Yamaha YK-X Series User manual

User’s Manual ENGLISH E
YAMAHA SCARA ROBOT
E35-Ver. 1.08
YK-XG
YK-Xseries

Before using the robot
(Be sure to read the following notes.)
At this time, our thanks for your purchase of thisYAMAHAYK-XG series SCARA
robot.
1. Please be sure to perform the following tasks before using the robot.
Failing to perform the tasks below will require re-teaching of the robot since the
origin position cannot be set to the same previous position. Robot malfunctions
(vibration, noise) may also occur.
The origin position of the YK-XG series robots is adjusted to the robot arm ex-
tended position at the factory prior to shipment, so the reference or standard coor-
dinates are temporarily set. The customer should set the origin position before
any other job. There are 2 types of origin position settings as shown below.
[1] Setting the robot arm extended position (the origin position adjusted
at the factory prior to shipment) as the origin position
(When setting the origin position with the robot arm extended, you
must check that there will not be any interference from any periph-
eral equipment during the next absolute reset.)
[2] Setting a position OTHER than the robot arm extended position
(the origin position adjusted at the factory prior to shipment) as the
origin position
[1] To set the robot arm extended position (the origin position adjusted
at the factory prior to shipment) as the origin position
Absolute Reset
TheYK-XG series robots only require the absolute reset to be performed once
when the robot is introduced. Once the absolute reset is performed, you do not
need to reperform it when the power is turned on next time. Set the origin
position while referring to absolute reset methods in "3. Adjusting the origin"
in Chapter 4 of this manual and in "Absolute Reset" of the "YAMAHA Robot
Controller User's Manual". Setting of standard coordinates is not required in
the above case. To set the standard coordinates with high accuracy, refer to "5.
Setting the Standard Coordinates" in Chapter 4 of this manual and "Setting the
Standard Coordinates" in the "YAMAHA Robot Controller User's Manual". If
the standard coordinate settings are incorrect, robot malfunctions (vibration,
excessive noise) may occur.
!
CAUTION
Never enter the robot movement range once the robot servo is turned on as
this is extremely hazardous.

[2] To set a position OTHER than the robot arm extended position (the
origin position adjusted at the factory prior to shipment) as the
origin position
1. Absolute reset
TheYK-XG series robots only require the absolute reset to be performed once
when the robot is introduced. Once the absolute reset is performed, you do not
need to reperform it when the power is turned on next time. Set the origin
position while referring to absolute reset methods in "3. Adjusting the origin"
in Chapter 4 of this manual and in "Absolute Reset" of the "YAMAHA Robot
Controller User's Manual". Set the origin position with the absolute reset.
!
CAUTION
Never enter the robot movement range once the robot servo is turned on as
this is extremely hazardous.
2. Affixing the origin position sticker
Set in emergency stop when absolute reset is complete, and immediately affix
the origin point sticker according to instructions in "6. Affixing Stickers for
Origin Positions, Movement Directions and Axis Names" in Chapter 4 of this
manual.
3. Setting the reference coordinates
Set the reference coordinates while referring to instructions in "5. Setting the
Reference Coordinates" in Chapter 4 of this manual and also to "Setting the
Reference Coordinates" in the "YAMAHA Robot Controller User's Manual".
Robot malfunctions (vibration, noise) may occur if the reference coordinates
are not set correctly.
Even though there is no problem with the robot, the following error messages are
issued when the robot and controller are connected and power first turned on.
(Actual error messages may differ according to how the robot and controller are
connected.)
Error messages issued when robot & controller are connected (RCX142)
17.81 : D?.ABS.battery wire breakage
17.83 : D?.Backup position data error 1
17.85 : D?.Backup position data error 2
17.92 : D?.Resolver disconnected during power off
17.93 : D?.Position backup counter overflow
etc.
2. If the X, Y or R axis rotation angle is small.
If the X, Y or R axis rotation angle is smaller than 5°so that it always moves in
the same position, an oil film is difficult to be formed on the joint support bear-
ing, possibly leading to damage to the bearing. In this type of operation, add a
movement so that the joint moves through 90°or more, about 5 times a day.
3. Do not remove the Z-axis upper-end mechanical stopper
Removing or moving the upper-end mechanical stopper attached to the Z-axis
spline can damage the Z-axis ball screw. Never remove or move it.

