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Chapter 1 About Safety

1-9

1-3

Special Training for Industrial Robot Operation

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

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Summary of Contents for FLIP-X Series

Page 1: ...User s Manual ENGLISH E YAMAHA SINGLE AXIS ROBOT E21 Ver 1 15 FLIP Xseries ...

Page 2: ......

Page 3: ...ery is connected 4 When a motor or cable was replaced At this point any of the following errors is issued immediately after controller power is turned on but this is not a malfunction The controller will operate normally by restarting When using ERCX SRCX DRCX or TRCX controllers 15 FEEDBACK ERROR 2 23 ABS BAT L VOLTAGE 24 ABS DATA ERROR When using a QRCX controller 17 80 D ABS encoder backup erro...

Page 4: ...ous in some cases If the origin position must be changed please consult our sales office or dealer 2 When using a rotary movement robot Applicable robots R5 R10 R20 X series single axis robots RF R axis of X series Cartesian robots SXYx MXYx RL RH R axis of X series Cartesian robots HXYx RM RS R axis of X series Cartesian robots ZRM ZRS On the above robots the customer should set the origin at the...

Page 5: ...truction 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 Specifications of robot models other than standard models may be omitted in this manual if they are common to those of standard models In this cas...

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Page 7: ...d Connections 2 1 2 1 Checking the product 2 3 2 2 Moving the robot 2 3 2 3 Robot Installation Conditions 2 5 2 3 1 Installation environments 2 5 2 3 2 Installation base 2 6 2 4 Installing the robot 2 7 2 4 1 T6 2 7 2 4 2 T7 2 9 2 4 3 T9 T9H 2 11 2 4 4 F10 2 14 2 4 5 F14 F14H 2 17 2 4 6 F17 F20 2 21 2 4 7 R5 R10 R20 2 23 2 4 8 B10 B14 B14H 2 26 2 4 9 F20N 2 27 2 5 Protective bonding 2 29 2 6 Conne...

Page 8: ...g belt tension F20N 3 12 Chapter 4 Periodic Inspection 4 1 Before beginning work 4 3 4 2 Periodic inspection 4 5 4 2 1 Daily inspection 4 5 4 2 2 Three month inspection 4 5 4 2 3 Six month inspection 4 6 4 2 4 Three year inspection 4 6 4 3 Applying grease 4 7 4 3 1 Applying grease T6 T7 type 4 7 4 3 2 Applying grease T9 F types 4 8 4 3 3 Applying grease B type 4 8 4 4 Adjusting and replacing a loo...

Page 9: ...1 10 F20N 5 12 5 1 11 R5 5 13 5 1 12 R10 5 14 5 1 13 R20 5 15 5 1 14 B10 5 16 5 1 15 B14 5 17 5 1 16 B14H 5 18 5 2 AC servo motor termination T F Type 5 19 5 3 AC servo motor termination R B Type F20N 5 20 5 4 Robot cables 5 21 Chapter 6 Troubleshooting 6 1 Positioning error 6 3 6 2 Feedback error 6 4 Appendix About machine reference iii Equation of moment of inertia calculation iv ...

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Page 11: ...ining for Industrial Robot Operation 1 9 1 4 Robot Safety Functions 1 10 1 5 Safety Measures for the System 1 11 1 6 Trial Operation 1 11 1 7 Work Within the Safeguard Enclosure 1 12 1 8 Automatic Operation 1 12 1 9 Adjustment and Inspection 1 12 1 10 Repair and Modification 1 12 1 11 Warranty 1 13 ...

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Page 13: ...ng the robot CAUTION Failure to follow CAUTION instructions may result in injury to the robot operator bystanders or persons inspecting or repairing the robot or damage to the robot and or robot controller NOTE Explains the key point in the operation in a simple and clear manner Refer to the instruction manual by any of the following methods to operate or adjust the robot safely and correctly 1 Op...

Page 14: ...uards so that no one can enter inside except from doors or panels equipped with safety interlocks The warning labels 1 Fig 1 1 are supplied with the robot and should be affixed to conspicuous spots on doors or panels equipped with safety interlocks DANGER Serious injury or death will result from impact with moving robot Keep outside of guard during operation Lock out power before approaching robot...

Page 15: ...obot WARNING Improper installation or operation can result in serious injury or death Read the user s manual and all warning labels before operation Improper Installation or operation can result in serious injury or death Read user s owner s manual and all warning labels before operation WARNING Fig 1 3 Warning label 3 4 Do not use the robot in environments containing inflammable gas etc WARNING T...

Page 16: ...e end effector may fly off or drop then provide appropriate safety protection taking into account the object size weight temperature and chemical properties 8 Use caution when removing the motor Vertical use robots WARNING The vertical axis will slide down when the motor is released causing a hazardous situation Turn off the robot controller and prop up the vertical axis with a support stand befor...

Page 17: ...ooling fan while it is rotating When removing the fan cover for inspection first turn off the controller and make sure the fan has stopped 12 Be careful not to touch the motor or speed reduction gear casing when hot WARNING The motor and speed reduction gear casing are extremely hot after automatic opera tion so burns may occur if these are touched Before handling these parts during inspection or ...

Page 18: ... acceleration coefficients according to the manipulator tip mass and moment of inertia If these are not correct drive unit service life may end prematurely and damage to robot parts or residual vibration during positioning may result 16 Do not use the robot for tasks requiring motor thrust CAUTION Avoid using the belt driven type robots for tasks which utilize motor thrust press fitting burr remov...

