Yamaha YK180X, YK120X User Manual

YAMAHA MOTOR CO., LTD.

OWNER'S MANUAL

Before using the robot (Be sure to read the following notes.)

At this time, our thanks for your purchase of this YAMAHA YK-X series SCARA
robot.

(1) Please be sure to perform the following tasks before using the robot.

Note that the robot may operate abnormally (abnormal vibration or noise) if
the following work is not carried out.

Before the YK-X Series is shipped, the position shown in "Chapter 7, 1-2 Exter­nal view and dimensions" is adjusted as the origin position, and the standard
coordinates are provisionally set.

1. Absolute Reset

Absolute reset must be carried out just once before the YK-X Series robot can
be used.
Once absolute reset is completed, it does not need to be carried out again when
the power is turned ON the next time.
Refer to "Chapter 4, 3. Adjusting the origin" in this manual and "Absolute
Reset" in the "YAMAHA Robot Controller owner's manual" for details on
absolute reset.

2. Setting the standard coordinates

Set the standard coordinates while referring to instructions in "5. Setting the
Standard coordinates" in Chapter 4 of this manual and also to "Setting the
Standard coordinates" in the "YAMAHA robot controller owner's manual".
Robot malfunctions (vibration, noise) may occur if the standard coordinates
are not set correctly.

Even though there is no problem with the robot, the following error messages are
issued when the robot and controller are connected and power first turned on.
(Actual error messages may differ according to how the robot and controller are
connected.)

Error messages issued when robot & controller are connected (RCX142)

17.27 : D?.ABS. backup failed (CPU)

17.80 : D?.ABS. backup failed (DRIVER)

17.81 : D?.ABS.battery wire breakage

17.92 : D?.Resolver disconnected during power off

17.93 : D?.Position backup counter overflow

17.94 : D?.ABS.battery low voltage
etc

(2) Caution when turning off the robot controller

On the YK120X and YK180X series robots, the harness exerts a large reaction
force on the X and Y axis arms. When the power to the robot controller is
turned off, the arm positions might move slightly due to the harness reaction
force, depending on where the arms are positioned. If the arms moved a large
distance in this case, the correct position data may not be backed up. To avoid
this, before turning off the power to the robot controller, press the emergency
stop button and check that the robot arms have completely stopped.

(3) Connection to the controller

The controller for the YK120X series robots (YK120X, YK150X) is designed
to provide 24V output and the model name "RCX142-T" is shown on the
serial number label (see Fig. 2-5). Do not connect other controllers to the
YK120X series robot. If operated from a controller other than the RCX142­T, the robot's motors may be damaged.

Introduction

The YAMAHA YK120X and YK180 series robots are SCARA type industrial
robots developed based on years of YAMAHA experience and achievements in
the automation field as well as efforts to streamline our in-house manufacturing
systems.
The SCARA robots have a two-joint manipulator consisting of an X-axis arm
and a Y-axis arm, and are further equipped with a vertical axis (Z-axis) and a
rotating axis (R-axis) at the tip of the manipulator. The YK120X and YK180
series robots can be used for a wide range of assembly applications such as
installation and insertion of various parts, application of sealant, and packing
operations.

This owner's manual describes the safety measures, handling, adjustment and
maintenance of YK120X series robots for correct, safe and effective use. Be sure
to read this manual carefully before installing the robot. Even after you have read
this manual, keep it in a safe and convenient place for future reference.
This owner's manual should be used with the robot and considered an integral
part of it. When the robot is moved, transferred or sold, send this manual to the
new user along with the robot. Be sure to explain to the new user the need to read
through this manual.

This owner's manual explains the YAMAHA industrial robots YK120X series
standard models (YK120X, YK150X), clean room models (YK120XC,
YK150XC), and YK180X series (YK180X, YK220X).
Some descriptions of YK120XC and YK150XC are not listed in this manual when
they are the same as standard models. Refer to the descriptions of standard models.
For information on difference between the clean room model and standard model,
refer to the description on the next page.
For details on specific operation and programming of the robot, refer to the separate
"YAMAHA robot controller owner's manual".

NOTES

•

The contents of this manual are subject to change without prior notice.

• Information furnished by YAMAHA in this manual is believed to be reliable.

However, if you find any part unclear or inaccurate in this manual, please
contact YAMAHA sales office or dealer.

YAMAHA MOTOR CO., LTD.
IM Company

Clean Room Models YK120XC, YK150XC

Compared to standard YX120X and YK150X, clean room models differ in the
following points.

1. Robot parameter has been changed. (See section 4 in chapter 2.)

The Z-axis speed is lowered to maintain the degree of cleanliness and the
bellows durability. (This is preset prior to shipment.)

2. Suction couplers have been added. (See section 6 in chapter 3.)

For the suction amount versus degree of cleanliness, see "1-1 Basic
specifications" in chapter 7. For the location of the suction couplers, see "1­2 External view and dimensions" in chapter 7.
The suction amount for each suction coupler is very important to maintain
the degree of cleanliness and the bellows durability, so always comply with
the instruction.

3. R-axis machine reference adjustment is different.

(See section 3-4-1-2 in chapter 4.)

The structure around the R-axis origin sensor differs from standard
specifications, so the method for adjusting the machine reference is different.
Since the Z-axis bellows type suction tube is attached to the R-axis, care
must be taken when performing return-to-origin so that the suction tube will
not entangle around the R-axis.

4. Different grease is used for the Z-axis drive mechanism.

(See section 4 in chapter 5.)

LG2 grease (NSK) suitable for clean room is used for the Z-axis ball screw,
ball spline and linear bushing shaft.
Use the LG2 clean room grease for periodic maintenance.

5. Specifications and external appearance are somewhat changed.

(See sections 1-1 and 1-2 in chapter 7.)

The X- and Y-axis repeated positioning accuracy and Z-axis maximum speed
are different from standard specifications.
The external appearance and dimensions are different in that the Z-axis
bellows, flexible tube and suction couplers are added.

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

4 Robot Safety Functions ......................................................................... 1-11

5 Safety Measures for the System ...........................................................1-12

6 Trial Operation .......................................................................................1-13

7 Work Within the Safeguard Enclosure ...................................................1-14

8 Automatic Operation ..............................................................................1-15

9 Adjustment and Inspection ....................................................................1-15

10 Repair and Modification .........................................................................1-15

11 Warranty ................................................................................................1-16

12 CE Marking ............................................................................................1-18

CHAPTER 2 Functions

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

2 Robot Controller ......................................................................................2-5

3 Robot initialization number list ................................................................. 2-6

4 Parameters for Clean Room Models YK120XC, YK150XC .....................2-7

CHAPTER 3 Installation

1 Robot Installation Conditions ................................................................... 3-1

1-1 Installation environments ...................................................................................... 3-1

1-2 Installation base ................................................................................................... 3-3

2 Installation ...............................................................................................3-5

2-1 Unpacking ............................................................................................................ 3-5

2-2 Checking the product ........................................................................................... 3-6

2-3 Moving the robot ................................................................................................... 3-7

2-4 Installing the robot ................................................................................................ 3-8

3 Protective Bonding ..................................................................................3-9

4 Robot Cable Connection ....................................................................... 3-11

5 User Wiring and User Tubing ................................................................ 3-13

6 Connecting a suction hose (YK120XC, YK150XC) ...............................3-16

7 Attaching The End Effector ....................................................................3-17

7-1 R-axis tolerable moment of inertia and acceleration coefficient ......................... 3-17

7-1-1 Acceleration coefficient vs. moment of inertia (YK120X) ..................................... 3-19

7-1-2 Acceleration coefficient vs. moment of inertia (YK150X) ..................................... 3-21

7-1-3 Acceleration coefficient vs. moment of inertia (YK180X, YK220X) ......................3-23

7-2 Equation for moment of inertia calculation ......................................................... 3-24

7-3 Example of moment of inertia calculation........................................................... 3-27

7-4 Attaching the end effector .................................................................................. 3-29

7-5 Gripping force of end effector ............................................................................. 3-32

8Working Envelope and Mechanical Stopper Positions for Maximum

Working Envelope..................................................................................3-33

CHAPTER 4 Adjustment

1 Overview ..................................................................................................4-1

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

3 Adjusting the origin ..................................................................................4-2

3-1 Absolute reset method ......................................................................................... 4-3

3-1-1 YK120X series (YK120X, YK150X)........................................................................ 4-3

3-1-1-1 Sensor method (R-axis) ........................................................................................ 4-3

3-1-1-2 Stroke end method (X-axis, Y-axis) ...................................................................... 4-4

3-1-1-3 Stroke end method (Z-axis) .................................................................................. 4-6

3-1-2 YK180X series (YK180X, YK220X)........................................................................ 4-7

3-1-2-1 Sensor method (R-axis) ........................................................................................ 4-7

3-1-2-2 Sensor method (X-axis, Y-axis) ............................................................................ 4-8

3-1-2-3 Stroke end method (Z-axis) .................................................................................. 4-9

3-2 Machine reference.............................................................................................. 4-10

3-3 Absolute reset procedures .................................................................................. 4-11

3-3-1 Sensor method (R-axis) ....................................................................................... 4-11

3-3-2 Stroke end method (X and Y axes of YK120X, YK150X) .....................................4-13

3-3-3 Stroke end method (Z-axis).................................................................................. 4-15

3-3-4 Sensor method (X and Y axes of YK180X, YK220X) ...........................................4-16

3-4 Adjusting the machine reference ........................................................................ 4-18

3-4-1 YK120X series (YK120X, YK150X)...................................................................... 4-19

3-4-1-1 Adjusting the R-axis machine reference (YK120X, YK150X) ............................. 4-19

3-4-1-2 Adjusting the R-axis machine reference (YK120XC, YK150XC) ........................ 4-21

3-4-1-3 Adjusting the X-axis machine reference ............................................................. 4-23

3-4-1-4 Adjusting the Y-axis machine reference .............................................................. 4-25

3-4-1-5 Adjusting the Z-axis machine reference ............................................................. 4-27

3-4-2 YK180X series (YK180X, YK220X)...................................................................... 4-30

3-4-2-1 Adjusting the R-axis machine reference (YK180X, YK220X) ............................. 4-30

3-4-2-2 Adjusting the X-axis machine reference ............................................................. 4-32

3-4-2-3 Adjusting the Y-axis machine reference .............................................................. 4-34

3-4-2-4 Adjusting the Z-axis machine reference ............................................................. 4-36

4 Setting the Soft Limits ............................................................................4-39

5 Setting the Standard Coordinates .........................................................4-42

6Affixing Stickers for Movement Directions and Axis Names ..................4-43

7 Removing the Robot Covers .................................................................4-45

CHAPTER 5 Periodic Inspecition

1 Overview ..................................................................................................5-1

2Precautions ..............................................................................................5-2

3 Daily Inspection .......................................................................................5-3

4 Six-Month Inspection ...............................................................................5-5

5 Replacing the Harmonic Drive Grease ....................................................5-8

5-1 Replacement period ............................................................................................. 5-8

CHAPTER 6 Increasing the robot operating speed

1 Increasing the robot operating speed ......................................................6-1

CHAPTER 7 Specifications

1 Manipulator ..............................................................................................7-1

1-1 Basic specification ................................................................................................ 7-1

1-2 External view and dimensions .............................................................................. 7-2

1-3 Robot inner wiring diagram ................................................................................ 7-14

1-4 Wiring table ........................................................................................................ 7-15

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

4 Robot Safety Functions ......................................................................... 1-11

5 Safety Measures for the System ...........................................................1-12

6 Trial Operation ....................................................................................... 1-13

7 Work Within the Safeguard Enclosure ...................................................1-14

8 Automatic Operation .............................................................................. 1-15

9 Adjustment and Inspection ....................................................................1-15

10 Repair and Modification .........................................................................1-15

11 Warranty ................................................................................................1-16

12 CE Marking ............................................................................................1-18

MEMO

1 Safety Information

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

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

DANGER

Failure to follow DANGER instructions will result in severe injury or death to the
robot operator, a bystander or a person inspecting or repairing 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, a bystander or a person inspecting or repairing the robot.

