning label 1 Bellows _ Sa Se Warning label 2 EL stopper Warning label 3 mechanical T i Plug YK XGP Sa R axis motor Z axis motor X axis arm X axis speed Y axis arm Varies seeed reduction gear reduction gear Va R axis speed J X axis mechanical stopper EIA reduction gear LZ au EN daB AE 24 oo Serial label LL User tubing 1 64 black f User tubing 2 64 red DIE M4 ground terminal End effector b attachment attachment Z axis spline X axis motor m un Tool flange mount type Standard type Tapped hole for user 1 2 B mig User tubing 3 94 blue 164 User tubing 4 04 white Connector for user wiring No 1 to 10 usable 23102 HM 00 2 Robot initialization number list The XGC P series robots are initialized for optimum setting default setting according to the robot model prior to 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 r
47. ble by everyone around the robot 3 Place a conspicuous sign prohibiting the operator or other personnel from entering the movement area of the manipulator To check the operation after the settings have been made refer to the section 4 5 1 Trial Operation in Chapter Safety Instructions of this manual This Chapter describes only the points that are different from the standard models For details about other explanations see the Installation Manual for YK XG series standard models 3 1 lt AJ O O 9 o o Q o 2 Adjusting the origin This section describes only the origin adjustment points that are different from the standard models For details about other explanations see the Installation Manual for YK XG series standard models B Adjusting the origin of the YK250XGC P YK350XGC P YK400XGC P YK500XGLC P or YK600XGLCIP e Since the joints of the X Y and R axis are covered it is difficult to understand the clearance between the sensor and dog After the return to origin has performed in the same manner as the standard model carefully adjust the machine reference so that the origin does not deviate even when you touch the arm etc accidentally during work After the machine reference has been adjusted turn the joint to check that the sensor does not collide with the dog e Since the joints are covered the origin positions of the X axis and Y axis cannot be changed e The R axis sensor uses a compact
48. bot models have a standard feature that allows changing the mechanical stopper positions On some other models the mechanical stopper positions can also be changed by using option parts e The Z axis has a mechanical stopper at the upper end and lower end The stopper positions can be changed by using option parts e No mechanical stopper is provided on the R axis AXIS MOVEMENT DOES NOT STOP IMMEDIATELY AFTER THE SERVO POWER SUPPLY IS SHUT OFF BY EMERGENCY STOP OR OTHER SAFETY FUNCTIONS 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from sliding downward when servo power 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 THE VERTICAL AXIS WILL SLIDE DOWNWARD WHEN THE Z AXIS BRAKE IS RELEASED CREATING A HAZARDOUS SITUATION e PRESS THE EMERGENCY STOP BUTTON AND PLACE A SUPPORT UNDER THE VERTICAL AXIS BEFORE RELEASING THE BRAKE e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACH gt S 22 6 2 Special training for industrial robot operation Operators or persons who handle the robot for tasks such as for teaching programming movement checks inspections adjustments and repairs must re
49. cases where an error occurs during automatic operation Automatic operation described here includes all operations in AUTO mode 1 Checkpoints before starting automatic operation Check the following points before starting automatic operation DANGER CHECK THAT NO ONE IS WITHIN THE SAFETY ENCLOSURE e CHECK THE SAFETY ENCLOSURE IS SECURELY INSTALLED WITH INTERLOCKS FUNCTIONAL e CHECK THAT THE PROGRAMMING BOX HANDY TERMINAL AND TOOLS ARE IN THEIR SPECIFIED LOCATIONS e CHECK THAT THE ALARM OR ERROR LAMPS ON THE ROBOT AND PERIPHERAL EQUIPMENT ARE NOT LIT OR FLASHING 2 During automatic operation and when errors occur After automatic operation starts check the operation status and the signal tower to ensure that the robot is in automatic operation DANGER NEVER ENTER THE SAFETY ENCLOSURE DURING AUTOMATIC OPERATION IF AN ERROR OCCURS IN THE ROBOT OR PERIPHERAL EQUIPMENT OBSERVE THE FOLLOWING PROCEDURE BEFORE ENTERING THE SAFETY ENCLOSURE 1 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 OTHER PERSONS FROM RESTARTING THE ROBOT 4 5 3 Precautions during operation 1 When the robot is damaged or an abnormal condition occurs e IF UNUSUAL ODORS NOISE OR SMOKE OCCUR DURING OPERATION IMMEDIATELY TURN OFF POWER TO PREVENT POSSIBLE ELECTRICAL SHOCK FIRE OR BREAKDOWN STOP USING THE ROBOT AND CONTACT
50. ceive 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 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 2012 YAMAHA MOTOR CO LTD 9 23 lt suouyonjjsu JOJDS Revision record Manual version Issue date Description Ver 1 00 May 2012 First edition Ver 1 01 Jun 2012 Description of Emergency action when a person is caught by robot was added the work sequence for working within the safety enclosure changed typing errors corrected etc YAMAHA Safety Instructions Jun 2012 Ver 1 01 This manual is based on Ver 1 01 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 believ
