Home

Safety Manual - Yamaha Robotics

1. OL AGIN 9 L ACOUT 1 AUTO SERVICE Maintenance switch s Input 1 Service 1 SRL1 L2 S2 Input2 Input 3 e ll Input 1 x o Input 2 Enable 11 nable Enable 12 21 Enable 22 o SAFETY 7 14 EMG1 O EMG2 DO COM MPRDY 1 When INTERLOCK INTERLOCK GND signal is not used SRL2 External emergency stop L2 L1 A2 Ta1 Ta2 T33 Service 1 SERVICE S14 DI COM Input 1 S24 bd S4 S34 GND Input 2 544 554 OUT T41 T42 HPB D SAFETY 24V 771 HPB D emergency stop HPB D emergency stop Output Input 1 X o lt Output 2 Input2 o SRL4 HPB D enable zi 131132 T HPB D enable Input 1 T12 T f 14 Output 1 p T21 28 Input 2 T22 24 Output 2 C 24V 123 1 133_ Enable 11 T 1 L Enable 12 2AN 43 Enable 21 GND Enable 22 GND 1 Wiring to check whether the controller is normal when using an alarm to shut off the main power 93313 Q6 00 Parts list Part name 51 Reset switch A22 series OMRON 52 Key selector switch A22 TK series OMRON 53 Safety door switch D4 series OMRON S4 Emergency stop button A22E series OMRON KM1 2 Contactor mirror contact LC1 D09 Schneider Electric Safety relay G7SA 3A1B OMRON Socket for safety relay P7SA 10F ND OMRON SRL1 Safety
2. Control power surge L absorber Pose d Motor power 1 Je AUTO MANUAL SERVICE mode selection 2 gt 424V Mods SERVICE Emergency stop Enable AUTO Close Open 9 9 SAFETY iN MANUAL SERVICE Open Close b X 9 ux SERVICE Q i SERVICE DIO2 13 7 Y T2 N 1 4 ra 5 I S2 T IN2 ie 5 2 15 3 ic 1 T3 7 17 Safety door N Y in 3 8 ir 6 T ji IN7 10 5 Ww T2 B M IN12 External 4 T3 i A IN8 emergency stop IN13 status T N COMDI 13 E STOP24V Internal 24V 14 E STOPRDY E STOP Ti status 02 Internal je DG O3 IN10 DC power 24V 24V q l V4 V2 GND O t G1 G2 55 COMMON ri CPU_OK INTERLOCK 47 Input output signals 48 gt P COMDI 501 N coMbI 93214 R6 00 Parts list Type No Key selector switch A22TK series OMRON Safety door switch D4 series OMRON Emergency stop button A22E series OMRON Contactor mirror contact 2018 1 42 SIEMENS Safety relay G7SA 3A1B OMRON Socket for safety relay P7SA 10F ND OMRON Safety controller G9SP series OMRON 2 33 lt 7 X Solos 7 X Solos
3. 3 12 32 forthe 3 13 3 2 1G e ESTERI e TEN Ree 32 2 323 ate god 3 2 4 Overview of circuit operation Introduction Thanks for purchasing the YAMAHA robot controller RCX340 RCX240 RCX221 RCX222 SR1 X SR1 P This manual describes the contents of the measures for the safety standards for the RCX340 RCX240 RCX221 RCX222 SR1 X SR1 P to be installed in each country When shipping or using the RCX240 RCX221 RCX222 SR1 X SR1 P overseas always read this manual thoroughly to operate the controller correctly Note that this manual describes only the contents of the measures for each country s safety standards For operations and programming of the robot controller refer to the user s manuals that come with the robot controller For information on the warranty also refer to the user s manuals that come with the robot controller Even after reading this manual keep it in a safe easily accessible place so that it can be referred to when needed This manual should be used with the robot and controller and considered an integral part of them When the robot and controller are moved transferred or sold send this manual to the new user along with the robot and controller Be sure to explain t
4. Safety circuit Controller RPB PNP specifications Emergency stop External C emergency stop SAFETY RPB Q7 13 13 B 5 14 141 lr AUTO SERVICE 1 DI COM Maintenance switch 4 GND aa 24V 24V 2 xt INTERLOCK 3 SERVICE DIO2 c 4 DO COM 5 MPRDY d 6 SERVO OUT 11 E STOP24V Internal 24V po 12 E STOPRDY E STOP H Status 24V ae STD DIO 424V GND amp GND GND STD DIO power 24V 1 gt 24V GND t 5 5 2 GND 24VG connector Ur CPU OK To PLC Input output signals 93210 R1 00 3 4 1 Category 4 A safety circuit configuration example of category 4 is shown below Category 4 safety circuit example L1 AC IN AC OUT Reset switch 51 4 AUTO SERVICE Maintenance switch 9 io Eg gt lt Input 1 Service 1SRL1 S2 Input 2 OTF Mil rur 977 2 on JoFF B Input 3 TAM A OFFION gt T31 Door switch D Input 1 Bd X T12 T S3 21
5. Recommended ferrite core 3 Manufacturer TDK Type No ZCAT2032 0930 Dimensional outline 30 0 1 13 0 1 o unit mm 93206 R1 00 20 511 11 021 unit mm 93207 R1 00 19 51 unit mm 93208 R1 00 2 29 4 3 External safety circuit examples This section describes category specific safety circuit configuration examples using the PBX E RPB E Customers should install the appropriate safety measures for their system by referring to the circuit example for each controller in order to use the robots more safely To comply with the robot safety standards EN ISO 10218 1 2011 it is necessary to use a SAFETY controller Circuit examples for the RCX221 222 controller and SR1 controller are not circuits that comply with EN ISO 10218 1 2011 and are applicable only to the category requirements of EN ISO 13849 1 2006 3 1 Safety requirements 3 1 1 CE marking To comply with the machinery directives the performance level PL required of the safety circuit must be evaluated Performance levels PL are determined by the following parameters 7 X Major factors that determine performance levels 59 95 1 Category 2 MTTFd Mean Time To Dangerous Failure 3 DCavg Average Diagnostic Coverage 4 CCF Common Cause Failure Checklist score gt 65 Please obtain the data on each component from the compone
6. YAMAHA robot External emergency stop circuit Emergency stop button Safety relay Safety door switch etc External device PLC etc 93201 R2 00 2 3 lt 1 2 Control system configuration 1 2 1 Basic configuration The basic block diagram of the RCX robot controller system is shown below RCX340 basic block diagram Basic block diagram gt yog Gf 5 3 5 8 tr a a oc a a n a O EN EN EN ENG ee gt lt DRIVER1 o D 5 5 5 aa 1 9 2 8 8 5 X Ze lt 5 E C m ES E 1 2 M3 M4 AC IN o L v DRIVER POWER N1 DH 93202 R8 00 RCX240 basic block diagram Basic block diagram RCX series AC DC AC DC 24V 5V 12 S IO CPU BOARD DRIVER POWER DRIVER 2 DRIVER 1 00 tw CN8 66 CN1556 CN8 CN1Y ROB I O XY ROB I O ZR BATT ZR 93202 R6 00 2 5 lt RCX221 basic block diagram Basic block diagram YSHLOW 7 X D POWER BOARD ASSY Solos CPU BOARD ASSY 93201 R1 00 RCX222 basic block diagram Basic block diagram Y
7. Potential hazard to human body Moving parts can pinch or crush hands To avoid hazard Keep hands away from the movable parts of the robot 90K41 001460 5 3 4 SUOHONASU Warning label 3 SCARA robots Cartesian robots controllers Some models A WARNING Improper installation or operation may cause serious injury Before installing or operating the robot read the manual and instructions on the warning labels and understand the contents 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 Read and understand manuals before operation of the robot HER SEHUACEHBUTURERTETEHIIETEADERER THUS Before starting the robot operation even after you have read through this manual read again the corresponding procedures and Safety instructions REIDI Sco in this manual nir eie SA 24 90K41 001290 Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual SUOHONASU Ajojos Potential hazard to human body Improper installation or operation may cause serious injury Before installing or operating the robot read the manual and instructions on the To avoid hazard warning labels and understand the contents 90K41 001290
8. 1 Hm Input2 7 o T22 sit Sa 1T i 761 5 54 Enable 11 4 Enable 12 62 Enable 21 B pot gt 1 1 1 T Enable 22 1 24 SAFETY TNT TT E STOP24V i E STOPRDY EE 0 DO COM When INTERLOCK p MPRpY 1 Ga e 424N GND signal is not used P INTERLOCK RL2 External emergency stop S L2 L1 A2 T31 T32 T33 Service 1 LS SERVICE DIO2 T11 S14 DI COM Input 1 X X T12 24 54 T21 534 GND Input 2 xX T22 544 554 ous T41 T42 SAFETY 24V RPB E emergency stop SRL3 E Output 1 RPB E emergency stop L1 A2 T31 a A P T11 Input 1 Bd A T12 Q Output 2 l T21 Input 2 Bj 22 SRL4 RPB E enable ii T81 T32 i RPB E enable Input 1 T Q T12 t 14 5 Output 1 yz 21 ML 23 Input 2 a T22 24 5 Output 2 24V 123 33 Enable 11 d t 1 34 Enable 12 24 B 143 Enable 21 GND 9 Enable 22 GND 1 Wiring to check whether the controller is normal when using an alarm to shut off the main power 93211 R1 00 Parts list Type No Manufacturer 51 Reset switch A22 series OMRON 52 Key selector switch A22 TK series OMRON 53 Safety door switch D4 series OMRON 54 Emergency stop button A22E series OMRON KM1 2 Contactor mirror contact LC1 D18 Schneider Electric 105 Safety relay G7SA 3A1B OMRON Socket for safety relay P7SA 10F ND OMRON
9. a ACIN 7 AC OUT Reset switch 1 51 Ne La Li AUTO SERVICE RE Maintenance swit a intenance Switch GND 24V lt gt t X Input 1 Service 1 SRL1 12 L1 32 Input M1 we OUT 4 M2 ON OFF B Input 3 E 424V _ 3 T31 24V Door switch T32 11115 53 Input 1 WA xX 112 122 o I21 14 122 S24 e 544 EN 161 554 PNE Enable 11 162 B 122 24V SAFETY J Hy T4114 E STOP24V E STOPRDY EN O DO COM MPRDY 1 M PRA When INTERLOCK INTERLOCK SRL2 GND signal is not used External emergency stop T11 Service 1 SERVICE DIO2 T12 DI COM S4 Input 1 T P T21 Y T22 514 Y1 S24 SAFETY 424V RPB E emergency stop OUT Input 1 RPB E emergency stop Input 2 9 9 a Output 1 24V RPB E enable 1 iid d Enable 11 RPB E enable Input 2 X Q Output 1 24V E 24V M GND 9H GND 1 Wiring to check whether the controller is normal when using an alarm to shut off the main power 93213 R1 00 Parts list Type No Reset switch Key selector switch Safety door switch Emergency stop button OMRON OMRON OMRON OMRON Schneider Electric A22 series A22 TK series D4 series A22E series LC1 D18 Contactor mirror contact Safety relay G7SA 3A1B OMRON Socket for safety relay P7SA 10F ND OMRON Safety relay unit G9SX GS226 O
10. Do not enter or allow the face and hands to intrude anywhere along the line where the linear conveyor guide rail may extend not only ejection side of the conveyor but also the insertion side If ejecting the slider on the linear conveyor then install a suitable ejection mechanism device to catch and stop the ejected slider Install a structure and a mechanism to catch and retain the slider on the side where the slider is inserted Install a safety enclosure outside the linear conveyor movement range Design the safety enclosure so that the slider and workpieces from the linear conveyor are not ejected outside of the enclosure 2 Preventing electrical shock DANGER Always comply with the instructions in this manual when installing operating and inspecting the linear conveyor module Failure to do so may lead to electrical shock serious injury or even death Please comply with the following items Read and FOLLOW the instructions in this manual when grounding the linear conveyor module and installing the termination module Do not touch the motor of the linear conveyor module when it is on Always comply with the instructions in the manual when performing maintenance and be sure to turn off the power before starting maintenance tasks If cracked or broken plastic motor parts are found stop using the linear conveyor module immediately and turn off the power 3 Strong magnetic field A WA
11. Serious injury may result from contact with a moving robot Keep outside of the robot safety enclosure during operation Press the emergency stop button before entering the safety enclosure A WARNING Install an interlock that triggers emergency stop when the door gate of the safety enclosure is opened The safety enclosure should be designed so that no one can enter inside except from the door gate equipped with an interlock device Warning label 1 See 3 Warning labels 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 gt S 16 4 6 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 DANGER Check the following points before starting robot operation No one is within the robot safety enclosure The programming unit is in the specified location The robot and peripheral equipment are in good condition 4 6 1 Trial operation After installing adjusting inspecting maintaining or repairing the robot perform trial operation using the following procedures 1 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 fol
12. 3 3 2 Overview of circuit operation This section describes an overview of the circuit operation for each safety circuit configuration example shown in the previous sections The safety controller is programmed so that the operation is performed in the table below Additionally the safety controller is programmed so that it complies with the required standards other than the operations Input Output Bera Mode select E Enabl mode TO Safety door dug E STOPRDY Contactor switch stop button switch AUTO mode outside safety enclosure Input a c Close Input b Open MANUAL SERVICE mode inside safety enclosure Input a c Open Input b Close 1 Emergency stop operation When the emergency stop button is pressed the controller main power motor drive power is shut down When the emergency stop button is pressed the category 0 emergency stop is activated regardless of other switch settings 2 Each mode operation by mode select switch setting 2 1 AUTO mode Mode select switch setting input a c Close input b Open RPB E enable switch is disabled The contactor turns on to supply the main power motor drive power to the controller only when all conditions shown below are satisfied Conditions The emergency stop button is closed The safety door is closed The MP RDY signal is on Output from the controller when the controller
13. 4 3 2 Precautions for robot controllers 5 11 4 4 Moving and installation 5 12 4 4 1 Precautions for robots 5 12 4 4 2 Precautions for robot controllers 5 13 4 5 Safety measures 5 15 4 5 1 Safety measures 5 15 4 5 2 Installing safety enclosure 5 16 4 6 Operation 5 17 4 6 1 Trial operation 5 17 4 6 2 Automatic operation 5 19 4 6 3 Precautions during operation 5 19 4 7 Inspection and maintenance 5 21 4 7 1 Before inspection and maintenance work 5 21 4 7 2 Precautions during service work 5 22 4 8 Disposal 23 5 Emergency action when a person is caught by robot 24 6 Cautions regarding strong magnetic fields S 24 7 Using the robot safely S 25 7 1 Movement range S 25 7 2 Robot protective functions S 26 7 3 Residual risk S 27 7 4 Special training for industrial robot operation S 27 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 Instructions guide Failure to take necessary safety measures or incorrect handling may result in trouble or damage to the robot and controller and also may cause personal injury to installation personnel robot operator or service personnel including fatal accidents Before using this product read this manual and relate
14. breakdown Securely install each cable connector into the receptacles or sockets Poor connections may cause the controller or robot to malfunction S 13 4 SUOHONASU SUOHONASU Ajojos 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 A WARNING 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 CAUTION AN 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 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 A WARNING Securely install the connectors into the robot control
15. connect it to the RCX340 series controller 1 3 1 1 Part names and functions The PBX E has an emergency stop button and an enable switch The contact outputs of these can be used to connect to the emergency stop circuit of the entire equipment via the SAFETY connector on the controller Additionally the PBX E is equipped with a manual lock ON OFF switch that sets the control priority When operating the teaching etc within the safety enclosure in the MANUAL mode set the manual lock switch to When the manual lock switch is set at ON the priority is set to the PBX E allowing you to control the robot 7 X operation When the manual lock switch is set at OFF the robot operation cannot be controlled 1 Display 3 Emergency stop button o 4 Manual lock switch 6 USB connector 2 Sheet key 5 Enable switch 7 PB connector 93203 R8 00 Main Functions Part name Function This is a liquid crystal display LCD with 20 characters x 15 lines showing various types of information Display The screen brightness is adjustable These keys are used to operate a robot or input programs The sheet keys are classified into 3 main types function keys control keys and data keys Emergency stop Pressing this button during operation immediately stops robot movement This is a contact b normally button closed