!

CAUTION

Failure to follow CAUTION instructions may result in injury to the robot opera­tor, a bystander or a person inspecting or repairing the robot, or damage to the
robot and/or robot controller.

Refer to the owner's 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 own­er's manual (available for an additional fee).

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

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

It is not possible to detail all safety items within the limited space of this manual.
So it is essential that the user have a full knowledge of basic safety rules and also
that the operator makes correct judgments on safety procedures during operation.
This manual and warning labels supplied with or affixed to the robot are written
in English. If the robot operator or service personnel does not understand Eng­lish, do not permit him to handle the robot.

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.

Warning labels 1 (Fig. 1-1) are affixed to the robot. Refer to Fig. 2-2 to
Fig. 2-4 in Chapter 2 for the position.

• Install a safeguard enclosure (protective enclosure) to keep any person from
entering within the movement 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 labels shown in Fig. 1-1 are supplied with the robot and should
be affixed to a conspicuous spot on doors or panels equipped with safety
interlocks.

DANGER

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

• Keep outside of guard during operation.

• Lock out power before approaching robot.

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

crushed.

Warning labels 2 (Fig. 1-2) are affixed to the robot. Refer to Fig. 2-2 in Chap­ter 2 for the position.
Be careful not to let hands or fingers be pinched or crushed by the moving
parts of the robot during transportation or teaching.

WARNING

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

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 on warning labels and in this manual.

Warn ing label 3 (Fig. 1-3) is affixed to the robot. Refer to Fig. 2-2 to
Fig. 2-4 in Chapter 2 for the position.

• Be sure to read the warning label and this manual carefully and make your
thoroughly 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 cautions in this manual
as well as descriptions in the this chapter (Chapter 1, "Using the Robot
Safely").

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

WARNING

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

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

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

gas, etc.

WARNING

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

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

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

magnetic interference, etc.

WARNING

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

1-3

CHAPTER 1 Using the Robot Safely

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

WARNING

The Z-axis will slide down when the Z-axis brake is released, causing a hazard­ous situation.

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

•Use caution not to let your body get caught between the Z-axis and installa­tion base when releasing the brake to perform direct teach.

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

WARNING

•End effectors must be designed and manufactured so that they cause no
hazards (for example, loosening of workpiece) even if power (electricity, air
pressure, etc.) is shut off or power fluctuations occur.

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

(8) Be cautious of possible Z-axis movement when the controller is

turned off or emergency stop is triggered. (2-axis robots with
air-driven Z-axis)

WARNING

The Z-axis moves up when the 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 moving parts of the
Z-axis.

•Keep the usual robot position in mind so that the Z-axis will not interfere with
obstacles during raising of the Z-axis, except in case of emergency stop.

(9) Use the following caution items when the Z-axis is interfering

with peripheral equipment. (2-axis robots with air driven Z-axis)

WARNING

When the Z-axis comes to a stop due to obstructions from peripheral equip­ment, the Z-axis may move suddenly when 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 stand under the Z-axis
because it will drop under its own weight.

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CHAPTER 1 Using the Robot Safely

(10)Use caution on Z-axis movement when air supply is stopped. (2-

axis robots with air-driven Z-axis)

WARNING

The Z-axis may suddenly drop 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 prop or support under the Z-axis before
cutting off the air supply.

(11) Use the following caution items when disassembling or replac-

ing the pneumatic equipment.

WARNING

Air or parts may fly outwards if pneumatic equipment is disassembled or parts
replaced while air is still supplied.

•Do service work after first turning off the controller and reducing the air pres­sure.

•Before reducing the air pressure, place a support stand under the Z-axis (2­axis robots with air driven Z-axis) since it will drop under its own weight.

(12)Cautions for removing Z-axis brake or Z-axis motor

WARNING

The Z-axis can drop and cause a hazard when the Z-axis brake or Z-axis motor
is removed.

•Turn off the controller and set a support stand under the Z-axis before re­moving the motor.

•Use caution not to allow hands or body to be squeezed or crushed by moving
parts on the Z-axis or between the Z-axis and the installation base.

(13)Use the following caution during inspection of controller.

WARNING

•When you need to touch the terminals or connectors on the outside of the
controller during inspection, always first turn off the controller power switch
and also the power source in order to prevent possible electrical shock.

•Never touch any internal parts of the controller.

For precautions on handling the controller, refer to the "YAMAHA robot control­ler owner's manual".

1-5

CHAPTER 1 Using the Robot Safely

(14) Consult us for corrective action when the robot is damaged or

malfunction occurs.

WARNING

If any part of the robot is damaged or any malfunction occurs, continuous op­eration may be very dangerous. Please consult YAMAHA 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

Abnormal operation of robot

(positioning error, excessive vibration, etc.)

Z-axis brake trouble Dropping of load

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

Flying outwards of damaged parts during robot

operation

Malfunction of robot

WARNING

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

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

(16) Use caution not to touch the high temperature motor or speed

reduction gear casing.

WARNING

The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched.
Before touching these parts during inspections or servicing, turn off the control­ler, wait for a while and check that the temperature has cooled.

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

WARNING

If warning labels are removed or difficult to see, necessary cautions may not be
taken, resulting in an accident.

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

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

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

1-6

CHAPTER 1 Using the Robot Safely

(18)Protective bonding

WARNING

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

(19)Always connect the robot to the specified controller.

WARNING

The controller for the YK120X series robots (YK120X, YK150X) is designed to
provide 24V output and the model name "RCX142-T" is shown on the serial
number label (see Fig. 2-5). Do not connect other controllers to the YK120X
series robot. If operated from a controller other than the RCX142-T, the robot's
motors may be damaged.

(20)Avoid fastening any cable or tube prepared by the user with the

machine harness, user signal wires or air tubes of the robot.

WARNING

Do not utilize the machine harness, user signal wires or air tubes of the robot to
fasten any cable or tube prepared by the user, as this may break the robot
harness wires or user signal wires causing malfunction of the robot. This will
also result in poor positioning accuracy.

(21)Do not use the robot in locations subject to strong vibrations.

WARNING

Do not operate the robot in locations subject to strong vibrations. The robot
installation bolts might work loose and the robot topple over. The bolts on the
robot body itself might also loosen, causing parts to fall off, etc.

(22)Be sure to make correct parameter settings.

!

CAUTION

The robot must be operated with correct tolerable moment of inertia and accel­eration coefficients according to the manipulator tip mass and moment of iner­tia. If this is not observed, premature end to the life of the drive units, damage to
the robot parts or residual vibration during positioning may result.

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

!

CAUTION

Avoid using the YK-X series robots for tasks which make use of motor thrust
(press-fitting, burr removal, etc.). These tasks may cause malfunctions of the
robot.

1-7

CHAPTER 1 Using the Robot Safely

(24) Do not apply excessive force to each section.

!

CAUTION

The YK120X series (YK120X, YK150X) and YK180X series (YK180X, YK220X)
are designed to be compact, so the joints could be damaged if excessive force
is applied, for example, during installation of an end effector. Make sure that
excessive force is not applied to the joints.

YK120X, YK150X

Axis

X-axis

Y-axis

R-axis

YK180X, YK220X

Axis

X-axis

Y-axis

R-axis

Tolerable radial load

100N (10.2kgf)

Tolerable radial load

275N (28.1kgf)

150N (15.3kgf)

150N (15.3kgf)

45N (4.6kgf)

45N (4.6kgf)

Tolerable thrust load

100N (10.2kgf)

45N (4.6kgf)

45N (4.6kgf)

Tolerable thrust load

900N (91.8kgf)

600N (61.2kgf)

600N (61.2kgf)

To le ra b le moment load

1.5Nm (15.3kgfcm)

0.45Nm (4.6kgfcm)

0.45Nm (4.6kgfcm)

Tolerable moment load

6.0Nm (61.2kgfcm)

3.3Nm (33.7kgfcm)

3.3Nm (33.7kgfcm)

Tolerable torque

1.7Nm (17.3kgfcm)

0.5Nm (5.1kgfcm)

0.3Nm (3.1kgfcm)

Tolerable torque

9.0Nm (91.8kgfcm)

4.0Nm (40.8kgfcm)

2.2Nm (22.4kgfcm)

(25) Check the machine reference value when the arm struck against

the mechanical stopper.

!

CAUTION

When the arm moves at high speed and strikes against a mechanical stopper
violently, the machine reference value may change. If this has happened, check
the machine reference value. Also check the mechanical stopper for any dam­age and the origin position for shift. If the machine reference value is outside
the recommended range, adjust the machine reference. In this case, re-teach­ing may be required if the origin position has shifted.

(26) Use caution not to apply excessive force to the machine har-

ness, user signal cables and air tubes.

!

CAUTION

A positioning error may occur if excessive force is applied to the machine har­ness, user signal cables or air tubes. A positioning error may also occur if the
machine harness, user signal cables or air tubes have deteriorated due to im­proper installation environment.

(27) Caution when turning off the robot controller

!

CAUTION

The XY arm positions might move slightly due to the harness reaction force
when the power to the robot controller is turned off, making it difficult to back up
the correct position data. To avoid this, before turning off the power to the robot
controller, press the emergency stop button and check that the robot arms have
completely stopped.

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CHAPTER 1 Using the Robot Safely

(28)Take the following precautions when transporting the robot.

!

CAUTION

If the robot is transported long distances by truck while mounted on an installation
base or packed in a case other than the dedicated carton box in which the robot
was shipped, the bolts installing the robot or the bolts on the robot body itself
might come loose due to vibration. The robot might then topple over or the
parts fall off.
When transporting the robot long distances, use the dedicated case in which
the robot was shipped from our factory.

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CHAPTER 1 Using the Robot Safely

3 Special Training for Industrial Robot Opera-

tion

Companies or factories using industrial robots must make sure that every person,
who operates or handles the robot such as for teaching, programming, movement
check, inspection, adjustment and repair, has received appropriate training and
also has the skills needed to perform the job correctly and safely.
Since the YK120X and YK180X series robots fall under the industrial robot
category, the user must observe local regulations and safety standards for industrial
robots, and provide special training for every person involved in robot-related
tasks (teaching, programming, movement check, inspection, adjustment, repair,
etc.).

1-10

4 Robot Safety Functions

(1) Overload detection

This function detects an overload applied to the motor and shuts off the servo
power. If an overload error occurs, take the following measures.

1. Insert a timer in the program.

2. Reduce the acceleration coefficient.

(2) Overheat detection

This function detects an abnormal temperature rise in the driver inside the
controller and shuts off the servo power. If an overheat error occurs, take the
following measures.

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: The working envelope is the area limited by soft limits.

CHAPTER 1 Using the Robot Safely

(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 movement range.
On the X-axis, Y-axis arm, mechanical stoppers are fixed at both ends of the
maximum movement range.
The Z-axis has a mechanical stopper at the upper end and lower end.
No mechanical stopper is provided on the R-axis.
Note: The movement range is the area limited by mechanical stoppers.

WARNING

Axis movement will not stop immediately after the servo power supply is shut
off by emergency stop or other safety functions.