51. d the stopper on the opposite Stopper damper 1 side is lost For the X axis stopper install the additional mechanical stopper by changing only the stopper position step Install the bolt and washer in the blank tapped hole in the standard stopper gt Step6 Installing the bolt in the standard stopper Io protect the blank tapered hole in the standard stopper tighten the bolt and washer to the specified torque 16Nm l63kgfcm 23213 HM 00 Be sure to put the seal washer 4 Otherwise the dust drip proof performance or the degree of Y axis standard stopper cleanliness may lower Y axis plus direction additional stopper Stopper after changing Step Y Check that the movement range IS the X axis plus direction position limited step Go out of the safety enclosure step Y Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller step 10 Set the soft limits in the X axis and Y axis plus directions When the stopper is installed in the minus direction set the soft limits in the minus direction Whether or not the X axis stops at a position before the stopper limited by the soft limit must be checked from the outside of the safety enclosure 2 11 lt step 4 Y Check that the X axis and Y axis stop 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
52. der If there is any damage due to transportation or insufficient parts please notify your distributor immediately O Controller RCX240 Robot YK250XGC P YK350XGC P YKA400XGC P YK500XGLC P YK600XGLC P Product configurations Standard 5 a Q o 3 Robot manipulator CD ROM User s Manual or User s Manual Warning label x1 Mounting bracket x2 Connector for user wiring x2 RCX240 controller Origin position stickers Standard coordinate setting jig option Ex E E RPB programming box etc 23204 HM 00 2 3 2 2 Moving the robot SERIOUS INJURY MAY OCCUR IF THE ROBOT FALLS AND PINS SOMEONE UNDER IT e DO NOT ALLOW ANY PART OF YOUR BODY TO ENTER THE AREA BENEATH THE ROBOT DURING WORK e ALWAYS WEAR A HELMET SAFETY SHOES AND GLOVES DURING WORK To check the mass of each robot refer to 1 1 Basic specifications in Chapter 5 step Y Fold the arms while referring to the Fig below Moving the robot ALA PPS AA I e FA 5 n Q o 3 Sr ALLE N LZ W Support Robot cable Support 23205 HM 00 step 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 steps Temporarily secure the robot by tightening the bolts 2 4 Stp Secure the robot main body firmly Secure
53. 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 When adding the stopper in one direction of the Y axis do not remove the standard stopper If this stopper is removed the stopper on the opposite side is lost step 4 Turn off the controller step Place a sign indicating the robot is being adjusted Place a sign indicating The robot is being adjusted fo keep others from touching the controller switch 2 10 Step Enter the safety enclosure gt Step4 Removing the tapped hole plug bolts and seal washer Stp Remove the bolts seal washers and washers Remove the tapped hole plug bolts seal washers and washers Additionally remove the stopper from the plus side of the X axis Seal washer 23211 HM 00 step Sandwich the damper among the bolt nut and seal washer and secure the parts 1 Sandwich the damper 1 among the P Step 5 Installing the damper bolt 2 nut 3 and seal washer 4 At 5 this time use the bolt and nut listed in Do not remove the standard stopper o the Table on the previous page Seal washer 4 O 2 Secure the parts to the arm by tightening the nut to the specified torque 42Nm O 428kgfcm F 23212 HM 00 9 When adding the stopper in one direction of the Y axis do not remove the standard stopper If this stopper is remove
54. ed 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 Warranty For information on the warranty period and terms please contact our distributor where you purchased the product E 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 Usage that exceeded the specifications or standard performance shown in the YAMAHA manual Product usage other than intended by YAMAHA AJUDIIDM Storage operating conditions and utilities that are outside the range specified in the manual Damage due to improper shipping or shipping methods Accident or collision damage Installation of other than genuine YAMAHA parts and or accessories ON ODO Ui A C N 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 B The follo
55. ed to the tip mass 23504 HM 00 YK350XGC YK350XGP Tool flange mount type C o D O zh Q Q O o 30h7 8 021 Detailed drawing D Scale 1 1 View of E 23502 HM 00 YK350XGC YK350XGP Working envelope Option e X axis additional stopper X axis mechanical stopper position can be changed to 119 position working envelope 117 Y axis additional stopper Y axis mechanical stopper position can be changed to 108 position working envelope 106 Other option Standard coordinate setting jig Note that the robot cannot be used at a position where the base flange robot cable spline bellows and tool flange interfere with each other in the working envelope shown above e X axis mechanical stopper position 131 Y axis mechanical stopper position 136 23506 HM 00 9 3 C o D O zh Q Q O o 1 2 3 YK400XGC P Connector for user wiring No 1 to 10 usable Cable clamp size 013 1 to 15 If not used cover the connectors with the caps supplied with the robot User tubing 3 64 blue User tubing 4 04 white r E 04 60 User tubing 1 64 black 140 60 y If the user tubing is not used attach the plug supplied with the robot 4 09 M8 bolt for installation 4 bolts used
