Yamaha RCX240 Supporting Supplement Manual Download Page 9

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Chapter 1

USING THE ROBOT SAFELY

Contents

1.1 Safety

information

1-1

1.2 Particularly important cautions

1-2

1.2.1 System design safety points

1-2

1.2.2 Installation safety points

1-3

1.2.3 Wiring safety points

1-4

1.2.4 Start-up and maintenance safety points

1-5

1.2.5 Safety precautions during robot operation

1-7

1.2.6 Precautions for disposal

1-8

1.3 Safety measures for robots

1-8

1.3.1 Safety measures for SCARA type robots

1-8

1.3.2 Safety measures for single-axis robots, Cartesian

robots, and pick & place robots

1-8

1.4 Motor overload precautions

1-8

1.5 Warning labels and marks

1.6 Industrial robot operating and maintenance

personnel

1-10

1.7 Make daily and periodic inspections

1-10

Summary of Contents for RCX240

Page 1: ...t Manual ENGLISH E YAMAHA ROBOT CONTROLLER CEmarking RCX240 RCX221 RCX222 IM Operations 882 Soude Naka ku Hamamatsu Shizuoka 435 0054 Japan URL http www yamaha motor jp robot index html YAMAHA MOTOR C...

Page 2: ......

Page 3: ...robot and controller and considered an integral part of them When the robot and controller are moved transferred or sold send this manual to the new user along with the robot and controller Be sure to...

Page 4: ...MEMO 2 Introduction...

Page 5: ...ARA type robots 1 8 1 3 2 Safety measures for single axis robots Cartesian robots and pick place robots 1 8 1 4 Motor overload precautions 1 8 1 5 Warning labels and marks 1 9 1 5 1 Warning labels 1 9...

Page 6: ...speed during SERVICE mode 3 14 3 4 3 3 Operation device control during SERVICE mode 3 14 Chapter 4 EMC COUNTERMEASURE 4 1 EMC countermeasure examples 4 1 4 1 1 RCX240 4 2 4 1 1 1 Configuration 4 2 4 1...

Page 7: ...1 6 1 1 2 RCX221 6 3 6 1 1 3 RCX222 6 5 6 1 2 Basic functions 6 7 6 1 3 External view 6 8 6 1 3 1 RCX240 6 8 6 1 3 2 RCX221 6 11 6 1 3 3 RCX221HP 6 12 6 1 3 4 RCX222 6 13 6 1 3 5 RCX222HP 6 14 6 2 Pro...

Page 8: ...MEMO iv General contents...

Page 9: ...ety precautions during robot operation 1 7 1 2 6 Precautions for disposal 1 8 1 3 Safety measures for robots 1 8 1 3 1 Safety measures for SCARA type robots 1 8 1 3 2 Safety measures for single axis r...

Page 10: ......

Page 11: ...r death to personnel robot installer operator or service personnel This manual describes safety precautions and operating points using the following symbols and signal words wDANGER DANGER INDICATES A...

Page 12: ...FFECT HUMAN LIFE EQUIPMENT DESIGNED TO CARRY OR TRANSPORT PERSONS EQUIPMENT OR SYSTEMS WHICH WILL SERIOUSLY AFFECT SOCIETY OR PUBLIC POLICY USE IN ENVIRONMENTS SUBJECT TO VIBRATION SUCH AS VEHICLES AN...

Page 13: ...TRICAL SHOCK MALFUNCTIONS PRODUCT DAMAGE OR DETERIORATED PERFORMANCE INSTALL THE ROBOT CONTROLLER AND PROGRAMMING BOX AT A LOCATION OUTSIDE THE ROBOT S WORKING ENVELOPE YET WHERE IT IS EASY TO OPERATE...

Page 14: ...s and poor cable contact may cause equipment malfunctions Do not modify the cables and do not place any heavy object on them Handle them carefully to avoid damage Damaged cables may cause malfunction...

Page 15: ...EL TRAINED IN SAFETY AND ROBOT OPERATION MAY OPERATE THE ROBOT OPERATION BY ANY PERSON WHO HAS NOT RECEIVED THE PROPER TRAINING IS VERY DANGEROUS AND MUST BE AVOIDED THE ROBOT AND ROBOT CONTROLLER ARE...

Page 16: ...IRED KNOWLEDGE AND EXPERTISE IS DANGEROUS AND MUST BE AVOIDED WHEN PERFORMING MAINTENANCE OR INSPECTION OF THE ROBOT CONTROLLER UNDER OUR INSTRUCTIONS WAIT AT LEAST 30 MINUTES AFTER TURNING THE POWER...

