Yamaha FLIP-X Series User manual

User’s Manual ENGLISH E
YAMAHA SINGLE-AXIS ROBOT
E21-Ver. 1.15
FLIP-Xseries

Before using the “X” series single-axis robot or
XY robot (Be sure to read the following notes.)
At this time, our thanks for your purchase of this YAMAHA “X” series robot.
The “X” series single-axis and XY robots use absolute position detectors that do not require
return-to-origin after turning on the controller power. However, when the controller power is
turned on in the following cases, return-to-origin must be performed just the very first time.
(1) When robot cable was first connected after delivery from YAMAHA.
(2) When robot cable was disconnected from the controller and then reconnected.
(3) When no absolute battery is connected.
(4) When a motor or cable was replaced.
At this point, any of the following errors is issued immediately after controller power is turned
on, but this is not a malfunction. The controller will operate normally by restarting.
When using ERCX, SRCX, DRCX or TRCX controllers:
15 : FEEDBACK ERROR 2
23 : ABS.BAT.L-VOLTAGE
24 : ABS.DATA.ERROR
When using a QRCX controller:
17.80 : D?.ABS.encoder backup error
17.81 : D?.ABS.encoder battery alarm
17.85 : D?.ABS.encoder system error
17.92 : D?.ABS.cable disconnected
17.93 : D?.ABS.data overflow
17.94 : D?.ABS.Battery degradation
When using a RCX40 controller:
17.27 : D?.ABS. backup failed (CPU)
17.80 : D?.ABS. backup failed (DRIVER)
17.81 : D?.ABS.battery wire breakage
17.92 : D?.Resolver disconnected during power off
17.93 : D?.Position backup counter overflow
17.94 : D?.ABS.battery low voltage
etc

[1] When using a linear movement robot
Applicable robots:
All “X” series single-axis robots except single-axis rotary movement robots (see [2])
Linear movement axes (X, Y, Z axes) of “X” series Cartesian robots
The above robots use the stroke end origin detection method. The motor side stroke end
is set as the origin at the factory prior to shipping
Set the origin position while referring to the following section in the robot controller
instruction manual.
When using ERCX, SRCX, DRCX or TRCX controllers:
See “9-1-1 Return-to-origin by the search method” in Chapter 9.
When using a QRCX controller:
See “11-9 Absolute Reset” in Chapter 11.
When using a RCX40 controller:
See “11-8 Absolute Reset” in Chapter 11.
CAUTION
Avoid changing the origin position to the non-motor side. Changing the origin position
to the non-motor side may cause a positional shift or robot breakdowns, and is also
dangerous in some cases. If the origin position must be changed, please consult our
sales office or dealer.
[2] When using a rotary movement robot
Applicable robots:
R5/R10/R20 (“X” series single-axis robots)
RF (R axis of “X” series Cartesian robots SXYx/MXYx)
RL/RH (R axis of “X” series Cartesian robots HXYx)
RM/RS (R axis of “X” series Cartesian robots ZRM/ZRS)
On the above robots, the customer should set the origin at the desired position.
Move the robot to the desired position and set it as the origin while referring to the
following section in the robot controller instruction manual.
When using ERCX, SRCX, DRCX or TRCX controllers:
See “9-1-1 Return-to-origin by the search method” in Chapter 9.
When using a QRCX controller:
See “11-9 Absolute Reset” in Chapter 11.
When using a RCX40 controller:
See “11-8 Absolute Reset” in Chapter 11.
After setting the origin position, affix the stickers (triangular stickers supplied with the
robot) to both the tool side and workpiece side so that they can be used as the alignment
marks. Use these marks as the reference position the next time the origin must be set.

