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FLIP-XC User`s Manual

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1. 6 1 3 AC servo motor termination C6 C10 C14 C14H C17 C17L C20 Connector specifications Servo motor CN1 7 polarities Pin contact BYM 001T P0 6 CN1 CN2 CN3 4 polarities Receptacle 175156 2 CN3 CN2 2 polarities CN4 2 polarities Socket contact BHF 001T 0 8BS CN4 Receptacle housing SMR 07V B Plug housing 176273 1 Receptacle housing SMR 02V B Plug housing SMP 02V BC Round terminal 1 25 M4 6 2 6 1 AC servo motor specifications Connector Wire Color Connection Connector wiring 2 Yellow 54 Blue 1 Red S3 Black R1 White R2 Green Shield Black 1 BK Gray BK Brown Red White Black Round terminal Yellow Green 1 Heat shrinkable tube suo eo oads o 6 3 6 2 Robot cables 6 2 Robot cables 6 2 1 Robot cables C4 C4H C5 C5H To controller lt CN1 Controller CN1 Resolver Drain wire 0 3 black KVC 36SB black white Red Red white Green Green white Yellow Yellow white 0 5sq Red white black suo eo oads Green Yellow Brown 6
2. 2 Inspection to be performed with the controller turned on AX WARNNIG THE ROBOT CONTROLLER MUST BE INSTALLED OUTSIDE THE SAFETY ENCLOSURE TO PREVENT A HAZARDOUS SITUATION IN WHICH YOU OR ANYONE ENTER THE SAFETY ENCLOSURE TO INSPECT THE CONTROLLER WHILE IT IS TURNED ON AX WARNING BODILY INJURY MAY OCCUR FROM COMING INTO CONTACT WITH THE FAN WHILE IT IS ROTATING WHEN REMOVING THE FAN COVER FOR INSPECTION FIRST TURN OFF THE CONTROLLER AND MAKE SURE THE FAN HAS STOPPED After turning on the controller check the following points Checkpoint Procedure Check if the fan rotates normally Check if objects blocking the fan are located and remove if any are found Check for abnormal noise from the rotating fan If abnormal noise is heard visually check and remove the cause If no cause is found contact your YAMAHA sales dealer Check for dust deposits on the fan cover Remove and clean if necessary Cooling fan at rear of controller pue uon gt adsuj IPod 5 5 5 3 Periodic inspection 3 Adjustment and parts replacement 1 After inspection if you notice any adjustment or parts replacement is needed first turn off the controller and then enter the safety enclosure to perform the necessary work After adjustment or replacement is finished again review the checkpoints explained in 1 and 2 above 2 If repair or parts replacement is requi
3. Emergency stop device Press the emergency stop button to check if it works Check for abnormal movement and excessive vibration Robot movement and noise If any abnormal symptom is found contact YAMAHA dealer Check if the brake works to stop vertical use robot from dropping more than 3mm from the stationary point If any abnormal operation is found contact YAMAHA dealer Vertical use robot brake operation 1 1 Visually check the movement when you press the emergency stop button from outside the safety enclosure and also when you turn off the controller 5 2 5 3 Periodic inspection 1 After inspection if you notice any adjustment or parts replacement is needed first 3 Adjustment and parts replacement turn off the controller and then enter the safety enclosure to perform the necessary work After adjustment or replacement is finished again review the checkpoints explained in 1 and 2 above 2 If repair or parts replacement is required for the robot or controller please contact your YAMAHA sales dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself 5 3 2 Three Month inspection Take the following precautions when performing 3 month inspection AX WARNING THE SLIDER OF VERTICAL USE ROBOT WILL SLIDE DOWN WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION DO NOT RELEASE THE BRAKE WHEN LUBRICATING VERTICAL USE ROBOT PARTS
4. When applying grease to the ball screws and linear guide take the following precautions ARNNIG 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 TREATMENT pue uon gt adsuj IPod 5 5 3 5 3 Periodic inspection AX WARNING DISPOSING OF GREASE AND THE CONTAINER PROPER DISPOSAL IS COMPULSORY UNDER FEDERAL STATE AND LOCAL REGULATIONS TAKE APPROPRIATE MEASURES IN COMPLIANCE WITH LEGAL REGULATIONS IN YOUR COUNTRY DO NOT PRESSURIZE THE EMPTY CONTAINER PRESSURIZING MAY CAUSE THE CONTAINER TO RUPTURE
5. 12 Use caution not to touch the controllerl cooling fan WARNING e BODILY INJURY MAY OCCUR FROM COMING INTO CONTACT WITH THE COOLING FAN WHILE IT IS ROTATING WHEN REMOVING THE FAN COVER FOR INSPECTION FIRST TURN OFF THE CONTROLLER AND MAKE SURE THE FAN HAS STOPPED 13 Consult us for corrective action when the robot is damaged or malfunctions occur WARNING IF ANY PART OF THE ROBOT IS DAMAGED OR ANY MALFUNCTION OCCURS CONTINUING THE OPERATION MAY BE VERY DANGEROUS PLEASE CONSULT YOUR YAMAHA SALES OFFICE OR DEALER FOR CORRECTIVE ACTION Damage or Trouble Possible Danger Damage to machine harness or robot cable Electrical shock malfunction of robot Flying outwards of damaged parts Damage to exterior of robot during robot operation Abnormal operation of robot ER Malfunction of robot positioning error excessive vibration etc Z axis brake trouble Dropping of load 14 Protective bonding AX WARNING BE SURE TO GROUND THE ROBOT AND CONTROLLER TO PREVENT ELECTRICAL SHOCK 1 6 15 Be sure to make correct parameter settings 1 2 Essential precautions AN CAUTION The robot must be operated with correct tolerable moment of inertia and acceleration coefficients according to the manipulator tip mass and moment of inertia If these are not correct drive unit service life may end prematurely and damage to robot parts or residual vibration during positio
6. Break case Suction air joint for 6mm dia Suction air joint for 6mm dia Vertical installation model with brake 2 1 2 1 Robot manipulator part names C10 C14 C14H C17 C17L C20 Shutter clamp plate Shutter clamp plate mounting screws 2 pieces Shutter Slider Slider cover suonoun4 Y Shutter clamp plate Motor wire Side cover Side cover mounting bolt Slider cover mounting screws 8 pieces Shutter clamp plate mounting screws 2 pieces Suction air joint for 12mm dia 2 2 Installation 3 1 Robot installation conditions 3 1 Robot installation conditions 3 1 1 Installation environments Be sure to install the robot in the following environments Items Specifications Allowable ambient 0 to 45 C temperature Allowable ambient humidity 35 to 85 RH non condensation Altitude 0 to 1000 meters above sea level Avoid installing near water cutting water oil dust metallic chips and organic solvent Ambient Avoid installation near corrosive gas and corrosive materials environments Avoid installation in atmosphere containing inflammable gas dust or liquid Avoid installation near objects causing electromagnetic interference electrostatic discharge or radio frequency interference uo yejjejsuj 0 Vibration Do not subject to impacts or vibrations Working space Allow sufficie
7. D Position backup counter overflow When using an TS X controller 82 ENCODER ERROR 83 ABS ENCODER ERR 8A ABS BATTERY ERR 8B ABS COUNT ERROR 8D ABS OVERFLOW ERR on CLC 9330u SUIMO OJ Y 0 X d 14 10404 SIXe 9 Su1s JY SuIsn 910199 9330u SUIMO OJ JY 0 ag X dI14 10404 1 3 15 JY Suisn 940199 Setting the origin position Set the origin position while referring to the following section in the robot controller user s manual When using an SR1 controller See 9 1 1 Return to origin by the search method in Chapter 9 of the HPB Operation Guide section When using an RCX240 controller See 11 9 Absolute reset in Chapter 4 When using an RCX222 controller See 11 8 Absolute reset in Chapter 4 When using an TS X controller See 6 2 Origin search return to origin in 6 Operating the robot of the HT1 Operation Guide section CAUTION Changing the origin position to the opposite side of the initial position may cause a position shift or robot breakdowns so use caution Avoid changing the origin detection method since it is dangerous in some cases If the origin position must be changed please consult our sales office or dealer General Contents Introduction U9 U07 P19UIN Chapter 1 Using the Robot Safely 1 1 Safety information 1 2 Essential precautions 1 1 1 3 1 3 Industrial robot operati
8. END EFFECTOR MAY FLY OFF OR DROP THEN PROVIDE APPROPRIATE SAFETY PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE WEIGHT TEMPERATURE AND CHEMICAL PROPERTIES 9 Use caution when removing the motor Vertical use robots WARNING THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE MOTOR IS RELEASED CAUSING A HAZARDOUS SITUATION e TURN OFF THE ROBOT CONTROLLER AND PROP UP THE VERTICAL AXIS WITH A SUPPORT STAND BEFORE REMOVING THE MOTOR e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS PARTS AND INSTALLATION BASE 1 5 1 2 Essential precautions 10 Be careful not to touch the motor or speed reduction gear casing when hot AX WARNING The motor and speed reduction gear casing are extremely hot after automatic operation so burns may occur if these are touched Before handling these parts during inspection or servicing turn off the controller wait for a while and check that the parts have cooled 11 Take the following safety precautions during inspection of controller A 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 oqoy ay 80 18