Page 19: ...ction adjustment and repair has received appropriate training and also has the skills needed to perform the job correctly and safely Since the FLIP X series robots fall under the industrial robot category the user must ob serve local regulations and safety standards for industrial robots and provide special training for every person involved in robot related tasks teaching programming movement che...

Page 20: ...ent range No mechanical stopper is provided on the rotating 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 Vertical axis brake An electromagnetic brake is installed on the vertical use robot to prevent the vertical axis from sliding down wh...

Page 21: ...hain 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 cor...

Page 22: ...d 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 ...

Page 23: ...ta 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 byYAMAHA orYAMAHA sales rep...

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Page 25: ...4 2 4 5 F14 F14H 2 17 2 4 6 F17 F20 2 21 2 4 7 R5 R10 R20 2 23 2 4 8 B10 B14 B14H 2 26 2 4 9 F20N 2 27 2 5 Protective bonding 2 29 2 6 Connections 2 30 2 6 1 Connecting the robot cables 2 30 2 6 2 Changing the cable routing direction F Type 2 32 2 6 3 Changing the cable routing direction B Type 2 33 2 6 4 Changing the motor orientation B type 2 35 2 6 5 User wiring 2 38 2 7 Setting the operating c...

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Page 27: ...B10 B14 or B14H Single axis robot SRCX Robot cable I O connector Battery Battery attachment Warning label Danger label Belt tension adjusting bolt Cover seal long stroke model only DPB POPCOM Memory card 1 1 1 1 1 1 set 1 1 1 3 1 1 1 Product name Qty Affix to a conspicuous spot in the system Affix to a conspicuous spot in the system See page 3 5 See page 4 18 Option Option Option 2 2 Moving the ro...

Page 28: ... hook Remove all loads attached to the robot manipulator end If any load is still attached the robot balance might shift while being carried and the robot topple over causing accidents Always wear a safety helmet shoes and gloves during work When moving the robot by equipment such as a forklift that requires a license only properly qualified personnel may operate such equipment The equipment and t...

Page 29: ...ching inspection repair etc For detailed information on how to install the robot controller refer to the separate YAMAHA Robot Controller User s Manual WARNING Avoid installing the robot in locations where the ambient conditions may exceed the allowable temperature or humidity or in environments where excessive moisture corrosive gases metallic powder or dust are generated Malfunctions failures or...

Page 30: ...m 500mm CAUTION The robot positioning accuracy might decrease if the installation surface precision is insufficient 3 Use an installation base of sufficient size to match the robot body so that the robot can be installed with the specified number of bolts Avoid installing the robot with less than the specified number of bolts or installing the robot closer to one end as shown at the lower right CA...

Page 31: ...ci dents might occur if the robot starts to operate during installation Installation method 1 Tap M4 holes into the installation base where the robot is to be secured For hole pitch see the external view and dimensions in 5 1 Robot Specifications of Chapter 5 2 Remove the screws securing the side covers of the robot and remove the side covers on both sides If necessary move the slider to a locatio...

Page 32: ...e Hex socket head M4 bolt strength 8 8T length longer than 20mm 30kg cm to 45kg cm CAUTION Be careful not to damage the shutter when tightening the bolts WARNING Be sure to tighten the bolt to the correct torque The wrong torque may not only cause robot position errors but also lead to serious accidents 4 Reattach the side covers after installing the robot M4 hex wrench Shutter ...

Page 33: ...ation base where the robot is to be secured For hole pitch see the external view and dimensions in 5 1 Robot Specifications of Chapter 5 2 Remove the screws securing the side cover of the robot and remove the side cover on one side If necessary move the slider to a location where it does not block the installation holes on the bottom of the robot frame 3 Secure the robot to the base with the speci...

Page 34: ...the robot unit to make ground connection The ground terminal location is shown below Ground terminal Robot cable CAUTION A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the power to the controller before making the ground connection Provide a terminal marked PE as the protective...

Page 35: ...ight occur if the robot starts to operate during installation Installation method A Drill holes through the installation base where the robot is to be secured Then secure the robot with the specified bolts from the bottom The bolts and tightening torque are shown below Bolt Tightening torque Hex socket head M8 bolt strength 8 8T length installation base thickness 12mm maximum 230kg cm to 370kg cm ...

Page 36: ...oes not block the installation holes on the bottom of the robot frame or else remove the upper cover 3 Secure the robot to the base with the specified bolts and torque The bolts and tightening torque are shown below Bolt Tightening torque Hex socket head M6 bolt strength 8 8T length longer than 25mm 100kg cm to 130kg cm WARNING Be sure to tighten the bolt to the correct torque The wrong torque may...

Page 37: ...obot cable CAUTION A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the power to the controller before making the ground connection Provide a terminal marked PE as the protective conductor for the entire system and connect it to an external protective conductor Also securely conn...

Page 38: ...nstallation Installation method A Drill holes through the installation base where the robot is to be secured Then secure the robot with the specified bolts from the bottom The bolts and tightening torque are shown below Bolt Tightening torque Hex socket head M5 bolt strength 8 8T length installation base thickness 9mm maximum 60kg cm to 90kg cm M5 bolt WARNING Be sure to tighten the bolt to the co...

