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FLIP-X Series M/M English

1. Parts Signal PIN Controller ROB S2 1 XY ZR S4 2 S1 3 S3 4 R1 5 R2 6 FG 7 MB 14 MB 16 24V 9 ORG 12 GND24 13 S 19 S 29 C 21 C 22 Z 2 Z 29 V5 24 DG 23 FG 25 FG 24V 27 ORG 30 GND24 31 HLIM 10 GND24 11 Controller MOTOR U 2 XM ZM V 3 W 4 FG 1 Controller MOTOR U 2 YM RM V 3 W 4 FG 1 Connection TO PIN Parts Wire 1 Resolver P1 0 3sq Red 2 White 3 Green 4 White 5 Yellow 6 White 7 Drain wire Grey Heat shrinkable tube 1 Brake BK1 0 3sq Blue 2 White ORG1 0 3sq 1 Purple 2 Blue 3 Brown 1 Linear P2 0 3sq Red 2 White 3 Green 4 White 5 Yellow 6 White 7 Blue 8 White 9 Drain wire Grey Heat shrinkable tube E 0 75sq Gray ORG2 1 Purple 2 Blue 3 Brown Grey 1 Motor M1 0 75sq Red 2 White 3 Black 4 Grey Heat shrinkable tube 1 Motor M2 0 75sq Red 2 White 3 Black When connected to the XY of the ROB I O connect to the MOTOR XM and YM When connected to the ZR of the ROB I O connect to the MOTOR ZM and RM Grey Heat shrin kable tube 9 19 lt 2 O Y O mE O o 4 Machine harness The following shows the wiring inside the cable carrier 4 1 N15 N15D N18 N18D Signal cable
2. Parts Signal PIN Controller ROB S 1 XY ZR S 2 3 C 4 Z 10 Z 11 5V 6 DG 5 FG 7 FG 24V 9 ORG 12 GND24 13 S2 19 S4 20 51 21 53 22 H1 23 R2 24 FG 25 MB 32 MB 34 24V 27 ORG 30 GND24 31 HLIM 28 GND24 29 Controller MOTOR U 2 XM ZM V 3 W 4 FG 1 Controller MOTOR U 2 YM RM V 3 W 4 FG 1 Connection PIN Parts 1 Linear P1 0 3sq Red 2 White 3 Green 4 White 5 Yellow 6 White 7 Blue 8 White 9 Drain wire Grey Heat shrinkable tube TO 0 75sq Gray ORG1 0 3sq 1 Purple 2 Blue 3 Brown 1 Resolver P2 Hed 2 White 3 Green 4 White 5 Yellow 6 White 7 Drain wire Grey Heat shrinkable tube O 1 Brake BK2 0 3sq Blue o 2 White o ORG2 L 1 Purple S 2 Blue Q 3 Brown 0 3sq Gray 2 o 1 Motor M1 0 75sq Red 2 White 3 Black Grey Heat shrinkable tube 1 Motor M2 0 75sq Red 2 White 3 Black 4 Grey Heat shrinkable tube When connected to the XY of the ROB I O connect to the MOTOR XM and YM When connected to the ZR of the ROB I O connect to the MOTOR ZM and RM o 1 lt z 2 Q o dt Q o 5 18 3 Robot combination 1st axis is FLIP X and 2nd axis is PHASER Connection controller RCX221 240 Cables for multi robot LIO TF E FAN FA 0 To robot 53503 0 00
3. The wire colors in show the flexing cable B Power cable Power cable To controller To robot 53503 Q6 00 Connection Motor wire nn Motor M 9 9 lt z 2 O o O mE O o 3 1 3 Cables for RDX robot with brake Signal cable Signal cable To controller Controller ENC Resolver P To robot 53501 N1 00 Blue Red Orange White Green Brown White Grey Yellow Red White Drain wire Grey Heat shrinkable tube B Power cable Power cable Motor wire 5 10 Connection 0 3sq Blue Red Orange White Green Grey Yellow Red White The wire colors in show the flexing cable Round terminal To robot 53504 N1 00 Red White Black Grey Heat shrinkable tube ORG BK wires ORG BK wires Controller I O To controller BK 24V ORG GND24V To robot Connection To robot 53506 N 1 00 5 11 4 z 2 O Y O mE O o 3 1 4 Cables for RDX robot without brake Signal cable Signal Controller ENC B Power cable 5 12 cable To controller Power cable Mot
4. 1 Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 button head bolt M3 4 CAUTION If the grease recommended by YAMAHA is not used this may cause the service life of the ball screw or linear guide to shorten 2 3 inspection to be performed with the controller turned on A 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 IS TURNED ON A WARNING BODILY INJURY MAY OCCUR FROM COMING INTO CONTACT WITH THE FAN WHILE IT IS ROTATING e WHEN REMOVING THE FAN COVER FOR INSPECTION FIRST TURN OFF THE CONTROLLER AND MAKE SURE THE FAN HAS STOPPED step Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller steps Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being inspected to keep others from operating the controller programming box or operation panel a step Perform the daily inspection Check the following points from outside the safety enclosure Checkpoint Procedure e Check if the fan rotates normally Check if objects blocking the fan are located and remove if any are found IDedsul 2 Cooling fan at rear of controller Check for abnormal noise from the rotating fan
5. 3 4 Replacing the drive and speed reduction belts B10 B14 B14H 4 1 Replacing the drive belt A WARNING e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED e BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY CAUTION M N Since a positional shift occurs after replacing the belt return to origin must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicati
6. H1 White Red White H2 Green Yellow White Shield Grey Heat shrinkable tube Red White Black Green Yellow The wire colors in show the motor wiring of the N15 N18 robots B10 B14 B14H R5 R10 R20 F20N N15 N18 This Fig shows the B10 robot 53501 AC 00 9 9 lt 1 6 Brake cable specifications Connector specifications Brake parts Receptacle housing SMR 02V B Pin contact SYM 001T P0 6 Connector Wire Color Connection Yellow Black Yellow Black The wire colors in show the motor wiring of the T9 T9H F10 F14 F14H robots T4L T4LH T5L T5LH T6L F8 F8L F8LH F17 F20 53502 A1 00 This Fig shows the compact brake 2 3 53501 A4 00 gt 5 6 2 Robot cables DC24V specifications TAL T5L 2 1 Single axis robot cables 2 1 1 Cables for ERCD Composite cable nua na 45 To controller To robot 53501 Q3 00 Composite flexing cable Lf j H To controller To robot 53503 Q3 00 Connection Controller CN1 FG Resolver Drain wire S2 Black Red S4 Yellow White S1 Blue Green S3 Orange White H1 Green Yellow R2 Brown White Faulty wiring detection 1 Grey Blue Faulty wiring Red White detection 2 ne Red
7. O o 1 4 AC servo motor termination T9 T9H F10 F14 F14H F17 F17L F20 B Connector specifications Servo motor Receptacle housing SMR 07V B CN1 7 polarities Pin contact SYM 001T P0 6 CN1 CN2 Receptacle housing 176273 1 CN3 4 polarities Receptacle Receptacle housing 175156 2 SMR 02V B CN3 CN2 2 polarities Plug housing SMP 02V BC CN4 2 polarities Socket contact SHF 001T 0 8BS CN4 Connector Round terminal 52 R1 25 4 Wire Color Yellow Connection 54 Blue 51 53 Black R1 White R2 Shield Green Grey Heat shrinkable tube BK Grey BK Brown Red White Black Yellow Green T9 T9H F10 F14 F14H F17 F17L F20 P 7 8 4 Round terminal NP Ml 2 3 El z AR 4 5 53502 A4 00 1 5 servo motor termination B10 B14 B14H R5 R10 R20 F20N N15 N18 Connector specifications Servo motor Receptacle housing SMR 07V B CN1 7 polarities Pin contact SYM 001T P0 6 CN1 Receptacle housing 176273 1 CN3 4 polarities Receptacle 52 175156 2 Wire Color Yellow CN3 54 Blue 51 53 Black
8. White Black Grey Green Pink Purple Purple White The wire colors in show the flexing cable 5 lt 3 Robot cables 200V specifications TALH T5LH T6L T9 T9H F8 F8L F8LH F10 F14 F14H F17 F17L F20 B10 B14 B14H R5 R10 R20 3 1 Single axis robot cables 3 1 1 Cables for TS X Signal cable Signal cable To controller Controller CN1 B Power cable Power cable To controller Motor wire Connection To robot 53501 M1 00 1 Resolver P Blue Red a Orange White 3 4 Green Brown White Grey Yellow Red White Drain wire Grey Heat shrinkable tube Brake BK Black Blue Yellow White Pink Purple White Blue ORG Blue Red Brown The wire colors in show the flexing cable Motor M 3 1 2 Cables for SR1 X Signal cable Signal cable To controller To robot 53501 Q6 00 Connection Controller CN1 Resolver P Blue Red Orange White Green Brown White Grey Yellow Red White Grey Heat shrinkable tube Brake BK Black Blue Yellow White Pink Purple White Blue Blue Red Brown
9. servo motor termination T4LH T5LH T L Connector specifications Servo motor Receptacle housing SMR 07V B CN1 7 polarities Pin contact SYM 001T P0 6 CN1 Receptacle housing 5557 04R 2 4 polarities Receptacle 55561 CN2 Connector i Wire Color Connection S2 Yellow S4 Blue S1 Red S3 Black H1 White R2 Green Shield Grey Heat shrinkable tube U Red V White W Black Yellow Green o o E OE Te gt A LE 1 ESA 53506 A1 00 This Fig shows the T4LH robot gt 5 2 1 3 servo motor termination F8 F8L F8LH Connector specifications Servo motor Receptacle housing SMR 07V B CN1 7 polarities Pin contact SYM 001T P0 6 CN1 CN2 Receptacle housing 176273 1 CNS 4 polarities Receptacle 175156 2 CN3 Receptacle housing SMR 02V B CN2 2 polarities Plug housing SMP 02V BC CN4 2 polarities Socket contact SHF 001T 0 8BS CN4 Wire Color Connection S2 Yellow S4 Blue S1 Red S3 Black H1 White R2 Green Shield Grey Heat shrinkable tube BK Brown BK Grey Red White Black Yellow Green 53502 A5 00 2 3 lt z 2 O Y O mE
10. Connection controller RCX240 Robot combination Cable type Cable model number 1st axis 2nd axis PHASER FLIP X KAU M4754 12 Flexing cable FLIP X PHASER KAU M4756 12 The number in shown in the model number has the following meaning Number in O Cable length 1 im Cables for ERCD only 5 23 Revision record Manual version Issue date Description Ver 1 00 Jun 2012 First edition Ver 1 01 Jul 2012 2 1 T4L T4LH T5L T5LH T6L was added to 2 Replacing the motor in Chapter 4 3 Replacing the insert was added to Chapter 4 Erroneous descriptions were corrected Maintenance Manual Single axis Robots FLIP X Series Jul 2012 Ver 1 01 This manual is based on Ver 1 01 of Japanese manual YAMAHA MOTOR CO LTD IM Operations All rights reserved No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or omissions If you find any part unclear in this manual please contact your distributor IM Operations 882 Soude Nakaku Hamamatsu Shizuoka 435 0054 Japan Tel 81 53 460 6103 Fax 81 53 460 681 1 Robot manuals can be downloaded from our company website Please use the following for more detailed information YAMAHA YAMAHA MOTOR CO LTD h
11. WARNING Ak e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY CAUTION N Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel Step Enter the safety enclosure j step Remove the upper cover Pull out the upper cover parallel with the axis movement direction gt Step5 Removing the slider mounting bolts step Remove the slider mounting bolts REE MM 2 pieces 53411 AC 00 step Replace the slider Se
12. Signal cable To controller To robot 53501 AA 00 5 Encoder P1 Resolver Yellow Drain wire Grey Heat shrinkable tube B Power cable O Y Oo Q zh O E Power cable O o To controller To robot 53503 AA 00 Connection Motor wire Green Yellow Green Yellow 5 20 4 2 F20N Signal cable Signal cable To controller To robot 53501 A9 00 Connection Encoder P Resolver Green White Yellow White Drain wire Grey Heat shrinkable tube Brake BK Brake BK 0 3sq Blue White B Power cable Power cable To controller To robot 53503 A9 00 Connection Motor wire EE Red White Black Green Yellow Green Yellow 5 21 lt 5 Cables models 5 1 Single axis robot cables B Cables for ERCD Cable type Standard cable Set model number Individual part model number Composite cable KX1 M4751 10 Flexing cable B Cables for TS X Cable type Standard cable Set model number KBY M4710 10 Composite cable KX1 M4752 10 Individual part model number Signal cable KBY M4751 10 Power cable KX7 M4752 10 Flexing cable B Cables for SR1 X Cable type Standard cable KBY M4720 10 Set model number 7
13. IF UNUSUAL ODORS NOISE OR SMOKE OCCUR DURING OPERATION IMMEDIATELY TURN OFF POWER TO PREVENT POSSIBLE ELECTRICAL SHOCK FIRE OR BREAKDOWN STOP USING THE ROBOT AND CONTACT YOUR DISTRIBUTOR e IFANY OF THE FOLLOWING DAMAGE OR ABNORMAL CONDITIONS OCCURS THE ROBOT THEN CONTINUING TO OPERATE THE ROBOT IS DANGEROUS IMMEDIATELY STOP USING THE ROBOT AND CONTACT YOUR DISTRIBUTOR Damage or abnormal condition Type of danger Damage to machine harness or robot cable Electrical shock robot malfunction Damage to robot exterior Damaged parts fly off during robot operation Abnormal robot operation position deviation vibration etc Robot malfunction Z axis vertical axis or brake malfunction Loads fall off 2 High temperature hazard WARNING Ak e DO NOT TOUCH THE ROBOT CONTROLLER AND ROBOT DURING OPERATION THE ROBOT CONTROLLER AND ROBOT BODY ARE VERY HOT DURING OPERATION SO BURNS MAY OCCUR IF THESE SECTIONS ARE TOUCHED THE MOTOR AND SPEED REDUCTION GEAR CASING ARE VERY HOT SHORTLY AFTER OPERATION SO BURNS MAY OCCUR IF THESE ARE TOUCHED BEFORE TOUCHING THOSE PARTS FOR INSPECTIONS OR SERVICING TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THEIR TEMPERATURE HAS COOLED gt 5 16 3 Use caution when releasing the Z axis vertical axis brake A WARNING THE VERTICAL AXIS WILL SLIDE DOWNWARD WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION PRESS THE EMERGENCY STOP BUTTON AND PLACE A SUPPORT UNDER
14. 4710 L10 Signal cable KBY M4755 10 Power cable KX7 M4752 10 Individual part model number Signal cable KX7 M4751 0 1 Power cable KX7 M4752 10 Flexing cable KX7 M4720 L10 B Cables for RDX robot with brake Cable type Standard cable Set model number KBH M4720 L1B Signal cable KX7 M4755 10 Power cable KX7 M4752 10 Individual part model number Signal cable KBH M4753 10 Power cable KBH M4752 10 ORG BK cable KBH M4421 00 Flexing cable KBH M4740 O B B Cables for RDX robot without brake Cable type Standard cable Flexing cable gt 5 22 Set model number 4710 KBH M4730 O A Signal cable KBH M4757 10 Power cable KBH M4752 O 0 ORG BK cable KBH M4421 00 Individual part model number Signal cable KBH M4751 10 Power cable KBH M4752 10 I O connector Signal cable KBH M4420 00 KBH M4756 10 Power cable KBH M4752 10 I O connector KBH M4420 00 5 2 Multi robot cables Cables for single axis multi robot Connection controller RCX240 Cable type Cable model number Flexing cable KX7 M4754 10 B Cables for two axis multi robot Connection controller RCX222 RCX240 Robot combination Cable type Cable model number 1st axis 2nd axis Flexing cable KX7 M4753 O 1
15. If abnormal noise is heard visually check and remove the cause If no cause is found contact your distributor Check for dust on the fan cover Remove and clean if necessary UOI Adjustment and parts replacement A WARNING e 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 e AFTER THE ADJUSTMENT OR REPLACEMENT WORK HAS BEEN COMPLETED INSPECT THE CHECKPOINTS STATED IN DAILY INSPECTION IN THIS SECTION F THE REPAIR OR PART REPLACEMENT OF THE ROBOT OR CONTROLLER IS REQUIRED CONTACT YOUR DISTRIBUTOR SUCH WORK NEEDS THE SPECIAL KNOWLEDGE AND SKILL SO ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPAIR OR PART REPLACEMENT WORK OF THE ROBOT OR CONTROLLER 2 3 Take the following precautions when performing 6 month inspection Six month inspection WARNING WHEN THE BRAKE OF THE VERTICAL AXIS IS RELEASED THE SLIDER AXIS MAY DROP LEADING TO HAZARDOUS SITUATION WHEN APPLYING THE GREASE TO THE VERTICAL AXIS PARTS DO NOT RELEASE THE BRAKE AX Inspection to be performed with the controller turned off step 4 Turn off the controller step Place a sign indicating the robot is being adjusted Place a sign showing that the robot is being inspected to keep others from operating the contr
16. cover on the motor side and remove the cover 53403 A5 00 step 7 Remove the motor cover O 3 gt 46 Remove the four screws securing the motor cover and remove the motor cover 53404 A5 00 step Remove the ground wire gt Step5 Removing the side cover Side cover gt Step6 Removing the end cover on the motor side End cover gt Step 7 Removing the motor cover step9 Remove the motor gt Step 9 Removing the motor Remove the four bolts securing the motor and remove the motor 53405 A5 00 step 10 Remove the wave washer and flat washer N CAUTION When removing the motor the flat washer might be left in the bearing inside the motor so use caution 53406 A5 00 step 1 1 Pull out the rotor Remove the four bolts securing the rotor and pull out the rotor 53407 A5 00 step 2 Install the new rotor step 93 Install the wave washer and flat washer Carefully check the wave washer and flat washer installation order gt Step 10 Removing the wave washer and flat washer Step 14 Install the new motor MODE step 19 Assemble in the reverse order of disassembly Step 13 Step 4 Wave washer Flat washer O 3 gt Step 11 Pulling out the rotor 2 3 B10 B14 B14H A WARNING e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTR
