Omron YRC User manual

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CONTENTS YRCX
User’s Manual
T-1
Safety Instructions
1. Safety Information S-1
2. Signal words used in this manual S-2
3. Warning labels S-3
3.1 Warning labels S-3
3.1.1 Warning label messages on robot and controller S-3
3.1.2 Supplied warning labels S-6
3.2 Warning symbols S-7
4. Important precautions for each stage of the robot life cycle S-8
4.1 Precautions for using robots and controllers S-8
4.2 Design S-9
4.2.1 Precautions for robots S-9
4.2.2 Precautions for robot controllers S-9
4.3 Moving and installation S-10
4.3.1 Precautions for robots S-10
4.3.2 Precautions for robot controllers S-11
4.4 Safety measures S-13
4.4.1 Safety measures S-13
4.4.2 Installing a safety enclosure S-14
4.5 Operation S-15
4.5.1 Trial operation S-15
4.5.2 Automatic operation S-17
4.5.3 Precautions during operation S-17
4.6 Inspection and maintenance S-19
4.6.1 Before inspection and maintenance work S-19
4.6.2 Precautions during service work S-20
4.7 Disposal S-21
5. Emergency action when a person is caught by robot S-22
6. Cautionsregardingstrongmagneticelds S-22
7. Using the robot safely S-23
7.1 Movement range S-23
7.2 Robot protective functions S-24
7.3 Residual risk S-25
7.4 Special training for industrial robot operation S-25
7.5 KC mark S-26
7.5.1 EMC standards S-26
7.5.2 Examples of EMC countermeasures S-26

CONTENTS YRCX
User’s Manual
T-2
Warranty
Important information before reading this manual
Introduction i
About this manual i
Overview of the YRCX ii
Before using the robot controller (Be sure to read the following notes) iii
Chapter 1 Using the robot safely
1. Emergency action when a person is caught by robot 1-1
2. Emergency stop 1-2
2.1 Emergency stop release and alarm reset 1-2
3. Power-ON procedures 1-4
4. Usage environments 1-5
Chapter 2 System overview
1. I/O interface overview 2-1
1.1 Mainsystemconguration 2-1
1.2 AxiscongurationfortheYRCX 2-2
2. Name of each part and control system 2-3
2.1 YRCXexternalview 2-3
2.2 Controller system 2-4
3. Optional devices 2-5
3.1 Programming box 2-5
3.2 Basic key operation 2-5
3.3 Expansion I/O board 2-5
4. Basic sequence from installation to operation 2-6
Chapter 3 Installation
1. Transport, unpacking 3-1
2. Installing the robot controller 3-1
2.1 Installation conditions 3-1
2.2 Installation methods 3-2

CONTENTS YRCX
User’s Manual
T-3
3. Connecting to the power 3-3
3.1 Powersupplyandgroundterminals 3-3
3.2 ACpowerconnectorwiring 3-4
3.3 Consideringpowercapacityandgeneratedheatamount 3-5
3.4 Installing an external leakage breaker 3-6
3.4.1 Selecting condition 3-6
3.5 Installing a circuit protector 3-6
3.6 Installing an electromagnetic contactor 3-6
3.7 Installinganoiselter 3-7
3.8 Installing a surge absorber 3-7
4. Connecting the absolute battery 3-8
5. Robot connections 3-9
5.1 Connecting the robot cables 3-9
5.2 Noise countermeasures 3-10
6. Connecting the programming box 3-10
7. I/O connections 3-11
8. Connecting the regenerative shorting connector 3-11
9. Connecting the brake power supply 3-12
10. Precautions for cable routing and installation 3-12
10.1 Wiring methods 3-12
10.2 Methods of preventing malfunctions 3-13
11. Checking the robot controller operation 3-14
11.1 Controllerwiring 3-14
11.2 Wiring example of emergency stop circuit for operation check 3-15
11.3 Operation check 3-15
Chapter 4 I/O interface
1. I/O interface overview 4-1
1.1 ID settings 4-2
1.2 Powersupply 4-2
1.3 Powerconnectorwiringwork 4-3
1.4 Connector I/O signals 4-4
1.4.1 StandardspecicationI/Oconnectorsignallist 4-4
1.4.2 ExpandedspecicationI/Oconnectorsignallist 4-5
1.5 Connector pin assignment lists 4-6
1.5.1 StandardspecicationI/Oconnector 4-6
1.5.2 ExpandedspecicationI/Oconnector 4-6