(5) Z-axis (vertical axis) brake

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

WARNING

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

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

•Use caution not to let your body get caught between the Z-axis and installa­tion base when releasing the brake to perform direct teach.

1-11

CHAPTER 1 Using the Robot Safely

5 Safety Measures for the System

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

1-12

6Trial Operation

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

(1) If a safeguard enclosure has not yet been provided right after installation of

the robot, rope off or chain off around the movement area of the manipulator
in place of the safeguard enclosure, and observe the following points.

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

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

3. Place a sign to keep the operator or other personnel from entering the
movement range of the manipulator.

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

1. Is the robot securely and correctly installed?

2. Are the electrical connections to the robot correct?

3. Are items such as air pressure correctly supplied?

4. Is the robot correctly connected to peripheral equipment?

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

6. Does the installation environment meet the specified standards.

(3) After the controller is turned on, check the following points from outside the

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 equipment
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?

CHAPTER 1 Using the Robot Safely

1-13

CHAPTER 1 Using the Robot Safely

7Work Within the Safeguard Enclosure

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

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

1) Adjusting the Z-axis machine reference (See Section 3-4-1-5 in Chapter

4.)

2) Setting the Soft Limits (See Section 4 in Chapter 4.)

3) Setting the Standard Coordinates (See Section 5 in Chapter 4.)

4) Teaching

For items 1) to 3), follow the precautions and procedure for each section. To
perform item 4), 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 operates correctly.

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

4. Check that emergency stop works correctly.

5. Select teaching mode and prohibit automatic operation.

2) Never enter the movement range of the manipulator while within the safe­guard enclosure.

1-14

8 Automatic Operation

Automatic operation described here includes all operations in AUTO mode.

(1) Check the following before starting automatic operation.

1. No one is within the safeguard enclosure.

2. The programming unit and tools are in their specified locations.

3. The alarm or error lamps on the robot and peripheral equipment do not
flash.

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

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

occurs.

1) After automatic operation has started, check the operation status and warn­ing lamp 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 equipment, observe the fol­lowing procedure 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 in­spected in order to keep any other person from touching the start switch
and restarting the robot.

CHAPTER 1 Using the Robot Safely

9 Adjustment and Inspection

Do not attempt any installation, adjustment, inspection or maintenance unless it
is described in this manual.

10 Repair and Modification

Do not attempt any repair, parts replacement and modification unless described
in this manual. These works require technical knowledge and skill, and may also
involve work hazards.

1-15

CHAPTER 1 Using the Robot Safely

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 de-

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

fects 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 : This warranty will not apply in the following

cases:
(1) Fatigue arising due to the passage of time,

natural wear and tear occurring during op­eration (natural fading of painted or plated
surfaces, deterioration of parts subject to
wear, etc.)

(2) Minor natural phenomena that do not affect

the capabilities of the robot and/or related
product (noise from computers, motors,
etc.).

(3) Programs, point data and other internal data

that were changed or created by the user.

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

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

2) Troubles caused by procedures prohibited in this manual.

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

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

5) Incorrect or inadequate maintenance and inspection.

6) Repairs by other than authorized dealers.

1-16

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.

1-17

CHAPTER 1 Using the Robot Safely

12 CE Marking

When the YAMAHA robots are exported to or used in EU (European Union)
countries, refer to the separate "YAMAHA robot controller owner's manual" or
"CE marking manual" for related information about CE marking.

1-18

CHAPTER 2

Functions

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

2 Robot Controller ......................................................................................2-5

3 Robot initialization number list ................................................................. 2-6

4 Parameters for Clean Room Models YK120XC, YK150XC ..................... 2-7

MEMO

1 Robot Manipulator

The YK-X series robots are available in 4-axis models having an X/Y-axis arm
(equivalent to human arm) and a Z/R-axis (equivalent to human wrist).
With these 4 axes, the YK-X series robots can move as shown in Fig. 2-1. By
attaching different types of end effector (gripper) to the end of the arm, a wide
range of tasks can be performed with high precision at high speeds.
The (+) and (-) signs show the direction of axis movement when the jog keys on
the programming unit are pressed (standard setting at the factory). Fig. 2-2 to Fig.
2-4 on the subsequent pages show part names and functions of each robot model.

Y-axis arm

CHAPTER 2 Functions

X-axis arm

Z-axis

(–)

(–)

(+)

(+)

(–)

Y-axis

R-axis

(–)

(+)

X-axis

Fig. 2-1 Manipulator movement

(+)

2-1

CHAPTER 2 Functions

Connector for user wiring (No.1 to 6)

Linear busing shaft

Warning label 1

Z-axis motor

R-axis motor

Y-axis arm

R-axis speed
reduction gear

Z-axis spline

End effector attachment

Ball screw

Y-axis speed
reduction gear

Z-axis brake

User tubing 2 (φ3)

User tubing 1 (φ3)

Viewed from direction A

Y- a xis motor

Y- axis
mechanical
stopper

X-axis arm

X-axis motor

Machine harness

User air tube

User signal cable

X-axis mechanical stopper

User tubing 2 (φ3)

X-axis speed
reduction gear

M3 ground terminal

Connector for user wiring (No.1 to 6)

Warning label 3

Warning label 2

User tubing 1 (φ3)

Robot cable

Serial label

User tap (* four positions)

Fig. 2-2 YK120X, YK150X

2-2

Connector for user wiring (No.1 to 6)

CHAPTER 2 Functions

Linear busing shaft

Warning label 1

Z-axis motor

R-axis motor

Y-axis arm

R-axis speed
reduction gear

Bellows
type suction coupler

Bellows

End effector attachment

Z-axis brake

Ball screw

Y- a x is
mechanical stopper

Y-axis speed
reduction gear

X-axis arm

X-axis motor

Y-axis motor

Warning label 3

Machine harness

Bellows
type suction coupler

User tubing 2

(φ3)

1

User tubing

Viewed from direction A

X-axis mechanical stopper

M3 ground terminal

X-axis speed
reduction gear

Connector for user wiring
(No.1 to 6)

Suction coupler for X, Y and R axis joints

(φ3)

User tubing 2

(φ3)

Suction coupler for base interior (φ6)

User tubing 1
(φ3)

Bellows
type suction coupler (φ3)

Robot cable

Warning label 2

Serial label

Fig. 2-3 YK120XC, YK150XC

2-3

CHAPTER 2 Functions

Ball screw

Y-axis motor

Connector for user wiring (No.1 to 6)

User tubing 2 (φ3)

User tubing 1 (φ3)

Viewed from direction A

Warning label 2

Warning label 1

R-axis motor

Y-axis arm

R-axis speed
reduction gear

Z-axis spline

End effector attachment

Z-axis motor
Z-axis brake

Y-axis speed
reduction gear

X-axis arm

X-axis motor

A

Warning label 3

Machine harness

User signal cable

Y-axis
mechanical stopper

X-axis
mechanical stopper

X-axis speed
reduction gear

M3 ground terminal

Connector for user wiring (No.1 to 6)

User tubing 2 (φ3)

User tubing 1 (φ3)

Robot cable

Fig. 2-4 YK180X, YK220X

Serial label

2-4

2 Robot Controller

The YK120X series robots (YK120X, YK150X) come with a robot controller
(RCX142-T).
The YK180X series robots (YK180X, YK220X) come with a robot controller
(RCX142).
Refer to the separate "YAMAHA robot controller owner's manual" for details on
the robot controller.

WARNING

For the YK120X series robots (YK120X, YK150X), always use the RCX142-T
controller that is designed to provide 24V output. The model name "RCX142-T"
is shown on the serial number label (see Fig. 2-5). Do not connect other robot
controllers to the YK120X series robots. If operated from a controller other than
the RCX142-T, the robot's motors may be damaged.

CHAPTER 2 Functions

MOTOR

PWR

ROB
I/O

ROB
I/O

SRV

ERR

XY

ZR

SAFETY

XM

YM

ZM

RM

MPB

COM

STD.DIO

OP.1 OP.3

OP.2 OP.4

RCX142

MODEL.

SER. NO.

MANUFACTURED

FACTORY AUTOMATION EQUIPMENT MADE IN JAPAN

BATT

XY

ZR

RGEN

P

N

ACIN

L

N

200-230V~

50-60Hz

MAX.300VA

Serial number label

RCX142-T

Fig. 2-5 Robot controller for YK120X series (YK120X, YK150X)

2-5

CHAPTER 2 Functions

3 Robot initialization number list

The YK-X series robots are initialized for optimum setting (default setting) ac­cording to the robot model prior to shipping. The robot controllers do not have to
be reinitialized during normal operation. However, if for some reason the con­troller must be reinitialized, proceed while referring to the list below.

!

CAUTION

Absolute reset must be performed after reinitializing the controller.
Before reinitializing the controller, read the descriptions in "3. Adjusting the ori­gin" in Chapter 4 and make sure you thoroughly understand the procedure.

!

CAUTION

When the controller is initialized, the "ARM LENGTH" and "OFFSET PULSE"
settings in the axis parameters will be erased, making the standard coordinate
settings invalid.
(Refer to "Chapter 4 Setting the Standard Coordinates" for details on the stand­ard coordinates.)
Write down the "arm length" and "offset pulse" values before hand, and input
each value again after completing the initialization process.

Robot initialization number

Robot initialization number

2020

2021

2115

2116

Robot model name

YK120X

YK150X

YK180X

YK220X

Applicable models

YK120X, YK120XC

YK150X, YK150XC

YK180X

YK220X

2-6

CHAPTER 2 Functions

4 Parameters for Clean Room Models YK120XC,

YK150XC

Part of robot parameters on clean room models has been changed to maintain the
degree of cleanliness and the Z-axis bellows durability.
Along with this robot parameter change shown below, you must take the following
precautions.

To purchasers of this robot

At this time our sincere thanks for your purchase of our robot.
Since this robot is custom designed and manufactured, a robot parameter has
been changed from the standard specifications. Please keep this sheet carefully
along with the owner's manual.
Check the following points before using the robot.

Precautions during use

Always make a backup of robot parameters.
Initializing the parameters deletes previous parameter settings. If necessary, load
the backup parameters.

Parameter changes

The following parameter has been changed. Blank portions indicate standard
specifications are used.

Axis settings

ChangesParameter No. Name

PRM37

Max. motor rotation

M1 M3M2

1500

M3

2-7

MEMO

2-8

CHAPTER 3

Installation

1 Robot Installation Conditions ................................................................... 3-1

1-1 Installation environments...................................................................................... 3-1

1-2 Installation base ................................................................................................... 3-3

2Installation ...............................................................................................3-5

2-1 Unpacking ............................................................................................................ 3-5

2-2 Checking the product ........................................................................................... 3-6

2-3 Moving the robot................................................................................................... 3-7

2-4 Installing the robot ................................................................................................ 3-8

3 Protective Bonding ..................................................................................3-9

4 Robot Cable Connection ....................................................................... 3-11

5 User Wiring and User Tubing ................................................................3-13

6 Connecting a suction hose (YK120XC, YK150XC) ...............................3-16

7 Attaching The End Effector ....................................................................3-17

7-1 R-axis tolerable moment of inertia and acceleration coefficient ......................... 3-17

7-1-1 Acceleration coefficient vs. moment of inertia (YK120X) ..................................... 3-19

7-1-2 Acceleration coefficient vs. moment of inertia (YK150X) ..................................... 3-21

7-1-3 Acceleration coefficient vs. moment of inertia (YK180X, YK220X) ......................3-23

7-2 Equation for moment of inertia calculation ......................................................... 3-24

7-3 Example of moment of inertia calculation........................................................... 3-27

7-4 Attaching the end effector .................................................................................. 3-29

7-5 Gripping force of end effector ............................................................................. 3-32

8Working Envelope and Mechanical Stopper Positions for Maximum

Working Envelope..................................................................................3-33

MEMO

1 Robot Installation Conditions

1-1 Installation environments

Be sure to install the robot in the following environments.

