Yamaha XY-X Series Owner'S Manual Download Page 11

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CHAPTER

Using the Robot Safely

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

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

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

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

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

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

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

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

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

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

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

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

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Summary of Contents for XY-X Series

Page 1: ...OWNER S MANUAL Get other manuals https www bkmanuals com ...

Page 2: ...Get other manuals https www bkmanuals com ...

Page 3: ...obot 2 1 2 Names of each part 2 2 3 Robot Controller 2 7 CHAPTER 3 Preparing the Robot 1 Robot Installation Environment 3 1 2 Unpacking the Robot 3 2 3 Checking the Product 3 3 4 Transporting the Robot 3 5 5 Installation 3 7 5 1 Installation base 3 7 5 2 Installing the Robot 3 8 6 Protective connections 3 9 7 Connecting the Robot Cables 3 10 7 1 Connecting with the DRCX controller 3 12 7 2 Connect...

Page 4: ...Harmonic grease replacement period 4 7 CHAPTER 5 Specifications 1 Specifications 5 1 1 1 Robot cable 5 1 1 2 User I O cable 5 5 CHAPTER 6 PXYX 1 Installation 6 1 1 1 Installation bolt types 6 1 1 2 Installation bolt nominal length 6 1 1 3 Tightening torque 6 1 1 4 Installation methods 6 2 2 Protective Connections 6 3 2 1 Ground terminal 6 3 2 2 Ground wire 6 4 2 3 Wiring method 6 4 3 Installing th...

Page 5: ... linear guide 7 13 5 2 Replenishing grease to the ball screw 7 14 CHAPTER 8 SXYX 1 Installation 8 1 1 1 Installation bolt types 8 1 1 2 Installation bolt nominal length 8 1 1 3 Tightening torque 8 2 1 4 Installation methods 8 2 2 Protective Connections 8 5 2 1 Ground terminal 8 5 2 2 Ground wire 8 6 2 3 Wiring methods 8 6 2 3 1 Arm type with cable carrier 8 7 2 3 2 Arm type with whipover cable mov...

Page 6: ...3 2 Adjusting the R axis belt tension ZRS 8 30 5 3 3 Replacing the R axis harmonic drive ZRS 8 31 CHAPTER 9 MXYX 1 Installation 9 1 1 1 Installation bolt types 9 1 1 2 Installation bolt nominal length 9 1 1 3 Tightening torque 9 1 1 4 Installation methods Arm type moving arm type pole type gantry type X axis 9 2 1 5 Installation methods Gantry type support axis 9 4 2 Protective Connections 9 5 2 1...

Page 7: ...ightening torque 10 5 1 2 4 Installation methods 10 5 1 3 Installation method 3 Gantry type support axis 10 6 2 Protective Connections 10 7 2 1 Ground terminal 10 7 2 2 Ground wire 10 8 2 3 Wiring methods 10 8 3 Installing the Tool 10 10 3 1 Arm type gantry type 2 axis model 10 11 3 2 Moving arm type 2 axis model 10 12 3 3 Pole type 2 axis model 10 13 3 4 ZH Arm type gantry type moving arm type 3r...

Page 8: ... arm type 3rd axis option XZ type 2 axis model 11 12 4 User Wiring and User Piping 11 13 4 1 Cable carrier type 11 13 4 1 1 Example of wiring and piping methods using cable carrier 11 13 4 1 2 Cable carrier specifications 11 15 4 1 3 User I O cable specifications 11 16 4 2 Whipover cable type 11 16 4 2 1 Examples of wiring and piping with Whipover cable 11 17 5 Changing the Motor Installation Posi...

Page 9: ...l 12 9 3 3 Pole type 2 axis model 12 10 3 4 ZH Arm type gantry type moving arm type 3rd axis option 12 11 3 5 ZL Arm type gantry type 12 12 3 6 ZPH Pole type 3rd axis option 12 13 3 7 RH Arm type gantry type 4th axis option 12 14 4 User Wiring and User Piping 12 15 4 1 Cable carrier type 12 15 4 1 1 Example of wiring and piping methods using cable carrier 12 15 4 1 2 Cable carrier specifications 1...

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Page 11: ...al Robot Operation 1 9 4 Robot Safety Functions 1 10 5 Safety Measures for the System 1 11 6 Trial Run 1 12 7 Work Within the Safeguard Enclosure 1 13 8 Automatic Operation 1 14 9 Adjustment and Inspection 1 14 10 Repair and Modification 1 14 11 Warranty 1 15 12 CE Marking 1 16 Get other manuals https www bkmanuals com ...

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Page 13: ...cing the robot CAUTION Failure to follow CAUTION instructions may result in injury to the robot opera tor bystanders or persons servicing the robot or damage to the robot and or robot controller NOTE Explains the keypoint in the operation in a simple and clear manner Refer to the instruction manual by any of the following methods to operate or adjust the robot safely and correctly 1 Operate or adj...

Page 14: ...arts Install a safety interlock that triggers emergency stop when the door or panel is opened Install safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks The warning label 1 Fig 1 1 are supplied with the robot and should be affixed to conspicuous places on doors or panels equipped with safety in terlocks 2 Use caution to prevent hands or fingers f...

Page 15: ...derstand the contents before attempting installation and operation of the robot Before starting robot operation be sure to reread the procedures and cau tions related to the work as well as the descriptions in this chapter Chapter 1 Using the Robot Safely Never install adjust inspect service or operate the robot in any manner that does not comply with the instructions in this manual Improper Insta...

Page 16: ...tical axis WARNING The Z axis will drop when the brake is released creating a hazardous situation Press the emergency stop button and prop up the Z axis with a support stand etc before releasing the brake Be careful not to let your body get caught between the Z axis and in stallation base etc when releasing the brake to perform direct teach ing 7 Provide safety measures for end effector gripper et...

Page 17: ...removed as the Z axis will suddenly move Turn the controller power OFF and stop the air supply before removing the interfering object The Z axis will naturally drop so prop it up with a support stand etc before stopping the air supply 10 Z axis movement when air supply is stopped WARNING The Z axis will drop when the air supply is stopped creating a hazardous situation Prop up the Z axis with a su...

Page 18: ...ion of the controller WARNING If the terminals or connectors on the outside of the controller must be touched during inspection etc always first turn the controller power OFF and the power source to prevent possible electrical shock Refer to the YAMAHA Robot Controller Instruction Manual for pre cautions on handling the controller Never touch any internal parts of the controller 15 Consult YAMAHA ...

Page 19: ...check that the part has cooled 18 Do not remove alter or stain the warning labels WARNING If the warning labels are removed or difficult to see then essential pre cautions might not be taken resulting in accidents Do not remove alter or stain the warning labels on the robot Do not allow the warning labels to be hidden by devices installed onto the robot by the user Provide proper lighting so that ...

Page 20: ... the tip mass and moment of inertia If these are not correct the drive unit serv ice life may end prematurely and damage to robot parts or residual vibration during positioning may result 22 Do not use the robot for tasks requiring motor thrust CAUTION Avoid using the belt driven type robots for tasks that utilize motor thrust press fitting burr removal etc These tasks may cause malfunctions in th...

Page 21: ... repair has received appropriate training and also has the skills needed to perform the job correctly and safely SinceYAMAHA Cartesian Robot XY Series falls under the industrial robot cat egory 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 inspectio...

Page 22: ...hese mechanical stoppers prevent the axis from exceeding the movable range No mechanical stopper is provided on the R axis Note that the movable range is the area limited by the mechanical stoppers 5 Z axis vertical axis brake An electromagnetic brake is installed on the Z axis to prevent the Z axis from dropping when the servo power is shut off This brake is working when the controller power is O...

Page 23: ...ions are more likely to occur from the automated system than from the robot itself Appropriate safety measures must be taken on the part of the system manufacturer according to the individual system The system manufacture should provide a proper instruction manual for safe correct operation and servicing of the system Get other manuals https www bkmanuals com ...

Page 24: ...nstalled 2 Are the electrical connections to the robot correct 3 Are items such as air pressure correctly supplied 4 Is the robot correctly connected to peripheral devices 5 Have safety measures safeguard enclosure etc been taken 6 Does the installation environment meet the specified standards 3 After the controller power is turned ON check the following points from outside the safeguard enclosure...

Page 25: ...To perform item 2 refer to the description in 2 below 2 Teaching When performing teaching within the safeguard enclosure comply with the instructions listed below 1 Check or perform the following points from outside the safeguard enclo sure 1 Make sure that no hazards are present within the safeguard enclosure by a visual check 2 Check that the programming unit MPB or TPB operates correctly 3 Chec...

Page 26: ...osure during automatic operation 3 If an error occurs in the robot or peripheral devices observe the following procedures before entering the safeguard enclosure 1 Press the emergency stop button to set the robot to emergency stop 2 Place a sign on the start switch indicating that the robot is being in spected in order to keep any other person from touching the start switch and restarting the robo...

Page 27: ...he following cases 1 Fatigue arising due to the passage of time natural wear and tear occurring during op eration 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 c...

Page 28: ...YAMAHA MOTOR CO LTD SOLE LIABILITY SHALL BE FOR THE DE LIVERY OF THE EQUIPMENT ANDYAMAHA 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 NOWARRANTYWHAT SOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO LTD 12 CE Marking Refer to the following YAMAHA Robot Controll...

Page 29: ...CHAPTER 2 Product Outline 1 Robot 2 1 2 Names of each part 2 2 3 Robot Controller 2 7 Get other manuals https www bkmanuals com ...

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Page 31: ... axis rotation These configuration axes can move in the following manner High accuracy and high speed work can be carried out over a wide range by installing work tools and indicate the jog key movement directions Default settings Robot movements with ZR axes X axis arm movement Z axis vertical R axis rotation Y axis arm movement Get other manuals https www bkmanuals com ...

Page 32: ... carrier between XY The machine harness between XY is wired inside Y axis wiring box Y axis slider tool installation section X axis wiring box X axis slider X axis stroke cover Y axis stroke cover Y axis motor Y axis X axis motor X axis Frame bracket Robot cable whipover cable between XY Y axis slider tool installation section Y axis wiring box X axis wiring box X axis slider Get other manuals htt...

Page 33: ...xis Support axis Support axis installation bracket X axis motor X axis Frame bracket Robot cable Y axis slider tool installation section X axis wiring box Cable carrier between XY The machine harness between XY is wired inside Y axis wiring box X axis slider Get other manuals https www bkmanuals com ...

Page 34: ... axis wiring box X axis stroke cover X axis X axis motor Y axis whipover cable Y axis bracket tool installation section Y axis Y axis stroke cover Y axis motor X axis slider X axis wiring box X axis stroke cover Y axis wiring box X axis X axis motor whipover cable between XY Y axis bracket tool installation section Y axis Y axis stroke cover Y axis motor X axis slider Get other manuals https www b...

Page 35: ...red inside X axis X axis motor Y axis wiring box Y axis motor Y axis Y axis slider tool installation section Robot cable Y axis relay harness Y axis stroke cover X axis slider Y axis motor Y axis Y axis slider tool installation section X axis stroke cover X axis Independent cable between XY X axis wiring box X axis motor Robot cable X axis slider Get other manuals https www bkmanuals com ...

Page 36: ...een XZ is wired inside Z axis wiring box Z axis motor Z axis Robot cable X axis wiring box X axis motor Z axis cover stroke Z axis slider X axis X axis stroke cover X axis X axis wiring box Robot cable X axis motor X axis stroke cover Z axis slider Z axis Z axis motor whipover cable between XY Get other manuals https www bkmanuals com ...

