Omron R6YXGL250, R6YXGL400, R6YXGL350, R6YXR400, R6YXGL600 User Manual
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CONTENTS
Safety Instructions
1. Safety Information S-1
2. Signal words used in this manual S-2
3. Warning labels S-3
3.1 Warning labels S-3
3.1.1 Warning label messages on robot and controller S-3
3.1.2 Supplied warning labels S-6
3.2 Warning symbols S-7
4. Important precautions for each stage of the robot life cycle S-8
4.1 Precautions for using robots and controllers S-8
4.2 Design S-9
4.2.1 Precautions for robots S-9
4.2.2 Precautions for robot controllers S-9
4.3 Moving and installation S-10
4.3.1 Precautions for robots S-10
4.3.2 Precautions for robot controllers S-11
4.4 Safety measures S-13
4.4.1 Safety measures S-13
4.4.2 Installing a safety enclosure S-14
4.5 Operation S-15
4.5.1 Trial operation S-15
4.5.2 Automatic operation S-17
4.5.3 Precautions during operation S-17
4.6 Inspection and maintenance S-19
4.6.1 Before inspection and maintenance work S-19
4.6.2 Precautions during service work S-20
4.7 Disposal S-21
YRCX
User’s Manual
5. Emergency action when a person is caught by robot S-22
6. Cautionsregardingstrongmagneticelds S-22
7. Using the robot safely S-23
7.1 Movement range S-23
7.2 Robot protective functions S-24
7.3 Residual risk S-25
7.4 Special training for industrial robot operation S-25
7.5 KC mark S-26
7.5.1 EMC standards S-26
7.5.2 Examples of EMC countermeasures S-26
T-1
CONTENTS
Warranty
Important information before reading this manual
Introduction i
About this manual i
Overview of the YRCX ii
Before using the robot controller (Be sure to read the following notes) iii
Chapter 1 Using the robot safely
1. Emergency action when a person is caught by robot 1-1
2. Emergency stop 1-2
2.1 Emergency stop release and alarm reset 1-2
3. Power-ON procedures 1-4
YRCX
User’s Manual
4. Usage environments 1-5
Chapter 2 System overview
1. I/O interface overview 2-1
1.1 Mainsystemconguration 2-1
1.2 AxiscongurationfortheYRCX 2-2
2. Name of each part and control system 2-3
2.1 YRCXexternalview 2-3
2.2 Controller system 2-4
3. Optional devices 2-5
3.1 Programming box 2-5
3.2 Basic key operation 2-5
3.3 Expansion I/O board 2-5
4. Basic sequence from installation to operation 2-6
Chapter 3 Installation
1. Transport, unpacking 3-1
T-2
2. Installing the robot controller 3-1
2.1 Installation conditions 3-1
2.2 Installation methods 3-2
CONTENTS
3. Connecting to the power 3-3
3.1 Powersupplyandgroundterminals 3-3
3.2 ACpowerconnectorwiring 3-4
3.3 Consideringpowercapacityandgeneratedheatamount 3-5
3.4 Installing an external leakage breaker 3-6
3.4.1 Selecting condition 3-6
3.5 Installing a circuit protector 3-6
3.6 Installing an electromagnetic contactor 3-6
3.7 Installinganoiselter 3-7
3.8 Installing a surge absorber 3-7
4. Connecting the absolute battery 3-8
5. Robot connections 3-9
5.1 Connecting the robot cables 3-9
5.2 Noise countermeasures 3-10
6. Connecting the programming box 3-10
YRCX
User’s Manual
7. I/O connections 3-11
8. Connecting the regenerative shorting connector 3-11
9. Connecting the brake power supply 3-12
10. Precautions for cable routing and installation 3-12
10.1 Wiring methods 3-12
10.2 Methods of preventing malfunctions 3-13
11. Checking the robot controller operation 3-14
11.1 Controllerwiring 3-14
11.2 Wiring example of emergency stop circuit for operation check 3-15
11.3 Operation check 3-15
Chapter 4 I/O interface
1. I/O interface overview 4-1
1.1 ID settings 4-2
1.2 Powersupply 4-2
1.3 Powerconnectorwiringwork 4-3
1.4 Connector I/O signals 4-4
1.4.1 StandardspecicationI/Oconnectorsignallist 4-4
1.4.2 ExpandedspecicationI/Oconnectorsignallist 4-5
1.5 Connector pin assignment lists 4-6
1.5.1 StandardspecicationI/Oconnector 4-6
1.5.2 ExpandedspecicationI/Oconnector 4-6
T-3
CONTENTS
1.6 Connector pin numbers 4-7
1.7 Typical input signal connection 4-7
1.8 Typical output signal connection 4-8
