Yamaha RCX222 User manual

RCX222
EUR2153130
E99
Ver. 1.30
UserʼsManual
YAMAHA2-AXISROBOTCONTROLLER

CONTENTS RCX222
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-8
3.2 Warning symbols S-9
4. Important precautions for each stage of the robot life cycle S-10
4.1 Precautions for using robots and controllers S-10
4.2 Essential precautions for the linear conveyor module S-11
4.3 Design S-12
4.3.1 Precautions for robots S-12
4.3.2 Precautions for robot controllers S-12
4.4 Moving and installation S-13
4.4.1 Precautions for robots S-13
4.4.2 Precautions for robot controllers S-14
4.5 Safety measures S-16
4.5.1 Safety measures S-16
4.5.2 Installing a safety enclosure S-17
4.6 Operation S-18
4.6.1 Trial operation S-18
4.6.2 Automatic operation S-20
4.6.3 Precautions during operation S-20
4.7 Inspection and maintenance S-22
4.7.1 Before inspection and maintenance work S-22
4.7.2 Precautions during service work S-23
4.8 Disposal S-24
5. Emergency action when a person is caught by robot S-25
6. Cautionsregardingstrongmagneticelds S-25
7. Using the robot safely S-26
7.1 Movement range S-26
7.2 Robot protective functions S-27
7.3 Residual risk S-28
7.4 Special training for industrial robot operation S-28

CONTENTS RCX222
User’s Manual
T-2
T-3
Warranty
Introduction 1
Before using the robot controller (Be sure to read the following notes) 2
Overview of the RCX series 3
Chapter 1 USING THE ROBOT SAFELY
1. Operating environment 1-1
Chapter 2 SYSTEM OVERVIEW
1. System overview 2-1
1.1 Mainsystemconguration 2-1
1.2 RCX22seriesaxisdenition 2-2
2. Part names and functions 2-3
2.1 RCX222 (Maximum number of axes: 2) 2-3
2.2 RCX222HP (Maximum number of axes: 2) 2-3
3. Control system 2-4
3.1 RCX222/RCX222HP 2-4
4. Optional devices 2-5
4.1 RPB programming box 2-5
4.2 I/O expansion 2-5
4.3 Regenerative unit 2-5
5. Basic sequence from installation to operation 2-6
Chapter 3 INSTALLATION
1. Unpacking 3-1
1.1 Packing box 3-1
1.2 Unpacking 3-1
2. Installing the robot controller 3-2
2.1 Installation conditions 3-2
2.2 Installation methods 3-4
3. Connector names 3-6
4. Connecting to the power 3-7

T-2
CONTENTS RCX222
User’s Manual
T-3
4.1 Connection example 3-7
4.2 Power supply and ground terminals 3-8
4.3 AC power connector wiring 3-9
4.4 Considering power capacity and generated heat amount 3-10
4.5 Installing an external leakage breaker 3-11
4.6 Installing a circuit protector 3-11
4.7 Installing an electromagnetic contactor 3-12
4.8 Installinganoiselter 3-12
4.9 Installing a surge absorber 3-13
5. Robot connections 3-14
5.1 Connecting the robot cables 3-14
5.2 Noise countermeasures 3-15
6. Connecting the RPB programming box 3-16
7. I/O connections 3-17
8. Connecting a host computer 3-18
9. Connecting the absolute battery 3-19
10. Replacing the absolute battery 3-21
11. Connecting a regenerative unit 3-22
12. Precautions for cable routing and installation 3-24
12.1 Wiring methods 3-24
12.2 Precautions for installation 3-26
12.3 Methods of preventing malfunctions 3-26
13. Checking the robot controller operation 3-27
13.1 Cable connection 3-27
13.2 Operation check 3-28
Chapter 4 OPERATION
1. Operation overview 4-1
2. The RCX robot controller 4-2
2.1 Part names 4-2
2.2 Main functions 4-2
3. RPB programming box 4-3