Introduction
The YAMAHA FLIP-X series is a family of single-axis industrial robots that use the
absolute positioning method as a standard feature to improve ease of use, resistance
to environmental conditions and maintenance work. A wide varaiety of product lineup
allows you to select the desired robot model that best matches your application.
This instruction manual describes the safety measures, handling, adjustment and
maintenance of FLIP-X series robots for correct, safe and effective use. Be sure to
read this manual carefully before installing the robot. Even after you have read this
manual, keep it in a safe and convenient place for future reference.
This instruction 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 and programming of the robot, refer to the separate
“YAMAHA Robot Controller User’s Manual”.
NOTES
• The contents of this manual are subject to change without prior notice.
• Information furnished by YAMAHA in this manual is believed to be reliable. However, if
you find any part unclear or inaccurate in this manual, please contact YAMAHA sales
office or dealer.
YAMAHA MOTOR CO., LTD.
IM Company

MEMO

Contents
Chapter 1 About Safety
1-1 Safety Information............................................................... 1-3
1-2 Essential Caution Items...................................................... 1-4
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 Safeguard Enclosure ............................ 1-12
1-8 Automatic Operation......................................................... 1-12
1-9 Adjustment and Inspection .............................................. 1-12
1-10 Repair and Modification ................................................... 1-12
1-11 Warranty ............................................................................. 1-13
Chapter 2 Installation and Connections ........................ 2-1
2-1 Checking the product ......................................................... 2-3
2-2 Moving the robot ................................................................. 2-3
2-3 Robot Installation Conditions ............................................ 2-5
2-3-1 Installation environments ............................................................................. 2-5
2-3-2 Installation base ............................................................................................ 2-6
2-4 Installing the robot .............................................................. 2-7
2-4-1 T6 ................................................................................................................. 2-7
2-4-2 T7 ................................................................................................................. 2-9
2-4-3 T9/T9H ....................................................................................................... 2-11
2-4-4 F10 .............................................................................................................. 2-14
2-4-5 F14/F14H ................................................................................................... 2-17
2-4-6 F17/F20 ...................................................................................................... 2-21
2-4-7 R5/R10/R20 ................................................................................................ 2-23
2-4-8 B10/B14/B14H ........................................................................................... 2-26
2-4-9 F20N ........................................................................................................... 2-27
2-5 Protective bonding............................................................ 2-29
2-6 Connections ...................................................................... 2-30
2-6-1 Connecting the robot cables ....................................................................... 2-30
2-6-2 Changing the cable routing direction (F Type) .......................................... 2-32
2-6-3 Changing the cable routing direction (B Type) .......................................... 2-33
2-6-4 Changing the motor orientation (B type) ................................................... 2-35
2-6-5 User wiring ................................................................................................. 2-38

2-7 Setting the operating conditions ..................................... 2-39
2-7-1 Payload ....................................................................................................... 2-39
2-7-2 Maximum speed setting ............................................................................. 2-40
2-7-3 Duty ............................................................................................................ 2-40
Chapter 3 Adjusting the robot
3-1 Attaching the upper cover (B10/B14/B14H) ...................... 3-3
3-2 Adjusting the timing belt tension (B10/B14/B14H) .......... 3-4
3-2-1 Adjusting the drive belt tension .................................................................... 3-5
Reference: Adjusting drive belt tension with a tension meter ...................... 3-6
3-2-2 Adjusting the speed reduction belt tension .................................................. 3-7
Reference: Adjusting speed reduction belt tension with a tension meter ..... 3-8
3-3 Installing and removing the cover (F20N)......................... 3-9
3-3-1 Stroke cover .................................................................................................. 3-9
3-3-2 Belt cover ................................................................................................... 3-10
3-3-3 Motor cover ................................................................................................ 3-11
3-4 Adjusting the timing belt tension (F20N) ........................ 3-12
Chapter 4 Periodic Inspection
4-1 Before beginning work ....................................................... 4-3
4-2 Periodic inspection ............................................................. 4-5
4-2-1 Daily inspection ........................................................................................... 4-5
4-2-2 Three-month inspection ............................................................................... 4-5
4-2-3 Six-month inspection ................................................................................... 4-6
4-2-4 Three-year inspection ................................................................................... 4-6
4-3 Applying grease .................................................................. 4-7
4-3-1 Applying grease (T6/T7 type) ...................................................................... 4-7
4-3-2 Applying grease (T9/F types) ....................................................................... 4-8
4-3-3 Applying grease (B type) ............................................................................. 4-8
4-4 Adjusting and replacing a loose shutter........................... 4-9
4-4-1 Replacing the shutter (T6) ............................................................................ 4-9
4-4-2 Adjusting shutter looseness (T6) ................................................................ 4-10
4-5 Replacing the motor ......................................................... 4-11
4-5-1 Replacing the motor (B10/B14/B14H) ...................................................... 4-11
4-5-2 Replacing the motor (F20N) ...................................................................... 4-13
4-6 Replacing the drive belt (B10/B14/B14H) ........................ 4-15
4-7 Replacing the speed reduction belt (B10/B14/B14H)..... 4-18
4-8 Replacing the slider .......................................................... 4-20
4-8-1 Replacing the slider (B10/B14/B14H) ....................................................... 4-20
4-8-2 Replacing the slider (F20N) ....................................................................... 4-21

