Yamaha TRANSERVO SSC04 User manual

User’s Manual ENGLISH E
E46-Ver. 1.02
SSC04/SSC05/SSC05 H
YAMAHA SINGLE-AXIS ROBOT TRANSERVOseries
IM Operations
882 Soude, Naka-ku, Hamamatsu, Shizuoka 435-0054.Japan
URL http://www.yamaha-motor.jp/robot/index.html
YAMAHA MOTOR CO., LTD.

Introduction
Introduction
Thank you for purchasing the YAMAHA single-axis robot TRANSERVO series.
This manual describes the safety measures, handling, adjustment and maintenance of
YAMAHA TRANSERVO series robots for correct, safe and effective use. Be sure to read
this manual carefully before installing the TRANSERVO series robot. Even after you have
read this manual, keep it in a safe and convenient place for future reference when needed.
• This user's manual should be used with the robot and considered an integral part of
it. When the robot is moved, transferred or sold, send this manual to the new user
along with the robot. Be sure to explain to the new user the need to read through this
manual.
• Specifications of robot models other than standard models may be omitted in this
manual if they are common to those of standard models. In this case, refer to the
specifications of standard models.
• For details on specific operation of the robot, refer to the separate user’s manual for the
robot controller being used.
NOTES
◆
The contents of this manual are subject to change without prior notice.
◆
While every effort has been made to ensure the contents of this manual are
correct, please contact us if you find any part of this manual to be unclear,
confusing or inaccurate.

MEMO

i
General Contents
General Contents
Chapter 1 Using the Robot Safely
1-1 Safety information 1-1
1-2 Essential precautions 1-3
1-3
Special training for industrial robot operation 1-9
1-4 Robot safety functions 1-10
1-5 Safety measures for the system 1-11
1-6 Trial operation 1-11
1-7 Work within the safety enclosure 1-12
1-8 Automatic operation 1-13
1-9 Warranty 1-14
Chapter 2 Product Overview
2-1 Checking the product 2-1
2-2 Robot part names 2-2
2-3 Robot installation conditions 2-3
2-4 Installation base 2-4
2-5 Installing the robot 2-5
2-6 The "Emergency Stop" stopping distance 2-6
2-7 Connections 2-6
2-7-1 Connecting the robot to the controller 2-6
2-7-2 Robot cable connections 2-8
2-7-3 Robot system configuration drawing 2-9
2-8 Setting the operating conditions 2-10
2-8-1 Payload 2-10
2-8-2 Duty 2-10
2-8-3 Push force vs. current limit value during stop 2-11
2-9 Suction hoses connection 2-13

General Contents
ii
Chapter 3 Periodic Inspection and Maintenance
3-1 Before beginning work 3-1
3-2 Periodic inspection 3-3
3-2-1 Daily inspection 3-3
3-2-2 Three-month inspection 3-3
3-2-3 Six-month inspection 3-4
3-2-4 Three-year inspection 3-4
3-3 Applying grease 3-5
3-4 Replacing the shutter 3-6
3-5 Adjusting shutter looseness 3-8
3-6 Replacing the motor 3-9
3-6-1 SSC04 3-9
3-6-2 SSC05, SSC05H 3-11
3-6-3 Verifying the machine reference 3-13
3-7 Replacing the coupling 3-15
3-7-1 SSC04 3-15
3-7-2 SSC05, SSC05H 3-17
Chapter 4 Specifications
4-1 Main unit specifications 4-1
4-1-1 SSC04 4-1
4-1-2 SSC05 4-4
4-1-3 SSC05H 4-7
4-1-4 About noise level 4-10
4-2 Motor specifications 4-10
4-2-1 Motor termination 4-10
4-2-2 Brake cable termination 4-12
4-3 Robot cables 4-13
Chapter 5 Troubleshooting
5-1 Positioning error 5-1