1.9 Dedicated input signal description 4-9
1.10 Dedicated output signal description 4-10
1.11 Dedicated I/O signal timing chart 4-12
1.11.1 From the controller power on to servo on 4-12
1.11.2 Controller emergency stop and servo on reset 4-13
1.11.3 Return-to -origin 4-14
1.11.4 Program reset and program execution 4-15
1.11.5 Stopping by program stop 4-16
1.12 General-purpose I/O signals 4-17
1.12.1 General-purpose input signals 4-17
1.12.2 General-purpose output signals 4-17
1.12.3 General-purpose output signal reset (off) 4-17
2. Ratings 4-18
2.1 Input 4-18
2.2 Output 4-18
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User’s Manual
3. Caution items 4-18
Chapter 5 SAFETY I/O interface
1. SAFETY I/O interface overview 5-1
1.1 Power 5-1
1.2 Connector I/O signals 5-1
1.3 Connectionexamplecombiningtheprogrammingboxwith
external emergency stop circuit 5-2
1.3.1 ConnectionexampleofcontrollerwithCEspecicationsandPBEX 5-2
1.4 Connections example of dedicated input signal 5-3
1.4.1 Emergencystopinputs(E-STOPRDY*,E-STOPCOM*) 5-3
1.4.2 AUTOmodeinputs(AUTO*+,AUTOCOM*) 5-3
1.5 Connection example of dedicated output signal 5-4
1.5.1 Emergencystopcontactoutputs(E-STOP*1,E-STOP*2) 5-4
1.5.2 Enableswitchcontactoutputs(ENABLE*1,ENABLE*2) 5-4
1.5.3 Motorpowerreadyoutputs(MPRDY*+,MPRDY*-) 5-5
Chapter 6 External communication interface
1. Overview 6-1
1.1 Communicationoverview 6-1
1.2 ONLINE and OFFLINE modes 6-2
1.3 Character code 6-3
T-4
CONTENTS
2. RS-232C 6-4
2.1 Connectors and cables 6-4
2.2 Communicationspecications 6-5
2.3 Connections 6-5
2.4 Communication parameter setting 6-6
2.5 Communicationowcontrol 6-7
2.5.1 Flow control during transmit 6-7
2.5.2 Flow control during receive 6-7
2.6 Other caution items 6-7
3. Ethernet 6-8
3.1 Connectors and cables 6-9
3.2 Communicationspecications 6-11
3.3 Connections 6-12
3.4 Parameter setting on controller (server) 6-13
3.4.1 Setting the communication mode and parameters 6-14
3.4.2 Initializing communication parameters 6-14
3.5 System setting on personal computer (client) 6-15
3.5.1 SettingtheTCP/IPprotocol 6-15
3.6 Connection check using "Ping" 6-16
3.7 Communicationexampleusing"TELNET.EXE" 6-16
3.8 Appendix 6-17
3.8.1 Exampleofnetworksystemconguration 6-17
3.8.2 Glossary 6-20
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User’s Manual
4. General Ethernet port (GEP) 6-22
4.1 GEP parameter setting 6-22
4.2 GEP parameter setting method 6-23
4.3 Initializing communication parameters 6-24
Chapter 7 Controller system settings
1. Overview 7-1
2. History 7-1
3. Check 7-2
4. Property 7-2
4.1 Robot information 7-2
4.2 Option information 7-3
4.3 Clock 7-3
4.4 Version 7-3
4.5 Conguration 7-4
T-5
CONTENTS
5. USB memory operation 7-4
5.1 Saving the data 7-4
5.2 Loading the data 7-5
6. Execution level 7-6
6.1 Changing the access level 7-6
7. Safety setting 7-7
8. Initialize 7-8
8.1 Initializing the data 7-8
8.2 Setting the clock 7-9
9. Generation 7-10
10. Parameters 7-10
10.1 Parameter setting conditions 7-10
10.2 Setting the parameters 7-10
10.3 Parameter list 7-12
10.4 Controller parameters 7-15
10.5 Robot parameters 7-17
10.6 Axis parameters 7-20
10.7 I/O parameters 7-27
10.8 Option board related parameters 7-29
YRCX
User’s Manual
Chapter 8 Periodic inspection
1. Before carrying out work 8-1
2. Maintenance parts 8-1
3. Periodic inspections 8-1
3.1 Daily inspections 8-1
3.2 Three-month inspections 8-2
4. Replacing the absolute battery 8-2
5. Replacing the memory battery 8-2
Chapter 9 Specications
1. Controller 9-1
1.1 Specications 9-1
1.2 Basic functions 9-2
1.3 Externalview 9-3
T-6
CONTENTS
2. Programming box 9-4
2.1 Basicspecications 9-4
2.2 Externalview 9-4
Troubleshooting
1. Alarm messages A-1
1.1 Alarm messages related to the controller A-1
1.1.1 Alarm group number list A-3
1.1.2 Alarmclassicationnumberlist A-4
1.1.3 Warning number list A-4
[0]Operationmessages A-4
[ 1] System events A-5
[ 2] Alarm related to the robot operation A-7