Page 37: ...user s order Refer to the separate YAMAHA Robot Controller Instruction Manual for de tails on the robot controller POWER CPU OK SERVO ALARM TRCX DRCX QRCX Robot Controller RCX40 MOTOR XM YM ZM RM PWR SRV ERR SAFETY MPB COM STD DIO BATT RGEN ACIN X Y Z R P N L N ROB I O XY ROB I O ZR OP 1 OP 3 OP 2 OP 4 RCX40 Get other manuals https www bkmanuals com ...

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Page 39: ... the Robot Cables 3 10 7 1 Connecting with the DRCX controller 3 12 7 2 Connecting with the TRCX controller 3 14 7 2 1 3 axis model 3 14 7 2 2 4 axis model 3 16 7 3 Connecting to the QRCX or RCX40 controller 3 18 8 Installing the Tool 3 20 9 User Wiring and User Piping 3 21 10 Setting the Robot 3 22 10 1 Setting the payload 3 22 10 2 Setting the maximum speed 3 23 10 3 Setting the acceleration 3 2...

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Page 41: ...ight otherwise occur Always install the robot in the following type of environment Item Specifications Allowable ambient temperature 0 to 40 C Allowable ambient relative humidity 35 to 80 RH with no dew condensation Altitude 0 to 1000m above mean sea level Ambient environment Avoid installing near water cutting water oil dust metallic chips or organic solvent Avoid installing near corrosive gas or...

Page 42: ...kages The packages are divided into the robot XY X Series robot controller RCX40 QRCX TRCX or DRCX Series and accessories according to the items ordered by the user Carefully unpack the packages while taking care not to damage the devices Robot XY X Series Accessories Robot controller RCX40 QRCX TRCX or DRCX Series Example of packaging state Get other manuals https www bkmanuals com ...

Page 43: ... An example of the common combination of components is shown below Check the products according to the actual order Example of combination with RCX40 controller OWNER S MANUAL Terminator Warning labels ZR axis unit option Robot XY X Series I O connector set for user RCX40 controller Controller power connector OP DI OP DO connector option MPB programming unit option STD I O connector Robot cable Ge...

Page 44: ...it option Robot XY X Series TRCX controller Controller power connector OP DI OP DO connector option TPB programming unit option STD I O connector I O connector set for user YA MA HA MO TO R CO LTD YAMAHA OWNER S MANUAL Robot cable DRCX connector Warning labels Robot XY X Series Controller power connector I O connector TPB programming unit option I O connector set for user Get other manuals https w...

Page 45: ...nd fingers could get caught and serious injury could result if the slider moves while transporting the robot Accidents could also result if the weight balance shifts and the robot drops etc Fix the slider with a rope etc to prevent movement during transporta tion Do not place fingers between frame and cover during transportation Do not tilt the robot during transportation WARNING Observe the follo...

Page 46: ...t Use of a hoist dolly or forklift is recommended for transporting the robot or controller Use sufficient caution when transporting robots with a long stroke or large payload as they are heavy Get other manuals https www bkmanuals com ...

Page 47: ...dity and stability to with stand the robot including tool and workpiece weight and the reaction gen erated during operation 2 The installation base surface must be machined to a flatness within 0 05mm 500mm 3 If there is a clearance between the installation base and robot frame when the robot is set on the base insert suitably thick shims in the clearance to prevent stress from being applied on th...

Page 48: ...chined into the installation base where the robot is to be secured Refer to the XY X Series catalog for the machining dimensions and posi tions 2 Fix the installation base at the specified position Securely fix the installation base so that it will not sway during robot opera tion Depending on the installation place or installation base shape this step may be carried out after the robot is fixed o...

Page 49: ...nnect to an external protective conductor Also securely con nect the ground terminal on the robot base to the protective conductor 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 XY X series robots do not have a ground terminal for this purpos...

Page 50: ...e motor connectors XM and ZM YM and RM and Robot I O connectors XY and ZR have the same shape Take special care when connecting as incorrect connections could cause malfunctions WARNING With the TRCX3 controller the motor connectors XM and ZM have the same shape Take special care when connecting as incorrect connections could cause malfunctions WARNING If the connector is insufficiently connected ...

Page 51: ...e tilted might cause the pins to make poor contact causing robot malfunc tion and the connector itself might even break CAUTION These connectors all work in only one direction Take a good look at the con nector shape before trying to attach it Connecting the wrong way may damage the connectors The robot cable is connected beforehand to the XY Series robot side Correctly install the other end of th...

Page 52: ...ok at the con nector shape before trying to attach it Connecting the wrong way may damage the connectors 1 Prepare the required tools Precision phillips head screwdriver 2 While referring to Table 3 1 and Fig 3 1 securely insert the motor connector into the correct position on the controller unitl a click is heard 3 While referring to Table 3 1 and Fig 3 1 insert the robot I O cable into the corre...

Page 53: ...3 13 Chapter 3 Preparing the Robot To robot Robot cable MOTOR connector ROBOT I O connector DRCX controller XY XM YM Fig 3 1 Connection to DRCX controller Get other manuals https www bkmanuals com ...

Page 54: ...he connectors CAUTION With the TRCX3 controller the MOTOR connectors XM and ZM have the same shape Take care not to reverse the robot cable XM and ZM when connecting 1 Prepare the required tools Precision phillips head screwdriver 2 While referring to Table 3 2 and Fig 3 2 securely insert the motor connector into the correct position on the controller unitl a click is heard 3 While referring to Ta...

Page 55: ...reparing the Robot To robot Robot cable MOTOR connector ROBOT I O connector MOTOR connector ROBOT I O connector XY Z ZM XM YM Fig 3 2 Connection to TRCX controller 3 axis model Get other manuals https www bkmanuals com ...

Page 56: ...ler the MOTOR connector and PI connector shapes are the same for the XY axis and ZR axis Take care not to reverse the robot cables XY and ZR when connecting 1 Prepare the required tools Precision phillips head screwdriver 2 While referring to Table 3 3 and Fig 3 3 securely insert the motor connector into the correct position on the controller unitl a click is heard 3 While referring to Table 3 3 a...

Page 57: ...aring the Robot To robot Robot cable MOTOR connector MOTOR connector ROBOT I O connector ROBOT I O connector XY XM YM ZR ZM R M Fig 3 3 Connection to TRCX controller 4 axis model Get other manuals https www bkmanuals com ...

Page 58: ...connector shapes are the same for the XY axis and ZR axis Take care not to reverse the robot cables XY and ZR when connecting 1 Prepare the required tools Precision phillips head screwdriver 2 While referring to Table 3 4 and Fig 3 4 Fig 3 5 securely insert the motor connector into the correct position on the controller unitl a click is heard 3 While referring to Table 3 4 and Fig 3 4 Fig 3 5 inse...

Page 59: ...he Robot Connect to YAMAHA robot Robot cable 1 2 XM YM ZM R M ZR XY Fig 3 4 Connection to QRCX controller XM YM XY ZR ZM RM Connect to YAMAHA robot Fig 3 5 Connection to RCX40 controller Get other manuals https www bkmanuals com ...

Page 60: ...cts on the other sections Y axis frame or X axis slider etc Failure to observe this could lead to vibration during operation especially dur ing positioning Install user s tools on the sections designated as tool installation sections such as the robot slider and bracket Refer to Chapter 2 2 Names of each part and expla nations for each robot in Chapter 6 and following for each robot for details on...

Page 61: ...ails on the actual wiring and piping methods and precautions The cable carrier contains a user I O cable 0 3sq 10 for user wiring so there is no need to add harnesses and route them through the cable carrier Refer to Chapter 3 12 Specifications for the specifications on the user I O wire and the explanation of each robot in Chapter 6 for details on the wiring methods whipover cable carrier type Th...

Page 62: ...tion and servo gain etc are automatically set for the cartesian robot XY X Series by inputting the controller payload parameters Set the total value of the tool weight and workpiece weight as a kg unit in the payload parameter List of payload parameters Controller Payload parameter DRCX PRM90 TRCX3 PRM130 TRCX4 PRM170 RCX40 QRCX Robot parameter 1 Tip weight Refer to the following sections in the R...

Page 63: ...ot near the center of the stroke the ball screw s free length will be shortened and resonance will not occur as easily If resonance does not occur when the robot is actually operated the speed can be increased Models requiring lower maximum speed setting FXYX X axis stroke 750mm or more SXYX X axis stroke 750mm or more MXYX X axis stroke 850mm or more HXYX X axis stroke 850mm or more Refer to the ...

Page 64: ...on is also effective if tool or workpiece vibration occurs due to a low tool rigidity List of acceleration parameters Controller Acceleration parameter DRCX X axis PRM51 Y axis PRM91 TRCX3 X axis PRM51 Y axis PRM91 Z axis PRM131 TRCX4 X axis PRM51 Y axis PRM91 Z axis PRM131 R axis PRM171 RCX40 QRCX Axis parameter 1 Acceleration coefficient Refer to the following sections in the Robot Controller In...

Page 65: ...aced One of the following errors will appear when the power is turned ON in any of the above cases but this is not an error The robot will operate normally when the power is turned ON again For DRCX or TRCX controller 15 FEEDBACK ERROR 2 23 ABS BAT L VOLTAGE 24 ABS DATA ERROR For QRCX controller 17 80 D ABS Encoder backup error 17 81 D ABS Encoder battery alarm 17 85 D ABS Encoder system error 17 ...

Page 66: ... controller Chapter 11 11 9 Absolute reset For RCX40 controller Chapter 11 11 8 Absolute reset 2 When robot contains a rotary axis Target rotary axis RF R axis for SXYX MXYX SXYBX RL RH R axis for HXYX RS R axis for ZRS unit The above rotary axes uses mark method return to origin Thus if the robot contains this type of axis the origin position of the rotary axis can be set freely by the user Refer...

Page 67: ...anual or 11 8 3 in RCX40 owner s manual first per form absolute reset for the rotating axis and then other linearmovement axes When performing absolute reset for each axis one by one see 11 9 2 in QRCX owner s manual or 11 8 2 in RCX40 owner s manual you can begin in any order Get other manuals https www bkmanuals com ...

Page 68: ...osition label Example ZRS Example RH After setting the origin position attach the label enclosed with the robot so that it acts as a match mark on the tool side and Robot side This match mark will be the reference for subsequent origin settings Figure Get other manuals https www bkmanuals com ...

Page 69: ...ily inspection 4 2 4 Three month inspection 4 2 5 Six month inspection 4 3 6 Three year inspection 4 4 7 Replenishing the grease 4 5 8 Maintenance and inspection of harmonic drives 4 6 8 1 Harmonic grease replacement period 4 7 Get other manuals https www bkmanuals com ...

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Page 71: ...pressed immediately when any hazard is sensed WARNING Always turn the controller power switch and external power distribu tion board switch OFF before starting adjustments and inspections that do not require robot operation Press the emergency stop button when robot operation is not required during the electrical system inspection Use only lubricant designated by YAMAHA or your dealer Use only par...

Page 72: ...speed reduction gear Pneumatic devices 4 Three month inspection Check the following points every three months and replenishing grease if re quired To replace grease see 7 Replenishing the grease Check items Clean off any dirt or contamination Replenish the grease after cleaning Replenish grease if the items on the left are dry or do not have enough grease Standard specifications Alvania No 2 Showa...

Page 73: ...heck the cables for damage Check the relay connectors etc for looseness Inspect the timing belt for abnormalities cracks or cuts Check the timing belt tension Check the terminals for looseness Check the connection connectors for looseness Check that the fan is rotating Check whether anything is obstructing the fan Check the rotating fan for abnormal sounds Check visually if any abnormal sound is h...

Page 74: ...at an earlier stage Check items Disassemble and check the harmonic drive Replace the grease Check the ball screws nuts and linear guide for looseness caused by wear Check point R axis speed reduction gear X axis Y axis and Z axis drive section Ball screw nut section motor section and linear guide To replace harmonic drive grease see 8 Maintenance and inspection Get other manuals https www bkmanual...

