T4P/T5P User`s Manual
Contents
1. 10801 42942 2 Buidiew 10 pue 001 1 e qeo 51 Buiduung jo seoe4 10 uonisod sued 10401 JO SSeuesoo 10 uoge eijsut 9 pue 100 0404 pue s1ojoeuuoo aly pnoe4100 sejqeo aly 100 Jo dn 198 10 10401 ayy Jaye uonisod 941 5 1 Revision record Manual version Issue date Description Ver 1 00 Apr 2003 English manual Ver 1 00 is based on Japanese manual Ver Ver 1 Oct 2005 English manual Ver 1 01 is based on Japanese manual Ver Ver 1 02 Jan 2006 English manual Ver 1 02 is based on Japanese manual Ver Ver 1 03 Aug 2006 English manual Ver 1 03 is based on Japanese manual Ver Ver 1 May 2007 English manual Ver 1 04 is based on Japanese manual Ver User s Manual Pico series TAP TSP May 2007 Ver 1 04 This manual is based on Ver 1 03 of Japanese manual YAMAHA MOTOR CO LTD IM Operations rights reserved No part of this publication may be reproduced in a2. y NOTE Explains the key point in the operation in a simple and clear manner It is not possible to list all safety items in detail within the limited space of this manual So it is essential that the user have a full knowledge of basic safety rules and also that the operator makes correct judgments on safety procedures during operation This manual and warning labels supplied with or affixed to the robot are written in English If the robot operator or service personnel does not understand English do not permit that person to handle the robot T mmm 1 2 Essential Caution Items About Safety EE 2 1 2 Essential Caution Items Particularly important cautions for handling or operating the robot are described below In addition safety information about installation operation inspection and maintenance is provided in each chapter Be sure to comply with these instructions to ensure safe use of the robot 1 Observe the following cautions during automatic operation Install a safeguard protective enclosure to keep any person from entering within the move ment range of the robot and suffering injury due to being struck by moving parts Install a safety interlock that triggers emergency stop when the door or panel is opened Install safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks DANGER SERIOUS INJURY OR DEATH WILL RESULT FROM IMPACT WI
3. 19 1 11 Warranty About Safety 110 1 11 Warranty The YAMAHA robot and or related product you have purchased are warranted against the defects or malfunctions as described below Warranty description If a failure or breakdown occurs due to defects in materi als or workmanship in the genuine parts constituting this YAMAHA robot and or related product within the warranty period then YAMAHA will repair or replace those parts free of charge hereafter called warranty repair Warranty Period The warranty period ends when any of the following applies 1 After 18 months one and a half year have elapsed from the date of shipment 2 After one year has elapsed from the date of installation 3 After 2 400 hours of operation Exceptions to the Warranty This warranty will not apply in the following cases 1 Fatigue arising due to the passage of time natural wear and tear occurring during operation natural fading of painted or plated surfaces deterioration of parts subject to wear etc 2 Minor natural phenomena that do not affect the capabilities of the robot and or related product noise from computers motors etc 3 Programs point data and other internal data that were changed or created by the user Failures resulting from the following causes are not covered by warranty repair 1 Damage due to earthquakes storms floods thunderbolt fire or any other natural or man made disasters 2 Tro
4. 4 M4x0 7 Depth 9 2 03 7 Depth 6 Between knocks 137 Stopper position 21 5 Stopper position Depth 8 147 A 35 D Mx50 B 1 EM NM 5 B Installation hole N 64 5 on inner surface 8 counterbore depth 4 5 1 2 gt 12mm or less 2 Effective stroke 50 100 150 200 250 300 x L 307 5 357 5 407 5 457 5 507 5 557 5 4 125 5 175 5 225 5 275 5 325 5 375 5 z n A D 125 5 1255 To install the robot use 454 M 0 1 2 3 0 1 hex bolts hexagonal 85 N 4 6 8 10 6 8 socket head bolts with m Weight kg 1 2 1 3 1 4 1 5 1 6 127 length under head of BB cross section 5 04 2 12 46 less than 12mm 4 1 Robot specifications 4 1 2 T5P Basic specifications E Static allowable load moment Dynamic allowable load moment mm Robot model T5P MY MP MR 0 90 Repetitive positioning accuracy mm 1 0 02 10 9 10 0 29 4 8 Lead 12 3kg 270 521 Reduction mechanism Ball screw 6kg 151 363 Ball screw lead mm 12 6 8 Lead 6 6kg 211 846 Maximum speed Horizontal use 750 375 5 12kg 111 415 mm sec 2 Vertical use 600 300 Bg Lead 12 1 5kg 209 249 Maximum Horizontal use 6 12 5 gt Lead 6 3kg 125 150 payload kg Vertical use 1
5. Controller side Motor side 4 4 Robot usage conditions 4 4 Robot usage conditions 4 4 1 Parameter settings according to payload Robot Lead length Payload Okg mm Acceleration Deceleration Maximum speed Acceleration Deceleration Maximum speed Acceleration Deceleration Maximum speed Acceleration Deceleration Maximum speed Acceleration 5 04 2 12 46 Deceleration Maximum speed Acceleration Deceleration Maximum speed Note 1 Acceleration and deceleration units are in 61 23rad s Note 2 Maximum speed unit is in 18 75rpm 55 4 6 S N Q 2 itioning error Pos 5 1 sued jeojueyoow eoejdeg uo sua jsn pe pue sped sseuesoo JO esneo Troubleshooting pue ejqeo ay 4 10 amp esiou Jo e 3194 S esneo eoujoe 3 uinjei Jaye uJnjeJ uonisod y uonIsod 991109 4 esiou aye Buiddpbis ujee 10 eq pue 40 10q01