[3]Alarmrelatedtotheprogramleoperation A-13
[ 4] Alarm related to the data input A-15
[ 5] Alarm related to the syntax of the robot language (compile) A-16
[ 6] Alarm related to the robot language execution A-23
[ 9] Alarm related to the memory A-33
[10] Alarm related to the environment and general hardware A-36
[12] Alarm related to the option board A-38
[14] Alarm related to the communication A-46
[17] Alarm related to the motor control A-49
[19]AlarmrelatedtotheYC-Link/E A-55
[21] Serious alarm related to software A-58
[22] Serious alarm related to hardware A-59
[26] Alarm related to the gripper A-62
[28]AlarmrelatedtothedriverI/F A-66
[ c] Warning A-67
1.2 Alarm messages related to the programming box A-68
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User’s Manual
2. Troubleshooting A-69
2.1 When trouble occurs A-69
2.2 Acquiring the alarm information A-70
2.2.1 Checking the alarm occurrence status A-70
2.2.2 Checking the alarm history A-70
2.3 Troubleshooting checkpoints A-71
2.3.1 Installation and power supply A-71
2.3.2 Robot operation A-72
2.3.3 I/O A-73
T-7
Safety Instructions
Contents
1. Safety Information S-1
2. Signal words used in this manual S-2
3. Warning labels S-3
3.1 Warning labels S-3
3.1.1 Warning label messages on robot and controller S-3
3.1.2 Supplied warning labels S-6
3.2 Warning symbols S-7
4. Important precautions for each stage of the robot life cycle
4.1 Precautions for using robots and controllers S-8
4.2 Design S-9
4.2.1 Precautions for robots S-9
4.2.2 Precautions for robot controllers S-9
4.3 Moving and installation S-10
4.3.1 Precautions for robots S-10
4.3.2 Precautions for robot controllers S-11
4.4 Safety measures S-13
4.4.1 Safety measures S-13
4.4.2 Installing a safety enclosure S-14
4.5 Operation S-15
4.5.1 Trial operation S-15
4.5.2 Automatic operation S-17
4.5.3 Precautions during operation S-17
4.6 Inspection and maintenance S-19
4.6.1 Before inspection and maintenance work S-19
4.6.2 Precautions during service work S-20
4.7 Disposal S-21
5.
Emergency action when a person is caught by robot
S-8
S-22
6. Cautions regarding strong magnetic fields S-22
7. Using the robot safely S-23
7.1 Movement range S-23
7.2 Robot protective functions S-24
7.3 Residual risk S-25
7.4 Special training for industrial robot operation S-25
7.5 KC mark S-26
7.5.1 EMC standards S-26
7.5.2 Examples of EMC countermeasures S-26
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 OMRON industrial robots and controllers*, carefully read and comply with the safety instructions and precautions in this "Safety Instructions"
guide. Failure to take necessary safety measures or incorrect handling may result in trouble or damage to the
robot and controller, and also may cause personal injury (to installation personnel, robot operator or service
personnel) including fatal accidents.
* The descriptions about the controller stated in this manual also include the contents of the robot driver.
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 OMRON robots, please take appropriate safety measures as required by the user’s individual system.
To use OMRON 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.
• Warning labels attached to the robots are written in English, Japanese, Chinese and Korean. This manual
is available in English or Japanese (or some parts in Chinese). Unless the robot operators or service
personnel understand these languages, do not permit them to handle the robot.
• Cautions regarding the official language of EU countries
For equipment that will be installed in EU countries, the language used for the manuals, warning labels,
operation screen characters, and CE declarations is English only.
Warning labels only have pictograms or else include warning messages in English. In the latter case,
messages in Japanese or other languages might be added.
Safety Instructions
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.
