Yamaha X-YX User Manual

OWNER'S MANUAL

CONTENTS

CHAPTER 1 Using the Robot Safely

1 Safety Information ..................................................................1-1

2 Essential Caution Items ..........................................................1-2

3 Special Training for Industrial Robot Operation ......................1-9

4 Robot Safety Functions ........................................................1-10

5 Safety Measures for the System .......................................... 1-11

6 Trial Run ...............................................................................1-12

7 Work Within the Safeguard Enclosure .................................. 1-13

8 Automatic Operation .............................................................1-14

9 Adjustment and Inspection ...................................................1-14

10 Repair and Modification ........................................................1-14

11 Warranty ...............................................................................1-15

12 CE Marking ...........................................................................1-16

CHAPTER 2 Product Outline

1 Robot ......................................................................................2-1

2 Names of each part ................................................................2-2

3 Robot Controller .....................................................................2-7

CHAPTER 3 Preparing the Robot

1 Robot Installation Environment ............................................... 3-1

2 Unpacking the Robot ..............................................................3-2

3 Checking the Product .............................................................3-3

4 Transporting the Robot ...........................................................3-5

5 Installation ..............................................................................3-7

5-1 Installation base ............................................................................... 3-7

5-2 Installing the Robot .......................................................................... 3-8

6 Protective connections ...........................................................3-9

7 Connecting the Robot Cables ............................................... 3-10

7-1 Connecting with the DRCX controller ............................................ 3-12

7-2 Connecting with the TRCX controller ............................................. 3-14

7-2-1 3-axis model .................................................................................. 3-14

7-2-2 4-axis model .................................................................................. 3-16

7-3 Connecting to the QRCX or RCX40 controller ............................... 3-18

8 Installing the Tool ..................................................................3-20

9 User Wiring and User Piping ................................................3-21

10 Setting the Robot ..................................................................3-22

10-1 Setting the payload ........................................................................ 3-22

10-2 Setting the maximum speed .......................................................... 3-23

10-3 Setting the acceleration ................................................................. 3-24

11 Absolute Reset .....................................................................3-25

CHAPTER 4 Periodic Inspections

1 Outline ....................................................................................4-1

2 Precautions ............................................................................. 4-1

3 Daily inspection ......................................................................4-2

4 Three-month inspection ..........................................................4-2

5 Six-month inspection ..............................................................4-3

6 Three-year inspection .............................................................4-4

7 Replenishing the grease .........................................................4-5

8 Maintenance and inspection of harmonic drives ....................4-6

8-1 Harmonic grease replacement period .............................................. 4-7

CHAPTER 5 Specifications

1 Specifications .........................................................................5-1

1-1 Robot cable ...................................................................................... 5-1

1-2 User I/O cable .................................................................................. 5-5

CHAPTER 6 PXYX

1 Installation ..............................................................................6-1

1-1 Installation bolt types ....................................................................... 6-1

1-2 Installation bolt nominal length......................................................... 6-1

1-3 Tightening torque ............................................................................. 6-1

1-4 Installation methods ......................................................................... 6-2

2 Protective Connections ........................................................... 6-3

2-1 Ground terminal ............................................................................... 6-3

2-2 Ground wire ..................................................................................... 6-4

2-3 Wiring method .................................................................................. 6-4

3 Installing the Tool ....................................................................6-5

4 User Wiring and User Piping ..................................................6-6

5 Periodic Inspections ...............................................................6-8

5-1 Replenishing grease to the linear guide........................................... 6-8

5-2 Replenishing grease to the ball screw ............................................. 6-9

CHAPTER 7 FXYX

1 Installation ..............................................................................7-1

1-1 Installation bolt types ....................................................................... 7-1

1-2 Installation bolt nominal length......................................................... 7-1

1-3 Tightening torque ............................................................................. 7-1

1-4 Installation methods ......................................................................... 7-2

2 Protective Connections ........................................................... 7-3

2-1 Ground terminal ............................................................................... 7-3

2-2 Ground wire ..................................................................................... 7-4

2-3 Wiring method .................................................................................. 7-4

3 Installing the Tool ....................................................................7-5

3-1 Arm type 2-axis model ..................................................................... 7-5

3-2 ZS (3rd-axis option) ......................................................................... 7-7

4 User Wiring and User Piping ..................................................7-8

4-1 Cable carrier type............................................................................. 7-8

4-1-1 Example of wiring and piping methods using cable carrier ............. 7-8

4-1-2 Cable carrier specifications ........................................................... 7-11

4-1-3 User I/O cable specifications .........................................................7-12

5 Periodic Inspections .............................................................7-13

5-1 Replenishing grease to the linear guide......................................... 7-13