6. ENS 28 Periodic Inspection 3 1 Before beginning work Periodic inspection and maintenance are essential to ensure safe and efficient operation of YAMAHA robots This chapter describes periodic inspection items and procedures for the YAMAHA Pico series robots Before beginning work read the precautions below and also in Chapter 1 About Safety and always follow the instructions DANGER IF THE INSPECTION OR MAINTENANCE PROCEDURE CALLS FOR OPERATION OF THE ROBOT STAY OUT OF THE WORKING AREA OF THE ROBOT DURING OPERATION DO NOT TOUCH ANY PARTS INSIDE THE CONTROLLER KEEP WATCHING THE ROBOT MOVEMENT AND SURROUNDING AREA SO THAT THE OPERA TOR CAN PRESS THE EMERGENCY STOP BUTTON IF ANY DANGER OCCURS WARNING WHEN THE DOES NOT NEED BE OPERATED DURING ADJUSTMENT OR MAINTENANCE ALWAYS TURN OFF THE CONTROLLER AND THE EXTERNAL SWITCH BOARD DO NOT TOUCH INTERNAL PARTS OF THE CONTROLLER FOR 5 SECONDS AFTER THE CONTROLLER HAS BEEN TURNED OFF PUT THE ROBOT IN EMERGENCY STOP WHEN PERFORMING ELECTRICAL INSPECTION NOT REQUIRING ROBOT MOVEMENT USE ONLY LUBRICANT AND GREASES SPECIFIED BY YAMAHA SALES OFFICE OR DEALER USE ONLY PARTS SPECIFIED BY YAMAHA SALES OFFICE OR DEALER TAKE SUFFICIENT CARE NOT TO ALLOW ANY FOREIGN MATTER TO CONTAMINATE THEM DURING ADJUSTMENT PARTS REPLACEMENT OR REASSEMBLY DO NOT MODIFY ANY PARTS ON THE ROBOT OR CONTROLLER MODIFICATION MAY RESULT IN UNSATISFACTORY SP
7. No mechanical stopper is provided on the rotating axis Note The movement range is the area limited by mechanical stoppers WARNING Ak AXIS MOVEMENT WILL NOT STOP IMMEDIATELY AFTER THE SERVO POWER SUPPLY IS 4 SHUT OFF EMERGENCY STOP OR OTHER SAFETY FUNCTIONS Vertical axis brake An electromagnetic brake is installed on the vertical use robot to prevent the vertical axis from sliding down when servo power is turned off This brake is working when the controller is off or the vertical axis servo power is off even when the controller is on The vertical axis brake can be released by means of the programming unit when the controller is on WARNING THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE IS RELEASED CREATING HAZARDOUS SITUATION PRESS THE EMERGENCY STOP BUTTON AND PROP THE VERTICAL AXIS WITH A SUPPORT STAND BEFORE RELEASING THE BRAKE USE CAUTION NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACH 1 5 Safety Measures for the System 1 5 Safety Measures for the System Since the robot is commonly used in conjunction with an automated system dangerous situations are more likely to occur from the automated system than from the robot itself Accordingly appropriate safety measures must be taken on the part of the system manu facturer according to the individual system The system manufacturer should provide
8. Pressing down hard on the shutter may cause the shutter to warp 3 17 EE 318 Specifications 4 1 Robot specifications 4 1 1 Basic specifications Static allowable load moment m E Dynamic allowable load moment mm Robot model T4P MY MP MR 0 90 Repetitive positioning accuracy mm 1 0 02 6 2 5 7 15 9 8 Lead 12 2kg 192 344 Reduction mechanism Ball screw 5kg 87 188 Ball screw lead mm 12 6 8 Lead 6 4kg 151 340 Maximum speed mm sec 2 750 375 5 8kg 87 301 Maximum Horizontal use 5 8 payload kg Vertical use Stroke mm 50 to 300 50mm pitch steps Cable length m 3 5 standard cable 5 or 10 Controller PRC 1 1 Positioning repeatability in one direction 2 See payload vs maximum speed graphs below W Payload vs maximum speed Lead 12mm Lead 8 5 2 25 5 55 83 g2 g3 a a2 1m 1 90 150 300 450 600 750 90 75 150 225 300 375 Maximum speed mm sec Demensions Robot Approx 250 Maximum speed mm sec Thrust N 288888 o 30 80 90 120 150 180 210 240 Current limit value Reference value The above data does not guarantee the thrust power accuracy maintained when the robot is stopped Use this data for reference only Motor cable length 185 3 Effective stroke 72 543
9. 4 5 4 4 1 Parameter settings according to 4 5 Chapter 5 Troubleshooting 5 12 Pos tioningierr r 5 1 About Safety 1 1 Safety Information Industrial robots are highly programmable mechanical devices that provide a large degree of freedom when performing various manipulative tasks To ensure correct and safe use of YAMAHA industrial robots carefully read this manual and make yourself well acquainted with the contents FOLLOW THE WARNINGS CAUTIONS AND INSTRUCTIONS INCLUDED IN THIS MANUAL Failure to take necessary safety measures or mishandling due to not following the instructions in this manual may result in trouble or damage to the robot and injury to personnel robot operator or service personnel including fatal accidents Warning information in this manual is shown classified into the following items DANGER FAILURE TO FOLLOW DANGER INSTRUCTIONS WILL RESULT IN SEVERE INJURY OR DEATH TO THE ROBOT OPERATOR BYSTANDERS OR PERSONS INSPECTING OR REPAIRING THE ROBOT WARNING FAILURE FOLLOW WARNING INSTRUCTIONS COULD RESULT IN SEVERE INJURY OR DEATH TO THE ROBOT OPERATOR BYSTANDERS OR PERSONS INSPECTING OR REPAIRING THE ROBOT CAUTION N Failure to follow CAUTION instructions may result in injury to the robot operator bystanders or persons inspecting or repairing the robot or damage to the robot and or robot controller