16. disposal method in 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 regula tions We do not collect and dispose of the used packing boxes and materials 3 Strong magnet A WARNING Strong magnets are installed in the robot Be careful when disposing of the robot See 6 Cautions regarding strong magnetic fields in Safety instructions for detailed information on strong magnetic fields S 23 lt SUOHONASU AJojos 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 Emergency action Release the axis while referring to the following section in the manual for the robot controller Emme we RCX240 Section 1 Freeing a person caught by the robot in Chapter 1 RCX340 Section 1 Emergency action when a person is caught by robot in Chapter 1 NE NOTE Make a printout of
17. m 5 g 5 ACIN gt lt D POWER BOARD ASSY o UM 5 N1 lt D o I O XY RPB ASSY 93202 R2 00 2 lt 1 2 2 Power supply and emergency stop system circuit configuration The control system s power supply system and emergency stop system circuit block diagram are shown below Power supply and emergency stop circuit block diagram Emergency stop button x Programming Box Selector switch CONTROL CIRCUIT BLOCK Enable switch 7 X Solos DRIVE CIRCUIT External emergency stop circuit User equipment DC280V REALY GND MOTOR POWER CIRCUIT AC200 to 230V IN RCX340 RCX240 RCX221 RCX222 1 The input power and each control power are insulated by the insulated transformer 2 The OV line for the 3 6VDC 5VDC 12VDC and 24VDC is not connected to the protective earth 3 For details about wiring diagram from the programming box refer to the connector input output signal table 4 Excluding RCX221 93201 R0 00 2 8 1 3 Programming box The programming box is a hand held unit specifically designed to connect to the controller in order to perform various operations The programming box allows all operations including manual operation of the robot programming and editing teaching and parameter setting 1 3 1 PBX E To use the programming box PBX E
18. switch stop button switch AUTO mode outside safety enclosure Input a Close Input b Open 7 X MANUAL mode inside safety enclosure Input a Open Input b Close Solos 1 Emergency stop operation When the emergency stop button is pressed the controller main power motor drive power is shut down When the emergency stop button is pressed the category 0 emergency stop is activated regardless of other switch settings 2 Each mode operation by mode select switch setting 2 1 AUTO mode Mode select switch setting input a Close input b Open PBX E enable switch is disabled The contactor turns on to supply the main power motor drive power to the controller only when all conditions shown below are satisfied Conditions The emergency stop button is closed The safety door is closed The MP RDY signal is on Output from the controller when the controller main power is ready to turn on N CAUTION Connect the PBX terminator or PBX E to the PB connector on the controller front panel If the PB connector on the controller front panel is open an emergency stop occurs 2 2 MANUAL mode Mode select switch setting input a Open input b Close PBX E enable switch is enabled The contactor turns on to supply the main power motor drive power to the controller only when all conditions shown below are satisfied Conditio
19. user wants to permit automatic operation and step operation even in SERVICE mode then the user can cancel this limiting function only in cases where judged not hazardous 0 default Automatic operation and step operation are prohibited in SERVICE mode 1 Automatic operation and step operation are permitted even in SERVICE mode Hold to Run function Determine whether to enable or disable the Hold to Run function In SERVICE mode the Hold to Run function is always enabled However if the user wants to disable the Hold to Run function even in SERVICE mode then the user can cancel this function only in cases where judged not hazardous 0 default Hold to Run function is enabled in SERVICE mode 1 Hold to Run function is disabled even in SERVICE mode 3 7 lt 2 EMC countermeasure examples Regarding EMC Directive the customer s final product entire system including the YAMAHA robot must provide the necessary countermeasures We at YAMAHA determine a model for single units of YAMAHA robots controller robot and peripheral device and verify that it complies with the relevant standards of EMC Directive In order to ensure the customer s final product entire system complies with EMC Directive the customer should take appropriate EMC countermeasures Typical EMC countermeasures for a single unit of YAMAHA robot are shown for reference AN CAUTION The following
20. 3 Programming DOX PBX E M 1311 Part names and functions 22 USD 1 3 2 1 Part names and functions LT D 14 CE specifications and KCs 2 14 141 MANUAL mode Applicable controller 2 14 MANUALmode parameter settihgs eerren EMT 2 15 1 4 2 SERVICE mode Applicable controller 240 221 222 1 2 16 1 4 2 1 Flow for enabling the SERVICE mode FUNCTIONS 2 17 14022 SERVICE mode parameter settings 2 17 2 countermeasure examples 2 19 21 REX SAO ere ZA me 2 1 2 Countermeasure components 220 ROX QZAO eR corse ENDE 2 2 1 ata NETUS URSUS 2 2 Countermeasure components 23 IREX221 REX 222s 2 3 15 Configuration esses eres thee esie 2 26 2 3 2 G ountermecsure coermpohettsv 2 27 3 External safety circuit examples 2 30 310 Safety requirements lt aa a ccc eI 2 30 esee eere A A A E A A UE 2 30 KESMA A ete 2 30 3 2 Circuit e
21. In the customer s final system the category required of the safety circuit should be determined by means of risk assessment and then the safety circuit with the corresponding category should be configured 2 30 3 2 Circuit examples for the RCX340 The following shows safety circuit configuration examples for the RCX340 Customers should install the appropriate safety measures for their system by referring to these safety circuit configuration examples in order to use the robots more safely The following shows an example with input output signals described below Operation mode switch door switch external emergency stop PBX E emergency stop PBX E enable MPRDY Contactor E STOPRDY AUTO N CAUTION The controller status output signals of the parallel I O and serial I O such as alarm signal should be monitored by the host device or safety controller 7 X 3 2 1 Category 3 A safety circuit configuration example of category 3 is shown below Category 3 safety circuit example D o Power wiring Safety circuit Controller PNP RBX E AC power ACIN Earth Li le Era 1 1 proc N1 Control power i 2 Suge zm a L absorber protector _ l pa J N 2 Motor power jo aq 1 L 1 Flo AUTO M
22. NPN PNP specifi cations for SVCE are determined by DI COM and DO COM inputs The input current SVCE should be 8mA or more 1 4 2 Flow for enabling the SERVICE mode functions SERVICE mode function is enabled Open turn OFF the SVCE contact If a serial unit is installed open turn OFF either one of the SAFETY connector SVCE contact or the serial SVCE contact or both Limiting functions in SERVICE mode starts working The limiting functions in SERVICE mode can be set individually Refer to the next section for details on the safety controls gt 3 6 1 4 3 Limiting functions in SERVICE mode The following 4 limiting functions can be set in SERVICE mode 1 Limiting the operation devices limiting command input from any device other than HPB D 2 Limiting the robot movement speed 3 Limiting the automatic operation and step operation prohibiting the automatic operation and step operation 4 Hold to Run function Refer to the controller user s manual for how to make each setting A WARNING iF CHANGING ANY OF THE LIMITING FUNCTIONS FROM THEIR DEFAULT SETTINGS IS LIKELY TO INCREASE THE RISK TO PERSONNEL OPERATING OR MAINTAINING THE ROBOT HOWEVER THE USER CAN CHANGE THE SETTINGS FOR THE LIMITING FUNCTIONS ONLY IN CASES WHERE JUDGED NOT HAZARDOUS IN THOSE CASES TAKE EXTRA CAUTION TO ENSURE SAFETY Limiting the operation devices Specify the devices that may be used to ope
23. SRL1 Safety relay unit G9SX GS226 OMRON SRL2 Safety relay unit G9SX AD322 OMRON SRL3 Safety relay unit G9SX BC202 OMRON SRL4 Safety relay unit G9SA 501 OMRON 2 37 4 3 4 2 Category 3 A safety circuit configuration example of category 3 is shown below Category 3 safety circuit example KM1 11 ACIN va AC OUT 1 Reset switch 51 AUTO SERVICE Maintenance switch 24V gt lt nput 1 5 Service 1 SRL1 12 52 Input 2 aA T nput 3 M Q T31 24V Door switch T32 o nput 1 133 53 1 2 514 4 npu 24 T S44 554 Enable 11 1 Enable 12 pu m Enable 21 NI bd Enable 22 GND GND 24V SAFETY TE sind NE MT T41 T42 E E p E STOPRDY l oH DO COM O When INTERLOCK GND signal is not used External emergency sto Service 1 SERVICE DIO2 3 o DI COM Input 1 v S4 GND Input 2 Bj X OUT SAFETY 124 KA4 KA5 RPB E emergency stop SRL2 To Output 1 RPB E emergency
24. THE USER MUST TAKE THE NECESSARY PROTECTIVE MEASURES SUCH AS ENABLE DEVICES ACCORDING TO RISK ASSESSMENT BY THE USER NEC m NOTE 0 The robot pauses when the SERVICE mode input is changed during program operation or jog movement The NPN PNP specifi cations for 0102 are determined as follows RCX240 Determined by STD DIO setting RCX221 RCX222 Determined by DI COM and DO COM input Current capacity of at least 7mA is required for DIO2 input When the RCX240 controller is set to SAFE mode it always enters the SERVICE mode unless power is supplied to STD DIO from the external 24 V power supply To cancel this state by software set the Watch on STD DIO DC24V parameter to INVALID 2 16 1 4 2 1 Flow for enabling the SERVICE mode functions Controller is set to SAFE mode SERVICE mode parameters have been set Open turn OFF the 0102 contact If a serial option board is installed SERVICE mode is entered when either one of 5102 or 0102 is open OFF Controller enters SERVICE mode with the operation level operating speed limit and exclusive control of the operation devices specified by the SERVICE mode parameters Refer to the next section for the SERVICE mode parameter settings 7 X 1 4 2 2 SERVICE mode parameter settings There are the following three parameters for SERVICE mode 1 SERVICE mode level 59 95 2 Operating speed limit during SERVICE mode 3 Operation d
25. both ends of the maximum movement range The positions of these mechanical stoppers cannot be changed No mechanical stopper is provided on the rotational axis Single axis robots Cartesian robots A WARNING Axis movement does not stop immediately after the servo is turned off by emergency stop or other protective functions so use caution CAUTION N If the robot moving at high speed collides with a mechanical stopper installed in the robot or available as option the robot may be damaged A DANGER When the linear conveyor module is used to insert or eject the slider mechanical stoppers cannot be attached to the module body due to the structural limits So install a device to catch and stop the slider being ejected at high speed from the module as well as other necessary safety measures 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from sliding downward when the servo is OFF This brake is working when the controller is OFF or the Z axis servo power is OFF even when the controller is ON The Z axis brake can be released by the programming unit handy terminal or by a command in the program when the controller is ON WARNING The vertical axis will slide downward when the brake is released causing a hazardous situation Take adequate safety measures in consideration by taking the weight and shape into account Before releasing the brake after pressing th
26. description and circuits are typical countermeasures used when the robot and controller are tested under YAMAHA installation conditions When the robot and controller are used while installed in the customer s system the actual test results may differ depending on installation conditions 2 1 SRI 2 1 1 Configuration AN CAUTION As shown in the following figure the ferrite cores and noise filter on the controller side should be placed as close to the controller body as possible The ferrite cores on the robot side should be placed as close to the robot body as possible Typical component layout for countermeasures SR1 X P ROB I O Robot series Power supply MOTOR Single axis 100 to 115V 200 to 230V Ground circuit or network SAFETY External safety circuit RGEN Regenerative unit Meaning of symbols a Noise filter MC1210L TDK Lambda Corporation AT Ferrite core ZCAT3035 1330 TDK Ferrite core ZCAT2032 0930 TDK Ferrite core 1 turn 93306 Q6 00 gt 3 8 2 1 2 Countermeasure components Surge absorber The SR1 does not need any external surge absorber However to further enhance the surge resistance install a surge absorber on the AC power line A recommended surge absorber is shown below Recommended surge absorber Manufacturer SOSHIN ELECTRIC CO LTD Type No LT C12G801WS Dimensional outline Status indicator
27. 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 A WARNING To check the robot controller operating status refer to this manual and to related manuals Design and install the system including the robot controller so that it will always work safely 5 Precautions for operation A WARNING Do not touch any electrical terminal Directly touching these terminals may cause electrical shock equipment damage and malfunction 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 A WARNING 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 5 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 See 7 1 Movement range in Safety instructions for details on the robot s movement range DANGER
28. moving the robot wear personal protective gear such as helmets and make sure that no one is within the surrounding area 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 gt 5 12 B Wiring 1 Protective measures against electrical shock A WARNING Always ground the robot to prevent electrical shock B Adjustment 1 Adjustment that requires removing a cover A WARNING Adjustment by removing a cover require specialized technical knowledge and skills and may also involve hazards if attempted by an unskilled person This adjustment must be performed only by persons who have the required qualifications described in 2 Qualification of operators workers in section 4 1 of this Safety instruc tions 4 4 2 Precautions for robot controllers Installation environment 1 Installation environment A WARNING YAMAHA robots are not designed to be explosion proof Do not use the robots and controllers in locations exposed to explosive or inflammable gases dust particles or liquid such as gasoline and solvents Failure to follow this instruction may cause serious accidents involving injury or death and lead fo fire A WARNING Use the robot controller in locations that support the environmental conditions specified in this manual Operation outside the specified environmental r
29. not therefore guarantee that YAMAHA robots conform to KCs in cases where the robot is used independently Customers who incorporate a YAMAHA robot into their final system which will be shipped to or used in Korea should therefore verify that the overall system is compliant with KCs 2 2 2 KCs mark For robots and controllers that apply to the KCs mark the Report of Declaration of Conformity is submitted to Korean Occupational Safety and Health Agency KOSHA and the KCs mark is affixed to robot controllers 2 2 3 Normative standards Electromagnetic Compatibility EMC Industrial robot manufacture and safety standards 1 4 2 2 4 Robots subject to KCs The following robot series products are subject to the KCs mark As of June 2014 Product Model name Controller Program RCX240 S KCs specifications FXYx 3 axes 3 axes SXYx 4 axes 3 axes Arm type 4 axes 3 axes 4 axes 3 axes 4 axes Cartesian robots 3 axes 4 axes Gantry type 3 axes 4 axes SXYx 3 axes Moving arm type MXYx 3 axes HXYx 3 axes MXYx 3 axes Pole type HXYx 3 axes YK250XG YK350XG YK400XG Standard type YK500XGL YK600XGL YK500XG YK600XG YK600XGH YK700XG YK800XG YK900XG YK1000XG YK250XGC YK350XGC YK400XGC YK500XGLC YK600XGLC SCARA robots YK500XGS YK600XGS YK700XGS YK800XGS YK900XGS i ype YK1000XGS YK250XGP YK350XGP YK400XGP
30. 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 4 Important precautions for each stage of the robot life cycle 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 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 n systems that significantly affect society and the general public n equipment intended to carry or transport people n environments which are subject to vibration such as onboard ships and vehicles 2 Qualification of operators workers Operators or persons who perform tasks for industrial robots such as teaching programming movement check inspec tion adjustment and repair must receive appropriate traini