56. eferring to the list below Absolute reset must be performed after reinitializing the controller Before reinitializing the controller read the descriptions stated in 2 Absolute reset in Chapter 4 of the Installation Manual for YK XG series standard models and make sure you thoroughly understand the procedure When the controller is initialized the ARM LENGTH and OFFSET PULSE settings in the axis parameters will be erased making the standard coordinate settings invalid For details about standard coordinates see 4 Setting the standard coordinates in Chapter 3 of the Installation Manual for YK XG series standard models If you do not want to change the origin position by initializing make a note of the ARM LENGTH and OFFSET PULSE settings before initializing and re enter their settings after initialization is complete SUONDUNF Robot initialization number Model name YK250XGC YK250XGP YK350XGC YK350XGP YK400XGC YK400XGP YK500XGLC YK500XGLP YK600XGLC YK600XGLP 1 3 Chapter 2 Installation Contents 1 Robot installation conditions 1 1 Sucking from the base rear side of the clean room model 2 1 Protection ratings for moisture and dust on dust drip proof models 2 2 Installation 2 3 2 1 Checking the product Moving the robot 3 User wiring and user tubing 2 6 4 Limiting the movement range with x and y axis mechanical stoppers 2 9 4 1 Installing the X ax
57. erated 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 8 If the X axis Y axis or R axis rotation angle is small If the X axis Y axis or R axis rotation angle is set smaller than 5 degrees then it will always move within the same position 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 S 17 lt suouyonijsu AJoJoS SUOHONIALSU AJoJoS 4 6 Inspection and maintenance Always perform daily and periodic inspections and make a pre operation check to ensure there are no problems 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 6 1 Before inspection and maintenance work 1 Do not attempt any work or operation unless described in this manual 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 personne
58. ers Operators or persons who handle the robot such as for teaching programming movement check inspection adjustment and repair must receive appropriate training and also have the skills needed to perform the job correctly and safely They must 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 standards for industrial robots THE ROBOT MUST BE OPERATED ONLY BY PERSONS WHO HAVE RECEIVED SAFETY AND OPERATION TRAINING OPERATION BY AN UNTRAINED PERSON IS EXTREMELY HAZARDOUS e ADJUSTMENT AND MAINTENANCE BY REMOVING A COVER REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATTEMPTED BY AN UNSKILLED PERSON THESE TASKS MUST BE PERFORMED ONLY BY PERSONS WHO HAVE ENOUGH ABILITY AND QUALIFICATIONS IN ACCORDANCE WITH LOCAL LAWS AND REGULATIONS FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT S 7 lt suouyonisu AJoJoS suouyonisu AJoJoS 4 2 Design 4 2 1 Precautions for robots 1 Provide safety measures for end effector gripper etc e END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY CAUSE NO HAZARDS SUCH AS A LOOSE WORKPIECE OR LOAD EVEN IF POWER ELECTRICITY AIR PRESSURE ETC I
59. f F Sri AO 183 Dimensions of base installation part Sr 4 117 56 YF 4150 200 Maximum 190 during arm rotation 839 809 Em 8 689 1 661 AS 632 10 Maximum 660 during arm rotation 614 510 User tubing 1 4 black If the user tubing is not used attach the plug supplied with the robot User tubing 2 04 red m oa LI LL o e Suction air joint 412 YK350XGC O Since this joint is not used attach the plug supplied with the robot to User tubing 3 the joint YK350XGP D 04 blue O User tubina 4 Connector for user wiring u 04 white 9 No 1 to 10 usable Cable clamp size 613 1 to 15 O If not used cover the connectors with O the caps supplied with the robot je o Se se O ER 71 J GT BR 58 V ad en pH 45 PEK js 32 al o UL Aah 3 Z d mechanical axis Upper end mechanical stopper position l 6 22 5 Ea Ge rises by 4mm during return to origin M4 ground terminal 10 126 Z axis lower end mechanical stopper position i31 95 5 t Standard clean room model dust drip proof model ES User tool installation range Width across flat 15 Cross section A A Z axis tip shape Tapped hole for user 6 M3x0 5 Depth 6 Scale 1 1 The weight of the tool attached here should be add
60. f the user tubing is not used attach the plug supplied with the robot Suction air joint 612 YK500XGLC Since this joint is not used attach the plug supplied with the robot to the joint YK500XGLP Connector for user wiring No 1 to 10 usable Cable clamp size 013 1 to 15 If not used cover the connectors with the caps supplied with the robot I User tool installation range Z axis tip shape 23510 HM 00 YK500XGLC YK500XGLP Tool flange mount type 30h7 021 94H7 90 through hole Detailed drawing D Scale 1 1 View ofE C o D O zh Q Q O o 23511 HM 00 YK500XGLC YK500XGLP Working envelope Option X axis additional stopper X axis mechanical stopper position can be changed to 119 position working envelope 117 Y axis additional stopper Y axis mechanical stopper position can be changed to 108 position working envelope 116 Other option Standard coordinate setting jig Note that the robot cannot be used at a position where the base flange robot cable spline bellows and tool flange interfere with each other in the working envelope shown above e X axis mechanical stopper position 131 Y axis mechanical stopper position 146 23512 HM 00 9 9 4 1 2 5 YK600XGLCIP Connector for user wiring 4 M3x0 5 Depth 5 No 1 to 10 usable Cable clamp size User