10. YAMAHA YAMAHA MOTOR CO LTD YAMAHA SINGLE AXIS ROBOT FLIP X series Pico type User s Manual enous gt E31 Ver 1 04 Introduction This manual describes the safety measures handling adjustment and mainte nance of YAMAHA Pico series robots for correct safe and effective use Be sure to read this manual carefully before installing the Pico series robot Even after you have read this manual keep it in a safe and convenient place for future reference when needed This instruction manual should be used with the robot and considered an inte gral part of it When the robot is moved transferred or sold send this manual to the new user along with the robot Be sure to explain to the new user the need to read through this manual Specifications of robot models other than standard models may be omitted in this manual if they are common to those of standard models In this case refer to the specifications of standard models For details on specific operation and programming of the robot refer to the separate PRC Single axis Robot Controller User s Manual NOTES The contents of this manual are subject to change without prior notice Information furnished by YAMAHA in this manual is believed to be reliable However if you find any part unclear or inaccurate in this manual please contact YAMAHA sales office or dealer YAMAHA MOTOR LTD IM Operations General Contents Chapter 1 About
11. side covers and motor cover using the reverse procedure Do not overtighten the end cover and motor cover mounting screws Tightening torque should be less than 0 4N m 10 Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter N CAUTION Do not press down on the shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp 315 3 7 Replacing the coupling Periodic Inspection EE 316 3 7 2 5 1 Remove the screws securing the top cover and remove the top cover 2 Remove the screws securing the side covers of the robot and remove the side covers on both sides 3 7 Replacing the coupling 5 Loosen the bolt M2 6 one piece securing the coupling and remove the coupling from the motor Then attach a new coupling to the motor Tightening torque 1 0N m 6 Attach the motor and secure it by tightening the bolts Tightening torque 2 0N m 7 Loosen the bolt securing the coupling on the ball screw side Tightening torque 1 0N m 8 Reattach the side covers and top cover using the reverse procedure Be careful not to overtighten the top cover mounting screws Tightening torque should be less than 0 4N m 9 Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter uonoadsuj 1 N CAUTION Do not press down on the shutter with excessive force
12. 3 3 Applying grease Follow these steps when applying grease to the robot ball screws and linear guides according to periodic maintenance 1 Remove the screw securing the robot side covers and remove the side covers 2 Coat the ball screw and linear guides with grease by hand and move the slider back and forth to spread the grease Applying grease to the ball screw ae Applying grease to the linear guide 3 Reattach the side covers 3 4 Replacing the shutter 3 4 Replacing the shutter Use the following procedure when the shutter must be replaced Make sure that the controller power switch is off before beginning work 3 4 1 1 Remove the 4 screws securing the slider cover and take off the slider cover uon gt adsuj 1 3 Remove the screws securing the shutter Remove the 2 screws on the endplate side and the 2 screws on the motor side 35 mm 3 4 Replacing the shutter Periodic Inspection gt 36 4 Remove shutter and shutter guide from robot Remove the shutter from the shutter guide and pass the new shutter through it 5 Reinstall the shutter motor cover and slider cover using the reverse procedure Be careful not to overtighten the motor cover mounting screws Tightening torque should be less than 0 4N m No NOTE Do not fully tighten the screws to secure the shutter on the endplate side at this time Fully tighten these screws after adjusting
13. 5 3 Stroke mm 50 to 600 50mm pitch steps Cable length m 3 5 standard cable 5 or 10 Reference value The above data does not guarantee the thrust power accuracy maintained when the robot is stopped Use this data for reference only 0 150 300 450 600 750 0 75 150 225 300 375 Maximum speed mm sec Maximum speed mm sec Controller PRC2 E Pushing thrust 2 1 Positioning repeatability in one direction 450 c 2 See payload vs maximum speed graphs below a T e 300 Payload vs maximum speed E 250 Lead 12mm Lead 6mm 2 200 BN 15 Zr 150 2 orizont usol Eat a 50 7 t 5 9060 90 120 150 180 20 240 a 2 Current limit value 0 0 un T5P Demensions Robot 324 L gt With motor U attached With brake 168 5 3 ai _ Effective stroke 74 5 3 57 6 4 M4x0 7 Depth 9 5 2 3H7 Depth 6 5 116 8 iti 40 5 amp g Stopper position 2510 02 2 9 57 6 e d r 1 1 9_ is 49 3 ke die IT 96 22 Stopper position L G 89 22 Stopper position 1 Approx 300 Motor cable length 128 5 A 34 5 Installation hole N 64 5 on inner surface 8 counterbore depth 4 5 View from direction Dep
14. Are the signal transmissions to the end effector and peripheral equipment correct 5 Does emergency stop work 6 Are the teaching and playback functions normal 7 Are the safety enclosure and interlock working as intended 8 Does the robot move correctly during automatic operation 67 1 7 Work Within the Safety enclosure 1 7 Work Within the Safety enclosure About Safety De 18 1 2 1 8 Work within the safety enclosure When work is required inside the safety enclosure always turn off the controller and place a sign indicating that the robot is being adjusted or serviced in order to keep any other person from touching the controller switch or operation panel except for the following cases 1 Soft limit settings See Section 4 in Chapter 4 2 Teaching For item 1 follow the precautions and procedure for each section To perform item 2 refer to the description in 2 below Teaching When performing teaching within the safety enclosure comply with the instructions listed below 1 Check or perform the following points from outside the safety enclosure 1 Make sure that no hazards are present within the safety enclosure by a visual check 2 Check that the programming unit TP 2 operates correctly 3 Check that no failures are found in the robot 4 Check that emergency stop works correctly 5 Select teaching mode and prohibit automatic operation 2 Never enter the movement range of the mani