CHAPTER 3 Installation

Items

Allowable ambient temperature

Allowable ambient humidity

Altitude

Ambient environments

Vibration

Air supply pressure, etc.

Working space

0 to 40°C

35 to 85% RH (non condensation)

0 to 1000 meters above sea level

Avoid installing near water, cutting water, oil, dust, metallic chips and
organic solvent.

Avoid installation near corrosive gas and corrosive materials.

Avoid installation in atmosphere containing inflammable gas, dust and liquid.

Avoid installation near objects causing electromagnetic interference,
electrostatic discharge and radio frequency interference.

Do not subject to impacts or vibrations.

Below 0.58MPa (6.0kgf/cm
compressor oil; filtration 40µm or less

Allow sufficient space margin to perform jobs (teaching, inspection,
repair, etc.)

Specifications

2

); clean dry air not containing deteriorated

For detailed information on how to install the robot controller, refer to the sepa­rate "YAMAHA robot controller owner's manual".

WARNING

Avoid installing the robot in locations where the ambient conditions may ex­ceed the allowable temperature or humidity, or in environments where water,
corrosive gases, metallic powder or dust are generated. Malfunction, failure or
short circuits may otherwise result.

WARNING

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

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

WARNING

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

3-1

CHAPTER 3 Installation

WARNING

Do not operate the robot in locations subject to strong vibrations. The robot
installation bolts might work loose and the robot topple over. The bolts on the
robot body itself might also loosen, causing parts to fall off, etc.

!

CAUTION

A positioning error may occur if the machine harness, user signal cables or air
tubes have deteriorated due to improper installation environment.

3-2

1-2 Installation base

1) Prepare a sufficiently rigid and stable installation base, taking account of the
robot weight including the end effector (gripper), workpiece and reaction
force while the robot is operating. The maximum reaction force (see Fig. 3-

1) applied to the X-axis and Z-axis of each robot during operation is shown
in the table below. These values are an instantaneous force applied to the
robot during operation and do not indicate the maximum load capacity.

Robot Mode

YK120X

YK150X

YK180X

YK220X

CHAPTER 3 Installation

The maximum reaction force

FXmax

N kgf Nm kgfm N kgf

23

27

196

157

2.3

2.7

20

16

M

X

max

3.3

3.3

18 1.8

18 1.8

0.34

0.34

6.7

6.7

6.7

6.7

F

Z

max

0.7

0.7

0.7

0.7

Fxmax

Load

Fzmax

Mxmax

Fig. 3.1 Maximum reaction force applied during operation

2) The parallelism of the installation base surface must be machined within a
precision of ±0.05mm/500mm. The robot base mount must be installed fac­ing down and in a level position.

3) Tap holes into the surface of the installation base. Refer to "1-2 External
view and dimensions" in Chapter 7 for machining dimensions and positions.

4) Securely fix the installation base on the floor with anchor bolts.

3-3

CHAPTER 3 Installation

WARNING

Do not place the robot on a moving installation base. Excessive loads will be
applied to the robot arm by movement of the installation base, resulting in dam­age to the robot.

!

CAUTION

The manipulator positioning might decrease if the installation surface precision
is insufficient.

!

CAUTION

If the installation base is not sufficiently rigid and stable or a thin metallic plate
is attached to the installation base, vibration (resonance) may occur during
operation, causing detrimental effects on the manipulator work.

3-4

2 Installation

2-1 Unpacking

WARNING

The robot and controller are heavy. Take sufficient care not to drop them during
moving or unpacking as this may damage the equipment or cause bodily injury.

!

CAUTION

When moving the robot or controller by equipment such as a folk-lift that re­quire a license, only properly qualified personnel may operate it. The equip­ment and tools used for moving the robot should be serviced daily.

CHAPTER 3 Installation

The package comes with a robot manipulator (YK120X series or YK180X series),
a robot controller and accessories, according to the order specifications. Transport
the package by dolly to near the installation base before unpacking. Take sufficient
care not to apply shocks to the equipment when unpacking it.

Robot manipulator

Case

Robot controller and

accessories

Fig. 3-2 Packed state

3-5

CHAPTER 3 Installation

2-2 Checking the product

After unpacking, check the product configuration and conditions.
The following configurations are typical examples, so please check that the prod­uct is as specified in your order.

!

CAUTION

If there is any damage due to transportation or insufficient parts, please notify
your YAMAHA sales office or dealer immediately.

Controller : RCX142-T, RCX142
Robot : YK120X, YK150X, YK180X, YK220X

Standard

Warning label ( × 1)

CD-ROM owner's manual

or

owner's manual

User wiring connector ( × 2)

User wiring pin ( × 20)

142

3
.

P

O

RCX

1
.
P

O

.
L
E
D
O

M

N

.

A

O

P
A

N

J

.

N

R

I

E

E

S

D

D

A

E

M
R
U

T
T

N

E

C

M

A

P

F

I

U

U
Q

N

E

A

N

M

O
I
T
A
OM
T
U

A
RY
O
T
C
FA

N
IO
T

U
A

C

B
P

M

R

O
T
O

M

P

S

E

B
O
R

M
X

O
/
I

Y
X

M
Y

B

O
R

O
/
I

R

Z

M

Z

M

R

ON

I
T
C
U

R
T

R

S
N
I

W

D
A
E
R

L

A
U
N
A
M

V
R

R
R

TT
A
B

Y
X

M
O

C

R
Z

N

E
G
R

4
.
P

O

2
.

P

P

O

N

O
I

D
.
D
T

S

N
I
C

A

Y
T
E
F

A

L

S

N

~

30V

-2
z

0

0

2

60H

A

-

V

0

0

5

0

5

.2
X
A

M

Rotation direction labels ( × 1)

A B
X Y
Z R

RCX142-T controller and accessories (YK120X, YK150X)
RCX142 controller and accessories (YK180X, YK220X)

Option

Robot manipulator
YK-120X series
(YK120X, YK150X)
YK-180X series
(YK180X, YK220X)

MPB programming unit, etc.

Refer to the "YAMAHA Robot Controller owner's manual" for details on the
controller accessories and options.

Fig. 3-3 Product configurations

3-6

2-3 Moving the robot

1) Fold in the arm and wind the robot cable as shown in Fig. 3-4.

2) The robot must be carried by two workers. One worker must hold the support
sections shown in the drawing with both hands, and the other worker must
carry the robot cable. Place the robot on the installation base, and temporar­ily tighten with the bolts. (Refer to section "2-4 Installing the robot" for the
bolt tightening torque values.)

CHAPTER 3 Installation

Robot cable

Support part

Bolt installation hole

Support part

Fig. 3-4

!

CAUTION

If the robot is transported long distances by truck while mounted on an installation
base or packed in a case other than the dedicated carton box in which the robot
was shipped, the bolts installing the robot or the bolts on the robot body itself
might come loose due to vibration. The robot might then topple over or the
parts fall off.
When transporting the robot long distances, use the dedicated case in which
the robot was shipped from our factory.

3-7

CHAPTER 3 Installation

2-4 Installing the robot

Install the robot securely with the four hex socket head bolts as shown in Fig. 3-

5.

WARNING

Be sure to use the specified type and number of bolts, and securely tighten
them to the correct torque. If the bolts are not tightened correctly, the robot may
cause positioning errors or fall over during operation, causing a serious acci­dent.

YK120X, YK150X

YK180X, YK220X

Tightening torque

Bolts UsedRobot Mode

M3

M6

Tightening torque

2.0Nm (20kgfcm)

15.3Nm (156kgfcm)

Hex socket head bolt

Installation base

Fig. 3-5 Installing the robot

3-8

3 Protective Bonding

WARNING

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

WARNING

Turn off the controller before grounding the robot.

The robot must be grounded as follows:

1) Provide a terminal marked "PE" for the protective conductor of the entire
system and connect it to an external protective conductor. In addition, se­curely connect the ground terminal on the robot pedestal to the same protec­tive conductor. (See Fig. 3-6.)

CHAPTER 3 Installation

(Symbol 417-IEC-5019)

2) When the end effector uses an electrical device which, if it malfunctions,
might make contact with the power supply, the user must provide proper
grounding on his own responsibility. The YK-X series robots do not have a
ground terminal for this purpose.

3) For details on protective bonding on the robot body to comply with CE mark­ing, follow the instructions on protective bonding explained in the "YAMAHA
robot controller owner's manual" or "CE marking manual".

4) Use a ground cable with a conductor wire cross section of at least 2.0mm
and a length within 1 meter.

2

3-9

CHAPTER 3 Installation

Ground symbol

M3 Ground terminal

Ground symbol

M3 Ground terminal

YK120X, YK150X YK180X, YK220X

Fig. 3-6 Ground terminal

3-10

4 Robot Cable Connection

The robot cable is pre-connected to each robot. Correctly install the other end of
the robot cable to the robot controller. For details on connections to the robot
controller, refer to Fig. 3-7 and the "YAMAHA RCX142 robot controller owner's
manual". After making connections, check the operation while referring to "6
Trial operation" in Chapter 1.

WARNING

•Before connecting the cables, check that there are no bends or breaks in the
connector pins of the robot cable and that the cables are not damaged. Bent
or broken pins or cable damage may cause malfunction of the robot.

•Ensure that the controller is off before connecting the robot cable to the
controller.

WARNING

The MOTOR connectors XM and ZM, and YM and RM each have identical
shapes. In addition, the PI connectors XY and ZR have identical shapes. Do
not confuse these connectors when making connections. Wrong connections
may result in malfunction and hazardous situations.

CHAPTER 3 Installation

WARNING

• If the connector installation is inadequate or if there are contact failures in
the pins, the robot may malfunction causing a hazardous situation. Recon­firm that each connector is securely installed before turning on the control­ler.

•To attach the PI connector securely, tighten the screws supplied with the
robot.

•Take caution not to apply an excessive load to the connectors due to stress
or tension on the cables.

WARNING

Lay out the cables so that they do not obstruct the movement of the manipula­tor. Determine the robot work area in which the robot cables will not interfere
with the load or workpiece picked up by the manipulator. (See "1-2 External
view and dimensions" in Chapter 7.) If the robot cables interfere with the mov­able parts of the robot, the cables may be damaged causing malfunction and
hazardous situations.

WARNING

Lay out the robot cables so as to keep the operator or any other person from
tripping on them. Bodily injury may result if someone trips on the cables.

3-11

CHAPTER 3 Installation

WARNING

For the YK120X series robots (YK120X, YK150X), always use the RCX142-T
controller that is designed to provide 24V output. The model name "RCX142-T"
is shown on the serial number label (see Fig. 2-5). Do not connect other robot
controllers to the YK120X series robots. If operated from a controller other than
the RCX142-T, the robot's motors may be damaged.

Controller side connector

Robot side connector

RCX142-T

Robot cable

XM

YM

ZM

RM

XY

ZR

Fig. 3-7 Robot cable connections

XM

YM

ZM

RM

XY

ZR

3-12

5 User Wiring and User Tubing

WARNING

Always turn off the controller and shut off air supply before attempting wiring
and piping work. If air or power is supplied during this work, the manipulator
may move erroneously causing a hazardous situation.

1) The robot has a user signal wire and air tube laid in parallel with the robot
body's machine harness. The signal wires and air tubes that can be used are
shown below.