Chapter 1 Using the Robot Safely
Contents
1-1 Safety information 1-1
1-2 Essential precautions 1-3
1-3
Special training for industrial robot operation 1-9
1-4 Robot safety functions 1-10
1-5 Safety measures for the system 1-11
1-6 Trial operation 1-11
1-7 Work within the safety enclosure 1-12
1-8 Automatic operation 1-13
1-9 Warranty 1-14

1
Using the Robot Safely
1-1 Safety information
1-1
1-1 Safety information
To ensure correct and safe use of YAMAHA industrial robots, carefully read this manual
and make yourself well acquainted with the contents. FOLLOW THE WARNINGS,
CAUTIONS AND INSTRUCTIONS included in this manual. Failure to take necessary
safety measures or mishandling due to not following the instructions in this manual may
result in trouble or damage to the robot and injury to personnel (robot operator or service
personnel) including fatal accidents.
Warning symbols and signal words used in this manual are classified as explained below.
Make sure that you fully understand the meaning of each symbol and comply with the
instructions.
wDANGER
FAILURE TO FOLLOW DANGER INSTRUCTIONS WILL RESULT IN SEVERE INJURY OR
DEATH TO THE ROBOT OPERATOR, BYSTANDERS OR PERSONS INSPECTING OR
REPAIRING THE ROBOT.
wWARNING
FAILURE TO FOLLOW WARNING INSTRUCTIONS COULD RESULT IN SEVERE INJURY
OR DEATH TO THE ROBOT OPERATOR, BYSTANDERS OR PERSONS INSPECTING
OR REPAIRING THE ROBOT.
cCAUTION
Failure to follow CAUTION instructions may result in injury to the robot
operator, bystanders or persons inspecting or repairing the robot, or
damage to the robot and/or robot controller.
nNOTE
Explains the key point in the operation in a simple and clear manner.
Reference
Gives useful information related to the robot operation.

Using the Robot Safely
1
1-1 Safety information
1-2
Refer to the user's manual by any of the following methods to operate or adjust the robot
safely and correctly.
1.Operate or adjust the robot while referring to the printed version of the user's
manual (available for an additional fee).
2.Operate or adjust the robot while viewing the CD-ROM version of the user's
manual on your computer screen.
3.Operate or adjust the robot while referring to a printout of the necessary pages
from the CDROM version of the user's manual.
It is not possible to list all safety items in detail within the limited space of
this manual. So it is essential that the user have a full knowledge of basic
safety rules and also that the operator makes correct judgments on safety
procedures during operation.
For specific safety information and standards, refer to the applicable local
regulations and comply with the instructions. This manual and warning labels
supplied with or attached to the robot are written in English. Unless the
robot operators or service personnel understand English, do not permit them
to handle the robot.
* Cautions regarding the official language of EU countries
For equipment that will be installed in EU countries, the language used for the
user's manuals, CE declarations, and operation screen characters is English only.
Warning labels only have pictograms or else include warning messages in English.
In the latter case, Japanese messages might be added.

1
Using the Robot Safely
1-2 Essential precautions
1-3
1-2 Essential precautions
Particularly important cautions for handling or operating the robot are described below. In
addition, precautions during installation, operation, inspection and maintenance are also
provided in each chapter. Be sure to comply with these instructions to ensure safe use of
the robot.
(1) Observe the following cautions during automatic operation.
• Install a safeguard (safety enclosure) to keep any person from entering within the
movement range of the robot and suffering injury due to being struck by moving
parts.
• Install a safety interlock that triggers emergency stop when the door or panel is
opened.
• Install a safety enclosure so that no one can enter inside except from doors or
panels equipped with safety interlocks.
• Warning labels 1 are supplied with the robot and should be affixed to conspicuous
spots on doors or panels of the safety enclosure.
wDANGER
SERIOUS INJURY OR DEATH WILL RESULT FROM IMPACT WITH MOVING ROBOT.
• KEEP OUTSIDE OF GUARD DURING OPERATION.
• LOCK OUT POWER BEFORE APPROACHING ROBOT.
Warning label 1
DANGER
Serious injury or death
will result from impact
with moving robot.
sKeep outside of guard
during operation.
sLock out power before
approaching robot.
(2) Use caution to prevent hands or fingers from being pinched or crushed.
• Use caution to prevent hands or fingers from being pinched or crushed by the
moving parts when carrying the robot or during teaching.
• Warning labels 2 are supplied with the robot and should be affixed to the robot or
conspicuous spots near the robot.
wWARNING
MOVING PARTS CAN PINCH OR CRUSH.
KEEP HANDS AWAY FROM ROBOT ARMS.