15. for shutter looseness in step 6 6 Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter Do not press down on shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp 3 4 Replacing the shutter 3 4 2 T5P 1 Remove the 4 screws securing the slider cover and take off the slider cover uonoadsuj 1 3 Remove the two screws securing the shutter on the end block side 3 7 m 3 4 Replacing the shutter Periodic Inspection 4 Remove the shutter and shutter guide from the robot Remove the shutter from the shutter guide and pass the new shutter through it 5 Reinstall the shutter top cover and slider cover using the reverse procedure Be careful not to overtighten the top cover mounting screws Tightening torque should be less than 0 4N m No NOTE Do not fully tighten the screws to secure the shutter on the endplate side at this time Fully tighten these screws after adjusting for shutter looseness in step 6 6 Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter Do not press down on shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp 3 5 Adjusting shutter looseness 3 5 Adjusting shutter looseness The shutter may elongate wi
16. parts or residual vibration during positioning may result 1 3 Special Training for Industrial Robot Operation 1 3 Special Training for Industrial Robot Operation Companies or factories using industrial robots must make sure that every person who handles the robot such as for teaching programming movement check inspection adjustment and repair has received appropriate training and also has the skills needed to perform the job correctly and safely Since the Pico series single axis robots fall under the industrial robot category the user must observe local regulations and safety standards for industrial robots and provide special training for every person involved in robot related tasks teaching programming movement check inspection adjustment repair etc 15 mm 1 4 Robot Safety Functions About Safety EEG 16 1 4 Robot Safety Functions 1 2 3 Overload detection This function detects an overload applied to the motor and shuts off the servo power Soft limits Soft limits can be set on each axis to limit the working envelope in manual operation after return to origin and during automatic operation Note The working envelope is the area limited by soft limits Mechanical stoppers If the servo power is suddenly shut off during high speed operation by emergency stop or safety functions these mechanical stoppers prevent the axis from exceeding the movement range
17. the robot cables 2 6 2 System Configuration Example 3 1 3 2 3 3 3 4 3 5 3 6 3 7 Before beginning wotk 5 1 ro Rome eeu Periodic inspection ane 3 2 1 Daily inspection 3 2 2 Three month inspection 3 2 3 Sixemonth iDspectiori ee Ote er RE e EO EE n Ere Ir e 3 274 Three year e ene t Db a e AA tege eds Applying Sr ase lee M Replacing the sh tter 2 titre 3 4 1 3 4 2 T5P Adjusting shutter eene enne n ntn nnns insit stia stint tint 3 9 Replacing the 3 10 BB 3 10 3 12 Replacing the coupling ssssssscssscsssssssssessscssccssecscsseecascssessceseseceseesscesseenees 3 14 E A 3 14 BS 3 16 Chapter 4 4 1 Robot specifications Me 4 1 TE MM EU MA N 4 1 45122 e SR o d en 4 2 4 2 Servo motor specifications ueesonesssssnssonsnnsnnsnnnsnnsnonssnnsnnnsnnsnnnsnnsnonssnsnonssnnsnnnsnnnnen 4 3 A 221 Seryo motor termina NOn esee rte 4 3 423 e E 4 4 4 4 Robot usage conditions 22 0020000002002200200000000000000200200000020
18. ECIFICATIONS OR THREATEN OPERATOR SAFETY WHEN ADJUSTMENT OR MAINTENANCE IS COMPLETE RETIGHTEN THE BOLTS AND SCREWS SECURELY DURING ROBOT ADJUSTMENT OR MAINTENANCE PLACE A SIGN INDICATING THAT THE ROBOT IS BEING ADJUSTED OR SERVICED TO PREVENT OTHERS FROM TOUCHING THE CONTROL KEYS OR SWITCHES PROVIDE A LOCK ON THE SWITCH KEYS OR ASK SOMEONE TO KEEP WATCH AS NEEDED uonoodsu When applying grease to the ball screws and linear guide take the following precautions A WARNING PRECAUTIONS WHEN HANDLING GREASE INFLAMMATION MAY OCCUR IF THIS GETS IN THE EYES BEFORE HANDLING THE GREASE WEAR YOUR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES INFLAMMATION MAY OCCUR IF THE GREASE COMES INTO CONTACT WITH SKIN BE SURE TO WEAR PROTECTIVE GLOVES TO PREVENT CONTACT WITH SKIN DO NOT TAKE ORALLY OR EAT EATING WILL CAUSE DIARRHEA AND VOMITING HANDS AND FINGERS MIGHT BE CUT WHEN OPENING THE CONTAINER SO USE PROTECTIVE GLOVES KEEP OUT OF THE REACH OF CHILDREN DO NOT HEAT THE GREASE OR PLACE NEAR AN OPEN FLAME SINCE THIS COULD LEAD TO SPARKS AND FIRES EMERGENCY TREATMENT IF GREASE GETS IN THE EYES WASH LIBERALLY WITH PURE WATER FOR ABOUT 15 MINUTES AND CONSULT A PHYSICIAN FOR TREATMENT IF GREASE COMES IN CONTACT WITH THE SKIN WASH AWAY COMPLETELY WITH SOAP AND WATER IF TAKEN INTERNALLY DO NOT INDUCE VOMITING BUT PROMPTLY CONSULT A PHYSICIAN FOR PROPER TREA