S-1
Safety Instructions
2. Signal words used in this manual
This manual uses the following safety alert symbols and signal words to provide safety instructions that must
be observed and to describe handling precautions, prohibited actions, and compulsory actions. Make sure
you understand the meaning of each symbol and signal word and then read this manual.
DANGER
This indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
This indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
This indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury, or
damage to the equipment.
NOTE
Explains the key point in the operation in a simple and clear manner.
S-2
3. Warning labels
Warning labels shown below are attached to the robot body and controller to alert the operator to potential
hazards. To ensure correct use, read the warning labels and comply with the instructions.
3.1 Warning labels
WARNING
If warning labels are removed or difficult to see, then the necessary precautions may not be taken, resulting in an
accident.
• Do not remove, alter or stain the warning labels on the robot body.
• Do not allow warning labels to be hidden by devices installed on the robot by the user.
• Provide proper lighting so that the symbols and instructions on the warning labels can be clearly seen from
outside the safety enclosure.
3.1.1 Warning label messages on robot and controller
Word messages on the danger, warning and caution labels are concise and brief instructions. For more specific
instructions, read and follow the "Instructions on this label" described on the right of each label shown below.
See “7.1 Movement range” for details on the robot’s movement range.
■Warning label 1
DANGER
Serious injury may result from contact with a moving robot.
• Keep outside of the robot safety enclosure during operation.
• Press the emergency stop button before entering the safety enclosure.
Safety Instructions
Potential hazard to human body
To avoid hazard
Serious injury may result from contact with a moving robot.
• Keep outside of the robot safety enclosure during operation.
• Press the emergency stop button before entering the safety enclosure.
■Warning label 2
WARNING
Moving parts can pinch or crush hands.
Keep hands away from the movable parts of the robot.
Instructions on this label
• Always install a safety enclosure to keep all persons
away from the robot movement range and prevent
injury from contacting the moving part of the robot.
Install an interlock that triggers emergency stop when
•
the door or gate of the safety enclosure is opened.
• The safety enclosure should be designed so that no
one can enter inside except from the door or gate
equipped with an interlock device.
• Warning label 1 that comes supplied with a robot
should be affixed to an easy-to-see location on the
door or gate of the safety enclosure.
90K41-001470
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.
Potential hazard to human body
To avoid hazard
Moving parts can pinch or crush hands.
Keep hands away from the movable parts of the robot.
90K41-001460
S-3
■Warning label 3
Safety Instructions
WARNING
Improper installation or operation may cause serious injury.
Before installing or operating the robot, read the manual and instructions on the warning labels and understand
the contents.
Instructions on this label
• Be sure to read the warning label and this manual
carefully to make you completely understand the
contents before attempting installation and operation
of the robot.
• Before starting the robot operation, even after you
have read through this manual, read again the
corresponding procedures and "Safety Instructions".
• Never install, adjust, inspect or service the robot in
any manner that does not comply with the
instructions in this manual.
Potential hazard to human body
To avoid hazard
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.
■Warning label 4
90K41-001290
CAUTION
Do not remove the parts on which Warning label 4 is attached.
Doing so may damage the ball screw.
Instructions on this label
The Z-axis ball screw will be damaged if the upper end
mechanical stopper on the Z-axis spline is removed or
moved. Never attempt to remove or move it.
90K41-001520
S-4
■Warning label 5 (YRCX/YRC controllers)
WARNING
These are precautions for OMRON and distributors' service personnel.
Customers must not attempt to open the covers.
WARNING
Wait at least 100 seconds after power-off before opening the covers.
Instructions on this label
• Wait at least 100 seconds after power-off
before opening the covers (*).
• Some parts in the controller still retain a high
voltage even after power-off, so electrical
shock may occur if those parts are touched.
Potential hazard to human body
To avoid hazard
Electrical shock
Wait at least 100 seconds after power-off before opening the covers (*).
* These are precautions for OMRON and distributors' service personnel. Customers must not attempt to open the covers.
90K41-001390
■Warning label 6 (Controller)*
* This label is attached to the front panel.
Safety Instructions
CAUTION
Refer to the manual.
取扱説明書参照
READ INSTRUCTION
MANUAL
Instructions on this label
This indicates important information that you must
know and is described in the manual.
Before using the controller, be sure to read the manual
thoroughly.
When adding external safety circuits or connecting a
power supply to the controller, read the manual
carefully and make checks before beginning the work.
Connectors have an orientation. Insert each connector
in the correct direction.
93005-X0-00
S-5
3.1.2 Supplied warning labels
Safety Instructions
Some warning labels are not affixed to robots but included in the packing box. These warning labels should be
affixed to an easy-to-see location.