Using the Robot Safely
1
1-2 Essential precautions
1-4
Warning label 2
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
WARNING
(3) Follow the instructions on warning labels and in this manual.
• Be sure to read the warning labels and this manual carefully and make sure you
thoroughly understand their contents before attempting installation and operation
of the robot.
• Before starting robot operation, be sure to reread the procedures and cautions
relating to your work as well as descriptions in this chapter (Chapter 1, "Using the
Robot Safely").
• Never install, adjust, inspect or service the robot in any manner that does not
comply with the instructions in this manual.
• Warning labels 3 are supplied with the robot and should be affixed to the robot or
conspicuous spots near the robot.
wWARNING
IMPROPER INSTALLATION OR OPERATION CAN RESULT IN SERIOUS INJURY OR
DEATH.
READ THE USER'S MANUAL AND ALL WARNING LABELS BEFORE OPERATION.
Warning label 3
Improper installation or operation
can result in serious injury or
death. Read user's(owner’s)
manual and all warning labels
before operation.
WARNING

1
Using the Robot Safely
1-2 Essential precautions
1-5
(4) Do not remove, alter or stain the warning labels.
wWARNING
IF WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE, THEN ESSENTIAL
PRECAUTIONS 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 THE SYMBOLS AND INSTRUCTIONS ON
THE WARNING LABELS CAN BE CLEARLY SEEN EVEN FROM OUTSIDE THE
SAFETY ENCLOSURE.
(5) Do not use the robot in environments containing inflammable gas, etc.
wWARNING
• THIS ROBOT WAS NOT DESIGNED FOR OPERATION IN ENVIRONMENTS WHERE
INFLAMMABLE OR EXPLOSIVE SUBSTANCES ARE PRESENT.
• DO NOT USE THE ROBOT IN ENVIRONMENTS CONTAINING INFLAMMABLE
GAS, DUST OR LIQUIDS. EXPLOSIONS OR FIRE MIGHT OTHERWISE RESULT.
(6) Do not use the robot in locations possibly subject to electromagnetic interference,
etc.
wWARNING
AVOID USING THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC
INTERFERENCE, ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY
INTERFERENCE. MALFUNCTIONS MIGHT OTHERWISE OCCUR.
(7) Use caution when releasing the brake of a vertical use robot.
wWARNING
THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE BRAKE IS RELEASED, CAUSING
A HAZARDOUS SITUATION.
• PRESS THE EMERGENCY STOP BUTTON AND PROP UP THE VERTICAL AXIS
WITH A SUPPORT STAND BEFORE RELEASING THE BRAKE.
• BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL
AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM
DIRECT TEACH.