19. ID INSTALLING THE ROBOT IN LOCATIONS WHERE THE AMBIENT CONDITIONS EXCEED THE ALLOWABLE TEMPERATURE OR HUMIDITY OR IN ENVIRONMENTS WHERE EXCESSIVE MOISTURE CORROSIVE GASES METALLIC POWDER OR DUST ARE GENER ATED MALFUNCTIONS FAILURES OR SHORT CIRCUITS MAY OTHERWISE RESULT WARNING THIS WAS NOT DESIGNED FOR OPERATION IN ENVIRONMENTS WHERE INFLAMMABLE OR EXPLOSIVE SUBSTANCES ARE PRESENT DO NOT USE THE ROBOT IN ENVIRONMENTS CONTAINING INFLAMMABLE GAS DUST OR LIQUIDS EXPLOSIONS OR FIRE COULD OTHERWISE RESULT WARNING AVOID USING THE ROBOT IN LOCATIONS SUBJECT ELECTROMAGNETIC INTERFERENCE ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE MALFUNCTIONS MAY OTHERWISE OCCUR WARNING DO NOT USE THE ROBOT IN LOCATIONS SUBJECT EXCESSIVE VIBRATION ROBOT INSTALLATION BOLTS MAY OTHERWISE BECOME LOOSE CAUSING THE MANIPULATOR TO FALL OVER 2 4 Installation base 2 4 Installation base To mount the robot use an installation base that satisfies the following conditions 1 The installation base is subjected to a great deal of stress while the robot is in operation Prepare a sufficiently rigid and stable installation base taking into account the robot weight including the end effector gripper and workpiece CAUTION If the installation base is not sufficiently rigid and stable vibration resonance may occur during operation causing adv
20. M3 4 pieces securing the motor and remove the motor y mu 5 Attach a new motor and tighten the bolts to secure the new motor Tightening torque 2 0N m 6 Tighten the bolt to secure the coupling on the motor side Tightening torque 1 0N m LS 312 3 6 Replacing the motor 7 Reattach the side covers and top cover using the reverse procedure Be careful not to overtighten the top cover mounting screws Tightening torque should be less than 0 4N m 8 Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter N CAUTION Do not press down on the shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp uonoadsuj 21 313 3 7 Replacing the coupling 3 7 Replacing the coupling 3 7 1 4 1 Remove the screws securing the motor cover and remove the motor cover Periodic Inspection EE 314 3 7 Replacing the coupling 5 Remove the bolts M2 6 2 pieces securing the motor and remove the motor 6 Loosen the bolt M2 6 one piece securing the coupling and remove the coupling from the motor Then attach a new coupling to the motor Tightening torque 1 0N m uonoadsuj 1 7 Attach the motor and secure it by tightening the bolts Tightening torque 1 0N m 8 Loosen the bolt securing the coupling on the ball screw side Tightening torque 1 0N m 9 Reattach the end cover
21. Safety 1 1 Safety Information 1 1 1 2 Essential Caution eoe ERR ERA Pea SAVE Meer 1 2 1 3 Special Training for Industrial Robot Operation 0020002000000000000020000000000000000 1 5 1 4 Robot Safety Functions ecoute eheu en ra eoe ine enn een Eo nean Panne aos 1 6 1 5 Safety Measures for the System uuscorsonssosssnssnnssonsnnnsonnsnnsnnnsnnsnonsnnsnonssnnsnnnsonsnnnsnnns 1 7 1 6 Trial Operation is E 1 7 1 7 Work Within the Safety enclosure 20 2200000200000020002000200000000020000000000000 00000 1 8 1 8 Automatic Operation sisisi nesses sensasie riia 1 8 1 9 Adjustment and Inspection ssccccsscsscsseccsecsesssessssssesssecseeseesesessesssesseesseeseese 1 9 1 10 Repair and Modification enne nein n sinn tanen asino 1 9 1 11 1 10 Chapter 2 Installation and Connections 2 1 2 2 2 3 2 4 2 5 2 6 Chapter 3 Checking the product 2 1 Robot part names TER E H 2 1 Robot Installation Conditions ee eren eren eene eene tente tnnt 2 2 Installation 2 3 to kennst eaae ee es a Peor 2 4 2 5 1 2 5 2 T5P Connections 2 6 1 Connecting
22. TH MOVING ROBOT KEEP OUTSIDE OF GUARD DURING OPERATION LOCK OUT POWER BEFORE APPROACHING ROBOT 2 Use caution to prevent hands or fingers from being pinched or crushed When moving the robot or performing teaching use caution to prevent hand or fingers from being pinched or crushed by the robot movable parts A WARNING MOVING PARTS CAN PINCH OR CRUSH KEEP HANDS AWAY FROM ROBOT ARMS 3 Follow the instructions on listed in this manual Before attempting installation and operation of the robot be sure to read this manual carefully and follow the instructions Before starting robot operation be sure to reread the procedures and cautions relating to your work as well as descriptions in this chapter Chapter 1 About Safety Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual WARNING IMPROPER INSTALLATION OR OPERATION RESULT IN SERIOUS INJURY OR DEATH READ THIS MANUAL CAREFULLY BEFORE STATING INSTALLATION AND OPERATION 4 Do not use the robot in environments containing inflammable gas etc WARNING THIS WAS NOT DESIGNED FOR OPERATION IN ENVIRONMENTS WHERE INFLAMMABLE OR EXPLOSIVE SUBSTANCES ARE PRESENT DO NOT USE THE ROBOT IN ENVIRONMENTS CONTAINING INFLAMMABLE GAS DUST OR LIQUIDS EXPLOSIONS OR FIRE MIGHT OTHERWISE RESULT 5 Do not use the robot in locations possibly subject to electrom
23. TICAL AXIS WILL SLIDE DOWN WHEN THE MOTOR IS RELEASED CAUSING HAZARDOUS SITUATION TURN OFF THE ROBOT CONTROLLER AND PROP UP THE VERTICAL AXIS WITH A SUPPORT STAND BEFORE REMOVING THE MOTOR CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS PARTS AND INSTALLATION BASE 9 Take the following safety precautions during inspection of con troller WARNING WHEN YOU NEED TO TOUCH THE TERMINALS OR CONNECTORS ON THE OUTSIDE OF THE CONTROLLER DURING INSPECTION ALWAYS FIRST TURN OFF THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER TO PREVENT POSSIBLE ELECTRICAL SHOCK NEVER TOUCH ANY INTERNAL PARTS OF THE CONTROLLER REFER TO THE YAMAHA ROBOT CONTROLLER USER S MANUAL FOR PRECAUTIONS ON HANDLING THE CONTROLLER 10 Consult us for corrective action when the robot is damaged or malfunctions occur WARNING IF ANY PART OF THE IS DAMAGED OR ANY MALFUNCTION OCCURS CONTINUING THE OPERATION MAY BE VERY DANGEROUS PLEASE CONSULT YOUR YAMAHA SALES OFFICE OR DEALER FOR CORRECTIVE ACTION Damage or Trouble Possible Danger Damage to machine harness or robot cable Electrical shock malfunction of robot Damage to exterior of robot Flying outwards of damaged parts during robot operation Abnormal operation of robot ier m Malfunction of robot