5-2 Replenishing grease to the ball screw ........................................... 7-14

CHAPTER 8 SXYX

1 Installation ..............................................................................8-1

1-1 Installation bolt types ....................................................................... 8-1

1-2 Installation bolt nominal length......................................................... 8-1

1-3 Tightening torque ............................................................................. 8-2

1-4 Installation methods ......................................................................... 8-2

2 Protective Connections ........................................................... 8-5

2-1 Ground terminal ............................................................................... 8-5

2-2 Ground wire ..................................................................................... 8-6

2-3 Wiring methods ................................................................................ 8-6

3 Installing the Tool .................................................................. 8-11

3-1 Arm type, pole type 2-axis model.................................................... 8-11

3-2 Moving arm type 2-axis model ....................................................... 8-13

3-3 ZF

3-4 RF

3-5 ZS/ZRS (Arm type 3/4-axis option, XZ type 2/3-axis model) ......... 8-16

2-3-1 Arm type with cable carrier ..............................................................8-7

2-3-2 Arm type with whipover cable, moving arm type, pole type ............ 8-9

2-3-3 XZ type .......................................................................................... 8-10

(Arm type, moving arm type, 3rd-axis option/XZ type 2-axis model) .........

(Arm type, moving arm type, 4th-axis option/XZ type 3rd-axis option) .....

8-14

8-15

3-6 ZFH (Arm type, gantry type, moving arm type 3rd-axis option)

3-7 ZFL

4 User Wiring and User Piping ................................................8-19

4-1 Cable carrier type........................................................................... 8-19

4-2 Whipover cable type ...................................................................... 8-24

5 Periodic inspections .............................................................. 8-26

5-1 Replenishing grease to the linear guide......................................... 8-26

5-2 Replenishing grease to the ball screw ........................................... 8-27

5-3 Periodic inspection of the ZS/ZRS unit .......................................... 8-29

CHAPTER 9 MXYX

XZ 2nd-axis option ......................................................................... 8-17

(Arm type, moving arm type, 3rd-axis option/XZ type 2-axis model) ...

4-1-1 Example of wiring and piping methods using cable carrier ........... 8-19

4-1-2 Cable carrier specifications ........................................................... 8-22

4-1-3 User I/O cable specifications .........................................................8-23

4-2-1 Examples of wiring and piping with whipover cable ...................... 8-24

5-3-1 Replenishing grease to the Z-axis ball screw and ball spline ........8-29

5-3-2 Adjusting the R-axis belt tension (ZRS) ........................................ 8-30

5-3-3 Replacing the R-axis harmonic drive (ZRS) .................................. 8-31

8-18

1 Installation ..............................................................................9-1

1-1 Installation bolt types ....................................................................... 9-1

1-2 Installation bolt nominal length......................................................... 9-1

1-3 Tightening torque ............................................................................. 9-1

1-4 Installation methods

(Arm type, moving arm type, pole type, gantry type X-axis) ............ 9-2

1-5 Installation methods (Gantry type support axis)............................... 9-4

2 Protective Connections ........................................................... 9-5

2-1 Ground terminal ............................................................................... 9-5

2-2 Ground wire ..................................................................................... 9-5

2-3 Wiring methods ................................................................................ 9-6

3 Installing the Tool ....................................................................9-7

3-1 Arm type, pole type 2-axis model..................................................... 9-7

3-2 Moving arm type 2-axis model ......................................................... 9-9

3-3 ZF

(Arm type, moving arm type, gantry type 3rd-axis option) ............. 9-10

3-4 RF

(Arm type, moving arm type, 4th-axis option/XZ type 3rd-axis option) ...

3-5 ZFH (Arm type, gantry type, moving arm type 3rd-axis option)

XZ 2nd-axis option ......................................................................... 9-12

3-6 ZFL

(Arm type, moving arm type, 3rd-axis option/XZ type 2-axis model) ...