Using the Robot Safely
1
1-2 Essential precautions
1-6
(8) Provide safety measures for end effector (gripper, etc.).
wWARNING
• END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY
CREATE NO HAZARDS (FOR EXAMPLE, A WORKPIECE THAT COMES LOOSE)
EVEN IF POWER (ELECTRICITY, AIR PRESSURE, ETC.) IS SHUT OFF OR POWER
FLUCTUATIONS OCCUR.
• IF THERE IS A POSSIBLE DANGER THAT THE OBJECT GRIPPED BY THE END
EFFECTOR MAY FLY OFF OR DROP, THEN PROVIDE APPROPRIATE SAFETY
PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE, WEIGHT,
TEMPERATURE AND CHEMICAL PROPERTIES.
(9) Use caution when removing the motor. (Vertical use robots)
wWARNING
THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE MOTOR IS RELEASED,
CAUSING A HAZARDOUS SITUATION.
• TURN OFF THE ROBOT CONTROLLER AND PROP UP THE VERTICAL AXIS WITH
A SUPPORT STAND BEFORE REMOVING THE MOTOR.
• BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL
AXIS PARTS AND INSTALLATION BASE.
(10) Be careful not to touch the motor and peripheral parts when hot.
wWARNING
The motor and speed reduction gear casing are extremely hot after
automatic operation, so burns may occur if these are touched.
Before handling these parts during inspection or servicing, turn off the
controller, wait for a while and check that the parts have cooled.
(11) Consult us for corrective action when the robot is damaged or malfunctions occur.
wWARNING
IF ANY PART OF THE ROBOT IS DAMAGED OR ANY MALFUNCTION OCCURS,
CONTINUING THE OPERATION MAY BE VERY DANGEROUS. PLEASE CONSULT
YOUR YAMAHA SALES OFFICE OR DEALER FOR CORRECTIVE ACTION.
Damage or Trouble Possible Danger
Damage to machine harness or robot cable Electrical shock, malfunction of robot
Damage to exterior of robot Flying outwards of damaged parts
during robot operation
Abnormal operation of robot
(positioning error, excessive vibration, etc.) Malfunction of robot
Z-axis brake trouble Dropping of load

1
Using the Robot Safely
1-2 Essential precautions
1-7
(12) Protective bonding
wWARNING
BE SURE TO GROUND THE ROBOT AND CONTROLLER TO PREVENT ELECTRICAL
SHOCK.
(13) Be sure to make correct parameter settings.
cCAUTION
The robot must be operated with correct tolerable moment of inertia and
acceleration coefficients according to the manipulator tip mass and
moment of inertia. If these are not correct, drive unit service life may end
prematurely, and damage to robot parts or residual vibration during
positioning may result.
(14) Take the following safety precautions during inspection of controller.
wWARNING
• WHEN YOU NEED TO TOUCH THE TERMINALS OR CONNECTORS ON THE
OUTSIDE OF THE CONTROLLER DURING INSPECTION, ALWAYS FIRST TURN OFF
THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER
TO PREVENT POSSIBLE ELECTRICAL SHOCK.
• NEVER TOUCH ANY INTERNAL PARTS OF THE CONTROLLER.
• REFER TO THE "YAMAHA ROBOT CONTROLLER USER'S MANUAL" FOR
PRECAUTIONS ON HANDLING THE CONTROLLER.
(15) Follow the specified procedures when installing, adjusting or inspecting the robot.
wWARNING
ALWAYS FOLLOW THE SPECIFIED PROCEDURES WHEN INSTALLING, ADJUSTING
OR INSPECTING THE ROBOT. NEVER ATTEMPT ANY PROCEDURE NOT DESCRIBED
IN THIS MANUAL.
(16) Do not attempt any repair, parts replacement and modification.
wWARNING
DO NOT ATTEMPT ANY REPAIR, PARTS REPLACEMENT AND MODIFICATION
UNLESS DESCRIBED IN THIS MANUAL.
THESE WORKS REQUIRE TECHNICAL KNOWLEDGE AND SKILL, AND MAY ALSO
INVOLVE WORK HAZARDS.