24. TMENT 3 1 3 2 Periodic inspection Periodic Inspection 3 2 Periodic inspection 3 2 1 Daily inspection Check the following points on a daily basis before and after robot operation Cables and shutter Check for scratches dents and excessively tight bends Replace if necessary Ball screws and bearings Check for unusual vibration and noise See 3 4 in this chapter Motor Check for unusual vibration and noise and for abnormal temperature rise 3 2 2 Three month inspection Check the following points every 3 months and apply grease if needed Checkpoints Check items Ball screw linear guide Check for dirt or grime If dirt or grime is found clean the See 3 3 in this chapter and ball bushing part Apply grease after cleaning Apply grease if the items checked are dry or do not have enough grease Recommended grease is as follows Standard model Use Alvania No Showa Shell Daphne Eponex No 2 Idemitsu Clean room model Use LG 2 NSK Shutter Check for slack Adjust if necessary See 3 5 in this chapter Coupling Check if the bolts are loose Tighten if necessary See 3 7 in this chapter CAUTION N Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw linear guide and linear bushing shaft 3 2 Periodic inspection 3 2 3 Six month inspection Check the following points every six months and make adjustments or apply g
25. a proper instruction manual for safe correct operation and servicing of the system 1 6 Trial Operation After making installations adjustments inspections maintenance or repairs to robot make a trial run using the following procedures 1 If a safety enclosure has not yet been provided right after instal lation of the robot rope off or chain off around the movement area of the manipulator in place of the safeguard and observe the following points 1 Use sturdy stable posts which will not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 3 Place a sign to keep the operator or other personnel from entering the movement range of the manipulator 2 Check the following points before turning on the controller 1 Is the robot securely and correctly installed 2 Are the electrical connections to the robot correct 3 Are items such as air pressure correctly supplied 4 the robot correctly connected to peripheral equipment 5 Have safety measures safety enclosure etc been taken 6 Does the installation environment meet the specified standards 3 After the controller is turned on check the following points from outside the safety enclosure 1 Does the robot start and stop as intended Can the operation mode be selected correctly 2 Does each axis move as intended within the soft limits 3 Does the end effector move as intended 4
26. ag netic interference etc WARNING AVOID USING THE ROBOT IN LOCATIONS SUBJECT ELECTROMAGNETIC INTERFERENCE ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE MALFUNCTIONS MIGHT OTHERWISE OCCUR 1 2 Essential Caution Items 6 Use caution when releasing the brake of a vertical use robot WARNING THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE IS RELEASED CAUSING HAZARDOUS SITUATION PRESS THE EMERGENCY STOP BUTTON AND PROP UP THE VERTICAL AXIS WITH A SUPPORT STAND BEFORE RELEASING THE BRAKE BECAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACH jnoqy 7 Provide safety measures for end effector gripper etc WARNING END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY CREATE NO HAZARDS FOR EXAMPLE A WORKPIECE THAT COMES LOOSE EVEN IF POWER ELECTRICITY AIR PRESSURE ETC IS SHUT OFF OR POWER FLUCTUATIONS OCCUR IF THERE IS A POSSIBLE DANGER THAT THE OBJECT GRIPPED BY THE END EFFECTOR MAY FLY OFF OR DROP THEN PROVIDE APPROPRIATE SAFETY PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE WEIGHT TEMPERATURE AND CHEMICAL PROPERTIES 8 Use caution when removing the motor Vertical use robots WARNING THE VER
27. e it 2 5 Installing the robot 5 Secure the robot to the base with the specified bolts 4 or more bolts and torque The bolts and tightening torque are shown below 4 recommended length 12mm 3 0N m to 4 5N m ee N CAUTION Be careful not to damage the shutter when tightening the bolts suonoauuo pue WARNING Ak BE SURE TO TIGHTEN THE BOLT TO THE CORRECT TORQUE THE WRONG TORQUE MAY NOT ONLY CAUSE ROBOT POSITION ERRORS BUT ALSO LEAD TO SERIOUS ACCIDENTS 6 Fit the motor side mechanical stopper into the head of the bolt and secure the stopper Fully insert the mechanical stopper so no gap exists between the plate and mechanical stopper ic 7 Reattach the side covers and motor cover after installing the robot Be careful not to overtighten the motor cover mounting screws Tightening torque should be less than 0 4N m 25 mm 2 5 Installing the robot Installation and Connections 2 5 2 T5P 1 Tap holes M4 x 0 7 4 or more locations into the installation base where the robot is to be secured For hole diameter and position see the external view and dimensions in 4 1 Robot specifications of this chapter4 2 Remove the screws securing the side covers of the robot and remove the side covers on both sides M NOTE If necessary move the slider to a location where it does not hide the installation holes on the bottom of the robo