17. step Place a sign indicating the robot is being adjusted gt Step4 Inserting the slider Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel Blidentravel guid step Enter the safety enclosure Fes oe step Insert the slider a Insert the slider into U shape groove at E the center of upper cover At this fime put the upper cover parallel with the axis movement direction 53301 AC 00 9 Secure the upper cover mounting screws temporarily Secure the upper cover mounting screws four screws temporarily and move the table from the motor side to the end of the anti motor side step Retighten the screws on the anti motor side Retighten the screws on the anti motor side and move the table to the motor side again step Y Retighten the upper cover mounting screws two screws on the motor side 53302AC 00 step Check the table movement Move the table by hand to check that the table movement is nof heavy 2 Adjusting the timing belt tension B10 B14 B14H The B10 B14 and B14H series robots use a timing belt to move the slider table If the tension of the timing belt is weak follow the steps below to adjust the belt tension A WARNING e BEFORE STARTING THE WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING WORK THIS MAY CAUSE SERIOUS ACCIDENT O
18. step Temporarily tighten the motor installation bolt step Install the adjustment bolt Remove the belt cover and install the adjustment bolt M5 step Apply a tension to the belt 53308 A9 00 gt Step8 Plucking the belt span with a hex wrench Step l Tighten the motor fixing bolt step Pluck the belt span with a hex wrench Put the head of the measuring meter close to the belt and pluck the center of the belt span with a hex wrench 53309 A9 00 51 9 Adjust the belt tension Adjust the belt tension by measuring the frequency with the tension meter while referring to the Table below Recommended tension meter U505 made by UNITTA Frequency Tension Span length Belt unit Hz N Kg mm weight kg m 207 0 219 8810 98 9 to 10 100 0 051 step 1O After the belt tension has been adjusted to the proper level measure the tension once again After the belt tension has been adjusted to the proper level retighten the motor mounting bolts and measure the tension once again As the bolts are retightened the tension may increase So carefully check this point step 1 1 Remove the adjustment bolt and install the belt cover 3 10 4 Adjusting shutter looseness T4L TALH T5L T5LH T6L The shutter may elongate with continued use In such cases adjust as follows N CAUTION Be sure to wear safety gloves before starting the work If you touch any steel mater
19. A CONSPICUOUS SIGN PROHIBITING THE OPERATOR OR OTHER PERSONNEL FROM ENTERING THE MOVEMENT AREA OF THE MANIPULATOR TO CHECK THE OPERATION AFTER THE ADJUSTMENT HAS BEEN MADE SEE 4 5 1 TRIAL OPERATION IN THE SAFETY INSTRUCTIONS 1 1 lt ex A Periodic inspecition l 2 2 1 2 2 2 3 2 4 Contents Before beginning work Periodic inspecition Daily inspection 2 2 Three month inspection 2 3 Six month inspection 2 5 Three year inspection 2 6 3 Applying the grease 3 1 3 2 3 3 3 4 3 5 TAL TALH TSL TSLH T6L 2 8 T9 T9H F10 F14 F14H F17 F17L F20 F20N 2 9 F8 F8L F8LH 2 10 N15 N15D N18 N18D 2 11 B10 B14 B14H 2 12 l Before beginning work Periodic inspection and maintenance are essential to ensure safe and efficient operation of YAMAHA robots This Chapter describes the periodic inspection of the FLIP X series Before beginning the work thoroughly read the safety precautions described below and the Safety Instructions to strictly observe the instructions Safety precautions DANGER IF THE INSPECTION OR MAINTENANCE PROCEDURE CALLS FOR OPERATION OF THE ROBOT STAY OUT OF THE WORKING AREA OF THE ROBOT DURING OPERATION KEEP WATCHING THE ROBOT MOVEMENT AND SURROUNDING AREA SO THAT THE OPERATOR CAN PRESS THE EMERGENCY STOP BUTTON IF ANY DANGER OCCURS A WARNING e THE ADJUSTMENT AND MAINTENANCE WORK WITH THE COVER REMOVED NEEDS THE SPECIAL KNOWLEDGE AND SKILL IF UNSKILLED WORK PERSON PERFORMS S
20. CONTROLLER POWER EXCEPT FOR THE FOLLOWING CASES Exception Work with power turned on but robot in emergency stop Follow the precautions and procedure described in 2 Adjusting the origin position in Chapter 3 Origin position setting SCARA robots Follow the precautions and procedure described in 4 Setting the Reference coordinate setting SCARA robots reference coordinates in Chapter 3 Follow the precautions and procedure described in 3 Setting the SCARA robots EE soft limits in Chapter 3 Soft limit settings E A Cartesian robots Follow the precautions and procedure described in Soft limit in Single axis robots each controller manual Work with power turned on SCARA robots Teaching Cartesian robots Refer to 5 Teaching within safety enclosure described below Single axis robots 5 Teaching within the safety enclosure When performing teaching within the safety enclosure check or perform the following points from outside the safety enclosure DANGER NEVER ENTER WITHIN THE MOVEMENT RANGE WHILE WITHIN THE SAFETY ENCLOSURE WARNING Ak MAKE A VISUAL CHECK TO ENSURE THAT NO HAZARDS ARE PRESENT WITHIN THE SAFETY ENCLOSURE e CHECK THAT THE PROGRAMMING BOX OR HANDY TERMINAL OPERATES CORRECTLY e CHECK THAT NO FAILURES ARE FOUND IN THE ROBOT e CHECK THAT EMERGENCY STOP WORKS CORRECTLY e SELECT TEACHING MODE AND DISABLE AUTOMATIC OPERATION o 15 lt SUOHONIALSU AJoJoS suouy
21. Check if emergency stop is triggered when Safety enclosure the door is opened Check if warning labels are affixed at the entrance and clearly visible Press the emergency stop button to check E top device mergency stop dev if it works Check for abnormal movement and If any abnormal operation is found excessive vibration and noise contact your distributor Robot movement Check if the brake works to stop the Z axis Z axis brake operation 1 from dropping more than 3mm from the stationary point If any abnormal operation is found contact your distributor 1 Visually check the Z axis movement when you press the emergency stop button from outside the safety enclosure and also 2 2 when you turn off the controller Adjustment and parts replacement A WARNING e 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 e AFTER THE ADJUSTMENT OR REPLACEMENT WORK HAS BEEN COMPLETED INSPECT THE CHECKPOINTS STATED IN DAILY INSPECTION IN THIS SECTION F THE REPAIR OR PART REPLACEMENT OF THE ROBOT OR CONTROLLER IS REQUIRED CONTACT YOUR DISTRIBUTOR SUCH WORK NEEDS THE SPECIAL KNOWLEDGE AND SKILL SO ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPAIR OR PART REPLACEMENT WORK OF THE R
22. EXCEPT FROM THE DOOR OR GATE EQUIPPED WITH AN INTERLOCK DEVICE e WARNING LABEL 1 SEE 3 WARNING LABELS IN SAFETY INSTRUCTIONS THAT COMES SUPPLIED WITH A ROBOT SHOULD BE AFFIXED TO AN EASY TO SEE LOCATION ON THE DOOR OR GATE OF THE SAFETY ENCLOSURE o 13 lt SUOHONIALSU AJoJoS 4 5 Operation When operating a robot ignoring safety measures and checks may lead to serious accidents Always take the following safety measures and checks to ensure safe operation DANGER CHECK THE FOLLOWING POINTS BEFORE STARTING ROBOT OPERATION NO ONE IS WITHIN THE ROBOT MOVEMENT RANGE THE PROGRAMMING UNIT IS IN THE SPECIFIED LOCATION e THE ROBOT AND PERIPHERAL EQUIPMENT ARE IN GOOD CONDITION 4 5 1 Trial operation After installing adjusting inspecting maintaining or repairing the robot perform trial operation using the following procedures suouyonisu AJoJoS l If a safety enclosure has not yet been provided right after installing the robot then rope off or chain off the movement range around the robot in place of the safety enclosure and observe the following points A DANGER PLACE A ROBOT IS MOVING AWAY SIGN TO THE OPERATOR OR OTHER PERSONNEL FROM ENTERING WITHIN THE MOVEMENT RANGE OF THE ROBOT A WARNING USE STURDY STABLE POSTS WHICH WILL NOT FALL OVER EASILY e THE ROPE OR CHAIN SHOULD BE EASILY VISIBLE TO EVERYONE AROUND THE ROBOT 2 Check the following points before turning on the cont
23. OR INDIRECT DAMAGES IN ANY MANNER RELATING TO THE PRODUCT Ver 1 00 201205 e 88 Overview Contents 1 Overview l Overview Before beginning the work thoroughly read the safety precautions described below and the Safety Instructions to strictly observe the instructions A WARNING THE ADJUSTMENT AND MAINTENANCE WORK WITH THE COVER REMOVED NEEDS THE SPECIAL KNOWLEDGE AND SKILL IF UNSKILLED WORK PERSON PERFORMS SUCH WORK THIS MAY INVOLVE RISK ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE INACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE ADJUSTMENT AND MAINTENANCE WORK WHILE REFERRING TO THIS MANUAL FOR DETAILS CONTACT YOUR DISTRIBUTOR A WARNING O MOIAIOA ALWAYS TURN OFF THE CONTROLLER BEFORE BEGINNING WORK SERIOUS ACCIDENTS MIGHT OCCUR IF THE ROBOT STARTS TO OPERATE DURING WORK NEVER ATTEMPT TO PERFORM WORK OTHER THAN THOSE DESCRIBED IN THIS MANUAL PLACE A CONSPICUOUS SIGN INDICATING THE ROBOT IS BEING ADJUSTED TO PREVENT OTHERS FROM TOUCHING THE CONTROLLER SWITCH PROGRAMMING BOX OR OPERATION PANEL IF A SAFETY ENCLOSURE HAS NOT YET BEEN PROVIDED RIGHT AFTER INSTALLATION OF THE ROBOT ROPE OFF OR CHAIN OFF THE MOVEMENT AREA AROUND THE MANIPULATOR IN PLACE OF A SAFETY ENCLOSURE AND OBSERVE THE FOLLOWING POINTS 1 USE STABLE POSTS WHICH WILL NOT FALL OVER EASILY 2 THE ROPE OR CHAIN SHOULD BE EASILY VISIBLE BY EVERYONE AROUND THE ROBOT 3 PLACE
24. SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION e Since a positional shift occurs after replacing the motor return to origin must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating The robot is being adjusted fo keep others from operating the controller or operation panel step Enter the safety enclosure gt Step4 Removing the upper cover step Remove the upper cover of the robot Remove the three screws securing the upper cover of the robot and remove the upper cover 3 53401 A5 00 Upper cover 4 5 lt stepB Remove the side cover step O Remove the two screws securing each side cover and remove fhe side covers 53402 A5 00 Remove the end cover on the motor side Remove the four screws securing the end
25. SLIDE DOWNWARD WHEN THE Z AXIS BRAKE IS RELEASED CREATING A HAZARDOUS SITUATION e PRESS THE EMERGENCY STOP BUTTON AND PLACE A SUPPORT UNDER THE VERTICAL AXIS BEFORE RELEASING THE BRAKE e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACH gt S 22 6 2 Special training for industrial robot operation Operators or persons who handle the robot for tasks such as for teaching programming movement checks inspections adjustments and repairs must receive appropriate training and also have the skills needed to perform the job correctly and safely They must also read the manual carefully to understand its contents before attempting the robot operation or maintenance Tasks related to industrial robots teaching programming movement check inspection adjustment repair etc must be performed by qualified persons who meet requirements established by local regulations and safety standards for industrial robots This manual does not serve as a guarantee of any industrial property rights or any other rights and does not grant a license in any form Please acknowledge that we bear no liability whatsoever for any problems involving industrial property rights which may arise from the contents of this manual 2012 YAMAHA MOTOR CO LTD 5 23 suouyonjjsu AJoJoOS Revision record Manual version Issue date Description Ver 1 00 May 2012
26. THE END EFFECTOR TO FLY OUTWARD OR DROP AND THE ROBOT TO MALFUNCTION 4 Mechanical stoppers If the servo power is shut off by emergency stop operation or safety function while the robot is moving then these mechanical stoppers prevent the axis from exceeding the movement range No mechanical stopper is provided on the rotational axis The movement range is the area limited by the mechanical stoppers e The X and Y axes have mechanical stoppers that are installed at both ends of the maximum movement range Some robot models have a standard feature that allows changing the mechanical stopper positions On some other models the mechanical stopper positions can also be changed by using option parts e The Z axis has a mechanical stopper at the upper end and lower end The stopper positions can be changed by using option parts e No mechanical stopper is provided on the R axis A WARNING AXIS MOVEMENT DOES NOT STOP IMMEDIATELY AFTER THE SERVO POWER SUPPLY IS SHUT OFF BY EMERGENCY STOP OR OTHER SAFETY FUNCTIONS 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from sliding downward when servo power is OFF This brake is working when the controller is OFF or the Z axis servo power is OFF even when the controller is ON The Z axis brake can be released by the programming unit handy terminal or by a command in the program when the controller is ON A WARNING THE VERTICAL AXIS WILL
27. by any of the following methods when installing operating or adjusting the robot and controller 1 Install operate or adjust the robot and controller while referring to the printed version of the manual available for an additional fee Install operate or adjust the robot and controller while viewing the CD ROM version of the manual on your computer screen Install operate or adjust the robot and controller while referring to a printout of the necessary pages from the CD ROM version of the manual 5 1 lt SUOHONIALSU AJoJoS SUOHONIALSU AJoJoS 2 Signal words used in this manual This manual uses the following safety alert symbols and signal words to provide safety instructions that must be observed and to describe handling precautions prohibited actions and compulsory actions Make sure you understand the meaning of each symbol and signal word and then read this manual DANGER THIS INDICATES AN IMMEDIATELY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY A WARNING THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY N CAUTION This indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to the equipment Not 9 NOTE Explains the key point in the operation in a simple and clear manner gt 5 2 3 Warning labels Warning labels shown
28. for grease application Using the following grease gun and grease will ensure correct refills of grease Grease gun model MG70 made by THK or equivalent Nozzle type N type made by THK or equivalent Grease AFB grease made by THK 70g cartridge or equivalent step Y Turn off the controller power a step Place a sign indicating the robot is being adjusted Place a sign indicating The robot is being adjusted to keep others from operating the controller or operation panel step Enter the safety enclosure step Wipe off the contaminated grease First wipe off the contaminated grease with a clean cloth rag wound on the stick CAUTION Do not put your finger in the slider movement range to prevent your finger from being caught in if the slider is moved by hand accidentally IDedsul 2 step Apply the grease Use the grease gun to apply the grease to the grease nipple of the linear guide through the clearance between the upper cover and frame gt 2 12 TIA Adjustment Contents 1 Adjusting the alignment B10 B14 B14H 2 Adjusting the timing belt tension B10 B14 B14H 3 2 2 1 Adjusting the drive belt tension 3 3 2 2 Adjusting the speed reduction belt tension 3 4 3 Adjusting the timing belt tension F20N 3 1 Installing and removing the cover 3 6 3 1 1 Stroke cover 3 6 3 1 2 Belt cover 3 8 3 1 3 Motor cover 3 9 3 2 Adjusting the timing belt tension 3 10 4 Adj
29. how to remove the cover see 3 Installing the robot in Chapter 2 of the Installation Manual step Remove the upper cover Remove the four screws securing the upper cover of the robot and remove the upper COVer Step Remove the end cover 2 located at the lower portion from both ends Remove the two screws securing the end cover of the robot and remove the end cover 2 For the N15 robot turn over the molding portion remove the screws Two screws each on the left and right and remove the end cover 2 53402 AA 00 step 7 Remove the cable cover 53403 AA 00 Provide a space of at least 300mm between each end of the robot and the wall Do not pull out the ball screw Allow a space of 300mm or more gt Step 5 6 Removing the cover End cover 2 Molding portion gt Step7 Removing the cable cover Cable cover y 4 11 lt AJ 3 step Disconnect the power cable and signal cable Use diagonal cuffers fo cut the insulock ties securing the motor cable and disconnect the power cable and signal cable i gt Step9 Moving the side cover step Y Move the side cover Loosen the screw securing the side cover and slide the side cover in the direction of arrow To a position that allows access to the motor unit The N18 robot has no side cover so skip this step 7 9 Side eicover 53404 00 step 10 Free the table slider and motor coupling Scr