Page 17: ...leave the SD memory card inserted into the programming box Doing so may cause malfunction or breakdown Insert the SD memory card into the programming box only when making a data backup or loading the...

Page 18: ...ical shock Use the protective ground terminal to ensure safety Refer to the robot user s manual for details 1 3 2 Safety measures for single axis robots Cartesian robots and pick place robots 1 Protec...

Page 19: ...so insert each connector in the correct direction 1 5 2 Warning marks The following warning marks are shown on the controller To use the YAMAHA robot and controller safely and correctly be sure to ob...

Page 20: ...rectly and safely They must read the user s manual carefully to understand its contents before attempting the robot operation Tasks related to industrial robots teaching programming movement check ins...

Page 21: ...2 2 1 Cautions regarding compliance with EC Directives 2 1 2 2 2 CE marking 2 1 2 2 3 Applicable EC Directives and their related standards 2 2 2 2 4 Robots subject to CE Marking 2 2 2 2 5 Cautions reg...

Page 22: ......

Page 23: ...o the EC Directives only within the scope of built in equipment This does not therefore guarantee that YAMAHA robots conform to EC Directives in cases where the robot is used independently Customers w...

Page 24: ...k assessment EN60204 1 Safety of machinery Electrical equipment of machines EMC Directive 2004 108 EC EN 55011 EMC Emission of ISM Equipment EN 61000 6 2 EMC Immunity for Industrial Environments Refer...

Page 25: ...and controller must therefore be grounded properly to prevent possible electrical shock For details refer to the controller user s manual and the robot user s manual Enclosure The robot controller cas...

Page 26: ...MEMO 2 4 Chapter 2 CE MARKING...

Page 27: ...configuration 3 6 3 3 Programming box RPB E 3 7 3 3 1 Part names and functions 3 7 3 3 2 RPB connector 3 9 3 4 SERVICE mode 3 11 3 4 1 What is SERVICE mode 3 11 3 4 2 Flow for enabling the SERVICE mo...

Page 28: ......

Page 29: ...d circular interpolation 3 1 1 Main system configuration 1 RCX240 Example YK500XG only All the axes on the robot controller are used as the main robot axes RPB E RPB MOTOR XM YM ZM RM PW R SRV SAFETY...

Page 30: ...ing one robot XM YM MOTOR RGEN TEMP ACIN N L L1 N1 SAFETY SRV ERR RPB ROB I O SD COM RDY E STOP B A BAT RCX222 EXT E STOP PIN11 12 OP 1 OP 2 External device PLC etc External emergency stop circuit Eme...

Page 31: ...B SAFETY BATT ZR ROB I O ZR BATT XY ROB I O XY RM ZM YM XM MOTOR TB2 TB1 N1 N L1 L ACIN DRIVER POWER RGEN CN5 CN11 CN9 CN9 CN8 CN6 CN1 CN4 CN2 CN7 CN10 CN3 HEATSINK TH1 FG CN3 CN4 CN6 CN7 CN1 CN2 CN12...

Page 32: ...ASSY DRIVER2 BOARD ASSY OP BOARD OP BOARD MOTOR RGEN XM YM ROB I O XY SD MEMORY COM SAFETY RPB TEMP N1 N L1 L ACIN MOTHER BOARD ASSY CN1 CN12 CN5 CN8 CN3 CN5 CN6 CN4 CN2 TB1 CN3 CN2 CN4 CN2 CN1 CN2 CN...

Page 33: ...2 BOARD ASSY DRIVER2 BOARD ASSY OP BOARD OP BOARD MOTOR RGEN XM YM ROB I O XY SD MEMORY COM SAFETY RPB TEMP N1 N L1 L ACIN MOTHER BOARD ASSY CN1 CN12 CN5 CN8 BATT A BATT B CN14 CN16 CN3 CN5 CN6 CN4 CN...

Page 34: ...TOR 280VDC REALY2 GND MOTOR POWER CIRCUIT CONTROL POWER CIRCUIT 5VDC 12VDC 24VDC 2 1 POWER CIRCUIT BLOCK 2 3 User equipment External emergency stop circuit SAFETY 1 The input power and each control po...

Page 35: ...also has a selector switch which can be used according to the customer s specifications and applications Display liquid crystal screen Selector switch Emergency stop button Sheet key B RPB Connector...

Page 36: ...ed in consideration of safety Pressing this switch to the middle position only enables robot operation This switch is disabled when LOCKIN1 to 4 of the SAFETY connector are not wired Configure an exte...