9. Robot type appears on the screen BAX 5 575 1 2 SYS PRM AXIS PRM100 4150 robot type read only 3 13 3 6 Setting the operating conditions uo yejjejsuj 4 Display PRM112 payload SYS PRM AXI S Press the a D keys to scroll up or ARPA E pel aa payload down the parameter list and select the range 0 gt MAX parameter you want to set 5 Set the parameter SYS PRM AXIS Enter the parameter value with the PRM112 10 Kg number keys and press payload range 0 gt MAX The parameter setting range is shown on the bottom line of the screen When setting is complete the cursor moves back to the beginning of the parameter data 3 6 2 Maximum speed setting In operation of a single axis robot with a long stroke ball screw resonance of the ball screw may occur In this case the maximum speed must be reduced to an appropriate level The maximum speed can be reduced by lowering the SPEED setting in automatic operation or by programming Use the desired method that matches your application If the maximum speed does not reach a hazardous level reducing the speed is unnecessary even when a robot has a long stroke axis CAUTION Do not operate the robot if the ball screw is vibrating The ball screw may otherwise wear out prematurely 7 NOTE For the maximum speed setting for stroke length refer to the specifications and outline dimension drawings shown in our rob
10. WRONG TORQUE MAY NOT ONLY CAUSE ROBOT POSITION ERRORS BUT ALSO LEAD TO SERIOUS ACCIDENTS DO NOT USE A BOLT LONGER THAN THE SPECIFIED LENGTH A BOLT THAT IS TOO LONG WILL PENETRATE INSIDE THE ROBOT FRAME AND CAUSE OPERATING DEFECTS OR MALFUNCTION 3 7 3 2 Installation uo yejjejsuj 3 8 M NOTE 7 For the dimensions and positions of holes and threading in the robot installation base refer to the outline dimension drawings shown in our robot catalog or our website www yamaha motor co jp global industrial robot index html Installing the C10 C14 C14H C17 C17L and C20 C14 C14H M6 bolt C17 C17L C20 M8 bolt AN CAUTION The robot frame is made of aluminum so be careful not to damage the screw threads when tightening the bolt 3 3 Protective bonding 3 3 Protective bonding AX WARNING ALWAYS GROUND THE ROBOT AND CONTROLLER UNIT TO PREVENT ELECTRICAL SHOCK Always use the ground terminal M4 screw on the side of the robot unit to make ground connection AN CAUTION e A secure ground connection less than 100Q resistance to ground is recommended e Use electrical wire thicker than AWG14 2mm as the ground wire WARNING ALWAYS TURN OFF THE POWER TO THE CONTROLLER BEFORE MAKING THE GROUND CONNECTION uo yejjejsuj 0 Provide a terminal with the PE marking as the protective conductor for the entire system and connect it to an external pro
11. 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 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 box Handy Terminal 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 manipulator while within the safety enclosure 1 8 Automatic operation Automatic operation described here includes all operations in AUTO mode 1 8 Automatic operation 1 Check the following before starting automatic operation 1 No one is within the safety enclosure 2 The programming box Handy Terminal and tools are in their specified locations 3 The alarm or error lamps on the robot and peripheral equipment do not flash 4 Th
12. found Check for abnormal noise from the rotating fan If abnormal noise is heard visually check and remove the cause If no cause is found contact your YAMAHA sales dealer Check for dust deposits on the fan cover Remove and clean if necessary Adjustment and parts replacement 1 After inspection if you notice any adjustment or parts replacement is needed first turn off the controller and then enter the safety enclosure to perform the necessary work After adjustment or replacement is finished again review the checkpoints explained in 1 and 2 above 5 4 Applying grease 2 If repair or parts replacement is required for the robot or controller please contact your YAMAHA sales dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself 5 4 Applying grease When applying grease according to periodic inspection follow the procedure described in this section Before beginning work carefully read the precautions below and also in Chapter 1 Using the Robot Safely 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 OPERATOR CAN PRESS THE EMERGENCY STOP BUTTON IF ANY DANGER OCCURS AA WARNING WHEN THE ROBOT DOES NOT NEED TO BE
13. given by b pabcx center line lt gt 129 9 _ 5 0 Wx 2 25 2 SS W Weight of prism m Mass of prism kg J 8 3 Duty To achieve maximum service life for the YAMAHA single axis robots the robot must be operated within the allowable duty 50 The duty is calculated as follows Operation time Operation time oT 100 Operation time Non operation time Duty If the robot duty is high an error such as overload or overheat occurs In this case increase the stop time to reduce the duty 8 3 Revision record Manual version Issue date Description Ver 2 00 Apr 2008 Addition of the description regarding C4H C5H C10 C17L Clerical error corrections etc Some explanations were corrected or added in Chapter 1 Using the Robot Safely Ver 2 03 Jun 2011 The description regarding Warranty was changed Clerical error corrections User s Manual YAMAHA FLIP XC Single axis Robot Jun 2011 Ver 2 03 This manual is based on Ver 2 03 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 o
14. in 5 4 2 Replenishing grease C10 C14 C14H C17 C17L C20 in this chapter to replace the shutter of the C10 C14 C14H C17 C17L 5 or C20 pue uon gt adsuj 5 19 MEMO 5 20 Specifications 6 1 AC servo motor specifications 6 1 servo motor specifications 6 1 1 AC servo motor termination C4 C4H C5 C5H Connector specifications Servo motor CN1 9 polarities Pin contact BYM 001T P0 6 CN1 CN2 4 polarities Receptacle 5556T CN2 Receptacle housing SMR 09V B Receptacle housing 5557 04R Connector wiring Connector Wire Color S2 Yellow S4 Blue 1 Red S3 Black Ri White R2 Green JP1 Red JP2 Red _ Shield Black 1 suo eo oads o _ U Red V White W Black Green Yellow 1 Heat shrinkable tube cn JE 6 1 suo eo oads 6 1 AC servo motor specifications 6 1 2 Brake cable specifications C4 C4H C5 C5H Connector specifications Brake parts Receptacle housing SMR 02V B Pin contact BYM 001T P0 6 Connector wiring 1 1 Yellow black 2 Yellow black LR Nur
15. with the robot as FLIP X series ge a standard unit The programming box HPB is optional 3 11 3 5 Suction hoses connection 3 5 Suction hoses connection The FLIP X Type C series robots are designed to connect to an air unit that suctions air inside the robot to maintain cleanliness When using the robot in a clean room adjust the suction air to the specified flow rate For the suction hose attachment position on each robot refer to 2 1 Robot manipulator part names in Chapter 2 Functions Suction hose Model No Hose diameter Number of hoses Suction rate N2 min C4 C4 with brake C4H C4H with brake C5 C5 with brake C5H C5H with brake C6 C6 with brake C10 C10 with brake C14 30 to 90 C14 with brake 30 to 90 C14H 30 to 90 C14H with brake 30 to 90 C17 30 to 90 C17 with brake 30 to 90 C17L 30 to 90 C17L with brake 30 to 90 C20 30 to 90 C20 with brake 30 to 90 o 20 to 30 20 to 30 20 to 30 20 to 30 20 to 30 20 to 30 5 oO 20 to 30 20 to 30 O O O 20 to 30 20 to 30 INIO NN 30 to 90 30 to 90 i NOTE On the C4 C4H C5 C5H and C6 arrange the air hoses so that the total suction rate will be 20 to 30 N2 min or more AN CAUTON Avoid excessive bends in the air hoses Lay out the
16. 16 5 5 Replacing the shutter 5 19 Chapter 6 Specifications 6 1 servo motor specifications 6 1 6 1 1 AC servo motor termination C4 C4H C5 C5H 6 1 6 1 2 Brake cable specifications C4 C4H C5 C5H C6 6 2 6 1 3 servo motor termination C6 C14 C14H C17 C17L C20 6 2 6 2 Robot cables 6 4 6 2 1 Robot cables C4 C4H C5 C5H 6 4 6 2 2 Robot cables C C10 C14 C 14H C17 C17L C20 6 5 Chapter 7 Troubleshooting 7 1 Positioning error 7 1 7 2 Feedback error 7 2 Chapter 8 Appendix 8 1 About machine reference 8 1 8 2 Equation of moment of inertia calculation 8 2 8 3 Duty 8 3 5 09 249499 MEMO Introduction The YAMAHA FLIP X series is a family of single axis industrial robots that use the absolute positioning method as a standard feature to improve ease of use resistance to environmental conditions and maintenance work A wide varaiety of product lineup allows you to select the desired robot model that best matches your application This user s manual describes the safety measures handling adjustment and maintenance of FLIP X series robots for correct safe and effective use Be sure to read this manual carefully before installing the robot Even after you have read this manual keep it in a safe and convenient place for future reference e This user s manual should be used with the robot and considered an integral part of it When the robot is moved transferred or
17. 4 6 2 Robot cables 6 2 2 Robot cables 6 C10 C14 C14H C17 C17L C20 O Signal cable To controller To robot A pe P un J FI ld A E gt a m pe u ORG u Controller CN1 Resolver 0 3sq Blue SPMCU 14K Orange Green Brown Grey Red Clear Shield Black Yellow Pink White suo eo oads o Blue Red O Power cable To controller To robot Connection Yellow Green 0 7559 Red 0 7559 White 0 75sq Motor wire oe 0 75sq MEMO 6 6 Troubleshooting 7 1 Positioning error 7 1 Positioning error Position deviates The position deviates after Robot bumped into something Operation was correct o moving the robot or set up or there are traces of bumping but position deviates 5 of workpiece tool into rubbing against something ga Is cable broken Are cables correctly wired Are connectors correctly fitted Replace the cable 1 Check tool and workpiece for warping 2 Check robot alignment Check wiring and connectors Are the robot tools and workp