30. of other than genuine YAMAHA parts and or accessories ON ODO Ui A C N Modification to original parts or modifications not conforming to standard specifications designated by YAMAHA including customizing performed by YAMAHA in compliance with distributor or customer requests 9 Pollution salt damage condensation Fires or natural disasters such as earthquakes tsunamis lightning strikes wind and flood damage etc 11 Breakdown due to causes other than the above that are not the fault or responsibility of YAMAHA B The following cases are not covered under the warranty 1 Products whose serial number or production date month amp year cannot be verified 2 Changes in software or internal data such as programs or points that were created or changed by the customer 3 Products whose trouble cannot be reproduced or identified by YAMAHA 4 Products utilized for example in radiological equipment biological test equipment applications or for other purposes whose warranty repairs are judged as hazardous by YAMAHA THE WARRANTY STATED HEREIN PROVIDED BY YAMAHA ONLY COVERS DEFECTS IN PRODUCTS AND PARTS SOLD BY YAMAHA TO DISTRIBUTORS UNDER THIS AGREEMENT ANY AND ALL OTHER WARRANTIES OR LIABILITIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXPRESSLY DISCLAIMED BY YAMAHA MOREOVER YAMAHA SHALL NOT BE HELD RESPONSIBLE FOR CONSEQUENT
31. shutter in Chapter 4 E contamination 1 Ball screw bearing Check for unusual vibration or noise If any trouble is found contact your distributor Check for unusual vibration and noise and Check with the load factor monitor that the load factor for abnormal temperature rise is 100 or less 2 Motor 1 According to the robot working conditions stripe marks caused by contamination may be produced on the shutter top surface close to the stop point If this occurs clean the shutter top surface with a cloth rag moistened with alcohol cleaning agent If this trouble occurs frequently contact your distributor 2 Some robot controller models cannot monitor the load factor inspection to be performed with the controller turned on A 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 IS TURNED ON step Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being inspected to keep others from operating the controller programming box or operation panel step Perform the daily inspection Check the following points from outside the safety enclosure Checkpoint Procedure Remarks Check if the safety enclosure is in place
32. tension step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel Step Enter the safety enclosure gt Step4 Removing the belt cover Step Remove the belt cover 53307 AC 00 step Measure the slack amount Apply the load shown in the table below to the center portion between both pulleys to measure the slack When the slack is within the range stated in the table no adjustment is needed 53308 AC 00 Load and slack for speed reduction belt tension Robot model SS ne Da DE Step 5 Measuring the slack amount B14 B14H 5 9 to 6 9 0 6 to 0 7 If the slack is beyond the range stated in the table above go fo the next Step Pulley step Loosen the motor plate mounting gt Step6 Loosening the motor plate mounting bolts bolts D 53309 AC 00 step 4 Move the motor case to adjust the slack If the value that has been measured in Step 5 is smaller than the value shown in the table move the motor case in the tension increase direction Conversely if the measured value is larger than the value shown in the table move the motor case in the tension decrease direction 53310 AC 00 Stp Measure the belt tension again Follow Step 4 to measure the belt tension gt Step 7 Adjusting the slack again When the measured value is within the ran
33. the Fig below e Tension meter Stay example Push pull scale Metal plate of 3 2mm thick 53303 AC 00 gt 3 2 2 1 Adjusting the drive belt tension step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel step Enter the safety enclosure step Take off the end cover step Remove the upper cover Remove the upper cover mounting screws and remove the upper cover N CAUTION On robot models having a long stroke the slider is fitted in the travel guide U groove inside the gt Step 6 Applying a tension upper cover so remove the upper cover by sliding it along the direction the robot moves step Apply a tension to the belt Install the belt tension adjustment bolt supplied with the robot gt 2 2 3 D 3 2 Loosen the belt stay mounting bolts eight bolts 3 Turn the agjustment bolt to apply a tension to the belt 53305 AC 00 Step Apply a load Move the slider by hand to a position at which the distance from the slider edge to the base block edge is 150mm ep Apply a load to the belt at a position 115mm or 129mm B14 away from the slider edge Adjusting the speed reduction belt tension 53304 AC 00 53306 AC 00 step Tighten the belt stay mounting bo
34. the shutter carefully handle it so that the shutter surface is not scratched Step Wipe off the contaminated grease First wipe off the contaminated grease with a clean cloth rag step7 Apply the grease gt Step 7 Applying the grease Apply an adequate amount of grease to the ball screw or linear guide so that it does not scatter surroundings N CAUTION gt For the TAL TALH robot the brush insertion portion is narrow So apply the grease with a small brush NAAA 23301 A1 00 51 Spread the grease Move the slider back and forth fo spread the grease N CAUTION gt _ Applying grease to the ball screw Do not put your finger in the slider movement range to prevent your finger from being caught in if the slider is moved by hand accidentally step Y Reattach the shutter to its original position MP RR S XN OF NOTE For details about how to adjust the shutter see TE 4 Adjusting shutter looseness in this Chapter LE 4g Applying grease to the linear guide 2 8 3 2 T9 T9H F10 F14 F14H F17 F17L F20 F20N Prepare the tools necessary for the replacement work e Phillips screwdriver Grease gun recommended grease gun THK s MG70 nozzle shape N type e Brush for grease application step Y Turn off the controller power steps Place a sign indicating the robot is being adjusted Place a sign indicating The robot is being adjusted fo keep others fro
35. 18 4 1 Replacing the drive belt 4 18 4 2 Replacing the speed reduction belt 4 20 5 Replacing the slider 4 21 5 1 B10 B14 B14H 4 21 5 2 F20N 4 22 6 Maintenance parts 4 23 6 1 Consumable parts 4 23 1 Replacing the shutter T4L T4LH T5L TS5LH T L When the shutter needs to be replaced follow the steps below WARNING Ak e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY CAUTION AN e Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Turn off the controller power gt Step4 Removing the slider cover step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep oth
36. BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work e s 3 D 3 3 1 Installing and removing the cover 3 1 1 Stroke cover Removing the stroke cover step 4 Turn off the controller power step Place a sign indicating the robot is gt Step 4 Removing the mounting screws being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel Step Enter the safety enclosure step Remove the mounting screws from both ends Remove the mounting screws M4 pan head screws 53302 A9 00 step Pull out the cover Move the table slide to the stroke end and pull out the cover gt Step5 Pulling out the cover 53301 A9 00 3 6 B Installing the stroke cover step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel Step En
37. CT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT 3 Shut off all phases of power supply A WARNING ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE CLEANING THE ROBOT AND CONTROLLER OR SECURELY TIGHTENING THE TERMINAL SCREWS ETC FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE OR MALFUNCTION 4 Allow a waiting time after power is shut off Allow time for temperature and voltage to drop A WARNING e WHEN PERFORMING MAINTENANCE OR INSPECTION OF THE ROBOT CONTROLLER UNDER YOUR DISTRIBUTOR S INSTRUCTIONS WAIT AT LEAST 30 MINUTES FOR THE RCX SERIES OR 5 MINUTES FOR THE SR1 SERIES AFTER TURNING THE POWER OFF SOME COMPONENTS IN THE ROBOT CONTROLLER ARE VERY HOT OR STILL RETAIN A HIGH VOLTAGE SHORTLY AFTER OPERATION SO BURNS OR ELECTRICAL SHOCK MAY OCCUR IF THOSE PARTS ARE TOUCHED THE MOTOR AND SPEED REDUCTION GEAR CASING ARE VERY HOT SHORTLY AFTER OPERATION SO BURNS MAY OCCUR IF THEY ARE TOUCHED BEFORE TOUCHING THOSE PARTS FOR INSPECTIONS OR SERVICING TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THE TEMPERATURE HAS COOLED 5 Precautions during inspection of controller A WARNING e WHEN YOU NEED TO TOUCH THE TERMINALS OR CONNECTORS ON THE OUTSIDE OF THE CONTROLLER DURING INSPECTION ALWAYS FIRST TURN OFF THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER TO PREVENT POSSIBLE ELECTRICAL SHOCK DO NOT DISASSEMBLE THE CONTROLLER NEVER TOUCH ANY INTERNAL PARTS OF THE CONTROLL
38. Controller ROB S2 1 XY ZR S4 2 S1 3 S3 4 R1 5 R2 6 DG 7 MB 14 MB 16 24V 9 ORG 12 GND24 13 S2 19 S4 20 S1 21 53 22 H1 23 R2 24 DG 25 MB 32 MB 34 24V 27 ORG 30 GND24 31 HLIM 10 GND24 11 HLIM 28 GND24 29 Controller MOTOR U 2 XM ZM V 3 W 4 FG 1 Controller MOTOR U 2 YM RM V 3 W 4 FG 1 Connection uu am PIN Parts Wire 1 Resolver P1 0 3sq Red 2 White 3 Green 4 White 5 Yellow 6 White 7 Drain wire Grey Heat shrinkable tube 1 Brake BK1 Blue 2 White ORG 1 Purple 2 Blue 3 Brown 1 Resolver P2 Hed 2 White 3 Green 4 White 5 Yellow 6 White 7 Drain wire Grey Heat shrinkable tube 1 Brake BK2 Blue e 2 White 5 ORG2 1 Purple L 2 Blue r 3 Brown 0 359 Grey 9 gt 0 3sq Grey o 1 Motor M1 0 75sq Red 2 White 3 Black 4 Grey Heat shrinkable tube 1 Motor M2 0 75sq Red 2 White 3 Black 4 Grey Heat shrinkable tube 9 15 2 Robot combination 1st axis is PHASER and 2nd axis is FLIP X Connection controller RCX221 240 Cables for multi robot ra EA AL I L A 255 L Fe TIER To controller To robot 53501 R0 00 5 16 9
39. D BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION Since a positional shift occurs after replacing the motor return to origin must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work Step 5 Disconnecting the motor cable connectors step Y Turn off the controller power gt A step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel step Enter the safety enclosure Step Remove the belt cover and motor cover 3 NL M 0 NOTE _S5 _ _ For details about how to remove the cover see 3 1 y Installing and removing the cover in Chapter 3 P Step6 Removing the motor mounting bolts step Disconnect the motor cable connectors Open the wi
40. DERAL STATE AND LOCAL REGULATIONS TAKE APPROPRIATE MEASURES IN COMPLIANCE WITH LEGAL REGULATIONS 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 A WARNING WHEN THE BRAKE OF THE VERTICAL AXIS IS RELEASED THE SLIDER AXIS MAY DROP LEADING TO HAZARDOUS SITUATION WHEN APPLYING THE GREASE TO THE VERTICAL AXIS PARTS DO NOT RELEASE THE BRAKE N CAUTION Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust 2 lt a Ioedsur 5 3 1 TAL TALH TS5L T5LH T6L Prepare appropriate Phillips screwdriver and brush for grease application step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel step Enter the safety enclosure UJ Stp Remove the two screws from side zu Remove the two screws from one side of the screws securing both ends of the shutter o N CAUTION At this time do not remove the cover completely gt A ze o O step Turn over the shutter from the side D where the screws have been O removed O N CAUTION When turning over
41. E ur step Remove the belt cover 3 step Remove the motor case and motor cover 53401 AC 00 step O Remove the motor Remove the four motor mounting bolts and remove the motor 53402 AC 00 step Y Remove the pulley Loosen the two set screws of the pulley and remove the pulley 53403 AC 00 step Replace the motor with a new one and attach the pulley to this new motor v zz At this time insert the pulley so that the D 4 5 b WALT face of the motor shaft is in contact with the set screws two locations vertically Projecting the set screws approx 0 1 to 0 2 will ensure the easy assembly work pio gt Step7 Removing the pulley step Y Install the motor to the motor plate step 10 Fit the belt onto the pulleys step 1 1 Adjust the belt tension Adjust the belt tension while referring to 2 Adjusting the timing belt tension B10 BIA BIAH in Chapter 3 step 12 Reattach the motor case and cover step 1 3 Reattach the belt cover 4 8 2 4 F20N A WARNING e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVE
42. ER DOING SO MAY CAUSE BREAKDOWN MALFUNCTION INJURY OR FIRE gt 5 18 4 6 2 Precautions during service work 1 Precautions when removing a motor Cartesian robots and vertical mount single axis robots A WARNING THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE MOTOR IS REMOVED CAUSING A HAZARDOUS SITUATION e TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER THE VERTICAL AXIS BEFORE REMOVING THE MOTOR BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BY THE DRIVING UNIT OF THE VERTICAL AXIS OR BETWEEN THE VERTICAL AXIS AND THE INSTALLATION BASE 2 Be careful when removing the Z axis motor SCARA robots WARNING Ak THE Z AXIS WILL SLIDE DOWNWARD WHEN THE Z AXIS MOTOR IS REMOVED CAUSING A HAZARDOUS SITUATION e TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER THE Z AXIS BEFORE REMOVING THE Z AXIS MOTOR BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BY THE DRIVING UNIT OF THE Z AXIS OR BETWEEN THE Z AXIS DRIVE UNIT AND THE INSTALLATION BASE 3 Do not remove the Z axis upper limit mechanical stopper N CAUTION Warning label 4 is attached to each SCARA robot For details on warning labels see 3 Warning labels in Safety instructions Removing the upper limit mechanical stopper installed to the Z axis spline or shifting its position will damage the Z axis ball screw Never attempt to remove it 4 Use caution when handling a robot that contains powerful magnets A WARNING POWERFUL MAGNETS ARE INSTALLED INSIDE THE R
43. First edition Ver 1 01 Jun 2012 Description of Emergency action when a person is caught by robot was added the work sequence for working within the safety enclosure changed typing errors corrected etc YAMAHA Safety Instructions Jun 2012 Ver 1 01 This manual is based on Ver 1 01 of Japanese manual YAMAHA MOTOR CO LTD IM Operations All rights reserved No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or omissions If you find any part unclear in this manual please contact your distributor Warranty For information on the warranty period and terms please contact our distributor where you purchased the product This warranty does not cover any failure caused by 1 Installation wiring connection to other control devices operating methods inspection or maintenance that does not comply with industry standards or instructions specified in the YAMAHA manual Usage that exceeded the specifications or standard performance shown in the YAMAHA manual Product usage other than intended by YAMAHA AJUDIIDM Storage operating conditions and utilities that are outside the range specified in the manual Damage due to improper shipping or shipping methods Accident or collision damage Installation
44. ION Since a positional shift occurs after replacing the belt return to origin must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work Step 4 Removing the belt cover step Y Turn off the controller power 9 step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel Step Enter the safety enclosure Stp Remove the belt cover 3 53408 AC 00 step49 Remove the motor plate bolts 4 pieces 53409 AC 00 P Step 5 Removing the motor plate bolts step Move the motor plate to a side Where the belt becomes loose and detach the belt from the pulleys Move the motor plate to the loosening side and detach the belt step Y Attach the belt First attach a new belt onto the small pulley and then fit it To the large pulley 53410 AC 00 step Adjust the belt tension For details see 2 Adjusting the timing belt tension B10 B14 B14H in Chapter 3 step Y Reattach the belt cover 4 20 5 Replacing the slider 5 1 B10 B14 B14H
45. ITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel Step Enter the safety enclosure step dd Remove the upper center cover step Remove the slider mounting bolts gt Step5 Removing the slider mounting bolts 2 pieces 3 53407 A9 00 step Replace the slider Secure a new Slider with the mounting bolts step Install the top center cover For details see 3 1 Installing and removing the cover in Chapter 3 4 22 6 Maintenance parts 6 1 Consumable parts TAL TALH Part name Shutter Part number KDC M229J xxx SHUTTER 1 Remarks 50st to 400st Insert KDC M2243 xxx INSERT Coupling resin part Slider T5L T5LH Part name KX1 M22L1 xxx SLIDER Part number Slider resin part Remarks Shutter KDD M229J xxx SHUTTER 1 50st to 800st Insert KDD M2243 xxx INSERT Coupling resin part Slider T6L Part name KX2 M22L1 xxx SLIDER P
46. K POOR GROUNDING MAY CAUSE ELECTRICAL SHOCK 5 11 lt SUOLLONILSUL AJoJoOS SUOHONAISU AJoJoS 4 4 Safety measures 4 4 1 Safety measures 1 Referring to warning labels and manual WARNING BEFORE STARTING INSTALLATION OR OPERATION OF THE BE SURE TO READ THE WARNING LABELS AND THIS MANUAL AND COMPLY WITH THE INSTRUCTIONS NEVER ATTEMPT ANY WORK OR OPERATION UNLESS DESCRIBED IN THIS MANUAL NEVER ATTEMPT ANY REPAIR PARTS REPLACEMENT AND MODIFICATION UNLESS DESCRIBED IN THIS MANUAL THESE TASKS REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS PLEASE CONTACT YOUR DISTRIBUTOR FOR ADVICE NU m NOTE For details on warning labels see 3 Warning labels in Safety instructions 2 Draw up work instructions and make the operators workers understand them A WARNING DECIDE ON WORK INSTRUCTIONS IN CASES WHERE PERSONNEL MUST WORK WITHIN THE ROBOT MOVEMENT RANGE TO PERFORM STARTUP OR MAINTENANCE WORK MAKE SURE THE WORKERS COMPLETELY UNDERSTAND THESE WORK INSTRUCTIONS Decide on work instructions for the following items in cases where personnel must work within the robot movement range to perform teaching maintenance or inspection tasks Make sure the workers completely understand these work instructions 1 Robot operating procedures needed for tasks such as startup procedures and handling switches 2 Robot speeds used during tasks such as teaching 3 Methods for
47. LER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY CAUTION AN Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work e Since a positional shift occurs after replacing the motor return to origin must be performed again and the point data re specified When removing the parts note their positional relation and assembly order nut section from the ball screw Ball screw Nut section Do not pull out step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating The robot is being adjusted fo keep others from operating the controller or operation panel Step Enter the safety enclosure step Remove the end covers 1 upper end covers from both ends of the robot 4 O3 NOTE For details about
48. LURE TO FOLLOW THIS WARNING MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH INSTALL A SAFETY ENCLOSURE OR A GATE INTERLOCK WITH AN AREA SENSOR TO KEEP ALL PERSONS AWAY FROM THE ROBOT MOVEMENT RANGE e WHEN IT IS NECESSARY TO OPERATE THE ROBOT WHILE YOU ARE WITHIN THE ROBOT MOVEMENT RANGE SUCH AS FOR TEACHING OR MAINTENANCE INSPECTION TASKS ALWAYS CARRY THE PROGRAMMING BOX WITH YOU SO THAT YOU CAN IMMEDIATELY STOP THE ROBOT OPERATION IN CASE OF AN ABNORMAL OR HAZARDOUS CONDITION FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH gt 5 12 WARNING e DURING STARTUP OR MAINTENANCE TASKS DISPLAY A SIGN WORK IN PROGRESS ON THE PROGRAMMING BOX AND OPERATION PANEL IN ORDER TO PREVENT ANYONE OTHER THAN THE PERSON FOR THAT TASK FROM MISTAKENLY OPERATING THE START OR SELECTOR SWITCH IF NEEDED TAKE OTHER MEASURES SUCH AS LOCKING THE COVER ON THE OPERATION PANEL e ALWAYS CONNECT THE ROBOT AND ROBOT CONTROLLER IN THE CORRECT COMBINATION USING THEM IN AN INCORRECT COMBINATION MAY CAUSE FIRE OR BREAKDOWN 4 Install system safeguards When configuring an automated system using a robot hazardous situations are more likely to occur from the automated system than the robot itself So the system manufacturer should install the necessary safety measures required for the individual system The system manufacturer should provide a proper manual for safe correct operation and servicing of the system AA WAR
49. NING TO CHECK THE ROBOT CONTROLLER OPERATING STATUS REFER TO THIS MANUAL AND TO RELATED MANUALS DESIGN AND INSTALL THE SYSTEM INCLUDING THE ROBOT CONTROLLER SO THAT IT WILL ALWAYS WORK SAFELY 5 Precautions for operation WARNING Ak e DO NOT TOUCH ANY ELECTRICAL TERMINAL DIRECTLY TOUCHING THESE TERMINALS MAY CAUSE ELECTRICAL SHOCK EQUIPMENT DAMAGE AND MALFUNCTION e DO NOT TOUCH OR OPERATE THE ROBOT CONTROLLER OR PROGRAMMING BOX WITH WET HANDS TOUCHING OR OPERATING THEM WITH WET HANDS MAY RESULT IN ELECTRICAL SHOCK OR BREAKDOWN 6 Do not disassemble and modify A WARNING NEVER DISASSEMBLE AND MODIFY ANY PART IN THE ROBOT CONTROLLER AND PROGRAMMING BOX DO NOT OPEN ANY COVER DOING SO MAY CAUSE ELECTRICAL SHOCK BREAKDOWN MALFUNCTION INJURY OR FIRE 4 4 2 Installing a safety enclosure Be sure to install a safety enclosure to keep anyone from entering within the movement range of the robot The safety enclosure will prevent the operator and other persons from coming in contact with moving parts of the robot and suffering injury A DANGER A SERIOUS INJURY MAY RESULT FROM CONTACT WITH A MOVING ROBOT KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE WARNING Ak INSTALL AN INTERLOCK THAT TRIGGERS EMERGENCY STOP WHEN THE DOOR OR GATE OF THE SAFETY ENCLOSURE IS OPENED e THE SAFETY ENCLOSURE SHOULD BE DESIGNED SO THAT NO ONE CAN ENTER INSIDE
50. NLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE ADJUSTMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY A WARNING THE MOTOR AND SPEED REDUCTION GEAR CASING ARE EXTREMELY HOT AFTER AUTOMATIC OPERATION SO BURNS MAY OCCUR IF THESE ARE TOUCHED BEFORE TOUCHING THESE PARTS TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THE PARTS HAVE COOLED INJURY CAN OCCUR IF HANDS OR FINGERS ARE SQUEEZED BETWEEN THE DRIVE PULLEY AND BELT ALWAYS TURN OFF THE CONTROLLER AND USE CAUTION WHEN HANDLING THESE PARTS N CAUTION e Since a positional shift occurs after adjusting the belt tension return to origin or absolute reset must be performed again and the point data re specified Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work gt a o 3 2 Prepare tools necessary for the adjustment work e Belt tension adjustment bolt accessory e Push pull scale e Stay The user must manufacture this stay while referring to
51. NS THAT GENERATE STRONG MAGNETIC FIELDS THE ROBOT MAY BREAKDOWN OR MALFUNCTION IF USED IN SUCH LOCATIONS 2 Do not use in locations subject to possible electromagnetic interference etc A WARNING DO NOT USE THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC INTERFERENCE ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE THE ROBOT MAY MALFUNCTION IF USED IN SUCH LOCATIONS CREATING HAZARDOUS SITUATIONS 3 Do not use in locations exposed to flammable gases A WARNING e YAMAHA ROBOTS ARE NOT DESIGNED TO BE EXPLOSION PROCF e DO NOT USE THE ROBOTS IN LOCATIONS EXPOSED TO EXPLOSIVE OR INFLAMMABLE GASES DUST PARTICLES OR LIQUID FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH OR LEAD TO FIRE B Moving 1 Use caution to prevent pinching or crushing of hands or fingers A WARNING MOVING PARTS CAN PINCH OR CRUSH HANDS OR FINGERS KEEP HANDS AWAY FROM THE MOVABLE PARTS OF THE ROBOT As instructed in Warning label 2 use caution to prevent hands or fingers from being pinched or crushed by movable parts when transporting or moving the robot For details on warning labels see 3 Warning labels in Safety instructions 2 Take safety measures when moving the robot To ensure safety when moving a SCARA robot with an arm length of 500mm or more use the eyebolts that come supplied with the robot Refer to the robot manual for details B Installation 1 Protect electrical wiring and h
52. OBOT DO NOT DISASSEMBLE THE ROBOT SINCE THIS MAY CAUSE INJURY DEVICES THAT MAY MALFUNCTION DUE TO MAGNETIC FIELDS MUST BE KEPT AWAY FROM THIS ROBOT 5 Use the following caution items when disassembling or replacing the pneumatic equipment SUPPLIED e DO SERVICE WORK AFTER TURNING OFF THE CONTROLLER REDUCING THE AIR PRESSURE AND EXHAUSTING THE RESIDUAL AIR FROM THE PNEUMATIC EQUIPMENT BEFORE REDUCING THE AIR PRESSURE PLACE A SUPPORT STAND UNDER THE Z AXIS 2 AXIS ROBOTS WITH AIR DRIVEN Z AXIS SINCE IT WILL DROP UNDER ITS OWN WEIGHT 6 Use caution to avoid contact with the controller cooling fan A WARNING TOUCHING THE ROTATING FAN MAY CAUSE INJURY IF REMOVING THE FAN COVER FIRST TURN OFF THE CONTROLLER AND MAKE SURE THE FAN HAS STOPPED 7 Precautions for robot controllers CAUTION A e Back up the robot controller internal data on an external storage device The robot controller internal data programs point data etc may be lost or deleted for unexpected reasons Always make a backup of this data Do not use thinner benzene or alcohol to wipe off the surface of the programming box The surface sheet may be damaged or printed letters or marks erased Use a soft dry cloth and gently wipe the surface Do not use a hard or pointed object to press the keys on the programming box Malfunction or breakdown may result if the keys are damaged Use your fingers to operate the keys Do not insert any SD memory ca
53. OBOT OR CONTROLLER 2 2 Three month inspection Take the following precautions when performing 3 month inspection A WARNING WHEN THE BRAKE OF THE VERTICAL AXIS IS RELEASED THE SLIDER AXIS MAY DROP LEADING TO HAZARDOUS SITUATION WHEN APPLYING THE GREASE TO THE VERTICAL AXIS PARTS DO NOT RELEASE THE BRAKE inspection to be performed with the controller turned off step 4 Turn off the controller IDedsul 2 step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being inspected to keep others from operating the controller switch UO step Perform the daily inspection Enter the safety enclosure and check the following points Checkpoint Procedure Remarks Manipulator bolts and screws Only for major bolts and screws exposed externally Check for looseness and tighten if necessary 1 Check for looseness at each terminal and connector on the panel Controller Check for dirt or grime If dirt or grime is found clean the part Apply grease after cleaning Apply grease if the items checked are Ball screw Linear guide dry or do not have enough grease Recommended grease Alvania grease S2 Showa Shell Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu See 3 Applying the grease in this Chapter Check for looseness See 5 Adjusting shutter looseness e Check for flow up clearance in Chapter 3 Shutter
54. OLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION Since a positional shift occurs after replacing the motor return to origin must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work Step 5 Removing the motor case and motor cover step Y Turn off the controller power step Place a sign indicating the robot is Dude SUE tor cover being adjusted pola o es Place a sign indicating the robot is being Eb e adjusted fo keep others from operating the J E eos controller or operation panel step Enter the safety enclosure et ay
55. ORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION Since a positional shift occurs after replacing the motor return to origin must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later Be sure fo wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Y Turn off the controller power steps Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel j step Enter the safety enclosure step Remove the parts securing t
56. ROBOT TO MALFUNCTION gt 5 10 B Wiring 1 Connection to robot controller The controller parameters are preset at the factory before shipping to match the robot model Check the specified robot and controller combination and connect them in the correct combination Since the software detects abnormal operation such as motor overloads the controller parameters must be set correctly to match the motor type used in the robot connected to the controller 2 Wiring safety points A WARNING ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE STARTING INSTALLATION OR WIRING WORK FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE N CAUTION Make sure that no foreign matter such as cutting chips or wire scraps get into the robot controller Malfunction breakdown or fire may result if these penetrate inside Do not apply excessive impacts or loads to the connectors when making cable connections This might bend the connector pins or damage the internal PC board e When using ferrite cores for noise elimination be sure to fit them onto the power cable as close to the robot controller and or the robot as possible to prevent malfunction caused by noise 3 Wiring method A WARNING SECURELY INSTALL THE CONNECTORS INTO THE ROBOT CONTROLLER AND WHEN WIRING THE CONNECTORS MAKE THE CRIMP PRESS CONTACT OR SOLDER CONNECTIONS CORRECTLY USING THE TOOL SPECIFIED BY THE CONNECTOR MANUFACTURER N CAUTION
57. S OR THREATEN OPERATOR SAFETY e WHEN ADJUSTMENT OR MAINTENANCE IS COMPLETE RETIGHTEN THE BOLTS AND SCREWS SECURELY PLACE A SIGN INDICATING THE ROBOT IS BEING ADJURED OR INSPECTED TO KEEP OTHERS FROM OPERATING THE CONTROLLER POWER SWITCH PROGRAMMING BOX HANDY TERMINAL OR OPERATION PANEL WHEN NECESSARY INSTALL AN APPROPRIATE SWITCH KEY LOCK MECHANISM OR ARRANGE A WATCHER N CAUTION Only qualified engineers who have the skill and license in accordance with the laws and regulations in each country are allowed to carry out the periodic inspection Never attempt to perform inspection adjustment repair or part replacement work of the robot and controller other than those described in this manual Such work requires special knowledge and may involve risk Before starting each adjustment work thoroughly read this Chapter to fully understand its contents If a safety enclosure has not yet been provided right after installation of the robot rope off or chain off the movement area around the manipulator in place of a safety enclosure and observe the following points 1 Use stable posts which will not fall over easily 2 The rope or chain should be easily visible by everyone around the robot 3 Place a conspicuous sign prohibiting the operator or other personnel from entering the movement area of the manipulator To check the operation after the adjustment has been made see 4 5 1 Trial operation in the Safety Instructions Be sure to wea
58. SSURE TO THE Z AXIS AIR CYLINDER SOLENOID VALVE IS REDUCED CREATING A HAZARDOUS SITUATION TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER THE Z AXIS BEFORE CUTTING OFF THE AIR SUPPLY 7 Make correct parameter settings N CAUTION The robot must be operated with the correct tolerable moment of inertia and acceleration coefficients that match the manipulator tip mass and moment of inertia Failure to follow this instruction will lead to a premature end to the drive unit service life damage to robot parts or cause residual vibration during positioning 8 If the X axis Y axis or R axis rotation angle is small N CAUTION If the X axis Y axis or R axis rotation angle is set smaller than 5 degrees then it will always move within the same position This restricted position makes it difficult for an oil film to form on the joint support bearing and so may possibly damage the bearing In this type of operation add a range of motion so that the joint moves through 90 degrees or more about 5 times a day 5 17 lt suouyonijsu AJoJoS SUOHONIALSU AJoJoS 4 6 Inspection and maintenance Always perform daily and periodic inspections and make a pre operation check to ensure there are no problems with the robot and related equipment If a problem or abnormality is found then promptly repair it or take other measures as necessary Keep a record of periodic inspections or repairs and store this record for at least 3 years 4 6 1 Bef