CHAPTER 3 Installation

User wiring

6 wires

User tubing

φ3, 2 tubes

(Robot models for custom specifications may have different wiring or tub­ing.)
The specifications of the user wires and air tubes are shown below. Always
observe the specifications.

User signal cable

Rated voltage

Allowable current

Nominal cross-section area of conductor

Shield

User Tubing

Maximum pressure

Outer diameter × inner diameter

Fluid

0.58MPa (6Kgf/cm

φ3×φ1.5

Dry clean air not containing deteriorated

compressor oil; filtration 40µm or less

30V

1.5A

0.1mm

No

2

2

)

2) User wiring connectors and user piping joints are provided on the arm side
and base side. Refer to "Chapter 7, 1-2. External view and dimensions" for
the positions.

3-13

CHAPTER 3 Installation

3) Signal wiring connections in the machine harness

4) Crimp the user wiring to the connector (supplied) using a crimping tool (J.S.T.

Connector pins 1 to 6 can be used.

Connector

Signal

User signal line

Connector

I O

(Arm side)

Connection

No

1
2
3
4
55

No

1
2
3

(Base side)

4

66

I O

(Robots models with non-standard specifications
may have different wiring colors.)

Mfg Co., Ltd. YC12) or solder as shown in Fig. 3-8.

Lock mechanism

Connector (supplied)

Robot side connector

Color

Orange
Orange
Orange
Orange
Orange
Orange

Cable to be
prepared by user

pin

Fig. 3-8

WARNING

Securely fix the connector (supplied) to the robot's connector using the lock
mechanism attached with the housing (See Fig. 3-8). The operation could mal­function if the connector dislocates.

WARNING

Do not utilize the machine harness, user signal wires or air tubes of the robot to
fasten any cable or tube prepared by the user, as this may break the robot
harness wires or user signal wires causing malfunction of the robot. This will
also result in poor positioning accuracy.

WARNING

Make sure that user wiring and piping connected with the user wiring connector
and user wiring joint do not interfere with the robot, get wound around the robot
or led around when the robot moves. The wiring and piping could be damaged
and result in malfunctioning.

3-14

CHAPTER 3 Installation

WARNING

Arrange the user wiring and piping installed with the user wiring connector and
user piping joint not to pose hazards for the operators. The operators could trip
on these parts and be injured.

!

CAUTION

Always use the supplied connectors and pins. Contact faults could occur if
other types are used.

Arm side and base side connector (supplied) Pin Manufacture

SM Connector SMR-6V-B

BYM-001T-0.6

or SYM-001T-P0.6

J.S.T. Mfg Co., Ltd.

5) To check the operation and signal transmission between the end effector and
the controller or peripheral equipment after making connections, refer to "6.
Trial operation" in Chapter 1.

3-15

CHAPTER 3 Installation

6

Connecting a suction hose (YK120XC, YK150XC)

WARNING

Always turn off the robot controller and shut off air supply before connecting a
suction hose.

Clean room models have two suction couplers (φ6) on the rear of the manipulator
base for air suction from the base interior and from the X, Y, R axis joints, and
also have one bellows type suction coupler (φ3) for the R-axis.
The required degree of cleanliness can be maintained by sucking air through
these suction couplers.
For the suction amount versus degree of cleanliness, see "1-1 Basic specifications"
in chapter 7. For the location of the suction couplers, see "1-2 External view and
dimensions" in chapter 7.

WARNING

Lay out the suction hoses so as to keep the operator or any other person from
tripping on them. Bodily injury may result if someone trips on the hoses.

!

CAUTION

Carefully connect the suction hoses to the suction couplers so that they do not
obstruct the movement of the robot manipulator.

3-16

CHAPTER 3 Installation

7 Attaching The End Effector

7-1 R-axis tolerable moment of inertia and acceleration coeffi-

cient

1) The moment of inertia of a load (end effector and workpiece) that can be
attached to the R-axis is limited by the strength of the robot drive unit and
residual vibration during positioning. It is therefore necessary to reduce the
acceleration coefficient in accordance with the moment of inertia.

2) The R-axis tolerable moment of inertia and the acceleration coefficient ver­sus R-axis moment of inertia for each robot model are shown in Fig. 3-9,
Fig. 3-10 and Fig. 3-11 on the subsequent pages. The symbols AX, AY, and A
in each figure respectively indicate the acceleration coefficients of the X­axis, Y-axis and R-axis. The symbol IR (JR) is the moment of inertia of the
load around the R-axis and m is the tip mass.

R

Example: YK120X
Assume that the mass of the load installed to the R-axis is 0.15kg and the
moment of inertia around the R-axis is 0.0005kgm2 (0.005kgfcmsec2). When
the tip mass parameter is set to 0.2kg, the robot can be operated by reducing
the X, Y and R-axis acceleration coefficients to 50%, as can be seen from
Fig. 3-9.
Be sure to select an optimum tip mass and acceleration coefficient param­eters that meet the mass of the load and moment of inertia before using the
robot.
To make settings for the tip mass and acceleration coefficient, refer to the
separate "YAMAHA robot controller owner's manual".

3) Methods for calculating the moment of inertia of the load are shown in Sec­tion 6-2, however, it is not easy to precisely figure out these values.
If a calculated value smaller than the actual moment of inertia is set, residual
vibrations may occur. If this happens, reduce the acceleration coefficient pa­rameter even further.

!

CAUTION

The robot must be operated with correct tolerable moment of inertia and accel­eration coefficients according to the manipulator tip mass and moment of iner­tia. If this is not observed, premature end to the life of the drive units, damage to
the robot parts or residual vibration during positioning may result.

3-17

CHAPTER 3 Installation

!

CAUTION

Depending on the Z-axis position, vibration may occur when the X, Y or R-axis
moves. If this happens, reduce the X, Y or R-axis acceleration to an appropri­ate level.

!

CAUTION

If the moment of inertia is too large, vibration may occur on the Z-axis depend­ing on its operation position. If this happens, reduce the Z-axis acceleration to
an approriate level.

3-18

CHAPTER 3 Installation

7-1-1 Acceleration coefficient vs. moment of inertia (YK120X)

AX, AY, AR (%)

100

80

60

40

20

AX, AY, AR (%)

100

80

60

0.00025 (0.0025

0

0

0.0005

0.005

)

0.0010

0.010

0.0015

0.015

0.0020

0.020

Ir (kgm2)
J

r (kgfcmsec

2

)

W=0.1kg

0.0008 (0.00008

)

40

20

AX, AY, AR (%)

100

80

60

40

20

0

0

0.0005

0.005

0.0010

0.010

0.0015

0.015

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

W=0.2kg

0.0005 (0.00005

0

0

0.0005

0.005

)

)

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

0.0010

0.010

0.0011 (0.011

0.0015

0.015

W=0.3kg

3-19

CHAPTER 3 Installation

AX, AY, AR (%)

100

80

60

40

20

AX, AY, AR (%)

100

80

60

0

0

0.00002 (0.0002

0.0005

0.005

0.00002 (0.0002

)

0.0010

0.010

0.0015

0.015

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

W=0.4kg

)

40

20

0

0

0.0005

0.005

0.0010

0.010

0.0015

0.015

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

W=0.5kg

Fig. 3-9

3-20

CHAPTER 3 Installation

7-1-2 Acceleration coefficient vs. moment of inertia (YK150X)

AX, AY, AR (%)

100

80

60

40

20

AX, AY, AR (%)

100

80

60

0.00004 (0.0004

0.00025(0.0025

0

0

0.0005

0.005

)

)

0.0010

0.010

0.0015

0.015

0.0020

0.020

Ir (kgm2)
J

r (kgfcmsec

2

)

W=0.1kg

0.00018 (0.0018

)

40

20

AX, AY, AR (%)

100

80

60

40

20

0

0

0.0005

0.005

0.0010

0.010

0.0015

0.015

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

W=0.2kg

0

0

0.0005

0.005

0.0010

0.010

0.0015

0.015

0.0011 (0.011

)

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

W=0.3kg

3-21

CHAPTER 3 Installation

AX, AY, AR (%)

100

80

60

40

20

AX, AY, AR (%)

100

80

60

0.00016 (0.0016

0

0

0.0005

0.005

)

0.0010

0.010

0.0015

0.015

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

W=0.4kg

0.00005 (0.0005

)

40

20

0

0

0.0005

0.005

0.0010

0.010

0.0015

0.015

0.0020

0.020

2

I

r (kgm

)

J

r (kgfcmsec

2

)

W=0.5kg

Fig. 3-10

3-22

CHAPTER 3 Installation

7-1-3

Acceleration coefficient vs. moment of inertia (YK180X, YK220X)

A

X, AY, AR

A

X, AY, AR

(%)

100

80

60

40

20

(%)

100

80

0.005

0.05

)

0.01

I

r

(kgm2)

0.1

J

r

(kgfcmsec2)

0.0005 (0.005

0

0

W=0.1 to 0.4kg

0.0005 (0.005

)

A

X, AY, AR

60

40

20

(%)

100

80

60

40

20

0

0

0.005

0.05

0.01

0.1

I

r

(kgm2)

J

r

(kgfcmsec2)

W=0.5 to 0.8kg

0.0005 (0.005

)

0

0

0.005

0.05

0.01

0.1

I

r

(kgm2)

J

r

(kgfcmsec2)

W=0.9, 1.0kg

Fig. 3-11

3-23

CHAPTER 3 Installation

7-2 Equation for moment of inertia calculation

Usually the R axis load is not a simple form, and the calculation of the moment of
inertia is not easy.
As a method, the load is replaced with several factors that resemble a simple form
for which the moment of inertia can be calculated. The total of the moment of
inertia for these factors is then obtained.
The objects and equations often used for the calculation of the moment of inertia
are shown below. Incidentally, there is the following relation:

2

J (kgfcmsec

1) Moment of inertia for material particle
The equation for the moment of inertia for a material particle that has a rota­tion center such as shown in Fig. 3-12 is as follows:
This is used as an approximate equation when x is larger than the object size.

I= mx

J=

) = I (kgm2) × 10.2.

2

2

(kgm

)

2

Wx

(kgfcmsec2)

g

... (Eq. 3.1)

x

g : Gravitational acceleration (cm/sec

2

)

m : Mass of material particle (kg)

W : Weight of material particle (kgf)

Fig. 3-12

2) Moment of inertia for cylinder (part 1)
The equation for the moment of inertia for a cylinder that has a rotation center
such as shown in Fig. 3-13 is given below.

42

ρπ D h

I=

J=

32

42

ρπ D h

32g

ρ : Density (kg/m
g : Gravitational acceleration (cm/sec

m : Mass of cylinder (kg)

W : Weight of cylinder (kgf)

mD

=

(kgm2)

8

WD

=

(kgfcmsec2)

8g

... (Eq. 3.2)

h

3

, kg/cm3)

2

)

D

3-24

Fig. 3-13

CHAPTER 3 Installation

3) Moment of inertia for cylinder (part 2)
The equation for the moment of inertia for a cylinder that has a rotation center
such as shown in Fig. 3-14 is given below.

2

ρπ D h

I=

J=

16

2

ρπ D h

16g

ρ : Density (kg/m

22

D

(

+

4

22

D

(

+

4

3

, kg/cm3)

h
3

h
3

m

)

=

4

W

)

=

4g

g : Gravitational acceleration (cm/sec

m : Mass of cylinder (kg)

W : Weight of cylinder (kgf)

22

D

(

+

4

22

D

(

+

4

2

)

h
3

h
3

D

)

(kgm

)

(kgfcmsec

2

)

2

)

... (Eq. 3.3)

h

Fig. 3-14

4) Moment of inertia for prism
The equation for the moment of inertia for a prism that has a rotation center
as shown in Fig. 3-15 is given as follows.

