Yamaha RCX40 User manual

User’s Manual ENGLISH E
YAMAHA 4-AXIS ROBOT CONTROLLER
E75-Ver. 12.00
RCX40

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Introduction
Our sincere thanks for your purchase of this YAMAHA robot controller.
This manual explains how to install and operate the robot controller. Be sure to read this
manual carefully as well as related manuals and comply with their instructions for using
the YAMAHA robot controllers safely and correctly.
For details on robot programs, refer to the separate “Programming Manual”.

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Safety precautions (Be sure to read before using)
Before using theYAMAHA robot controller, be sure to read this manual and related manu-
als, and follow their instructions to use the robot controller safely and correctly.
Warning and caution items listed in this manual relate to YAMAHA robot controllers.
When this robot controller is used in a robot controller system, please take appropriate
safety measures needed by the user’s individual system.
This manual classifies safety caution items and operating points into the following levels,
along with symbols for “WARNING”, “CAUITON” and “NOTE”.
wWARNING
Failure to follow WARNING instructions could result in severe injury or death to the
operator, bystanders or persons inspecting or repairing the robot controller or robot.
cCAUTION
Failure to follow CAUTION instructions may result in injury to the operator, bystanders or persons
inspecting or repairing the robot controller or robot, and may damage the robot controller or robot.
nNOTE
Explains the key point in the operation in a simple and clear manner.
Note that the items classified into “CAUTION” might result in serious injury depending
on the situation or environmental conditions. So always comply with the CAUTION and
WARNING instructions as these are essential for safety.
Keep this manual carefully so that the operator can refer to it when needed. Also make
sure that this manual reaches the end user.
When installing the RCX40 robot controller, please take into account all the instructions
and precautions described in Chapter 3, "Installation".

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[System design safety points]
wWARNING
• Refer to this manual for details on the operating status of the robot controller and
related instruction manuals.
Design and configure the system including the robot controller so that it will
always work safely.
• The robot controller has an emergency stop terminal to trigger emergency stop.
Using this terminal, prepare a physical interlock circuit so that the system
including the robot controller will work safely.
cCAUTION
• Do not bundle control lines or communication cables together or in close contact with the
robot controller main circuit or power lines. As a general rule, separate them by at least
100mm. Noise in the main circuit or power lines may cause faulty operation or malfunctions.
• Data (programs, point data, etc.) stored in the robot controller is not guaranteed to be
unchanged, so be sure to save it into an external storage device.
[Installation safety points]
wWARNING
• Securely install the connectors into the robot controller, and when wiring the
connectors, make the crimp, press-contact or solder connections correctly, using
the tool specified by the manufacturer.
• Always shut off all phases of the power supply externally before starting
installation or wiring work. Failure to shut off all phases could lead to electric
shocks or product damage.
cCAUTION
• Use the robot controller within the environment specifications listed in this manual.
Using the controller in an environment outside the specification range could lead to electric
shocks, fires, malfunctions, product damage or deteriorated performance.
• Tighten the screws on the robot controller firmly to make secure connections.
• Never directly touch the conductive sections or electronic parts other than the rotary switches
and DIP switches on the outside panel of the robot controller.
• Securely install each connection cable connector into the receptacles or sockets.
Poor connections will cause faulty operation or malfunctions.
[Wiring safety points]
wWARNING
• Always shut off all phases of the power supply externally before starting
installation or wiring work. Failure to shut off all phases could lead to electric
shocks or product damage.
• Always attach the terminal cover (supplied) before turning on the power to the
robot controller after installation and wiring work are complete. Failure to attach
the terminal cover could lead to fire, electrical shock, product damage or
malfunctions.
cCAUTION
• Tighten the terminal screws within the specified torque range.
A loose terminal screw could lead to short-circuit, faulty operation or malfunctions. In
contrast, if the terminal screw is too tight, short-circuit, faulty operation or malfunctions could
also occur due to screw damage.
• Make sure that foreign matter, such as cutting chips or wire scraps, do not enter the robot
controller.
• Always store the cables connected to the robot controller in a conduit or clamp them securely
in place.
If the cables are not stored in a conduit or properly clamped, excessive play or movement, or
mistakenly pulling on the cable may damage the connector or cables, and poor cable contact
may lead to faulty operation or malfunctions.
• When disconnecting the cable, detach by holding the connector itself and not by tugging on the
cable. Loosen the screws on the connector (if fastened with the screws), and then disconnect
the cable.
Detaching by pulling on the cable itself may damage the connector or cables, and poor cable
contact may lead to faulty operation or malfunctions.