Chapter 5 Specifications
5-1 Robot specifications ........................................................... 5-3
5-1-1 T6 ................................................................................................................. 5-3
5-1-2 T7 ................................................................................................................. 5-4
5-1-3 T9 ................................................................................................................. 5-5
5-1-4 T9H .............................................................................................................. 5-6
5-1-5 F10 ................................................................................................................ 5-7
5-1-6 F14 ................................................................................................................ 5-8
5-1-7 F14H ............................................................................................................. 5-9
5-1-8 F17 .............................................................................................................. 5-10
5-1-9 F20 .............................................................................................................. 5-11
5-1-10 F20N ........................................................................................................... 5-12
5-1-11 R5 ............................................................................................................... 5-13
5-1-12 R10 ............................................................................................................. 5-14
5-1-13 R20 ............................................................................................................. 5-15
5-1-14 B10 ............................................................................................................. 5-16
5-1-15 B14 ............................................................................................................. 5-17
5-1-16 B14H .......................................................................................................... 5-18
5-2 AC servo motor termination (T/F Type) ........................... 5-19
5-3 AC servo motor termination (R/B Type, F20N) ............... 5-20
5-4 Robot cables...................................................................... 5-21
Chapter 6 Troubleshooting
6-1 Positioning error ................................................................. 6-3
6-2 Feedback error .................................................................... 6-4
Appendix
About machine reference .............................................................. iii
Equation of moment of inertia calculation................................... iv

MEMO

Chapter 1
About Safety
1-1 Safety Information ............................................................... 1-3
1-2 Essential Caution Items ...................................................... 1-4
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 Safeguard Enclosure ............................. 1-12
1-8 Automatic Operation ......................................................... 1-12
1-9 Adjustment and Inspection ............................................... 1-12
1-10 Repair and Modification .................................................... 1-12
1-11 Warranty .............................................................................. 1-13

1-2
MEMO

Chapter 1 About Safety
1-3
1-1 Safety Information
Industrial robots are highly programmable, mechanical devices that provide a large degree of
freedom when performing various manipulative tasks.
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 meas-
ures 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 information in this manual is shown classified into the following items.
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the robot
operator, bystanders or persons inspecting or repairing the robot.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the
robot operator, bystanders or persons inspecting or repairing the robot.
CAUTION
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.
NOTE
Explains the key point 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 adjust the robot while referring to the printed version of the instruction manual
(available for an additional fee).
2. Operate or adjust the robot while viewing the CD-ROM version of the instruction manual on
your computer screen.
3. Operate or adjust the robot while referring to a printout of the necessary pages from the CD-
ROM version of the instruction 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.
This manual and warning labels supplied with or affixed to the robot are written in English. If the
robot operator or service personnel does not understand English, do not permit that person to
handle the robot.

Chapter 1 About Safety
1-4
1-2 Essential Caution Items
Particularly important cautions for handling or operating the robot are described below. In addi-
tion, safety information about installation, operation, inspection and maintenance is 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 (protective 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 safeguards so that no one can enter inside except from doors or panels equipped
with safety interlocks.
· The warning labels 1 (Fig. 1-1) are supplied with the robot and should be affixed to
conspicuous spots on doors or/ panels equipped with safety interlocks.
DANGER
Serious injury or death will result from impact with moving robot.
· Keep outside of guard during operation.
· Lock out power before approaching robot.
(2) Use caution to prevent hands or fingers from being pinched or crushed.
Warning labels 2 (Fig. 1-2) are affixed to the robot.
WARNING
Moving parts can pinch or crush.
Keep hands away from robot arms.
DANGER
Serious injury or death
will result from impact
with moving robot.
•Keep outside of guard
during operation.
• Lock out power before
approaching robot.
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
WARNING
Fig. 1-1 Warning label 1 Fig. 1-2 Warning label 2