59. THE VERTICAL AXIS BEFORE RELEASING THE BRAKE BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL AXIS AND THE INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM DIRECT TEACH 4 Be careful of Z axis movement when the controller is turned off or emergency stop is triggered air driven Z axis A WARNING THE Z AXIS STARTS MOVING UPWARD WHEN POWER TO THE CONTROLLER OR PLC IS TURNED OFF THE PROGRAM IS RESET EMERGENCY STOP IS TRIGGERED OR AIR IS SUPPLIED TO THE SOLENOID VALVE FOR THE Z AXIS AIR CYLINDER e DO NOT LET HANDS OR FINGERS GET CAUGHT AND SQUEEZED BY ROBOT PARTS MOVING ALONG THE Z AXIS e KEEP THE USUAL ROBOT POSITION IN MIND SO AS TO PREVENT THE Z AXIS FROM HANGING UP OR BINDING ON OBSTACLES DURING RAISING OF THE Z AXIS EXCEPT IN CASE OF EMERGENCY STOP 5 Take protective measures when the Z axis interferes with peripheral equipment air driven Z axis A WARNING WHEN THE Z AXIS COMES TO A STOP DUE TO OBSTRUCTION FROM PERIPHERAL EQUIPMENT THE Z AXIS MAY MOVE SUDDENLY AFTER THE OBSTRUCTION IS REMOVED CAUSING INJURY SUCH AS PINCHED OR CRUSHED HANDS e TURN OFF THE CONTROLLER AND REDUCE THE AIR PRESSURE BEFORE ATTEMPTING TO REMOVE THE OBSTRUCTION e BEFORE REDUCING THE AIR PRESSURE PLACE A SUPPORT UNDER THE Z AXIS BECAUSE THE Z AXIS WILL DROP UNDER ITS OWN WEIGHT 6 careful of Z axis movement when air supply is stopped air driven Z axis A WARNING THE Z AXIS WILL SLIDE DOWNWARD WHEN THE AIR PRE
60. TION THAT IS OUTSIDE THE ROBOT MOVEMENT RANGE YET WHERE IT IS EASY TO OPERATE AND VIEW ROBOT MOVEMENT INSTALL THE ROBOT CONTROLLER IN LOCATIONS WITH ENOUGH SPACE TO PERFORM WORK TEACHING INSPECTION ETC SAFELY LIMITED SPACE NOT ONLY MAKES IT DIFFICULT TO PERFORM WORK BUT CAN ALSO CAUSE INJURY INSTALL THE ROBOT CONTROLLER IN A STABLE LEVEL LOCATION AND SECURE IT FIRMLY AVOID INSTALLING THE CONTROLLER UPSIDE DOWN OR IN A TILTED POSITION PROVIDE SUFFICIENT CLEARANCE AROUND THE ROBOT CONTROLLER FOR GOOD VENTILATION INSUFFICIENT CLEARANCE MAY CAUSE MALFUNCTION BREAKDOWN OR FIRE B installation To install the robot controller observe the installation conditions and method described in the manual 1 Installation A WARNING SECURELY TIGHTEN THE SCREWS FOR THE L SHAPED BRACKETS USED TO INSTALL THE ROBOT CONTROLLER IF NOT SECURELY TIGHTENED THE SCREWS MAY COME LOOSE CAUSING THE CONTROLLER TO DROP 2 Connections WARNING ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE STARTING INSTALLATION OR WIRING WORK FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE e NEVER DIRECTLY TOUCH CONDUCTIVE SECTIONS AND ELECTRONIC PARTS OTHER THAN THE CONNECTORS ROTARY SWITCHES AND DIP SWITCHES ON THE OUTSIDE PANEL OF THE ROBOT CONTROLLER TOUCHING THEM MAY CAUSE ELECTRICAL SHOCK OR BREAKDOWN e SECURELY INSTALL EACH CABLE CONNECTOR INTO THE RECEPTACLES OR SOCKETS POOR CONNECTIONS MAY CAUSE THE CONTROLLER OR
61. UCH WORK THIS MAY INVOLVE RISK ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE ADJUSTMENT AND MAINTENANCE WORK WHILE REFERRING TO THIS MANUAL WHEN THE ROBOT DOES NOT NEED TO BE OPERATED DURING ADJUSTMENT OR MAINTENANCE ALWAYS TURN OFF THE CONTROLLER AND THE EXTERNAL SWITCH BOARD e WHEN YOU NEED TO TOUCH THE TERMINALS OR CONNECTORS ON THE OUTSIDE OF THE CONTROLLER DURING INSPECTION ALWAYS FIRST TURN OFF THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER TO PREVENT POSSIBLE ELECTRICAL SHOCK NEVER TOUCH INTERNAL PARTS OF THE CONTROLLER e WHEN ONLY MAKING ELECTRICAL INSPECTIONS AND REQUIRING NO MECHANICAL MOVEMENT OF THE ROBOT KEEP THE EMERGENCY STOP BUTTON PRESSED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY BE SURE TO USE THE LUBRICANT SPECIFIED BY YOUR DISTRIBUTOR BE SURE TO USE THE PARTS SPECIFIED BY YOUR DISTRIBUTOR WHEN REPLACING PARTS TAKE SUFFICIENT CARE NOT TO ALLOW ANY FOREIGN MATTER TO CONTAMINATE THEM DURING ADJUSTMENT PARTS REPLACEMENT OR REASSEMBLY e DO NOT MODIFY ANY PARTS ON THE ROBOT OR CONTROLLER MODIFICATION MAY RESULT IN UNSATISFACTORY SPECIFICATION
62. V YAMAHA SINGLE AXIS ROBOT FLIP X Series FS FSL FSLH F10 F14 F14H F17 F17L F20 F20N N15 N15D N18 N18D B10 B14 B14H R5 R10 R20 Ver 1 01 CONTENTS FLIP X Maintenance Manual Safety Instructions 1 Safety Information 2 Signal words used in this manual 3 Warning labels 3 1 Warning labels 3 1 1 Warning label messages 3 1 2 Supplied warning labels 3 2 Warning symbols 4 Major precautions for each stage of use 4 1 Precautions for using robots and controllers 4 2 Design 4 21 Precautions for robots 4 2 2 Precautions for robot controllers 4 3 Moving and installation 4 3 1 Precautions for robots 4 3 2 Precautions for robot controllers 4 4 Safety measures 4 4 1 Safety measures 4 4 2 Installing a safety enclosure 4 5 Operation 4 5 1 Trial operation 4 5 2 Automatic operation 4 5 3 Precautions during operation 4 6 Inspection and maintenance 4 6 1 Before inspection and maintenance work 4 6 2 Precautions during service work 4 7 Disposal 5 Emergency action when a person is caught by robot 6 Using the robot safely 6 1 Robot safety functions 6 2 Special training for industrial robot operation Warranty 9 5 5 6 5 7 9 7 5 8 8 8 8 8 5 9 S 9 10 S 12 12 S 13 S 14 S 14 S 16 S 16 S 18 S 18 S 19 S 20 S 21 S 22 S 22 S 23 T4 CONTENTS FLIP X Chapter 1 Overview 1 Overview Chapter2 Periodic inspecition 1 Before begi
63. When disconnecting the cable from the robot controller detach by gripping the connector itself and not by tugging on the cable Loosen the screws on the connector if fastened with the screws and then disconnect the cable Trying to detach by pulling on the cable itself may damage the connector or cables and poor cable contact will cause the controller or robot to malfunction 4 Precautions for cable routing and installation N CAUTION Always store the cables connected to the robot controller in a conduit or clamp them securely in place If the cables are not stored in a conduit or properly clamped excessive play or movement or mistakenly pulling on the cable may damage the connector or cables and poor cable contact will cause the controller or robot to malfunction Do not modify the cables and do not place any heavy objects on them Handle them carefully to avoid damage Damaged cables may cause malfunction or electrical shock If the cables connected to the robot controller may possibly become damaged then protect them with a cover etc e Check that the control lines and communication cables are routed at a gap sufficiently away from main power supply circuits and power lines etc Bundling them together with power lines or close to power lines may cause faulty operation due to noise 5 Protective measures against electrical shock A WARNING BE SURE TO GROUND THE CONTROLLER USING THE GROUND TERMINAL ON THE POWER TERMINAL BLOC
64. art number Slider resin part Remarks Shutter KDE M229J xxx SHUTTER 1 50st to 800st Insert KDD M2243 xxx INSERT Coupling resin part Slider m BIO Part name m B14 Part name B14H Part name KX3 M22L1 xxx SLIDER Part number KY1 M225E xxx BELT Slider resin part Remarks Motor drive unit KY1 M225F xxx BELT STROKE 150 to 2250 Movable part KY1 M225G xxx BELT STROKE Part number KY1 M225E xxx BELT 200 to 2500 Movable part Remarks Motor drive unit KY2 M225F xxx BELT STROKE 150 to 3050 Movable part KY2 M225G xxx BELT STROKE Part number KY1 M225E xxx BELT 200 to 3000 Movable part Remarks Motor drive unit KY2 M225F xxx BELT STROKE 150 to 3050 Movable part KY2 M225G xxx BELT STROKE 200 to 3000 Movable part 4 23 3 77774 1 Wiring specifications Contents servo motor specifications 1 1 AC servo motor termination T4L T5L 1 2 servo motor termination TALH T5LH T6L 1 3 AC servo motor termination F8 F8L F8LH 1 4 servo motor termination T9 T9H F10 F14 F14H F17 F17L F20 1 5 AC servo motor termination B10 B14 B14H R5 R10 R20 F20N N15 N18 1 6 Brake cable specifications 5 1 5 2 5 3 5 4 5 5 5 6 2 Robot cables DC24V specifications T4L TSL 2 1 Single axis robot cable
65. below are attached to the robot body and controller to alert the operator to potential hazards To ensure correct use read the warning labels and comply with the instructions 3 1 Warning labels A WARNING IF WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE THEN THE NECESSARY PRECAUTIONS MAY NOT BE TAKEN RESULTING IN AN ACIDENT DO NOT REMOVE ALTER OR STAIN THE WARNING LABELS ON THE ROBOT BODY e DO NOT ALLOW WARNING LABELS TO BE HIDDEN BY DEVICES INSTALLED ON THE ROBOT BY THE USER e PROVIDE PROPER LIGHTING SO THAT THE SYMBOLS AND INSTRUCTIONS ON THE WARNING LABELS CAN BE CLEARLY SEEN FROM OUTSIDE THE SAFETY ENCLOSURE 3 1 1 Warning label messages Word messages on the danger warning and caution labels are concise and brief instructions For more specific instructions read and follow the Instructions on this label described on the right of each label shown below 1 Warning label 1 SCARA robots Cartesian robots DANGER SERIOUS INJURY MAY RESULT FROM CONTACT WITH A MOVING ROBOT e KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE Instructions on this label Always install a safety enclosure to keep all persons DANGER fi 5 away from the robot movement range and prevent injury from contacting the moving part of the robot BR DE Install an interlock that triggers emergency stop mE when the door or gate of the saf
66. ce personnel including fatal accidents Before using this product read this manual and related manuals and take safety precautions to ensure correct handling The precautions listed in this manual relate to this product To ensure safety of the user s final system that includes YAMAHA robots please take appropriate safety measures as required by the user s individual system To use YAMAHA robots and controllers safely and correctly always comply with the safety rules and instructions For specific safety information and standards refer to the applicable local regulations and comply with the instructions e This manual and warning labels supplied with or attached to the robot are written in English Unless the robot operators or service personnel understand English do not permit them to handle the robot e Cautions regarding the official language of EU countries For equipment that will be installed in EU countries the language used for the manuals warning labels operation screen characters and CE declarations is English only Warning labels only have pictograms or else include warning messages in English In the latter case messages in Japanese or other languages might be added It is not possible to list all safety items in detail within the limited space of this manual So please note that it is essential that the user have a full knowledge of safety and also make correct judgments on safety procedures Refer to the manual
67. cement work e Phillips screwdriver e Grease gun recommended grease gun THK s MG70 nozzle shape H type e Brush for grease application step Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel Step Enter the safety enclosure step Wipe off the contaminated grease First wipe off the contaminated grease with a clean cloth rag wound on the stick N CAUTION Do not put your finger in the slider movement range to prevent your finger from being caught in if the slider is moved by hand accidentally Apply grease by either of the following methods B Linear guide step Apply the grease Step5 Applying the grease to the linear guide When using the grease nipples apply grease into the two grease nipples on the left and right side of the slider 4 grease nipples for F8LH Then move the table slider back and forth to help spread the grease around Grease nipple mm 23301 A5 00 Ball screw step Apply the grease Apply an adequate amount of grease to the ball screw so that it does not scatter surroundings Move the table slider back and forth to spread the grease 23302 4500 B Step 5 Applying the grease to the ball screw Ball screw DM CO 2 10 3 4 N15 N15D N18 N18D Prepare the tools necessary for the replacement work e Ph
68. cts blocking the fan are located and remove if any are found IDedsul 2 Cooling fan at rear of controller 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 distributor Check for dust on the fan cover Remove and clean if necessary UOI Adjustment and parts replacement A WARNING e 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 e AFTER THE ADJUSTMENT OR REPLACEMENT WORK HAS BEEN COMPLETED INSPECT THE CHECKPOINTS STATED IN DAILY INSPECTION IN THIS SECTION F THE REPAIR OR PART REPLACEMENT OF THE ROBOT OR CONTROLLER IS REQUIRED CONTACT YOUR DISTRIBUTOR SUCH WORK NEEDS THE SPECIAL KNOWLEDGE AND SKILL SO ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPAIR OR PART REPLACEMENT WORK OF THE ROBOT OR CONTROLLER 2 4 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 Checkpoint Procedure Remarks Check for wear and looseness in the ball If any abnormality is found contact screw nut and linear guide your distributor Ball screw nut sections an
69. cure a new slider temporarily with the mounting bolts 2 pieces step Y Reattach the upper cover For details see Installing and removing the cover in Chapter 3 step Move the slider table back and forth along the axis a few times step Y Move the slider gt Step9 Cover seal Peel off the seal with a diameter of 12mm from the upper cover on the anti motor side Move the slider to a position where the slider mounting bolts can be seen from this hole 51412 AC 00 step 1 0 Retighten the slider mounting bolts Tighten the slider mounting bolts fully then again shift the slider table 20mm to align the other bolt with the hole and fully tighten to secure the slider table step Adhere the accessory seal Adhere the accessory seal close the hole 4 21 lt Bolt tightening hole 5 2 F20N A WARNING e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT W
70. d linear guides 2 6 3 Applying the grease To apply the grease in accordance with the periodic inspection follow the steps below Before applying the grease thoroughly read the cautions stated in the Safety Guide and Before beginning work in this Chapter to strictly observe the instructions 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 THIS GREASE GETS IN THE EYES WASH LIBERALLY WITH PURE WATER FOR ABOUT 15 MINUTES AND CONSULT A PHYSICIAN FOR TREATMENT IF THIS 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 TREATMENT A WARNING DISPOSING OF GREASE AND THE CONTAINER PROPER DISPOSAL IS COMPULSORY UNDER FE
71. e adequate lighting Provide enough lighting to ensure safety during work 3 Install an operation status light A WARNING INSTALL A SIGNAL LIGHT SIGNAL TOWER AT AN EASY TO SEE POSITION SO THAT THE OPERATOR WILL BE AWARE OF THE ROBOT STOP STATUS TEMPORARILY STOPPED EMERGENCY STOP ERROR STOP ETC 4 Do not use robots for tasks requiring motor thrust N CAUTION Avoid using the belt driven robots for tasks which make use of motor thrust press fitting burr removal etc These tasks may cause the robot to malfunction 5 Clean work tools Work tools such as welding guns and paint nozzles mounted on the robot manipulator tip should preferably be cleaned automatically when needed 4 2 2 Precautions for robot controllers 1 Emergency stop input terminal A Dr AA EACH ROBOT CONTROLLER HAS AN EMERGENCY STOP INPUT TERMINAL TO TRIGGER EMERGENCY STOP USING THIS TERMINAL INSTALL A SAFETY CIRCUIT SO THAT THE SYSTEM INCLUDING THE ROBOT CONTROLLER WILL WORK SAFELY 2 Maintain clearance CAUTION Do not bundle control lines or communication cables together or in close to the main power supply or power lines Usually separate these by at least 100mm Failure to follow this instruction may cause malfunction due to noise gt 5 8 4 3 Moving and installation 4 3 1 Precautions for robots B Installation environment 1 Do not use in strong magnetic fields A WARNING DO NOT USE THE ROBOT NEAR EQUIPMENT OR IN LOCATIO