9-11

9-13

4 User Wiring and User Piping ................................................9-14

4-1 Cable carrier type........................................................................... 9-14

4-2 Whipover cable type ...................................................................... 9-19

5 Periodic Inspections .............................................................9-21

5-1 Replenishing grease to the linear guide......................................... 9-21

5-2 Replenishing grease to the ball screw ........................................... 9-22

CHAPTER 10 HXYX

1 Installation ............................................................................10-1

1-1 Installation method 1

1-2 Installation method 2 (XZ type) ...................................................... 10-4

1-3 Installation method 3 (Gantry type support axis) ........................... 10-6

4-1-1 Example of wiring and piping methods using cable carrier ........... 9-14

4-1-2 Cable carrier specifications ........................................................... 9-17

4-1-3 User I/O cable specifications .........................................................9-18

4-2-1 Examples of wiring and piping with Whipover cable ..................... 9-19

(Arm type, moving arm type, pole type, gantry type X-axis) .......... 10-1

1-1-1 Installation bolt types .....................................................................10-1

1-1-2 Installation bolt nominal length ...................................................... 10-1

1-1-3 Tightening torque........................................................................... 10-2

1-1-4 Installation methods ...................................................................... 10-2

1-2-1 Installation bolt .............................................................................. 10-4

1-2-2 Installation bolt nominal length ...................................................... 10-4

1-2-3 Tightening torque........................................................................... 10-5

1-2-4 Installation methods ...................................................................... 10-5

2 Protective Connections ......................................................... 10-7

2-1 Ground terminal ............................................................................. 10-7

2-2 Ground wire ................................................................................... 10-8

2-3 Wiring methods .............................................................................. 10-8

3 Installing the Tool ................................................................10-10

3-1 Arm type, gantry type 2-axis model .............................................. 10-11

3-2 Moving arm type 2-axis model ..................................................... 10-12

3-3 Pole type 2-axis model................................................................. 10-13

3-4 ZH

(Arm type, gantry type, moving arm type 3rd-axis option/XZ type 2-axis model) ....

3-5 ZL

(Arm type, gantry type, moving arm type 3rd-axis option/XZ type 2-axis model) ....

3-6 ZPH (Pole type 3rd-axis option) ................................................... 10-16

3-7 RH

(Arm type, moving arm type, gantry type 4th-axis option/XZ type 3rd-axis option) .....

10-14

10-15

10-17

4 User Wiring and User Piping ..............................................10-18

4-1 Cable carrier type......................................................................... 10-18

4-1-1 Example of wiring and piping methods using cable carrier ......... 10-18

4-1-2 Cable carrier specifications ......................................................... 10-20

4-1-3 User I/O cable specifications .......................................................10-21

4-2 Whipover cable type .................................................................... 10-22

4-2-1 Examples of wiring and piping with Whipover cable ................... 10-22

5 Periodic Inspections ...........................................................10-24

5-1 Replenishing grease to the linear guide....................................... 10-24

5-2 Replenishing grease to the ball screw ......................................... 10-25

CHAPTER 11 FXYBX/SXYBX

1 Installation ............................................................................ 11-1

1-1 Installation bolt types ...................................................................... 11-1

1-2 Installation bolt nominal length........................................................ 11-1

1-3 Tightening torque ............................................................................ 11-2

1-4 Installation methods ........................................................................11-2

2 Protective connections ......................................................... 11-3

2-1 Ground terminal .............................................................................. 11-3

2-2 Ground wire .................................................................................... 11-4

2-3 Wiring methods (Cable carrier type) ............................................... 11-4

2-4 Wiring methods (Whipover cable type) ...........................................11-6

3 Installing the Tool .................................................................. 11-7

3-1 FXYBX arm type 2-axis model ........................................................ 11-7

3-2 SXYBX arm type 2-axis model........................................................ 11-8

3-3 SXYBX-ZF (XZ type 2-axis, arm type 3rd-axis option) ................... 11-9

3-4 ZS/ZRS (FXYBX, SXYBX 3/4-axis option).................................... 11-10

3-5 ZFH (Arm type, gantry type, moving arm type 3rd-axis option)

XZ 2nd-axis option ........................................................................ 11-11

3-6 ZFL

(Arm type, moving arm type, 3rd-axis option/XZ type 2-axis model) ...

11-12

4 User Wiring and User Piping .............................................. 11-13

4-1 Cable carrier type.......................................................................... 11-13

4-1-1 Example of wiring and piping methods using cable carrier ......... 11-13

4-1-2 Cable carrier specifications ......................................................... 11-15

4-1-3 User I/O cable specifications ....................................................... 11-16

4-2 Whipover cable type ..................................................................... 11-16

4-2-1 Examples of wiring and piping with Whipover cable ................... 11-17

5 Changing the Motor Installation Position ............................ 11-19

5-1 Changing the motor installation position .......................................11-19

6 Installing the Cover ............................................................. 11-21

7 Adjusting the Timing Belt Tension ....................................... 11-22

7-1 Adjusting the drive belt tension .....................................................11-23

7-2 Adjusting the speed reduction belt tension ................................... 11-25

8 Periodic inspections ............................................................ 11-27

8-1 Replacing the motor ...................................................................... 11-27

8-2 Replacing the drive belt ................................................................ 11-28