Page 39: ...to a location where it does not block the installation holes on the bottom of the robot frame 3 Secure the robot to the base with the specified bolts and torque The bolts and tightening torque are shown below Bolt Tightening torque Hex socket head M5 bolt strength 8 8T length longer than 20mm 60kg cm to 90kg cm WARNING Be sure to tighten the bolt to the correct torque The wrong torque may not only...

Page 40: ...the ground terminal as shown Ground terminal Motor upper cover Motor lower cover End plate CAUTION A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the power to the controller before making the ground connection Provide a terminal marked PE as the protective conductor for the ent...

Page 41: ...controller before installing the robot Serious acci dents might occur if the robot starts to operate during installation Installation method A Drill holes through the installation base where the robot is to be secured Then secure the robot with the specified bolts from the bottom The bolts and tightening torque are shown below Bolt Tightening torque Hex socket head M6 bolt strength 8 8T length ins...

Page 42: ...alfunctions CAUTION The robot frame is made of aluminum so be careful not to damage the screw threads when tightening the bolt Installation method B 1 Tap M6 holes into the installation base where the robot is to be secured For hole pitch see the external view and dimensions in 5 1 Robot Specifications of Chapter 5 2 Remove the screws securing the upper cover of the robot and remove the upper cove...

Page 43: ...e are shown below Bolt Tightening torque Hex socket head M6 bolt strength 8 8T length longer than 20mm 100kg cm to 130kg cm WARNING Be sure to tighten the bolt to the correct torque The wrong torque may not only cause robot position errors but also lead to serious accidents 4 Reattach the upper cover after installing the robot M6 hex wrench ...

Page 44: ...plate Motor cable CAUTION A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the power to the controller before making the ground connection Provide a terminal marked PE as the protective conductor for the entire system and connect it to an external protective conductor Also secure...

Page 45: ...ation base where the robot is to be secured For hole pitch see the external view and dimensions in 5 1 Robot Specifications of Chapter 5 2 Remove the screws securing the upper cover of the robot and remove the upper cover If necessary move the slider to a location where it does not block the installation holes on the bottom of the robot frame 3 Secure the robot to the base with the specified bolts...

Page 46: ...e robot unit to make ground connection The ground terminal location is shown below Ground terminal End plate Motor cable CAUTION A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the power to the controller before making the ground connection Provide a terminal marked PE as the pr...

Page 47: ...turn off the power to the controller before installing the robot Serious acci dents might occur if the robot starts to operate during installation Installation method Tap holes into the installation base where the robot is to be secured For hole diameter and pitch see the external view and dimensions in 5 1 Robot Specifications of Chapter 5 M6 bolt Installation base M6 bolt Installation base ...

Page 48: ...cm to 130kg cm Protective bonding WARNING Always ground the robot and controller unit to prevent electrical shock Always use the ground terminal M4 screw inside the robot unit to make ground connection The ground terminal location is shown below Ground terminal M4 screw WARNING A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 ...

Page 49: ...ned on However data containing the origin position may be lost if the absolute battery is removed from the controller or the battery dies When this happens origin return or origin reset must be performed after the battery is reconnected The R5 R10 and R20 robots utilize the mark method refer to controller manual that does not use sensors Use a triangular seal enclosed in the package to affix it at...

Page 50: ...ength 8 8T 60kg cm to 90kg cm Length installation base thickness 10mm maximum B14 B14H Hex socket head M6 bolt Strength 8 8T 100kg cm to 130kg cm Length installation base thickness 10mm maximum WARNING Be sure to tighten the bolt to the correct torque The wrong torque may not only cause robot position errors but also lead to serious accidents Do not use a bolt longer than the specified length A bo...

Page 51: ... the installation base where the robot is to be secured For hole pitch see the external view and dimensions in 5 1 Robot Specifications of Chapter 5 2 Remove the screws securing the upper cover of the robot and remove the upper cover If necessary move the slider to a location where it does not block the installation holes on the bottom of the robot frame 3 Secure the robot to the base with the spe...

Page 52: ... M4 screw is provided inside the cable box so always ground the unit The position of the grounding terminal is shown below Cable box Cable carrier Robot cable Ground terminal CAUTION A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the power to the controller before making the gr...

Page 53: ...A secure ground connection less than 100 ohm resistance to ground is recom mended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the controller before making the ground connection Provide a terminal marked PE as the protective conductor for the entire system and connect it to an external protective conductor Also securely connect the ground terminal on the r...

Page 54: ...SRCX robot controller user s manual for the controller connectors WARNING Before connecting the cables check that there are no bends or breaks in the robot cable connector pins and that the cables are not damaged Bent or broken pins or cable damage may cause robot malfunctions CAUTION After connecting the relay connectors on the robot cables fit the connector hoods together securely ...

Page 55: ...ler SRCX RS 232C communication control RS 232C or communication control communication cable Encoder signal Motor power Power supply AC100 115 200 230V 10 Single axis robot Input 16 general purpose pins 7 custom purpose pins Output 13 general purpose pins 3 custom purpose pins I O control 24V power supply built in Programming box TPB option IC memory card 8K 64K option PC External control PLC POPCO...

Page 56: ...motor covers and endplate 2 Remove the robot cable from the endplate 3 Change the cable extraction routing direction Top extraction Clip the endplate cable installation slot with wire nippers or similar tool fit a robot cable grommet into that slot and route the cable out through that slot Side extraction Fit a robot cable grommet into the side routing bracket and route the cable out through that ...