CONTENTS RCX222
User’s Manual
T-4
T-5
3.1 Part names 4-3
3.2 Main functions 4-3
3.3 Connection to the robot controller 4-4
3.4 Changing the RPB screen settings 4-5
4. Turning power on and off 4-6
5. Operation keys 4-8
5.1 RPB screen 4-8
5.2 Operation key layout 4-9
5.3 Basic key operation 4-10
5.4 Function keys 4-11
5.5 Control keys 4-13
5.6 Data keys 4-15
5.7 Other keys 4-15
6. Emergency stop 4-16
6.1 Emergency stop reset 4-17
6.2 Overload error reset 4-19
7. Modeconguration 4-21
7.1 Basic operation modes 4-21
7.2 Other operation modes 4-22
7.3 Mode hierarchy 4-23
8. "SERVICE" mode 4-28
8.1 Operation device 4-28
8.2 Prohibition of "AUTO" mode operation 4-28
8.3 Hold-to-Run function 4-28
8.4 Limits on robot moving speed 4-29
9. "AUTO" mode 4-30
9.1 Automatic operation 4-33
9.2 Stopping the program 4-34
9.3 Resetting the program 4-35
9.4 Switching task display 4-37
9.5 Switching the program 4-38
9.6 Changing the automatic movement speed 4-39
9.7 Executing the point trace 4-40
9.7.1 PTP motion mode 4-42
9.7.2 ARCH motion mode 4-43
9.7.3 Linear interpolation motion mode 4-45
9.8 Direct command execution 4-46

T-4
CONTENTS RCX222
User’s Manual
T-5
9.9 Break point 4-47
9.9.1 Setting break points 4-48
9.9.2 Deleting break points 4-49
9.10 Executing a step 4-50
9.11 Skipping a step 4-50
9.12 Executing the next step 4-51
10. "PROGRAM" mode 4-52
10.1 Scrolling a program listing 4-53
10.2 Program editing 4-54
10.2.1 Cursor movement 4-56
10.2.2 Insert/Overwrite mode switching 4-57
10.2.3 Inserting a line 4-58
10.2.4 Deleting a character 4-58
10.2.5 Deleting a line 4-58
10.2.6 User function key display 4-59
10.2.7 Quitting program editing 4-60
10.2.8 Specifying the copy/cut lines 4-60
10.2.9 Copying the selected lines 4-61
10.2.10Cutting the selected lines 4-61
10.2.11 Pasting the data 4-62
10.2.12Backspace 4-62
10.2.13Line jump 4-63
10.2.14Searching a character string 4-64
10.3 Directory 4-65
10.3.1 Cursor movement 4-67
10.3.2 Registering a new program name 4-67
10.3.3 Directory information display 4-68
10.3.4 Copying a program 4-69
10.3.5 Erasing a program 4-70
10.3.6 Renaming a program 4-71
10.3.7 Changing the program attribute 4-72
10.3.8 Displaying object program information 4-73
10.3.9 Creating a sample program automatically 4-74
10.4 Compiling 4-76
10.5 Line jump and character string search 4-77
10.6 Registering user function keys 4-77
10.7 Resetting an error in the selected program 4-81
11. "MANUAL" mode 4-82
11.1 Manual movement 4-84
11.2 Displaying and editing point data 4-87

CONTENTS RCX222
User’s Manual
T-6
T-7
11.2.1 Point data input and editing 4-89
11.2.1.1 Restoring point data 4-90
11.2.2 Point data input by teaching 4-91
11.2.3 Point data input by direct teaching 4-93
11.2.4 Point jump display 4-94
11.2.5 Copying point data 4-95
11.2.6 Erasing point data 4-97
11.2.7 Point data trace 4-98
11.2.8 Point comment input and editing 4-98
11.2.8.1 Point comment input and editing 4-100
11.2.8.2 Point data input by teaching 4-100
11.2.8.3 Jump to a point comment 4-101
11.2.8.4 Copying a point comment 4-101
11.2.8.5 Erasing point comments 4-103
11.2.8.6 Point comment search 4-104
11.2.9 Point data error reset 4-105
11.3Displaying,editingandsettingpalletdenitions 4-106
11.3.1 Editing pallet definitions 4-108
11.3.1.1 Point setting in pallet definition 4-109
11.3.1.1.1 Editing the point in pallet definition 4-110
11.3.1.1.2 Setting the point in pallet definition by teaching 4-110
11.3.2 Pallet definition by teaching 4-111
11.3.3 Copying a pallet definition 4-114
11.3.4 Deleting a pallet definition 4-115
11.4 Changing the manual movement speed 4-116
11.5 Displaying, editing and setting shift coordinates 4-117
11.5.1 Editing shift coordinates 4-119
11.5.1.1 Restoring shift coordinates 4-120
11.5.2 Editing the shift coordinate range 4-121
11.5.2.1 Restoring a shift coordinate range 4-123
11.5.3 Shift coordinate setting method 1 4-124
11.5.4 Shift coordinate setting method 2 4-127
11.6 Displaying,editingandsettinghanddenitions 4-130
11.6.1 Editing hand definitions 4-133
11.6.1.1 Restoring hand definitions 4-134
11.6.2 Hand definition setting method 1 4-135
11.7 Changing the display units 4-137
11.8 Absolute reset 4-138
11.8.1 Checking absolute reset 4-139
11.8.2 Absolute reset on each axis 4-140
11.8.3 Absolute reset on all axes 4-147
11.9 Setting the standard coordinates 4-153