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[Start-up and maintenance safety points]
wWARNING
• When operating the robot, only personnel trained in safety and robot operation
may operate it.
• Never allow anyone to enter the robot movement range when the robot controller
is turned on. Serious accident including fatal injury or death could otherwise
result.
• This robot controller is not designed for explosion-proof. Do not use it in locations
exposed to inflammable gases, gasoline or solvent that could cause explosion or
fire.
• Do not touch any electrical terminal while power is supplied to the robot
controller. This may cause electrical shocks, faulty operation or malfunctions.
• Always shut off all phases of the power supply externally before cleaning or
tightening the terminal screws.
Failure to shut off all phases could lead to electric shocks, product damage or
malfunctions.
A loose screw could lead to dropping, short circuit or malfunctions.
If the screw is too tight, short circuit or malfunctions could also occur due to
screw damage.
• Never disassemble or modify the robot controller.
This may lead to breakdowns, malfunctions, injury or fire.
• Always shut off all phases of the power supply externally before installing or
removing an option board.
Failure to shut off all phases could lead to breakdowns or malfunctions.
• When using ferrite cores for noise elimination, fit them to the power cable as close
to the robot controller as possible, to prevent faulty operation or malfunctions due
to noise.
• When performing maintenance of the robot controller under instructions from
YAMAHA or YAMAHA sales dealer, turn off the robot controller and wait for at least
30 minutes. Some parts in the robot controller may be hot or applied at a high
voltage shortly after operation, so burns or electrical shocks may occur if those
parts are touched.
[Precautions for disposal]
cCAUTION
• When disposing of this product discard it as industrial waste.
[Other precautions]
cCAUTION
• Please note that the state of California USA has legal restrictions on the handling of
manganese dioxide lithium batteries. See the following website for more information:
http://www.dtsc.ca.gov/hazardouswaste/perchlorate
This manual does not constitute a concession of rights or a guarantee of
industrial rights. Please acknowledge that we bear no liability whatsoever
for conflicts with industrial rights arising from the contents of this manual.
2007 YAMAHA MOTOR CO., LTD.

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Before using the robot controller
(Be sure to read the following notes.)
Please be sure to perform the following tasks before using the robot controller.
Failing to perform these tasks will require absolute reset for origin position setting each
time the power is turned on or may cause abnormal operation (vibration, noise).
[1] When connecting the power supply to the robot controller
Always make a secure connection to the ground terminal on the robot controller to
ensure safety and prevent malfunctions due to noise.
[2] When connecting the battery cable to the robot controller
The absolute battery is fully charged when the robot controller is shipped to the
customer. However, it is left disconnected to prevent battery discharge. After installing
the controller, always be sure to connect the absolute battery while referring to “9.
Connecting the absolute battery” in Chapter 3 before connecting the robot cables.
An error (relating to absolute settings) is always issued if the robot controller power is
turned on without making the absolute battery connections, so the origin position is
not detected. This means the robot connected to this controller cannot be used as
absolute specifications.
[3] When connecting robot cables to the robot controller
Be sure to keep robot cables separate from the robot controller power connection
lines and other equipment power lines. Using in close contact with lines carrying
power may cause malfunctions or abnormal operation.
Reference
Absolute reset is always required when
the robot controller power is first
turned on after connecting the robot
cable to the robot controller. Perform
absolute reset while referring to “11.8
Absolute reset” in Chapter 4,
“Operation”.
Absolute reset is also required after the
robot cable was disconnected from the
robot controller and then reconnected.
Reference
Refer to “4. Connecting the power” in
Chapter 3, “Installation”.

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Overview of the RCX series
TheYAMAHA RCX series robot controllers were developed based on years ofYAMAHA
experience and achievements in robotics and electronics. These controllers are specifically
designed to operate YAMAHA industrial robots efficiently and accurately.
Despite its compact size, the RCX series controllers serve as multi-axis controllers with a
variety of functions.
Major features and functions are:
1. Multi-task function
Up to 8 tasks* can be run simultaneously in a specified priority. (Low priority tasks
are halted while high priority tasks are run.)
I/O parallel processing and interrupt processing are also available, so that operational
efficiency of the total robot system including peripheral units is greatly improved.
(*: Refer to the programming manual for more details on multi-tasking.)
2. Robot language
The RCX series controller comes with a BASIC-like high-level robot language that
conforms to the industrial robot programming language SLIM*1. This robot language
allows easy programming even of complex movements such as multi-task operations
and uses a compiling method*2 for rapid execution of programs.
(*1: Standard Language for Industrial Manipulators)
(*2: This compiling method checks the syntax in a robot language program, converts
it into intermediate codes, and creates an execution file (object file) before actually
performing the program.)
3. Movement command
• Arch motion
Spatial movement during pick-and-place work can be freely set according to the
work environment. This is effective in reducing cycle time.
• Three-dimensional CP control
Three-dimensional interpolation control for linear and circular movements is
possible.
4. Maintenance
Software servo control provides unit standardization. This means compatibility with
most YAMAHA robot models, thus simplifying maintenance and adjustment.
5. CE marking*
As a product ofYAMAHA robot series, the RCX series robot controller is designed to
conform to machinery directives, low-voltage directives and EMC (Electromagnetic
compatibility) directives. In this case, the robot controller is set to operate under SAFE
mode. (* For CE marking compatibility, see the CE marking compatibility manual.)
This manual explains how to handle and operate theYAMAHA robot controllers correctly
and effectively, as well as I/O interface connections.
Read this manual carefully before installing and using the robot controller. Also refer to
the separate “Programming Manual” and “Robot User’s Manual” as needed.