31. support under the vertical axis before removing the motor 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 A WARNING The Z axis will slide downward when the Z axis motor is removed causing a hazardous situation Turn off the controller and Place a support under the Z axis before removing the Z axis motor 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 CAUTION AN 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 A WARNING Powerful magnets are installed inside the robot Do not disassemble the robot since this may cause injury Devices that may malfunction due to magnetic fields must be kept away from this robot See 6 Cautions regarding strong magnetic fields in Safety instructions for detailed information on strong magnetic fields 5 Use the following caution items when disassembling or replacing
32. the controller and turns off the servo If an overheat error occurs take the following measures to avoid the error 1 Insert a timer in the program 2 Reduce the acceleration 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 A WARNING Soft limit function is not a safety related function intended to protect the human body To restrict the robot movement range to protect the human body use the mechanical stoppers installed in the robot or available as options 4 Mechanical stoppers If the servo is turned off by emergency stop operation or protective function while the robot is moving then these mechanical stoppers prevent the axis from exceeding the movement range The movement range is the area limited by the mechanical stoppers The X and Y axes have mechanical stoppers that are installed at both ends of the maximum movement range Some robot 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 SCARA robots option parts The Z axis has a mechanical stopper at the upper end and lower end The stopper positions can be changed by using option parts No mechanical stopper is provided on the R axis The linear movement axis has a mechanical stopper at
33. the pneumatic equipment A WARNING Air or parts may fly outward if pneumatic equipment is disassembled or parts replaced while air is still supplied Do service work after turning off the controller reducing the air pressure and exhausting the residual air from the pneumatic equipment Before reducing 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 A WARNING Touching the rotating fan may cause injury If removing the fan cover first turn off the controller and make sure the fan has stopped 7 Precautions for robot controllers CAUTION Back up the robot controller internal data 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 Do notuse 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 gt 5 22 4 8 Disposal When disposing of robots and related items handle them carefully as industrial wastes Use the correct
34. the relevant page in the manual and post it a conspicuous location near the controller 6 Cautions regarding strong magnetic fields Some YAMAHA robots contain parts generating strong magnetic fields which may cause bodily injury death or device malfunction Always comply with the following instructions Persons wearing medical electronic devices such as cardiac pacemakers or hearing aids must keep away from the linear single axis robot and linear conveyor Stay at least 100mm away Persons wearing ID cards purses and or wristwatches must keep away from the linear single axis robot and linear conveyor Do not attempt to disassemble the linear single axis robot and linear conveyor including surrounding covers Do not bring tools close to the internal parts of the robot and the linear conveyor magnets Always attach the magnet protective cover supplied when handling shipping or storing the linear convey or s slider when removing it from the module 5 24 7 Using the robot safely 7 1 Movement range When a tool or workpiece is attached to the robot manipulator tip the actual movement range enlarges from the movement range of the robot itself Figure A to include the areas taken up by movement of the tool and workpiece attached to the manipulator tip Figure B The actual movement range expands even further if the tool or workpiece is offset from the manipulator tip The movement range here is de
35. 3203 R1 00 2 26 2 3 2 Countermeasure components Surge absorber The RCX221 222 does not need any external surge absorber However to further enhance the surge resistance install a surge absorber on the AC power line A recommended surge absorber is shown below Recommended surge absorber Manufacturer SOSHIN ELECTRIC CO LTD Type No LT C12G801WS Dimensional outline X Status indicator Green Normal Red Abnormal Solos qu 49 1 0 Wire line Wire earth Black Green Yellow gt 3 38 1 0 unit mm 93204 R1 00 2 2 4 B Noise filter Always install an external noise filter on the AC power line A recommended noise filter is shown below Recommended noise filter Manufacturer TDK Lambda Corporation Type No MBS 1215 22 Dimensional outline 105 0 5 xod Solos 22MAX 95 1 22MAX Case unit mm 93205 R1 00 2 28 Ferrite core Install ferrite cores according to the customer s final product entire system Recommended ferrite cores are shown below Recommended ferrite core 1 Manufacturer TDK Type No ZCAT3035 1330 Dimensional outline Recommended ferrite core 2 Manufacturer TDK Type No ZCAT2132 1130 Dimensional outline 36 041 32 0 1 E CTEK
36. 38 1 0 unit mm 93205 R6 00 2 20 Noise filter Always install an external noise filter on the AC power line A recommended noise filter is shown below Recommended noise filter Manufacturer TDK Lambda Corporation Type No RSHN 2016 Dimensional outline 12741 115 0 5 8 H gt lt 6 4 2 04 5 35 1 Solos 23218 QL 00 E Ferrite core Install ferrite cores according to the customer s final product entire system Recommended ferrite cores are shown below Recommended ferrite core 1 Manufacturer TDK Type No ZCAT3035 1330 Dimensional outline 30 0 1 13 0 1 unit mm 93207 R6 00 Recommended ferrite core 2 Manufacturer TDK Type No ZCAT2132 1130 Dimensional outline 36 0 1 20 5 1 11 0 1 i unit mm 93208 R6 00 2 21 lt 2 2 RCX240 2 2 1 Configuration AN CAUTION As shown in the following figure the ferrite cores and noise filter on the controller side should be placed as close to the controller body as possible The ferrite cores on the robot side should be placed as close to the robot body as possible Typical component layout for countermeasures RCX240 ROB I O 7 X Robot series Single axis Power supply Cartesian 200 to 230V N SCARA Ground P amp P Solos c
37. ANUAL mode selection Mode a b 1 AUTO ____ close Close Open i Emergency stop Enable MANUAL Open Close pf TT SAFETY C IN1 13 uc t T2 3 115 x S2 T IN2 16 B Safety door TTP I 1916 20 5 5V E STOP status 1 IN3 ING A IN7 7 02 53 External emergency stop X E STOP status 2 AUTO status 1 AUTO status 2 MPRDY status 1 MPRDY status 2 DC power 24 O To PLC o Input output signals 2 1 gt 424V 2 93209 R8 00 Parts list Key selector switch A22TK series OMRON Safety door switch D4 series OMRON Emergency stop button A22E series OMRON Contactor mirror contact 3RT2018 1FB42 SIEMENS Safety controller G9SP series OMRON 2 31 4 3 2 2 Overview of circuit operation This section describes an overview of the circuit operation for each safety circuit configuration example shown in the previous sections The safety controller is programmed so that the operation is performed in the table below Additionally the safety controller is programmed so that it complies with the required standards other than the operations Input Output Operation E TOWN ode selec mergenc nable mode 9 Safety door i AUTO mode E STOPRDY Contactor
38. B Warning label 4 SCARA robots This label is not attached to omnidirectional type SCARA robots N CAUTION Do not remove the parts on which Warning label 4 is attached Doing so may damage the ball screw Instructions on this label Po netremeve the a The Z axis ball screw will be damaged if the upper end WARE CONSE MAG IE mechanical stopper on the Z axis spline is removed or moved Never attempt to remove or move it 90K41 001520 Warning label 5 controllers Cartesian robots single axis robots Some robot models A WARNING Ground the controller to prevent electrical shock Ground terminal is located inside this cover Read the manual for details Instructions on this label High voltage section inside Use the ground terminal inside the cover To prevent electrical shock be sure to ground the Se ASAT et robot using the ground terminal BAAS Malet 24 AN ABO Ain T Riv 90K41 001480 Potential hazard to human body Electrical shock To avoid hazard Ground the controller 90K41 001480 B Warming label 6 controllers TS X TS P A WARNING Before touching the terminals or connectors on the outside of the controller turn off the power and wait at least 10 minutes to avoid burns or electrical shock Motors and heatsinks become hot during and shortly after operation so do not touch them N
39. CAUTION Before using the controller be sure to read the manual thoroughly Be sure to ground the ground terminal Instructions on this label This indicates a high voltage is present Touching the terminal block or connector may cause electrical shock This indicates the area around this symbol may Risk of electric shock Do not touch terminals become very hot within 10 minutes of turning off power St Motors and heatsinks become hot during and shortly Risk of burn Do not touch heatsink when power is on after operation Do not touch them to avoid burns KEOBNAY This indicates important information that you must Read Manual before installing Before using the controller be sure to read the BH MICLT RECARO E ids PRESS Use proper grounding techniques manual thoroughly e u cc When adding external safety circuits or connecting a SORS 000820 power supply to the controller read the manual carefully and make checks before beginning the work Be sure to ground the ground terminal to avoid electrical shock Potential hazard to human body To avoid hazard Electrical shock Do not touch the terminal section for 10 minutes after power off Do not touch them to avoid burns Do not touch the motors and heatsinks during power on Improper installation or operation may cause Before installing or operating the robot read the man
40. D i and support software i POPCOM are sold separately Single axis robot X series External emergency stop circuit Emergency stop button Safety relay Safety door switch etc 93301 Q6 00 3 1 lt 1 2 Control system configuration 1 2 1 Basic configuration The basic block diagram of the SR1 robot controller system is shown below SRI Basic block diagram yo OPTION BOARD MOTHER BOARD ASSY BAT CONTROL BOARD ASSY RGEN DRIVER POWER BOARD ASSY AC VOLTAGE SELECT FAN MOTOR ASSY 2 MOTOR DRIVER2 BOARD ASSY 1 Installed only in SR1 X 2 Installed only in SR1 X 20 and SR1 P 20 93302 Q6 00 3 2 1 2 2 Power supply and emergency stop system circuit configuration The control system s power supply system and emergency stop system circuit block diagram are shown below Power supply and emergency stop circuit block diagram 4 Emergency stop button ABS BATTERY CONTROL 3 6V 2 CIRCUIT BLOCK POSITION BACKUP CIRCUIT HPB D SAFETY SAFETY 3 o DRIVE o CIRCUIT External o emergency stop circuit DC5V 12V 15V User equipment DC280V AC200 to 230V IN MOTOR POWER CIRCUIT 5 AC200V POWER CIRCUIT BLOCK 1 The input power and each control power are insulated by the insulated transfor
41. DI DO AUTO MANUAL PROGRAM SYSTEM monitor UTILITY mode mode mode mode mode mode Solos 93203 R0 00 SERVICE mode includes AUTO and MANUAL modes in the basic operation mode and is selected by opening turning OFF the DIO2 contact SERVICE mode input Normal mode is maintained as long as the DIO2 contact is closed ON If a serial option board is installed SERVICE mode is entered when either of 5102 0102 is open OFF Normal mode is entered only when both 5102 and 0102 contacts are closed When the 0102 contact is open OFF the controller is in SERVICE mode with the operation level operating speed limit and exclusive control of the operating devices specified by the SERVICE mode parameters The following functions can be selected in SERVICE mode 1 Robot is controlled only by RPB E operation 2 Automatic operation is prohibited 3 Robot operating speed is set to below 396 of the maximum speed 4 Robot operation is possible only by hold to run control The Hold to Run function allows the robot to move including program execution only during the time that the RPB E operation key is kept pressed In SAFE mode setting therefore the operations in AUTO mode and MANUAL mode differ from those in normal mode depending on the SERVICE mode parameter settings A WARNING RESTRICTION ON THE ROBOT MOVING SPEED IS NOT A SAFETY RELATED FUNCTION TO REDUCE THE RISK OF COLLISION BETWEEN THE ROBOT AND WORKERS
42. G YAMAHA robots are not designed to be explosion proof 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 A WARNING 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 instruc tions 2 Take safety measures when moving robots To ensure safety when moving a SCARA robot with an arm length of 500mm or more use the eyebolts that come supplied with the robot Always refer to the robot user s manual for details When moving other robots please comply with the transport methods described in their respective user s manuals 3 Take measures to prevent the robot from falling When moving the robot by lifting it with equipment such as a hoist or crane wear personal protective gear and be careful not to move the robot at greater than the required height Make sure that there are no persons on paths used for moving the robot A WARNING A robot falling from a high place and striking a worker may cause death or serious injury When
43. Green Normal Red Abnormal e o 19 1 0 Wireline Wire earth Black Green Yellow y D p N o N 22 5 1 0 unit mm 93307 Q6 00 3 9 lt e n o o B Noise filter Always install an external noise filter on the AC power line A recommended noise filter is shown below Recommended noise filter Manufacturer TDK Lambda Corporation Type No MC1210L Dimensional outline 971 0 4 8 6 M4 SEE NOTE A NOTES e A Input side terminal Output side terminal l nput Terminal 3 Qutput Terminal 2 Input Terminal 4 Output Terminal Base Plate Base Plate 18 B These are for customer s chassis mounting All must be screwed in order to conform the vibration spec C Model name Specifications Lot No and Country of Manufacture are shown here FRONT SEAL N SEE NOTE C p 2 94 5 For Mounting SEE NOTE B To oF Sean 8 2 26 8 34 5 1 0 cp x unit mm 93308 Q6 00 3 10 Ferrite core Install ferrite cores according to the customer s final product entire system Recommended ferrite cores are shown below Recommended ferrite core 1 Manufacturer TDK Type No ZCAT3035 1330 Dimens
44. MA Way YAMAHA ROBOT CONTROLLER Safety standards application guide CE RCX340 RCX240 RCX221 RCX222 SR1 X SR1 P KCs RCX240 Ver 1 00 General Contents Introduction i 1 Safety Information 5 1 2 Signal words used in this manual 5 2 3 Warning labels 5 3 31 Waming labels m ee e e a e 5 3 311 Warning label messages on robot and controller 5 3 3 12 5 7 3 2 Waming symbols 5 8 4 Important precautions for each stage of the robot cycle 5 9 41 Precautions for using robots and controllers 5 9 4 2 Essential precautions for the linear conveyor Module S 10 LE Mee Le 5 11 431 5 11 5 11 44 installation e E Lu n E Ee Eee ETE 5 12 ZA UTI tenes NOS 5 12 preceutiensieneongconirelermgee 5 13 4 5 medsures vere ov EET REL CEU 15 Slo Cun RE E TEE 5 15 5 16 46 5 17 Ore Colle gta ERE TCR CERE ER 5 17 AUtOnmalicuoDpernediep ess e OU IUIUS 5 19 ELI 5 19 4 7ZInspechoniandimaintenancom ________________ 5 21 4 7 1 Before inspection and maintenance ELITS