Using the Robot Safely
1
1-2 Essential precautions
1-8
(17) Location for installing the controller and the Handy Terminal
The robot controller and the Handy Terminal should be installed at a location that is
outside the robot movement range yet where it is easy to operate and view the robot
performing tasks.
(18) Protect electrical wiring and hydraulic/pneumatic hoses as needed.
Install a cover or similar item to protect the electrical wring and hydraulic/pneumatic
hoses from possible damage.
(19) Install an operation status light.
Install an operation status light (signal light tower, etc.) at an easy-to-see position so
the operator will know whether the robot is merely stopped or is in emergency-error
stop.
(20) Clean work tools, etc.
Work tools such as welding guns and paint nozzles which are mounted in the robot
arm will preferably be cleaned automatically.
(21) Provide adequate lighting.
Make sure to provide enough lighting to ensure safety during work.
(22) Prevent the gripped object from flying outwards.
If the object or workpiece gripped by the robot might fly outward or drop and create
a hazard to the operator, then protective equipment should be installed by taking the
size, weight, temperature and chemical properties of the object into account.
(23) Draw up "work instructions" and makes sure the operator learns them well.
Decide on "work instructions" for the following items in cases where personnel
must work within the robot movement range to perform teaching, maintenance or
inspection. Make sure the workers know these "work instructions" well.
(1)
Robot operating procedures needed for tasks such as startup procedures and
handling switches
(2) Robot speeds used during tasks such as teaching
(3) Methods for workers to signal each other when two or more workers perform
tasks
(4) Steps that the worker should take when a problem or emergency occurs
(5) Steps to take after the robot has come to a stop when the emergency stop device
was triggered, including checks for cancelling the problem or error state and
safety checks in order to restart the robot.
(6) In cases other than above, the following actions should be taken as needed to
prevent hazardous situations due to sudden or unexpected robot operation or
faulty robot operation, as listed below.
1.Show a display on the operator panel
2.Ensure the safety of workers performing tasks within the robot movement range
3.Clearly specify position and posture during work

1
Using the Robot Safely
1-3 Special training for industrial robot operation
1-9
Position and posture where worker can constantly check robot movements and
immediately move to avoid trouble if an error/problem occurs
4.Install noise prevention measures
5.Use methods for signaling operators of related equipment
6.Use methods to decide that an error has occurred and identify the type of error
Implement the "work instructions" according to the type of robot, installation
location, and type of work task.
When drawing up the "work instructions", make an effort to include opinions from
the workers involved, equipment manufacture's technicians, and workplace safety
consultants, etc.
(24) Display a sign on operation panel during work
Display an easy to understand sign or message on the Handy Terminal or operation
panel during the job task, to prevent anyone other than the operators for that job task
from mistakenly operating a start or selector switch. If needed, take other measures
such as locking the cover on the operation panel.
(25) Make daily and periodic inspections.
(1) Always make sure that daily and periodic inspections are performed, and make
a pre-work check to ensure there are no problems with the robot or related
equipment. If a problem or abnormality is found, then promptly repair it or take
other measures as necessary.
(2) When you make periodic inspections or repairs, make a record and store it for at
least 3 years.
1-3 Special training for industrial robot operation
Operators or persons who handle the robot such as for teaching, programming, movement
check, inspection, adjustment, and repair must receive appropriate training and also have
the skills needed to perform the job correctly and safely. They must read the user's manual
carefully to understand its contents before attempting the robot operation.
Tasks related to industrial robots (teaching, programming, movement check, inspection,
adjustment, repair, etc.) must be performed by qualified persons who meet requirements
established by local regulations and safety standards for industrial robots.

Using the Robot Safely
1
1-4 Robot safety functions
1-10
1-4 Robot safety functions
(1) Overload detection
Detects motor overload conditions and shuts off the power.
(2) Abnormal temperature detection
This function detects abnormally high temperatures at the controller's driver, and
shuts off the power. The following measures should be taken when an error (overload
error, abnormal temperature error) occurs.
1.Reduce the speed.
2.Insert a "stop period" in the operation.
3.Reduce the acceleration coefficient.
(3) Soft limits
Soft limits can be set on each axis to limit the working envelope in manual operation
after return-to-origin and during automatic operation.
Note: The working envelope is the area limited by soft limits.
wWARNING
SOFT LIMITS MUST BE SET WITHIN THE MOVEMENT RANGE (MECHANICAL
STOPPER). IF THE SOFT LIMIT IS SET OUTSIDE THE MOVEMENT RANGE, THE ROBOT
AXIS MAY COLLIDE WITH THE MECHANICAL STOPPER AT HIGH SPEED, CAUSING
THE OBJECT GRIPPED BY THE END EFFECTOR TO FLY OR DROP AND THE ROBOT
TO MALFUNCTION.
(4) Mechanical stoppers
The mechanical stoppers prevent axis motion from exceeding the permissible motion
range when the power is shut off by an emergency stop or by a safety function during
high-speed robot movement.
Note: The movement range is the area limited by mechanical stoppers.
wWARNING
AXIS MOVEMENT WILL NOT STOP IMMEDIATELY AFTER THE POWER IS SHUT OFF
BY EMERGENCY STOP OR OTHER SAFETY FUNCTIONS.
(5) Vertical axis brake
Vertical axis is equipped with an electromagnetic brake to prevent the vertical axis
from falling when a power shut off occurs. This brake is engaged when the robot
positioner power is OFF, and when the robot positioner power is ON while the
vertical axis servo is OFF.
The vertical axis brake can be released from the handy terminal HT1 when the robot
positioner power is ON.