8-3 Replacing the speed reduction belt............................................... 11-31

8-4 Replacing the slider ...................................................................... 11-32

8-5 Replenishing the grease ............................................................... 11-33

8-5-1 Replenishing grease to the linear guide ...................................... 11-33

8-5-2 Replenishing grease to the ball screw (ZF) ................................. 11-35

8-6 Periodic inspection of the ZS/ZRS unit ......................................... 11-36

CHAPTER 12 HXYLX

1 Installation ............................................................................12-1

1-1 Installation method 1

1-2 Installation method 3 (Gantry type support axis) ........................... 12-5

2 Protective Connections ......................................................... 12-6

2-1 Ground terminal ............................................................................. 12-6

2-2 Ground wire ................................................................................... 12-7

2-3 Wiring methods .............................................................................. 12-7

3 Installing the Tool ..................................................................12-8

3-1 Arm type, gantry type 2-axis model ............................................... 12-8

3-2 Moving arm type 2-axis model ....................................................... 12-9

3-3 Pole type 2-axis model................................................................. 12-10

3-4 ZH

3-5 ZL (Arm type, gantry type) ........................................................... 12-12

3-6 ZPH (Pole type 3rd-axis option) ................................................... 12-13

3-7 RH (Arm type, gantry type 4th-axis option) .................................. 12-14

8-6-1 Replenishing grease to the Z-axis ball screw and ball spline ...... 11-36

8-6-2 Adjusting the R-axis belt tension (ZRS) ...................................... 11-37

8-6-3 Replacing the R-axis harmonic drive (ZRS) ................................ 11-38

(Arm type, moving arm type, pole type, gantry type X-axis) .......... 12-1

1-1-1 Installation bolt types .....................................................................12-1

1-1-2 Installation bolt nominal length ...................................................... 12-1

1-1-3 Tightening torque........................................................................... 12-2

1-1-4 Installation methods ...................................................................... 12-2

(Arm type, gantry type, moving arm type 3rd-axis option) ............ 12-11

4 User Wiring and User Piping ..............................................12-15

4-1 Cable carrier type......................................................................... 12-15

4-1-1 Example of wiring and piping methods using cable carrier ......... 12-15

4-1-2 Cable carrier specifications ......................................................... 12-17

4-1-3 User I/O cable specifications .......................................................12-18

4-2 Whipover cable type (moving arm type/pole type 3-axis) ............ 12-19

4-2-1 Examples of wiring and piping with Whipover cable ................... 12-19

5 Periodic Inspections ...........................................................12-21

5-1 Replenishing grease to the linear guide....................................... 12-21

5-2 Replenishing grease to the ball screw ......................................... 12-22

5-3 Adjusting the timing belt tension (X-axis) ..................................... 12-24

5-4 Replacing the motor (X-axis) ....................................................... 12-25

5-5 Installing and removing the cover ................................................ 12-27

5-5-1 Stroke cover ................................................................................ 12-27

5-5-2 Belt cover .................................................................................... 12-28

5-5-3 Motor cover ................................................................................. 12-29

MEMO

CHAPTER 1

Using the Robot Safely

1 Safety Information ..................................................................1-1

2 Essential Caution Items ..........................................................1-2

3 Special Training for Industrial Robot Operation ......................1-9

4 Robot Safety Functions ........................................................1-10

5 Safety Measures for the System .......................................... 1-11

6 Trial Run ...............................................................................1-12

7 Work Within the Safeguard Enclosure .................................. 1-13

8 Automatic Operation .............................................................1-14

9 Adjustment and Inspection ...................................................1-14

10 Repair and Modification ........................................................1-14

11 Warranty ...............................................................................1-15

12 CE Marking ...........................................................................1-16

MEMO

1 Safety Information

Industrial robots are highly programmable machines that provide a large degree
of freedom in movement. To ensure correct and safe use of YAMAHA robots,
carefully read this manual to make yourself well acquainted with the contents.
FOLLOW THE WARNINGS, CAUTIONS AND INSTRUCTIONS INCLUDED
IN THIS MANUAL. Failure to take necessary safety measures or mishandling
due to not observing the instructions in this manual may result in trouble or dam­age to the robot and injury to personnel (robot installer, operator or service per­sonnel) including fatal accidents.

Warning information in this manual is classified into the following items.

DANGER

Failure to follow DANGER instructions will result in severe injury or death
to the robot operator, bystanders or persons servicing the robot.

Chapter 1 Using the Robot Safely

WARNING

Failure to follow WARNING instructions could result in severe injury or
death to the robot operator, bystanders or persons servicing the robot.

!