61. ine vibrates The Z axis spline of the YK250XGC P YK350XGC P YK400XGC P YK500XGLC P and YK600XGLC P tends to vibrate in a Z axis operation speed range of 2096 to 4096 If the Z axis spline vibrates operate it beyond this operation speed range 2 If the machine harness projects toward the base rear side In the YK250XGC P YK350XGC P YK400XGC P YK500XGLC P and YK600XGLC P the machine harness may project toward the base rear side according to the arm position The maximum projection amount is described in 1 2 External view and dimensions in Chapter 5 So refer to this section for further information Projection of the machine harness toward the base rear side Example YK250XGC P 117 IF Maximum 240 Projection amount 56 150 100 during arm rotation 839 777 809 o LO Machine harness 689 1 661 632110 6141 Maximum 660 during arm rotation i 1510 428 283 264 1 246 el E p d 5 1731 h i 167 133 FY 670 User tool 120 38 installation a ne as O BB ee ll Emm 94 5 2 016 h7 0 018 I T 2 HE loo JA HO O AAA iQ Z axis upper end mechanical stopper position Z axis rises by 4mm during return to origin 95 5 i Z axis lower end mechanical stopper position 23001 HM 00 If there is an interference object on the base rear side be sure to keep a sufficient sp
62. is Y axis additional mechanical stoppers 2 10 Limiting the movement range with Z axis mechanical stopper 2 13 Working envelope and mechanical stopper positions for maximum working envelope 2 13 Installing the user wiring and tubing newly Passing the user wiring and tubing through the spline 2 15 9 Detaching or attaching the covers 2 16 10 Installing the tool flange 2 21 l Robot installation conditions The installation conditions for the clean room models are identical to the standard models The installation conditions for the dust drip proof models are identical to the standard models except for the moisture and dust conditions This Chapter describes only the points that are different from the standard models For details about other explanations see the Installation Manual for YK XG series standard models 1 1 Sucking from the base rear side of the clean room model Suck from the suction air joint on the base rear side at a suction air flow of 30No min as shown in the Fig below If the Z axis bellows become dented when sucking reduce the suction air flow 5 a Q o 3 Suction air joint Clean room model Suction air joint 912 23201 HM 00 2 1 1 2 Protection ratings for moisture and dust on dust drip proof models The protection ratings for moisture and dust on the YK250XGP YK350XGP YK400XGP YK500XGLP and YK600XGLP dust drip proof models are equivalent to IP65 e DO NOT IMMERSE AND U
63. ist 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 procedures 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 Install operate or adjust the robot and controller while viewing the CD ROM version of the manual on your computer screen Install operate or adjust the robot and controller while referring to a printout of the necessary pages from the CD ROM version of the manual S 1 4 SUOHONIALSU AJoJoS SUOHONIALSU AJoJoS 2 Signal words used in this manual This 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 DANGER THIS INDICATES AN IMMEDIATELY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY WARNING THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY This indicates a potentially hazardous situation which if not avoided c
64. l will take appropriate action e NEVER ATTEMPT INSTALLATION ADJUSTMENT INSPECTION AND MAINTENANCE UNLESS DESCRIBED IN THIS MANUAL NEVER ATTEMPT ANY REPAIR AND PARTS 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 2 Precautions during repair and parts replacement 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 UNTRAINED PERSON IS EXTREMELY HAZARDOUS 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 ADJUSTMENT AND MAINTENANCE BY REMOVING A COVER REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATTEMPTED BY AN UNSKILLED PERSON FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT 3 Shut off all phases of power supply ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE CLEANING THE ROBOT AND CONTROLLER OR SECURELY TIGHTENING THE TERMINAL SCREWS ETC FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE OR MALFUNCTION
65. ly Are items such as air pressure correctly supplied e Is the robot correctly connected to peripheral equipment e Have safety measures safety enclosure etc been taken e Does the installation environment meet the specified standards 3 After the controller is turned on check the following points from outside the safety enclosure e Does the robot start stop and enter the selected operation mode as intended e Does each axis move as intended within the soft limits e Does the end effector move as intended Are the correct signals being sent to the end effector and peripheral equipment e Does emergency stop function Are teaching and playback functions normal Are the safety enclosure and interlocks functioning as intended S 14 4 Working inside safety enclosures Before starting work within the safety enclosure always first confirm from outside the enclosure that each safety function is operating correctly see the previous section 2 3 A DANGER NEVER ENTER WITHIN THE MOVEMENT RANGE WHILE WITHIN THE SAFETY ENCLOSURE 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 WHEN WORK WITHIN THE SAFETY ENCLOSURE IS REQUIRED ALWAYS TURN OFF THE CONTROLLER POWER EXCEPT FOR THE FOLLOWING CASES Exception Work with power turned on but robot in emergency stop Origin position setting S