Warning label is attached to the robot body.
Warning label comes supplied with the robot and should be affixed to an easy-to-see location on the door or gate of the
safety enclosure.
Warning label comes supplied with the robot and should be affixed to an easy-to-see location.
SCARA robots
1
*
Warning label 1
Warning label 2
Warning label 3
*1: See "Part names" in each SCARA robot manual for label positions.
1
*
1
*
S-6
3.2 Warning symbols
!
Warning symbols shown below are indicated on the robots and controllers to alert the operator to potential
hazards. To use the OMRON robot safely and correctly always follow the instructions and cautions indicated
by the symbols.
1. Electrical shock hazard symbol
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
WARNING
Motors, heatsinks, and regenerative units become hot, so do not touch them.
Instructions by this symbol
Safety Instructions
3. Caution symbol
CAUTION
Always read the manual carefully before using the controller.
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
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 beginning the work.
Connectors must be attached while facing a certain
direction, so insert each connector in the correct
direction.
93007-X0-00
S-7
Safety Instructions
4. Important precautions for each stage of the robot life cycle
This section describes major precautions that must be observed when using robots and controllers. Be sure to
carefully read and comply with all of these precautions even if there is no alert symbol shown.
4.1 Precautions for using robots and controllers
General precautions for using robots and controllers are described below.
1. Applications where robots cannot be used
OMRON robots and robot controllers are designed as general-purpose industrial equipment and cannot be used for the
following applications.
DANGER
OMRON 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
• 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 perform tasks for industrial robots (such as teaching, programming, movement check, inspection, adjustment, and repair) must receive appropriate training and also have the skills needed to perform the tasks
correctly and safely.
Those tasks must be performed by qualified persons who meet requirements established by local regulations and standards for industrial robots. They must also read the manual carefully and understand its contents before attempting the
robot operation or maintenance.
WARNING
• It is extremely hazardous for persons who do not have the above qualifications to perform tasks for industrial
robots.
• Adjustment and maintenance that require removing a cover must be performed by persons who have the
above qualifications. Any attempt to perform such tasks by an unqualified person may cause an accident
resulting in serious injury or death.
S-8
4.2 Design
4.2.1 Precautions for robots
1. Restricting the robot moving speed
WARNING
Restriction on the robot moving speed is not a safety-related function.
To reduce the risk of collision between the robot and workers, the user must take the necessary protective
measures such as enable devices according to risk assessment by the user.
2. Restricting the movement range
See “7.1 Movement range” for details on the robot’s movement range.
WARNING
Soft limit function is not a safety-related function intended to protect the human body.
To restrict the robot movement range to protect the human body, use the mechanical stoppers installed in the
robot (or available as options).
CAUTION
If the robot moving at high speed collides with a mechanical stopper installed in the robot (or available as
option), the robot may be damaged.
3. Provide safety measures for end effector (gripper, etc.)
Safety Instructions
WARNING
• End effectors must be designed and manufactured so that they cause no hazards (such as a loose workpiece
or load) even if power (electricity, air pressure, etc.) is shut off or power fluctuations occur.
• If the object gripped by 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.
4. Provide adequate lighting
Provide enough lighting to ensure safety during work.
5. Install an operation status light
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.).
4.2.2 Precautions for robot controllers
1. Emergency stop input terminal
DANGER
Each robot controller has an emergency stop input terminal to trigger emergency stop. Using this terminal, install
a safety circuit so that the system including the robot controller will work safely.
For the robot driver without emergency stop input terminal, construct a safety circuit including the emergency
stop function using an external circuit.
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.
S-9
4.3 Moving and installation
Safety Instructions
4.3.1 Precautions for robots
■Installation environment
1. Do not use in strong magnetic fields
WARNING
Do not use the robot near equipment or in locations that generate strong magnetic fields. The robot may BREAK
DOWN or malfunction if used in such locations.
2. Do not use in locations subject to possible electromagnetic interference, etc.
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
WARNING
• OMRON robots are not designed to be explosion-proof.
• Do not use the robots in locations exposed to explosive or inflammable gases, dust particles or liquid. Failure to
follow this instruction may cause serious accidents involving injury or death, or lead to fire.
■Moving
1. Use caution to prevent pinching or crushing of hands or fingers
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".
2. Take safety measures when moving robots
To ensure safety when moving a SCARA robot with an arm length of 500mm or more, use the eyebolts that come supplied
with the robot. Always refer to the robot user’s manual for details.