CAUTION

Failure to follow CAUTION instructions may result in injury to the robot opera­tor, bystanders or persons servicing the robot, or damage to the robot and/or
robot controller.

NOTE

Explains the keypoint in the operation in a simple and clear manner.

Refer to the instruction manual by any of the following methods to operate or
adjust the robot safely and correctly.

1. Operate or adjust the robot while referring to the printed version of the in­struction manual (available for an additional fee).

2. Operate or adjust the robot while viewing the CD-ROM version of the in­struction manual on your computer screen.

3. Operate or adjust the robot while referring to a printout of the necessary
pages from the CD-ROM version of the instruction manual.

It is not possible to list all safety items in detail within the limited space of this
manual. Thus, it is essential that the user have full knowledge of basic safety
rules and that the operator makes correct judgments on safety procedures during
operation.
When exporting this robot, the warning labels and instruction manuals must be
changed to export specifications.

1-1

Chapter 1 Using the Robot Safely

2 Essential Caution Items

Particularly important cautions for handling or operating the robot are described
below. In addition, safety information about installation, operation, inspection
and maintenance is provided in each chapter. Be sure to comply with these in­structions to ensure safe use of the robot.

(1) Observe the following cautions during automatic operation

DANGER

Serious injury will result from impact with moving robot.

• Keep outside safeguard enclosure during automatic operation.

• Press the emergency stop button before entering the safeguard enclo­sure.

The warning label 1 (Fig. 1-1) is attached to the robot.

• Install a safeguard enclosure to keep all personnel from entering within the
movable range of the robot and suffering injury due to being struck by
moving parts.

• Install a safety interlock that triggers emergency stop when the door or
panel is opened.

• Install safeguards so that no one can enter inside except from doors or
panels equipped with safety interlocks.

• The warning label 1 (Fig. 1-1) are supplied with the robot and should be
affixed to conspicuous places on doors or panels equipped with safety in­terlocks.

(2) Use caution to prevent hands or fingers from being pinched or

crushed.

WARNING

Moving parts can pinch or crush.
Keep hands always from robot arms.

Warning label 2 (Fig. 1-2) is affixed to the robot.
Use caution to prevent hands or fingers from being pinched or crushed in the
robot’s moving parts during transporting the robot or teaching, etc.

DANGER

Serious injury or death
will result from impact
with moving robot.

• Keep outside of guard

during operation.

• Lock out power before
approaching robot.

WARNING

Moving parts can
pinch or crush.
Keep hands away
from robot arms.

Fig. 1-1 Warning label 1 Fig. 1-2 Warning label 2

1-2

Chapter 1 Using the Robot Safely

(3) Follow the instructions listed on warning labels and in this

manual.

WARNING

Improper installation or operation can result in serious injury. Read the
Instruction Manual and all warning labels before operation.

The warning label 3 (Fig. 1-3) is attached to the robot.

• Be sure to read the warning labels and this manual carefully and make sure
to thoroughly understand the contents before attempting installation and
operation of the robot.

• Before starting robot operation, be sure to reread the procedures and cau­tions related to the work as well as the descriptions in this chapter (Chapter

1. “Using the Robot Safely”).

• Never install, adjust, inspect, service or operate the robot in any manner
that does not comply with the instructions in this manual.

WARNING

Improper Installation or operation
can result in serious injury or
death.
Read owner's manual and all
warning labels before operation.

Fig. 1-3 Warning label 3

1-3

Chapter 1 Using the Robot Safely

(4) Do not use the robot in environments containing inflammable

gas, etc.

WARNING

• This robot is not designed for operation in environments where inflam­mable of explosive substances are present.

• Do not use the robot in environments containing inflammable gas,
dust or liquids.
Explosions or fire might otherwise result.

(5) Do not use the robot in locations possible subject to electro-

magnetic interference, etc.

WARNING

Avoid using the robot in locations subject to electromagnetic interfer­ence, electrostatic discharge or radio frequency interference.
Malfunctions might otherwise occur.

(6) Use caution when releasing the brake for the Z-axis (vertical axis).

WARNING

The Z-axis will drop when the brake is released, creating a hazardous
situation.

• Press the emergency stop button and prop up the Z-axis with a support
stand, etc., before releasing the brake.

• Be careful not to let your body get caught between the Z-axis and in­stallation base, etc., when releasing the brake to perform direct teach­ing.

(7) Provide safety measures for end effector (gripper, etc.)

WARNING

• End effectors must be designed and manufactured so that they create
no hazards (for example, a workpiece that comes loose) even if power
(electricity, air pressure, etc.) is shut off or a power fluctuation occurs.