72. ection in the manual for the robot controller Controller Refer to RCX240 Section 8 Freeing a person caught by the robot in Chapter 1 Non N m NOTE 9 Make a printout of the relevant page in the manual and post it a conspicuous location near the controller SUOHONILSU AJoJoS 5 21 lt suouyonijsu AJoJoS 6 Using the robot safely 6 1 Robot safety functions Safety functions for YAMAHA robots are described below 1 Overload detection This function detects an overload applied to the motor and shuts off the servo power If an overload error occurs take the following measures to avoid such errors 1 Insert a timer in the program 2 Reduce the acceleration coefficient 2 Overheat detection This function detects an abnormal temperature rise in the driver inside the controller and shuts off the servo power If an overheat error occurs take the following measures to avoid the error 1 Insert a timer in the program 2 Reduce the acceleration coefficient 3 Soft limits Soft limits can be set on each axis to limit the working envelope in manual operation after return to origin and during automatic operation The working envelope is the area limited by soft limits A WARNING SOFT LIMITS MUST BE SET WITHIN THE MOVEMENT RANGE MECHANICAL STOPPER IF THE SOFT LIMIT IS SET OUTSIDE THE MOVEMENT RANGE THEN THE ROBOT AXIS MAY COLLIDE WITH THE MECHANICAL STOPPER AT HIGH SPEED CAUSING THE OBJECT GRIPPED BY
73. ers from operating the controller or operation panel M3 hex wrench Step Enter the safety enclosure Step Remove the slider cover Remove the four screws securing the slider cover and remove the slider cover 3 53401 A1 00 Stp Remove the screws gt Step5 Removing the shutter mounting screws Remove the screws Two screws each securing the shutter from the end block and motor y 53402 A1 00 Step Pull out the shutter Pull out the shutter from the shutter passing portion Endplate step Y Pass a new shutter gt Step7 Replacing the shutter 53403 A1 00 step Reinstall the shutter and the slider cover using the reverse of the above procedure selig OF NOTE Do not fully tighten the screws to secure the shutter on the endplate side at this time Shutter Fully tighten these screws after adjusting for shutter looseness in step 9 N step Y Secure the shutter Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shuffer gt Step9 Adjusting the shutter looseness 53404 A1 00 N CAUTION Do not press down on the shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp 9 O O 3 4 2 2 Replacing the motor 2 1 TA4L TALH TSL T5LH T6L A WARNING e BEFORE STARTING THE REPLACEMENT W
74. erstand the contents before attempting installation and operation Read and understand manuals before operation of the robot HER Before starting the robot operation even after you EZO MESS 2 have read through this mantel read again the idc ss RE corresponding procedures and Safety instructions REFS 9 SIE in this manual 90K41 001290 7 Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual 90K41 001290 4 Warning label 4 SCARA robots N CAUTION Do not remove the parts on which Warning label 4 is attached Doing so may damage the ball screw Instructions on this label Do not remove the parts 0 HES 05H E A a n The Z axis ball screw will be damaged if the upper end mechanical stopper on the Z axis spline is removed moved Never attempt to remove or move it 90K41 001520 5 Read instruction manual label Controller N CAUTION Refer to the manual Instructions on this label This indicates important information that you must A EA know and is described in the manual Before using the controller be sure to read the manual thoroughly When adding external safety circuits or connecting a Mik BSH READ INSTRUCTION power supply to the controller read the manual ANNE carefully and make checks before beginning the wo
75. ety enclosure is Stay clear of moving machine Can cause serious injury opened UREA The safety enclosure should be designed so that no Ei one can enter inside except from the door or gate EB SLBKETHES SENS equipped with an interlock device 90K41 001470 e Warning label 1 that comes supplied with a robot should be affixed to an easy to see location on the door or gate of the safety enclosure 90K41 001470 2 Warning label 2 SCARA robots Cartesian robots single axis robots Warning label 2 is not attached to some small single axis robots but is supplied with the robots A WARNING MOVING PARTS CAN PINCH OR CRUSH HANDS KEEP HANDS AWAY FROM THE MOVABLE PARTS OF THE ROBOT Instructions on this label Use caution to prevent hands and fingers from being pinched or crushed by the movable parts of the robot when transporting or moving the robot or during teaching Pinch or crush hazard bhta atnda 90K41 001460 90K41 001460 S 3 4 SUOHONILSU AJoJoS suouyonj su AJoJoOS 3 Warning label 3 SCARA robots Cartesian robots A WARNING IMPROPER INSTALLATION OR OPERATION MAY CAUSE SERIOUS INJURY BEFORE INSTALLING OR OPERATING THE ROBOT READ THE MANUAL AND INSTRUCTIONS ON THE WARNING LABELS AND UNDERSTAND THE CONTENTS Instructions on this label Be sure to read the warning label and this manual carefully to make you completely und
76. ew Freeing the coupling e When workpiece is on table slider lt N15 gt AJ 3 Hole for motor and coupling clamp screw Hole for motor and coupling clamp screw e When no workpiece is on table slider 53405 AA 00 gt 4 12 step 1 Y Remove the U nut and washer Secure the notched portion of the ball screw with a spanner and remove the U nut and washer 53406 00 step 12 Loosen the bolts securing the ball SCrew Loosen the four bolts securing the ball screw on the opposite side 53407 AA 00 step 13 Remove the three bolts securing the holder and remove the one ball screw tension bolt 53408 00 Step Remove the two screws securing the damper Skip this step for the N18 robot 53409 A A 00 gt Step 11 Removing the U nut and washer Ball screw mounting bolts Ball screw tensioner bolt 4 13 4 O 3 9 O O 3 step 19 Remove the motor Remove the four screws securing the motor and remove the motor At this time be careful not to allow the ball screw shaft to come out of the nut 53410 AA 00 53411 AA 00 step 96 Install a new motor Tighten the bolts to the following torque Robot Bolt Tightening torque Hex socket head bolt 5 Hex socket head bolt M6 60kgf cm to 90kgf cm 100kgf cm to 130kgf cm step 1 Y Assemble in the reverse order
77. ge shown in the table the belt tension adjustment is completed If the measured value is beyond the range repeat Steps 5 fo 7 step9 Tighten the motor plate bolts securely 2 2 3 D 3 step 1 Reattach the belt cover Reference Adjusting speed reduction belt tension with tension meter We recommend using a tension meter to adjust the belt tension more accurately Recommended tension meter U 505 Made by UNITTA Measurement method Pluck the belt at the load application position while referring to Step 5 so as to adjust the belt tension to the value shown below Frequency Unit mass Robot del T N h Bel h obot mode ension N Hz Span length mm elt width mm gwidth mm length m B10 44 to 49 180 to 190 B14 B14H 44 to 49 180 to 190 3 5 4 3 Adjusting the timing belt tension F20N The F20N robot uses a timing belt If the tension of the timing belt is weak follow the steps below to adjust the belt tension First the following describes how to install and remove the cover A WARNING e BEFORE STARTING THE WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE ADJUSTMENT WORK WITH THE COVER REMOVED e
78. ginning the work Connectors must be attached while facing a certain direction so insert each connector in the correct direction 93007 X0 00 gt 5 6 4 Major precautions for each stage of use This section describes major precautions that must be observed when using robots and controllers Be sure to carefully read and comply with all of these precautions even if there is no alert symbol shown 4 1 Precautions for using robots and controllers General precautions for using robots and controllers are described below 1 Applications where robots cannot be used YAMAHA robots and robot controllers are designed as general purpose industrial equipment and cannot be used for the following applications DANGER YAMAHA ROBOT CONTROLLERS AND ROBOTS ARE DESIGNED AS GENERAL PURPOSE INDUSTRIAL EQUIPMENT AND CANNOT BE USED FOR THE FOLLOWING APPLICATIONS IN MEDICAL EQUIPMENT SYSTEMS WHICH ARE CRITICAL TO HUMAN LIFE e IN SYSTEMS THAT SIGNIFICANTLY AFFECT SOCIETY AND THE GENERAL PUBLIC IN EQUIPMENT INTENDED TO CARRY OR TRANSPORT PEOPLE IN ENVIRONMENTS WHICH ARE SUBJECT TO VIBRATION SUCH AS ONBOARD SHIPS AND VEHICLES 2 Qualification of operators workers Operators or persons who handle the robot such as for teaching programming movement check inspection adjustment and repair must receive appropriate training and also have the skills needed to perform the job correctly and safely They must read the manual carefully to u
79. he gt Step4 Removing the parts securing the shutter shutter y Remove the two M4 screws securing the End a shutter EET shutter from each of the end block and M4 screw 2 pcs R D motor sides 53413 A1 00 step Remove the cover stroke Remove the two M4 screws securing the cover stroke from each of the left and right 53414 A1 00 Parts securing the shutter Motor side M4 screw 2 pcs gt Step5 Removing the cover stroke M4 screws securing the cover stroke M4 screws securing the cover stroke 4 3 lt step O Remove the bolts securing the gt Step6 Removing the bolts securing the motor motor Remove the two 5 bolts securing the motor 53415 A1 00 step 7 Remove the motor 53416 A1 00 step Install a new motor step Y Assemble in the reverse order of disassembly Step 6 Step 4 MS bolt 2 pcs gt Step7 Removing the motor 3 2 2 F8 F8L F8LH A WARNING e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING
80. ial part by bare hand this may cause rust Prepare an appropriate Phillips screwdriver N CAUTION When the robot is installed vertically slowly move the robot at a JOG speed to check the position where the shutter becomes loose mostly before entering the safety enclosure step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel Step Enter the safety enclosure step Loosen the screw lightly Lightly loosen the two screws securing the shutter on the end block side At this time do not remove the screws gt e 2 3 D 3 step Secure the shutter While stretching the shutter by fingers tighten The screws To secure the shutter so that it does nof become loose N CAUTION Do not press down on the shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp Adjusting the looseness 53303 A 1 00 3 11 4 17 17770 8 Replacement Contents 1 Replacing the shutter T4L T4LH T5L TSLH T6L 4 2 Replacing the motor 4 3 4 3 2 1 T4L T4LH TSL TSLH T6L 2 2 F8 F8L F8LH 4 5 2 3 BIO B14 B14H 4 8 2 4 F20N 4 9 2 5 NI15 NI5D N18 NI8D 4 11 2 6 Checking the grid position 4 15 Replacing the insert T4L T4LH T5L T5LH T6L 4 16 Replacing the drive and speed reduction belts B10 B14 B14H 4
81. illips screwdriver Grease gun recommended grease gun THK s MG70 nozzle shape H type e Brush for grease application step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating The robot is being adjusted fo keep others from operating the controller or operation panel Step Enter the safety enclosure step Wipe off the contaminated grease First wipe off the contaminated grease with a clean cloth rag N CAUTION Do not put your finger in the slider movement range to prevent your finger from being caught in if the slider is moved by hand accidentally a Iloedsur 2 Apply grease by either of the following methods UOI Linear guide step Apply the grease gt Step5 Applying the grease to the linear guide When using a grease gun apply grease into gt the four grease nipples two each on both sides of the ball guide bearing Then move the table slider back and forth to help soread the grease around 23301 00 Ball screw step Apply the grease Apply an adequate amount of grease to the ball screw so that it does not scatter surroundings Move the table slider back and forth fto spread the grease 23302 00 2 11 lt 3 5 B10 B14 B14H Apply grease to the linear guide every 3 months Prepare the tools necessary for the replacement work e Phillips screwdriver e Grease gun e Brush
82. ing the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating The robot is being adjusted fo keep others from operating the gt Step4 Removing the parts securing the shutter Parts securing the shutter End block side ENT gt M4 screw 2 pcs controller or operation panel Step Enter the safety enclosure step Remove the parts securing the shutter Remove the two M4 screws securing the shutter from each of the end block and motor sides 3 Parts securing the shutter Motor side 53417 A1 00 M4 screw 2 pcs step Remove the cover stroke Remove the two M4 screws securing the cover stroke from each of the left and right gt Step5 Removing the cover stroke 53418 A1 00 M4 screws securing the cover stroke step 6 Remove the bolts securing the motor Remove the two M5 bolts securing the motor 53419 A1 00 M4 screws securing the cover stroke M5 bolt 2 pcs 4 16 Stp Remove the insert 53420 A1 00 step Install a new insert step Y Assemble in the reverse order of disassembly Step 6 Step 4 gt Step7 Removing the insert Insert Consumable part 4 17 lt 2 Q
83. k that the positioning is correct during operation e Check for unusual noise during operation See 3 Replacing the insert in Chapter 4 1 Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 button head bolt M3 4 5 M6 M8 N CAUTION If the grease recommended by YAMAHA is not used this may cause the service life of the ball screw or linear guide to shorten 2 5 inspection to be performed with the controller turned on A 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 IS TURNED ON A WARNING BODILY INJURY MAY OCCUR FROM COMING INTO CONTACT WITH THE FAN WHILE IT IS ROTATING e WHEN REMOVING THE FAN COVER FOR INSPECTION FIRST TURN OFF THE CONTROLLER AND MAKE SURE THE FAN HAS STOPPED step Turn on the controller Check that no one is inside the safety enclosure and then turn on the controller steps Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being inspected to keep others from operating the controller programming box or operation panel a step Perform the daily inspection Check the following points from outside the safety enclosure Checkpoint Procedure e Check if the fan rotates normally Check if obje
84. ler power step Place a sign indicating the robot is being adjusted Vo a Place a sign indicating the robot is being r ex M adjusted keep others from operating the Nob bolts controller or operation panel 5 Step Enter the safety enclosure step Fit the cover Fit the cover so that the notch of the cover passes through the portion between the hex socket head bolts step Tighten the hex socket head bolts Tighten the hex socket head bolts with a spanner or socket wrench stepO Tighten the screws M4 from the top to secure the cover 3 8 3 1 3 Motor cover Removing the motor cover step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel step Enter the safety enclosure step Cut the insulock tie Cut the Insulock tie binding the motor cable with a pair of nippers and remove 53306 A9 00 step Pull out the motor cover Remove the hex socket head bolts M4 two bolts and pull out the motor cover 53307 A9 00 Installing the motor cover step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted fo keep others from operating the controller or operation panel step Enter the safety enclosure step Secure the mo
85. lts temporarily step Y Check the slack amount Pulley It is accepted that the slack is within the Pulley range stated in the table below when the belt is pushed with a specified load gt Step 7 Load application position If the slack is beyond the range repeat Steps 5 and 6 to adjust the belt tension xA De Hd REN Cpl OS TM Load and slack for drive belt tension Robot model N kgf B10 4 9 to 5 9 0 5 to 0 6 B14 B14H 5 9 to 6 9 0 6 to 0 7 step 10 Tighten the belt stay mounting bolts step Remove the belt tension adjustment bolt step l 2 Reattach the upper cover and end cover E a o NOTE See also 1 Installing and removing the cover in this Chapter N Reference Adjusting drive belt tension with a tension meter We recommend using a tension meter to adjust the belt tension more accurately Recommended tension meter U 505 Made by UNITTA Measurement method Pluck the belt at the load application position in Step 7 to adjust the belt tension to the value shown below For details on how to use the tension meter refer to the tension meter Instruction Manual Frequency R T N h Bel h obot mode ension N Hz Span length mm elt width mm Imm length Imp B10 127 to 147 86 to 93 B14 B14H 169 to 188 79 to 84 gt 2 c o 3 2 2 2 Adjusting the speed reduction belt