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Contents
Chapter 1 Safety
1. Safety .........................................................................................1-1
1.1 Safety precautions during robot operation ........................................... 1-2
1.2 Safety precautions during maintenance ............................................... 1-2
1.3 Precautions for motor overload ........................................................... 1-2
1.4 Warning labels .................................................................................... 1-3
1.5 Warning marks ................................................................................... 1-3
2. Warranty ...................................................................................1-4
3. Operating environment .............................................................1-5
Chapter 2 System overview
1. System overview ........................................................................2-1
1.1 Main system configuration .................................................................. 2-1
1.2 Axis definition for the RCX40 .............................................................. 2-3
2. Part names and functions...........................................................2-4
2.1 RCX40 (Maximum number of axes: 4 axes) ......................................... 2-4
3. Controller system ......................................................................2-5
3.1 Basic configuration ............................................................................. 2-5
4. Optional devices........................................................................2-6
4.1 MPB programming device................................................................... 2-6
4.2 Expansion I/O board ........................................................................... 2-6
4.3 Regenerative unit ................................................................................ 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 .......................................................................................... 3-2
2.2 Installation methods ............................................................................ 3-3
3. Connectors ................................................................................3-5
4. Power connections ....................................................................3-6
4.1 AC200 to 230V single-phase specifications ......................................... 3-6
4.2 Power capacity ................................................................................... 3-6
4.3 External leakage breaker installation ................................................... 3-8
4.4 Circuit protector installation................................................................ 3-8
4.5 Current control switch installation ...................................................... 3-8
5. Robot cable connections ...........................................................3-9
6. Connecting the MPB programming unit ..................................3-10
7. I/O connections.......................................................................3-11
8. Connecting a host computer....................................................3-12

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9. Connecting the absolute battery ..............................................3-13
10. Replacing the absolute battery ................................................3-15
11. Connecting a regenerative unit................................................3-18
12. Precautions for cable routing and installation .........................3-19
12.1 Wiring methods ................................................................................ 3-19
12.2 Precautions for installation ................................................................ 3-19
12.3 Methods of preventing malfunctions ................................................. 3-19
13. Checking the robot controller operation .................................3-21
13.1 Cable connection.............................................................................. 3-21
13.2 Emergency stop input signal connection ........................................... 3-22
13.3 Operation check ............................................................................... 3-22
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. MPB programming unit .............................................................4-3
3.1 Part names .......................................................................................... 4-3
3.2 Main functions .................................................................................... 4-4
3.3 Connection to the robot controller ...................................................... 4-5
4. Turning power on and off ..........................................................4-6
5. Operation keys ..........................................................................4-7
5.1 MPB screen......................................................................................... 4-7
5.2 Operation key layout .......................................................................... 4-8
5.3 Basic key operation............................................................................. 4-9
5.4 Function keys.................................................................................... 4-10
5.5 Control keys...................................................................................... 4-12
5.6 Data keys .......................................................................................... 4-14
5.7 Other keys ........................................................................................ 4-14
6. Emergency stop .......................................................................4-15
6.1 Emergency stop reset ........................................................................ 4-16
7. Mode configuration .................................................................4-18
7.1 Basic operation modes ...................................................................... 4-18
7.2 Other operation modes ..................................................................... 4-19
7.3 Mode hierarchy ................................................................................. 4-20
8. “SERVICE” mode .....................................................................4-24
8.1 Operation device .............................................................................. 4-24
8.2 Prohibition of “AUTO” mode operation ............................................ 4-24
8.3 Hold-to-Run function ........................................................................ 4-24
8.4 Limitations on robot operating speed ................................................ 4-24
9. “AUTO” mode.........................................................................4-25
9.1 Automatic operation ......................................................................... 4-28
9.2 Stopping the program........................................................................ 4-29