Page 75: ...emedial measures If the grease gets into eyes flush eyes for 15 minutes with clean water and then see doctor If the grease gets on skin wash off completely with water and soap If the grease is consumed do not induce vomiting and instead con sult with a doctor immediately CAUTION Use of grease not recommended by YAMAHA may lead to a drop in the ball screw linear guide ball spline and linear bushing...

Page 76: ...opening the can to prevent injury to hands Store the grease out of the reach of children Do not heat the grease or place it near fire There is a risk of igniting or fires Remedial measures If the grease gets into eyes flush eyes for 15 minutes with clean water and then see doctor If the grease gets on skin wash off completely with water and soap If the grease is consumed do not induce vomiting and...

Page 77: ...tions and replace the grease The ZRS unit s R axis also uses a harmonic drive but the grease does not need to be replaced 8 1 Harmonic grease replacement period The harmonic grease should be replaced when the total number of wave genera tor rotations reaches 1 5 108 times at 10 C to 40 C Thus the replacement period will differ according to the following usage conditions n Number of arm movements i...

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Page 79: ...CHAPTER 5 Specifications 1 Specifications 5 1 1 1 Robot cable 5 1 1 2 User I O cable 5 5 Get other manuals https www bkmanuals com ...

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Page 81: ... Brake U Green Green Purple Black Red Gray Brown Green Orange Blue Yellow Yellow Black Green White Orange White Pink Black Pink Brown White Blue Red Red White White 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 3sq 0 3sq twisted pair 0 3sq YP y 0 3sq XP r XY q Yellow Green YM 0 XM o ORG i Resolver W V U 2 3 XBK t R1 R2 DG S2 S4 S1 S3 MB MB S3 24 23 22 21 20 19 6 6 5 5 7 4 3 2 1 4 3 2 1 R1 DG ...

Page 82: ...B MB S3 24 23 22 21 20 19 6 6 5 5 7 4 3 2 1 4 3 2 1 R1 DG S2 7 14 7 5 6 2 1 2 1 1 3 2 3 2 1 6 5 4 3 2 3 2 1 4 FG 4 3 25 S4 Resolver S1 R2 Ring tongue terminal W V Brake YBK o MB MB 1 4 18 ZM t 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair Brake Green Black Red Gray Brown Green Orange Pink Blue Yellow 0 75sq 0 75sq 0 75sq 0 75sq 0 3sq 0 3sq twisted pair 0 3sq ZP 0 Z w ...

Page 83: ...1 20 19 6 6 5 5 7 4 3 2 1 4 3 2 1 R1 DG S2 7 14 7 5 6 2 1 2 1 1 3 2 3 2 1 6 5 4 3 2 3 2 1 4 FG 4 3 25 S4 Resolver S1 R2 Ring tongue terminal W V Brake YBK o MB MB 1 4 16 ZM RM t 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair Brake Green Black Red Gray Brown Green Orange Blue Yellow 0 75sq 0 75sq 0 75sq 0 75sq 0 3sq ZP RP 0 ZR w Yellow Green ZM RM 6 Resolver W V U 2 3 Z...

Page 84: ...LIM GND24 HLIM 29 Green Green 10 11 28 16 RM y ZM t 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair 0 3sq twisted pair 4 Brake U Green Green Purple Black Red Gray Brown Green Orange Blue Yellow Green White Orange White Pink Brown White Blue Red White 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 75sq 0 3sq 0 3sq ZR w Yellow Green Reso...

Page 85: ...0 1 Signal General purpose I O Remarks NO 1 2 3 4 5 6 7 8 9 10 NO 1 2 3 4 5 6 7 8 9 10 Red White Green White Yellow White Blue White Purple White 0 3sq twisted pair Connector I O q Connector I O w Part name Part No Connectors and pins fitted onto the connectors on both ends of this signal wire are also enclosed These can be used freely by the user Maker J S T Mfg Co Ltd Connector type SMR 10V B Pi...

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Page 87: ...stallation methods 6 2 2 Protective Connections 6 3 2 1 Ground terminal 6 3 2 2 Ground wire 6 4 2 3 Wiring method 6 4 3 Installing the Tool 6 5 4 User Wiring and User Piping 6 6 5 Periodic Inspections 6 8 5 1 Replenishing grease to the linear guide 6 8 5 2 Replenishing grease to the ball screw 6 9 Get other manuals https www bkmanuals com ...

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Page 89: ... bolt head could interfere with the linear guide s bearings and be damaged If the installation base is made of steel secure 1D or more 4mm or more for M4 for the screw fitting length When using aluminum secure 1 5D or more 6mm or more for M4 The rail thickness is 5mm Refer to Fig 6 1 Recommended nominal length When installation base is made of steel 10mm or more When installation base is made of a...

Page 90: ...tch the shutter when installing the side covers 1 Tap M4 coarse screw thread holes into the installation base where the robot is to be installed Refer to the XY X Series catalog for the hole positions 2 Remove the M3 small screw fixing the X axis side cover and remove the side cover 3 Fix the robot onto the installation base with the designated bolt 4 Return the side covers to the original state a...

Page 91: ...could contact the robot due to a failure or the specifications the user must provide proper grounding since the robot does not have a ground terminal for those devices Refer to the following explanations and connect the robot side ground terminal with the external protective conductor s ground terminal using a ground wire 2 1 Ground terminal The ground terminal is located on the end face of the X ...

Page 92: ...nuity may not be secured if the lock washer is dislocated Connect the ground wire to the ground terminal located on the end face of the X axis wiring box An M4 small screw with spring washer and lock washer are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten them Refer to Fig 6 3 M4 small ...

Page 93: ...der Refer to Fig 6 4 Install the user tool onto theY axis slider using these holes Tolerance between knock 0 02 4 M4 0 7 Depth9 20 0 02 43 35 90 30 Y axis 2 φ3H7 Depth6 9 Fig 6 4 NOTE The dimensions shown with 90 and 43 indicate the maximum outline dimen sions of the stainless cover covering the slider The actual tool installation surface is the shaded section shown above Select the screw under he...

Page 94: ...s and air tubes through the cable carrier These can be stored easily just by pressing on the outside of the cable carrier 4 Open the Y axis wiring box cover 5 Rubber grommets are also attached to the Y axis wiring box Open holes in these grommets and pass the cables and air tubes through CAUTION 1 The wires could be damaged if the Insulock ties are tightened too much 2 Manually move the robot by t...

Page 95: ... sure that the total cross sectional area of all wires and pipes including the YAMAHA cable inside the cable carrier does not exceed 30 of the cable carrier s cross sectional area The cross sectional shape of the cable carrier and the shape of the cable mounted initially by YAMAHA are shown below Power wire φ7 6 Signal wire φ8 2 62 50 19 25 Fig 6 5 Get other manuals https www bkmanuals com ...

Page 96: ...se from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc 1 Turn the controller power OFF 2 Place a sign indicati...

Page 97: ...ch as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc 1 Turn the controller power OFF 2 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 3 Remove the side cover Refer to 1 4 Installation 4 Apply grease onto the ball screw s shaft wit...

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Page 99: ... 3 Installing the Tool 7 5 3 1 Arm type 2 axis model 7 5 3 2 ZS 3rd axis option 7 7 4 User Wiring and User Piping 7 8 4 1 Cable carrier type 7 8 4 1 1 Example of wiring and piping methods using cable carrier 7 8 4 1 2 Cable carrier specifications 7 11 4 1 3 User I O cable specifications 7 12 5 Periodic Inspections 7 13 5 1 Replenishing grease to the linear guide 7 13 5 2 Replenishing grease to the...

Page 100: ...MEMO Get other manuals https www bkmanuals com ...

Page 101: ...washers or spring washers with the tightening bolt The bolt head could interfere with the linear guide s bearings and be damaged If the installation base is made of steel secure 1D or more 6mm or more for M6 for the screw fitting length When using aluminum secure 1 5D or more 9mm or more for M6 The frame thickness is 24mm Refer to Fig 7 1 Recommended nominal length 35mm or more 24 Fig 7 1 1 3 Tigh...

Page 102: ...ccidents 1 Tap M6 coarse screw thread holes into the installation base where the robot is to be installed Refer to the XY X Series catalog for the hole positions 2 Fix the robot onto the installation base with the designated bolt from within the clearance between the X axis stroke cover and frame NOTE Remove the stroke cover and carry out the work if it is difficult to install the robot Get other ...

Page 103: ...bot due to a failure or the specifications the user must provide proper grounding since the robot does not have a ground terminal for those devices Refer to the following explanations and connect the robot side ground terminal with the external protective conductor s ground terminal using a ground wire 2 1 Ground terminal The ground terminal is located on the end face of the X axis wiring box Refe...

Page 104: ...tinuity may not be secured if the lock washer is dislocated Connect the ground wire to the ground terminal located on the end face of the X axis wiring box An M4 small screw with spring washer and lock washer are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten Refer to Fig 7 3 M4 small scr...

Page 105: ... during operation and lead to serious accidents 3 1 Arm type 2 axis model Eight M5 coarse thread tap holes and two φ5 reamer holes are opened on the Y axis slider Refer to Fig 7 4 Install the user tool onto theY axis slider using these holes M5 coarse thread tap holes are also opened on the slider side Use these to fix light loads other than the tool such as a wiring retainer Tolerance between kno...

Page 106: ...eeds 12mm the bolt end could contact the bottom NOTE There is a step on the top of the slider The actual tool installation surface is the shaded section shown above Select the nominal length of the tool fixing bolt so that the fitting length of the screw fixing the tool is 8mm or more 12mm or less Get other manuals https www bkmanuals com ...

Page 107: ... attached for the 3rd axis install the tool on the ZS shaft as shown below Use the φ12 section on the shaft and fix the tool with a bolt coupling or split clamp Fig 7 6 ZS Slit Spline shaft End effector or stay Tap section Hole diameter Bolt Fig 7 7 Example For split clamp Recommended bolt M4 or more Quantity 2 or more Tightening torque 4 5N m 46kgfm Hole diameter φ12 0 018 Hole for rotation stop ...

Page 108: ...al axis wiring box and can be used freely Refer to the User wiring specifications at the end of this section for details The wiring and piping methods for a 2 axis arm type are explained be low as an example 4 1 1 Example of wiring and piping methods using cable carrier 1 Remove the four M4 small screws and open the X axis wiring box cover 2 Rubber grommets are attached to the end face of X axis w...

Page 109: ...is lid in to close it Open and close this lid as necessary 4 Remove the two M4 small screws on the Y axis wiring box and loosen two places Loosen same on opposite side Remove same on opposite side 5 Using the small screws loosened on theY axis wiring box cover as a support point turn and open the box Get other manuals https www bkmanuals com ...

Page 110: ...ned too much 2 Manually move the robot by the full stroke before fixing to confirm that the harness and air tube etc are not pulled in the cable carrier These could be damaged if pulled during operation Lay the required harness and air tubes etc in theY axis box and fix with the harness retainer 8 Assemble the wiring box cover at the original position Get other manuals https www bkmanuals com ...

Page 111: ...ross sectional shape of the cable carrier and the shape of the cable mounted initially by YAMAHA are shown below Fig 7 8 19 50 62 25 19 50 62 25 57 25 57 73 73 25 35 35 Cable carrier between X Y 3 axis specifications ZS Cable carrier between Y Z 2 axis specifications 2 axis I O specifications User I O wire φ10 1 Power wire φ7 6 Signal wire φ8 2 User I O wire φ10 1 User I O wire φ10 1 Signal wire φ...

Page 112: ...reely by the user are laid as a standard between the X axis wiring box and final axis wiring box Connectors and pins fitted onto the connectors on both ends of this signal wire are also enclosed Attach these to the user wiring to eliminate wiring led through the robot Crimp the enclosed pins onto the user wiring and insert into the connector Recommended crimping tool YC 122R J S T Mfg Co Ltd Refer...