• If there is a possible danger that the object gripped by the end effector
may fly off or drop, then provide appropriate safety protection taking
into account the object size, weight, temperature and chemical proper­ties.

1-4

Chapter 1 Using the Robot Safely

(8) Movement of Z-axis at controller power shut off and emergency

stop (for ZAS)

WARNING

The Z-axis will start to rise when the controller power is shut off, the PLC
power is shut off, the program is reset, emergency stop is applied, and
when the supply of air to the Z-axis air cylinder’s solenoid valve is started.

• Take care not to pinch or crush hands, etc., in the Z-axis moving sec­tions.

• If there are any interferences in the Z-axis' upward travel path, reevaluate
the robot position, except for emergencies.

(9) Pay attention to interference of Z-axis with peripheral devices

(for ZAS)

WARNING

If the Z-axis interferes with a peripheral device and stops, there is a risk of
pinching hands, etc., when the interfering object is removed as the Z-axis
will suddenly move.

• Turn the controller power OFF and stop the air supply before removing
the interfering object.

• The Z-axis will naturally drop, so prop it up with a support stand, etc.,
before stopping the air supply.

(10)Z-axis movement when air supply is stopped

WARNING

The Z-axis will drop when the air supply is stopped, creating a hazardous
situation.
Prop up the Z-axis with a support stand, etc., before turning the controller
power OFF and stopping the air supply.

(11) Use caution when disassembling and replacing the pneumatic

devices

WARNING

If the pneumatic devices are disassembled or replaced while the air is
supplied, the parts or air could scatter.

• Turn the controller power OFF, stop the air supply and release all re­sidual pressure from the pneumatic devices before starting work.

• The Z-axis will naturally drop, so prop it up with a support stand, etc.,
before stopping the air supply.

1-5

Chapter 1 Using the Robot Safely

(12)Use caution when disassembling and replacing the motor

WARNING

When disassembling or assembling the motor for a ball-screw drive type
robot, a strong magnetic attraction force will be present between the motor
stator (fixed coil) and rotor (rotating magnet), causing a risk of pinching
hands, etc.
A YAMAHA-trained operator must carry out this work using the YAMAHA­recommended jigs.

(13)Use caution when removing the Z-axis brake

WARNING

The Z-axis will naturally drop when the brake is removed, causing a haz­ardous situation.

• Prop up the Z-axis with a support stand, etc., before turning the control
power OFF and removing the brake.

• Be careful not to let your body get caught between the Z-axis drive
section and Z-axis installation base, etc.

(14)Take the following safety precautions during inspection of the

controller

WARNING

• If the terminals or connectors on the outside of the controller must be
touched during inspection, etc., always first turn the controller power
OFF and the power source to prevent possible electrical shock.

• Refer to the "YAMAHA Robot Controller Instruction Manual" for pre­cautions on handling the controller. Never touch any internal parts of
the controller.

(15)Consult YAMAHA for corrective action when the robot is dam-

aged or malfunctions occur.

WARNING

If any part of the robot is damaged or any malfunction occurs, continuing
the operation may be very dangerous. Please consult your YAMAHA sales
office or dealer for corrective action.

Damage or Trouble Possible Danger

Damage to machine harness or robot cable Electrical shock, malfunction of robot

Damage to exterior of robot Flying outward of damaged parts during

robot operation

Abnormal operation of robot (positioning error,
excessive vibration, etc.)

Z-axis brake trouble

1-6

Malfunction of robot

Dropping of load

Chapter 1 Using the Robot Safely

(16)Use caution not to touch the controller rear panel cooling fan

WARNING

• Injury may occur from coming into contact with the cooling fan while it
is rotating.

• When removing the fan cover for inspection, first turn OFF the control­ler and make sure that the fan has stopped.

(17)Be careful not to touch the motor or speed reduction gear cas-

ing when hot.

WARNING

The motor and speed reduction gear casing are extremely hot after auto­matic operation, so burns may occur if these are touched.

• Before handling these parts during inspection or servicing, turn the
controller power OFF, wait for a while and check that the part has cooled.

(18)Do not remove, alter or stain the warning labels

WARNING

If the warning labels are removed or difficult to see, then essential pre­cautions might not be taken resulting in accidents.

• Do not remove, alter or stain the warning labels on the robot.

• Do not allow the warning labels to be hidden by devices installed onto
the robot by the user.

• Provide proper lighting so that the symbols and instructions on the
warning labels can be clearly seen even from outside the safeguard
enclosure.

(19)Protective connections

WARNING

Be sure to ground the robot and controller to prevent electrical shock.

(20)Be sure to make correct parameter settings - Part 1

!