86. m operating the controller or operation panel Step Enter the safety enclosure step Wipe off the contaminated grease First wipe off the contaminated grease with a clean cloth rag wound on stick N CAUTION Do not put your finger in the slider movement range to prevent your finger from being caught in if the slider is moved by hand accidentally a Ioedsur 2 Apply grease by either of the following methods UOI B Linear guide step Apply the grease gt Step5 Applying the grease to the linear guide Use the grease gun to apply the grease the grease nipple of the linear guide through the clearance between the upper cover and frame 23301 A4 00 Ball screw step Apply the grease Apply the grease to the screw thread roofs thinly and uniformly with The brush Move the slider back and forth spread the grease 23302 A4 00 step O Wipe off the excess grease Finally wipe off the excess grease with a clean cloth rag N CAUTION When the robot is mounted vertically go outside the safety enclosure once Check that no one is inside the safety enclosure and then turn on the controller power After that slowly move the slider two or three times in the manual mode and turn off the controller power Enter the safety enclosure again and continue the work 2 9 lt a Ioedsur 5 UOI 3 3 F8 F8L F8LH Prepare the tools necessary for the repla
87. nderstand its contents before attempting the robot operation or maintenance Tasks related to industrial robots teaching programming movement check inspection adjustment repair etc must be performed by qualified persons who meet requirements established by local regulations and standards for industrial robots A WARNING THE ROBOT MUST BE OPERATED ONLY BY PERSONS WHO HAVE RECEIVED SAFETY AND OPERATION TRAINING OPERATION BY AN UNTRAINED PERSON IS EXTREMELY HAZARDOUS ADJUSTMENT AND MAINTENANCE BY REMOVING A COVER REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATTEMPTED BY AN UNSKILLED PERSON THESE TASKS MUST BE PERFORMED ONLY BY PERSONS WHO HAVE ENOUGH ABILITY AND QUALIFICATIONS IN ACCORDANCE WITH LOCAL LAWS AND REGULATIONS FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT 5 7 lt suouyonisu AJoJoS suouyonisu AJoJoS 4 2 Design 4 2 1 Precautions for robots 1 Provide safety measures for end effector gripper etc WARNING END EFFECTORS MUST DESIGNED AND MANUFACTURED SO THAT THEY CAUSE NO HAZARDS SUCH AS A LOOSE WORKPIECE OR LOAD EVEN IF POWER ELECTRICITY AIR PRESSURE ETC IS SHUT OFF OR POWER FLUCTUATIONS OCCUR F THE OBJECT GRIPPED BY THE END EFFECTOR MIGHT POSSIBLY FLY OFF OR DROP THEN PROVIDE APPROPRIATE SAFETY PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE WEIGHT TEMPERATURE AND CHEMICAL PROPERTIES 2 Provid
88. ng the robot is being adjusted to keep others from operating the controller or operation panel gt Step7 Removing the cover 1 O 3 Step Enter the safety enclosure Step Remove the end cover Remove the end cover from the anti motor IA lt y de e 39 47 5 eg A na a Wace cte Ey a mn end Ads xx end E or ST A Gov 3 step B Remove the upper cover For models with a long stroke pull out the cover parallel with the axis movement direction step O Remove the motor Remove the motor while referring to 2 2 d mon BIO BIA BIAH of 2 Replacing the motor in i this Chapter If is unnecessary to remove the motor if installed horizontally or downwards gt Step8 Removing the belt stay step7 Remove the cover 1 53404 AC 00 step Remove the belt stay Remove the belt stay bolts four bolts x 2 and remove the belt stay from the slider table 53405 AC 00 4 18 step Y Detach the belt gt Step9 Removing the belt stay Remove the belt stay bolts two bolts x 2 and detach the belt from the main unit 53406 AC 00 step 10 Attach a new belt step 1 1 Attach the belt 1 First attach the belt from the upper side of the driven pulley and push it out with a thin rod 53407 AC 00 2 Pass the belt through from the lower side of the slider table and route the belt edge under the drive pulley Then use a narrow r
89. nning work 2 Periodic inspecition 2 1 Daily inspection 2 2 Three month inspection 2 3 Six month inspection 2 4 Three year inspection 3 Applying the grease 3 1 T4L T4LH T5L T5LH T6L 3 2 T9 T9H F10 F14 F14H F17 F17L F20 F20N 3 3 F8 F8L F8LH 3 4 N15 N15D N18 N18D 3 5 B10 B14 B14H Chapter 3 Adjustment 1 Adjusting the alignment B10 B14 B14H 2 Adjusting the timing belt tension B10 B14 B14H 2 1 Adjusting the drive belt tension 2 2 Adjusting the speed reduction belt tension 3 Adjusting the timing belt tension F20N 3 1 Installing and removing the cover 3 1 1 Stroke cover 3 1 2 Belt cover 3 1 3 Motor cover 3 2 Adjusting the timing belt tension 4 Adjusting shutter looseness T4L T4LH T5L T5LH T6L Chapter 4 Replacement 1 Replacing the shutter T4L T4LH T5L T5LH T6L 2 Replacing the motor 2 1 TAL TALH TSL TSLH T6L 2 1 2 2 2 2 2 3 2 5 2 6 2 7 2 8 2 10 2 11 2 12 3 1 3 2 3 4 3 6 3 6 3 6 3 8 3 9 3 10 4 3 4 3 CONTENTS FLIP X Maintenance Manual 2 2 F8 F8L F8LH 2 3 B10 B14 B14H 2 4 F20N 2 5 N15 N15D N18 N18D 2 6 Checking the grid position 3 Replacing the insert T4L T4LH T5L T5LH T6L 4 Replacing the drive and speed reduction belts B10 B14 B14H 4 1 Replacing the drive belt 4 2 Replacing the speed reduction belt 5 Replacing the slider 5 1 B10 B14 B14H 5 2 F20N 4 22 6 Maintenance parts 6 1 Consumable parts Chapter 5 Wiring specificatio
90. ns 1 AC servo motor specifications 1 1 AC servo motor termination T4L T5L 1 2 AC servo motor termination T4LH T5LH T6L 1 3 AC servo motor termination F8 F8L F8LH 1 4 servo motor termination T9 T9H F10 F14 F14H F17 F17L F20 1 5 AC servo motor termination B10 B14 B14H R5 R10 R20 F20N N15 N18 1 6 Brake cable specifications 2 Robot cables DC24V specifications TAL T5L 2 Single axis robot cables 2 4 1 Cables for ERCD 3 Robot cables 200V specifications 4 5 4 8 4 9 4 11 4 15 4 16 4 18 4 18 4 20 4 21 4 21 4 23 4 23 5 1 5 1 5 2 5 3 5 4 5 5 5 6 5 7 3 7 5 8 TALH TSLH T6GL T9 T9H F8 F8L F8LH F10 F14 F14H F17 F17L F20 B10 B14 B14H R5 R10 R20 3 1 Single axis robot cables 3 11 Cables for TS X 31 2 Cables for SR1 X 3 1 8 Cables for RDX robot with brake 3 1 4 Cables for RDX robot without brake 3 2 Multi robot cables 3 2 1 Cables for single axis multi robot 3 2 2 Cables for two axis multi robot 5 8 5 8 5 9 5 10 5 12 5 13 5 13 5 14 CONTENTS FLIP X Maintenance Manual 4 Machine harness 41 N15 N15D N18 N18D 4 2 F20N 5 Cables models 5 1 Single axis robot cables 5 2 Multi robot cables 5 20 5 20 5 21 5 22 5 22 5 23 Safety Instructions Contents 1 Safety Information 5 1 2 Signal words used this manual 5 2 3 Warning labels S 3 3 3 1 Warning labels S 3 1 1 Warning label messages 5 3 3 1 2 Su
91. od or similar tool to make the belt edge face upwards gt Step 11 Attaching the belt 3 Finally while making the belt mesh between the drive pulley and drive pulley idler turn the drive pulley so the belt comes out upwards step l 2 Attach the belt stays to both ends of the belt step 13 Reattach the belt stay to the table Tighten the belt stay mounting bolts temporarily step 14 Adjust the belt tension For details see 2 Adjusting the timing belt tension B10 B14 B14H in Chapter 3 O 3 step 15 Reattach the upper cover For details see 1 Installing and removing the cover Chapter 3 step 16 Reattach the end cover 4 19 lt 4 2 Replacing the speed reduction belt A WARNING e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUT
92. of disassembly Proceed while making sure the positional relation and assembly order of the parts are correct CAUTION When installing the ball screw apply the proper amount of molybdenum grease to the clamp portion see photo below A 53412 AA 00 step 18 Adjust the coupling position and secure the coupling After replacing the motor adjust the coupling position so that the grid position is within 50 20 which is displayed by performing return to origin 4 14 Step 15 Removing the motor lt N15 gt F N Te Balliscrew Pr Step 15 Cautions on motor removal work a ANN E ET Allow space of 300mm or more Ball screw Nut section Do not pull out Step 17 Applying the grease N15 2 6 Checking the grid position After the motor has been replaced follow the steps below to perform the return to origin and check the grid position The following describes how to check the grid position of the model SR1 For other controller models see the manual for relevant controller model Step 7 Press OPRT on the initial menu screen 54401 A0 00 Step Press ORG 54402 A0 00 Step Press yes to perform return Step Step D Step 6 to origin To cancel the operation press no 54403 A0 00 This screen appears during return to origin Pressing during operation stops the robot and displays a message Then p
93. oller Switch a Step Perform the daily inspection Enter the safety enclosure and check the following points Procedure Remarks Checkpoint Major bolts and screws on E j Check for looseness and tighten if necessary 1 exterior of robot main unit Check for looseness in the ball screw and linear guide iD dsul 2 Tighten if necessary If problem is not solved or wear and Ball screw and linear e Check for vibration during operation o backlash are found please contact guide Tighten drive section and X and Y axis installation gt our distributor bolts if necessary y e Check for wear and backlash If any abnormality is found contact your distributor Check for loose terminals Controller e Check for loose connectors Application of grease to ball screw nut and linear guide Apply Alvania No 2 Showa Shell Alvania S2 Showa Shell or Daphne Eponex No 2 Idemitsu to the ball screw nut and linear guide every 6 months See 4 Applying the grease in this Chapter e Check the timing belt for fault scratch or crack Belt See Chapter 3 Adjustment Check the tension of the timing belt praes e If the friction is the cause of the trouble make the adjustment so that the interference between the mating part and slider is eliminated e If the slider is broken contact your distributor Slider Check for unusual wear or damage Chec
94. onisu AJoJoS 4 5 2 Automatic operation Check the following points when operating the robot in AUTO mode Observe the instructions below in cases where an error occurs during automatic operation Automatic operation described here includes all operations in AUTO mode 1 Checkpoints before starting automatic operation Check the following points before starting automatic operation DANGER CHECK THAT NO ONE IS WITHIN THE SAFETY ENCLOSURE CHECK THE SAFETY ENCLOSURE IS SECURELY INSTALLED WITH INTERLOCKS FUNCTIONAL A WARNING CHECK THAT THE PROGRAMMING BOX HANDY TERMINAL AND TOOLS ARE IN THEIR SPECIFIED LOCATIONS CHECK THAT THE ALARM OR ERROR LAMPS ON THE ROBOT AND PERIPHERAL EQUIPMENT ARE NOT LIT OR FLASHING 2 During automatic operation and when errors occur After automatic operation starts check the operation status and the signal tower to ensure that the robot is in automatic operation DANGER NEVER ENTER THE SAFETY ENCLOSURE DURING AUTOMATIC OPERATION WARNING IF AN ERROR OCCURS IN THE ROBOT OR PERIPHERAL EQUIPMENT OBSERVE THE FOLLOWING PROCEDURE BEFORE ENTERING THE SAFETY ENCLOSURE 1 PRESS THE EMERGENCY STOP BUTTON TO SET THE ROBOT TO EMERGENCY STOP 2 PLACE A SIGN ON THE START SWITCH INDICATING THAT THE ROBOT IS BEING INSPECTED IN ORDER TO KEEP OTHER PERSONS FROM RESTARTING THE ROBOT 4 5 3 Precautions during operation 1 When the robot is damaged or an abnormal condition occurs WARNING
95. or wire Connection Resolver P 53509 N 1 00 Blue Red Orange White Green Brown White Grey Yellow Red White Drain wire Grey Heat shrinkable tube The wire colors in show the flexing cable Round terminal To robot 53511 N1 00 Red White Black Grey Heat shrinkable tube 3 2 Multi robot cables 3 2 1 Cables for single axis multi robot Connection controller RCX240 Cables for multi robot To controller Parts Controller ROB I O ZR Controller MOTOR ZM Connection 2 DR 53501 00 00 Parts Resolver P3 Red White Green White Yellow White Drain wire Brake BK3 Blue White Motor M3 This cable is connected to the ZR connector of the ROB I O and the MOTOR ZM connector 9 13 lt 3 2 2 Cables for two axis multi robot 1 Robot combination 1st axis is FLIP X and 2nd axis is FLIP X Connection controller RCX221 222 240 Cables for multi robot 22 y ouem P EUM Fe HE a m AAA To controller To robot 53501 R2 00 5 14 Parts Signal PIN
96. ore inspection and maintenance work 1 Do not attempt any work or operation unless described in this manual Never attempt any work or operation unless described in this manual If an abnormal condition occurs please be sure to contact your distributor Our service personnel will take appropriate action A WARNING e NEVER ATTEMPT INSTALLATION ADJUSTMENT INSPECTION AND MAINTENANCE UNLESS DESCRIBED IN THIS MANUAL NEVER ATTEMPT ANY REPAIR AND PARTS REPLACEMENT UNLESS DESCRIBED IN THIS MANUAL THESE TASKS REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS PLEASE BE SURE TO CONTACT YOUR DISTRIBUTOR FOR ADVICE 2 Precautions during repair and parts replacement A WARNING WHEN IT IS NECESSARY TO REPAIR OR REPLACE PARTS OF THE ROBOT OR CONTROLLER PLEASE BE SURE TO CONTACT YOUR DISTRIBUTOR AND FOLLOW THE INSTRUCTIONS THEY PROVIDE INSPECTION AND MAINTENANCE OF THE ROBOT OR CONTROLLER BY AN UNSKILLED UNTRAINED PERSON IS EXTREMELY HAZARDOUS Adjustment maintenance and parts replacement require specialized technical knowledge and skills and also may involve hazards These tasks must be performed only by persons who have enough ability and qualifications required by local laws and regulations A WARNING ADJUSTMENT AND MAINTENANCE BY REMOVING A COVER REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATTEMPTED BY AN UNSKILLED PERSON FOR DETAILED INFORMATION PLEASE CONTA
97. plied with the robots Single axis robots 5 5 lt suouyonjjsu AJoJoOS suouyonjjsu AJoJoOS 3 2 Warning symbols Warning symbols shown below are printed on the robot and controller to alert the operator to potential hazards To use the YAMAHA robot safely and correctly always follow the instructions and cautions indicated by the symbols l Electrical shock hazard symbol A WARNING TOUCHING THE TERMINAL BLOCK OR CONNECTOR MAY CAUSE ELECTRICAL SHOCK SO USE CAUTION Instructions by this symbol This indicates a high voltage is present Touching the terminal block or connector may cause electrical shock 93006 X0 00 2 High temperature hazard symbol A WARNING MOTORS HEATSINKS AND REGENERATIVE UNITS BECOME HOT SO DO NOT TOUCH THEM Instructions by this symbol This indicates the area around this symbol may become very hot Motors heatsinks and regenerative units become hot during and shortly after operation To avoid burns be careful not to touch those sections 93008 X0 00 3 Caution symbol N CAUTION Always read the manual carefully before using the controller Instructions by this symbol This indicates important information that you must know and is described in the manual Before using the controller be sure to read the manual thoroughly When adding external safety circuits or connecting a power supply to the controller read the manual carefully and make checks before be