Page 37: ...PB E has an emergency stop button and an enable switch they do not function independently because the controller is designed on the assumption that an external safety circuit is configured 1 RCX240 Ea...

Page 38: ...No Name Emergency stop contact Line 1 13 Connected to SAFETY connector 13 E STOPIN1 14 14 E STOPIN2 Emergency stop contact Line 2 15 15 E STOPIN3 16 16 E STOPIN4 Enable contact Line 1 17 17 LCKIN1 18...

Page 39: ...I02 contact is closed ON If a serial I O option board is installed SERVICE mode is entered when either one of SI02 or DI02 is open OFF Normal mode is entered only when both SI02 and DI02 contacts are...

Page 40: ...CX240 Determined by STD DIO setting RCX221 RCX222 Determined by DI COM and DO COM input Current capacity of at least 7mA is required for DI02 input When the RCX240 controller is set to SAFE mode it al...

Page 41: ...for SERVICE mode 1 SERVICE mode level 2 Operating speed limit during SERVICE mode 3 Operation device control during SERVICE mode These parameter settings determine the operation level operating speed...

Page 42: ...l 3 Enabled Prohibited Default setting 3 4 3 2 Limitations on operating speed during SERVICE mode The maximum robot operating speed can be specified Setting Description 3 Robot operating speed is limi...

Page 43: ...MEASURE Contents 4 1 EMC countermeasure examples 4 1 4 1 1 RCX240 4 2 4 1 1 1 Configuration 4 2 4 1 1 2 Countermeasure components 4 3 4 1 2 RCX221 RCX222 4 8 4 1 2 1 Configuration 4 8 4 1 2 2 Counterm...

Page 44: ......

Page 45: ...rective In order to ensure the customer s final product entire system complies with EMC Directive the customer should take appropriate EMC countermeasures Typical EMC countermeasures for a single unit...

Page 46: ...DIO OP DIO NETWORK COM RPB SAFETY RGEN RS 232C RCX240 Noise filter NF2020A UP SOSHIN ELECTRIC CO LTD Ferrite core ZCAT3035 1330 TDK Ferrite core ZCAT2132 1130 TDK Ferrite core ZCAT2032 0930 TDK Ferri...

Page 47: ...install a surge absorber on the AC power line A recommended surge absorber is shown below Recommended surge absorber Manufacturer SOSHIN ELECTRIC CO LTD Type No LT C12G801WS Status indicator F 4 3 0 3...

Page 48: ...oise filter is shown below Recommended noise filter Manufacturer SOSHIN ELECTRIC CO LTD Type No NF2020A UP 85p1 71 6 70p0 5 F4 5 18 34p0 5 40p0 5 50p1 40p1 28 8 10 No Part name Input terminal Case Nam...

Page 49: ...ded ferrite core 1 Manufacturer TDK Type No ZCAT3035 1330 39 0p1 34 0p1 30 0p1 13 0p1 Dimensional outline unit mm Recommended ferrite core 2 Manufacturer TDK Type No ZCAT2132 1130 20 5p1 11 0p1 36 0p1...

Page 50: ...MC COUNTERMEASURE Recommended ferrite core 4 Manufacturer Takeuchi Kogyo Co Ltd Type No TFT 274015S 40 0 43 8 90 1 F27 4 F43 8 20 7 Ferrite Plastic case Clamped state Dimensional outline unit mm 4 1 E...

Page 51: ...MEASURE 4 7 Recommended ferrite core 5 Manufacturer Takeuchi Kogyo Co Ltd Type No SFT 72SNB 026K 25 0 29 4 61 3 28 0 35 6 40 4 F12 2 29 4 Ferrite Plastic case Clamped state Dimensional outline unit mm...

Page 52: ...as close to the robot body as possible Power supply 200 to 230V Ground L N L1 N1 ROB I O XY MOTOR XM YM OP DIO NETWORK COM RPB SAFETY RGEN Robot series Single axis Cartesian P P I O circuit network R...

Page 53: ...nce install a surge absorber on the AC power line A recommended surge absorber is shown below Recommended surge absorber Manufacturer SOSHIN ELECTRIC CO LTD Type No LT C12G801WS Status indicator F 4 3...

Page 54: ...ine A recommended noise filter is shown below Recommended noise filter Manufacturer TDK Lambda Corporation Type No MBS 1215 22 L C L C F4 8 8 5 M4 Mounting holes C L NAME PLATE 105 0 5 18 0 5 45 0 5 6...