Page 57: ...d so available space can be efficiently used Methods for changing the cable routing extraction direction are shown below When rotating 180 degrees 1 Remove the four screws securing the motor cover 2 Remove the motor cover and rotate it 180 degrees 3 Reattach the motor cover and tighten the four screws to secure the motor cover and cables Motor cover Motor cover Rotate 180 Rotate 180 degrees degree...

Page 58: ...emove the cables from the motor cover and trim the unused cable extraction slots with wire nippers or similar tool 3 Fit the robot cable grommets into the new cable extraction slots and route the cables out through those slots 4 Reattach the motor cover and tighten the four screws to secure the motor cover and cables Motor cover Motor cover Grommet ...

Page 59: ...to operate during work Motor orientation in B type robots B10 B14 B14H series can be changed to use space more efficiently If the motor case is hanging up on an object and hampers installation of the robot use the following method to change the motor orientation 1 Remove the screws securing the belt cover and remove the belt cover 2 Remove the motor plate bolts 4 pieces Motor plate Motor plate bol...

Page 60: ...leys change the motor orientation as desired and lightly tighten the motor plate bolts 4 pieces Now shift the motor case towards the large pulley as shown by the arrow 4 First fit the belt onto the small motor pulley and then onto the large pulley Motor plate Motor plate bolt ...

Page 61: ...See 3 2 2 Adjusting the speed reduction belt tension in Chapter 3 7 Reattach the belt cover CAUTION Check that the belt teeth correctly mesh with the large pulley teeth A poor intermesh may cause positioning errors or shorten the belt service life CAUTION Since a positional shift occurs after adjusting the belt tension absolute reset and the point data Motor case Motor plate bolt ...

Page 62: ...e cables and tubes inside the cable carrier will move during robot operation applying tension to both ends Gently secure the cables to allow for some slack so a large amount of force is not applied to cable connector during robot movement Breaks or electrical discontinuity may occur if the cables are fastened too tightly with snap bands or fastening ties so allow for some slack and gently secure t...

Page 63: ...ollowing method to set the payload parameter on a single axis robot controller SCRX When setting this parameter on other controllers DRCX QRCX RCX40 refer to their control ler instruction manuals 1 Connect the programming box DPB to the single axis robot controller SCRX 2 Press F 3 on the initial screen display 3 Next press F 1 PRM 4 The current setting for the No 0 parameter robot type No appears...

Page 64: ... setting versus the robot stroke length see Chapter 4 Specifications If the maximum speed does not reach a hazardous level reducing the speed is unnecessary even when a robot has a long stroke axis CAUTION Do not operate the robot if the ball screw is vibrating The ball screw may otherwise wear out prematurely 2 7 3 Duty To achieve maximum service life for the YAMAHA single axis robots the robot m...

Page 65: ...tension 3 5 Reference Adjusting drive belt tension with a tension meter 3 6 3 2 2 Adjusting the speed reduction belt tension 3 7 Reference Adjusting speed reduction belt tension with a tension meter 3 8 3 3 Installing and removing the cover F20N 3 9 3 3 1 Stroke cover 3 9 3 3 2 Belt cover 3 10 3 3 3 Motor cover 3 11 3 4 Adjusting the timing belt tension F20N 3 12 ...

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Page 67: ...dge of the upper cover 1 Turn off the controller 2 Insert the slider into the U groove provided along the center of the upper cover while holding the upper cover in parallel with the robot movement axis 3 Lightly tighten the four screws to temporarily secure the upper cover move the slider table from the motor side all the way to the non motor side and fully tighten the screws on the non motor sid...

Page 68: ...r wait for a while and check that the parts have cooled WARNING Injury can occur if hands or fingers are squeezed between the drive pulley and belt Always turn off the controller and use caution when handling these parts CAUTION Since a positional shift occurs after adjusting the belt tension absolute reset and the point data Push pull scale Slack Load Pulley Pulley Belt L 2 L 2 Push pull scale Sl...

Page 69: ...upper cover by sliding it along the direction the robot moves 4 Attach the belt tension adjusting bolt supplied as shown and loosen the eight bolts 4 bolts on each side securing the belt stays Then turn the belt tension adjusting bolt to apply tension 5 Move the slider by hand to a position at which the distance from the slider edge to the base block edge is 150mm Apply a load to the belt at a pos...

Page 70: ...tach the upper cover and then the end cover See 3 1 Attaching the upper cover in Chapter 3 Reference Adjusting drive belt tension with a tension meter We recommend using a tension meter to adjust the belt tension more accurately Recommended tension meter U 505 Made by UNITTA Measurement method To make the drive belt tension adjustment of step 5 pull the belt to a position where a load is to be app...

Page 71: ...d measure the slack or tension When the slack is within the allowable range no adjustment is required If not within allowable range adjust the tension or slack with the procedure below Table 2 2 Load and slack for speed reduction belt tension Robot model Load N Load kgf Slack mm B10 B14 B14H 5 9 to 6 9 5 9 to 6 9 0 6 to 0 7 0 6 to 0 7 3 3 4 If the belt tension must be adjusted loosen the motor pla...

Page 72: ...belt cover Reference Adjusting speed reduction belt tension with a tension meter We recommend using a tension meter to adjust the belt tension more accurately Recommended tension meter U 505 Made by UNITTA Measurement method To make the drive belt tension adjustment of step 3 pull the belt to a position where a load is to be applied and adjust the belt tension by measuring the frequency with the t...