Chapter 1 About Safety
1-5
(3) Follow the instructions on listed on warning labels and in this manual.
· Be sure to read the warning labels and this manual carefully and make sure you thor-
oughly understand their contents before attempting installation and operation of the ro-
bot.
· 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.
· The warning labels 3 (Fig. 1-3) are supplied with the robot and should be affixed to the
robot or conspicuous spots near the robot.
WARNING
Improper installation or operation can result in serious injury or death.
Read the user’s manual and all warning labels before operation.
Improper Installation or operation
can result in serious injury or
death. Read user's(owner's)
manual and all warning labels
before operation.
WARNING
Fig. 1-3 Warning label 3
(4) Do not use the robot in environments containing inflammable gas, etc.
WARNING
· 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.
(5) Do not use the robot in locations possibly subject to electromagnetic interference, etc.
WARNING
Avoid using the robot in locations subject to electromagnetic interference, electro-
static discharge or radio frequency interference. Malfunctions might otherwise occur.

Chapter 1 About Safety
1-6
(6) Use caution when releasing the brake of a vertical use robot.
WARNING
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.
(7) Provide safety measures for end effector (gripper, aD9).
WARNING
· 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.
(8) Use caution when removing the motor. (Vertical use robots)
WARNING
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.
(9) Take the following safety precautions during inspection of controller.
WARNING
· When you need to touch the terminals or connectors on the outside of the control-
ler 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.

Chapter 1 About Safety
1-7
(10) Consult us for corrective action when the robot is damaged or malfunctions occur.
WARNING
If any part of the robot is damaged or any malfunction occurs, continuing the opera-
tion 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
(11) Use caution not to touch the controller rear panel cooling fan.
WARNING
·Bodily injury may occur from coming into contact with the cooling fan while it is
rotating.
·When removing the fan cover for inspection, first turn off the controller and make
sure the fan has stopped.
(12) Be careful not to touch the motor or speed reduction gear casing when hot.
WARNING
The motor and speed reduction gear casing are extremely hot after automatic opera-
tion, 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 part has cooled.
(13) Do not remove, alter or stain the warning labels.
WARNING
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 safeguard enclosure.

Chapter 1 About Safety
1-8
(14) Protective bonding
WARNING
Be sure to ground the robot and controller to prevent electrical shock.
(15) Be sure to make correct parameter settings.
CAUTION
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.
(16) Do not use the robot for tasks requiring motor thrust.
CAUTION
Avoid using the belt-driven type robots for tasks which utilize motor thrust (press-
fitting, burr removal, etc.). These tasks may cause malfunctions in the robot.

Chapter 1 About Safety
1-9
1-3 Special Training for Industrial Robot Operation
Companies or factories using industrial robots must make sure that every person, who handles the
robot such as for teaching, programming, movement check, inspection, adjustment and repair,
has received appropriate training and also has the skills needed to perform the job correctly and
safely.Since the FLIP-X series robots fall under the industrial robot category, the user must ob-
serve local regulations and safety standards for industrial robots, and provide special training for
every person involved in robot-related tasks (teaching, programming, movement check, inspec-
tion, adjustment, repair, etc.).

Chapter 1 About Safety
1-10
1-4 Robot Safety Functions
(1) Overload detection
This function detects an overload applied to the motor and shuts off the servo power.
(2) Overheat detection
This detects an abnormal temperature rise in the controller driver and shuts off the servo
power.
If an overload or overheat error occurs, take the following measures.
1. Insert a timer in the program.
2. 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.
(4) Mechanical stoppers
If the servo power is suddenly shut off during high-speed operation by emergency stop or
safety functions, these mechanical stoppers prevent the axis from exceeding the movement
range.
No mechanical stopper is provided on the rotating axis.
Note: The movement range is the area limited by mechanical stoppers.
WARNING
Axis movement will not stop immediately after the servo power supply is shut off by
emergency stop or other safety functions.
(5) Vertical axis brake
An electromagnetic brake is installed on the vertical use robot to prevent the vertical axis
from sliding down when servo power is turned off. This brake is working when the control-
ler is off or the vertical axis servo power is off even when the controller is on.
The vertical axis brake can be released by means of the programming unit or by a command
in the program when the controller is on.
WARNING
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 installa-
tion base when releasing the brake to perform direct teach.