1
Using the Robot Safely
1-5 Safety measures for the system
1-11
wWARNING
THE VERTICAL AXIS WILL SLIDE DOWN WHEN THE BRAKE IS RELEASED, CREATING
A HAZARDOUS SITUATION.
• PRESS THE EMERGENCY STOP BUTTON AND PROP THE VERTICAL AXIS WITH A
SUPPORT STAND BEFORE RELEASING THE BRAKE.
• USE CAUTION NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE VERTICAL
AXIS AND INSTALLATION BASE WHEN RELEASING THE BRAKE TO PERFORM
DIRECT TEACH.
1-5 Safety measures for the system
Since the robot is commonly used in conjunction with an automated system, dangerous
situations are more likely to occur from the automated system than from the robot
itself. Accordingly, appropriate safety measures must be taken on the part of the system
manufacturer according to the individual system. The system manufacturer should provide
a proper instruction manual for safe, correct operation and servicing of the system.
1-6 Trial operation
After making installations, adjustments, inspections, or maintenance or repairs to the
robot, make a trial run using the following procedures.
(1) If a safety enclosure has not yet been provided right after installation of the robot,
rope off or chain off around the movement area of the manipulator in place of the
safety enclosure, and observe the following points.
1.Use sturdy, stable posts which will not fall over easily.
2.The rope or chain should be easily visible by everyone around the robot.
3.Place a sign to keep the operator or other personnel from entering the movement
range of the manipulator.
(2) Check the following points before turning on the controller.
1.Is the robot securely and correctly installed?
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 equipment?
5.Have safety measures (safety enclosure, etc.) been taken?
6.Does the installation environment meet the specified standards.

Using the Robot Safely
1
1-7 Work within the safety enclosure
1-12
(3) After the controller is turned on, check the following points from outside the safety
enclosure.
1.Does the robot start and stop as intended? Can the operation mode be selected
correctly?
2.Does each axis move as intended within the soft limits?
3.Does the end effector move as intended?
4.Are the signal transmissions to the end effector and peripheral equipment correct?
5.Does emergency stop work?
6.Are the teaching and playback functions normal?
7.Are the safety enclosure and interlock working as intended?
8.Does the robot move correctly during automatic operation?
1-7 Work within the safety enclosure
(1) Work within the safety enclosure
When work is required inside the safety enclosure, always turn off the controller and
place a sign indicating that the robot is being adjusted or serviced in order to keep
any other person from touching the controller switch or operation panel, except for
the following cases.
1) Soft limit settings
2) Teaching
For item 1), follow the precautions and procedure for each section. To perform item 2),
refer to the description in (2) below.
(2) Teaching
When performing teaching within the safety enclosure, comply with the instructions
listed below.
1) Check or perform the following points from outside the safety enclosure.
1. Make sure that no hazards are present within the safety enclosure by a visual
check.
2. Check that the handy terminal is operating normally.
3. Check that no failures are found in the robot.
4. Check that emergency stop works correctly.
5. Select teaching mode and prohibit automatic operation.
2) Never enter the movement range of the manipulator while within the safety
enclosure.