Page 73: ...lling the stroke cover 1 Place the table slide near the stroke end and pass the cover between the table slide and motor block 2 Fix the cover to the end block At this time move the table slide to the stroke center and confirm that it does not interfere with the cover If the table slide interferes with the cover adjust by tightening the fixing screw Refer to following photographs When cover contact...

Page 74: ...ch After removing the M4 screws on the top pull the cover upward and off Refer to the following photograph M4 screw two screws M4 hexagon bolt two bolts Installing the belt cover 1 Fit the cover so that the notch on the cover passes between the hexagon bolts Tighten the hexagon bolts with a spanner or socket wrench and then fix from above with the M4 screws ...

Page 75: ... pair of nippers and remove 2 Remove the two M6 hexagon bolts and pull the motor cover upward and off Refer to the following photograph Installing the motor cover 1 Insert the motor cover into the installation hole and fix with two M6 hexagon bolts 2 Using the o5 hole open on the motor cover fix the motor cable with an Insulock tie ...

Page 76: ... the middle of the belt span with a hex wrench or similar tool 5 Adjust the belt tension by measuring the frequency with the tension meter while referring to the table below Frequency Hz Span length mm Belt unit weight kg m Tension N Tension kg 207 to 219 88 to 98 9 to 10 0 051 100 Recommended tension meter U505 made by UNITTA 6 When the appropriate tension has been set tighten the motor installat...

Page 77: ...9 F types 4 8 4 3 3 Applying grease B type 4 8 4 4 Adjusting and replacing a loose shutter 4 9 4 4 1 Replacing the shutter T6 4 9 4 4 2 Adjusting shutter looseness T6 4 10 4 5 Replacing the motor 4 11 4 5 1 Replacing the motor B10 B14 B14H 4 11 4 5 2 Replacing the motor F20N 4 13 4 6 Replacing the drive belt B10 B14 B14H 4 15 4 7 Replacing the speed reduction belt B10 B14 B14H 4 18 4 8 Replacing t...

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Page 79: ...be operated during adjustment or maintenance always turn off the controller and the external switch board Do not touch internal parts of the controller for 5 seconds after the controller has been turned off Use only lubricant and greases specified by YAMAHA sales office or dealer Use only parts specified by YAMAHA sales office or dealer Take sufficient care not to allow any foreign matter to conta...

Page 80: ...s to prevent contact with skin Do not take orally or eat Eating will cause diarrhea and vomiting Hands and fingers might be cut when opening the container so use protective gloves Keep out of the reach of children Do not heat the grease or place near an open flame since this could lead to sparks and fires Emergency Treatment If grease gets in the eyes wash liberally with pure water for about 15 mi...

Page 81: ...following points every 3 months and apply grease if needed Checkpoints Check items Notes Check for dirt or grime If dirt or grime is found clean the part Apply grease after cleaning Apply grease if the items checked are dry or do not have enough grease Recommended grease is as follows Standard model Use Alvania No Showa Shell Daphne Eponex No 2 Idemitsu Clean room model Use LG 2 NSK Ball screw lin...

Page 82: ...g the timing belt tension in chapter 3 On robot models using a long stroke check the slider inside the upper cover for abnormal wear or damage See 3 1 Attaching the upper cover in Chapter 3 If problem is not solved or wear and backlash are found please contact us See 4 3 in this chapter Main bolts and screws on robot Ball screw and linear guide Controller Lubrication of ball screw nut and linear g...

Page 83: ... periodic maintenance 1 Check that the controller power switch is turned off 2 Remove the screw securing the robot side covers and remove the side covers 3 Coat the ball screw and linear guides with grease by hand and move the slider back and forth to spread the grease Applying grease to the ball screw Applying grease to the linear guide 4 Reattach the side covers Ball screw Linear guide ...

Page 84: ...ew and linear guides with grease by hand and move the slider back and forth to spread the grease Method B Fit the grease nipple into the M6 tap hole on the flange of the ball screw nut Supply grease to the grease nipple and move the slider back and forth to spread the grease Slider M6 tap hole for grease nipple Flange of ball screw nut CAUTION Be sure to always remove the grease nipple after apply...

Page 85: ... 1 Check that the controller power switch is turned off 2 Remove the 4 screws securing the slider cover and take off the slider cover 3 Remove the screws securing the shutter Remove the 2 screws on the endplate side and the 2 screws on the motor side 4 Remove the shutter from the shutter guide and pass the new shutter through it M3 hex wrench Endplate Shutter guide Shutter ...

Page 86: ...ter with your fingers so that there is no looseness in the shutter CAUTION Do not press down on the shutter with excessive force Pressing down hard on the shutter may cause the shutter to warp 4 4 2 Adjusting shutter looseness T6 The shutter may elongate with continued use In such cases adjust as follows 1 Slightly loosen the two screws securing the endplate side of the shutter Do not remove 2 Whi...

Page 87: ...in must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later 1 Turn off the controller 2 Remove the belt cover 3 Remove the motor case and motor cover Motor case Motor cover 4 Remove the four bolts installing the motor to the motor plate and remove the motor ...