Page 113: ...refer to that Chapter before starting this work 5 1 Replenishing grease to the linear guide Grease must be replenished to this linear guide periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robo...

Page 114: ... axis and Z axis use a ball screw Grease must be replenished to this ball screw periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as ...

Page 115: ... from the clearance between the ball screw nut and screw Wipe off any excessive grease Recommended grease gun MG70 THK N type nozzle 7 Remove the grease nipple 8 Return the stroke cover to the original position Y axis 1 Turn the controller power OFF 2 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 3 Remove the stroke cover 4 Apply grease to the...

Page 116: ... power ON 3 Remove the screws M4 6 screws fixing the cover and pull the cover up ward and off M4 screw M4 screw Fig 7 9 ZS 4 Wipe off any excessive grease adhered on the ball screw shaft and ball spline shaft 5 Apply a thin coat of grease on the screw shaft with a finger 6 Return the cover to the original position Get other manuals https www bkmanuals com ...

Page 117: ... RF Arm type moving arm type 4th axis option XZ type 3rd axis option 8 15 3 5 ZS ZRS Arm type 3 4 axis option XZ type 2 3 axis model 8 16 3 6 ZFH Arm type gantry type moving arm type 3rd axis option XZ 2nd axis option 8 17 3 7 ZFL Arm type moving arm type 3rd axis option XZ type 2 axis model 8 18 4 User Wiring and User Piping 8 19 4 1 Cable carrier type 8 19 4 1 1 Example of wiring and piping meth...

Page 118: ... ZS ZRS unit 8 29 5 3 1 Replenishing grease to the Z axis ball screw and ball spline 8 29 5 3 2 Adjusting the R axis belt tension ZRS 8 30 5 3 3 Replacing the R axis harmonic drive ZRS 8 31 Get other manuals https www bkmanuals com ...

Page 119: ... the following type of installation bolt Hexagon socket head cap screw M6 Strength 8 8T 1 2 Installation bolt nominal length CAUTION Do not use washers or spring washers with the tightening bolt The bolt head could interfere with the linear guide s bearings and be damaged When using method A determine the nominal length so that the length of the screw from the robot bottom is 9mm or more 27mm or l...

Page 120: ...2 7N m 100kgf cm to 130kgf cm 1 4 Installation methods WARNING Always use the designated bolt and securely tighten it with the correct torque Failure to observe this could cause the robot position to deviate and could also lead to serious accidents Method A 1 Open a φ6 5 through hole on the installation base s robot installation surface 2 Set the robot on the installation base and fix with M6 bolt...

Page 121: ...untersunk head screws M4 5 screws fixing the X axis stroke cover When using the whipover cable for the arm type pole type or moving arm type first loosen the small screws M5 2 screws fixing the X axis wiring box Then slide the X axis wiring box back and forth and remove the coun tersunk head screws Refer to Fig 8 3 Loosen M5 small screw 2 screws Fig 8 3 Get other manuals https www bkmanuals com ...

Page 122: ...ignated bolts 5 After installing return the stroke cover and X axis wiring box to the original positions CAUTION If the X axis wiring box was slid in step 2 install so that the end face of the X axis wiring box and end face of the X axis are on the same plane The X axis wiring box and frame bracket could interfere CAUTION Take care not to catch the wiring when assembling the stroke cover Get other...

Page 123: ...fications the user must provide proper grounding since the robot does not have a ground terminal for those devices Refer to the following explanations and connect the robot side ground terminal with the external protective conductor s ground terminal using a ground wire 2 1 Ground terminal The ground tap is located on the inside of the X axis wiring box X axis wiring box Ground terminal Fig 8 4 Ar...

Page 124: ...imp an M4 ring tongue terminal on the end of the wire connected to the robot 2 3 Wiring methods WARNING Accurately insert the lock washer between the ring tongue terminal and robot Proper continuity may not be secured if the lock washer is dislocated CAUTION Take care not to catch the harness and ground wire from the X axis with the cover of X axis wiring box when installing the cover Get other ma...

Page 125: ...axis wiring box and loosen the M4 small screw on the end face Remove Loosen X axis wiring box Fig 8 7 2 Open the X axis wiring box cover Lift up the back of the wiring box push it forward and then pull it upward and off Refer to Fig 8 8 Fig 8 8 Opening the wiring box Get other manuals https www bkmanuals com ...

Page 126: ...e the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten Refer to Fig 8 9 M4 small screw with spring washer Ring tongue terminal Lock washer Fig 8 9 4 Return the wiring box cover to the original position following steps 1 and 2 in reverse Lead out the ground wire from the user wiring outlet on the end face of the X axis wiring box Get ...

Page 127: ... X axis wiring box An M4 small screw with spring washer and lock washer are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten Refer to Fig 8 11 M4 small screw with spring washer Ring tongue terminal Lock washer Fig 8 11 3 Return the cover to the original position Lead out the ground wire fro...

Page 128: ... with spring washer and lock washer are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten Refer to Fig 8 13 M4 small screw with spring washer Ring tongue terminal Lock washer Fig 8 13 3 Return the cover to the original position Lead out the ground wire from the user wiring outlet on the end ...

Page 129: ...peration and lead to serious accidents 3 1 Arm type pole type 2 axis model Eight M6 coarse thread tap holes and two φ6 reamer holes are opened on the Y axis slider Refer to Fig 8 14 and Fig 8 15 Install the user tool onto the Y axis slider using these holes M5 coarse thread tap holes are also opened on the slider side Use these to fix light loads other than the tool such as a wiring retainer 70 11...

Page 130: ... could be damaged during tightening If the fitting length exceeds 8mm the bolt end could contact the bottom NOTE There is a step on the top of the slider The actual tool installation surface is the shaded section shown above Select the nominal length of the tool fixing bolt so that the fitting length of the screw fixing the tool is 6mm or more 8mm or less Refer to the cross section drawings in Fig...

Page 131: ...9 50 15 12 M6 1 0 through hole 110 Tolerance between knock 0 02 60 70 5 10 2 φ6H7 Depth6 35 100 10 Plate thickness 17 Fig 8 16 Moving arm type CAUTION If the fitting length is less than 9mm the threads could be damaged during tightening If the length of the bolt screw is 27mm or more from the installation surface the screw could contact the Y axis Select the minimum fixing bolt screw length so tha...

Page 132: ...ap holes are opened on the slider side Use these as required to fix light loads other than the tool such as the wiring retainer 2 φ5H7 Depth15 110 4 M5 0 8 Depth12 86 100 Tolerance between knock 0 02 70 9 9 50 18 10 4 M5 0 8 Depth9 Stroke cover 9 1 Fig 8 17 ZF CAUTION If the bolt fitting length is 12mm or more from the installation surface the bolt will contact the bottom Select the maximum nomina...

Page 133: ... could dislocate and fly off the installation section during robot operation When using the 4th axis model with RF rotary axis unit for the 4th axis install the tool onto the RF shaft in the following manner Use the φ20 section on the shaft and fix the tool with a bolt coupling or split clamp 13 56 6 φ65h7 φ22 φ20h7 41 20 8 M8 1 25 Depth20 Depth16 19 Width across flat 4 M6 1 0 37 5 56 6 Fig 8 18 R...

Page 134: ... the 3rd or 4th axis install the tool onto the ZS or ZRS shaft in the following manner The ZS and ZRS shaft have the same shape Use the φ12 section on the shaft and fix the tool with a bolt coupling or split clamp Fig 8 19 ZS ZRS Fig 8 20 Example For split clamp Recommended bolt M4 or more Quantity 2 or more Tightening torque 4 5N m 46kgfm Hole diameter φ12 0 018 Hole for rotation stop tool 41 36 ...

Page 135: ...Install the tool using these holes The tap depth is 9mm Fig 8 21 Tool installation ZFH NOTE There is a step on the ZFH frame The actual tool installation surface is the shaded section shown above CAUTION If the fitting length is less than 9mm the threads could be damaged during tightening If the screw length exceeds 27mm from the installation surface the screw could contact the bottom 62 100 112 S...

Page 136: ...e opened on the slider side Use these as required to fix light loads other than the tool such as the wiring retainer 70 8 110 43 70 156 70 0 02 9 9 18 120 50 10 9 1 100 Tolerance between knock 0 02 6 M5 0 8 Depth12 2 φ5H7 Depth15 6 M5 0 8 Depth9 Stroke cover Fig 8 22 ZFL Select the maximum nominal length of the tool fixing bolt so that the screw fit ting length is 12mm or less YAMAHA recommends a ...

Page 137: ...ng these ducts A 0 3sq 10 core flexible cable is wired from the X axis wiring box to the final axis wiring box and can be used freely Refer to the User wiring specifications at the end of this section for details The wiring and piping methods for a 2 axis arm type are explained be low as an example 4 1 1 Example of wiring and piping methods using cable carrier 1 Open the X axis wiring box cover Re...

Page 138: ...cover 5 There is a harness retainer also in the Y axis box Remove this and lay out the wires in the Y axis box 6 CAUTION 1 The wires could be damaged if the harness retainer is tightened too much 2 Manually move the robot by the full stroke before fixing to confirm that the harness and air tube etc are not pulled in the cable carrier These could be damaged if pulled during operation After leading ...

Page 139: ...covers Assemble the wiring box cover at the original position State with cover installed State of X axis wiring box when wiring is completed Pass the X axis wiring through this notch Lay out the wires on the protection material Wire lead out port Wire protection material Get other manuals https www bkmanuals com ...

Page 140: ...gnal wire φ10 1 Signal wire φ11 Power wire φ9 8 Signal wire φ10 1 User I O wire φ10 1 Power wire φ7 6 Signal wire φ8 2 User I O wire φ11 Power wire φ9 8 Signal wire φ11 25 77 93 57 73 57 73 57 73 93 25 77 93 77 25 25 25 25 35 35 35 57 73 25 35 57 73 25 35 57 73 25 35 35 35 35 Signal wire φ11 Power wire φ7 6 Signal wire φ10 1 Signal wire φ8 2 Power wire φ7 6 2 axis specifications X Y cable carrier ...

Page 141: ...reely by the user are laid as a standard between the X axis wiring box and final axis wiring box Connectors and pins fitted onto the connectors on both ends of this signal wire are also enclosed Attach these to the user wiring to eliminate wiring led through the robot Crimp the enclosed pins onto the user wiring and insert into the connector Recommended crimping tool YC 122R J S T Mfg Co Ltd Refer...

Page 142: ... 5 6 7 8 9 10 Brown Red Orange Blue Purple Gray White Connector I O q Connector I O w I O P BK BK M P I O Y Z M R Z R Y ORG ORG Controller side Air tube Air tube Tool side qe wr t Fig 8 24 Whipover cable user wire specifications 4 2 1 Examples of wiring and piping with whipover cable CAUTION Securely crimp the pin and insert into the pin connector Failure to do so will prevent the signals and powe...

Page 143: ...tches in the rubber grommets attached to the cover and set the required cables and air tubes etc in the Y axis wiring box Crimp the enclosed connectors onto the user cables beforehand 8 Connect the connectors in the same manner as the X axis and connect the air tubes with the air couplers 9 CAUTION Take care not to catch the wiring or air couplers when installing the covers When completed with all...

Page 144: ...near guide periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc 1 Turn the contr...

Page 145: ...otor side and then start the work 5 Install the stroke cover 6 Confirm the surrounding safety and then turn the controller power ON 5 2 Replenishing grease to the ball screw The X axis Y axis and Z axis use a ball screw Grease must be replenished to this ball screw periodically Refer to section 5 3 1 for details on replenishing the grease to the ZS ZRS unit ball screw Select the grease from the fo...