66. mation furnished by YAMAHA in this manual is believed to be reliable However if you find any part unclear or inaccurate in this manual please contact your distributor YAMAHA MOTOR CO LTD IM Operations A rl Functions Contents 1 Robot manipulator 1 1 Manipulator movement 1 1 1 2 Part names 1 2 2 Robot initialization number list 1 Robot manipulator This Chapter describes only the points that are different from the standard models For details about other explanations see the Installation Manual for YK XG series standard models 1 1 Manipulator movement The YK XG 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 XG 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 SUONDUNF Manipulator movement ES gt dei IT LJ SY Y axis arm Z axis 23101 HM 00 1 1 lt 1 C gt O O o 1 2 Part names YK250XGC P YK350XGC P YK400XGC P YK500XGLC P YK600XGLC P Connector for user wiring No 1 to 10 usable o User tubing 3 64 blue User tu
67. model Robot Model User wiring User tubing YK250XGC P YK350XGC P YK400XGC P YK500XGLC P YK600XGLC P 10 wires 4 4 tubes Robot models for custom specifications may have different wiring or tubing The specifications of the user wires and air tubes are shown below Always observe the specifications User Wiring 5 2 Q o 3 Rated voltage Allowable current Nominal cross section area of conductor Shield User Tubing Maximum pressure 0 58MPa 6Kgf cm Outer diameter x inner diameter 64mm x 2 5mm Dry clean air not containing deteriorated compressor oil Fluid filtration 40um or less Connector for the user wiring and joint for the user tubing are provided on each of the arm and base sides For details about locations see 1 2 External view and dimensions in Chapter 5 If the connector for the user wiring and the joint for the user tubing of the YK250XGC P YK350XGC P YK400XGC P YK500XGLC P or YK600XGLC P are not used attach the cap and plug respectively Otherwise moisture or dust may penetrate inside the robot See the Fig below Plug and cap gt yl A NOS A Plug TODO Y axis arm side Base side 23231 HM 00 2 6 E Signal wiring connections in the machine harness e YK250XGC P YK350XGC P YX400XGC P YK500XGLC P YK600XGLC P Connector pins 1 to 10 can be used Connector Connection Connector Brown Red
68. 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 e Place a display sign on the operator panel e Ensure the safety of workers performing tasks within the robot movement range e Clearly specify position and posture during work Specify a position and posture where worker can constantly check robot movements and immediately move to avoid trouble if an error problem occurs e Take noise prevention measures e Use methods for signaling operators of related equipment Use methods to decide that an error has occurred and identify the type of error 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 3 Take safety measures DANGER NEVER ENTER THE ROBOT MOVEMENT RANGE WHILE THE ROBOT IS OPERATING OR THE MAIN POWER IS TURNED ON FAILURE TO FOLLOW THIS WARNING MAY CAUSE SERIO
69. n If the Z axis spline vibrates operate it beyond this operation speed range Noise level Equivalent sound level of robot Laeq A when there is 10dB or larger difference from the back ground sound pressure level Position where the noise level is measured 75 1dB 1 25m apart from the back of the robot Note The noise level can be higher when the robot is set nearby the objects that cause sound reflection 1 6m height from the floor surface 9 1 C B D O h O Q O o 1 2 External view and dimensions 1 2 1 YK250XGC P User tubing 3 04 blue Connector for user wiring ina 4 64 whi Vo 1 to 10 usable Cable clamp size ARI APO 4 M3x0 5 Depth 5 BEE 13 1 to 15 212 There is no phase relationship with the R axis origin If not used cover the connectors with Since this tapped hole is used for the wiring or tubing the caps supplied with th gt SAS clamp do not apply a large load rn NO O 3 ieee NS 4818 CO 148 SU T ce co 4 09 M8 bolt for installation 4 bolts used 12 183 Dimensions of base installation part View of F 117 Scale 1 1 150 Maximum 240 during arm rotation If the user tubing is not used attach the plug supplied with the robot User tubing 2 64 red 839 809 689 661 632110 Maximum 6
70. n Manual SCARA Robots Y K XG Series Jul 2012 Ver 1 00 This manual is based on Ver 1 00 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 IM Operations 882 Soude Nakaku Hamamatsu Shizuoka 435 0054 Japan Tel 81 53 460 6103 Fax 81 53 460 681 1 Robot manuals can be downloaded from our company website Please use the following for more detailed information YAMAHA YAMAHA MOTOR CO LTD http www yamaha motor co jp global industrial robot
71. n compliance with your local regulations or entrust disposal to a licensed industrial waste disposal company 1 Disposal of lithium batteries 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 2 Disposal of packing boxes and materials When disposing of packing boxes and materials use the correct disposal method in compliance with your local regulations We do not collect and dispose of the used packing boxes and materials 3 Strong magnet STRONG MAGNETS ARE INSTALLED IN THE ROBOT BE CAREFUL WHEN DISPOSING OF THE ROBOT gt 5 20 5 Emergency action when a person is caught by robot If a person should get caught between the robot and a mechanical part such as the installation base then release the axis B Emergency action Release the axis while referring to the following section in the manual for the robot controller Controller Refer to RCX240 Section 8 Freeing a person caught by the robot in Chapter 1 Make a printout of the relevant page in the manual and post it a conspicuous location near the controller o 2 4 SUOHONILSU AJoJoS SUOHONAISU AJoJoS 6 Using the robot safely 6 1 Robot safety functions Safety functions for YAMAHA robots are described below 1 Overload detection This function detects an overlo