CONTENTS YRCX
User’s Manual
T-4
1.6 Connector pin numbers 4-7
1.7 Typical input signal connection 4-7
1.8 Typical output signal connection 4-8
1.9 Dedicated input signal description 4-9
1.10 Dedicated output signal description 4-10
1.11 Dedicated I/O signal timing chart 4-12
1.11.1 From the controller power on to servo on 4-12
1.11.2 Controller emergency stop and servo on reset 4-13
1.11.3 Return-to-origin 4-14
1.11.4 Program reset and program execution 4-15
1.11.5 Stopping by program stop 4-16
1.12 General-purpose I/O signals 4-17
1.12.1 General-purpose input signals 4-17
1.12.2 General-purpose output signals 4-17
1.12.3 General-purpose output signal reset (off) 4-17
2. Ratings 4-18
2.1 Input 4-18
2.2 Output 4-18
3. Caution items 4-18
Chapter 5 SAFETY I/O interface
1. SAFETY I/O interface overview 5-1
1.1 Power 5-1
1.2 Connector I/O signals 5-1
1.3 Connectionexamplecombiningtheprogrammingboxwith
external emergency stop circuit 5-2
1.3.1 ConnectionexampleofcontrollerwithCEspecicationsandPBEX 5-2
1.4 Connections example of dedicated input signal 5-3
1.4.1 Emergencystopinputs(E-STOPRDY*,E-STOPCOM*) 5-3
1.4.2 AUTOmodeinputs(AUTO*+,AUTOCOM*) 5-3
1.5 Connection example of dedicated output signal 5-4
1.5.1 Emergencystopcontactoutputs(E-STOP*1,E-STOP*2) 5-4
1.5.2 Enableswitchcontactoutputs(ENABLE*1,ENABLE*2) 5-4
1.5.3 Motorpowerreadyoutputs(MPRDY*+,MPRDY*-) 5-5
Chapter 6 External communication interface
1. Overview 6-1
1.1 Communicationoverview 6-1
1.2 ONLINE and OFFLINE modes 6-2
1.3 Character code 6-3

CONTENTS YRCX
User’s Manual
T-5
2. RS-232C 6-4
2.1 Connectors and cables 6-4
2.2 Communicationspecications 6-5
2.3 Connections 6-5
2.4 Communication parameter setting 6-6
2.5 Communicationowcontrol 6-7
2.5.1 Flow control during transmit 6-7
2.5.2 Flow control during receive 6-7
2.6 Other caution items 6-7
3. Ethernet 6-8
3.1 Connectors and cables 6-9
3.2 Communicationspecications 6-11
3.3 Connections 6-12
3.4 Parameter setting on controller (server) 6-13
3.4.1 Setting the communication mode and parameters 6-14
3.4.2 Initializing communication parameters 6-14
3.5 System setting on personal computer (client) 6-15
3.5.1 SettingtheTCP/IPprotocol 6-15
3.6 Connection check using "Ping" 6-16
3.7 Communicationexampleusing"TELNET.EXE" 6-16
3.8 Appendix 6-17
3.8.1 Exampleofnetworksystemconguration 6-17
3.8.2 Glossary 6-20
4. General Ethernet port (GEP) 6-22
4.1 GEP parameter setting 6-22
4.2 GEP parameter setting method 6-23
4.3 Initializing communication parameters 6-24
Chapter 7 Controller system settings
1. Overview 7-1
2. History 7-1
3. Check 7-2
4. Property 7-2
4.1 Robot information 7-2
4.2 Option information 7-3
4.3 Clock 7-3
4.4 Version 7-3
4.5 Conguration 7-4

CONTENTS YRCX
User’s Manual
T-6
5. USB memory operation 7-4
5.1 Saving the data 7-4
5.2 Loading the data 7-5
6. Execution level 7-6
6.1 Changing the access level 7-6
7. Safety setting 7-7
8. Initialize 7-8
8.1 Initializing the data 7-8
8.2 Setting the clock 7-9
9. Generation 7-10
10. Parameters 7-10
10.1 Parameter setting conditions 7-10
10.2 Setting the parameters 7-10
10.3 Parameter list 7-12
10.4 Controller parameters 7-15
10.5 Robot parameters 7-17
10.6 Axis parameters 7-20
10.7 I/O parameters 7-27
10.8 Option board related parameters 7-29
Chapter 8 Periodic inspection
1. Before carrying out work 8-1
2. Maintenance parts 8-1
3. Periodic inspections 8-1
3.1 Daily inspections 8-1
3.2 Three-month inspections 8-2
4. Replacing the absolute battery 8-2
5. Replacing the memory battery 8-2
Chapter 9 Specications
1. Controller 9-1
1.1 Specications 9-1
1.2 Basic functions 9-2
1.3 Externalview 9-3

CONTENTS YRCX
User’s Manual
T-7
2. Programming box 9-4
2.1 Basicspecications 9-4
2.2 Externalview 9-4
Troubleshooting
1. Alarm messages A-1
1.1 Alarm messages related to the controller A-1
1.1.1 Alarm group number list A-3
1.1.2 Alarmclassicationnumberlist A-4
1.1.3 Warning number list A-4
[0]Operationmessages A-4
[ 1] System events A-5
[ 2] Alarm related to the robot operation A-7
[3]Alarmrelatedtotheprogramleoperation A-13
[ 4] Alarm related to the data input A-15
[ 5] Alarm related to the syntax of the robot language (compile) A-16
[ 6] Alarm related to the robot language execution A-23
[ 9] Alarm related to the memory A-33
[10] Alarm related to the environment and general hardware A-36
[12] Alarm related to the option board A-38
[14] Alarm related to the communication A-46
[17] Alarm related to the motor control A-49
[19]AlarmrelatedtotheYC-Link/E A-55
[21] Serious alarm related to software A-58
[22] Serious alarm related to hardware A-59
[26] Alarm related to the gripper A-62
[28]AlarmrelatedtothedriverI/F A-66
[ c] Warning A-67
1.2 Alarm messages related to the programming box A-68
2. Troubleshooting A-69
2.1 When trouble occurs A-69
2.2 Acquiring the alarm information A-70
2.2.1 Checking the alarm occurrence status A-70
2.2.2 Checking the alarm history A-70
2.3 Troubleshooting checkpoints A-71
2.3.1 Installation and power supply A-71
2.3.2 Robot operation A-72
2.3.3 I/O A-73