Page 146: ...wer OFF 3 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 4 Remove the stroke cover of the axis to which grease is to be replenished Refer to section 1 Installation for details on removing the X axis cover 5 Install the grease nipple onto the ball screw flange 6 Using a grease gun replenish grease from the grease nipple Sufficient grease has bee...

Page 147: ... splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc 1 Turn the controller power OFF 2 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 3 Remove the screws M4 6 screws fixing the cover and pull the cover up ward and off Fig 8 26 ZS 4 Wip...

Page 148: ...n Deflection Load Pulley Pulley Belt Fig 8 27 Adjusting the belt tension 1 Turn the controller power OFF 2 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 3 Remove the cover M4 6 screws 4 The following work must be carried out by two operators One operator must apply a vertical load on the center of the belt with the push pull scale and the othe...

Page 149: ...s 6 to 8 and adjust 9 Tighten the M4 bolt q with the specified tightening torque Specified torque 4 5N m 46kgf cm 10 Return the cover to the original position qR axis motor fixing bolt M4 R axis motor Tension decreases Tension increases Fig 8 28 ZRS belt tension 5 3 3 Replacing the R axis harmonic drive ZRS The ZRS R axis speed reduction gear uses a harmonic drive The ZRS uses a harmonic drive as ...

Page 150: ...60 h D N θ years n Number of robot movements in one minute θ Average axis rotation in one movement N Deceleration rate 50 for ZRS R axis h Number of operation hours per day D Number of operation days per year Example TheYK500X X axis harmonic drive replacement period when the axis rotates an average quarter turn every movement and the robot moves ten times in one minute Operation hours 24 hours da...

Page 151: ...xis option 9 10 3 4 RF Arm type moving arm type 4th axis option XZ type 3rd axis option 9 11 3 5 ZFH Arm type gantry type moving arm type 3rd axis option XZ 2nd axis option 9 12 3 6 ZFL Arm type moving arm type 3rd axis option XZ type 2 axis model 9 13 4 User Wiring and User Piping 9 14 4 1 Cable carrier type 9 14 4 1 1 Example of wiring and piping methods using cable carrier 9 14 4 1 2 Cable carr...

Page 152: ...MEMO Get other manuals https www bkmanuals com ...

Page 153: ...he bolt head could interfere with the linear guide s bearings and be damaged If the installation base is made of steel secure 1D or more 8mm or more for M8 for the screw fitting length When made of aluminum secure 1 5D or more 12mm or more for M8 The frame thickness is 26 5mm Refer to Fig 9 1 Recommended nominal length When installation base is made of steel 35mm or more When installation base is ...

Page 154: ... the XY X Series catalog for the hole positions 2 Loosen the small screws M5 4 screws fixing the X axis wiring box The wiring box can be slid along the T slot when these screws are loosened Re fer to Fig 9 2 Fig 9 2 3 Remove the countersunk head screws fixing the X axis stroke cover M4 countersunk head screw 6 screws Fig 9 3 MXY X axis CAUTION The screws indicated with an asterisk in the above dra...

Page 155: ...stroke cover 5 Fix the robot onto the installation base with the designated bolts 6 After installing return the stroke cover and X axis wiring box to the original positions CAUTION Always install the X axis wiring box at the original position The amount of pro jection from the cable carrier s stroke end could change or the cable carrier and Y axis bracket could contact Refer to Fig 9 5 10 Fig 9 5 ...

Page 156: ... with bolts Do not tighten the guide rail bolt at this time Securely fix the X axis section onto the installation base 2 When the ZR axis is provided or if tools are already attached move as close to the X axis side as possible so that a load is not applied on the guide rail 3 Loosen the bolt for theY axis and support installation bracket Refer to following drawing 4 Temporarily fix the guide rail...

Page 157: ...r grounding since the robot does not have a ground terminal for those devices Refer to the following explanations and connect the robot side ground tap with the external protective conductor s ground terminal using a ground wire 2 1 Ground terminal The ground terminal is located on the inside of the X axis wiring box Ground terminal X axis wiring box Fig 9 6 2 2 Ground wire Use an AWG14 2 0mm2 or ...

Page 158: ...ing box and pass the ground wire through Ground wire 3 Connect the ring tongue terminal of the ground wire to the ground terminal on the robot An M4 small screw with spring washer and lock washer are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten Refer to Fig 8 9 M4 small screw with sprin...

Page 159: ...er holes are opened on the Y axis slider installation surface Refer to Fig 9 8 and Fig 9 9 Install the user tool onto the Y axis slider using these holes Four M5 coarse thread tap holes are also opened on the slider side Use these to fix light loads other than the tool such as a wiring retainer CAUTION If the fitting length is less than 6mm the threads could be damaged during tightening Note that ...

Page 160: ...w depth 70 110 Tolerance between knock 0 02 124 140 2 φ6H7 Depth8 8 M6 1 0 Depth8 135 45 50 19 4 M5 0 8 Depth7 23 5 23 5 19 4 M5 0 8 Depth7 50 20 45 90 6 Thread insert depth 20 8 Allowable screw depth 70 110 Tolerance between knock 0 02 124 140 2 φ6H7 Depth8 8 M6 1 0 Depth8 135 Get other manuals https www bkmanuals com ...

Page 161: ...t Fig 9 10 Moving arm type CAUTION If the fitting length is less than 9mm the threads could be damaged during tightening If the length of the bolt screw is 30mm or more from the installation surface the screw could contact the Y axis Select the minimum fixing bolt screw length so that the screw fitting length is 9mm or more Tolerance between knock 0 02 12 M6 1 0 130 110 60 100 70 44 32 2 φ6H7 Dept...

Page 162: ...les are opened on the slider side Use these as required to fix light loads other than the tool such as the wiring retainer Fig 9 11 ZF CAUTION If the bolt fitting length is 12mm or more from the installation surface the bolt will contact the bottom Select the maximum nominal length of the tool fixing bolt so that the screw fit ting length is 12mm or less YAMAHA recommends a screw fitting length of...

Page 163: ... could dislocate and fly off the installation section during robot operation When using the 4th axis model with RF rotary axis unit for the 4th axis install the tool onto the RF shaft in the following manner Use the φ20 section on the shaft and fix the tool with a bolt coupling or split clamp Fig 9 12 RF 13 56 6 4 M6X1 0 φ65h7 φ22 φ20h7 41 20 8 Depth16 19 Width across flat Depth20 56 6 37 5 M8 1 2...

Page 164: ...Install the tool using these holes The tap depth is 9mm Fig 9 13 Tool installation ZFH NOTE There is a step on the ZFH frame The actual tool installation surface is the shaded section shown above CAUTION If the fitting length is less than 9mm the threads could be damaged during tightening If the screw length exceeds 27mm from the installation surface the screw could contact the bottom 62 100 112 S...

Page 165: ...e opened on the slider side Use these as required to fix light loads other than the tool such as the wiring retainer 70 8 110 43 70 156 70 0 02 9 9 18 120 50 10 9 1 100 Tolerance between knock 0 02 6 M5 0 8 Depth12 2 φ5H7 Depth15 6 M5 0 8 Depth9 Stroke cover Fig 9 14 ZFL Select the maximum nominal length of the tool fixing bolt so that the screw fit ting length is 12mm or less YAMAHA recommends a ...

Page 166: ...ay the wiring and piping to the tool using these ducts A 0 3sq 10 core flexible cable is wired from the X axis wiring box to the final axis wiring box and can be used freely The wiring and piping methods for a 2 axis arm type are explained below as an example 4 1 1 Example of wiring and piping methods using cable carrier 1 Remove the four M4 small screws and open the X axis wiring box cover 2 Rubb...

Page 167: ...ox cover and lay the required wiring and piping 6 CAUTION 1 The wires could be damaged if the harness retainer is tightened too much 2 Manually move the robot by the full stroke before fixing to confirm that the harness and air tube etc are not pulled in the cable carrier These could be damaged if pulled during operation When completed with the wiring fix with the harness retainer in the wiring bo...

Page 168: ...ower wire φ9 8 Power wire φ9 8 Power wire φ7 6 Signal wire φ10 1 Signal wire φ11 Signal wire φ10 1 User I O wire φ10 1 Power wire φ7 6 Signal wire φ8 2 User I O wire φ10 1 Power wire φ9 8 Signal wire φ 11 25 77 93 57 73 57 73 57 73 93 25 77 93 77 25 25 25 25 35 35 35 35 35 35 Power wire φ9 8 Signal wire φ11 Power wire φ7 6 Signal wire φ8 2 57 73 25 35 57 73 25 35 57 73 25 35 2 axis specifications ...

Page 169: ...reely by the user are laid as a standard between the X axis wiring box and final axis wiring box Connectors and pins fitted onto the connectors on both ends of this signal wire are also enclosed Attach these to the user wiring to eliminate wiring led through the robot Crimp the enclosed pins onto the user wiring and insert into the connector Recommended crimping tool YC 122R J S T Mfg Co Ltd Refer...

Page 170: ...9 10 Connector I O q Connector I O w Brown Red Orange Blue Purple Gray White I O P BK BK M P I O Y Z M R Z R Y ORG ORG Controller side Air tube Air tube qe wr t Tool side Fig 9 16 Whipover cable user wire specifications 4 2 1 Examples of wiring and piping with Whipover cable CAUTION Securely crimp the pin and insert into the pin connector Failure to do so will prevent the signals and power from be...

Page 171: ...air couplers 6 Open the Y axis wiring box cover 7 Rubber grommets are also attached to the Y axis wiring box Open holes in these grommets and pass the tool side cables and air tubes through 8 Connect the connectors in the same manner as the X axis and connect the air tubes with the air couplers CAUTION Take care not to catch the wiring or air couplers when installing the covers 9 When completed wi...

Page 172: ...rease must be replenished to this linear guide periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specifi...

Page 173: ...xis and Z axis use a ball screw Grease must be replenished to this ball screw periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as in...

Page 174: ...urn the controller power ON 4 Remove the stroke cover of the axis to which grease is to be replenished 5 Install the grease nipple on the M6 tap on the ball screw flange surface 6 Using a grease gun replenish grease from the grease nipple Sufficient grease has been replenished when new grease starts to seep out to the screw shaft Wipe off any excessive grease Recommended grease gun MG70 THK H type...

Page 175: ...2 Ground wire 10 8 2 3 Wiring methods 10 8 3 Installing the Tool 10 10 3 1 Arm type gantry type 2 axis model 10 11 3 2 Moving arm type 2 axis model 10 12 3 3 Pole type 2 axis model 10 13 3 4 ZH Arm type gantry type moving arm type 3rd axis option XZ type 2 axis model 10 14 3 5 ZL Arm type gantry type moving arm type 3rd axis option XZ type 2 axis model 10 15 3 6 ZPH Pole type 3rd axis option 10 16...

Page 176: ... 4 2 1 Examples of wiring and piping with Whipover cable 10 22 5 Periodic Inspections 10 24 5 1 Replenishing grease to the linear guide 10 24 5 2 Replenishing grease to the ball screw 10 25 Get other manuals https www bkmanuals com ...

Page 177: ...oving arm type pole type gantry type X axis Install the arm type moving arm type pole type and gantry type X axis in the following manner 1 1 1 Installation bolt types Use the following type of installation bolt Hexagon socket head cap screw M8 Strength 8 8T 1 1 2 Installation bolt nominal length WARNING Do not use washers or spring washers with the tightening bolt The bolt head could interfere wi...

Page 178: ...ad to serious accidents 1 Tap M8 coares screw thread holes into the installation base where the robot is to be installed Refer to the XY X Series catalog for the hole positions 2 Loosen the small screws M5 4 screws fixing the X axis wiring box The wiring box can be slid along the T slot when these screws are loosened Fig 10 2 3 Remove the countersunk head screws fixing the X axis stroke cover M4 c...