Page 88: ...ws make perpendicular contact with the flat faces of the motor shaft To make sure this is correct tighten each set screw so their tips slightly protrude inwards about 0 1 to 0 2mm and then insert the pulley onto the motor shaft 7 Install the motor to the motor plate 8 Fit the belt onto the pulleys 9 Adjust the belt tension See 3 2 Adjusting the timing belt tension in Chapter 3 10 Reattach the moto...

Page 89: ... so you can correctly reassemble the parts later 1 Turn the controller power OFF 2 Remove the belt cover and motor cover Refer to Chapter 3 3 3 3 Installing and removing the cover 3 Open the cover of the box fixed onto the table slide and disconnect the motor wiring connec tor 4 Remove the motor installation bolts M6 4 bolts Wiring box Motor cable Motor cover Motor installation bolt 5 Pull the bel...

Page 90: ...Motor Pulley Boss 8 Replace the motor and install the pulley onto the motor Refer to the drawing above Take care to the orientation and order of the rings at this time 9 Install the motor onto the block Temporarily tighten the fixing bolts 10 Install the belt Refer to Chapter 3 3 3 4 Adjusting the timing belt F20N and adjust the belt tension 11 Install the motor cover and belt cover 12 Connect the...

Page 91: ...then remove the upper cover On robot models having a long stroke remove the upper cover by sliding it along the axis of robot movement This is required because the slider is fitted in the travel guide U groove inside the upper cover 2 Remove the motor See the procedure in 4 5 Replacing the motor in Chapter 4 It is unnec essary to remove the motor if installed horizontally or downwards 3 Remove the...

Page 92: ... along the robot axis as instructed below 7 First route the belt edge onto the idle pulley and use a narrow rod or similar tool to push out the belt edge as shown 8 Pass the belt through from the lower side of the slider table and route the belt edge under the drive pulley Then use a narrow rod or similar tool to make the belt edge face upwards ...

Page 93: ...e belt stays to both ends of the belt 11 Install the belt stays onto the slider table and lightly tighten the bolts to temporarily secure the stays 12 Adjust the belt tension See the procedure explained in 3 2 Adjusting the timing belt ten sion in Chapter 3 13 Reattach the upper cover See the procedure explained in 3 1 Attaching the upper cover in Chapter 3 14 Reattach the end cover ...

Page 94: ...shift occurs after replacing the belt return to origin must be performed again and the point data re specified When removing the parts check and mark the part positions versus each other so you can correctly reassemble the parts later 1 Remove the belt cover 2 Remove the motor plate bolts 4 pieces Motor plate bolt ...

Page 95: ...pulley and detach the belt from the pulleys 4 First fit the new belt onto the motor pulley small pulley and then onto the large pulley 5 Adjust the belt tension See the procedure explained in 3 2 2 Adjusting the speed reduction belt tension in Chapter 3 6 Reattach the belt cover ...

Page 96: ...er cover See the procedure explained in 3 1 Attaching the upper cover in Chapter 3 6 Move the slider table back and forth along the axis a few times 7 Remove the cover seal 12mm diameter affixed to the upper cover on the non motor side A hole appears under the cover seal Move the slider to the point where you can see the slider mounting bolt through this hole Cover seal Bolt tightening hole 8 Tigh...

Page 97: ...0N 1 Turn the controller power OFF 2 Remove the top center cover 3 Remove the two slider installation bolts Slider Installation bolt 4 Replace the slider and fix with the installation bolt 5 Install the top center cover Refer to Chapter 3 3 3 3 Installing the cover ...

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Page 99: ... 6 5 1 5 F10 5 7 5 1 6 F14 5 8 5 1 7 F14H 5 9 5 1 8 F17 5 10 5 1 9 F20 5 11 5 1 10 F20N 5 12 5 1 11 R5 5 13 5 1 12 R10 5 14 5 1 13 R20 5 15 5 1 14 B10 5 16 5 1 15 B14 5 17 5 1 16 B14H 5 18 5 2 AC servo motor termination T F Type 5 19 5 3 AC servo motor termination R B Type F20N 5 20 5 4 Robot cables 5 21 ...

Page 100: ...5 2 MEMO ...

Page 101: ... 280 95 55 550 135 0 90 200 50 20 145 25 0 Unit mm Unit mm 2 Note 1 This is the position at which the slider is stopped by mechanical stoppers at both ends Effective stroke L A M N Weight kg 50 297 5 95 0 6 2 5 100 347 5 145 1 8 2 7 150 397 5 195 2 10 3 1 200 447 5 245 3 12 3 3 250 497 5 295 4 14 3 5 300 547 5 345 5 16 3 7 350 597 5 395 0 6 4 0 400 647 5 445 1 8 4 2 450 697 5 495 2 10 4 5 500 747 ...

Page 102: ...ion at which the slider is stopped by mechanical stoppers at both ends Note 2 When installing the unit washers etc cannot be used in the counter bore hole Note 3 This is the weight of models without a break The models equipped with a brake are 0 5kg heavier than these values Effective stroke L A N Weight kg 150 425 27 5 5 3 2 250 525 67 5 6 3 7 350 625 47 5 8 4 1 450 725 27 5 10 4 5 550 825 67 5 1...

Page 103: ...45 324 82 0 199 53 0 237 58 0 0 581 184 0 391 202 0 1176 420 0 90 320 69 0 161 38 0 172 41 0 Unit mm Unit mm Note 1 This is the position at which the slider is stopped by mechanical stoppers at both ends Note 2 When installing the unit washers etc cannot be used in the counter bore hole Note 3 This is the weight of models without a break The models equipped with a brake are 0 5kg heavier than thes...