18. CONTACT WITH SKIN e 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 TREATMENT 5 4 1 Replenishing grease C4 C4H C5 C5H C6 1 Prepare the required tools and grease Phillips head screwdriver Hex wrench set Recommended grease NSK LG 2 2 Turn off the controller 92ueugjurew pue uon gt adsuj IPod o 3 Place a sign indicating that the robot is being inspected to keep others from operating the controller switch 4 Enter the safety enclosure 5 10 5 4 Applying grease 5 Detach the tool gripper etc on the slider remove the screws securing the slider cover and take off the slider cover NET Removing the slider cover 6 Remove the screws securing the shutter clamp plates at both ends Motor side Stroke end side 7 Press on the shutter with fingers to get some slack in the slider While gripping the slack part of the shutter
19. DO NOT ATTEMPT TO WELD HEAT UP DRILL HOLES OR CUT THIS CONTAINER THIS MIGHT CAUSE THE CONTAINER TO EXPLODE AND THE REMAINING MATERIALS INSIDE IT TO IGNITE CAUTION Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw linear guide and linear bushing shaft 1 Inspection to be performed with the controller turned off 1 Turn off the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller switch 3 Enter the safety enclosure and check the following points Checkpoint Procedure Robot manipulator bolts and screws only main externally exposed bolts and screws Check for looseness and tighten securely if necessary 1 Check for loose terminals and connectors on the controller panel Clean if dust deposits and debris are found Apply Grease lubrication of ball grease after cleaning Screw linear guide and Apply grease if the checked parts are dry or grease is ball bushing insufficient On clean room models use LG 2 grease NSK Check for looseness or slack Adjust if necessary See 4 3 Adjusting shutter looseness in Chapter 4 Controller Shutter pue uon gt adsuj IPod 5 4 5 3 Periodic inspection Tightening torque Tightening torque kgf cm 1 Bolt tightening torque Bolt size M3 button head bolt M3 M4 M5 M6 M8
20. OPERATED DURING ADJUSTMENT OR MAINTENANCE ALWAYS TURN OFF THE CONTROLLER AND THE EXTERNAL SWITCH BOARD DO NOT TOUCH INTERNAL PARTS OF THE CONTROLLER FOR 10 MINUTES AFTER THE CONTROLLER HAS BEEN TURNED OFF 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 SPECIFICATIONS OR THREATEN OPERATOR SAFETY WHEN ADJUSTMENT OR MAINTENANCE IS COMPLETE RETIGHTEN THE BOLTS AND SCREWS SECURELY DURING ROBOT ADJUSTMENT OR MAINTENANCE PLACE A SIGN INDICATING THAT THE ROBOT IS BEING ADJUSTED OR SERVICED TO PREVENT OTHERS FROM TOUCHING THE CONTROL KEYS OR SWITCHES PROVIDE A LOCK ON THE SWITCH KEYS OR ASK SOMEONE TO KEEP WATCH AS NEEDED pue uon gt adsuj IPod 5 5 9 5 4 Applying grease When applying grease to the ball screws and linear guide take the following precautions 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 e INFLAMMATION MAY OCCUR IF THE GREASE COMES INTO CONTACT WITH SKIN BE SURE TO WEAR PROTECTIVE GLOVES TO PREVENT
21. THE ROBOT THE CABLES MAY BE DAMAGED CAUSING MALFUNCTION AND HAZARDOUS SITUATIONS WARNING LAY OUT THE ROBOT CABLES SO AS TO KEEP THE OPERATOR OR ANY OTHER PERSON FROM TRIPPING ON THEM BODILY INJURY MAY RESULT IF SOMEONE TRIPS ON THE CABLES 3 10 3 4 Robot cable connection For wiring of each cable refer to 6 1 AC servo motor specifications and 6 2 Robot cables in Chapter 6 O Robot cable connections SRI X YAMAHA Robot cable power cable MO connector Motor wire Robot cable signal cable Pa connector Origin sensor wire only robots with origin sensor E N BK connector Brake wire only robots with brake Resolver signal wire making connections fasten the hoods securely Single axis robot FLIP X series uo yejjejsuj System Configurations RS 232C Robot controller SR1 communication control SRI X d RS 232C or 75 communication control SD Resolver signal communication cable ioe Motor power option Programming box HPB option Input 16 general purpose pins 7 custom purpose pins Output 16 general purpose pins POPCOM 3 custom purpose pins communication software Power supply AC100 115 200 230V control 24V power supply built in c o o gt Single axis robot WI The controller is supplied
22. UCE VOMITING BUT PROMPTLY CONSULT A PHYSICIAN FOR PROPER TREATMENT pue uon gt adsuj o 5 6 5 3 Periodic inspection Ak WARNING DISPOSING OF GREASE AND THE CONTAINER PROPER DISPOSAL IS COMPULSORY UNDER FEDERAL STATE AND LOCAL REGULATIONS TAKE APPROPRIATE MEASURES IN COMPLIANCE WITH LEGAL REGULATIONS IN YOUR COUNTRY DO NOT PRESSURIZE THE EMPTY CONTAINER PRESSURIZING MAY CAUSE THE CONTAINER TO RUPTURE DO NOT ATTEMPT TO WELD HEAT UP DRILL HOLES OR CUT THIS CONTAINER THIS MIGHT CAUSE THE CONTAINER TO EXPLODE AND THE REMAINING MATERIALS INSIDE IT TO IGNITE CAUTION Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw linear guide and linear bushing shaft 1 Inspection to be performed with the controller turned off 1 Turn off the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller switch 3 Enter the safety enclosure and check the following points Checkpoint Procedure Robot manipulator bolts and screws only main Check for looseness and tighten externally exposed bolts securely if necessary 1 and screws Check for backlash in the ball screw and linear guide Tighten securely if necessary Check for vibration during operation Tighten the drive parts and axis installation bolts securely if necessary Check for wear and backlash Che
23. Y EQUIPMENT SUCH AS A FORKLIFT THAT REQUIRES A LICENSE ONLY PROPERLY QUALIFIED PERSONNEL MAY OPERATE SUCH EQUIPMENT THE EQUIPMENT AND TOOLS USED FOR MOVING THE ROBOT SHOULD BE SERVICED DAILY AN CAUTION When moving or carrying the robot by hand avoid placing the hand and fingers on the shutter of the robot Pressing down on the shutter even by a little force may cause the shutter to warp or deform resulting in a premature life end of the related parts 3 2 Installation 3 2 3 Installing the robot Securely fix the robot with hex socket head bolts AA WARNING BE SURE TO INSTALL THE ROBOT WITH THE SPECIFIED NUMBER OF BOLTS AND TIGHTENING TORQUE IF NOT THE ROBOT MAY FALL OVER DURING OPERATION RESULTING IN SERIOUS ACCIDENTS 3 2 3 1 Installing the C4 C4H C5 C5H and C6 C4 C4H Drill holes through the installation base and secure the robot to the base with M4 bolts from the bottom C5 C5H C6 Drill holes through the installation base and secure the robot to he base with M5 bolts from the bottom A WARNING ALWAYS TURN OFF THE POWER TO THE CONTROLLER BEFORE INSTALLING THE ROBOT SERIOUS ACCIDENTS MIGHT OCCUR IF THE ROBOT STARTS TO OPERATE DURING INSTALLATION uo yejjejsuj 0 O Installation method Drill holes through the installation base where the robot is to be secured Then secure the robot with the specified bolts from the underside of the installation base The bolt and tightening torque are shown bel
24. YAMAHA YAMAHA MOTOR CO LTD YAMAHA SINGLE AXIS ROBOT FLIP X series FLIP XC User s Manual STE YAMAHA MOTOR CO LTD IM Operations 882 Soude Naka ku Hamamatsu Shizuoka 435 0054 Japan URL http www yamaha motor jp robot index html E27 Ver 2 03 Before using the single axis robot FLIP X series Be sure to read the following notes Thanks for your purchasing YAMAHA single axis robot FLIP X series Before using this robot read the following notes and set the origin position The X series single axis and XY robots use absolute position detectors that do not require return to origin after turning on the controller power However when the controller power is turned on in the following cases return to origin must be performed just the very first time 1 When robot cable was first connected after delivery from YAMAHA 2 When robot cable was disconnected from the controller and then reconnected 3 When no absolute battery is connected 4 When a motor or cable was replaced At this point any of the following errors is issued immediately after controller power is turned on but this is not a malfunction The controller will operate normally by restarting When using an SR1 controller 15 FEEDBACK ERROR 2 23 ABS BAT L VOLTAGE 24 ABS DATA ERROR etc When using an RCX240 RCX222 controller 17 81 D ABS battery wire breakage 17 92 D Resolver disconnected during power off 17 93
25. adsuj IPod 5 15 5 4 Applying grease 5 4 2 Replenishing grease C10 C14 C14H C17 C17H C20 1 Prepare the required tools and grease ePhillips head screwdriver eGrease gun Recommended grease NSK LG 2 2 Turn off the controller 3 Place a sign indicating that the robot is being inspected to keep others from operating the controller switch 4 Enter the safety enclosure 5 Detach the tool gripper etc on the slider remove the screws securing the slider cover and take off the slider cover AN CAUTION The slider cover is fastened to the slider with the four screws at the inner positions on the slider Do not loosen and remove the screws at the outer positions on the slider 1 be Removing the slider cover 6 Remove the screws securing the shutter clamp plates at both ends pue uon gt adsuj IPod 5 16 5 4 Applying grease 7 Wipe away the old grease with a clean cloth Next use a grease gun to supply grease into the grease nipple for the linear guide Also apply grease by hand to the thread valley of the ball screw Then move the slider back and forth to spread the grease Finally remove excess grease with a clean cloth Applying grease to the linear guide Applying grease to the ball screw When a vertical installation model is used go outside the safety enclosure once check that no one is inside the safety enclosure and turn on t