When moving other robots, please comply with the transport methods described in their respective user’s manuals.
3. Take measures to prevent the robot from falling
When moving the robot by lifting it with equipment such as a hoist or crane, wear personal protective gear and be
careful not to move the robot at higher than the required height.
Make sure that there are no persons on paths used for moving the robot.
WARNING
A robot falling from a high place and striking a worker may cause death or serious injury. When moving the
robot, wear personal protective gear such as helmets and make sure that no one is within the surrounding area.
■Installation
1. Protect electrical wiring and hydraulic/pneumatic hoses
Install a cover or similar item to protect the electrical wiring and hydraulic/pneumatic hoses from possible damage.
S-10
■Wiring
1. Protective measures against electrical shock
WARNING
Always ground the robot to prevent electrical shock.
■Adjustment
1. Adjustment that requires removing a cover
WARNING
Adjustment by removing a cover require specialized technical knowledge and skills, and may also involve
hazards if attempted by an unskilled person. This adjustment must be performed only by persons who have the
required qualifications described in “2. Qualification of operators/workers” in section 4.1 of this “Safety Instructions”.
4.3.2 Precautions for robot controllers
■Installation environment
1. Installation environment
WARNING
OMRON robots are not designed to be explosion-proof. Do not use the robots and controllers in locations
exposed to explosive or inflammable gases, dust particles or liquid such as gasoline and solvents. Failure to
follow this instruction may cause serious accidents involving injury or death, and lead to fire.
Safety Instructions
WARNING
• 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 must be installed at a location that is outside the robot safety
enclosure yet where it is easy to operate and view robot movement.
• Install the robot controller in locations with enough space to perform work (teaching, inspection, etc.) safely.
Limited space not only makes it difficult to perform work but can also cause injury.
• Install the robot controller in a stable, level location and secure it firmly. Avoid installing the controller upside
down or in a tilted position.
• Provide sufficient clearance around the robot controller for good ventilation. Insufficient clearance may cause
malfunction, breakdown or fire.
■Installation
To install the robot controller, observe the installation conditions and method described in the manual.
1. Installation
WARNING
Securely tighten the screws to install the robot controller. If not securely tightened, the screws may come loose
causing the controller to drop.
2. Connections
WARNING
• Always shut off all phases of the power supply externally before starting installation or wiring work. Failure to do
this may cause electrical shock or product damage.
• Never directly touch conductive sections and electronic parts other than the connectors, rotary switches, and
DIP switches on the outside panel of the robot controller. Touching them may cause electrical shock or
breakdown.
• Securely install each cable connector into the receptacles or sockets. Poor connections may cause the
controller or robot to malfunction.
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■Wiring
Safety Instructions
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
WARNING
Always shut off all phases of the power supply externally before starting installation or wiring work. Failure to do
this may cause electrical shock or product damage.
CAUTION
• Make sure that no foreign matter such as cutting chips or wire scraps get into the robot controller. Malfunction,
breakdown or fire may result if these penetrate inside.
• Do not apply excessive impacts or loads to the connectors when making cable connections. This might bend
the connector pins or damage the internal PC board.
• When using ferrite cores for noise elimination, be sure to fit them onto the power cable as close to the robot
controller and/or the robot as possible, to prevent malfunction caused by noise.
3. Wiring method
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.
CAUTION
When disconnecting the cable from the robot controller, detach by gripping the connector itself and not by
tugging on the cable. Loosen the screws on the connector (if fastened with the screws), and then disconnect the
cable. Trying to detach by pulling on the cable itself may damage the connector or cables, and poor cable
contact will cause the controller or robot to malfunction.
4. Precautions for cable routing and installation
CAUTION
• 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.
• 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
WARNING
Be sure to ground the ground terminals of the robot and controller. Poor grounding may cause electrical shock.
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4.4 Safety measures
4.4.1 Safety measures
1. Referring to warning labels and manual
WARNING
• Before starting installation or operation of the robot, be sure to read the warning labels and this manual, and
comply with the instructions.
• Never attempt any repair, parts replacement and modification unless described in this manual. These
tasks require specialized technical knowledge and skills and may also involve hazards. Please contact your
distributor for advice.
NOTE
For details on warning labels, see "3. Warning labels".
2. Draw up "work instructions" and make the operators/workers understand them
WARNING
Decide on "work instructions" in cases where personnel must work within the robot safety enclosure to perform
startup or maintenance work. Make sure the workers completely understand these "work instructions".
Decide on "work instructions" for the following items in cases where personnel must work within the robot safety
enclosure to perform teaching, maintenance or inspection tasks. Make sure the workers completely understand these
"work instructions".