Page 104: ...tailed chart Note 2 φ11 13 22 N M8 1 25 43 23 87 7 94 20 17 5 13 98 Grounding terminal 2 5 179 60 N 1 A 60 Z Note2 209 with brakes 60 90 2 φ6H7 Depth8 4 M6 1 0 Depth18 129 Note1 179 2 Effective stroke 94 44 Note1 82 Between knocks 0 02 Approx 250 Motor cable length 209 2 with brakes 159 with brakes 10 50 4 M5 0 8 Depth4 The same position on the opposite surface at two 2 locations 95 5 20 L Effecti...

Page 105: ...n detailed chart Note 2 5 N φ5 5 26 71 102 VIEW Y 68 110 109 100 Between knocks 0 02 70 86 165 2 Effective stroke 95 117 Note1 45 Note1 2 φ5H7 Depth15 4 M5 0 8 Depth12 97 Approx 250 Motor cable length 195 2 with brakes 147 with brakes 127 with brakes 80 200 195 with brakes M 200 A 45 175 200 M 200 A 35 Z Note2 N M5 0 8 Depth10 165 205 2 with brakes 10 18 4 M5 0 8 Depth9 The same position on the op...

Page 106: ...00 2 with brakes 150 with brakes Note1 L Effective stroke 255 20 50 19 4 M5 0 8 Depth7 The same position on the opposite surface at two 2 locations 23 5 77 5 75 30 with brakes 4 Distance from center of slider top to center of gravity of object being transported 83 90 45 0 L Horizontal Vertical Horizontal Vertical 100 0 01 Ball screw Class C7 10 600 55 10 156 150 1050 50 pitch 3 5 Standard 5 10 SRC...

Page 107: ... 157 138 132 N φ7 Depth9 143 with brakes 168 with brakes 210 2 Effective stroke 110 110 Between knocks 0 02 140 124 70 2 φ6H7 Depth8 8 M6 1 0 Depth8 135 Note1 35 Note1 Approx 250 Motor cable length 240 2 with brakes 165 with brakes Note1 L Effective stroke 320 45 50 19 4 M5 0 8 Depth7 The same position on the opposite surface at two 2 locations 23 5 77 5 75 30 with brakes 40 5 20 62 11 5 17 14 17 ...

Page 108: ...97 5 L Effective stroke 365 30 with brakes 120 142 155 240 2 157 5 Note1 Effective stroke 125 42 5 Note1 154 Between knocks 0 02 2 φ6H7 Depth10 Approx 250 Motor cable length 270 2 with brakes 187 5 with brakes Note1 8 M8 1 25 Depth25 76 5 30 24 13 22 56 5 17 3 Distance from center of slider top to center of gravity of object being transported Stroke mm 850 950 1050 1150 1250 Maximum speed mm sec 1...

Page 109: ...with brakes 30 13 27 39 17 90 20 4 Distance from center of slider top to center of gravity of object being transported 90 45 0 L Horizontal Vertical Horizontal Vertical 600 0 01 Ball screw Class C7 250 1250 100 pitch 3 5 Standard 5 10 SRCX 20 SRCX 20 R 20 1200 120 25 468 10 600 45 936 Stroke mm 850 950 1050 1150 1250 Maximum speed mm sec 1020 510 225 840 420 210 720 360 180 600 300 150 480 240 SPE...

Page 110: ...9 6 1950 2370 100 970 11 26 71 8 2050 2470 200 1016 11 26 74 90 45 0 L AC servo motor output W Repeatability mm 1 Deceleration mechanism Ball screw lead mm Maximum speed mm sec Maximum payload kg Continuous rated thrust N Stroke mm Cable length m Controller 400 0 04 Ball screw Class C10 SRCX 20 20 1000 1200 2 80 312 1150 to 2050 100 pitch 3 Standard 5 10 1 Repeatability for single oscillation 2 A ...

Page 111: ... J must be smaller than the values shown in the table above For example enter 4kg if W is 3kg and J is 0 48kgf cm sec2 Enter the above mass parameter value for the controller and optimum accelera tion is automatically set based on this value AC servo motor output W Maximum speed deg sec Repeatability sec Maximum Allowable Moment Inertia Rated torque kg m Speed reduction ratio Rotation range deg Ca...

Page 112: ...ter value for the controller and optimum accelera tion is automatically set based on this value AC servo motor output W Maximum speed deg sec Repeatability sec Maximum Allowable Moment Inertia Rated torque kg m Speed reduction ratio Rotation range deg Cable length m Controller 100 360 30 3 71kgf cm sec2 0 36kgm2 1 10 1 50 360 3 5 Standard 5 10 SRCX 05 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0 25 0 49 ...

Page 113: ...15 16 17 18 19 20 0 93 1 8 2 8 3 7 4 6 5 6 6 5 7 4 8 4 9 3 10 2 11 2 12 1 13 1 14 0 14 9 15 9 16 8 17 7 18 7 payload parametersW kg AllowableMomentInertiaJ kgf cm sec2 payload parametersW kg AllowableMomentInertiaJ kgf cm sec2 Mechanical unit specifications Allowable Moment Inertia Note J W Approx 150 Cable length Note1 Note2 Remove the cover when using counterbored holes The cable extraction slot...