28. erse effects on the robot work 2 The installation base surface must be machined within a flatness of 0 05mm 500mm CAUTION N The robot positioning accuracy might decrease if the installation surface precision is insuffi cient 3 Use an installation base of sufficient size to match the robot body so that the robot can be installed with the specified number of bolts Avoid installing the robot with less than the specified number of bolts 4 bolts or installing the robot closer to one end as shown at the lower right suonoauuo pue Installation base Installation base Good example Bad example CAUTION N Using less than the specified number of bolts to install the robot may cause vibration and poor positioning accuracy 29 mm 2 5 Installing the robot 2 5 Installing the robot 2 5 1 1 holes 4 x 0 7 4 or more locations into the installation base where the robot is to be secured For hole diameter and position see the external view and dimensions in 4 1 Robot specifications of this chapter4 2 Remove the screws securing the motor cover of the robot and remove the motor cover Installation and Connections If necessary move the slider to a location where it does not hide the installation holes the bottom of the robot frame 4 Hold the mechanical stopper on the motor side between your fingers and pull it toward you to remov
29. mediately 2 2 Robot part names T4P Motor cover Slider Slider cover End cover Shutter Shutter mounting plate Side cover N S c e gt gt c e gt un Endplate Side cover mounting screw T5P Motor Top cover Slider Slider cover Motor block Side cover Shutter mounting plate Endplate Side cover mounting screw 21 m 2 3 Robot Installation Conditions Installation and Connections 22 2 3 Robot Installation Conditions Be sure to install the robot in the following environments Allowable ambient temperature 0 to 45 C Allowable ambient humidity Below 90 RH no condensation Altitude 0 to 1000 meters above sea level Ambient environments Avoid installing near water cutting water oil dust metallic chips and organic Solvent Avoid installation near corrosive gas and corrosive materials Avoid installation in atmosphere containing inflammable gas dust and liquid Avoid installation near objects causing electromagnetic interference electrostatic discharge and radio frequency interference Vibration Do not subject to impacts or vibrations Working space Allow sufficient space margin to perform jobs teaching inspection repair etc For the controller installation conditions refer to PRC Single axis Robot Controller User s Manual WARNING AVO
30. ny form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or omissions If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives
31. positioning error excessive vibration etc Z axis brake trouble Dropping of load 1 9 mm 1 2 Essential Caution Items About Safety EE 14 11 careful not to touch motor speed reduction gear casing when hot WARNING THE MOTOR AND SPEED REDUCTION GEAR CASING ARE EXTREMELY HOT AFTER AUTO MATIC OPERATION SO BURNS MAY OCCUR IF THESE ARE TOUCHED BEFORE HANDLING THESE PARTS DURING INSPECTION OR SERVICING TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THE PART HAS COOLED 12 Do not remove alter or stain the warning labels WARNING Ak IF WARNING LABELS ARE REMOVED OR DIFFICULT SEE THEN ESSENTIAL PRECAU TIONS MIGHT NOT BE TAKEN RESULTING IN ACCIDENTS DO NOT REMOVE ALTER OR STAIN THE WARNING LABELS ON THE ROBOT DO NOT ALLOW THE WARNING LABELS TO BE HIDDEN BY DEVICES INSTALLED ONTO THE ROBOT BY THE USER PROVIDE PROPER LIGHTING SO THAT THE SYMBOLS AND INSTRUCTIONS ON THE WARNING LABELS CAN BE CLEARLY SEEN EVEN FROM OUTSIDE THE SAFETY ENCLOSURE 13 Protective bonding WARNING SURE GROUND THE ROBOT AND CONTROLLER PREVENT ELECTRICAL SHOCK 14 Be sure to make correct parameter settings CAUTION N The robot must be operated with the correct acceleration according to the tolerable moment of inertia and manipulator tip mass or moment of inertia If this is not observed drive unit service life may end prematurely and damage to robot
32. pulator while within the safety enclosure Automatic Operation 1 2 Checks before operation Check the following points before starting automatic operation 1 No one is within the safety enclosure 2 The programming unit and tools are in their specified locations 3 The alarm or error lamps on the robot and peripheral equipment do not flash 4 The safety enclosure is securely installed with safety interlocks actuated Precautions during operation or when an error occurs 1 After operation has started check the operation status and signal light to ensure that the robot is in automatic operation 2 Never enter the safety enclosure during operation 3 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 any other person from touching the start switch and restarting the robot 1 9 Adjustment and Inspection 1 9 Adjustment and Inspection Do not attempt any installation adjustment inspection or maintenance unless it is de scribed in this manual 1 10 Repair and Modification Do not attempt any repair parts replacement and modification unless described in this manual These works require technical knowledge and skill and may also involve work hazards
33. rease if necessary Checkpoints Check items Main bolts and screws Check for looseness If loose tighten on robot Ball screw and linear Check for looseness in the ball screw and linear guide If problem is not solved or guide Tighten if necessary wear and backlash are Check for vibration during operation found please contact us Tighten drive section and X and Y axis installation bolts if necessary Check for wear and backlash If any abnormality is found contact YAMAHA sales office or dealer Controller Check for loose terminals Check for loose connectors Lubrication of ball screw Apply Alvania No 2 Showa Shell See 3 3 in this chapter nut and linear guides Daphne Eponex No 2 Idemitsu Sekiyu to the ball screw nut and linear guides uonoadsu 21 Coupling Check if the bolts are loose Tighten if necessary See 3 7 in this chapter CAUTION N Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw linear guide and linear bushing shaft 3 2 A Three year inspection Inspect the following points once every three years and contact us if any problem is found Set an earlier inspection interval if parts are subject to long term or frequent usage Ball screw nut sections Check for wear and looseness in the ball screw nut and Contact us if trouble is and linear guides linear guide found 3 3 Applying grease Periodic Inspection