T-6
CONTENTS RCX222
User’s Manual
T-7
11.10 Executing the user function keys 4-154
12. "SYSTEM" mode 4-155
12.1 Parameters 4-157
12.1.1 Parameter list 4-159
12.1.2 Robot parameters 4-161
12.1.3 Axis parameters 4-165
12.1.4 Other parameters 4-185
12.1.5 Parameters for option boards 4-201
12.1.5.1 Option DIO setting 4-203
12.1.5.2 Serial IO setting 4-204
12.1.5.3 Setting the network parameters 4-209
12.2 Communication parameters 4-211
12.3 OPTION parameters 4-220
12.3.1 Setting the area check output 4-221
12.3.2 Setting the "SERVICE" mode 4-230
12.3.2.1 Saving the "SERVICE" mode parameters 4-236
12.3.2.2 Help display in "SERVICE" mode 4-237
12.3.3 SIO settings 4-238
12.3.4 Double-carrier setting 4-241
12.3.4.1 Before using a double-carrier 4-241
12.3.4.2 Setting the double-carrier parameters 4-242
12.4 Initialization 4-245
12.4.1 Initializing the parameters 4-246
12.4.2 Initializing the memory 4-247
12.4.3 Initializing the communication parameters 4-248
12.4.4 Clock setting 4-249
12.4.5 System generation 4-250
12.5 Self diagnosis 4-251
12.5.1 Controller check 4-252
12.5.2 Error history display 4-253
12.5.3 Displaying the absolute battery condition 4-254
12.5.4 Displaying the total operation time 4-255
12.5.5 System error details display 4-256
12.6 Backup processes 4-257
12.6.1 SD memory card 4-258
12.6.1.1 Loading files 4-260
12.6.1.2 Saving files 4-262
12.6.1.3 Deleting files 4-264
12.6.1.4 Previewing files 4-265
12.6.2 Internal flash ROM 4-266
12.6.2.1 Loading files 4-267

CONTENTS RCX222
User’s Manual
T-8
T-9
12.6.2.2 Saving files 4-269
12.6.2.3 Initializing the files 4-270
13. "MONITOR" mode 4-271
14. "UTILITY" mode 4-274
14.1 Canceling emergency stop; Motor power and servo on/off 4-276
14.1.1 Canceling emergency stop 4-276
14.1.2 Motor power and servo on/off 4-277
14.2 Overload error reset and motor and servo power on/off 4-279
14.2.1 Emergency stop reset 4-279
14.2.2 Overload error reset 4-279
14.3Enabling/disablingthesequenceexecutionag 4-280
14.4 Resetting the output ports 4-281
14.5 Changing the execution level 4-282
14.5.1 Changing the execution level 4-283
14.5.2 Displaying the Help message 4-284
14.6 Changing the access level (operation level) 4-285
14.6.1 Entering the password 4-286
14.6.2 Changing the access level 4-287
14.6.3 Displaying the Help message 4-288
Chapter 5 PARALLEL I/O INTERFACE
1. Standard I/O interface overview 5-1
1.1 ID setting 5-2
1.2 Connector I/O signals 5-3
1.3 Connector pin numbers 5-6
1.4 Connecting the power supply 5-7
1.4.1 NPN/PNP power connector wiring 5-8
1.5 Typical input signal connection 5-9
1.6 Typical output signal connection 5-10
1.7 Dedicated I/O signals 5-11
1.7.1 Dedicated input signals 5-11
1.7.2 Dedicated output signals 5-13
1.8 General-purpose I/O signals 5-15
1.8.1 General-purpose output reset 5-15
1.9 Dedicated I/O signal timing charts 5-16
1.9.1 Turning the power on 5-16
1.9.2 Emergency stop and servo ON 5-18
1.9.3 ABS (absolute) reset 5-19
1.9.4 Mode switching 5-20
1.9.5 Automatic operation 5-21