ρ abc(a +b )

I=

ρ abc(a +b )

J=

12g

12

222

2

=

2

=

m(a +b )

W(a +b )

2

12

2

2

12g

... (Eq. 3.4)

2

)

(kgm

(kgfcmsec2)

h
2

c

3

ρ : Density (kg/m

, kg/cm3)

g : Gravitational acceleration (cm/sec

m : Mass of prism (kg)

W : Weight of prism (kgf)

1/2a

b

2

)

a

Fig. 3-15

3-25

CHAPTER 3 Installation

5) When the object's center line is offset from the rotation center.
The equation for the moment of inertia, when the center of the cylinder is
offset by the distance "x" from the rotation center as shown in Fig. 3-16, is
given as follows.

I=

J=

=

ρπD h

32

ρπD h

32g

WD

8g

4

4

2

+

+

+

Wx

g

ρπD hx

ρπD hx

2

22

4

=

2

2

4g

(kgfcmsec

... (Eq. 3.5)

mD

2

)

2

8

2

mx

+

(kgm

2

)

h

Center line

Rotation center

ρ : Density (kg/m

g : Gravitational acceleration (cm/sec

3

, kg/cm3)

2

)

D

x

m : Mass of cylinder (kg)

W : Weight of cylinder (kgf)

Fig. 3-16

In the same manner, the moment of inertia of a cylinder as shown in Fig. 3-17
is given by

22

D

(

+

4

22

D

(

+

4

22

D

h

+

4

3

h

)

+

3

h

)

+

3

Wx

)

+

g

22

ρπ D h x

4

22

ρπ D h x

4g

2

(kgfcmsec2)

m

=

4

... (Eq. 3.6)

22

D

(

+

4

D

h

)

3

mx

+

Cneter line

2

h

(kgm

x

I=

J=

=

2

ρπ D h

16

2

ρπ D h

16g

W

4g

(

2

)

Fig. 3-17

In the same manner, the moment of inertia of a prism as shown in Fig. 3-18 is
given by

ρabc(a + b )

I=

ρabc(a + b )

J=

=

22

12

2

12g

2

W(a + b )

2

12g

+ ρabcx2=

2

+

Wx

+

ρabcx

g

m : Mass of prism (kg)

W : Weight of prism (kgf)

2

g

2

(kgfcmsec

22

m(a +b )

12

2

)

... (Eq. 3.7)

+ mx

c

2

(kgm

b

2

)

Center line

x

a

Fig. 3-18

3-26

7-3 Example of moment of inertia calculation

Let's discuss an example in which the chuck and workpiece are at a position
offset by 10cm from the R-axis by a stay, as shown in Fig. 3-19.
The moment of inertia is calculated with the following three factors, assuming
that the load material is steel and its density ρ is 0.0078kg/cm3.

R-axis

CHAPTER 3 Installation

6cm

2cm

4cm

Workpiece

2cm

Stay

1cm

Chuck

Fig. 3-19

2cm

2cm

1cm

10cm

4cm

1) Moment of inertia of the stay

From Fig. 3-20, the weight of the
stay (Ws) is given as follows:

Ws = ρabc = 0.0078 × 12 × 2 × 2

= 0.37 (kgf)

2cm

2cm

Center line

R-axis

5cm

12cm

Fig. 3-20

The moment of inertia of the stay (Js) is then calculated from Eq. 3-7.

2

= 0.014 (kgfcmsec2)

3-27

Js =

2+22

0.37 × (12
12 × 980 980

)

+

0.37 × 5

CHAPTER 3 Installation

2) Moment of inertia of the chuck

When the chuck form resem­bles that shown in Fig. 3-21,
the weight of the chuck (Wc)
is
Wc = 0.0078 × 2 × 4 × 6
= 0.37 (kgf)

6cm

The moment of inertia of the
chuck (Jc) is then calculated
from Eq. 3-7.

2+42

Jc =

0.37 × (2

)

12 × 980

0.37 × 10

+

2

980

2

= 0.038 (kgfcmsec

)

3) Moment of inertia of workpiece

When the workpiece form
resembles that shown in Fig.

3-22, the weight of the
workpiece (Ww) is

2

h = 0.0078π × 22 × 4

ρπD

Ww =

= 0.098 (kgf)

44

4cm

2cm

4cm

10cm

Fig. 3-21

10cm

R-axis

R-axis

The moment of inertia of the

2cm

workpiece (Jw) is then calcu­lated from Eq. 3-5.

0.097 × 2

Jw=

8 × 980 980

= 0.010 (kgfcmsec

2

0.097 × 10

+

2

2

)

4) Total weight

The total weight (W) is calculated as follows:
W = Ws + Wc + Ww = 0.84 (kgf)

5) Total moment of inertia

The total moment of inertia (J) is then obtained as follows:

J = Js + Jc + Jw = 0.062 (kgfcmsec2)

3-28

Fig. 3-22

7-4 Attaching the end effector

WARNING

Before attaching the end effector, be sure to turn off the controller.

The manipulator part to which an end effector is attached must have adequate
strength and rigidity, as well as gripping force to prevent positioning errors. Table
3-1 shows the maximum load that can be applied to the end effector attachment
of each robot model. Recommended methods for attaching end effectors are shown
in Table 3-2 and Fig. 3-25. Refer to Fig. 3-23 for details on the end effector
attachment of each robot model.
When checking end effector operation, refer to "6 Trial Operation" in Chapter 1.

CHAPTER 3 Installation

User tool installation range

10

Robot Mode

YK120X

YK150X

YK180X

YK220X

Retaining ring to set the user tool

φ6

YK120X, YK150X

FXYmax FZmax FRmax MRmax Mmax

N kgf N kgf N kgf Nm kgfm Nm

27

27

27 2.8 6.7 0.7 15.7 1.6 4.5 0.46 0.9 0.09

30 3.1 6.7 0.7 18.6 1.9 4.5 0.46 0.9 0.09

2.8

2.8

0

-0.012

YK180X, YK220X

Fig. 3-23 Z-axis tip shape

Table 3-1

6.7

6.7

0.7

0.7

9.8

12

1.0

1.3

Never loosen this bolt.

User tool installation range

15

0

φ10 h7

-0.015

0.5

0.5

0.05

0.05

0.4

0.4

kgfm

0.04

0.04

3-29

CHAPTER 3 Installation

End effector

Stay

Frmax

Mrmax

Fzmax

Mmax

Fxymax

Fig. 3-24 Maximum load applied to end effector attachment

Table 3-2

Robot Mode

YK120X, YK150X

YK180X, YK220X 2 or more 4.5 46 10

Bolts Used

Number of bolts

M3 or lager 2 or more 2.0 20 6

M4 or lager

Tightening torque

Nm kgfcm

Hole diameter

Bolt

diameter(mm)

+0.012
0

+0.015
0

End effector or stay

Slot

Spline shaft

Fig. 3-25

3-30

CHAPTER 3 Installation

WARNING

The end effector attachment must have adequate strength to withstand the
loads listed in Table 3-1. If too weak, the attachment may break during robot
operation and fragments fly off causing accidents or injuries.

WARNING

The end effector attachment must have sufficient rigidity versus the loads listed
in Table 3-1. If this rigidity is inadequate, the end effector may vibrate during
robot operation causing bad effects on the manipulator operation.

WARNING

•When the end effector is attached by slot clamping, always observe the con­ditions listed in Table 3-2. If these are ignored, the end effector may come
loose and fly off during robot operation, resulting in an accident or injury.

• In cases where other attachment methods are used, be sure that the end
effector will not come off when the loads listed in Table 3-1 are applied.

!

CAUTION

The YK120X series (YK120X, YK150X) and YK180X series (YK180X, YK220X)
is designed to be compact, so the joints could be damaged if excessive force is
applied, for example, during installation of an end effector.
Make sure that excessive force is not applied to the joints.

YK120X, YK150X

Axis

X-axis

Y-axis

R-axis

YK180X, YK220X

Axis

X-axis

Y-axis

R-axis

Tolerable radial load

100N (10.2kgf)

45N (4.6kgf)

45N (4.6kgf)

Tolerable radial load

275N (28.1kgf)

150N (15.3kgf)

150N (15.3kgf)

Tolerable thrust load

100N (10.2kgf)

45N (4.6kgf)

45N (4.6kgf)

Tolerable thrust load

900N (91.8kgf)

600N (61.2kgf)

600N (61.2kgf)

To le ra b le moment load

1.5Nm (15.3kgfcm)

0.45Nm (4.6kgfcm)

0.45Nm (4.6kgfcm)

Tolerable moment load

6.0Nm (61.2kgfcm)

3.3Nm (33.7kgfcm)

3.3Nm (33.7kgfcm)

Tolerable torque

1.7Nm (17.3kgfcm)

0.5Nm (5.1kgfcm)

0.3Nm (3.1kgfcm)

Tolerable torque

9.0Nm (91.8kgfcm)

4.0Nm (40.8kgfcm)

2.2Nm (22.4kgfcm)

3-31

CHAPTER 3 Installation

7-5 Gripping force of end effector

The gripping force of the end effector must have a sufficient extra margin of
strength versus the workpiece weight and reaction force applied to the workpiece
during robot operation.
The reaction force applied to the workpiece during operation can be calculated
from the acceleration applied to the end effector attachment. The maximum ac­celeration on the end effector attachment of each robot model is listed in the table
below. When the workpiece position is offset to the end effector attachment, the
accelerations Amax and A
versus the arm length. When the R-axis rotates during operation, this acceleration

R

A

max must be taken into account.

Table 3-3 Maximum acceleration during robot operation

XY

max become larger by an amount equal to the offset

Robot Model

YK120X

YK150X

YK180X

YK220X

Amax(m/sec2) AXYmax(m/sec2) Azmax(m/sec2) ARmax(rad/sec2)

20 8.4 23 267

25 11 16 267

50 16 16 767

61 19 16 767

ARmax

Amax

Azmax

AXYmax

Fig. 3-26 Maximum acceleration on end effector attachment

WARNING

The gripping force of the end effector must have a sufficient extra margin of
strength to prevent the workpiece from coming loose and flying off during robot
operation.
If the gripping force is too weak, the workpiece may come loose and fly off
causing accidents or injuries.

3-32

CHAPTER 3 Installation

8Working Envelope and Mechanical Stopper

Positions for Maximum Working Envelope

Working envelope and mechanical stopper positions for the maximum working
envelope of each robot are shown in "1-2 External view and dimensions" in Chapter

7.
An example using the YK120X is described below. (Refer to Fig. 7-1.) Other
robot models are the same.

1) X and Y axes
Do not attempt operation outside the working envelope. The working enve­lope described in this manual is an area with the robot frontal reference.

2) Z-axis
Do not attempt work outside the working envelope. In particular, do not at­tempt work in the area between the working envelope and mechanical stop­per position. Mechanical stoppers are installed at both the upper and lower
ends of the movement range.

WARNING

The robot cable, user wiring or tubing may be damaged if the robot load inter­feres with them resulting in hazardous robot malfunctions. Do not operate at
points where the load may interfere with the robot cable, user wiring or tubing.

3) R-axis
The R-axis has no mechanical stoppers.

!

CAUTION

Since the R-axis has no mechanical stoppers, make certain that the end effec­tor wiring and tubing do not become entangled during operation.