Page 179: ...ver Take care not to lose these plates 4 Remove the stroke cover If the cover is difficult to remove manually move theY axis to the motor side stroke end The cover will be easier to remove 5 Fix the robot onto the installation base with the designated bolts Get other manuals https www bkmanuals com ...

Page 180: ...llowing type of installation bolt Hexagon socket bolt M8 Strength 8 8T 1 2 2 Installation bolt nominal length WARNING Do not use washers or spring washers with the tightening bolt The bolt head could interfere with the linear guide s bearings and be dam aged If the installation base is made of steel secure 1D or more 8mm or more for M8 for the screw fitting length When made of aluminum secure 1 5D...

Page 181: ...nd could also lead to serious accidents 1 Tap M8 holes into the installation base where the robot is to be installed Refer to the XY X Series catalog for the hole positions 2 Remove the screws fixing the X axis stroke cover M4 countersunk head screw 6 screws 3 Remove the stroke cover If the cover is difficult to remove manually move theY axis to the motor side stroke end The cover will be easier t...

Page 182: ...ools are already attached move as close to the X axis side as possible so that a load is not applied on the guide rail 3 Loosen the bolt for theY axis and support installation bracket Refer to following drawing 4 Temporarily fix the guide rail onto the installation base with bolts The parallelism of the guide rail and X axis must be set using a dial gauge or pick gauge etc 5 To easily set the para...

Page 183: ...bot due to a failure or the specifications the user must provide proper grounding since the robot does not have a ground terminal for those devices Refer to the following explanations and connect the robot side ground tap with the external protective conductor s ground terminal using a ground wire 2 1 Ground terminal The ground terminal is located on the inside of the X axis wiring box Refer to Fi...

Page 184: ...ethods CAUTION Accurately insert the lock washer between the ring tongue terminal and robot Proper continuity may not be secured if the lock washer is dislocated 1 Loosen the four M4 small screws and open the X axis wiring box cover 2 Open holes or notches in the grommets on the end face of the X axis wiring box and pass the ground wire through Ground terminal X axis wiring box Get other manuals h...

Page 185: ...er are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten Refer to Fig 10 9 M4 small screw with spring washer Ring tongue terminal Lock washer Fig 10 9 4 Return the X axis wiring box cover to the original position Get other manuals https www bkmanuals com ...

Page 186: ...alling a tool to prevent an accident WARNING Before installing a tool check that the robot is securely fixed to the base WARNING The user is responsible for determining the required bolt type and tight ening torque and accurately installing the tool Improper installation can cause the tool to dislocate during operation and lead to serious accidents Get other manuals https www bkmanuals com ...

Page 187: ...ype gantry type CAUTION If the fitting length is less than 16mm the threads could be damaged during tightening Note that if the fitting length exceeds 25mm the bolt end could con tact the cover Select the nominal length of the tool fixing bolt so that the fitting length of the screw fixing the tool is 16mm or more 25mm or less Refer to the cross section drawings in Fig 10 10 120 8 M8 1 25 Depth25 ...

Page 188: ... on the bracket Fig 10 11 HXYX moving arm type CAUTION If the fitting length is less than 16mm the threads could be damaged during tightening If the fitting length is longer than 30mm the screw could contact the Y axis Select the minimum fixing bolt screw length so that the screw fitting length is 16mm or more 4 M8 1 25 120 Tolerance between knock 0 02 63 133 78 2 φ6H7 Depth8 20 12 5 168 Get other...

Page 189: ...pe CAUTION If the screw s fitting length is less than 16mm the screw threads could be dam aged during tightening If the screw length from the installation surface is longer than 30mm the screw end could contact the frame Select the under head length of the bolt fixing the tool so that the screw length from the slider installation surface is 16mm or more 30mm or less 31 2 30 Effective female screw ...

Page 190: ...the ZH frame in the following manner M6 coarse thread tap holes are opened on the frame s workpiece installation sur face Install the tool using these holes The tap depth is 10mm Select the under head length of the installation bolt so that the screw length from the installation surface is 9mm or more 27mm or less Fig 10 13 Tool installation ZH NOTE There is a step on the ZH frame The actual tool ...

Page 191: ...as the wire retainer Fig 10 14 ZL CAUTION If the fitting length is less than 6mm the threads could be damaged during tightening If the fitting length is longer than 8mm the end of the screw could contact the cover stroke NOTE There is a step on the top of the slider The actual tool installation surface is the shaded section shown above Select the nominal length of the bolt for fixing the tool so t...

Page 192: ...ket Fig 10 15 ZPH CAUTION If the fitting length is less than 9mm the threads could be damaged during tightening If the bolt screw length exceeds 30mm from the installation surface the screw could contact the Y axis Select the minimum nominal length of the fixing bolt so that the length is 9mm or more from the tool installation surface Tolerance between knock 0 02 12 M6 1 0 130 110 60 100 70 44 32 ...

Page 193: ...ttached to the 4th axis install the tool onto the shaft at the end of RH Five M8 coarse thread tap holes are opened on the end of the shaft Install the tool using these holes The tool can also be installed with a bolt coupling or split clamp using the outer diameter of the shaft Fig 10 16 RH NOTE The φ75 section shown below is the non movable section The rotary shaft is the section below φ38 PCD 2...

Page 194: ...Lay the wiring and piping to the tool using these ducts A 0 3sq 10 core flexible cable is wired from the X axis wiring box to the final axis wiring box and can be used freely The wiring and piping methods for a 2 axis arm type are explained below as an example 4 1 1 Example of wiring and piping methods using cable carrier 1 Remove the four M4 small screws and open the X axis wiring box cover 2 Rub...

Page 195: ...box cover and lay the required wiring and piping 6 CAUTION 1 The wires could be damaged if the harness retainer is tightened too much 2 Manually move the robot by the full stroke before fixing to confirm that the harness and air tube etc are not pulled in the cable carrier These could be damaged if pulled during operation When completed with the wiring fix with the harness retainer in the wiring b...

Page 196: ... wire φ10 1 Signal wire φ11 Signal wire φ10 1 User I O wire φ10 1 Power wire φ7 6 Signal wire φ8 2 User I O wire φ9 2 Power wire φ9 0 Signal wire φ9 2 25 77 93 57 73 57 73 57 73 93 25 77 93 77 25 25 25 25 35 35 35 35 35 35 2 axis specifications X Y cable carrier 3 axis specifications X Y cable carrier 4 axis specifications X Y cable carrier 2 axis I O specifications Y axis cable carrier XZ type 2 ...

Page 197: ...sed freely by the user are laid as a standard between the X axis wiring box and final axis wiring box Connectors and pins fitted onto the connectors on both ends of this signal wire are also enclosed Attach these to the user wiring to eliminate wiring led through the robot Crimp the enclosed pins onto the user wiring and insert into the connector Recommended crimping tool YC 122R J S T Mfg Co Ltd ...

Page 198: ... Blue Purple Gray White I O P BK BK M P I O Y Z M R Z R Y ORG ORG Controller side Air tube Air tube qe wr t Tool side Fig 10 18 Whipover cable user wire specifications 4 2 1 Examples of wiring and piping with Whipover cable CAUTION Securely crimp the pin and insert into the pin connector Failure to do so will prevent the signals and power from being supplied cor rectly and may prevent the device f...

Page 199: ...bber grommets are also attached to the Y axis wiring box Open holes in these grommets and pass the tool side cables and air tubes through 8 Connect the connectors in the same manner as the X axis and connect the air tubes with the air couplers 9 CAUTION Take care not to catch the wiring or air couplers when installing the covers When completed with all wiring work return each wiring box cover to t...

Page 200: ...rting this work 5 1 Replenishing grease to the linear guide Grease must be replenished to this linear guide periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case appl...

Page 201: ...n with a rag etc apply a light coat of grease di rectly onto the guide rail with a finger NOTE Due to the structure of ZH grease can be replenished only with this method When replenishing grease to ZH turn the power OFF when near the center of the stroke and then apply grease to the top and bottom of the guide 5 Return the stroke cover to the original position 5 2 Replenishing grease to the ball s...

Page 202: ...le onto the M6 tap hole on the ball screw flange surface and replenish grease using the grease gun Sufficient grease has been replenished when new grease starts to seep out to the screw shaft Wipe off any excessive grease Recommended grease gun MG70 THK H type nozzle Method 2 After wiping off the grease adhered on the rail and on the bearing seal section with a rag etc apply a light coat of grease...

Page 203: ... 11 9 3 4 ZS ZRS FXYBX SXYBX 3 4 axis option 11 10 3 5 ZFH Arm type gantry type moving arm type 3rd axis option XZ 2nd axis option 11 11 3 6 ZFL Arm type moving arm type 3rd axis option XZ type 2 axis model 11 12 4 User Wiring and User Piping 11 13 4 1 Cable carrier type 11 13 4 1 1 Example of wiring and piping methods using cable carrier 11 13 4 1 2 Cable carrier specifications 11 15 4 1 3 User I...

Page 204: ... reduction belt 11 31 8 4 Replacing the slider 11 32 8 5 Replenishing the grease 11 33 8 5 1 Replenishing grease to the linear guide 11 33 8 5 2 Replenishing grease to the ball screw ZF 11 35 8 6 Periodic inspection of the ZS ZRS unit 11 36 8 6 1 Replenishing grease to the Z axis ball screw and ball spline 11 36 8 6 2 Adjusting the R axis belt tension ZRS 11 37 8 6 3 Replacing the R axis harmonic ...

Page 205: ...installation base and secur ing with M6 bolts from below M6 tap holes are opened on the bottom of the robot 1 1 Installation bolt types Use the following type of installation bolt FXYBX Hexagon socket head cap screw M5 Strength 8 8T SXYBX Hexagon socket head cap screw M6 Strength 8 8T 1 2 Installation bolt nominal length FXYBX Select the under head length so that the screw length from the bottom o...

Page 206: ...The following tightening torque is recommended as a guide FXYBX Recommended torque 60 to 90kgf cm SXYBX Recommended torque 100 to 130kgf cm 1 4 Installation methods WARNING Always use the designated bolt and securely tighten it with the correct torque Failure to observe this could cause the robot position to deviate and could also lead to serious accidents 1 Open a through hole on the installation...

Page 207: ...robot due to a failure or the specifications the user must provide proper grounding since the robot does not have a ground terminal for those devices Refer to the following explanations and connect the robot side ground tap with the external protective conductor s ground terminal using a ground wire 2 1 Ground terminal The ground terminal for the cable carrier type is provided in the X axis wiring...

Page 208: ...s Crimp an M4 ring tongue terminal on the end of the wire connected to the robot 2 3 Wiring methods Cable carrier type CAUTION Accurately insert the lock washer between the ring tongue terminal and robot Proper continuity may not be secured if the lock washer is dislocated CAUTION Take care not to catch the harness and ground wire from the X axis with the cover of X axis wiring box when installing...

Page 209: ...ring box 3 Connect the ground wire to the ground terminal attached to the top of the X axis wiring box An M4 small screw with spring washer and lock washer are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue terminal and M4 small screw with spring washer and then tighten Refer to Fig 11 8 M4 small screw with spring washer Ring tongue terminal Lock wash...

Page 210: ...nd wire from the user wiring outlet on the end face of the X axis wiring box 2 4 Wiring methods Whipover cable type For the independent cable type wire the ground wire to the ground terminal on the end face of the X axis wiring box Refer to 3 in 2 3 Wiring methods Cable carrier type for details Get other manuals https www bkmanuals com ...

Page 211: ... and accurately installing the tool Improper installation can cause the tool to dislocate during operation and lead to serious accidents 3 1 FXYBX arm type 2 axis model Four M5 coarse thread tap holes and two φ5 reamer holes are opened on the Y axis slider Refer to Fig 11 9 Install the user tool onto the Y axis slider using these holes Four M5 coarse thread tap holes are also opened on the slider ...