Page 114: ...22 1750 2060 200 1320 420 3 8 22 1850 2160 100 1320 600 3 9 24 1950 2260 200 1320 780 3 9 24 2050 2360 100 1320 780 3 10 26 2150 2460 200 1320 960 3 10 26 2250 2560 100 1320 960 3 11 28 2350 2660 200 1320 1140 3 11 28 2450 2760 100 1320 1140 3 12 30 2550 2860 200 1320 1320 3 12 30 Note 1 Stop positions set by mechanical stoppers at both ends Note 2 Motor can be installed in upward downward or hori...

Page 115: ...ot movement axis Note 3 Motor can be installed on the right or left side of the robot movement axis Note 4 Cables can be extracted in upward downward forward or rearward directions Motor installation for LU models Motor installation for RU models Motor installation for R models Motor installation for RD models 60 178 167 11 178 167 1 1 20 90 5 50 Effective stroke A 12 5 M M6 1 0 Depth10 200 100 85...

Page 116: ...te 3 Motor can be installed on the right or left side of the robot movement axis Note 4 Cables can be extracted in upward downward forward or rearward directions 167 178 11 92 195 103 178 167 11 103 195 92 8 3 5 5 1 5 1 5 3 5 235 3 70 5 Note1 153 152 5 Note1 124 70 140 45 90 5 50 12 5 L 1 5 78 108 A 200 100 85 B 200 C E D 85 100 free 90 11 78 240 Note1 322 5 3 167 94 22 5 136 34 5 146 134 G 167 5 ...

Page 117: ...t Plug housing Receptacle Receptacle housing Plug housing Socket contact Round terminal 1 2 3 4 5 6 7 8 9 CN1 7 polarities CN1 CN2 CN3 4 polarities CN3 CN2 2 polarities CN4 2 polarities CN4 Connector wiring Connector Pin No Signal Wire Color Connection 1 2 3 4 5 6 7 1 2 1 2 3 4 CN1 CN2 CN3 S2 S4 S1 S3 R1 R2 Shield BK BK U V W PE Yellow Blue Red Black White Green Black Gray Brown Red White Black Ye...

Page 118: ...housing Pin contact Plug housing Receptacle Receptacle housing 1 2 3 4 5 6 CN1 7 polarities CN1 CN2 CN3 4 polarities CN3 CN2 2 polarities Connector wiring Connector Pin No Signal Wire Color Connection 1 2 3 4 5 6 7 1 2 1 2 3 4 CN1 CN2 CN3 S2 S4 S1 S3 R1 R2 Shield BK BK U V W PE Yellow Blue Red Black White Green Black Yellow Yellow Red White Black Yellow green Motor Motor with brake Motor Heat shri...

Page 119: ...S3 R1 R2 D G BK BK 1 2 3 4 5 6 9 17 18 1 2 3 4 5 6 7 1 2 Resolver Brake 0 3sq Blue Orange Green Brown Grey Red Black yellow Drain wire To controller To robot Power line Parts Signal PIN Connection PIN Parts Wire FG U V W 1 2 4 3 4 1 2 3 0 75sq 0 75sq 0 75sq 0 75sq Yellow Green Red White Black Motor wire To controller To robot ...

Page 120: ...5 22 MEMO ...

Page 121: ...Chapter 6 Troubleshooting 6 1 Positioning error 6 3 6 2 Feedback error 6 4 ...

Page 122: ...6 2 MEMO ...

Page 123: ...Check tool and workpiece for warping 2 Check robot alignment 3 Check robot coupling for slipping and belt for teeth skipping Are cables correctly wired Are connectors correctly fitted Are the robot tools and workpiece correctly installed Yes Yes No Check installation method Check wiring and connectors Check for looseness of robot mechanical parts No Check or replace the motor cable and controller ...

Page 124: ... error is occurring perform continuity check 1 Check motor power supply lines U V and W 2 Check encoder signal lines for phases A and B 1 Check position shift by repetitive accuracy measurement 2 If replacement motor is available check by exchanging the motors Replace motor Is external noise large Take noise reduction measures Yes Yes No No No No No No No Yes Yes Yes Yes Yes Yes No Yes Feedback er...

Page 125: ...Appendix About machine reference iii Equation of moment of inertia calculation iv ...

Page 126: ...ii MEMO ...

Page 127: ... origin is complete See the figure below NOTE The FLIP X series uses an absolute type position detector You do not have to per form return to origin each time the robot controller is turned on and readjust the machine reference value If for some reason the machine reference adjustment becomes necessary please contact YAMAHA sales office or dealer MANUAL 50 S0H0 Machine Reference M1 51 M2 57 M3 51 ...

Page 128: ...culation 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 1 Moment of inertia for cylinder The moment of inertia...

Page 129: ... from the rotation center The moment of inertia J when the center of the cylinder is offset by a distance x from the rotation center as shown below is given by D h J ρπD4 h 32g WD2 8g kgf cm sec2 Weight of cylinder kgf Mass of cylinder kg Density kg cm3 Gravitational acceleration cm sec 2 x ρπD2 hx2 4g Wx2 g mD2 8 mx2 kgm2 center line rotation center W m e g In the same manner the moment of inerti...

Page 130: ...o part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO LTD Information furnished by YAMAHA in this manual is believed to be reliable However no responsibility is assumed for possible inaccuracies or omissions If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives Series ...

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