3-33

MEMO

3-34

CHAPTER 4

Adjustment

1 Overview ..................................................................................................4-1

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

3 Adjusting the origin ..................................................................................4-2

3-1 Absolute reset method ......................................................................................... 4-3

3-1-1 YK120X series (YK120X, YK150X)........................................................................ 4-3

3-1-1-1 Sensor method (R-axis) ........................................................................................ 4-3

3-1-1-2 Stroke end method (X-axis, Y-axis) ...................................................................... 4-4

3-1-1-3 Stroke end method (Z-axis) .................................................................................. 4-6

3-1-2 YK180X series (YK180X, YK220X)........................................................................ 4-7

3-1-2-1 Sensor method (R-axis) ........................................................................................ 4-7

3-1-2-2 Sensor method (X-axis, Y-axis) ............................................................................ 4-8

3-1-2-3 Stroke end method (Z-axis) .................................................................................. 4-9

3-2 Machine reference.............................................................................................. 4-10

3-3 Absolute reset procedures .................................................................................. 4-11

3-3-1 Sensor method (R-axis) ....................................................................................... 4-11

3-3-2 Stroke end method (X and Y axes of YK120X, YK150X) .....................................4-13

3-3-3 Stroke end method (Z-axis).................................................................................. 4-15

3-3-4 Sensor method (X and Y axes of YK180X, YK220X) ...........................................4-16

3-4 Adjusting the machine reference ........................................................................ 4-18

3-4-1 YK120X series (YK120X, YK150X)...................................................................... 4-19

3-4-1-1 Adjusting the R-axis machine reference (YK120X, YK150X) ............................. 4-19

3-4-1-2 Adjusting the R-axis machine reference (YK120XC, YK150XC) ........................ 4-21

3-4-1-3 Adjusting the X-axis machine reference ............................................................. 4-23

3-4-1-4 Adjusting the Y-axis machine reference .............................................................. 4-25

3-4-1-5 Adjusting the Z-axis machine reference ............................................................. 4-27

3-4-2 YK180X series (YK180X, YK220X)...................................................................... 4-30

3-4-2-1 Adjusting the R-axis machine reference (YK180X, YK220X) ............................. 4-30

3-4-2-2 Adjusting the X-axis machine reference ............................................................. 4-32

3-4-2-3 Adjusting the Y-axis machine reference .............................................................. 4-34

3-4-2-4 Adjusting the Z-axis machine reference ............................................................. 4-36

4 Setting the Soft Limits ............................................................................4-39

5 Setting the Standard Coordinates .........................................................4-42

6Affixing Stickers for Movement Directions and Axis Names ..................4-43

7 Removing the Robot Covers .................................................................4-45

MEMO

1 Overview

YA MAHA robots have been completely adjusted at the factory or by the sales
representative before shipment, including the origin position adjustment. If the
operating conditions are changed and the robot must be adjusted, then follow the
procedures described in this chapter.

2 Safety Precautions

(1) Read and understand the contents of this chapter completely before attempt-

ing to adjust the robot.

(2) Place a conspicuous sign indicating the robot is being adjusted, to prevent

others from touching the controller switch, programming unit or operation
panel.

CHAPTER 4 Adjustment

(3) If a safeguard enclosure has not yet been provided right after installation of

the robot, rope off or chain off the movement area around the manipulator in
place of a safeguard enclosure, and observe the following points.

qUse stable posts which will not fall over easily.
wThe rope or chain should be easily visible by everyone around the robot.
ePlace a conspicuous sign prohibiting the operator or other personnel from

entering the movement area of the manipulator.

(4) To check operation after adjustment, refer to "6. Trial Operation" in Chapter 1.

4-1

CHAPTER 4 Adjustment

3 Adjusting the origin

All models of the YK120X series and YK180X series robots use an absolute type
position detector.
The origin position (zero pulse point) can be determined by absolute reset. Once
absolute reset is performed, you do not have to repeat absolute reset when turning
the power on next time.
However, absolute reset is required if any of the following cases occur. The robot
is shipped from the factory in condition "c" (below), so please perform absolute
reset after installing the robot. For more details on absolute reset, refer to "Absolute
Reset" in Chapter 4 of the "YAMAHA robot controller owner's manual".

a. Absolute-related error occurred on the axis.
b. Power drop was detected in the absolute battery for the driver installed

inside the robot controller.

c. Cable connecting the robot unit to the controller was disconnected.

(This is the status when shipped from the factory.)
d. Robot generation was changed.
e. Parameters were initialized.
f. Axis parameters "Origin shift", "Origin method", "Origin direction" or

"Motor direction" were changed.
g. Motor was replaced. (Motor wiring connector was removed.)
h. Data in the ALL data file (extension: ALL) or parameter file (extension:

PRM) was written into the controller by way of the RS-232C.

The following sections explain how to perform absolute reset.

!

CAUTION

If any of the above cases occur after installing the robot, absolute reset must be
performed again. The robot must be moved to the origin position to perform
absolute reset. Select a robot position where the origin position will not interfere
with peripheral devices after setup is completed.

!

CAUTION

After performing absolute reset, move the robot to a known point to check
whether the origin position is correctly set. When doing this check, move the
robot at the slowest possible speed.

The YK120X series and YK180X series absolute methods include the sensor
method and stroke end method.
The YK120X series uses the stroke end method for the X-axis, Y-axis and Z-axis,
and the sensor method for the R-axis.
The YK180X series uses the stroke end method for the Z-axis, and the sensor
method for the X-axis, Y-axis and R-axis.

4-2

3-1 Absolute reset method

3-1-1 YK120X series (YK120X, YK150X)

3-1-1-1 Sensor method (R-axis)

In the sensor method, the target axis is automatically operated for the absolute
reset, and the absolute reset is performed at the position where the proximity
sensor provided on the target axis detects the detection area (dog).
The absolute reset in the sensor method can be executed with the teaching pen­dant (MPB), RS-232C communication, and dedicated input.

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

CHAPTER 4 Adjustment

!

CAUTION

The origin cannot be detected in any axis which is not positioned on the plus
side from the origin (See Fig. 4-1.) before starting the return-to-origin opera­tion. (Factory setting at shipment.)
In this case, press the STOP key to interrupt the return-to-origin operation,
move the target axis to the plus side of the origin, and reperform the origin
return operation.
If the return-to-origin operation is not stopped, the robot will continue moving
and could collide with the peripheral devices. The R-axis does not have a me­chanical stopper, so the wiring and piping installed on the end effector could
become entangled.

R-axis dog

R-axis

Plus side

R-axis Sensor

Plus side

R-axis Sensor

R-axis

Minus side

Minus side

YK120X, YK150X YK120XC, YK150XC

Fig. 4-1 View of R-axis from below

4-3

CHAPTER 4 Adjustment

3-1-1-2 Stroke end method (X-axis, Y-axis)

With the stroke end method, the X and Y-axes are pushed against the mechanical
stopper, and after the axis end is detected, absolute reset is performed from a
position slightly back from the axis end.

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

!

CAUTION

Before starting return-to-origin operation, move the X-axis to a position on the
plus side from the origin position (See Fig. 4-2), and the Y-axis to a position on
the minus side, so that the robot is positioned in a right-handed system as
shown in Fig. 4-2.
When the return-to-origin operation starts, the X-axis will move to the minus
side and the Y-axis will move to the plus side. After pushing against the me­chanical stopper, the axes will return slightly, and the return-to-origin will be
completed.
The X and Y-axes will move to the positions shown in Fig. 4-3 during return-to­origin, so make sure that the tool on the end, the robot and the peripheral
devices do not interfere. The maximum tolerable load radius (when load is cy­lindrical object) is shown in Fig. 4-3. If return-to-origin is performed with a load
larger than this radius installed on the R-axis, the base and load could interfere.

4-4

Plus side

CHAPTER 4 Adjustment

113°±4°

Plus side

139°±4°

Minus side

Minus side

Fig. 4-2 Default origin position (YK120X, YK150X, YK120XC, YK150XC)

121°

147° (143°)

R38

Maximum
tolerable
load radius

YK150X (YK150XC) YK120X (YK120XC)

*1

Fig. 4-3 X and Y-axis maximum movement position during

X and Y-axis stopper origin position setting

147°

R13

Maximum
tolerable
load radius

(143

°)

*1

*1 When load is cylindrical object

121°

4-5

CHAPTER 4 Adjustment

3-1-1-3 Stroke end method (Z-axis)

With this method, the Z-axis is pushed against the mechanical stopper, and after
the axis end is detected, absolute reset is performed from a position slightly back
from the axis end.

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

4-6

3-1-2 YK180X series (YK180X, YK220X)

3-1-2-1 Sensor method (R-axis)

In the sensor method, the target axis is automatically operated for the absolute
reset, and the absolute reset is performed at the position where the proximity
sensor provided on the target axis detects the detection area (dog).
The absolute reset in the sensor method can be executed with the teaching pen­dant (MPB), RS-232C communication, and dedicated input.

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

!

CAUTION

CHAPTER 4 Adjustment

The origin cannot be detected in any axis which is not positioned on the plus
side from the origin (See Fig. 4-4.) before starting the return-to-origin opera­tion. (Factory setting at shipment.)
In this case, press the STOP key to interrupt the return-to-origin operation,
move the target axis to the plus side of the origin, and reperform the origin
return operation.
If the return-to-origin operation is not stopped, the robot will continue moving
and could collide with the peripheral devices. The R-axis does not have a me­chanical stopper, so the wiring and piping installed on the end effector could
become entangled.

R-axis Sensor

M

i

n

u

s

s

i

R-axis dog

d

e

e

id

s

s

u

l

P

4-7

Fig. 4-4

CHAPTER 4 Adjustment

3-1-2-2 Sensor method (X-axis, Y-axis)

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

!

CAUTION

The origin cannot be detected in any axis which is not positioned on the plus
side from the origin (See Fig. 4-5.) before starting the return-to-origin opera­tion. (Factory setting at shipment.)
In this case, press the STOP key to interrupt the return-to-origin operation,
move the target axis to the plus side of the origin, and reperform the origin
return operation.
If the return-to-origin operation is not stopped, the robot will continue moving
and could collide with the peripheral devices.
The X and Y-axes will move to the positions shown in Fig. 4-5 during return-to­origin, so make sure that the tool on the end, the robot and the peripheral
devices do not interfere. The maximum tolerable load radius (when load is cy­lindrical object) is shown in Fig. 4-5. If return-to-origin is performed with a load
larger than this radius installed on the R-axis, the base and load could interfere.
Since the X-axis arm first returns to the origin, the tool on the end might interfere
with the robot base (pedestal) if the Y-axis arm is near its origin.

X-axis origin is at 0°±5° with
respect to front of robot base

Plus side Minus side Plus side Minus side

R19

Maximum
tolerable
load radius

Minus side

Plus side

X-axis origin is at 0°±5° with
respect to front of robot base

133°±5°

*1

R17

Maximum
tolerable
load radius

Minus side

133°±5

°

*1

Plus side

YK180X

YK220X

*1 When load is cylindrical object

Fig. 4-5 Default origin position

4-8

3-1-2-3 Stroke end method (Z-axis)

With this method, the Z-axis is pushed against the mechanical stopper, and after
the axis end is detected, absolute reset is performed from a position slightly back
from the axis end.

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

CHAPTER 4 Adjustment

4-9

CHAPTER 4 Adjustment

3-2 Machine reference

The YK-X Series position detector uses a resolver having one position that can
perform absolute reset in respect to one motor rotation.
When absolute reset is performed with the sensor method or stroke end method,
the origin position will be set to a position where it can be reset immediately after
the origin sensor reacts to the dog (where the origin signal is detected) or the
stroke end (mechanical stopper) is detected.
The machine reference means the position relationship between the position where
the robot detects the origin signal and the position where the absolute reset can be
performed soon after the origin signal detection. (See Fig. 4-6.) The machine
reference is expressed in the ratio of interval A to interval B shown in Fig. 4-6.
Interval A is the minimum distance between the positions where absolute reset
can be performed and interval B is the distance between the position where the
origin signal is detected and the position where absolute reset can be performed
soon after the origin signal detection.
The machine reference value is displayed on the optional MPB screen. (Unit: %)

Machine reference value = B/A × 100(%)

!