34. t frame 3 Secure the robot to the base with the specified bolts 4 or more bolts and torque The bolts and tightening torque are shown below Robot Type Bot Tightening torque recommended length 15mm 3 0N m to 4 5N m CAUTION Be careful not to damage the shutter when tightening the bolts WARNING SURE TIGHTEN THE BOLT THE TORQUE THE WRONG TORQUE NOT ONLY CAUSE ROBOT POSITION ERRORS BUT ALSO LEAD TO SERIOUS ACCIDENTS 4 Reattach the side covers after installing the robot 2 6 Connections 2 6 Connections 2 6 1 Connecting the robot cables Connect the robot cables to the mating connectors on the controller as shown below Refer to the PRC single axis robot controller user s manual for the controller connectors suornoauuo pue uonyejjejsuj Robot controller PRC Robot cable signal wire gt Robot cable motor wire Li Pico series 5 WARNING BEFORE CONNECTING THE CABLES THAT THERE ARE NO BENDS OR BREAKS IN THE ROBOT CABLE CONNECTOR PINS AND THAT THE CABLES ARE NOT DAMAGED BENT OR BROKEN PINS OR CABLE DAMAGE MAY CAUSE ROBOT MALFUNCTIONS 2 6 2 System Configuration Example System configuration P Tu IC memory card voltage 4 Windows E support software P 2 YPB Win 2 a RS485 conversion adapter Air chuck gripper 27 m
35. th 8 Effective stroke 50 100 150 200 250 300 350 400 450 500 550 600 L 293 343 393 443 493 543 593 643 693 743 793 843 XB A 130 180 230 280 330 380 430 480 530 580 630 680 D 230 230 230 230 230 230 install the robot use M 0 1 2 3 4 5 0 1 2 3 4 5 hex bolts hexagonal N 4 6 8 10 12 14 6 8 10 12 14 16 socket head bolts with Weight kg ee 23 2 4 2 5 2 6 27 2 8 2 9 3 0 3 1 3 2 3 3 a length under head BB cross section of less than 15mm 4 2 Servo motor specifications 4 2 Servo motor specifications 4 2 1 Servo motor termination Connector specifications Servo motor Housing 51030 0930 Japan MOLEX CN1 Contact 50084 8060 Japan MOLEX Housing 51111 0610 Japan MOLEX CN2 Contact Connector wiring Connector Signal name Wire Color Blue 50397 8100 Japan MOLEX value in for model with brake Brown Orange Purple 5 04 2 12 46 Not used Not used Red Black Black Shield Blue Orange Red Yellow Brown Only for model with brake 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 2 3 4 5 White Only for model with brake 4 3 Robot cable 4 3 Robot cable B Signal wires Controller side Motor side Specifications Power wires
36. th continued use In such cases adjust as follows 1 Slightly loosen the two screws securing the endplate side of the shutter Do not remove 2 While pulling on the shutter with your fingers tighten the screws so that there is no looseness See step 6 of 3 4 Replacing the shutter uonoadsuj 21 39 3 6 Replacing the motor 3 6 Replacing the motor 3 6 1 4 1 Remove the screws securing the motor cover and remove the motor cover Periodic Inspection LS 310 3 6 Replacing the motor 5 Remove the bolts M2 6 2 pieces securing the motor and remove the motor 6 Attach a new motor and tighten the bolts to secure the new motor Tightening torque 1 0N m 7 Tighten the bolt to secure the coupling on the motor side Tightening torque 1 0N m 8 Reattach the end cover side covers and motor cover using the reverse procedure Do not overtighten the end cover and motor cover mounting screws Tightening torque should be less than 0 4N m 9 Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter uonoadsuj 4 N CAUTION Do not press down on the shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp 311 u 3 6 Replacing the motor 3 6 2 T5P 1 Remove the screws securing the motor cover and remove the motor cover Periodic Inspection 4 Remove the bolts
37. ubles caused by procedures prohibited in this manual 3 Modifications to the robot and or related product not approved by YAMAHA or YAMAHA sales representatives 4 Use of any other than genuine parts and specified grease and lubricants 5 Incorrect or inadequate maintenance and inspection 6 Repairs by other than authorized dealers YAMAHA MOTOR CO LTD MAKES NO OTHER EXPRESS OR IMPLIED WAR RANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU OF ALL EXPRESSED OR IMPLIED WAR RANTIES INCLUDING WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR WARRANTIES ARISING FROM A COURSE OF DEAL ING OR USAGE OF TRADE YAMAHA MOTOR CO LTD SOLE LIABILITY SHALL BE FOR THE DELIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO LTD SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES WHETHER ARISING FROM CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY YAMAHA MOTOR CO LTD MAKES NO WARRANTY WHATSOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO LTD 2 1 Checking the product After unpacking make sure that all components and accessories are included as speci fied in your order Also check the product for any damage on the exterior which might have occurred during transportation If there are any missing parts or damage due to transportation please notify your YAMAHA sales office or dealer im
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