72. nd Q Machine harness Robot cable e Check for damage Bellows Check for breakage o Cables prepared by user Check for scratch dent or excessive bend o O O e Check that the air pressure level is correct o O Regulator Joint Check for air leak e O Air tube Solenoid valve Check that the drain is discharged 9 O Air cylinder Check the air filter for contamination or damage o O Exterior of robot e Check for damage o A Major bolts and screws of robot main body those exposed to Check for looseness 1 o the outside Check the terminal on the outside of the e O controller for looseness Controller Check the connection connector for looseness 2 o e Remove the old grease with a cloth rag and Application of grease to Z axis apply the grease e spline and Z axis ball screw 3 YK XG L C LG2 NSK YK XG L P Alvania grease S2 Showa Shell Z axis ball screw and ball spline Check for play o O A E Inspection with the controller turned on Check that the safeguard enclosure is located e at its specified position e Check that the emergency stop turns on when safeguard enclosure the safeguard enclosure is open e Check that the warning label is affixed to the e entrance e Check that the emergency stop turns on when Emergency stop switch Dose o Robot operation Check for unusual operation vibration or noise e Functional check of Z axis Drop amount from the Z axis rest state is 3mm e brake 4 or less
73. nd the X axis arm as shown in The Fig on the right and then remove the plug bolt and seal washer Enlarged hole N 23302 HM 00 step Insert the pin 1 1 Put the robot in the arm posture allowing insertion of the pin and make the X axis arm almost aligned with the Y axis 2 Adjust the arm positions so that the pin can be inserted into the enlarged hole in the Y axis arm and the hole in the X axis arm without jamming and then insert the pin into the holes 23303 HM 00 step Secure the pin 1 with the bolt 2 Lightly tighten the bolt so that the pin does not move step Make a note of the Y axis position pulse value 1 Enter MANUAL gt POINT mode 2 Lightly apply a clockwise torque to the Y axis while holding the X axis arm 3 Make a note of the Y axis position pulse value displayed on POS when the torque is unloaded 4 Lightly apply a counterclockwise torque to the Y axis while holding the X axis arm 5 Make a note of the Y axis position pulse value displayed on POS when the torque is unloaded step Y Determine the direction of the gt Step9 X axis direction X axis Move the X axis arm in the direction that Y direction you want to set as the direction of the X axis At this time make a note of the X axis position pulse value displayed on POS e g gt 23303 F6 00 X direction step 10 Enter the 11 Arm length mm values Enter the following values in
74. ntroller be sure to read the manual thoroughly When adding external safety circuits or connecting a power supply to the controller read the manual carefully and make checks before beginning the work Connectors must be attached while facing a certain direction so insert each connector in the correct direction 93005 X0 00 This label is attached near the power input connector on the front panel 3 1 2 Supplied warning labels Some 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 Q Warning label is attached to the robot body O 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 Warning label 1 DANGER EE R Stay clear of moving machine Can cause serious injury l 5 T ART 5cIBA2S77j 4 9h 5 90K41 001470 Warning label 2 Pinch or crush hazard bhta eV 5D 90K41 001460 Warning label 3 Read and understand manuals before operation ZAHM HVS ES oBillcv IT ZEATERIT SIE 90K41 001290 Warn i ng Do not remove the parts 0 FES Beals
75. ould result in minor or moderate injury or damage to the equipment Explains the key point in the operation in a simple and clear manner gt S 2 3 Warning labels Warning labels shown below are attached to the robot body and controller to alert the operator to potential hazards To ensure correct use read the warning labels and comply with the instructions 3 1 Warning labels IF WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE THEN THE NECESSARY PRECAUTIONS MAY NOT BE TAKEN RESULTING IN AN ACIDENT e DO NOT REMOVE ALTER OR STAIN THE WARNING LABELS ON THE ROBOT BODY e DO NOT ALLOW WARNING LABELS TO BE HIDDEN BY DEVICES INSTALLED ON THE ROBOT BY THE USER e PROVIDE PROPER LIGHTING SO THAT THE SYMBOLS AND INSTRUCTIONS ON THE WARNING LABELS CAN BE CLEARLY SEEN FROM OUTSIDE THE SAFETY ENCLOSURE 3 1 1 Warning label messages Word 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 1 Warning label 1 SCARA robots Cartesian robots A DANGER SERIOUS INJURY MAY RESULT FROM CONTACT WITH A MOVING ROBOT e KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE Instructions on this label Always install a safety enclosure to keep all persons DANGER fe 5 away from the robot