CAUTION

It is necessary for the machine reference to be adjusted in a specified range in
order to keep the repeatability precision of the absolute reset position. (Factory­adjusted at shipment.)
Refer to "Chapter 4, 3-4 Adjusting the machine reference" for the machine ref­erence adjustment method .

Recommended machine reference value: 40 to 60% (26 to 74% only for Z-axis)

Machine reference

Origin signal detection

Origin signal

Resolver

BA

Positions where absolute reset

can be performed

One motor revolution

Machine reference display on MPB screen

ON

OFF

MPB

MANUAL >RST. ABS 50% [MG] [S0H0J]

Machine reference (%)

M1= 50

M4= 66

M1 M2 M3 M4 M5

R-axis

M2= 56

X-axis Y- axis Z-axis

M3= 52

Fig. 4-6

4-10

3-3 Absolute reset procedures

3-3-1 Sensor method (R-axis)

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat­ing the robot controller.

1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

CHAPTER 4 Adjustment

2) Place a sign indicating the robot is being adjusted, to keep others from touch­ing the controller switch or operation panel.

3) Set the controller to MANUAL mode, if not in MANUAL mode.

4) Press the F13 (LOWER+F3) key to select "RST. ABS".

5) Select the R-axis for absolute reset. (R-axis: M4)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.

!

CAUTION

The Z-axis of the stroke end method first rises during the absolute reset of all
axes (default setting). Be careful that your fingers do not get pinched or crushed
by any sudden movement.

6) Confirm that the R-axis, to perform absolute reset, is at a position on the plus
side of the origin (See Fig. 4-1, Fig. 4-4 ).
If it is not at the plus side, then press the jog key to move the target axis to the
plus side.
When performing absolute reset for the other axes at the same time, confirm
that the other axes are also at an appropriate position. (Refer to procedures
for absolute reset of other axes)

4-11

CHAPTER 4 Adjustment

7) Since the message "Reset ABS encoder OK?" is displayed, check that there

8) After the absolute reset is completed, check that the R-axis machine refer-

are not any obstacles in the robot movement range, and press the F4 key
(YES).

ence value displayed on the MPB is between 40 and 60 (recommended range).
If the machine reference value is outside the recommended range, then the
next absolute reset may not be properly performed.
In this case, refer to "3-4 Adjusting the machine reference", and make the
necessary adjustments.

4-12

CHAPTER 4 Adjustment

3-3-2 Stroke end method (X and Y axes of YK120X, YK150X)

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat­ing the robot controller.

1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

2) Place a sign indicating the robot is being adjusted, to keep others from touch­ing the controller switch or operation panel.

3) Set the controller to MANUAL mode, if not in MANUAL mode.

4) Press the F13 (LOWER+F3) key to select "RST. ABS".

5) Select the X-axis or Y-axis for absolute reset. (X-axis: M1, Y-axis: M2)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.

!

CAUTION

The Z-axis of the stroke end method first rises during the absolute reset of all
axes (default setting). Be careful that your fingers do not get pinched or crushed
by any sudden movement.

6) Confirm that the X-axis is at a position on the plus side of the origin (See
Fig. 4-2), and that the Y-axis is at the minus side. Make sure that the robot is
positioned in a right-handed system as shown in Fig. 4-2. If the axes are not
at these positions, press the jog keys, etc., and move the target axes. When
performing absolute reset for the other axes at the same time, confirm that
the other axes are also at an appropriate position. (Refer to procedures for
absolute reset of other axes)

7) Since the message "Reset ABS encoder OK?" is displayed, check that there
are not any obstacles in the robot movement range, and press the F4 key
(YES).

4-13

CHAPTER 4 Adjustment

8) After the absolute reset is completed, check that the X-axis and Y-axis ma­chine reference value displayed on the MPB is within the absolute reset tol­erance range (40 to 60).
If the machine reference value is outside the absolute reset tolerance range,
then the next absolute reset may not be properly performed.
In this case, refer to "Chapter 4, 3-4 Adjusting the machine reference" and
make the necessary adjustments.

4-14

3-3-3 Stroke end method (Z-axis)

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat­ing the robot controller.

1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

2) Place a sign indicating the robot is being adjusted, to keep others from touch­ing the controller switch or operation panel.

CHAPTER 4 Adjustment

3) Set the controller to MANUAL mode, if not in MANUAL mode.

4) Press the F13 (LOWER+F3) key to select "RST. ABS".

5) Select M3 (Z-axis). (Z-axis: M3)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.

6) Since the message "Reset ABS encoder OK?" is displayed, check that there
are not any obstacles in the robot movement range, and press the F4 key
(YES).

7) After the absolute reset is completed, check that the machine reference value
displayed on the MPB is within the absolute reset tolerance range (26 to 74).
If the machine reference value is outside the absolute reset tolerance range,
then the next absolute reset may not be properly performed.
In this case, refer to "Chapter 4, 3-4 Adjusting the machine reference" and
make the necessary adjustments.

4-15

CHAPTER 4 Adjustment

3-3-4 Sensor method (X and Y axes of YK180X, YK220X)

WARNING

Serious injury might occur from physical contact with the robot during opera­tion.
Never enter within the robot movement range during absolute reset.

The operation procedure using the MPB is described next. (Press the ESC key on
the MPB if you want to return to the preceding step.)
See the "YAMAHA robot controller owner's manual" for information on operat­ing the robot controller.

1) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

2) Place a sign indicating the robot is being adjusted, to keep others from touch­ing the controller switch or operation panel.

3) Set the controller to MANUAL mode, if not in MANUAL mode.

4) Press the F13 (LOWER+F3) key to select "RST. ABS".

5) Select the X-axis or Y-axis for absolute reset. (X-axis: M1, Y-axis: M2)
To perform absolute reset on all axes, select "ALL" with the F11 (LOWER+F1)
key.

!

CAUTION

The Z-axis of the stroke end method first rises during the absolute reset of all
axes (default setting). Be careful that your fingers do not get pinched or crushed
by any sudden movement.

6) Move the X and Y axes to a position on the plus side of their origins (See Fig.
4-5) so that the robot is positioned in a left-handed system as shown in Fig. 4-

5. If the axes are not at these positions, press the jog keys, etc. and move the
target axes. When performing absolute reset for the other axes at the same
time, check that the other axes are also at an appropriate position. (Refer to
procedures for absolute reset of other axes.)

7) Since the message "Reset ABS encoder OK?" is displayed, check that there
are not any obstacles in the robot movement range, and press the F4 key
(YES).

4-16

CHAPTER 4 Adjustment

8) After the absolute reset is completed, check that the X-axis and Y-axis ma­chine reference value displayed on the MPB is within the absolute reset tol­erance range (40 to 60).
If the machine reference value is outside the absolute reset tolerance range,
then the next absolute reset may not be properly performed.
In this case, refer to "Chapter 4, 3-4 Adjusting the machine reference" and
make the necessary adjustments.

4-17

CHAPTER 4 Adjustment

3-4 Adjusting the machine reference

!

CAUTION

If any machine reference is adjusted, the origin position may change.
Before the adjustment, mark off the reference mark at the current origin posi­tion on the main body of the robot.
After the machine reference is adjusted, be sure to check that the origin posi­tion has not deviated.
If the origin position changes after the machine reference has been adjusted,
then the standard coordinate and point data must be reset.

!

CAUTION

When the arm moves at high speed and strikes against a mechanical stopper
violently, the machine reference value may change. If this has happened, check
the machine reference value. Also check the mechanical stopper for any dam­age and the origin position for shift. If the machine reference value is outside
the recommended range, adjust the machine reference. In this case, re-teach­ing may be required if the origin position has shifted.

4-18

CHAPTER 4 Adjustment

3-4-1 YK120X series (YK120X, YK150X)

3-4-1-1 Adjusting the R-axis machine reference (YK120X, YK150X)

The adjustment method for the R-axis machine reference is as follows.

1) Prepare the necessary tools.

• Phillips-head screwdriver

2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.
Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.

5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.

6) Turn off the controller and enter the safeguard enclosure.

7) Mark off the reference mark at the current origin position on the R-axis joint
area of the robot.
At this time, be careful to prevent the origin position from deviating since the
R-axis is touched.

8) Using a Phillips screwdriver, loosen the two screws fixing the dog at the R­axis joint. (See Fig. 4-7.)

!

CAUTION

The screw only needs to be loosened and does not need to be removed com­pletely.

9) Move the dog in the following manner.
When machine reference < 40%: Move dog in A direction
When machine reference > 60%: Move dog in B direction
The movement guide is 2.3mm/100%.

10) Tighten the screw and fix the dog.

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CHAPTER 4 Adjustment

11) Go out of the safeguard enclosure, and check that no one is inside the safe-

12) Perform the absolute reset from outside the safeguard enclosure.

13) After the absolute reset is completed, read the machine reference value dis-

14) If the machine reference value is in the range between 40 and 60 (recom-

guard enclosure. Then turn on the controller.

played on the MPB.

mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.

A

Screw

B

R-axis dog

R-axis Sensor

R-axis

Fig. 4-7 Adjustment of R-axis machine reference (View from below)

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CHAPTER 4 Adjustment

3-4-1-2

Adjusting the R-axis machine reference (YK120XC, YK150XC)

The adjustment method for the R-axis machine reference is as follows.

1) Prepare the necessary tools.

• Hex wrench set

2) Check that no one is inside the safeguard enclosure, and then turn on the
controller.

3) Perform the absolute reset from outside the safeguard enclosure.
Refer to "3-3 Absolute reset procedures" for information about the absolute
reset method.

4) If any machine reference value displayed on the MPB is not in the range
between 40 and 60 (recommended range) after the absolute reset has been
completed, then proceed with the following adjustment procedure.

5) Place a sign indicating that the robot is being adjusted in order to keep others
from operating the controller or operation panel.

6) Turn off the controller and enter the safeguard enclosure.

7) Mark off the reference mark at the current origin position on the R-axis joint
area of the robot.
At this time, be careful to prevent the origin position from deviating since the
R-axis is touched.

8) Using a hex wrench, loosen the set screws (4 pieces) securing the dog ring to
the R-axis joint. (See Fig. 4-8.)

!

CAUTION

The set screws only need to be loosened, and do not need to be completely
removed.

9) Move the dog ring in the following manner.
When machine reference < 40%: Move dog ring in A direction
When machine reference > 60%: Move dog ring in B direction
The movement guide is 2.9mm/100%.

10) Tighten the set screws to secure the dog ring. Rotate the R-axis by hand to
check that the dog and sensor do not come in contact with each other. (See
Fig. 4-8.)

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CHAPTER 4 Adjustment

11) Go out of the safeguard enclosure, and check that no one is inside the safe-

12) Perform the absolute reset from outside the safeguard enclosure.

13) After the absolute reset is completed, read the machine reference value dis-

14) If the machine reference value is in the range between 40 and 60 (recom-

guard enclosure. Then turn on the controller.

played on the MPB.

mended range), then the machine reference has been completely adjusted.
If it is outside the recommended range, then repeat the procedure that starts
in 5) to readjust it.

Set screw (4 pieces)

BA

Dog ring

R-axis

Fig. 4-8 Adjustment of R-axis machine reference

4-22