45. MRON Safety relay unit G9SX BC202 OMRON 2 39 lt 3 4 4 Overview of circuit operation This section describes an overview of the circuit operation for each safety circuit configuration example shown in the previous sections 1 During AUTO mode The main power is supplied only when the enable switch is disabled the controller is in a normal state MPRDY is ON with no internal alarms occurring and also all the following conditions are met Conditions Maintenance mode switch is in AUTO open M2 closed Door switch s NC contact is closed External emergency stop button s NC contact is closed RPB E emergency stop button s NC contact is closed CAUTION Connect the RPB terminator or RPB E to the RPB connector on the controller front panel If the RPB connector on the controller front panel is open an emergency stop occurs 7 X 2 During maintenance Solos The main power is supplied only when the door switch is disabled the controller is in a normal state MPRDY is ON with no internal alarms occurring and also all the following conditions are met Conditions Maintenance mode switch is in SERVICE M1 closed M2 open External emergency stop button s NC contact is closed RPB E emergency stop button s NC contact is closed RPB E enable switch s NO contact is closed AN CAUTION Always disconnect the RPB terminator from the RPB co
46. RNING The linear conveyor module contains powerful permanent magnets and electromagnets that generate strong magnetic fields Always comply with the precautions listed in this manual when using the linear conveyor module Those persons wearing medical electronic devices such as cardiac pacemakers or hearing aids are at particular risk of major injury or even death Always attach the magnet protective cover supplied when handling shipping or storing the slider when removing it from the linear conveyor module s guide rails Do not approach the motor of the linear conveyor module while the power is on Stay at least 100mm away Do not attempt to disassemble the linear conveyor module including surrounding covers Do not place any tools near the slider magnets and the linear conveyor motor while the power is on 4 High temperature hazard A WARNING The motor for the linear conveyor module is mounted on the module and so it is easy to come into contact with To allow heat generated during operation to DISSIPATE install the module on a base made from good heat conducting material such as metal The motor reaches high temperatures during and IMMEDIATELY after operation so touching it at those times may cause burns Before touching the motor first turn off the controller power then wait a while and check that the temperature has DROPPED sufficiently gt 5 10 4 3 Design 4 3 1 Precautions for robots 1 Restric
47. RPB E RPB Programmin 9 with enable switch without enable switch Differences in main specifications RCX221 RCX222 controller pq CE specifications Normal specifications Service mode Provided Not provided RPB E RPB Programmin ing box with enable switch without enable switch E Differences in main specifications SR1 series controller CE specifications Normal specifications Service mode Provided Not provided HPB D HPB with enable switch without enable switch Programming box 5 10 1 1 4 5 seinsDo N 2 2 1 _ Measures for CE marking Safety standards 2 1 1 Cautions regarding compliance with EC Directives The YAMAHA robot robot and controller is not in itself a robot system The YAMAHA robot is just one component that is incorporated into the customer s system built in equipment and we declare that YAMAHA robots conform to the EC Directives only within the scope of built in equipment This does not therefore guarantee that YAMAHA robots conform to EC Directives in cases where the robot is used independently Customers who incorporate a YAMAHA robot into their final system which will be shipped to or used in the EU should therefore verify that the overall system is compliant with EC Directives Differences between YAMAHA robots
48. S 21 AW CUMING SSNS OIM EET ILI S 22 23 5 Emergency action when person is caught by robot S 24 6 Cautions regarding strong magnetic fields S 24 7 Using the robot safely 5 25 TW Movement range 5 25 _____________________ 5 26 73 5 27 7 4 Special training for industrial robot operation 5 27 1 Overview 1 1 2 Safety standards 1 2 21 Measures for CE aeea 1 2 211 Cautions regarding compliance with EC Directives 1 2 2 12 ee ehe elder sts 1 2 2 1 3 Applicable EC Directives and their related standards 1 3 24 Robor s bject ESSE 1 3 2 1 5 Cautions regarding the official language of EU countries 1 3 22 Moasures for K Csi 2 2 1 Cautions regarding compliance with KCs 2 2 2 22 PE TEUER EET EE 224 RODOTS 3 Usage conditions 1 System overview 2 1 TALE 2 1 2 1 1 2 Control system configuration 2 4 BASE 2 4 1 2 2 Power supply emergency stop system circuit configuration 2 8 1
49. Safety door switch D4 series OMRON S4 Emergency stop button A22E series OMRON KM1 2 Contactor mirror contact LC1 D09 Schneider Electric Safety relay G7SA 3A1B OMRON Socket for safety relay P7SA 10F ND OMRON SRL1 Safety relay unit G9SX GS226 OMRON SRL2 Safety relay unit G9SX BC202 OMRON SRL3 Safety relay unit G9SA 501 OMRON KA1 to 5 gt 3 16 3 2 3 Category 2 A safety circuit configuration example of category 2 is shown below Category 2 safety circuit example 1 L1 It ACIN T ta AC OUT Reset switch 51 2 n AUTO SERVICE Maintenance switch l GND 24V Input 1 Service 1 SRL1 52 Input2 Input 3 eo Door switch 53 Input 1 Enable 11 SAFETY E EMG1 T EMG2 DO COM gt lt MPRDY 1 Dd When INTERLOCK GND signal is not used INTERLOCK External emergency stop Service 1 BS SERVICE DI COM 54 Input 1 HPB D SAFETY HPB D emergency stop Input 1 OUT HPB D emergency stop Input 2 Output 1 HPB D enable T Enable 11 HPB D enable Input 2 Output 1 24V 24V GND GND 1 Wiring to check whether the controller is normal when using an alarm to shut off the main power 93315 Q6 00 Parts list Part name Type No Manufacturer Reset swit
50. YK500XGLP YK600XGLP Clean type Dust proof amp drip proof type Q eo eo Q gt c 5 E lt o eo eo G Q Q Q Q o Orbit type YK500TW Robot products may not be applicable to KCs depending on their uses operating conditions or environments For details contact your distributor before purchasing a product N CAUTION The robots shown below are subject to the KCs mark However as the Report of Declaration of Conformity has not been made these robots cannot be used in Korea Additionally special order robots are also not applicable to the KCs mark For details contact your distributor Cartesian robots NXY SXYxC YK X series all models YK120XG YK150XG YK180XG SCARA robots YK300XGS YK400XGS YK500XGP to YK1000XGP YK400XR Planned to declare in the second half of 2014 Pick and place type robots YP X series Robot controllers RCX340 series Planned to declare in the second half of 2014 1 5 3 The following description gives major operating conditions for YAMAHA robot series products Usage conditions EMC Electromagnetic compatibility YAMAHA robot series products are designed for use in industrial environments Applicable definition relating to the EMC Directive Refer to the EN61000 6 2 IEC61000 6 2 Standard Clause 1 Scope In order to conform to the EMC Directive the c
51. al for label positions 2 This label is not attached to some small single axis robots but is supplied with the robots S 7 4 SUOHONASU AJOJOS SUOHONASU 3 2 Warning symbols Warning symbols shown below are indicated on the robots and controllers 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 1 Electrical shock hazard symbol A WARNING 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 A WARNING 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 N CAUTION Always read the manual carefully before using the controller Instructions by this symbol This indicates important 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
52. al 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 3 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 N CAUTION Do not bundle control lines or communication cables together or in close to the main power supply or power lines Usually separate these by at least 100mm Failure to follow this instruction may cause malfunction due to noise S 11 4 Ajojos SUOHONASU 4 4 Moving and installation 4 4 1 Precautions for robots B installation environment 1 Do not use in strong magnetic fields A WARNING Do not use the robot near equipment or in locations that generate strong magnetic fields The robot may BREAK DOWN or malfunction if used in such locations 2 Do not use in locations subject to possible electromagnetic interference etc A WARNING Do not use the robot in locations subject to electromagnetic interference electrostatic discharge or radio frequency interference The robot may malfunction if used in such locations creating hazardous situations 3 Do not use in locations exposed to flammable gases A WARNIN
53. ange may cause electrical shock fire malfunction or product damage or deterioration The robot controller and programming box must be installed at a location that is outside the robot safety enclosure 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 Installation To install the robot controller observe the installation conditions and method described in the manual 1 Installation A WARNING Securely tighten the screws to install the robot controller If not securely tightened the screws may come loose causing the controller to drop 2 Connections A WARNING 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 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
54. ch A22 series OMRON Key selector switch A22 TK series OMRON Safety door switch D4 series OMRON Emergency stop button A22E series OMRON Contactor mirror contact LC1 D09 Schneider Electric Safety relay G7SA 3A1B OMRON Socket for safety relay P7SA 10F ND OMRON Safety relay unit G9SX GS226 OMRON Safety relay unit G9SX BC202 OMRON 3 17 lt 3 2 4 Overview of circuit operation Thi s section describes an overview of the circuit operation for each safety circuit configuration example shown in the previous sections 1 During AUTO mode The main power is supplied only when the enable switch is disabled the controller is in a normal state MPRDY is ON with no internal alarms occurring and also all the following conditions are met Conditions Maintenance mode switch is in AUTO open M2 closed Door switch s NC contact is closed External emergency stop button s NC contact is closed HPB D emergency stop button s NC contact is closed N CAUTION _ Connect the HPB terminator or HPB D to the HPB connector on the controller front panel If the HPB connector on the controller front panel is open an emergency stop occurs 2 During maintenance e o o AN gt 3 18 The main power is supplied only when the door switch is disabled the controller is in a normal state MPRDY is ON with no internal alarms occurring and also all the f
55. ct your distributor for advice 2 Precautions during repair and parts replacement A WARNING When it is necessary to repair or replace parts of the robot or controller please be sure to contact your distributor and follow the instructions they provide Inspection and maintenance of the robot or controller by an unskilled 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 A WARNING Adjustment and maintenance by removing a cover require specialized technical knowledge and skills and may also involve hazards if attempted by an unskilled person This adjustment must be performed only by persons who have the required qualifications described in 2 Qualification of operators workers in section 4 1 of this Safety instructions 3 Shut off all phases of power supply A WARNING 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 malfunc tion 4 Allow a waiting time after power is shut off Allow time for temperature and voltage to drop A WARNING When performing maintenance or inspection of the robot controller under yo
56. d manuals and take safety precautions to ensure cor rect handling The precautions listed in this manual relate to this product To ensure safety of the user s final system that in cludes YAMAHA robots please take appropriate safety measures as required by the user s individual system To use YAMAHA robots and controllers safely and correctly always comply with the safety rules and instruc tions For specific safety information and standards refer to the applicable local regulations and comply with the instructions Warning labels attached to the robots are written in English Japanese Chinese and Korean This manual is available in English or Japanese or some parts in Chinese Unless the robot operators or service personnel understand these languages do not permit them to handle the robot 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 list all safety items in detail within the limited space of this manual So please note that it is essential that the user have a full knowledge of safety and also make correct judgments on safety proce dures Refer to the manual by any of th
57. d 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 A WARNING If warning labels are removed or difficult to see then the necessary precautions may not be taken resulting in an accident Do not remove alter or stain the warning labels on the robot body Do not allow warning labels to be hidden by devices installed on the robot by the user Provide proper lighting so that the symbols and instructions on the warning labels can be clearly seen from outside the safety enclosure Warning labels 3 1 1 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 See 7 1 Movement range in Safety instructions for details on the robot s movement range B Warning label 1 SCARA robots Cartesian robots DANGER Serious injury may result from contact with a moving robot Keep outside of the robot safety enclosure during operation Press the emergency stop button before entering the safety enclosure Warning label messages on robot and controller Instructions on this label DANGER fe 218 Always install a safety enclosure to keep all persons away from the robot movement range and prevent injury fr
58. e damage to robot parts or cause residual vibration during positioning 8 If the X axis Y axis or R axis rotation angle is small CAUTION AN 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 gt 5 20 4 7 Inspection and maintenance Always perform daily and periodic inspections and make a pre operation check to ensure there are no prob lems with the robot and related equipment If a problem or abnormality is found then promptly repair it or take other measures as necessary Keep a record of periodic inspections or repairs and store this record for at least 3 years 4 7 1 Before inspection and maintenance work 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 personnel will take appropriate action A WARNING Never attempt inspection maintenance repair and part replacement unless described in this manual These tasks require specialized technical knowledge and skills and may also involve hazards Please be sure to conta
59. e emergency stop button place a support under the vertical axis so that it will not slide down Be careful not to let your body get caught between the vertical axis and the installation base when performing tasks direct teaching etc with the brake released gt 5 26 7 3 Residual risk To ensure safe and correct use of YAMAHA robots and controllers System integrators and or end users implement machinery safety design that conforms to 15012100 Residual risks for YAMAHA robots and controllers are described in the DANGER or WARNING instructions provided in each chapter and section Read them carefully 7 4 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 receive appropriate training and also have the skills needed to perform the job correctly and safely They must also read the manual carefully to understand its contents before attempting the robot operation or maintenance Tasks related to industrial robots teaching programming movement check inspection adjustment repair etc must be performed by qualified persons who meet requirements established by local regulations and safety standards for industrial robots Comparison of terms used in this manual with ISO This manual ISO 10218 1 Note Maximum movement range maximum space Area limited by mechanical stoppers Movemen
60. e 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 lt AJOJOS SUOHONASU 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 A WARNING This indicates a potentially hazardous situation which if not avoided could result in death or serious injury N CAUTION This indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to the equipment Nt M q NOTE Explains the key point in the operation in a simple and clear manner gt 5 2 3 Warning labels shown below are attache