98. pplied warning labels 5 5 3 2 Warning symbols S 6 4 Major precautions for each stage of use 4 1 Precautions for using robots and controllers S 7 4 2 Design 5 8 4 2 1 Precautions for robots 5 8 4 2 2 Precautions for robot controllers 9 8 4 3 Moving and installation S 9 4 3 1 Precautions for robots S 9 4 3 2 Precautions for robot controllers S 10 4 4 Safety measures 12 4 4 1 Safety measures 5 12 4 4 2 Installing a safety enclosure 9 13 4 5 Operation 5 14 4 5 1 Trial operation 5 14 4 5 2 Automatic operation 5 16 4 5 3 Precautions during operation 9 16 4 6 Inspection and maintenance 5 18 4 6 1 Before inspection and maintenance work 5 18 4 6 2 Precautions during service work 5 19 4 7 Disposal S 20 5 Emergency action when a person is caught by robot S 21 6 Using the robot safely 5 22 6 1 Robot safety functions 5 22 6 2 Special training for industrial robot operation 5 23 1 Safety Information Industrial robots are highly programmable mechanical devices that provide a large degree of freedom when performing various manipulative tasks To ensure safe and correct use of YAMAHA industrial robots and controllers carefully read and comply with the safety instructions and precautions in this Safety Instructions guide Failure to take necessary safety measures or incorrect handling may result in trouble or damage to the robot and controller and also may cause personal injury to installation personnel robot operator or servi
99. r safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work For details about cautions on controller see the User s Manual for controller a Ioedsur 2 UOI 2 1 2 Periodic inspecition 2 1 Daily inspection The following is an inspection list that must be performed every day before and after operating the robot inspection to be performed with the controller turned off step 4 Turn off the controller step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being inspected to keep others from operating the controller switch Step Perform the daily inspection Enter the safety enclosure and check the following points Checkpoints Procedure Remarks a Make the adjustment so that any stress is not applied to the cables If any damage is found replace the defective cable according to the conditions See also 2 2 Robot cables in Chapter 5 of the separate Installation Manual Check for damage dent and excessively tight bends Cables Check for scratches dents and IDedsul 2 excessively tight bends See 5 Adjusting the shutter looseness in Chapter 3 Shutter e Check for flow up clearance When the shutter replacement is needed see 1 gt e Check the shutter top surface for Replacing the
100. rd other than specified into the SD memory card slot in the programming box Malfunction or breakdown may result if the wrong memory card is inserted 5 19 lt A WARNING AIR OR PARTS MAY FLY OUTWARD IF PNEUMATIC EQUIPMENT IS DISASSEMBLED OR PARTS REPLACED WHILE AIR IS STILL suouyonijsu AJoJoS suouyonjjsu AJoJoOS 4 7 Disposal When disposing of robots and related items handle them carefully as industrial wastes Use the correct disposal method in compliance with your local regulations or entrust disposal to a licensed industrial waste disposal company 1 Disposal of lithium batteries When disposing of lithium batteries use the correct disposal method in compliance with your local regulations or entrust disposal to a licensed industrial waste disposal company We do not collect and dispose of the used batteries 2 Disposal of packing boxes and materials When disposing of packing boxes and materials use the correct disposal method in compliance with your local regulations We do not collect and dispose of the used packing boxes and materials 3 Strong magnet A WARNING STRONG MAGNETS ARE INSTALLED IN THE ROBOT BE CAREFUL WHEN DISPOSING OF THE ROBOT gt 5 20 5 Emergency action when a person is caught by robot If a person should get caught between the robot and a mechanical part such as the installation base then release the axis Emergency action Release the axis while referring to the following s
101. ressing returns to the screen of step2 When return to origin ends normally the machine reference value appears on the bottom right of the screen Press to display the grid position 54404 A0 00 P Step 1 P Step 2 P Step6 Initial menu screen MENU select menu llEbiTHoPRTESYS AMON Operation mode OPR T select menu Honc BSTEPEBAUTO gt Step 3 4 Return to origin OPRT ORG SEARCH ORG search OK iles Hno OPRT ORG SEARCH searching Grid position display OPRT ORG SEARCH origin complete grid position 50 4 15 4 9 O 3 3 Replacing the insert T4L TALH T5L T5LH T6L A WARNING e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING THE REPLACEMENT WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE REPLACEMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION Be sure to wear safety gloves before start
102. ring box cover that is secured To the table slide and disconnect the motor cable connectors Motor cover 53401 A9 00 step O Remove the four motor mounting bolts M6 53402 A9 00 step Y Pull the belt off the pulley LZ 53403 A9 00 gt Step 7 Removing the belt step amp Remove the motor 3 step9 Pull out the pulley from the motor Step 7 0 Step 7 7 Step 12 Step 7 3 Step 14 gt 4 10 Remove the four bolts M6 securing the pulley fastening boss and pull out the pulley from the motor Loosen the bolts while securing The machined surface of the boss with pliers 53404 A9 00 Replace the motor with a new one and attach the pulley to this new motor Take care to the orientation and order of the rings at this fime 53405 A9 00 Install the motor onto the block Temporarily tighten the fixing bolts 53406 A9 00 Install the belt Adjust the belt tension while referring to 3 Adjusting the timing belt tension F2ON in Chapter 3 Reattach the motor cover and belt cover Reattach the cover Connect the motor cable connectors store the cables in the wiring box and reattach the cover gt Step9 Removing the mounting bolts 4 M6 Hexagon bolt gt Step 11 Installing the motor 2 5 N15 N15D N18 N18D WARNING Ak e BEFORE STARTING THE REPLACEMENT WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROL
103. rk Connectors must be attached while facing a certain direction so insert each connector in the correct direction 93005 X0 00 This label is attached near the power input connector on the front panel 3 1 2 Supplied warning labels Some warning labels are not affixed to robots but included in the packing box These warning labels should be affixed to an easy to see location Q Warning label is attached to the robot body Warning label comes supplied with the robot and should be affixed to an easy to see location on the door or gate of the safety enclosure Warning label comes supplied with the robot and should be affixed to an Warning label 1 DANGER fi B amp EE R Stay clear of moving machine Can cause serious injury REM ASE HA ek T ART 5cIBA2S77j 4 9h 5 90K41 001470 Warning label 2 Pinch or crush hazard bhta eV 5D 90K41 001460 Warning label 3 Read and understand manuals before operation FR FNA HVS Sl ES 1 SIE 90K41 001290 Warn i ng Do not remove the parts 0 FES Beals Y A label 4 VR RE Eo easy to see location SCARA robots Cartesian robots 1 For the label positions see the SCARA robot user s manual 1 2 Part names in Chapter 1 2 This label is not attached to some small single axis robots but is sup
104. roller e Is the robot securely and correctly installed Are the electrical connections to the robot wired correctly Are items such as air pressure correctly supplied e Is the robot correctly connected to peripheral equipment e Have safety measures safety enclosure etc been taken e Does the installation environment meet the specified standards 3 After the controller is turned on check the following points from outside the safety enclosure e Does the robot start stop and enter the selected operation mode as intended e Does each axis move as intended within the soft limits e Does the end effector move as intended Are the correct signals being sent to the end effector and peripheral equipment e Does emergency stop function Are teaching and playback functions normal Are the safety enclosure and interlocks functioning as intended gt S 14 4 Working inside safety enclosures Before starting work within the safety enclosure always first confirm from outside the enclosure that each safety function is operating correctly see the previous section 2 3 A DANGER NEVER ENTER WITHIN THE MOVEMENT RANGE WHILE WITHIN THE SAFETY ENCLOSURE A WARNING WHEN WORK IS REQUIRED WITHIN THE SAFETY ENCLOSURE PLACE A SIGN WORK IN PROGRESS IN ORDER TO KEEP OTHER PERSONS FROM OPERATING THE CONTROLLER SWITCH OR OPERATION PANEL A WARNING WHEN WORK WITHIN THE SAFETY ENCLOSURE IS REQUIRED ALWAYS TURN OFF THE
105. s 2 1 1 Cables for ERCD 3 Robot cables 200V specifications 9 7 5 7 0 7 5 8 TALH TSLH T6L T9 T9H F8 F8L F8LH F10 F14 F14H F17 F17L F20 B10 B14 B14H R5 R10 R20 3 1 Single axis robot cables 3 1 1 Cables for TS X 3 1 2 Cables for SR1 X 3 1 3 Cables for RDX robot with brake 3 1 4 Cables for RDX robot without brake 3 2 Multi robot cables 3 2 1 Cables for single axis multi robot 3 2 2 Cables for two axis multi robot 4 Machine harness 4 1 N15 N15D N18 N18D 4 2 F20N 5 Cables models 5 1 Single axis robot cables 5 2 Multi robot cables 1 servo motor specifications 1 1 AC servo motor termination T4L T5L Connector specifications Servo motor Receptacle housing SMR 09V B CN1 9 polarities Pin contact SYM 001T P0 6 CN1 Receptacle housing 5557 04R CN2 4 polarities Receptacle Connector wiring Connector Pin No 1 52 55561 Wire Color Yellow CN2 2 54 Blue 51 53 H1 H2 JP1 Red JP2 Red Shield Grey Heat shrinkable tube N l l l l l l l t l l l l l l l l l l l l l l l l l l l l l l 1 U Red MO V White W Black T4L T5L Yellow Green This Fig shows the T4L robot 53501 A1 00 9 1 1 2
106. ter the safety enclosure Measures to be taken if the cover is in step Pass the cover through the portion Step 5 contact with the table slide between the table slide and motor block Move the table slide to the stroke end and pass the cover through the portion between the table slide and motor block step Secure the cover to the end block Move the table slide to the center of the stroke and make sure that the table slide does not interfere with the cover If the table slide interferes with the cover tighten the cover mounting screws to make the adjustment thejtablefslide tightenjthe cover 53303 A9 00 gt 2 2 3 D 3 Measures to be taken if the cover is in gt Step5 contact with the motor block 53304 A9 00 3 7 lt 3 1 2 Belt cover Removing the belt cover step Y Turn off the controller power step Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted to keep others from operating the controller or operation panel Step Enter the safety enclosure step Loosen the hex socket head bolts M4 Loosen the hex socket head bolts MA two bolts with a spanner or socket wrench 4 step Remove the belt cover gt Step5 Removing the belt cover After the screws M4 have been removed c from the top pull out the cover upward o a 53305 A9 00 2 Installing the belt cover TED step Y Turn off the control
107. tor cover Insert the motor cover into the mounting holes and secure it with the hex socket head bolts M two bolts stepB Secure the cable with the insulock ie Use the 5 hole the motor cover fo secure the motor cable with the insulock tie P Step4 Cutting the insulock tie gt Step 5 Pulling out the motor cover 3 9 lt gt 2 2 3 D 3 3 2 Adjusting the timing belt tension A WARNING THE MOTOR AND SPEED REDUCTION GEAR CASING ARE EXTREMELY HOT AFTER AUTOMATIC OPERATION SO BURNS MAY OCCUR IF THESE ARE TOUCHED BEFORE TOUCHING THESE PARTS TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THE PARTS HAVE COOLED A WARNING INJURY CAN OCCUR IF HANDS OR FINGERS ARE SQUEEZED BETWEEN THE DRIVE PULLEY AND BELT ALWAYS TURN OFF THE CONTROLLER AND USE CAUTION WHEN HANDLING THESE PARTS N CAUTION Since a positional shift occurs after adjusting the belt tension return to origin or absolute reset must be performed again and the point data re specified Prepare tools necessary for the adjustment work e Belt tension adjustment bolt accessory e Tension meter step 4 Turn off the controller power steps Place a sign indicating the robot is gt Step 6 Applying a tension to the belt being adjusted Place a sign indicating The robot is being adjusted to keep others from operating the controller or operation panel gt 2 e 3 2 Step Enter the safety enclosure
108. ttp www yamaha motor co jp global industrial robot
109. usting shutter looseness TAL TALH TSL TSLH T6L 1 Adiusting the alignment B10 B14 B14H On robot models having a long stroke a slider travel guide U groove is provided inside the upper cover The slider must be aligned with this U groove when attaching the upper cover A WARNING e BEFORE STARTING THE WORK BE SURE TO DISCONNECT THE ROBOT FROM THE CONTROLLER OR TURN OFF THE CONTROLLER POWER IF THE ROBOT OPERATES DURING WORK THIS MAY CAUSE SERIOUS ACCIDENT ONLY QUALIFIED ENGINEERS WHO HAVE THE SKILL AND LICENSE IN ACCORDANCE WITH THE LAWS AND REGULATIONS IN EACH COUNTRY ARE ALLOWED TO CARRY OUT THE ADJUSTMENT WORK WITH THE COVER REMOVED BE CAREFUL NOT TO NEGLECT TIGHTENING SCREWS OR BOLTS IF ANY COVER IS NOT SECURED FIRMLY THIS MAY CAUSE NOISE COVER DROPPING AND FLYING HAND ENTANGLEMENT IN DRIVE UNIT DURING TEACHING OR BURN DUE TO HAND IN CONTACT WITH HOT SURFACE SO BE SURE TO TIGHTEN ALL THE SCREWS AND BOLTS SECURELY N CAUTION If the slider and upper cover alignment is poor the slider may wear out prematurely Insert the slider into the U groove correctly so that the slider is not worn away or damaged by the edge of the upper cover Be sure to wear safety gloves before starting the work If you touch any steel material part by bare hand this may cause rust Be careful not to drop any screw or bolt during cover removal work step Y Turn off the controller power gt 2 2 3 D 3
110. workers to signal each other when two or more workers perform tasks 4 Steps that the worker should take when a problem or emergency occurs 5 Steps to take after the robot has come to a stop when the emergency stop device was triggered including checks for cancelling the problem or error state and safety checks in order to restart the robot 6 In cases other than above the following actions should be taken as needed to prevent hazardous situations due to sudden or unexpected robot operation or faulty robot operation as listed below e Place a display sign on the operator panel e Ensure the safety of workers performing tasks within the robot movement range e Clearly specify position and posture during work Specify a position and posture where worker can constantly check robot movements and immediately move to avoid trouble if an error problem occurs e Take noise prevention measures e Use methods for signaling operators of related equipment Use methods to decide that an error has occurred and identify the type of error Implement the work instructions according to the type of robot installation location and type of work task When drawing up the work instructions make an effort to include opinions from the workers involved equipment manufacturer technicians and workplace safety consultants etc 3 Take safety measures DANGER NEVER ENTER THE ROBOT MOVEMENT RANGE WHILE THE ROBOT IS OPERATING OR THE MAIN POWER IS TURNED ON FAI
111. ydraulic pneumatic hoses Install a cover or similar item to protect the electrical wiring and hydraulic pneumatic hoses from possible damage B Wiring 1 Protective measures against electrical shock A WARNING ALWAYS GROUND THE ROBOT TO PREVENT ELECTRICAL SHOCK 5 9 lt suouyonisu AJoJoS SUOHONALSU AJoJoS Adjustment 1 Adjustment that requires removing a cover WARNING AX YAMAHA ROBOT CONTROLLERS ARE NOT DESIGNED TO BE EXPLOSION PROOF DO NOT USE THEM IN LOCATIONS EXPOSED TO EXPLOSIVE OR INFLAMMABLE GASES GASOLINE OR SOLVENT FAI LURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH OR LEAD TO FIRE FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT 4 3 2 Precautions for robot controllers B Installation environment 1 Installation environment A WARNING YAMAHA ROBOTS AND ROBOT CONTROLLERS ARE NOT DESIGNED TO BE EXPLOSION PROOF DO NOT USE THEM IN LOCATIONS EXPOSED TO EXPLOSIVE OR INFLAMMABLE GASES GASOLINE OR SOLVENT FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH AND LEAD TO FIRE WARNING Ak e USE THE ROBOT CONTROLLER IN LOCATIONS THAT SUPPORT THE ENVIRONMENTAL CONDITIONS SPECIFIED IN THIS MANUAL OPERATION OUTSIDE THE SPECIFIED ENVIRONMENTAL RANGE MAY CAUSE ELECTRICAL SHOCK FIRE MALFUNCTION OR PRODUCT DAMAGE OR DETERIORATION THE ROBOT CONTROLLER AND PROGRAMMING BOX SHOULD BE INSTALLED AT A LOCA

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