1. Robot operating procedures needed for tasks such as startup procedures and handling switches
2. Robot speeds used during tasks such as teaching
3. Methods for workers to signal each other when two or more workers perform tasks
4. Steps that the worker should take when a problem or emergency occurs
5. Steps to take after the robot has come to a stop when the emergency stop device was triggered, including checks for
cancelling the problem or error state and safety checks in order to restart the robot.
6. In cases other than above, the following actions should be taken as needed to prevent hazardous situations due to
sudden or unexpected robot operation or faulty robot operation as listed below.
• Place a display sign on the operator panel
• Ensure the safety of workers performing tasks within the robot safety enclosure
• Clearly specify position and posture during work
Specify a position and posture where worker can constantly check robot movements and immediately move to
avoid trouble if an error/problem occurs
• Take noise prevention measures
• Use methods for signaling operators of related equipment
• Use methods to decide that an error has occurred and identify the type of error
Implement the "work instructions" according to the type of robot, installation location, and type of work task.
When drawing up the "work instructions", make an effort to include opinions from the workers involved, equipment
manufacturer technicians, and workplace safety consultants, etc.
Safety Instructions
3. Take safety measures
DANGER
• Never enter the robot movement range while the robot is operating or the main power is turned on. Failure to
follow this warning may cause 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.
• When it is necessary to operate the robot while you are within the robot movement range such as for teaching
or maintenance/inspection tasks, always carry the programming box with you so that you can immediately
stop the robot operation in case of an abnormal or hazardous condition. Install an enable device in the
external safety circuit as needed. Also set the robot moving speed to 3% or less. Failure to follow these
instructions may cause serious accidents involving injury or death.
See “7.1 Movement range” for details on the robot’s movement range.
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Safety Instructions
WARNING
• During startup or maintenance tasks, display a sign "WORK IN PROGRESS" on the programming box and
operation panel in order to prevent anyone other than the person for that task from mistakenly operating the
start or selector switch. If needed, take other measures such as locking the cover on the operation panel.
• Always connect the robot and robot controller in the correct combination. Using them in an incorrect
combination may cause fire or breakdown.
4. Install system
When configuring an automated system using a robot, hazardous situations are more 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.
WARNING
To check the robot controller operating status, refer to this manual and to related manuals. Design and install the
system including the robot controller so that it will always work safely.
5. Precautions for operation
WARNING
• Do not touch any electrical terminal. Directly touching these terminals may cause electrical shock, equipment
damage, and malfunction.
• Do not touch or operate the robot controller or programming box with wet hands. Touching or operating them
with wet hands may result in electrical shock or breakdown.
6. Do not disassemble and modify
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.
See “7.1 Movement range” for details on the robot’s movement range.
DANGER
Serious injury may result from contact with a moving robot.
• Keep outside of the robot safety enclosure during operation.
• Press the emergency stop button before entering the safety enclosure.
WARNING
• Install an interlock that triggers emergency stop when the door or gate of the safety enclosure is opened.
• The safety enclosure should be designed so that no one can enter inside except from the door or gate
equipped with an interlock device.
• Warning label 1 (See "3. Warning labels") that comes supplied with a robot should be affixed to an easy-to-see
location on the door or gate of the safety enclosure.
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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 safety enclosure.
• The programming unit is in the specified location.
• The robot and peripheral equipment are in good condition.
4.5.1 Trial operation
After installing, adjusting, inspecting, maintaining or repairing the robot, perform trial operation using the
following procedures.
1. If a safety enclosure has not yet been provided right after installing the robot:
Then rope off or chain off the movement range around the robot in place of the safety enclosure and observe the
following points.
See “7.1 Movement range” for details on the robot’s movement range.
DANGER
Place a "Robot is moving - KEEP AWAY!" sign to keep the operator or other personnel from entering within the
movement range of the robot.
Safety Instructions
WARNING
• Use sturdy, stable posts which will not fall over easily.
• The rope or chain should be easily visible to everyone around the robot.
2. Check the following points before turning on the controller.
• Is the robot securely and correctly installed?
• Are the electrical connections to the robot wired correctly?
• Are items such as air pressure correctly supplied?
• Is the robot correctly connected to peripheral equipment?
• Have safety measures (safety enclosure, etc.) been taken?
• Does the installation environment meet the specified standards?
3. After the controller is turned on, check the following points from outside the safety enclosure.
• Does the robot start, stop and enter the selected operation mode as intended?