Page 212: ...stallation surface is the shaded section shown above 3 2 SXYBX arm type 2 axis model Eight M6 coarse thread tap holes and two φ6 reamer holes are opened on the Y axis slider Refer to Fig 11 10 Install the user tool onto the Y axis slider using these holes Four M5 coarse thread tap holes are also opened on the slider side Use these as required Fig 11 10 SXYBX arm type Tolerance between knock 0 02 8...

Page 213: ...ollowing manner Four M5 coarse thread tap holes and a φ5 reamer hole are opened on the slider s workpiece installation surface Use these to install the tool Four M5 coarse thread tap holes are also opened on the slider side Use these as required Fig 11 11 ZF Select the maximum length so that the screw length of the tool fixing bolt is 12mm or less The screw fitting length should be 8mm or more CAU...

Page 214: ...axis install the tool onto the ZS or ZRS shaft in the following manner The ZS and ZRS shaft have the same shape Use the φ12 section on the shaft and fix the tool with a bolt coupling or split clamp Hole for rotation stop tool 41 36 12 0 0 018 φ5 M8 1 25 Depth15 Fig 11 12 Tool installation ZS ZRS Slit Spline shaft End effector or stay Tap section Hole diameter Bolt Fig 11 13 Example For split clamp...

Page 215: ...ace Install the tool using these holes The tap depth is 9mm Fig 11 14 Tool installation ZFH NOTE There is a step on the ZFH frame The actual tool installation surface is the shaded section shown above CAUTION If the fitting length is less than 9mm the threads could be damaged during tightening If the screw length exceeds 27mm from the installation surface the screw could contact the bottom 62 100 ...

Page 216: ...s are opened on the slider side Use these as required to fix light loads other than the tool such as the wiring retainer 70 8 110 43 70 156 70 0 02 9 9 18 120 50 10 9 1 100 Tolerance between knock 0 02 6 M5 0 8 Depth12 2 φ5H7 Depth15 6 M5 0 8 Depth9 Stroke cover Fig 11 15 ZFL Select the maximum nominal length of the tool fixing bolt so that the screw fit ting length is 12mm or less YAMAHA recommen...

Page 217: ...ser wiring specifications at the end of this section for details The wiring and piping methods for a 2 axis arm type are explained below as an example 4 1 1 Example of wiring and piping methods using cable carrier 1 Open the X axis wiring box cover Refer to 2 3 Wiring methods in Chapter 2 Protective Connections 2 Remove the harness retainer located at the cable carrier outlet Hexagon socket bolt M...

Page 218: ...re fixing to confirm that the harness and air tube etc are not pulled in the cable carrier These could be damaged if pulled during operation After leading all wires fix the wires with the harness retainer 7 CAUTION Take care not to catch the harness or air tube with the cover Assemble the wiring box cover at the original position State of X axis wiring box when wiring is completed State with cover...

Page 219: ...e of the cable mounted initially by YAMAHA are shown below Fig 11 16 X Y cable carrier 3 axis specifications Y Z cable carrier 2 axis specifications 2 axis I O specifications 4 axis specifications Signal wire φ8 2 Power wire φ7 6 User I O wire φ10 1 25 Signal wire φ10 1 Power wire φ9 8 User I O wire φ10 1 User I O wire φ10 1 Power wire φ9 6 Signal wire φ8 2 85 100 85 100 73 25 35 35 35 35 35 35 25...

Page 220: ...mended crimping tool YC 122R J S T Mfg Co Ltd Refer to 1 2 User I O wiring in Chapter 5 Specifications for details on the wiring specifications 4 2 Whipover cable type CAUTION Do not clamp the wires or tubes to the outside of the independent cable The independent cable could sag or break and ultimately be disconnected The signal wires 0 3mm2 7 wires and air tubes 4 2 5 2 tubes are incorpo rated in...

Page 221: ...ubes etc through Crimp the enclosed connectors onto the cable before hand 5 Pull the I O connector and air tube out of the X axis wiring box In the same manner pull the user cable and air tube passed in step 4 out from the wiring box CAUTION Carefully pull out the minimum length of wiring and air tube with which connec tions can be made If these are pulled with force trouble such as dislocation or...

Page 222: ...ot to catch the wiring or air couplers when installing the covers Remove the upper cover of the Y axis wiring box Set the harness and air tube from the grommets on the X axis wiring box X axis wiring box end face resin cover When leading out the wires from the Y axis wiring box use the grommets on the upper cover Carry out wiring and piping Remove the four M4 screws Carry out wiring and piping r t...

Page 223: ...r case can be suppressed to a minimum and space can be used effectively The methods for changing the motor installa tion position are described below 1 Remove the screws securing the belt cover and remove the cover 2 Remove the four bolts installing the motor plate Motor plate Motor plate bolt 3 Detach the belt from the pully Change the motor orientation as desired and temporarily tighten the four...

Page 224: ...case Motor case Motor plate installation bolt 6 Refer to Chapter 11 7 1 2 Adjusting the speed reduction belt tension and adjust the belt tension 7 Install the belt cover CAUTION Confirm that the large pulley teeth and belt teeth are correctly engaged Positional deviation or premature belt damage could occur if the teeth are not sufficiently engaged Get other manuals https www bkmanuals com ...

Page 225: ...ge of the cover 1 Turn the controller power OFF 2 Insert the slider into the U character groove on the center of the upper cover Set the upper cover so that it is parallel with the axis movement direction at this time Slider travel groove Slider 3 Temporarily fasten the four upper cover installation screws move the table from the motor side to the counter motor side end and then completely tighten...

Page 226: ...these parts may be contacted CAUTION The position will deviate when the belt tension is adjusted Carry out return to origin or absolute reset and reset the point data The X axis and theY axis for the FXYBX and SXYBX use a timing belt to drive the slider If the timing belt tension is week adjust the belt tension with the following pro cedures Fig 11 19 Adjusting the speed reduction belt tension Fig...

Page 227: ...cover 3 Remove the upper cover installation screws and remove the upper cover 4 FXYBX X axis SXYBX X Y axes Attach the enclosed belt tension adjustment bolt and loosen the eight belt stay installation bolts Turn the enclosed adjustment bolt to apply tension on the belt Belt stay Adjustment bolt Belt stay installation bolt FXYBX Y axis Loosen the belt holder fixing bolt on slot side and turn the ad...

Page 228: ...1 Drive belt load and deflection 7 Tighten the belt stay installation bolt and remove the belt tension adjustment bolt 8 Refer to Chapter 11 6 Installing the Cover and install the upper cover Finally install the end cover Reference Adjusting the drive belt tension with a tension meter Use of a belt tension gauge is recommended to obtain more accurate measure ments Recommended tension meter U 505 U...

Page 229: ...XYBX X axis Y axis 5 9 to 6 9 3 9 to 4 6 5 9 to 6 9 0 6 to 0 7 0 4 to 0 47 0 6 to 0 7 3 3 3 Table 11 2 Speed reduction belt load and deflection 4 If adjustments are required loosen the motor plate installation bolt 5 If the value measured in step 3 is less than Table 11 2 move the motor case in the direction to increase the tension If larger than the values given in Table 11 2 move the motor case ...

Page 230: ...ith a tension measuring instrument Use of a belt tension gauge is recommended to obtain more accurate measure ments Recommended tension gauge U 505 UNITTA Measurement method In step 3 of the adjustment of the speed reduction belt tension pull the belt at the position where the load is applied and adjust to the following values Model Tension N Frequency Hz Span length mm Belt width mm FXYBX X axis ...

Page 231: ...t starts moving during the periodic inspection 8 1 Replacing the motor CAUTION The position will deviate when the motor is replaced After replacing the motor return to origin must be carried out and the point data must be reset Remem ber the relation of the installation positions when removing any parts 1 Turn the controller power OFF 2 Remove the belt cover 3 Remove the motor case and motor cover...

Page 232: ... motor case and cover 11 Install the belt cover 8 2 Replacing the drive belt CAUTION The position will deviate when the belt is replaced After replacing the belt return to origin must be carried out and the point data must be reset Remem ber the relation of the installation positions when removing any parts 1 Remove the end cover from the counter motor end and remove the upper cover On robot model...

Page 233: ...ion bolts 4 bolts 2 stays and remove the belt stays from the table Belt stay Table Belt stay installation bolt FXYBX Y axis Remove the two belt stay installation bolts and remove the belt stay from the table 5 Remove the belt stay bolts 2 bolts 2 stays and remove the belt Get other manuals https www bkmanuals com ...

Page 234: ...dge upwards 9 Finally mesh the belt between the drive pulley and drive pulley idler and turn the drive pulley 10 Attach the belt stays to the belt 11 Install the belt stays onto the slider table and temporarily tighten the belt stay installation bolts 12 Refer to Chapter 11 7 Adjusting the Timing Belt Tension and adjust the belt tension 13 Refer to Chapter 11 6 Installing the Cover and install the...

Page 235: ...tallation positions when removing any parts 1 Remove the belt cover 2 Remove the four motor plate installation bolts Motor plate installation bolt 3 Place the motor plate near the loose side and remove the belt 4 First attach the new belt to the small pulley and then fit it onto the large pulley 5 Refer to Chapter 11 7 1 2 Adjusting the speed reduction belt tension and adjust the tension 6 Install...

Page 236: ...der installation bolt 4 Replace the slider and temporarily tighten the two installation bolts 5 Refer to Chapter 11 6 Installing the cover and install the upper cover 6 Move the table two or three times along the full stroke 7 Remove the 12mm diameter label attached to the upper cover on the counter motor side and move the slider until the slider installation bolt is visible from this hole Cover l...

Page 237: ...e ZF unit is attached for the 3rd axis the replenishment work can be carried out easier by moving the Z axis slider to near the motor near the origin and turning the controller power OFF CAUTION If the X axis stroke is 2150mm or more for the FXYBX or 2450mm or more for the SXYBX a slider mechanism is provided in the X axis stroke cover to sup port the inner self weight When removing the X axis str...

Page 238: ... to the rail Recommended grease gun MG70 THK N type nozzle SXYBX X axis Y axis The X axis and Y axis each have four linear guide bearings Replenish grease to all four bearings Wipe off any excessive grease that has seeped out to the rail Recommended grease gun MG70 THK N type nozzle Z axis ZF One linear guide bearing is attached A grease nipple is attached to the counter motor side of the slider s...

Page 239: ...ated with the grease nipple installed 1 Prepare the following recommended grease nipple beforehand Recommended grease nipple A M6X1 type JIS B1575 2 Turn the controller power OFF NOTE The replenishment work can be carried out easier by moving the Z axis slider to near the motor near the origin and turning the controller power OFF 3 Place a sign indicating Work In Progress so that other operators d...

Page 240: ...h as splatter proof grease may be applied when the robot is delivered In this case apply the appropriate grease as indicated in the delivery specification drawings etc 1 Turn the controller power OFF 2 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 3 Remove the screws M4 6 screws fixing the cover and pull the cover up ward and off M4 screw M4 s...

Page 241: ...tion Deflection Load Pulley Pulley Belt Fig 11 23 Adjusting the belt tension 1 Turn the controller power OFF 2 Place a sign indicating Work In Progress so that other operators do not turn the controller power ON 3 Remove the cover M4 6 screws 4 The following work must be carried out by two operators One operator must apply a vertical load on the center of the belt with the push pull scale and the ...

Page 242: ...at steps 6 to 8 and adjust 9 Tighten the M4 bolt q with the specified tightening torque Specified torque 4 5N m 46kgf cm 10 Return the cover to the original position qR axis motor fixing bolt M4 R axis motor Tension decreases Tension increases Fig 11 24 ZRS belt tension 8 6 3 Replacing the R axis harmonic drive ZRS The ZRS R axis speed reduction gear uses a harmonic drive The ZRS uses a harmonic d...