61. e 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 1 3 5 10 2 2 Measures for KCs KCs is a system that conforms to Occupational Safety and Health Act and Report of Declaration of Conformity of hazardous machines and devices For machines specified in this system the KCs mark needs to be indicated by conducting the forced certification or Report of Declaration of Conformity Industrial robots that have manipulators with 3 or more axes are specified as machines needing the Report of Declaration of Conformity in South Korea s Ministry of Employment and Labor Notification No 1201 46 Its safety standards are defined in separate table 2 of this notification This section describes basic items necessary to make the RCX240 series compliant with KCs 2 2 1 Cautions regarding compliance with KCs The YAMAHA robot series is one component that is incorporated into the customer s system built in equipment The Report of Declaration of Conformity is performed based on the preconditions that additional safety measures are taken for the customer s system For the contents of the safety measures refer to Chapter 2 This does
62. e setting results are not saved the present settings still remain enabled until the controller power is turned off For details about how to set the MANUAL mode parameters refer to the Operator s manual 1 Operation device control in MANUAL mode Set the operational devices Operation device Dedicated input Setting Enable Disable Description Sets whether or not the operation from the dedicated input is enabled RS 232C Enable Disable Sets whether or not the operation from the RS 232C input is enabled Ethernet Enable Disable Initial values All devices are set Enable Sets whether or not the operation from the Ethernet input is enabled A WARNING TO REDUCE THE RISK OF UNEXPECTED OPERATION DISABLE OPERATION DEVICES OTHER THAN THOSE TO BE USED N CAUTION Dedicated input is SI when a serial board is connected 2 15 4 7 X Solos 1 4 2 SERVICE mode Applicable controller RCX240 221 222 SR1 SERVICE mode is used to perform work using the RPB E within the safety enclosure of the robot system This mode is enabled only when the controller is set to SAFE mode SAFE mode has been set at shipment The controllers with the CE specifications and KCs specifications are set to SAFE mode N CAUTION The controllers with the CE specifications and KCs specifications must be set to SAFE mode Basic operation mode Basic operation modes 7 X SERVICE mode
63. ed when the contacts of AUTO1 and AUTO2 AUTO mode input are closed high level MANUAL mode is entered when these contacts are opened low level The controller is in MANUAL mode with the operation level operating speed limit and exclusive control of the operating devices specified by the MANUAL mode parameters The following functions can be selected in MANUAL mode 1 Robot is controlled only by PBX E operation 2 Automatic operation is prohibited 3 Robot operating speed is set to below 396 of the maximum speed 4 Robot operation is possible only by hold to run control The Hold to Run function allows the robot to move including program execution only during the time that the PBX E operation key is kept pressed A WARNING RESTRICTION ON THE ROBOT MOVING SPEED IS NOT A SAFETY RELATED FUNCTION TO REDUCE THE RISK OF COLLISION BETWEEN THE ROBOT AND WORKERS THE USER MUST TAKE THE NECESSARY PROTECTIVE MEASURES SUCH AS ENABLE DEVICES ACCORDING TO RISK ASSESSMENT BY THE USER NEA m NOTE 9 If the AUTO mode input is changed during program operation or jog movement the emergency stop is activated The AUTO mode input specifications are PNP The input current needs a capacity of 7mA or more If the external 24V power is not supplied the controller always enters the MANUAL mode and the automatic operation cannot be performed 2 14 1 4 1 1 MANUAL mode parameter settings When the MANUAL mode parameters are edited and thes
64. 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 See 7 1 Movement range in Safety instructions for details on the robot s movement range A WARNING Make a visual check to ensure that no hazards are present within the safety enclosure Check that the programming box or handy terminal operates correctly Check that no failures are found in the robot Check that emergency stop works correctly Select teaching mode and disable automatic operation gt 5 18 4 6 2 Automatic operation Check the following points when operating the robot in AUTO mode Observe the instructions below in 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 Check the safety enclosure is securely installed with interlocks functional A WARNING Check that the programming box handy terminal and tools are in their specified locations Check that the signal tower lamps or other alarm displays installed for the system are not lit or flashing indicating no error is occurring on the robot and per
65. ent This is a contact B normally closed type switch The A165E S 02 made by OMRON is used This is a 3 position switch designed in consideration of safety Pressing this switch to the middle position only enables robot operation This switch is disabled when LOCKIN1 to 4 in the HPB D SAFETY connector are not wired Configure an external safety circuit so that the state of this switch determines the robot operating Enable switch state as follows Switch released Emergency stop state Switch in middle position Operable state Switch pressed Emergency stop state The A4E B200HS made by OMRON is used Emergency stop button HPB connector Use this connector to connect the HPB programming box to the robot controller The contact outputs of the emergency stop button and enable switch are connected Attaching the supplied 15 pin D sub connector female directly to this safety connector enables the emergency stop button only HPB D SAFETY connector 1 3 2 HPB connector and HPB D SAFETY connector The HPB D has an emergency stop button and an enable switch The contact outputs of these can be used to connect to the emergency stop circuit of the entire equipment via the SAFETY connector on the controller and the HPB D SAFETY connector This section describes signal connections N CAUTION Do not change or modify the cable and connector In addition to the input output signals for controlling the programming box
66. ery Electrical equipment of machines Part 1 General requirements Machinery Directive 2006 42 EC EN 55011 Industrial scientific and medical equipment Radio frequency disturbance characteristics Limits and methods of measurement EN 61000 6 2 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments EMC Directive 2004 108 EC 2 1 4 Robots subject to CE Marking The following robot series products are subject to CE marking Controller Robot Name FLIP X series PHASER series XY X series YP X series YK X series YK XG series YK XR series YK TW series RCX340 RCX240 Single axis robots Cartesian type robots Pick and place type robots SCARA type robots EN 55011 Industrial scientific and medical equipment Radio frequency disturbance characteristics Limits and methods of measurement EN 61000 6 2 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments RCX221 RCX222 Single axis robots Cartesian type robots Pick and place type robots FLIP X series PHASER series XY X series YP X series SR1 Single axis robots FLIP X series PHASER series Q eo eo Q 3 Q c 5 lt eo eo eo G Q Q Q Q o 2 1 5 Cautions regarding the official language of EU countries For equipment that will b
67. evice control during SERVICE mode These parameter settings determine the operation level operating speed limit and exclusive control of the operation devices during SERVICE mode Even after editing the SERVICE mode parameters the present settings still remain enabled until the controller power is turned off unless the edited parameters are saved For how to set the SERVICE mode parameters refer to the controller user s manual A WARNING CHANGING THE SERVICE MODE PARAMETERS FORM THEIR DEFAULT SETTINGS IS LIKELY TO INCREASE THE RISK TO PERSONNEL OPERATING OR MAINTAINING THE ROBOT THESE PARAMETERS CAN BE CHANGED IF THE CUSTOMER ASSUMES RESPONSIBILITY BUT EXTRA CAUTION SHOULD BE TAKEN TO ENSURE SAFETY 2 17 4 1 SERVICE mode level The SERVICE mode level can be selected to enable or disable the Hold to Run function and to permit or prohibit the operation in AUTO mode The Hold to Run function allows the robot to move including program execution only during the time that the RPB E operation key is kept pressed Hold to Run function AUTO mode operation Level 0 Disabled Permitted Level 1 Enabled Permitted Level 2 Disabled Prohibited Level 3 Enabled Prohibited Default setting Limitations on operating speed during SERVICE mode xod The maximum robot operating speed can be specified Setting Deseription S 396 Robot operating speed is limited to below 3 of maximum speed 10096 Robot operating s
68. fined as the range of robot motion including all areas through which the robot arms the tool and workpiece attached to the manipulator tip and the solenoid valves attached to the robot arms move To make the robot motion easier to understand the figures below only show the movement ranges of the tool attachment section tool and workpiece Please note that during actual operation the movement range includes all areas where the robot arms and any other parts move along with the robot SUOHONASU Movement range Figure A Movement range of robot itself Figure B Movement range when tool and workpiece are attached to manipulator tip 93009 X0 00 CAUTION To make the robot motion easier to understand the above figures only show the movement ranges of the tool attachment section tool and workpiece In actual operation the movement range includes all areas where the robot arms and any other parts move along with the robot gt S 25 lt SUOHONASU 7 2 Robot protective functions Protective functions for YAMAHA robots are described below 1 Overload detection This function detects an overload applied to the motor and turns off the servo If an overload error occurs take the following measures to avoid such errors 1 Insert a timer in the program 2 Reduce the acceleration 2 Overheat detection This function detects an abnormal temperature rise in the driver inside
69. g tasks such as teaching 3 Methods for workers to signal each other when two or more workers perform tasks 4 Steps that the worker should take when a problem or emergency occurs 5 Steps to take after the robot has come to a stop when the emergency stop device was triggered including checks for cancelling the problem or error state and safety checks in order to restart the robot 6 In cases other than above the following actions should be taken as needed to prevent hazardous situations due to sudden or unexpected robot operation or faulty robot operation as listed below Place a display sign on the operator panel Ensure the safety of workers performing tasks within the robot safety enclosure 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 Take noise prevention measures 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 opera
70. he RCX221 RCX222 Turning on this switch opens the contact and turning it off closes the contact The switch ON OFF function is disabled if not wired Emergency stop button Selector switch This is a 3 position switch designed in consideration of safety Pressing this switch to the middle position only enables robot operation This switch is disabled when LOCKIN1 to 4 of the SAFETY connector are not wired Configure an external safety circuit so that the state of this switch determines the robot operating Enable switch state as follows Switch released Emergency stop state Switch in middle position Operable state Switch pressed Emergency stop state The HE2B M200PB made by IDEC is used RPB connector Use this connector to connect the RPB programming box to the robot controller 2 11 lt 1 3 2 2 RPB connector The RPB E has an emergency stop button and an enable switch The contact outputs of these can be used to connect to the emergency stop circuit of the entire equipment via the SAFETY connector on the controller This section describes signal connections CAUTION Do not change or modify the cable and connector Along with the input output signals for the programming box the RPB connector includes signals used to configure an external safety circuit and so changing or modifying the cable and connector is very dangerous Always configure an external safety circuit by using the SAFETY connec
71. he SERVICE mode can be enabled or disabled by selecting the HPB D menu or by using PRM372 Service mode enable parameter When the SERVICE mode function is enabled the controller constantly monitors whether SERVICE mode is entered When the SERVICE mode input SVCE contact is open OFF the controller is in SERVICE mode If a serial unit is installed SERVICE mode is entered when either one of the SAFETY connector SVCE contact or the serial SVCE contact is open OFF This means that only when both SAFETY connector SVCE contact and serial I O SVCE contact are closed ON the controller is not in SERVICE mode In the SERVICE mode the following limiting functions will work Limiting functions that work in SERVICE mode Limits command input from any device other than HPB D Limits robot movement speed Prohibits automatic operation and step operation Enables hold to run function Hold to run function permits the robot to move only when the HPB D key is kept pressed The limiting functions in SERVICE mode can be set individually A WARNING RESTRICTION ON THE ROBOT MOVING SPEED IS NOT A SAFETY RELATED FUNCTION TO REDUCE THE RISK OF COLLISION BETWEEN THE ROBOT AND WORKERS THE USER MUST TAKE THE NECESSARY PROTECTIVE MEASURES SUCH AS ENABLE DEVICES ACCORDING TO RISK ASSESSMENT BY THE USER m NOTE The robot pauses when the SERVICE mode input is changed during program operation or jog movement The
72. iagram with enable switch Emergency stop Enable Solos HPB D SAFETY Controller PNP specifications E STOP Status INTERLOCK SERVICE GND Door 424V Wiring to check whether controller is normal when using alarm to shut off main power KA GND External emergency stop Internal 24V OUT Safety output DO COM DO COM 24VG Input output signals 93311 Q6 00 3 13 lt Reference Connection diagram without enable switch category B Emergency stop 6 Controller Safety circuit N1 PNP specifications L E STOP NT Status AUTOcSERVICE Maintenance switch 424V GND 24V EE 75 17 En E INTERLOCK CN 2 SERVICE External emergency circuit DO COM 5 5 MPRDY 11 EMG1 Internal 24V 12 EMG na gJ READY 1 DIsCOM P 14 00 157 DO COM 0 26 DL COM c a 39 DO COM GND 5 407 do com 424VG To PLC Input output signals 24 GND 93310 Q6 00 gt 3 14 3 2 1 Category 4 A safety circuit configuration example of category 4 is shown below Category 4 safety circuit example
73. ional outline Recommended ferrite core 2 Manufacturer TDK Type No ZCAT2032 093 Dimensional outline 0 36 0 1 32 041 30 041 13 01 o unit mm 93309 06 00 o unit mm 93310 Q6 00 3 11 lt 3 External safety circuit examples This section describes category specific safety circuit configuration examples using the HPB D To use the robots more safely take the appropriate safety measures by referring to the circuit examples 3 1 _ Safety requirements 3 1 1 CE marking To comply with the machinery directives the performance level PL required of the safety circuit must be evaluated Performance levels PL are determined by the following parameters Major factors that determine performance levels 1 Category 2 MTTFd Mean Time To Dangerous Failure 3 DCavg Average Diagnostic Coverage 4 CCF Common Cause Failure Checklist score gt 65 Please obtain the data on each component from the component manufacturer The performance level PL of a safety circuit is determined by the following flow Flow for determining performance levels 1 Determine the performance level PLr required of the safety circuit by means of risk assessment 2 Configure the safety circuit that satisfies the requirements of the category that meets PLr 3 Calculate the safety circuit s
74. ipheral devices 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 A WARNING 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 6 3 Precautions during operation 1 When the robot is damaged or an abnormal condition occurs A WARNING 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 your distributor If any 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 malfuncti