26. air hoses to keep the hose length to the air unit as short as possible Too long of a hose may prevent obtaining the specified suction flow rate 3 12 3 6 Setting the operating conditions 3 6 Setting the operating conditions 3 6 1 Payload Optimal acceleration for the YAMAHA FLIP X Type C series robots is automatically determined by setting the controller payload parameters Set the total weight of the workpiece and the end effectors such as grippers attached to the robot slider in the payload parameter as shown below AN CAUTION Be sure to enter an accurate value when making this setting since a mistake will cause troubles such as vibration or a shorter machine service life span O To set the payload parameter Use the following method when setting the payload parameter on a single axis robot controller SR1 When setting this parameter on other controllers RCX142 RCX222 refer to their controller user s manuals uo yejjejsuj 0 1 Press F3 SYS on the initial menu MENU screen select menu The SYS system mode screen MEDI TMOPRTRSYS appears H 2 Press 1 PRM to enter the SYS parameter setting mode 13 B El mu The SYS PRM mode screen appears PP Me RM Bs uPMINITBnext 3 Select the parameter group SYS PRM Press Ft AXIS to select the axis select menu parameter The current setting for PRM100
27. ck for looseness at the terminals Check for looseness at the connectors Grease lubrication of Apply LG 2 grease to the ball screw ball screw nut and nut section and linear guide every 6 linear guide months If equipment problems cannot be resolved or wear and backlash are found contact your YAMAHA sales dealer Ball screw linear guide Controller pue uon gt adsuj IPod 5 5 7 5 3 Periodic inspection 2 pue uon gt adsuj IPod o 3 5 8 1 Bolt tightening torque Bolt size M3 button head bolt Tightening torque Tightening torque kgf cm M4 M5 M6 M8 Inspection to be performed with the controller turned on Ak WARNING THE ROBOT CONTROLLER MUST BE INSTALLED OUTSIDE THE SAFETY ENCLOSURE TO PREVENT A HAZARDOUS SITUATION IN WHICH YOU OR ANYONE ENTER THE SAFETY ENCLOSURE TO INSPECT THE CONTROLLER WHILE IT 1 TURNED ON AX WARNING BODILY INJURY MAY OCCUR FROM COMING INTO CONTACT WITH THE FAN WHILE IT 1 ROTATING WHEN REMOVING THE FAN COVER FOR INSPECTION FIRST TURN OFF THE CONTROLLER AND MAKE SURE THE FAN HAS STOPPED After turning on the controller check the following points Checkpoint Procedure Cooling fan at rear of controller Check if the fan rotates normally Check if objects blocking the fan are located and remove if any are
28. closure 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 15 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 15 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 1 11 1 7 Work within the safety enclosure 3 Ajayes oqoy ay 80 8 After the controller is turned on check the following points from outside the safety enclosure 1 Does the robot start and stop as intended the operation mode be selected correctly 2 Does each axis move as intended within the soft limits 3 Does the end effector move as intended 4 Are the signal transmissions to the end effector and peripheral equipment correct Does emergency stop work Are the teaching and playback functions normal Are the safety enclosure and interlock working as intended N O Does the robot move correctly during automatic operation 1 7 Work within the safety enclosure 1 2 1 12
29. cluding 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 1 Show a display on the operator panel 2 Ensure the safety of workers performing tasks within the robot movement range 3 Clearly specify position and posture during work Position and posture where worker can constantly check robot movements and immediately move to avoid trouble if an error problem occurs 4 Install noise prevention measures 5 Use methods for signaling operators of related equipment 6 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 manufacture s technicians and workplace safety consultants etc 1 3 Industrial robot operating and maintenance personnel 26 Display a sign on operation panel during work Display an easy to understand sign or message on the programming box Handy Terminal and operation panel during the job task to prevent anyone other than the operators for that job task from mistakenly operating a start or selector switch If needed take other measur
30. count the robot weight including the end effector gripper and workpiece CAUTION the installation base is not sufficiently rigid and stable vibration resonance may occur during operation causing adverse effects on the robot work 2 The installation base surface must be machined within a flatness of 0 05mm 500mm AN CAUTION The robot positioning accuracy might decrease if the installation surface precision is insufficient uo yejjejsuj 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 or installing the robot closer to one end as shown at the lower right Robot installation example Installation base Good example Bad example Installation base gt CAUTION Using less than the specified number of bolts to install the robot may cause vibration and poor positioning accuracy 3 2 3 2 Installation m NOTE For the dimensions and positions of holes and threading in the robot installation base refer to the outline dimension drawings shown in our robot catalog or our website www yamaha motor co jp global industrial robot index html 3 2 Installation 3 2 1 Checking the product After unpacking make sure that all components and accessories are included as specified in your order Also check the product fo
31. e safety enclosure is securely installed with safety interlocks actuated 2 Observe the following during automatic operation or in cases where an error occurs 1 After automatic operation has started check the operation status and signal light to ensure that the robot is in automatic operation 2 Never enter the safety enclosure during automatic operation Ajayes oqoy ay Suis A 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 Warranty For information on the product warranty please contact your local agent where you purchased your product 1 13 MEMO 1 14 2 1 Robot manipulator part names 2 1 Robot manipulator part names C4 C4H C5 C5H C6 Shutter clamp plate Shutter clamp plate mounting screws 2 pieces Motor case Slider Slider cover Slider cover mounting screws 4 pieces suonoun4 N Shutter clamp plate Shutter clamp plate Suction air joint i mounting screws 2 pieces for 6mm dia Side cover Side cover mounting screw Suction air joint for 6mm dia Standard model Motor case
32. erform return to origin each time the robot controller is turned on and readjust the machine reference value If for some reason the machine reference adjustment becomes necessary please contact YAMAHA sales office or dealer Machine reference Origin signa Origin detection signal Machine reference Machine reference E Origin dog detection Stroke end detection ion x Zero signal Pulse 1 4th of one turn of motor Machine reference value display examples OPRT ORG SEARCH OPRT ORG SEARCH origin complete origin complete machine ref X 50 machine ref 50 Y 50 SR1 DRCX Two FLIP X control gt ABS 50 MG SOHOJ Machine reference 1 32 M2 M4 40 RCX142 Multiple FLIP X control 8 1 8 2 Equation of moment of inertia calculation 8 2 Equation of moment of inertia calculation CAUTION he robot must be operated with correct tolerable moment of inertia and acceleration coefficients according to the manipulator tip mass and moment of inertia If this is not observed premature end to the life of the drive units damage to the robot parts or residual vibration during positioning may result Usually the axis load is not a simple form and the calculation of the moment of inertia xipuadd y 2 is not easy As a method the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated The total of the
33. es such as locking the cover on the operation panel 27 Make daily and periodic inspections 1 Always make sure that daily and periodic inspections are performed and make a pre work check to ensure there are no problems with the robot or related equipment If a problem or abnormality is found then promptly repair it or take other measures as necessary 2 When you make periodic inspections or repairs make a record and store it for at least 3 years Ajayes oqoy ay Suis A 1 3 Industrial robot operating and maintenance personnel Operators or persons who handle the robot such as for teaching programming movement check inspection adjustment and repair must receive appropriate training and also have the skills needed to perform the job correctly and safely They must read the user s manual carefully to understand its contents before attempting the robot operation 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 1 9 1 4 Robot safety functions 1 4 Robot safety functions D 2 3 Ajayes 10q03 ay 80 8 Overload detection This function detects an overload applied to the motor and shuts off the servo power Overheat detection This detects an abnormal temperature rise in the controller driver and sh