• Does each axis move as intended within the soft limits?
• Does the end effector move as intended?
• Are the correct signals being sent to the end effector and peripheral equipment?
• Does emergency stop function?
• Are teaching and playback functions normal?
• Are the safety enclosure and interlocks functioning as intended?
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4. Working inside safety enclosures
Safety Instructions
Before starting work within the safety enclosure, always confirm from outside the enclosure that each protective
function is operating correctly (see the previous section 2.3).
DANGER
Never enter within the movement range while within the safety enclosure.
See “7.1 Movement range” for details on the robot’s movement range.
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.
WARNING
When work within the safety enclosure is required, always turn off the controller power except for the following
cases:
Exception
Work with power turned on, but robot in emergency stop
Origin position setting SCARA robots
Standard coordinate setting SCARA robots
Soft limit settings SCARA robots
Follow the precautions and procedure described in "Adjusting the
origin".
Follow the precautions and procedure described in "Setting the
standard coordinates".
Follow the precautions and procedure described in "Setting the soft
limits".
Work with power turned on
Teaching SCARA robots
Refer to "5. Teaching within safety enclosure" described below.
5. Teaching within the safety enclosure
When performing teaching within the safety enclosure, check or perform the following points from outside the safety
enclosure.
DANGER
Never enter within the movement range while within the safety enclosure.
See “7.1 Movement range” for details on the robot’s movement range.
WARNING
• Make a visual check to ensure that no hazards are present within the safety enclosure.
• Check that the programming box or handy terminal operates correctly.
• Check that no failures are found in the robot.
• Check that emergency stop works correctly.
• Select teaching mode and disable automatic operation.
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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.
WARNING
• Check that the programming box / handy terminal and tools are in their specified locations.
• Check that the signal tower lamps or other alarm displays installed for the system are not lit or flashing,
indicating no error is occurring on the robot and peripheral devices.
2. During automatic operation and when errors occur
After automatic operation starts, check the operation status and the signal tower to ensure that the robot is in automatic
operation.
DANGER
Never enter the safety enclosure during automatic operation.
Safety Instructions
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
• If unusual odors, noise or smoke occur during operation, immediately turn off power to prevent possible
electrical shock, fire or breakdown. Stop using the robot and contact your distributor.
• If any of the following damage or abnormal conditions occurs the robot, then continuing to operate the robot
is dangerous. Immediately stop using the robot and contact your distributor.
Damage or abnormal condition Type of danger
Damage to machine harness or robot cable Electrical shock, robot malfunction
Damage to robot exterior Damaged parts fly off during robot operation
Abnormal robot operation (position deviation, vibration, etc.) Robot malfunction
Z-axis (vertical axis) or brake malfunction Z-axis unit falls off
2. High temperature hazard
WARNING
• Do not touch the robot controller and robot during operation. The robot controller and robot body are very hot
during operation, so burns may occur if these sections are touched.
• The motor and speed reduction gear casing are very hot shortly after operation, so burns may occur if these
are touched. Before touching those parts for inspections or servicing, turn off the controller, wait for a while and
check that their temperature has cooled.
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3. Use caution when releasing the Z-axis (vertical axis) brake
Safety Instructions
WARNING
The vertical axis will slide downward when the brake is released, causing a hazardous situation. Take adequate
safety measures in consideration by taking the weight and shape into account.
• Before releasing the brake after pressing the emergency stop button, place a support under the vertical axis so
that it will not slide down.
• Be careful not to let your body get caught between the vertical axis and the installation base when performing
tasks (direct teaching, etc.) with the brake released.
4. Be careful of Z-axis movement when the controller is turned off or emergency stop is triggered
(air-driven Z-axis)
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.
• Do not let hands or fingers get caught and squeezed by robot parts moving along the Z-axis.
• Keep the usual robot position in mind so as to prevent the Z-axis from hanging up or binding on obstacles
during raising of the Z-axis except in case of emergency stop.
5. Take protective measures when the Z-axis interferes with peripheral equipment (air-driven Z-axis)
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.
• Turn off the controller and reduce the air pressure before attempting to remove the obstruction.
• Before reducing the air pressure, place a support under the Z-axis because the Z-axis will drop under its own
weight.
6. Be careful of Z-axis movement when air supply is stopped (air-driven Z-axis)
WARNING
The Z-axis will slide downward when the air pressure to the Z-axis air cylinder solenoid valve is reduced, creating
a hazardous situation.
Turn off the controller and place a support under the Z-axis before cutting off the air supply.
7. Make correct parameter settings
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
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.
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