75. ircuit network Meaning of symbols Noise filter _ NF2020A UP SOSHIN ELECTRIC CO LTD or RSHN 2020 TDK Lambda Ferrite core ZCAT3035 1330 TDK A Ferrite core ZCAT2132 1130 TDK Ferrite core 1 turn TP Ferrite core 2 turns 93204 R6 00 2 22 2 2 2 Countermeasure components Surge absorber The RCX240 does not need any external surge absorber However to further enhance the surge resistance install a surge absorber on the AC power line A recommended surge absorber is shown below Recommended surge absorber Manufacturer SOSHIN ELECTRIC CO LTD Type No LT C12G801WS Dimensional outline X Status indicator Green Normal Red Abnormal Solos 19 1 0 Wire line Wire earth Black Green Yellow x D p N E N 22 5 1 0 unit mm 93205 R6 00 2 23 lt 7 X Solos Noise filter Always install an external noise filter on the AC power line A recommended noise filter is shown below Recommended noise filter 1 Manufacturer SOSHIN ELECTRIC CO LTD Type No NF2020A UP Dimensional outline 8541 5 R2 25 Length 6 1 4 o Paname 50 1 Input terminal M4 Case PBT Name plate Output terminal Recommended noise filter 2 2 24 Manufacturer TDK Lambda Corpora
76. issions If you find any part unclear in this manual please contact your distributor 10177788 Measures for each country s safety standards 2 1 Pa Moll 22 2 1 3 2 1 4 2 1 5 2 2 22 222 2 2 3 2 2 4 Contents 1 Overview i 1 2 Safety standards 2 1 2 Measures for CE marking Cautions regarding compliance with EC Directives CE marking Applicable EC Directives and their related standards Robots subject to CE Marking Cautions regarding the official language of EU countries Measures for KCs Cautions regarding compliance with KCs KCs mark Normative standards Robots subject to KCs 12 12 1 3 1 3 1 3 1 4 1 4 1 4 1 4 1 5 3 Usage conditions 1 6 This section provides a basic description of how the RCX series SR1 series controllers comply with the safety standards of each country The following shows the basic differences among the controllers with CE specifications KCs specifications that comply with the safety standards and normal specifications Differences in main specifications RCX340 controller CE specifications Normal specifications AUTO MANUAL mode input Provided Not provided PBX E PBX Programmin roga ing with enable switch without enable switch Differences in main specifications RCX240 controller CE specifications and KCs specifications Normal specifications Service mode Provided Not provided
77. le contact Line 1 LCKIN3 Enable contact Line 2 LCKIN4 KEY1 KEY2 Selector switch 7 X Circuit diagram Solos RCX221 RCX222 Emergency stop Enable Selector SAFETY 93202 R1 00 2 13 4 1 4 CE specifications and KCs specifications The CE specifications and KCs specifications provide functions necessary for the work inside the safety enclosure that is applicable to the safety standards These functions are used when performing the work that uses the programming box PBX E RPB E inside the safety enclosure of the robot system 1 4 1 MANUAL mode Applicable controller RCX340 The AUTO mode inputs of the SAFETY connectors A9 A10 B9 and B10 are used when performing the work with the PBX E inside the safety enclosure of the robot system These AUTO mode inputs are enabled only with the CE specifications For the CE specifications they have been set enabled before shipment AN CAUTION The controllers applicable to the safety standards always have the CE specifications 7 X Basic operation mode Solos Basic hierarchy 93207 R8 00 In the CE specifications the AUTO mode and MANUAL mode are changed using the AUTO AUTO mode inputs of the SAFETY connector The operations inside four hierarchies may vary depending on the MANUAL mode and AUTO mode For details refer to the Operator s manual In the SAFETY connector AUTO mode is enter
78. ler and when wiring the connectors make the crimp press contact or solder connections correctly using the tool specified by the connector manufacturer CAUTION A 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 CAUTION A 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 elc 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
79. lowing points See 7 1 Movement range in Safety instructions for details on the robot s movement range 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 A WARNING Use sturdy stable posts which will not fall over easily The rope or chain should be easily visible to everyone around the robot 2 Check the following points before turning on the controller Is the robot securely and correctly installed Are the electrical connections to the robot wired correctly Are items such as air pressure correctly supplied Is the robot correctly connected to peripheral equipment Have safety measures safety enclosure etc been taken Does the installation environment meet the specified standards 3 After the controller is turned on check the following points from outside the safety enclosure Does the robot start stop and enter the selected operation mode as intended Does each axis move as intended within the soft limits Does the end effector move as intended Are the correct signals being sent to the end effector and peripheral equipment Does emergency stop function Are teaching and playback functions normal Are the safety enclosure and interlocks functioning as intended 5 17 4 Ajojos SUOHONASU AJOJOS 4 Working inside safety enclosures Before
80. main power is ready to turn on N CAUTION Connect the RPB terminator or RPB E to the RPB connector on the controller front panel If the RPB connector on the controller front panel is open an emergency stop occurs 2 2 MANUAL SERVICE mode Mode select switch setting input a c Open input b Close RPB E enable switch is enabled The contactor turns on to supply the main power motor drive power to the controller only when all conditions shown below are satisfied Conditions The emergency stop button is closed The safety door is opened RPB E enable switch is closed intermediate position The MP RDY signal is on Output from the controller when the controller main power is ready to turn on AN CAUTION Always disconnect the RPB terminator from the RPB connector on the controller front panel and connect the RPB E to the RPB connector 2 34 3 4 Circuit examples for the RCX221 RCX222 The following shows category specific safety circuit configuration examples for the RCX221 RCX222 Customers should install the appropriate safety measures for their system by referring to these safety circuit configuration examples in order to use the robots more safely The example shown here provide the following input output signals Reset switch maintenance mode switch door switch and external emergency stop Programming box emergency stop output and enable output N CAUTION The controller stat
81. mer 2 The OV line for the 3 6VDC 5VDC 12VDC and 24VDC is not connected to the protective earth 3 Refer to the HPB D connector input output signal table for the wiring diagram from the HPB D 4 Excluding SR1 P 93303 Q6 00 3 3 lt 1 3 Programming box HPB D The programming box HPB D is a hand held unit specifically designed to connect to the controller in order to perform various operations The HPB D allows all operations including manual operation of the robot programming and editing teaching and parameter setting 1 3 1 Part names and functions The HPB D has an emergency stop button and an enable switch The contact outputs of these can be used to connect to the emergency stop circuit of the entire equipment via the SAFETY connector on the bottom of the HPB D HPB D Rear side TEACHING BOX 1 Liquid crystal display C 3 Emergency stop button 7Y h e 4 Enable switch 2 Operation keys 5 HPB Connector 6 HPB D SAFETY connector 93304 Q6 00 Main Functions Part name Function Liquid crystal This is a liquid crystal display LCD with 20 characters x 4 lines showing various types of display information These keys are used to operate a robot or input programs Operation keys The keys are divided into 2 main groups function keys and data entry operation keys Pressing this button during operation immediately stops robot movem
82. ng and also have the skills needed to perform the tasks correctly and safely Those tasks must be performed by qualified persons who meet requirements established by local regulations and standards for industrial robots They must also read the manual carefully and understand its contents before attempting the robot operation or maintenance A WARNING t is extremely hazardous for persons who do not have the above qualifications to perform tasks for industrial robots Adjustment and maintenance that require removing a cover must be performed by persons who have the above qualifications Any attempt to perform such tasks by an unqualified person may cause an accident resulting in serious injury or death 5 9 lt SUOHONASU SUOHONASU Ajojos 4 2 Essential precautions for the linear conveyor module The linear conveyor module is a YAMAHA robot so safety measures must be followed and safety equipment must be installed just as required for other YAMAHA robots This section describes essential precautions for handling the linear conveyor module Precautions for each stage in the robot life cycle are listed from the next section so be sure to read the whole section of Safety Instruction in this manual 1 Slider ejection DANGER The slider and workpieces ejected at high SPEED from the linear conveyor module may strike persons causing serious and POSSIBLY fatal injuries Please comply with the following points
83. nnector on the controller front panel and connect the RPB E to the RPB connector 2 40 SRI 1 2 W251 1 2 2 1 3 1 3 1 1 3 2 1 4 1 4 1 1 4 2 1 4 3 series Contents overview System overview Main system configuration 3 1 Control system configuration 3 2 Basic configuration 3 2 Power supply and emergency stop system circuit configuration 3 3 Programming box HPB D 3 4 Part names and functions 3 4 HPB connector and HPB D SAFETY connector 3 5 SERVICE mode 3 6 What is SERVICE mode 3 6 Flow for enabling the SERVICE mode functions WE Limiting functions in SERVICE mode countermeasure examples 3 8 SRI ZIP 20152 Configuration Countermeasure components External safety circuit examples 3 12 3 2 3 2 1 3 2 2 3 2 3 3 2 4 Safety requirements 3 12 CE marking 3 12 Circuit examples for the SR1 3 13 Category 4 3 15 Category 3 3 16 Category 2 3 17 Overview of circuit operation 3 18 1 System overview 1 1 System overview 1 1 1 Main system configuration SRI System for controlling one robot Programming box HPB D 8 SD memory card et 581 controller Support software POPCOM o o RS 232C communication control control AC IN Programming box HPB
84. ns The emergency stop button is closed The safety door is opened The enable switch of the pendant is closed intermediate position The MP RDY signal is on Output from the controller when the controller main power is ready to turn on AN CAUTION Always disconnect the PBX terminator from the PB connector on the controller front panel and connect the PBX E to the PB connector gt 2 32 3 3 Circuit examples for the RCX240 The following shows safety circuit configuration examples for the RCX240 Customers should install the appropriate safety measures for their system by referring to these safety circuit configuration examples in order to use the robots more safely The following shows an example with input output signals described below Operation mode switch door switch external emergency stop RPB E emergency stop RPB E enable MPRDY CAUTION AN Contactor E STOPRDY by the host device 3 3 1 Category 3 A safety circuit configuration example of category 3 is shown below Category 3 safety circuit example Power wiring AC power _ Safety circuit The controller status output signals of the parallel I O and serial I O such as alarm signals should be monitored Controller PNP RPB E P circuit protector Noise N breaker filter
85. nt manufacturer The performance level PL of a safety circuit is determined by the following flow Flow for determining performance levels 1 Determine the performance level PLr required of the safety circuit by means of risk assessment 2 Configure the safety circuit that satisfies the requirements of the category that meets PLr 3 Calculate the safety circuit s performance level PL from the MTTFd DCavg and CCF of the devices used for the safety circuit and then make sure that the calculated PL is equal to or higher than the performance level PLr required of the safety circuit PLr lt PL In the customer s final system the performance level PLr required of the safety circuit should be determined by means of risk assessment and then the safety circuit with the corresponding performance level PL should be configured Safety parts subject to performance level calculation The table below shows the safety parts and B10d reference values N CAUTION Please obtain the latest information from the parts manufacturers Parts Name Model Name Emergency stop button XA1E BV302R Enable switch A4E B200HS Emergency stop button XA1E BV302R Enable switch HE2B M200PB 3 1 2 KCs mark To comply with South Korea s Ministry of Employment and Labor Notification it is necessary to evaluate the performance category required for the safety circuit through the risk assessments
86. o the new user the need to read through this manual Specifications of the robot and controller models other than standard models may be omitted in this manual In that case refer to the specifications of standard models For details on specific operation of the robot controller refer to the user s manuals that come with the robot controller NOTES The contents of this manual are subject to change without prior notice While every effort has been made to ensure the contents of this manual are correct please contact us if you find any part of this manual to be unclear confusing or inaccurate 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 YAMAHA MOTOR CO LTD IM Operations Safety Instructions Contents 1 Safety Information 5 1 2 Signal words used this manual 5 2 3 Warning labels 5 3 31 Warning labels 5 3 3 1 1 Warning label messages on robot and controller 5 3 3 1 2 Supplied warning labels S 7 3 2 Warning symbols 5 8 4 Important precautions for each stage of robot life cycle 9 41 Precautions for using robots and controllers 5 9 4 2 Essential precautions for the linear conveyor module S 10 4 3 Design 5 11 4 3 1 Precautions for robots 5 11
87. oid valve for the Z axis air cylinder Do not let hands or fingers get caught and squeezed by robot parts moving along the Z axis 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 A WARNING 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 off the controller and reduce the air pressure before attempting to remove the obstruction 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 A WARNING 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 N CAUTION The robot must be operated with the correct tolerable moment of inertia and acceleration coefficients that match the manipulator tip mass and moment of inertia Failure to follow this instruction will lead to a premature end to the drive unit service lif
88. ollowing conditions are met Conditions Maintenance mode switch is in SERVICE closed M2 open External emergency stop button s NC contact is closed HPB D emergency stop button s NC contact is closed HPB D enable switch s NO contact is closed CAUTION Always disconnect the HPB terminator from the HPB connector on the controller front panel and connect the HPB D to the HPB connector Revision record Manual version Issue date Description Ver 1 00 Aug 2014 First edition Reference Manual Robot Controller Safety standards application guide Aug 2014 Ver 1 00 This manual is based on Ver 1 00 of Japanese manual YAMAHA MOTOR LTD IM Operations All rights reserved No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR 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 6811 Robot manuals can be downloaded from our company website Please use the following for more detailed information http global yamaha motor com business robot YAMAHA YAMAHA MOTOR CO LTD
89. om contacting the moving part of the robot fik Install an interlock that triggers emergency stop when Stay clear of moving machine Can cause serious injury 18101 US ATS CBAGTHEISRNSYO 90K41 001470 the door or gate of the safety enclosure is opened The safety enclosure should be designed so that no one can enter inside except from the door or gate equipped with an interlock device 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 Potential hazard to human body Serious injury may result from contact with a moving robot Keep outside of the robot safety enclosure during operation To avoid hazard Press the emergency stop button before entering the safety enclosure 90K41 001470 B 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 A WARNING 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 Pinch or crush hazard pinched or crushed by the movable parts of the robot when transporting or moving the robot during teaching SENSO L 90K41 001460 _