Page 243: ...8 n 60 h D N θ years n Number of robot movements in one minute θ Average axis rotation in one movement N Deceleration rate 50 for ZRS R axis h Number of operation hours per day D Number of operation days per year Example TheYK500X X axis harmonic drive replacement period when the axis rotates an average quarter turn every movement and the robot moves ten times in one minute Operation hours 24 hour...

Page 244: ...11 40 MEMO Get other manuals https www bkmanuals com ...

Page 245: ... type support axis 12 5 2 Protective Connections 12 6 2 1 Ground terminal 12 6 2 2 Ground wire 12 7 2 3 Wiring methods 12 7 3 Installing the Tool 12 8 3 1 Arm type gantry type 2 axis model 12 8 3 2 Moving arm type 2 axis model 12 9 3 3 Pole type 2 axis model 12 10 3 4 ZH Arm type gantry type moving arm type 3rd axis option 12 11 3 5 ZL Arm type gantry type 12 12 3 6 ZPH Pole type 3rd axis option 1...

Page 246: ... pole type 3 axis 12 19 4 2 1 Examples of wiring and piping with Whipover cable 12 19 5 Periodic Inspections 12 21 5 1 Replenishing grease to the linear guide 12 21 5 2 Replenishing grease to the ball screw 12 22 5 3 Adjusting the timing belt tension X axis 12 24 5 4 Replacing the motor X axis 12 25 5 5 Installing and removing the cover 12 27 5 5 1 Stroke cover 12 27 5 5 2 Belt cover 12 28 5 5 3 M...

Page 247: ... arm type pole type gantry type X axis Install the arm type moving arm type pole type and gantry type X axis in the following manner 1 1 1 Installation bolt types Use the following type of installation bolt Hexagon socket head cap screw M6 Strength 8 8T 1 1 2 Installation bolt nominal length WARNING Do not use washers or spring washers with the tightening bolt The bolt head could interfere with th...

Page 248: ...lt and securely tighten it with the correct torque Failure to observe this could cause the robot position to deviate and could also lead to serious accidents 1 Tap M8 coares screw thread holes into the installation base where the robot is to be installed Refer to the XY X Series catalog for the hole positions 2 Remove the screws securing the upper cover of the robot and remove the upper cover If n...

Page 249: ...T length longer than 45mm F17 longer than 50mm F20 230kg cm to 370kg 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 Refer to Chapter 12 5 5 Installing and removing the cover and install the cover Get other manuals https www bkmanuals com ...

Page 250: ...UTION A secure ground connection less than 100 ohm resistance to ground is rec ommended Use electrical wire thicker than AWG14 2mm2 as the ground wire WARNING Always turn off the power to the controller before making the ground con nection Provide a terminal marked PE as the protective conductor for the entire sys tem and connect it to an external protective conductor Also securely connect the gro...

Page 251: ...tools are already attached move as close to the X axis side as possible so that a load is not applied on the guide rail 3 Loosen the bolt for theY axis and support installation bracket Refer to following drawing 4 Temporarily fix the guide rail onto the installation base with bolts The parallelism of the guide rail and X axis must be set using a dial gauge or pick gauge etc 5 To easily set the par...

Page 252: ...t due to a failure or the specifications the user must provide proper grounding since the robot does not have a ground terminal for those devices Refer to the following explanations and connect the robot side ground tap with the external protective conductor s ground terminal using a ground wire 2 1 Ground terminal The ground terminal is located on the inside of the X axis wiring box Refer to Fig ...

Page 253: ...ll screws and open the X axis wiring box cover 2 Pass the ground wire through the cable lead out port on the X axis wiring box fixed Cable lead out port 3 Connect the ring tongue terminal of the ground wire to the ground terminal on the robot An M4 small screw with spring washer and lock washer are attached to the ground terminal Arrange the parts in the order of the lock washer ring tongue termin...

Page 254: ...e during operation and lead to serious accidents 3 1 Arm type gantry type 2 axis model Eight M8 coarse thread tap holes and two φ6 reamer holes are opened on the Y axis slider installation surface Refer to Fig 12 5 Install the user tool onto the Y axis slider using these holes Four M5 coarse thread tap holes are also opened on the slider side Use these to fix light loads other than the tool such a...

Page 255: ...odel The moving arm type has an aluminum cast bracket on the end of the Y axis Install the tool on this bracket Twelve M8 coarse thread tap holes and two φ6 reamer holes are opened on the bracket 4 M8 1 25 120 Tolerance between knock 0 02 63 133 78 2 φ6H7 Depth8 20 12 5 168 Fig 12 6 HXYLX moving arm type Select the minimum fixing bolt screw length so that the screw fitting length is 16mm or more C...

Page 256: ...ale screw depth 1 5 15 4 M8 1 25 Depth30 160 185 Tolerance between knock 0 02 2 φ8H7 Depth10 180 65 50 12 5 4 M5 0 8 Depth15 The same position on the opposite surface at two locations Fig 12 7 HXYLX pole type Select the under head length of the bolt fixing the tool so that the screw length from the slider installation surface is 16mm or more 30mm or less CAUTION If the screw s fitting length is le...

Page 257: ...ad length of the installation bolt so that the screw length from the installation surface is 9mm or more 27mm or less 100 10 17 22 22 78 Refer to the XY X Series catalog for the M6 tap position Fig 12 8 Tool installation ZH NOTE There is a step on the ZH frame The actual tool installation surface is the shaded section shown above CAUTION If the fitting length is less than 9mm the threads could be ...

Page 258: ... 19 4 M5 0 8 Depth7 50 20 45 90 6 Thread insert depth 20 8 Allowable screw depth 70 110 Tolerance between knock 0 02 124 140 2 φ6H7 Depth8 8 M6 1 0 Depth8 135 Fig 12 9 ZL NOTE There is a step on the top of the slider The actual tool installation surface is the shaded section shown above Select the nominal length of the bolt for fixing the tool so that the screw fitting length is 6mm or more 8mm or...

Page 259: ...cket Tolerance between knock 0 02 12 M6 1 0 130 110 60 100 70 44 32 2 φ6H7 Depth6 20 10 Fig 12 10 ZPH Select the minimum nominal length of the fixing bolt so that the length is 9mm or more from the tool installation surface CAUTION If the fitting length is less than 9mm the threads could be damaged during tightening If the bolt screw length exceeds 30mm from the installation surface the screw coul...

Page 260: ...xis install the tool onto the shaft at the end of RH Five M8 coarse thread tap holes are opened on the end of the shaft Install the tool using these holes The tool can also be installed with a bolt coupling or split clamp using the outer diameter of the shaft 5 M8 1 25 Depth20 PCD 20 φ35h7 φ38 φ75h8 φ980 0 2 30 3 50 10 Fig 12 11 RH NOTE The φ75 section shown below is the non movable section The ro...

Page 261: ...nd R axes Lay the wiring and piping to the tool using these ducts A 0 3sq 10 core flexible cable is wired from the X axis wiring box to the final axis wiring box and can be used freely The wiring and piping methods for a 2 axis arm type are explained below as an example 4 1 1 Example of wiring and piping methods using cable carrier 1 Remove the four M4 small screws and open the X axis wiring box f...

Page 262: ...iring box movable and lay the required wiring and piping 6 CAUTION 1 The wires could be damaged if the harness retainer is tightened too much 2 Manually move the robot by the full stroke before fixing to confirm that the harness and air tube etc are not pulled in the cable carrier These could be damaged if pulled during operation When completed with the wiring fix with the harness retainer in the ...

Page 263: ...0 1 Signal wire φ11 User I O wire φ10 1 Power wire φ7 6 Signal wire φ8 2 User I O wire φ10 1 Power wire φ9 8 Signal wire φ11 25 77 93 57 73 57 73 57 73 93 77 25 25 25 25 35 35 35 35 35 User I O wire φ10 1 Power wire φ9 8 Power wire φ7 6 Signal wire φ10 1 Signal wire φ8 2 93 77 25 35 2 axis specifications X Y cable carrier 3 axis specifications X Y cable carrier 4 axis specifications X Y cable carr...

Page 264: ...used freely by the user are laid as a standard between the X axis wiring box and final axis wiring box Connectors and pins fitted onto the connectors on both ends of this signal wire are also enclosed Attach these to the user wiring to eliminate wiring led through the robot Crimp the enclosed pins onto the user wiring and insert into the connector Recommended crimping tool YC 122R J S T Mfg Co Ltd...

Page 265: ... Brown Red Orange Blue Purple Gray White I O P BK BK M P I O Y Z M R Z R Y ORG ORG Controller side Air tube Air tube qe wr t Tool side Fig 12 14 Whipover cable user wire specifications 4 2 1 Examples of wiring and piping with Whipover cable CAUTION Securely crimp the pin and insert into the pin connector Failure to do so will prevent the signals and power from being supplied cor rectly and may pre...

Page 266: ...ets are also attached to the Y axis wiring box Open holes in these grommets and pass the tool side cables and air tubes through 8 Connect the connectors in the same manner as the X axis and connect the air tubes with the air couplers 9 CAUTION Take care not to catch the wiring or air couplers when installing the covers When completed with all wiring work return each wiring box cover to the origina...

Page 267: ...arting this work 5 1 Replenishing grease to the linear guide Grease must be replenished to this linear guide periodically Select the grease from the following recommended types Recommended grease Alvania No 2 Showa Shell Daphne Eponex No 2 Idemitsu CAUTION When designated by YAMAHA and the user special grease such as splatter proof grease may be applied when the robot is delivered In this case app...

Page 268: ...on with a rag etc apply a light coat of grease di rectly onto the guide rail with a finger NOTE Due to the structure of ZH grease can be replenished only with this method When replenishing grease to ZH turn the power OFF when near the center of the stroke and then apply grease to the top and bottom of the guide 5 Return the stroke cover to the original position 5 2 Replenishing grease to the ball ...

Page 269: ...tall the grease nipple onto the M6 tap hole on the ball screw flange surface and replenish grease using the grease gun Sufficient grease has been replenished when new grease starts to seep out to the screw shaft Wipe off any excessive grease Recommended grease gun MG70 THK H type nozzle Method 2 Wipe off any grease adhered on the ball screw with a rag etc and directly apply grease into the ball sc...

Page 270: ...ad near the belt and pull the center of the belt span with a hexagon wrench etc 5 Refer to the following table and adjust the belt tension 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 6 When the appropriate tension has been set tighten the motor installation bolt and measure the tension again Note that the tension will increase as the...

Page 271: ...r so you can correctly reas semble the parts later 1 Turn the controller power OFF 2 Remove the belt cover and motor cover 3 Open the cover of the box fixed onto the table slide and disconnect the motor wiring connector 4 Remove the motor installation bolts M6 four bolts Wiring box Motor cable Motor cover Motor installation bolt 5 Pull the belt off the pulley Refer to the following photograph Pull...

Page 272: ...ce the motor and install the pulley onto the motor Refer to the photo graph 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 section 5 3 Adjusting the timing belt and adjust the belt tension 11 Install the motor cover and belt cover 12 Connect the motor wiring connector store ...

Page 273: ...he 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 cover fixing screw Refer to following photographs When cover contacts table slide Tighten the ...

Page 274: ...rews on the top pull the cover up ward 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 Get other manuals https www bkmanuals com ...

Page 275: ... 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 hexa gon bolts 2 Using the φ5 hole open on the motor cover fix the motor cable with an Insulock tie Get other manuals https www bkmanuals com ...

Page 276: ...y 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 OWNER S MANUAL Cartesian robot Get other manuals https www bkmanuals com ...

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Summary of Contents for XY-X Series

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Yamaha XY-X Series, Owner'S Manual, Page: 11 / 276

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Summary of Contents for XY-X Series

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