Page 55: ...ded ferrite core 1 Manufacturer TDK Type No ZCAT3035 1330 39 0p1 34 0p1 30 0p1 13 0p1 Dimensional outline unit mm Recommended ferrite core 2 Manufacturer TDK Type No ZCAT2132 1130 20 5p1 11 0p1 36 0p1...

Page 56: ...4 12 Chapter 4 EMC COUNTERMEASURE MEMO...

Page 57: ...1 5 1 2 Circuit examples for the RCX240 5 2 5 1 2 1 Category 4 5 4 5 1 2 2 Category 3 5 5 5 1 2 3 Category 2 5 6 5 1 2 4 Overview of circuit operation 5 7 5 1 3 Circuit examples for the RCX221 RCX222...

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Page 59: ...cklist score 65 Please obtain the data on each component from the component manufacturer The performance level PL of a safety circuit is determined by the following flow Flow for determining performan...

Page 60: ...I O and serial I O such as alarm signals should be monitored by the host device Overall connection diagram with enable switch AC OUT Emergency stop Enable 17 18 19 20 13 14 15 16 3 Controller PNP spe...

Page 61: ...RPB SAFETY MPRDY Status N1 L1 N L 4 2 11 13 14 MPRDY E STOP24V E STOPRDY 5V P COM P COMDI N COMDI 12 N COM E STOP Status GND 24V_GND 47 48 49 50 27 29 STD DIO COMMON CPU_OK contact A normally open P C...

Page 62: ...2 ON OFF OFF OUT B A Y1 Enable 11 Enable 12 Enable 21 Enable 22 Enable 11 Enable 12 Enable 21 Enable 22 Service 1 Service 2 Input 3 Service 1 Service 2 33 34 43 44 T23 GND GND T33 24V Y1 S24 S14 T33 S...

Page 63: ...12 Enable 21 Enable 22 Enable 11 Enable 12 Enable 21 Enable 22 Service 1 Service 2 33 34 43 44 T23 GND GND 24V Y1 T42 T41 L1 L2 Y2 1 KA2 KA3 KA4 KA5 KA1 Maintenance switch Input 2 Input 1 S2 AUTO SERV...

Page 64: ...GND T42 T41 L1 L2 Y2 1 24V 24V T11 T12 T21 T22 S24 S14 T33 24V Y1 24V 24V KA2 KA1 SRL2 Maintenance switch Input 2 Input 1 S2 AUTO SERVICE Input 3 Service 1 Service 2 24V 24V GND 24V GND ON ON OFF OFF...

Page 65: ...p button s NC contact is closed cCAUTION Connect the RPB terminator or RPB E to the RPB connector on the controller front panel If the RPB connector on the controller front panel is open an emergency...

Page 66: ...f the parallel I O and serial I O such as alarm signals should be monitored by the host device Overall connection diagram with enable switch AC OUT Emergency stop Enable 17 18 19 20 13 14 15 16 13 Con...

Page 67: ...Controller PNP specifications Internal 24V RPB RPB SAFETY N1 L1 N L 14 3 5 4 11 12 SERVICE DI02 MPRDY E STOP24V E STOPRDY DO COM 6 SERVO OUT E STOP Status GND 24V_GND 1 2 17 STD DIO CPU OK 24V 24VG 2...

Page 68: ...11 Enable 12 Enable 21 Enable 22 Enable 11 Enable 12 Enable 21 Enable 22 Service 1 Input 3 Service 1 33 34 43 44 T23 GND GND T33 24V Y1 S24 S14 T33 S44 S34 24V S54 Y1 A2 T42 T41 L2 L1 L2 Y2 1 KA2 KA3...

Page 69: ...3 44 T23 GND GND T33 24V Y1 T42 T41 L1 L2 Y2 KA2 KA3 KA4 KA5 KA1 Maintenance switch Input 2 Input 1 S2 AUTO SERVICE Input 3 Service 1 24V E STOP24V E STOPRDY MPRDY SERVICE DI02 DI COM Service 1 INTERL...

Page 70: ...ntenance switch Input 2 Input 1 S2 AUTO SERVICE Input 3 Service 1 24V E STOP24V SAFETY E STOPRDY MPRDY SERVICE DI02 DI COM Service 1 1 INTERLOCK DO COM 24V GND When INTERLOCK signal is not used 24V GN...

Page 71: ...op button s NC contact is closed cCAUTION Connect the RPB terminator or RPB E to the RPB connector on the controller front panel If the RPB connector on the controller front panel is open an emergency...

Page 72: ...MEMO 5 14 Chapter 5 EXTERNAL SAFETY CIRCUIT EXAMPLES...