90. on N CAUTION As shown in the following figure the ferrite cores and noise filter on the controller side should be placed as close to the controller body as possible The ferrite cores on the robot side should be placed as close to the robot body as possible Typical component layout for EMC countermeasures RCX340 E 5 Robot series Power supply Single axis 200 to 230V o o Ground META KBG M6563 00 Cartesian KBG M6563 107 SCARA KBG M6563 00 KBG M6563 10 5 232 External safety circuit Absolute battery Meaning of symbols al Noise filter NF2020A UP SOSHIN ELECTRIC CO LTD or RSHN 2016 TDK Lambda L Ferrite ZCAT3035 1330 TDK Z Ferrite core ZCAT2132 1130 TDK IT Ferrite core 1 turn Ferrite core 2 turns 93208 R8 00 2 19 4 2 1 2 Countermeasure components Surge absorber The RCX340 does not need any external surge absorber However to further enhance the surge resistance install a surge absorber on the AC power line A recommended surge absorber is shown below Recommended surge absorber Manufacturer SOSHIN ELECTRIC CO LTD Type No LT C12G801WS Dimensional outline 7 X Status indicator Green Normal neg Red Abnormal 2 ce o Lo E 1 9 1 0 Wire line Wire earth Black Green Yellow gt e 8 0 22 5 1 0
91. on Z axis unit falls off 2 High temperature hazard A WARNING 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 S 19 lt SUOHONASU SUOHONASU 3 Use caution when releasing the Z axis vertical axis brake A WARNING The vertical axis will slide downward when the brake is released causing a hazardous situation Take adequate safety measures in consideration by taking the weight and shape into account Before releasing the brake after pressing the emergency stop button place a support under the vertical axis so that it will not slide down Be careful not to let your body get caught between the vertical axis and the installation base when performing tasks direct teaching etc with the brake released 4 Be careful of Z axis movement when the controller is turned off or emergency stop is triggered air driven Z axis A WARNING The Z axis starts moving upward when power to the controller or PLC is turned off the program is reset emergen cy stop is triggered or air is supplied to the solen
92. operation 2 40 1 System overview 1 1 System overview The RCX series controllers are designed for use with a SCARA robot or Cartesian robot mainly for assembly and pick and place applications Applications also include various inspection instruments sealers and spray equipment utilizing linear and circular interpolation 1 1 1 Main system configuration m RCX340 7 X System for controlling one robot 59 95 External device PLC etc YAMAHA robot 93201 R8 00 2 1 lt 7 X Solos 2 2 RCX240 Example YK500XG only All the axes on the robot controller are used as the main robot axes System for controlling one robot E A Ant 908 a E A X A EPs 3 9 dada YAMAHA robot External device PLC etc External emergency stop circuit Emergency stop button Safety relay Safety door switch etc 93201 R6 00 RCX221 RCX222 Example XY X series System for controlling one robot 7 X 59 95
93. orm various operations The RPB E allows all operations including manual operation of the robot programming and editing teaching and parameter setting 1 3 2 1 Part names and functions The RPB E has an emergency stop button and an enable switch The contact outputs of these can be used to connect to the emergency stop circuit of the entire equipment via the SAFETY connector on the controller The RPB E also has a selector switch which can be used according to the customer s specifications and applications RPB E 1 Display liquid crystal screen 4 Selector switch rear side 7 X o RPB eras Box Solos 3 Emergency stop button E 2 Sheet key 5 Enable switch 2 6 Connector Part name Function 5 93202 R0 00 Main Functions Display liquid This is a liquid crystal display LCD with 40 characters x 15 lines showing various types of crystal screen information The screen brightness is adjustable These keys are used to operate a robot or input programs Sheet keys y The sheet keys are classified into 3 main types function keys control keys and data keys Pressing this button during operation immediately stops robot movement This is a contact B normally closed type switch The XA1E BV302R made by IDEC is used This switch can be used as needed by wiring to the RPB SEL connector on the RCX240 or to the SAFETY connector on t
94. peed is not limited Solos Default setting 3 Operation device control during SERVICE mode The operation device can be specified Settins Deseription S Only RPB E operation is enabled RPB DI RPB E and dedicated input are enabled RPB COM RPB E and online commands are enabled ALL RPB E dedicated input and online command operation device are enabled Default setting N CAUTION Dedicated input is SI when a serial board is connected 2 18 2 EMC countermeasure examples Regarding EMC Directive the customer s final product entire system including the YAMAHA robot must provide the necessary countermeasures We at YAMAHA determine a model for single units of YAMAHA robots controller robot and peripheral device and verify that it complies with the relevant standards of EMC Directive In order to ensure the customer s final product entire system complies with EMC Directive the customer should take appropriate EMC countermeasures Typical EMC countermeasures for a single unit of YAMAHA robot are shown for reference N CAUTION The following description and circuits are typical countermeasures used when the robot and controller are tested under YAMAHA installation conditions When the robot and controller are used while installed in the customer s system the actual test results may differ depending on installation conditions 7 X 2 1 RCX340 59 95 2 11 Configurati
95. performance level PL from the MTTFd DCavg and CCF of the devices used for the safety circuit and then make sure that the calculated PL is equal to or higher than the performance level PLr required of the safety circuit PLr lt PL In the customer s final system the performance level PLr required of the safety circuit should be determined by means of risk assessment and then the safety circuit with the corresponding performance level PL should be configured Safety parts subject to performance level calculation The table below shows the safety parts and B10d reference values AN CAUTION Please obtain the latest information from the parts manufacturers Emergency stop button A165E S 02 Enable switch A4E B200HS gt 3 12 3 2 Circuit examples for the SR1 The following shows category specific safety circuit configuration examples for the SR1 Customers should install the appropriate safety measures for their system by referring to these safety circuit configuration examples in order to use the robots more safely The example shown here provide the following input output signals Reset switch maintenance mode switch door switch and external emergency stop Programming box emergency stop output and enable output N CAUTION The controller status output signals of the parallel I O and serial I O such as alarm signals should be monitored by the host device Overall connection d
96. rate the robot In SERVICE mode only the HPB D can be used as the robot operation device and any command input from all other device is disabled However if the user wants to permit a command input from other devices even in SERVICE mode 2 then the user can cancel this limiting function only in cases where judged not hazardous Sem Bempm 0 default Only command inputs from the HPB D are permitted in SERVICE mode Only command inputs from the HPB D and parallel I O are permitted in SERVICE mode Only command inputs from the HPB D and optional unit are permitted in SERVICE mode o Any command input is permitted even in SERVICE mode Limiting the robot movement speed This function limits robot moving speed In SERVICE mode robot moving speed is limited to below 3 of the maximum speed However if the user wants to set the robot moving speed faster than 3 even in SERVICE mode then the user can cancel this limiting function only in cases where judged not hazardous Settins 0 default Robot movement speed is limited to 3 of maximum speed in SERVICE mode 1 Robot movement speed is not limited even in SERVICE mode Limiting the automatic operation and step operation Determine whether to permit or prohibit the automatic operation and step operation In SERVICE mode automatic operation and step operation are prohibited and cannot be performed However if the
97. relay unit G9SX GS226 OMRON SRL2 Safety relay unit G9SX AD322 OMRON SRL3 Safety relay unit G9SX BC202 OMRON SRL4 Safety relay unit G9SA 501 OMRON KA1 to 5 3 15 lt 3 2 2 Category 3 A safety circuit configuration example of category 3 is shown below Category 3 safety circuit example L1 ACIN Wi AC OUT Reset switch 51 T AUTO amp SERVICE Maintenance switch Input 1 Service 1 SRL1 Li 52 Input 2 a Input 3 Door switch Input 1 o S3 Input 2 Enable 11 Tet o Enable 12 gt Enable 21 Enable 22 Y2 SAFETY EMG1 EMG2 DO COM When INTERLOCK GND signal is not used INTERLOCK External emergency stop Service 1 SERVICE DI COM Input 1 v S4 GND Input 2 OUT HPB D SAFETY HPB D emergency stop Output 1 HPB D emergency stop j Input 1 Output 2 Input 2 HPB D enable HPB D enable Input 1 Output 1 Input 2 Output 2 ES Enable 11 A Enable 12 24V B Enable 21 GND Enable 22 GND 1 Wiring to check whether the controller is normal when using an alarm to shut off the main power 93314 Q6 00 Parts list Part name S1 Reset switch A22 series OMRON 52 Key selector switch A22 TK series OMRON 53
98. robot and controller and robot systems A YAMAHA robot robot and controller is just one component in a robot system and is not in itself a robot system This is because a YAMAHA robot does not include the end effector s or any equipment devices or sensors required for the robot to perform its tasks as defined in Industrial Robot system of the ISO 10218 1 2011 Standard Clause 3 11 2 1 2 marking YAMAHA robots are components that are incorporated into the customer s system built in equipment We therefore declare regarding EC Directives that YAMAHA robots are Partly completed machinery and so we do not affix a CE mark to the robots 1 2 2 1 3 Applicable EC Directives and their related standards The tables below show directives and related standards applied to YAMAHA robots RCX240 RCX340 EC Directive Related Standards ENISO12100 Safety of machinery General principles for design Risk assessment and risk reduction EN 1S010218 1 Robots and robotic devices Safety requirements for industrial robots Part 1 Robots EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements Machinery Directive 2006 42 EC EMC Directive 2004 108 EC RCX221 RCX222 SR1 EC Directive Related Standards EN 15012100 Safety of machinery General principles for design Risk assessment and risk reduction EN 60204 1 Safety of machin
99. s label This indicates important 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 have an orientation Insert each connector in the correct direction 93005 X0 00 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 Warning label is attached to the robot body Warning label comes supplied with the robot and should be affixed to an easy to see location on the door or gate of the safety enclosure Warning label comes supplied with the robot and should be affixed to an easy to see location Cartesian Single axis robots robots DANGER fe Aa Stay clear of moving machine Can cause serious injury MR sei aso Warning label 1 HTS CBKETHETSRNGY 90K41 001470 Pinch or crush hazard Warning label 2 EATTHETSBNGY 90K41 001460 Read and understand manuals before operation BMEBI Su TIS HAS 81 24 oBllcv 27 VE 90K41 001290 Warning label 3 1 See Part names in each SCARA robot manu
100. se can be used to connect to the emergency stop circuit of the entire equipment via the SAFETY connector on the controller This section describes signal connections CAUTION Do not change or modify the cable and connector Along with the input output signals for the programming box the PB connector includes signals used to configure an external safety circuit and so changing or modifying the cable and connector is very dangerous Always configure an external safety circuit by using the SAFETY connector Although PBX E has emergency stop button and an enable switch they do not function independently because the controller is designed on the assumption that an external safety circuit is configured m RCX340 7 X Each pin of the PB connector on the PBX E is connected to the SAFETY connector Pin to pin connections are as follows PB connector SAFETY connector A Connected connector Solos Emergency stop contact E STOP11 Line 1 E STOP12 Emergency stop contact E STOP21 Line 2 Connected to E STOP22 SAFETY connector ENABLE1 Enable contact Line 1 ENABLE1 ENABLE2 ENABLE2 Enable contact Line 2 Circuit diagram Emergency stop Enable SAFETY 93206 R8 00 2 10 1 3 2 RPB E The programming box RPB E is a hand held unit specifically designed to connect to the controller in order to perf
101. starting work within the safety enclosure always confirm from outside the enclosure that each protective function is operating correctly see the previous section 2 3 DANGER Never enter within the movement range while within the safety enclosure See 7 1 Movement range in Safety instructions for details on the robot s movement range A WARNING When work is required within the safety enclosure place a sign Work in progress in order to keep other persons from operating the controller switch or operation panel A WARNING 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 Follow the precautions and procedure described in Adjusting the origin Origin position setting SCARA robots Follow the precautions and procedure described in Setting the Standard coordinate setting SCARA robots standard coordinates Follow the precautions and procedure described in Setting the soft SCARA robots limits Soft limit settings 5 mE Cartesian robots Follow the precautions and procedure described in Soft limit in Single axis robots each controller manual Work with power turned on SCARA robots Teaching Cartesian robots Refer to 5 Teaching within safety enclosure described below Single axis robots 5 Teaching within the safety
102. stop 11 2 31 IE Input 1 Bd 4 H i Output 2 Lt Lt Input 2 w S14 NI p 524 IET peri GND GND SRL3 RPB E enable T3 RPB E enable T11 13 Input 7 o T2 T 1 14 Q Output 1 T A T21 gt s 23 Input 2 9 T22 24 Q Output 2 24V T 4 41 S8 Enable 11 A 34 Enable 12 24V B gt _ 43 Enable 21 44 _ Enable 22 s 1 Wiring to check whether the controller is normal when using an alarm to shut off the main power 93212 R1 00 Parts list Type No Manufacturer 51 Reset switch A22 series OMRON 52 Key selector switch A22 TK series OMRON 3 Safety door switch D4 series OMRON S4 Emergency stop button A22E series OMRON KM1 2 Contactor mirror contact LC1 D18 Schneider Electric Safety relay G7SA 3A1B OMRON Socket for safety relay P7SA 10F ND OMRON SRL1 Safety relay unit G9SX GS226 OMRON SRL2 Safety relay unit G9SX BC202 OMRON SRL3 Safety relay unit G9SA 501 OMRON KA1 to 5 2 38 3 4 3 Category 2 A safety circuit configuration example of category 2 is shown below Category 2 safety circuit example KM1 ame
103. t range restricted space Area limited by movable mechanical stoppers Working envelope operational space Area limited by software limits Within safety enclosure safeguarded space See 7 1 Movement range in Safety instructions for details on the robot s movement range S 27 4 Ajojos Revision record Manual version Issue date Description Ver 1 00 May 2012 First edition 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 Description of warning labels was added descriptions of soft limits mechanical stoppers and work performed with vertical axis brake released were changed and residual risk description was added Warning on restricting the robot moving speed was added and description of warning label language was changed Apr 2014 Description of warning labels was added and description of Qualification of operators workers was changed etc YAMAHA Safety Instructions Apr 2014 Ver 1 06 This manual is based on Ver 1 06 of Japanese manual YAMAHA MOTOR CO LTD IM Operations All rights reserved No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or om