76. p 13 Cautions on detaching or attaching the covers 2 18 step 14 Place the cover on the base side gt Step 14 Placing the cover 23224 HM 00 Place the cover so that itis not damaged step I 39 Reattach the cover in the reverse order of detachment It is recommended to replace the O rings and seals with new ones If These parts are not replaced or reattached the dust drip a proof PEnonnanes or the degree of Tf ae cleanliness may lower Tr For details about the bellows clamp position IH see the Fig on the right 23225 HM 00 at o e mb gl 5 o uen Q Q F Clamp The bellows end face is flush with the clamp ring end face Rubber IZA gt Clamp ring Rubber gt Clamp ring 2 Bellows end face Install the bellows and clamp at the positions shown in the Fig above Tolerance 0 5 mm Ha Rubber NA UM Almost this orientation ZZ ZZ IS Reattach the clamp so that the projection part of the clamp shown in the Photo is located in the clearance of the black rubber 2 19 B Base cover It is recommended to replace the seals with new ones If these parts are not replaced or reattached the dust drip proof performance or the degree of cleanliness may lower Removing the base front cover Base front cover ih I Ja D ED VIE
77. portant information that you must know and is described in the manual Before using the controller be sure to read the manual thoroughly When adding external safety circuits or connecting a power supply to the controller read the manual carefully and make checks before beginning the work Connectors must be attached while facing a certain direction so insert each connector in the correct direction 93007 X0 00 gt 9 6 4 Major precautions for each stage of use This 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 1 Applications where robots cannot be used YAMAHA robots and robot controllers are designed as general purpose industrial equipment and cannot be used for the following applications A DANGER YAMAHA ROBOT CONTROLLERS AND ROBOTS ARE DESIGNED AS GENERAL PURPOSE INDUSTRIAL EQUIPMENT AND CANNOT BE USED FOR THE FOLLOWING APPLICATIONS IN MEDICAL EQUIPMENT SYSTEMS WHICH ARE CRITICAL TO HUMAN LIFE e IN SYSTEMS THAT SIGNIFICANTLY AFFECT SOCIETY AND THE GENERAL PUBLIC IN EQUIPMENT INTENDED TO CARRY OR TRANSPORT PEOPLE IN ENVIRONMENTS WHICH ARE SUBJECT TO VIBRATION SUCH AS ONBOARD SHIPS AND VEHICLES 2 Qualification of operators work
78. ral units the movement range is limited When the robot is shipped from factory the movement range is set to the maximum level The movement range can be limited by shifting the X axis and Y axis mechanical stopper positions Follow the steps below to limit the movement range The following shows the mechanical stopper positions and movement range 5 AL Q o 3 Mechanical stopper position and maximum movement position Y axis standard stopper position Y axis additional stopper position YK250XGC P YK350XGC P YK250XGC P YK350XGC P Y axis standard stopper position Y axis additional stopper position YK400XGC P YK500XGLC P YK600XGLC P YK400XGC P YK500XGLC P YK600XGLC P 23210 HM 00 2 9 lt As option parts are ordered and then they are installed the movement ranges of the X axis and Y axis can be narrowed The movement range of the X axis can be narrowed by moving only the existing stopper Note that the stopper position may slightly deviate due to the part machining accuracy and mounting position After changing the mechanical stopper positions set the soft limits to the values shown below B Soft limits Standard stopper Additional stopper Stopper position in X axis plus or minus direction 131 Maximum movement position in X axis plus or 129 minus direction 136 YK250XGC P YK350XGC P 146 YK400XGC P YK500XGLC P YK600XGLC P Maximum movement position in Y
79. roller step Press the emergency stop button Press the emergency stop button on the RPB to put the robot in The emergency stop status step 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 step Enter the safety enclosure while holding the RPB 2 16 step49 Disconnect the user wiring and gt Step 5 6 Disconnecting the user wiring and tubing tubing from the spline Disconnect all of the user wiring and tubing SELL that have passed through the spline from the spline 23217 HM 00 step Loosen the screw of the clamp Bellows step Remove the bellows and remove the SE O ring 23218 HM 00 Clamp A Stp Remove the rolling mechanism part and O ring gt Step7 Removing the bellows 23219 HM 00 CR step Y To prevent the Z axis from dropping be sure to prop the spline or end effector with a support stand 5 a Q o 3 step 10 Release the Z axis brake Make sure that dropping of the Z axis is prevented Then carefully move down the Z axis to a position close to the lower end of O ring 1 the Z axis N 23220 HM 00 For details about how to release the Z axis brake see the YAMAHA Robot Controller User s Manual P Steps Removing the rolling mechanism part Rolling mechanism part Hex socket head bolt M3 length 10 4 pcs YAMAHA s part No 91312 03010
80. safety enclosure 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 Bi Soft limits described previously B Installing the additional stoppers in both the plus and minus directions Install the additional stoppers in both the plus and minus directions while referring to the Fig below Installing the additional stoppers in both the plus and minus directions 5 n Q o 3 Use the bolt and seal washer to protect the tapped hole Y axis plus direction additional stopper Use the bolt and washer to protect the tapped hole AN X axis plus direction additional stopper gt m E X axis minus direction additional stopper Y axis minus direction additional stopper Move the standard stopper to this position and secure it 1 Bolt tightening torque 16Nm 163kgfcm 2 Bolt tightening torque 42Nm 428kgfcm 23214 HM 00 gt 2 12 5 limiting the movement range with Z axis mechanical stopper The Z axis additional mechanical stopper cannot be installed in the YK250XGC P YK350XGC P YKAOOXGC P YKSOOXGLC P and YK6OOXGLC P as they are equipped with bellows 6 Working envelope and mechanical stopper positions for maximum working envelope Working envelope of each robot and mechanical stopper positions for the maximum working envelope are shown in 1