CAUTION

Always input the correct parameters matching the payload and stroke (working
envelope) before operating the robot.

1-7

Chapter 1 Using the Robot Safely

(21)Be sure to make correct parameter settings - Part 2

!

CAUTION

When using a rotary axis (RF, RH, etc.) the robot must be operated with the
tolerable moment of inertia and correct acceleration coefficients according to
the tip mass and moment of inertia. If these are not correct, the drive unit serv­ice life may end prematurely, and damage to robot parts or residual vibration
during positioning may result.

(22) Do not use the robot for tasks requiring motor thrust.

!

CAUTION

Avoid using the belt-driven type robots for tasks that utilize motor thrust (press
fitting, burr removal, etc.).
These tasks may cause malfunctions in the robot.

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Chapter 1 Using the Robot Safely

3

Special Training for Industrial Robot Operation

Companies or factories using industrial robots must make sure that every person,
who handles the robot such as for teaching, programming, movement check, in­spection, adjustment and repair, has received appropriate training and also has
the skills needed to perform the job correctly and safely.
Since YAMAHA Cartesian Robot XY Series falls under the industrial robot cat­egory, the user must observe local regulations and safety standards for industrial
robots, and provide special training for every person involved in robot-related
tasks (teaching, programming, movement check, inspection, adjustment, repair,
etc.).

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Chapter 1 Using the Robot Safely

4 Robot Safety Functions

(1) Overload detection

This function detects an overload applied to the motor and shuts off the servo
power.

(2) Overheat detection

This detects an abnormal rise in the controller driver temperature and shuts
off the servo power.
If an overload or overheat error occurs, take the following measuring.

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. Note that
the working envelope is the area limited by soft limits.

(4) Mechanical stoppers

If the servo power is suddenly shut off during high-speed operation by emer­gency stop or safety functions, these mechanical stoppers prevent the axis
from exceeding the movable range.
No mechanical stopper is provided on the R-axis.
Note that the movable range is the area limited by the mechanical stoppers.

(5) Z-axis (vertical axis) brake

An electromagnetic brake is installed on the Z-axis to prevent the Z-axis
from dropping when the servo power is shut off. This brake is working when
the controller power is OFF or if the Z-axis servo is OFF even when the
controller power is ON.
The Z-axis brake can be released by means of the programming unit or by a
command in the program when the controller power is ON.

WARNING

The Z-axis will drop when the brakes are released, creating a hazardous
situation.

• Press the emergency stop button and prop up the Z-axis with a support
stand, etc., before releasing the brake.

• Be careful not to let your body get caught between the Z-axis and in­stallation base, etc., when releasing the brake to perform direct teach­ing.

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Chapter 1 Using the Robot Safely

5 Safety Measures for the System

When the robot is commonly used in conjunction with an automated system,
dangerous situations are more likely to occur from the automated system than
from the robot itself. Appropriate safety measures must be taken on the part of
the system manufacturer according to the individual system.
The system manufacture should provide a proper instruction manual for safe,
correct operation and servicing of the system.

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Chapter 1 Using the Robot Safely

6 Trial Run

After making installations, adjustments, inspections, maintenance or repairs to
the robot, carry out trial run using the following procedures.

(1) If a safeguard enclosure has not yet been provided right after installa-

tion of the robot, rope off or chain off the movable range in place of
the safeguard enclosure, and observe the following points.

1. Use sturdy, stable posts that will not fall over easily.

2. The rope or chain should be easily visible by everyone around the robot.

3. Place a sign to keep the operator or other personnel from entering the
movable range.

(2) Check the following points before turning the controller ON.

1. Is the robot securely and correctly installed?

2. Are the electrical connections to the robot correct?

3. Are items such as air pressure correctly supplied?

4. Is the robot correctly connected to peripheral devices?

5. Have safety measures (safeguard enclosure, etc.) been taken?

6. Does the installation environment meet the specified standards?

(3) After the controller power is turned ON, check the following points

from outside the safeguard enclosure.

1. Does the robot start and stop as intended? Can the operation mode be
selected correctly?

2. Does each axis move as intended within the soft limits?

3. Does the end effector move as intended?

4. Are the signal transmissions to the end effector and peripheral devices
correct?

5. Does emergency stop work?

6. Are the teaching and playback functions normal?

7. Are the safeguard enclosure and interlock working as intended?

8. Does the robot move correctly during automatic operation?

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Chapter 1 Using the Robot Safely

7 Work Within the Safeguard Enclosure

(1) When work is required in the safeguard enclosure, always turn the

controller power OFF and place a sign indicating that the robot is
being adjusted or serviced in order to keep any other personnel from
touching the controller power switch or operation panel, except for
the following cases.