34. he controller Then slowly move the slider back and forth a few times in MANUAL mode to spread the grease Next turn off the controller again and re enter the safety enclosure to continue the job 8 Place the shutter rubber plates and shutter clamp plates in order on the robot body and lightly tighten the screws do not tighten securel y No m NOTE Place the shutter on the robot body so that it is clamped in the center of long holes at both ends of the shutter pue uon gt adsuj IPod Shutter clamp position 9 Reattach the slider cover and lightly fasten with the screws 5 17 5 4 Applying grease 10 While moving the slider back and forth by hand a few times check that the shutter does not slacken or jerk to the right or left If slack or sway occurs in the shutter loosen the screws securing the shutter clamp plate on the side where the shutter 15 loose While pulling pressing down on both ends of the shutter with your fingers tighten the two screws to secure the shutter clamp plate p gt p Instralling the shutter Noll NOTE When securing the shutter clamp plate tighten equally on left and right a little at a time Avoid excessive tightening as this may cause the shutter to slacken or warp When a vertical installation model is used go outside the safety enclosure once check that no one is inside the safety enclosure and turn on the contr
35. ial precautions 5 Do not use the robot in environments containing inflammable gas etc WARNING THIS ROBOT WAS 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 6 Do not use the robot in locations possibly subject to electromagnetic interference etc AX WARNING AVOID USING THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC INTERFERENCE ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE MALFUNCTIONS MIGHT OTHERWISE OCCUR Ajayes Jogoy ay Suis A 7 Use caution when releasing the brake of a vertical use robot WARNING THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION e PRESS THE EMERGENCY STOP BUTTON AND PROP UP THE VERTICAL AXIS WITH A SUPPORT STAND BEFORE RELEASING THE BRAKE e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACH 8 Provide safety measures for end effector gripper etc WARNING e 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
36. iece correctly installed Check installation method Check for looseness of robot mechanical parts Does the position return after return to origin operation Mechanical cause Yes 1 Check for looseness of mechanical parts Retighten Electrical cause if necessary 2 Replace mechanical parts Is there a large source of noise nearby Take measures against noise Check or replace the motor cable and controller 7 1 7 2 Feedback error 7 2 Feedback error Feedback error Much mechanical friction No Any foreign matter N E inside Adjust mechanical alignment Is brake installed Is there electrical N eS Rd Repair Is brake sound heard when turning power Turn power off and check for friction by moving manually Is 24V supplied to Ne Replace power supply unit or repair defective parts ENT Replace motor with brake duum Initialize parameters Are parameters for ontroller and robot OK Yes Yes Is there electrical Are wiring and connector No Securely connect wiring and connector No Yes When feedback error is occurring perform Are connector pins continuity check securely inserted 1 Check motor power supply lines U V and W No Ves 2 Check encoder signal lines for phases A and B Securely insert pins or repair defec
37. ler 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 box or by a command in the program when the controller is on 1 5 Safety measures for the system WARNING THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION e PRESS THE EMERGENCY STOP BUTTON AND PROP UP THE VERTICAL AXIS WITH A SUPPORT STAND BEFORE RELEASING THE BRAKE BE CAREFUL 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 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 Ajayes oqoy ay 80 8 A itself Accordingly appropriate safety measures must be taken on the part of the system manufacturer according to the individual system The system manufacturer should provide a proper instruction manual for safe correct operation and servicing of the system 1 6 Trial operation After making installations adjustments inspections or maintenance or repairs to the robot make a trial run using the following procedures 1 Ifa safety enclosure has not yet been provided right after installation of the robot rope off or chain off around the movement area of the manipulator in place of the safety en
38. lider to one end and lightly insert the shutter between the roller and the robot body Then push gently on the slider to pass the shutter through it NS m NOTE Pass the shutter through the slider so it fits in the center of the robot body Do not push on the shutter with excessive force as this may deform or damage the shutter IM Inserting the shutter Pushing the slider to pass the shutter through it When a vertical installation model is used the slider won t move by hand so rotate the roller with your fingers to pass the shutter through the slider pue uon gt adsuj 5 14 Pass the shutter through the other end of the slider in the same way 5 13 5 4 Applying grease 15 Reattach the shutter clamp plates removed in step 6 and finger tighten the screws do not tighten securely On the stroke end side of the C5 and C6 place the spacer plate between the shutter and the shutter clamp plate Plate Spacer plate C5 C6 only 16 Move the slider back and forth by hand a few times so that the shutter fits in the center of the robot body 17 Move the slider to one end and while pressing down on the shutter in the center of the slider tighten the shutter clamp plate screws alternately a little at a time N IZ m NOTE When securing the shutter clamp plate tighten equally on left and right a little at a time Avoid excessive tightening as this may cause the shutter t
39. mbols and signal words used in this manual are classified as explained below Make sure that you fully understand the meaning of each symbol and comply with the instructions 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 AX WARNING FAILURE TO FOLLOW WARNING INSTRUCTIONS COULD RESULT IN SEVERE INJURY OR DEATH TO THE ROBOT OPERATOR BYSTANDERS OR PERSONS INSPECTING OR REPAIRING THE ROBOT ga gt A p UN za lt CAUTION 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 NOTE Explains the key point in the operation in a simple and clear manner 1 1 1 1 Safety information Refer to the user s manual by any of the following methods to operate or adjust the robot safely and correctly c 2 ga p gt A UN 2 2 lt 1 2 1 Operate or adjust the robot while referring to the printed version of the user s manual available for an additional fee 2 Operate or adjust the robot while viewing the CD ROM version of the user s manual on your computer screen 3 Operate or adjust the robot while referring to a printout of the necessary pages from the CD ROM version of the user s manual It i
40. merely stopped or is in emergency error stop 1 7 1 2 Essential precautions c 2 ga ma gt A UN D o lt 1 8 22 23 24 25 Clean work tools etc Work tools such as welding guns and paint nozzles which are mounted in the robot arm will preferably be cleaned automatically Provide adequate lighting Make sure to provide enough lighting to ensure safety during work Prevent the gripped object from flying outwards If the object or workpiece gripped by the robot might fly outward or drop and create a hazard to the operator then protective equipment should be installed by taking the size weight temperature and chemical properties of the object into account Draw up work instructions and makes sure the operator learns them well Decide on work instructions for the following items in cases where personnel must work within the robot movement range to perform teaching maintenance or inspection Make sure the workers know these work instructions well 1 Robot operating procedures needed for tasks such as startup procedures and handling switches 2 Robot speeds used during tasks such as teaching 3 Methods for workers to signal each other when two or more workers perform tasks 4 Steps that the worker should take when a problem or emergency occurs 5 Steps to take after the robot has come to a stop when the emergency stop device was triggered in
41. missions If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives
42. moment of inertia for these factors is then obtained The objects and equations often used for the calculation of the moment of inertia are shown below 1 Moment of inertia for cylinder The moment of inertia J for a cylinder having a rotation center such as shown below is given by 4 2 qa POT kgf cm sec 329 89 3 kgm a kg p Density kg cm Gravitational acceleration cm sec W Weight of cylinder kgf m Mass of cylinder kg 2 Moment of inertia for rectangular parallelepiped The moment of inertia J for a rectangular parallelopiped having a rotation center as shown below is given by y _ b _W a b kgf cm sec 12g 12g m a b ge TOU kom T kgm Density kg cm Gravitational acceleration cm sec C Weight of prism kgf wb gt Mass of prism kg oo 8 2 8 3 Duty 3 When the object s center line is offset from the rotation center The moment of inertia when the center of the cylinder is offset by a distance from the rotation center as shown below is given by ja pxD h 0 hx center line 329 49 rotation WD We center kgf cm sec gg sA A 2 mx Weight of cylinder kgf Mass of cylinder kg Density kg cm D Gravitational acceleration cm sec X i In the same manner the moment of inertia J of a prism as shown below is