Page 73: ...1 2 RCX221 6 3 6 1 1 3 RCX222 6 5 6 1 2 Basic functions 6 7 6 1 3 External view 6 8 6 1 3 1 RCX240 6 8 6 1 3 2 RCX221 6 11 6 1 3 3 RCX221HP 6 12 6 1 3 4 RCX222 6 13 6 1 3 5 RCX222HP 6 14 6 2 Programmi...

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Page 75: ...tes Position display units Pulses mm millimeters deg degrees Speed setting 1 100 1 increments setting possible during program execution Acceleration deceleration setting Automatic acceleration setting...

Page 76: ...ot 4 slots Parallel I O board General purpose input 24 points board output 16 points board 4 boards maximum compatible with NPN PNP specifications CC Link board Dedicated input 16 points dedicated out...

Page 77: ...llimeters deg degrees Speed setting 1 to 100 1 increments setting can be changed by program Acceleration deceleration setting Automatic acceleration setting by robot model and tip weight parameter Set...

Page 78: ...immunity IEC61000 4 4 Level 3 Protective structure IP10 Options Options board Option slot 2 slots including STD DIO Parallel I O board STD DIO Dedicated input 10 points dedicated output 12 points Gene...

Page 79: ...tting 1 to 100 1 increments setting can be changed by program Acceleration deceleration setting Automatic acceleration setting by robot model and tip weight parameter Setting by accel coefficient and...

Page 80: ...structure IP10 Options Options board Option slot 2 slots including STD DIO Parallel I O board STD DIO Dedicated input 10 points dedicated output 12 points General purpose input 16 points general purpo...

Page 81: ...ommands START SUSPEND CUT statements etc etc Functions Arithmetic functions SIN COS TAN functions etc Character string functions STR LEFT MID RIGHT functions etc Point functions WHERE JTOXY XYTOJ func...

Page 82: ...IO OP 2 OP 4 See Note 1 See Note 1 L type bracket attached to front 7 M3 threaded mounting hole for L type bracket top panel thickness 2mm 7 M3 threaded mounting hole for L type bracket top panel thic...

Page 83: ...O ZR BATT ZR RM SAFETY 13 14 EXT E STOP STD DIO OP 2 OP 4 7 M3 threaded mounting hole for L type bracket top panel thickness 2mm See Note 1 See Note 1 7 M3 threaded mounting hole for L type bracket t...

Page 84: ...e Note 1 7 M3 threaded mounting hole for L type bracket top panel thickness 2mm L type bracket attached to side option Bracket can be attached to rear Battery holder RCX240 with RGU 3 option installed...

Page 85: ...STOP OP 1 OP 2 16 16 50 50 14 126 130 100 250 210 225 22 158 210 6 M3 5 5 Standard RCX221 unit mm Bottom view RG2 TEMP RGEN RCX221 RG2 XM YM MOTOR RGEN TEMP ACIN N L L1 N1 SAFETY SRV ERR RPB ROB I O S...

Page 86: ...OP 2 16 16 50 50 126 210 158 22 130 158 100 250 210 28 225 6 M3 14 RCX221HP High power version unit mm 5 5 130 158 100 28 5 Bottom view HP RG2 TEMP RGEN 6 M3 RCX221 XM YM MOTOR RGEN TEMP ACIN N L L1...

Page 87: ...E STOP OP 1 OP 2 16 16 50 50 130 100 250 210 225 22 158 210 6 M3 5 5 14 Standard RCX222 unit mm Bottom view RG2 TEMP RGEN XM YM MOTOR RGEN TEMP ACIN N L L1 N1 SAFETY SRV ERR RPB ROB I O SD COM RDY E S...

Page 88: ...6 16 50 50 126 210 158 22 130 158 100 250 210 28 225 6 M3 5 5 14 HP RCX222HP High power version unit mm Bottom view RG2 TEMP RGEN XM YM MOTOR RGEN TEMP ACIN N L L1 N1 SAFETY SRV ERR RPB ROB I O SD COM...

Page 89: ...splay 40 characters 15 lines Effective number of lines for RCX221 RCX222 8 lines Emergency stop button Normally closed contact with lock function Enable switch 3 position type Power DC 12V Operating e...

Page 90: ...4 1 2 3 5 6 6 16 Chapter 6 SPECIFICATIONS 6 2 2 External view 6 2 2 1 RPB E 136 180 250 50 2 140 RPB E external view Selector switch Enable switch unit mm 6 2 Programming box...

Page 91: ...MEMO...

Page 92: ...inaccuracies or omissions If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives Robot Controller Supporting Supplement Manual CEmarking RCX240 RCX221 RCX222...

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