104. the HPB connector and HPB D SAFETY connector include signals used to configure an external safety circuit and so changing or modifying the cable and connector is very dangerous Always configure an external safety circuit by using the SAFETY connector on the controller and the HPB D SAFETY connector Pin to pin connections are as follows SR1 Controller internal SAFETY connector HPB connector connection Remarks Name Pin No Pin No Name o Internal 24V i Internally connected to pin 14 in B SAFETY connector o Internally connected to pin 15 in E STOP STOP status circuit input SAFETY connector D o SAFETY connector E STOPIN1 E STOPIN2 E STOPIN3 E STOPIN4 LCKIN1 LCKIN2 LCKIN3 LCKIN4 Emergency stop contact Line 1 Emergency stop contact Line 2 Enable contact Line 1 DOIN Enable contact Line 2 Internally connected to pin 9 in HPB HPB EMG2 connector Internally connected to pin 6 in HPB connector 1 Circuit diagram HPB D Emergency stop Enable HPB SAFETY HPB D SAFETY 93305 Q6 00 3 5 lt 1 4 SERVICE mode This section describes SERVICE mode 1 4 1 What is SERVICE mode SERVICE mode is used to perform work using the HPB D within the safety enclosure of the robot system To use the SERVICE mode function it must be enabled T
105. ting or the main power is turned on Failure to follow this warning may cause serious accidents involving injury or death Install a safety enclosure or a gate interlock with an area sensor to keep all persons away from the robot movement range 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 Install an enable device in the external safety circuit as needed Also set the robot moving speed to 3 or less Failure to follow these instructions may cause serious accidents involving injury or death See 7 1 Movement range in Safety instructions for details on the robot s movement range S 15 4 SUOHONASU SUOHONASU A WARNING 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 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 When configuring an automated system using a robot hazardous situations are more
106. ting the robot moving speed A WARNING Restriction on the robot moving speed is not a safety related function To reduce the risk of collision between the robot and workers the user must take the necessary protective measures such as enable devices according to risk assessment by the user 2 Restricting the movement range See 7 1 Movement range in Safety instructions for details on the robot s movement range A WARNING Soft limit function is not a safety related function intended to protect the human body To restrict the robot movement range to protect the human body use the mechanical stoppers installed in the robot or available as options N CAUTION If the robot moving at high speed collides with a mechanical stopper installed in the robot or available as option the robot may be damaged 3 Provide safety measures for end effector gripper etc A WARNING 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 is shut off or power fluctuations occur If the object gripped by end effector might possibly fly off or drop then provide appropriate safety protection taking into account the object size weight temperature and chemical properties 4 Provide adequate lighting Provide enough lighting to ensure safety during work 5 Install an operation status light A WARNING Install a sign
107. tion Type No RSHN 2016 Dimensional outline 12731 115 0 5 52 1 13 1 13 1 Earth terminal unit mm 93206 R6 00 35 1 23218 QL 00 Ferrite core Install ferrite cores according to the customer s final product entire system Recommended ferrite cores are shown below Recommended ferrite core 1 Manufacturer TDK Type No ZCAT3035 1330 Dimensional outline 30 0 1 13 01 7 X 8 o unit mm 93207 R6 00 Recommended ferrite core 2 Manufacturer TDK Type No ZCAT2132 1130 Dimensional outline 36 0 1 unit mm 93208 R6 00 2 25 4 2 3 RCX221 RCX222 2 3 1 Configuration N CAUTION As shown in the following figure the ferrite cores and noise filter on the controller side should be placed as close to the controller body as possible The ferrite cores on the robot side should be placed as close to the robot body as possible Typical component layout for EMC countermeasures Robot series Single axis Cartesian 7 X Power supply 200 to 230V Ground Solos RCX222 only Meaning of symbols Noise filter MBS1215 22 TDK Lambda Corporation L Ferrite core ZCAT3035 1330 TDK Ferrite core ZCAT2132 1130 TDK Ferrite core ZCAT2032 0930 TDK lr Ferrite core 1 turn Ferrite core 2 turn 9
108. to noise 5 Protective measures against electrical shock A WARNING Be sure to ground the ground terminals of the robot and controller Poor grounding may cause electrical shock gt 5 14 4 5 Safety measures 4 5 1 Safety measures 1 Referring to warning labels and manual A WARNING 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 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 Nee M NOTE For details on warning labels see 3 Warning labels in Safety instructions 2 Draw up work instructions and make the operators workers understand them A WARNING Decide on work instructions in cases where personnel must work within the robot safety enclosure to perform startup or maintenance work Make sure the workers completely understand these work instructions Decide on work instructions for the following items in cases where personnel must work within the robot safety enclosure to perform teaching maintenance or inspection tasks Make sure the workers completely understand these work instructions 1 Robot operating procedures needed for tasks such as startup procedures and handling switches 2 Robot speeds used durin
109. tor Although RPB E has an emergency stop button and an enable switch they do not function independently because the controller is designed on the assumption that an external safety circuit is configured RCX240 Each pin of the RPB connector on the RPB E is connected to each pin of the SAFETY connector and RPB SEL connector 7 X Pin to pin connections are as follows RPB connector Connector Connected connector No No Solos Emergency stop contact E STOPIN1 Line 1 E STOPIN2 Emergency stop contact E STOPIN3 Line 2 Connected to E STOPIN4 SAFETY connector LCKIN1 Enable contact Line 1 LCKIN2 LCKIN3 LCKIN4 Connected to KEY1 RPB SEL connector KEY2 Enable contact Line 2 Selector switch Circuit diagram RCX240 Emergency stop Enable Selector SAFETY 1 o o1 0 0 0 0 0 0 0 0 5 SEL 93203 6 00 gt 2 12 RCX221 RCX222 Each pin of the RPB connector on the RPB E is connected to each pin of the SAFETY connector Pin to pin connections are as follows RPB connector Connector pin i Connected connector pin No No Emergency stop contact E STOPIN1 Line 1 E STOPIN2 Emergency stop contact E STOPIN3 Line 2 E STOPIN4 Connected to LCKIN1 SAFETY connector LCKIN2 Enab
110. type switch The XA1E BV302R made by IDEC is used This switch sets the priority that controls the robot operation Be sure to set the switch to ON in the MANUAL mode Selecting will set the priority to the PBX E allowing you to control the robot operation When the switch is set at OFF the robot operation cannot be controlled Manual lock switch This is a 3 position switch designed in consideration of safety Pressing this switch to the middle position only enables robot operation When the ENABLE 11 12 21 and 22 wirings of the SAFETY connector are not connected the function of this switch cannot be used Configure an external safety circuit so that the state of this switch determines the robot operating state as follows Switch released Emergency stop state Switch in middle position Operable state Switch pressed Emergency stop state The A4E B200HS made by OMRON is used Enable switch This connector is used to read write between the USB memory and the internal memory of the controller The connector is intended to connect the USB memory and programming box The connector is used to save various data of the controller and perform the maintenance of the programming box USB connector PB connector Use this connector to connect the PBX E programming box to the robot controller 1 3 1 2 PB connector The PBX E has an emergency stop button and an enable switch The contact outputs of the
111. ual and instructions serious injury on the warning labels and understand the contents Electrical shock Be sure to ground the ground terminal 90K41 000950 B Warming label 7 controllers RCX240 controllers RCX340 A WARNING These are precautions for YAMAHA and distributors service personnel Customers must not attempt to open the covers A WARNING Wait at least 100 seconds after power off before opening the covers Instructions on this label b Wait at least 100 seconds after power off not open cover Residual voltage is present for 100 seconds after turning off the power before opening the covers WON 100 Some parts in the controller still retain a high HUS BS 100222 AWS 9 gt A voltage even after power off so electrical shock may occur if those parts are touched 100 MHIRABEMNSSOCAN EMI BWC E 90K41 001390 Potential hazard to human body Electrical shock To avoid hazard Wait at least 100 seconds after power off before opening the covers These are precautions for YAMAHA and distributors service personnel Customers must not attempt to open the covers 90K41 001390 S 5 lt AJOJOS SUOHONASU B Warning label 8 single axis linear motor robots A B Warning label 9 single axis linear motor robots AN CAUTION A magnetic scale is located inside this co
112. upis seinsDo N gt 1 6 ie RCX series Contents 1 System overview 1 1 System overview 111 Main system configuration 1 2 Control system configuration 1 2 1 Basic configuration 1 2 2 Power supply and emergency stop system circuit configuration 1 3 Programming box 1 3 1 PBX E 1 3 1 1 Part names and functions 1 3 1 2 PB connector 1 8 2 RPB E 1 8 2 1 Part names and functions 1 3 2 2 connector 1 4 specifications and KCs specifications 1 4 1 Manual mode Applicable controller RCX340 1 4 1 1 MANUAL mode parameter settings 1 4 2 SERVICE mode Applicable controller RCX240 221 222 SR1 1 4 2 4 Flow for enabling the SERVICE mode functions 1 4 2 2 SERVICE mode parameter settings 2 countermeasure examples 21 RCX340 2 1 1 Configuration 2 1 2 Countermeasure components 2 2 RCX240 2 2 1 Configuration 2 2 2 Countermeasure components 2 3 RCX221 RCX222 2 3 1 Configuration 2 3 2 Countermeasure components 3 External safety circuit examples 31 Safety requirements 3 1 1 CE marking 3 1 2 KCs mark 3 2 Circuit examples for the RCX340 3 2 1 Category 3 3 2 2 Overview of circuit operation 3 3 Circuit examples for the RCX240 3 3 1 Category 3 3 3 2 Overview of circuit operation 2 11 3 4 Circuit examples for the RCX221 RCX222 2 35 3 4 1 Category 4 2 37 3 4 2 Category 3 2 38 3 4 3 Category 2 2 39 3 4 4 Overview of circuit
113. ur distributor s instructions wait at least the time specified for each controller 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 For information on how long you should wait after turning the power off see the user s manual for each controller 8 5 Precautions during inspection of controller A WARNING When you need fo 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 Do not disassemble the controller Never touch any internal parts of the controller Doing so may cause breakdown malfunction injury or fire S 21 lt SUOHONASU SUOHONASU 4 7 2 Precautions during service work 1 Precautions when removing a motor Cartesian robots and vertical mount single axis robots A WARNING The vertical axis will slide down when the motor is removed causing a hazardous situation off the controller and place a
114. us output signals of the parallel I O and serial I O such as alarm signals should be monitored by the host device 7 X Overall connection diagram with enable switch X Safety circuit L1 Controller RPB E PNP specifications L1 y L Emergency stop Enable AC IN N19 AC OUT ND SAFETY Reset 13 13 7 5 14 14 2 P4 nc Maintenance 5 15 15 5 16 16 Door 5 17 17 5 d 5 18 18 5 External 5 19 19 5 emergency stop 6420 20 DI COM OUT K Safety output INTERLOCK 5 SERVICE DIO2 24V Wiring to check whether controller 4 DO COM d when using alarm to shut 5 MPRDY oma power 6 SERVO OUT O 11 E STOP24Y 24 GND 12 E STOPRDY E STOP Status 24V_GND GND ir dd SIDDO Power connector 424V b 1 gt 24V GND GND Wiring to check whether controller is 4 24VG i normal when not using alarm to shut eee 1 off main powerr lt CO ta 22 v GND To PLC Input output signals 93209 R1 00 2 35 lt 7 X Solos gt 2 36 Reference Connection diagram without enable switch category
115. ustomer must evaluate the finished product entire system and take necessary countermeasures Refer to EMC countermeasures for single units of YAMAHA robots which are described in the next chapter in this manual Installation conditions Protective structure YAMAHA robots are classified as built in equipment and have a Class I protective structure against electrical shock The robot and controller must therefore be grounded properly to prevent possible electrical shock For details refer to the controller user s manual and the robot user s manual Enclosure The robot controller case is not designed as an enclosure that conforms to the EN60204 1 IEC60204 1 Standard Suitable protection should therefore be provided to prevent the danger of electrical shock due to inadvertent contact and ambient environment problems dust water etc Insulation co ordination Regarding insulation co ordination YAMAHA robots and controllers are designed to meet the following conditions Overvoltage category RCX340 is applicable to overvoltage category 11 Pollution degree 2 Take proper countermeasures as needed if the robot or controller is used in environments more severe than these levels Explosion proof YAMAHA robots and robot controllers are not designed to meet explosion proof specifications Do not use them in environments exposed to flammable gases gasoline or solvents which could cause explosion or fire sp1Dp
116. ver Bringing a magnet close to it may cause malfunction Magnetic scale embedded keep magnets away ARERR WIDER SEXE A7 AAIS ALS 7 st t 2 HERAT ILA HA EIT TS CAUTION Powerful magnets are installed in the robot Instructions on this label To prevent the robot from operating improperly due to magnetic scale malfunction do not bring a strong magnet to the cover Do not bring tools close to the magnetic scale 90K41 001510 Do not attempt to disassemble the robot to avoid possible injury Do not bring any device that may malfunction due to magnetic fields close to the robot Strong magnet keep away devices vulnerable to magnetism Instructions on this label HIDES SER TMS ER EH as SEALE SALSA Sa tek 217 7710 514 A RRA WS Shee eT 6 3 Be sure to read 6 Cautions regarding strong magnetic fields in Safety instructions and make sure you fully understand its contents before handling or operating the robot Potential hazard to human body Injury or death may result in some cases To avoid hazard B Warning label 10 Controller A This label is attached to the front panel CAUTION Refer to the manual A amp E CAUTION D ILLI READ INSTRUCTION MANUAL Make you understand the precautions regarding strong magnetic fields 90K41 001500 Instructions on thi
117. xamples for the LO 6 can 2 31 32 1 S aite JOVIS 3 2 2 Overview of circuit operation 3 3 circuilrlexamplesitosthelRe X240 2 33 33 2 33 3 3 2 OVemiew of cicit operation 2 34 3 4 Circuit examples for the RCX221 RCX222 2 35 3 4 Category 4 3 4 2 Category 3 3 4 3 Category 2 3AA Ovemiew of circuit operation mE 2 40 1 System overview 3 1 Sy E OV MO 3 1 DS CUR 3 1 1 2 Control system configuration n 3 2 RUNE E E 3 2 1 2 2 Power supply and emergency stop system circuit configuration 3 3 IF3mProgramrmingibox HPBzD ME M ERE A RE TREE ER 1 3 2 HPB connector and HPB D SAFETY connector 14 SERVICE mode SEIS VIG Ei OCIO UT 3 6 SERVI Em esiemctioms T I 3 6 MA Siin tim MGC S oe 3 7 2 EMC countermeasure examples 3 8 21 iSRI Ie regs ce r yey eweeveees 3 8 23 d c onficurciiomnes eer tee e RII eru e EE NEN 3 8 2 152 Countermeasure cornpolemlse 3 9 3 External safety circuit examples 3 12 3 1 Safety reguiremenms eer EET ERE 3 12

Safety Manual - Yamaha Robotics

Contents

Download Pdf Manuals

Related Search

Related Contents