81. se gt 5 8 4 3 Moving and installation 4 3 1 Precautions for robots B Installation environment 1 Do not use in strong magnetic fields DO NOT USE THE ROBOT NEAR EQUIPMENT OR IN LOCATIONS THAT GENERATE STRONG MAGNETIC FIELDS THE ROBOT MAY BREAKDOWN OR MALFUNCTION IF USED IN SUCH LOCATIONS 2 Do not use in locations subject to possible electromagnetic interference etc 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 3 Do not use in locations exposed to flammable gases e YAMAHA ROBOTS ARE NOT DESIGNED TO BE EXPLOSION PROCF e DO NOT USE THE ROBOTS IN LOCATIONS EXPOSED TO EXPLOSIVE OR INFLAMMABLE GASES DUST PARTICLES OR LIQUID FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH OR LEAD TO FIRE B Moving 1 Use caution to prevent pinching or crushing of hands or fingers MOVING PARTS CAN PINCH OR CRUSH HANDS OR FINGERS KEEP HANDS AWAY FROM THE MOVABLE PARTS OF THE ROBOT 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 instructions 2 Take safety measures when moving the robot To ensure safety when moving a SCARA robot with an arm length of
82. sensor So carefully check that the tightening torque of the hex nut is as small as 1Nm 10kgfcm If tightened to a torque larger than this level the sensor may break R axis origin sensor and hex nut AJ O O o Y E O o 23301 HM 00 gt 3 2 3 Standard coordinate setting using a standard coordinate setup ig Use a standard coordinate setup jig option to set the standard coordinates more accurately The following describes how to set the standard coordinates using the standard coordinate setup jig Standard coordinate setup jig option Part No KDM M1577 000 91312 04065 step 4 Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller steps Put the robot in the emergency stop status Press the emergency stop button on the RPB to put the robot in The emergency stop status For details about emergency stop and how to cancel the emergency stop see the YAMAHA Robot Controller User s Manual step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel AJ O O 9 o o Q o step Enter the safety enclosure while holding the RPB gt Step5 Removing the plug bolt step Remove the plug bolt and seal washer Put the robot in the posture with the positional relationship between the Y axis arm a
83. structions 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 Before using this product read this manual and related manuals and take safety precautions to ensure correct handling The precautions listed in this manual relate to this product To ensure safety of the user s final system that includes 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 instructions For specific safety information and standards refer to the applicable local regulations and comply with the instructions e This manual and warning labels supplied with or attached to the robot are written in English Unless the robot operators or service personnel understand English do not permit them to handle the robot e Cautions regarding the official language of EU countries For equipment that will be installed in EU countries the language used for the manuals warning labels operation screen characters and CE declarations is English only Warning labels only have pictograms or else include warning messages in English In the latter case messages in Japanese or other languages might be added It is not possible to l
84. the robot main body firmly with the four hex socket head bolts as shown in the Fig below 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 ARE NOT TIGHTENED CORRECTLY THE ROBOT MIGHT FALL OVER DURING OPERATION CAUSING A SERIOUS ACCIDENT Tightening torque Robot Model Bolts Used Tightening torque 37Nm 380kgfcm YK250XGC P YK350XGC P YK400XGC P YK500XGLC P YK600XGLC P M8 Depth of tapped holes in installation base Iron installation base Bolt diameter x 1 5 or more Aluminum installation base Bolt diameter x 3 0 or more JIS B 1176 hex socket head bolt or equivalent Recommended bolt Strength class JIS B 1051 12 9 or equivalent 5 AL Q o 3 Installing the robot uU RA gt ER aS Hex socket head bolt Installation base 23230 HM 00 2 5 3 User wiring and user tubing ALWAYS TURN OFF THE CONTROLLER AND SHUT OFF AIR SUPPLY BEFORE ATTEMPTING WIRING AND PIPING WORK IF AIR OR POWER IS SUPPLIED DURING THIS WORK THE MANIPULATOR MAY MOVE ERRONEOUSLY CAUSING A HAZARDOUS SITUATION The YK XGC P 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
85. wing cases are not covered under the warranty 1 Products whose serial number or production date month amp 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 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 Introduction Contents Before using the robot Be sure to read the following notes Introduction Before using the robot Be sure to read the following notes Thank you for purchasing YAMAHA SCARA ROBOT YK XGCY P series This manual describes only the points that are different from the standard models For details about other explanations see the Installation Manual and Maintenance Manual for YK XG series standard models l If the Z axis spl

YK-XG Series I/M English

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