43. ng and maintenance personnel 1 9 1 4 Robot safety functions 1 5 Safety measures for the system 1 6 Trial operation 1 7 Work within the safety enclosure 1 8 Automatic operation 1 9 Warranty Chapter 2 Functions 2 1 Robot manipulator part names Chapter 3 Installation 3 1 Robot installation conditions 3 1 1 Installation environments 3 1 2 Installation base 3 2 Installation 3 2 1 Checking the product 3 2 2 Moving the robot 3 2 3 Installing the robot 3 2 3 1 Installing the C4 C4H C5 C5H and 3 2 3 2 Installing the C10 C14 C14H C17 C17L and C20 3 3 Protective bonding 3 4 Robot cable connection 3 5 Suction hoses connection 1 10 1 13 2 1 3 3 3 3 10 3 12 S U9JUO 3 6 Setting the operating conditions 3 13 3 6 1 Payload 3 13 3 6 2 Maximum speed setting 3 14 3 6 3 Duty 3 14 Chapter 4 Adjusting the Robot 4 1 Overview 4 1 4 2 Safety precautions 4 1 4 3 Adjusting shutter looseness 4 2 4 3 1 Adjusting the shutter looseness C4 C4H C5 C5H 4 2 4 3 2 Adjusting the shutter looseness C10 C14 C14H C17 C17L C20 4 3 Chapter 5 Periodic Inspection and Maintenance 5 1 Before beginning work 5 1 5 2 Precautions 5 1 5 3 Periodic inspection 5 2 5 3 1 Daily inspection 5 2 5 3 2 Three Month inspection 5 3 5 3 3 Six Month inspection 5 6 5 4 Applying grease 5 9 5 4 1 Replenishing grease C4 C4H C5 C5H C6 5 10 5 4 2 Replenishing grease C10 C14 C14H C17 C17H C20 5
44. ning may result 16 Do not use the robot for tasks requiring motor thrust CAUTION Avoid using the belt driven type robots for tasks which utilize motor thrust pressfitting burr removal etc These tasks may cause malfunctions in the robot Ajayes oqoy ay Suis A 17 Follow the specified procedures when installing adjusting or inspecting the robot AX WARNING ALWAYS FOLLOW THE SPECIFIED PROCEDURES WHEN INSTALLING ADJUSTING OR INSPECTING THE ROBOT NEVER ATTEMPT ANY PROCEDURE NOT DESCRIBED IN THIS MANUAL 18 Do not attempt any repair parts replacement and modification AX WARNING 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 19 Location for installing the controller and the programming box or Handy Terminal The robot controller programming box and Handy Terminal should be installed at a location that is outside the robot movement range yet where it is easy to operate and view the robot performing tasks 20 Protect electrical wiring and hydraulic pneumatic hoses as needed Install a cover or similar item to protect the electrical wring and hydraulic pneumatic hoses from possible damage 21 Install an operation status light Install an operation status light signal light tower etc at an easy to see position so the operator will know whether the robot is
45. nt space margin to perform jobs teaching inspection repair etc For detailed information on how to install the robot controller refer to the separate YAMAHA Robot Controller User s Manual AA WARNING AVOID INSTALLING THE ROBOT IN LOCATIONS WHERE THE AMBIENT CONDITIONS MAY EXCEED THE ALLOWABLE TEMPERATURE OR HUMIDITY OR IN ENVIRONMENTS WHERE EXCESSIVE MOISTURE CORROSIVE GASES METALLIC POWDER OR DUST ARE GENERATED MALFUNCTIONS FAILURES OR SHORT CIRCUITS MAY OTHERWISE RESULT AA WARNING THIS ROBOT 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 AA WARNING AVOID USING THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC INTERFERENCE ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE MALFUNCTIONS MAY OTHERWISE OCCUR Ak WARNING DO NOT USE THE ROBOT IN LOCATIONS SUBJECT TO EXCESSIVE VIBRATION ROBOT INSTALLATION BOLTS MAY OTHERWISE BECOME LOOSE CAUSING THE MANIPULATOR TO FALL OVER 3 1 3 1 Robot installation conditions 3 1 2 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 ac
46. o slacken or warp M pue uon gt adsuj 5 14 5 4 Applying grease 18 Use the same procedure to tighten the screws on the other shutter clamp plate alternately a little at a time After tightening check that the shutter does not protrude or bulge above the slider If the shutter is protruding loosen the screws on the shutter clamp plates on both ends and repeat the adjustment in steps 16 and 17 AN CAUTION the shutter protrudes bulges above the slider the shutter surface might rub against the slider cover creating dust or grit This will also shorten the shutter service life Correct shutter installation on the slider 19 While moving the slider back and forth by hand a few times check that the shutter does not slacken or jerk to the right or left If slack or sway occurs in the shutter repeat the adjustment from step 16 to step 18 When a vertical installation model is used go outside the safety enclosure once check that no one is inside the safety enclosure and turn on the controller Then slowly move the slider back and forth a few times in MANUAL mode to spread the grease Then turn off the controller again and re enter the safety enclosure to continue the job 20 Reattach the slider cover 21 Go outside the safety enclosure 22 Check that no one is inside the safety enclosure and then turn on the controller pue uon gt
47. oller Then slowly move the slider back and forth a few times in MANUAL mode to spread the grease Next turn off the controller again and re enter the safety enclosure to continue the job 11 Move the slider back and forth by hand and then remove the slider cover Check the inner side of the slider cover for scratches caused by rubbing against the shutter If scratches are found reattach the slider cover and loosen the screws on either shutter clamp plate Then repeat the adjustment in step 10 pue uon gt adsuj IPod o Inner side of slider cover 5 18 5 5 Replacing the shutter 12 Firmly tighten those screws on the shutter and cover which were lightly attached At this point gradually tighten the screws on the shutter Finally move the slider back and forth by hand and check that no looseness or slack occurs in the shutter and also that the shutter does not slacken or jerk to the right or left 13 Go outside the safety enclosure 14 Check that no one is inside the safety enclosure and then turn on the controller When a vertical installation model is used slowly move the slider back and forth a few times in MANUAL mode to make the same check as explained in step 12 5 5 Replacing the shutter When replacing the shutter of the C4 C4H C5 C5H or C6 refer to the procedure explained in 5 4 1 Replenishing grease C4 C4H C5 C5H C6 in this chapter Likewise refer to the procedure explained
48. ot catalog or our website www yamaha motor co jp global industrial robot index html 3 6 3 Duty To achieve maximum service life for the YAMAHA single axis robots the robot must be operated within the allowable duty 5096 The duty is calculated as follows tion ti Duty partian tme x100 Operation time Non operation time If the robot duty is too high an error such as overload or overheat occurs In this case increase the stop time to reduce the duty 3 14 Adjusting the Robot YAMAHA robots have been completely adjusted at the factory or sales representative 4 1 Overview before shipment However when the operating conditions are changed and adjustment of the robot becomes necessary follow the procedure described in this chapter 4 2 Safety precautions 1 Read and understand the contents of this chapter completely before attempting to adjust the robot 2 Place a conspicuous sign indicating the robot is being adjusted to prevent others from touching the controller switch programming box or operation panel 3 Ifa safety enclosure has not yet been provided right after installation of the robot rope off or chain off the movement area around the manipulator in place of a safety enclosure and observe the following points 1 Use stable posts which will not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 3 Place a conspicuous sign
49. ow C4 C4H Hex socket head M4 bolt strength 8 8T length installation base thickness 5mm maximum is recommended Bolt Tightening torque 30kgfecm to 45kgf cm C5 C5H C6 Hex socket head 5 bolt strength 8 8T length installation Bolt base thickness 5mm maximum is recommended Tightening torque 60kgf cm to 90kgf cm A WARNING 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 e DO NOT USE A BOLT LONGER THAN THE SPECIFIED LENGTH BOLT THAT IS TOO LONG WILL PENETRATE INSIDE THE ROBOT FRAME AND CAUSE OPERATING DEFECTS OR MALFUNCTION M NOTE For the dimensions and positions of holes and threading in the robot installation base refer to the outline dimension drawings shown in our robot catalog or our website www yamaha motor co jp global industrial robot index html 3 5 3 2 Installation Installing the C4 C4H C5 C5H and C6 uo yejjejsuj 7 CA CAH 4 bolt C5 C5H C6 M5 bolt CAUTION The robot frame is made of aluminum so be careful not to damage the screw threads when tightening the bolt 3 6 3 2 Installation 3 2 3 2 Installing the C10 C14 C14H C17 C17L and C20 C10 Drill holes through the installation base and secure the robot to the base with M5 bolts from the bottom C14 C14H Drill holes through the installation base and sec