1) Soft limit settings

2) Teaching

For item 1), follow the precautions and procedure for each section.
To perform item 2), refer to the description in (2) below.

(2) Teaching

When performing teaching within the safeguard enclosure, comply with the
instructions listed below.

1) Check or perform the following points from outside the safeguard enclo­sure.

1. Make sure that no hazards are present within the safeguard enclosure

by a visual check.

2. Check that the programming unit MPB or TPB operates correctly.

3. Check that no failures are found in the robot.

4. Check that emergency stop works correctly.

5. Select teaching mode and prohibit automatic operation.

2) Never enter the movable range of the robot while within the safeguard
enclosure.

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Chapter 1 Using the Robot Safely

8 Automatic Operation

(1) Check the following before starting automatic operation.

1. No one is within the safeguard enclosure.

2. The programming unit or tools, etc., are in their specified location.

3. The alarm or error lamps, etc., on the robot and peripheral devices do not
flash.

4. The safeguard enclosure is securely installed with safety interlocks, etc.,
actuated.

(2) Observe the following during automatic operation or in cases where

an error occurs.

1) After automatic operation has started, check the operation status and warn­ing lamps to ensure that the robot is in automatic operation.

2) Never enter the safeguard enclosure during automatic operation.

3) If an error occurs in the robot or peripheral devices, observe the following
procedures before entering the safeguard 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 in-

spected in order to keep any other person from touching the start switch
and restarting the robot.

9 Adjustment and Inspection

WARNING

Do not attempt any installation, adjustment, inspection or maintenance
unless described in this manual. Unexpected accidents or troubles may
otherwise result.

10 Repair and Modification

WARNING

Do not attempt any repair, part replacement or modification unless de­scribed in this manual. These matters require technical knowledge and
skills, and may also involve work hazards.

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11 Warranty

The YAMAHA robot and/or related product you have purchased are warranted
against the defects or malfunctions as described below.

Warranty description : If a failure or breakdown occurs due to defects

Warranty Period :The warranty period ends when any of the fol-

Chapter 1 Using the Robot Safely

in materials or workmanship in the genuine parts
constituting this YAMAHA robot and/or related
product within the warranty period, then
YAMAHA will repair or replace those parts free
of charge (hereafter called "warranty repair").

lowing applies:

1) After 18 months (one and a half year) have
elapsed from the date of shipment

2) After one year has elapsed from the date of
installation

3) After 2,400 hours of operation

Exceptions to the Warranty

Failures resulting from the following causes are not covered by warranty repair.

1) Damage due to earthquakes, storms, floods, thunderbolt, fire or any other
natural or man-made disasters.

2) Troubles caused by procedures prohibited in this manual.

: This warranty will not apply in the following

cases

1) Fatigue arising due to the passage of time,
natural wear and tear occurring during op­eration (natural fading of painted or plated
surfaces, deterioration of parts subject to
wear, etc.)

2) Minor natural phenomena that do not affect
the capabilities of the robot and/or related
product (noise from computers, motors, etc.).

3) Programs, point data and other internal data
that were changed or created by the user.

3) Modifications to the robot and/or related product not approved by
YAMAHA or YAMAHA sales representatives.

4) Use of any other than genuine parts and specified grease and lubricants.

5) Incorrect or inadequate maintenance and inspection.

6) Repairs by other than authorized dealers.

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Chapter 1 Using the Robot Safely

YAMAHA MOTOR CO., LTD. MAKES NO OTHER EXPRESS OR IMPLIED
WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU
OF ALL EXPRESSED OR IMPLIED WARRANTIES, INCLUDING WARRAN­TIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE,
OR WARRANTIES ARISING FROM A COURSE OF DEALING OR USAGE
OF TRADE.
YAMAHA MOTOR CO., LTD. SOLE LIABILITY SHALL BE FOR THE DE­LIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO., LTD. SHALL
NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES (WHETHER
ARISING FROM CONTRACT, WARRANTY, NEGLIGENCE OR STRICT
LIABILITY). YAMAHA MOTOR CO., LTD. MAKES NO WARRANTY WHAT­SOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED
BY YAMAHA MOTOR CO., LTD.

12 CE Marking

Refer to the following YAMAHA Robot Controller Instruction Manuals for de­tails on the related CE Marking for export to or use in EU regions.

• QRCX-E Instruction Manual

• ERCX/SRCX/DRCX compatible with CE marking supplement manual

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CHAPTER 2

Product Outline

1 Robot ......................................................................................2-1

2 Names of each part ................................................................2-2

3 Robot Controller .....................................................................2-7

MEMO