50. prohibiting other personnel from entering the movement area of the manipulator 4 To check operation after adjustment refer to 1 6 Trial operation in Chapter 1 10403 ay Sunsn py A 4 1 4 3 Adjusting shutter looseness 4 3 Adjusting shutter looseness The shutter may elongate or develop a slight stretch after long term use Continuous operation with a stretched shutter may cause a slack or a gap between the shutter and the cover of the robot and degrade the degree of cleanliness In such cases adjust looseness in the shutter as explained below 4 3 1 Adjusting the shutter looseness C4 C4H C5 C5H 1 Prepare the tools required for adjustment Phillips head screwdriver 2 Turn off the controller 3 Place a sign indicating the robot is being adjusted to keep others from operating the controller switch 4 Enter the safety enclosure 5 While moving the slider back and forth by hand find the position where the shutter is loosest When a vertical installation model is used slowly move the robot in jog before entering the safety enclosure and find the position of maximum shutter looseness 6 Loosen the screws securing the shutter clamp plate on the side where the shutter is loose yOqoy ay Sunsn py O Motor side Stroke end side 4 2 4 3 Adjusting shutter looseness 7 While pulling pressing down on both ends of the shutter with your fingers tighten the two screws to secu
51. pt any inspection adjustment repair and parts replacement not described in this manual This work requires specialized technical knowledge and skill and may also involve work hazards 3 When inspection is required inside the safety enclosure always turn off the controller and also the external switch board 4 If the inspection or maintenance procedure calls for operation of the robot stay outside the safety enclosure 5 Place a sign indicating the robot is being inspected to keep others from operating the controller switch programming box or operation panel 6 Use only the lubricants specified by YAMAHA or YAMAHA sales dealers 7 To check the operation after inspection refer to 1 6 Trial operation in Chapter 1 AX 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 pue uonoadsu IPod 5 For precautions on handling the controller refer to the YAMAHA Robot Controller User s Manual 5 1 5 3 Periodic inspection 5 3 Periodic inspection 5 3 1 Daily inspection The following is an inspection list that must be performed every day before and after operating the robot 1 Inspection to be performed with the controller turned off 1 T
52. r 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 immediately uornej ejsu 0 Example Controller SR1 Robot C14 Product name Single axis robot SR1 Robot cable connector Battery Battery attachment Warning label 1 Danger label Affix to a conspicuous spot in the system Warning label 3 Warning label Affix to a conspicuous spot in the system HPB Option POPCOM Option SD memory card Option 3 3 3 2 Installation 3 2 2 Moving the robot Using a hoist carrying cart dolly or forklift is recommended for moving a single axis robot or controller Use sufficient caution when moving robot models with a long stroke or designed for large payload since they are heavy uo yejjejsuj 3 4 Moving the robot WARNING SERIOUS INJURY MAY OCCUR IF THE ROBOT FALLS AND PINS SOMEONE UNDER IT USE A HOIST AND ROPE WITH CARRYING CAPACITY STRONG ENOUGH TO SUPPORT THE ROBOT WEIGHT MAKE SURE THE ROPE STAYS SECURELY ON THE HOIST HOOK REMOVE ALL LOADS ATTACHED TO THE ROBOT MANIPULATOR END IF ANY LOAD 1 STILL ATTACHED THE ROBOT BALANCE MIGHT SHIFT WHILE BEING CARRIED AND THE ROBOT TOPPLE OVER CAUSING ACCIDENTS ALWAYS WEAR A SAFETY HELMET SHOES AND GLOVES DURING WORK WHEN MOVING THE ROBOT B
53. re the shutter clamp plate At this point alternately tighten the two screws a little at a time Motor side Stroke end side 8 While moving the slider back and forth by hand a few times check that no looseness or slack occurs in the shutter and also that the shutter does not jerk to the right or left If any abnormalities are found repeat the adjustment in steps 6 and 7 9 Go outside the safety enclosure 10 Check that no one is inside the safety enclosure and then turn on the controller Net n NOTE When securing the shutter clamp plate tighten equally on left and right a little at a time Avoid excessive tightening as this may cause the shutter to slacken or warp IM 0goy ay Sunsn py 4 3 2 Adjusting the shutter looseness C10 C14 C14H C17 C17L C20 1 Prepare the tools required for adjustment Phillips head screwdriver 2 Turn off the controller 3 Place a sign indicating the robot is being adjusted to keep others from operating the controller switch 4 Enter the safety enclosure 5 While moving the slider back and forth by hand find the position where the shutter looseness is maximum When a vertical installation model is used slowly move the robot in jog before entering the safety enclosure and find the position of maximum shutter looseness 4 3 4 3 Adjusting shutter looseness 6 Loosen the screws securing the shutter clamp plate on the side where the shutter loo
54. red for the robot or controller please contact your YAMAHA sales dealer This work requires specialized technical knowledge and skill so do not attempt it by yourself 5 3 3 Six Month inspection Take the following precautions when performing 6 month inspection AX WARNING THE SLIDER OF VERTICAL USE ROBOT WILL SLIDE DOWN WHEN THE BRAKE 1 RELEASED CAUSING A HAZARDOUS SITUATION DO NOT RELEASE THE BRAKE WHEN LUBRICATING THE VERTICAL USE ROBOT PARTS 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 GREASE COMES IN CONTACT WITH THE SKIN WASH AWAY COMPLETELY WITH SOAP AND WATER IF TAKEN INTERNALLY DO NOT IND
55. ring injury due to being struck by moving parts Install a safety interlock that triggers emergency stop when the door or panel is opened Install a safety enclosure so that no one can enter inside except from doors panels equipped with safety interlocks ga ma gt A o c emt on 2 c lt e Warning labels 1 are supplied with the robot and should be affixed to conspicuous spots on doors or panels equipped with safety interlocks DANGER SERIOUS INJURY OR DEATH WILL RESULT FROM IMPACT WITH MOVING ROBOT KEEP OUTSIDE OF GUARD DURING OPERATION LOCK OUT POWER BEFORE APPROACHING ROBOT Warning label 1 DANGER Serious injury or death will result from impact with 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 Warning label 2 is affixed to the robot Use caution to prevent hands or fingers from being pinched or crushed by the moving parts when carrying the robot or during teaching WARNING MOVING PARTS CAN PINCH OR CRUSH HANDS KEEP HANDS AWAY FROM ROBOT ARMS 1 3 1 2 Essential precautions Warning label 2 44 WARNING Moving parts can A pinch or crush Keep hands away from robot arms 3 Follow the instructions on warning labels and in this manual Be sure to read the warning labels and this manual caref
56. s 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 For specific safety information and standards refer to the applicable local regulations and comply with the instructions This manual and warning labels supplied with or attached to the robot are written in English Unless the robot operators or service personnel understand English do not permit them to handle the robot Cautions regarding the official language of EU countries For equipment that will be installed in EU countries the language used for the user s manuals CE declarations and operation screen characters is English only Warning labels only have pictograms or else include warning messages in English In the latter case Japanese messages might be added 1 2 Essential precautions Particularly important cautions for handling or operating the robot are described below In addition precautions during installation operation inspection and maintenance are also provided in each chapter Be sure to comply with these instructions to ensure safe use of the robot 1 2 Essential precautions 1 Observe the following cautions during automatic operation Install a safeguard safety enclosure to keep any person from entering within the movement range of the robot and suffe
57. seness occurs 7 While pulling pressing down on both ends of the shutter with your fingers tighten the two screws to secure the shutter clamp plate At this point tighten the two screws alternately a little at a time 10403 ay Sunsn py O 8 While moving the slider back and forth by hand a few times check that no looseness or slack occurs in the shutter and also that the shutter does not sway right and left If any abnormality is found repeat the adjustment in steps 6 and 7 9 Go outside the safety enclosure 10 Check that no one is inside the safety enclosure and then turn on the controller el n NOTE When securing the shutter clamp plate tighten equally on left and right a little at a IM time Avoid excessive tightening as this may cause the shutter to slacken or warp 4 4 Periodic Inspection and Maintenance 5 1 Before beginning work Periodic inspection and maintenance are essential to ensure safe and efficient operation of 5 1 Before beginning work YAMAHA robots This chapter describes periodic inspection items and procedures for the FLIP XC robot Before beginning work carefully read the next section 5 2 Precautions and also Chapter 1 Using the Robot Safely and follow the instructions 5 2 Precautions 1 Periodic inspection must be performed by or in the presence of personnel who have received the Robot Training given by YAMAHA or YAMAHA sales dealers 2 Do not attem
58. slowly pull the shutter out from the slider pue uonoadsuj Pushing to get slack in the shutter Pulling out the shutter 5 11 5 4 Applying grease 8 Remove the screws securing the right or left side cover 9 Move the slider to one end motor side and pull the side cover outwards Then move the side cover towards the stroke end side to separate it from the slider Removing the side cover 10 Wipe away the old grease with a clean cloth Next apply grease by hand to the ball screw and linear guide Then move the slider back and forth to spread the grease and remove excess grease with a clean cloth pue uon gt adsuj IPod Applying grease to the ball screw Applying grease to the linear guide When a vertical installation model is used go outside the safety enclosure once check that no one is inside the safety enclosure and turn on the controller Then slowly move the slider back and forth a few times in MANUAL mode to spread the grease Next turn off the controller again and re enter the safety enclosure to continue the job 5 12 5 4 Applying grease 11 Reinstall the side cover and perform the procedure of step 9 in reverse order to tighten the screws securing the side cover 12 Reinstall the parts made of stainless steel that came off when the side cover was removed Motor side Stroke end side 13 Move the s
59. 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 e 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 of the robot refer to the separate user s manual for the robot controller being used 4 The contents of this manual are subject to change without prior notice 4 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 YAMAHA MOTOR CO LTD IM Operations MEMO Using the Robot Safely 1 1 Safety information Industrial robots are highly programmable mechanical devices that provide a large degree 1 1 Safety information 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 sy
60. tective conductor Also securely connect the ground terminal on the robot frame to the protective conductor Symbol 417 IEC5019 3 9 3 4 Robot cable connection 3 4 Robot cable connection Connect the robot cables to the mating connectors on the controller as shown Refer to the SR1 robot controller users manual for the controller connectors WARNING e BEFORE CONNECTING THE CABLES CHECK 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 ENSURE THAT THE CONTROLLER IS OFF BEFORE CONNECTING THE ROBOT CABLE TO THE CONTROLLER AN CAUTION After connecting the relay connectors on the robot cables fit the connector hoods together securely uo yejjejsuj WARNING IF THE CONNECTOR INSTALLATION IS INADEQUATE OR IF THERE ARE CONTACT FAILURES IN THE PINS THE ROBOT MAY MALFUNCTION CAUSING A HAZARDOUS SITUATION RECHECK THAT EACH CONNECTOR IS SECURELY INSTALLED BEFORE TURNING ON THE CONTROLLER e TAKE CAUTION NOT TO APPLY AN EXCESSIVE LOAD TO THE CONNECTORS DUE TO STRESS OR TENSION ON THE CABLES Ak WARNNIG LAY OUT THE ROBOT CABLES SO THAT THEY DO NOT OBSTRUCT THE ROBOT MOVEMENT DETERMINE THE ROBOT WORK AREA IN WHICH THE ROBOT CABLES WILL NOT INTERFERE WITH THE LOAD OR WORKPIECE PICKED UP BY THE ROBOT MANIPULATOR TIP IF THE ROBOT CABLES INTERFERE WITH THE MOVABLE PARTS OF
61. tive pins 15 motor resistance Replace motor since motor has shorted or burnt out Take noise reduction measures Yes No 15 motor encoder Replace motor Yes 1 Check position shift by repetitive accuracy measurement 2 If replacement motor is available check by exchanging the motors Yes No Is external Yes Is controller noise large ardware OK CS 1 If replacement controller is available check by exchanging the controllers 7 2 8 1 About machine reference The position detector built into the motor issues a 0 pulse each time the motor rotates 1 4th of one turn When return to origin is performed a difference in distance occurs between the position where the origin signal is detected and the point at which the next 0 pulse is received This is called the machine reference and is usually expressed as a percent with 100 being equal to 1 4th of one turn of the motor The machine reference value must be within the allowable range 25 to 75 8 1 About machine reference to maintain axis movement repeatability To check the machine reference value an optional programming box HPB MPB or RPB is needed The machine reference value is displayed on the LCD screen of the programming box when return to origin is complete See the figure below xipuadd y Ve m NOTE The FLIP X series uses an absolute type position detector You do not have to p
62. ully and make sure you thoroughly understand their contents before attempting installation and operation of the robot 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 Using the Robot Safely Ajayes oqoy ay Suis Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual e The warning labels 3 are supplied with the robot and should be affixed to the robot or conspicuous spots near the robot A WARNING IMPROPER INSTALLATION OR OPERATION CAN RESULT IN SERIOUS INJURY OR DEATH READ THE USER S MANUAL AND ALL WARNING LABELS BEFORE INSTALLATION OR OPERATION Warning label 3 WARNING Improper Installation or operation can result in serious injury or death Read user s owner s manual and all warning labels before operation 4 Do not remove alter or stain the warning labels A WARNING IF WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE THEN ESSENTIAL PRECAUTIONS MIGHT NOT BE TAKEN RESULTING IN ACCIDENTS e DO NOT REMOVE ALTER OR STAIN THE WARNING LABELS ON THE ROBOT e 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 1 4 1 2 Essent
63. ure the robot to the base with M6 bolts from the bottom C17 C17L C20 Drill holes through the installation base and secure the robot to he base with M8 bolts from the bottom WARNING ALWAYS TURN OFF THE POWER TO THE CONTROLLER BEFORE INSTALLING THE ROBOT SERIOUS ACCIDENTS MIGHT OCCUR IF THE ROBOT STARTS TO OPERATE DURING INSTALLATION O Installation method Drill holes through the installation base where the robot is to be secured Then secure the robot with the specified bolts from the underside of the installation base The bolt and tightening torque are shown below C10 Hex socket head M5 bolt strength 8 8T length installation base thickness 10mm maximum is recommended 1 Bolt uo yejjejsuj Tightening torque 60kgfecm to 90kgf cm C14 C14H Hex socket head M6 bolt strength 8 8T length installation base thickness 10mm maximum is recommended 1 Tightening torque 100kgf cm to 130kgf cm 1 Because the robot frame has a cavity inside the tapped holes it is possible to use bolts whose length is up to the installation base thickness 20mm Even in this case the length of the bolt thread engagement is 10mm C17 C17L C20 Bolt Hex socket head M8 bolt strength 8 8T length installation base thickness 15mm maximum is recommended Tightening torque 230kgfecm to 370kgfecm WARNING BE SURE TO TIGHTEN THE BOLT TO THE CORRECT TORQUE THE
64. urn off the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller switch 3 Enter the safety enclosure and check the following points Checkpoints Check items Check for scratches dents and Cables and shutter excessively tight bends Replace if necessary Stain or grime on the shutter surface 1 Ball screws and Check for unusual vibration and noise bearings Check for unusual vibration and noise and for abnormal temperature rise 1 Depending on robot operating conditions stain or grime may appear in a stripe pattern near the slider stop point on the shutter surface this is found use cloth moistened with alcohol or detergent to wipe away the stain or grime If this occurs frequently please consult your YAMAHA sales dealer Motor 2 Inspection to be performed with the controller turned on Check that no one is inside the safety enclosure and then turn on the controller 2 Place a sign indicating the robot is being inspected to keep others from operating the controller programming box or operation panel 3 Check the following points from outside the safety enclosure Checkpoint Procedure Check if the safety enclosure is in place Check if emergency stop is triggered when the door is Safety enclosure opened Check if warning labels are affixed at the entrance and clearly visible pue uon gt adsuj IPod
65. uts off the servo power If an overload or overheat error occurs take the following measures 1 Insert a timer in the program 2 Reduce the acceleration coefficient 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 No mechanical stopper is provided on the rotating axis Note The working envelope is the area limited by soft limits WARNING 4 WARNING 5 1 10 SOFT LIMITS MUST SET WITHIN THE MOVEMENT RANGE MECHANICAL STOPPER IF THE SOFT LIMIT IS SET OUTSIDE THE MOVEMENT RANGE THE ROBOT AXIS MAY COLLIDE WITH THE MECHANICAL STOPPER AT HIGH SPEED CAUSING THE OBJECT GRIPPED BY THE END EFFECTOR TO FLY OR DROP AND THE ROBOT TO MALFUNCTION 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 No mechanical stopper is provided on the rotating axis Note The movement range is the area limited by mechanical stoppers AXIS MOVEMENT WILL NOT STOP IMMEDIATELY AFTER THE SERVO POWER SUPPLY IS SHUT OFF BY 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 control

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