Introduction
The YAMAHA YK-XG series robots are SCARA type industrial robots devel-
oped based on years of YAMAHA experience and achievements in the automa-
tion field as well as efforts to streamline our in-house manufacturing systems.
The YK-XG series robots have a two-joint manipulator consisting of an X-axis
arm and a Y-axis arm, and are further equipped with a vertical axis (Z-axis) and a
rotating axis (R-axis) at the tip of the manipulator. The YK-XG series robots can
be used for a wide range of assembly applications such as installation and inser-
tion of various parts, application of sealant, and packing operations.
This instruction manual describes the safety measures, handling, adjustment and
maintenance of YK-XG 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.
This manual describes the YK500XG, YK600XG, YK600XGH, YK700XG,
YK800XG, YK900XG, and YK1000XG. 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 Using the Robot Safely
1Safety Information ........................................................................................1-1
2Essential Caution Items ...............................................................................1-2
3Special Training for Industrial Robot Operation ...........................................1-8
4Robot Safety Functions................................................................................1-9
5Safety Measures for the System ................................................................1-10
6Trial Operation ........................................................................................... 1-11
7Work Within the Safeguard Enclosure .......................................................1-12
8Automatic Operation ..................................................................................1-13
9Adjustment and Inspection.........................................................................1-13
10 Repair and Modification .............................................................................1-13
11 Warranty ....................................................................................................1-14
12 CE Marking ................................................................................................1-16
CHAPTER 2 Functions
1Robot Manipulator........................................................................................2-1
2Robot Controller ...........................................................................................2-3
3Robot initialization number list .....................................................................2-4
CHAPTER 3 Installation
1 Robot Installation Conditions .......................................................................3-1
1-1 Installation environments ........................................................................................... 3-1
1-2 Installation base ........................................................................................................ 3-2
2Installation ....................................................................................................3-4
2-1 Unpacking ................................................................................................................. 3-4
2-2 Checking the product ................................................................................................ 3-5
2-3 Moving the robot ........................................................................................................ 3-6
2-3-1 Moving the YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG,
YK1000XG ................................................................................................................... 3-6
2-4 Installing the robot ..................................................................................................... 3-8
3Protective Bonding .......................................................................................3-9
4Robot Cable Connection ............................................................................ 3-11

5User Wiring and User Tubing .....................................................................3-12
6 Attaching The End Effector ........................................................................3-16
6-1 R-axis tolerable moment of inertia and acceleration coefficient .............................. 3-16
6-1-1 Acceleration coefficient vs. moment of inertia (YK500XG) ........................................ 3-17
6-1-2 Acceleration coefficient vs. moment of inertia (YK600XG) ........................................ 3-17
6-1-3 Acceleration coefficient vs. moment of inertia (YK600XGH) ..................................... 3-18
6-1-4 Acceleration coefficient vs. moment of inertia (YK700XG, YK800XG) ...................... 3-18
6-1-5 Acceleration coefficient vs. moment of inertia (YK900XG, YK1000XG) .................... 3-19
6-2 Equation for moment of inertia calculation .............................................................. 3-20
6-3 Example of moment of inertia calculation ................................................................ 3-23
6-4 Attaching the end effector ....................................................................................... 3-25
6-5 Gripping force of end effector .................................................................................. 3-29
7Limiting the Movement Range with X-Axis Mechanical Stoppers ..............3-30
7-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ... 3-31
8Working Envelope and Mechanical Stopper Positions for Maximum Working
Envelope ....................................................................................................3-33
CHAPTER 4 Adjustment
1 Overview ......................................................................................................4-1
2Safety Precautions .......................................................................................4-1
3Adjusting the origin ......................................................................................4-2
3-1 Absolute reset method .............................................................................................. 4-3
3-1-1 Sensor method (X-axis, Y-axis, and R-axis) ................................................................ 4-3
3-1-2 Stroke end method (Z-axis) ......................................................................................... 4-3
3-2 Machine reference ..................................................................................................... 4-4
3-3 Absolute reset procedures ........................................................................................ 4-5
3-3-1 Sensor method (X-axis, Y-axis, and R-axis) ................................................................ 4-5
3-3-2 Stroke end method (Z-axis) ......................................................................................... 4-7
3-4 Changing the origin position and adjusting the machine reference ........................... 4-8
3-4-1 Sensor method ............................................................................................................ 4-9
3-4-1-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ..... 4-9
3-4-2 Stroke end method .................................................................................................... 4-27
3-4-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ... 4-27
4Setting the Soft Limits ................................................................................4-31
5Setting the Standard Coordinates ..............................................................4-34
5-1 Standard coordinate setting using a standard coordinate setup jig (option) ........... 4-35
6Affixing the Stickers for Movement Directions and Axis Names ................4-38

CHAPTER 5 Periodic Inspecition
1 Overview ......................................................................................................5-1
2Precautions ..................................................................................................5-2
3Daily Inspection............................................................................................5-3
4Six-Month Inspection ...................................................................................5-5
5Replacing the Harmonic Drive .....................................................................5-9
5-1 Replacement period .................................................................................................. 5-9
5-2 Basic replacement procedure for harmonic drive and precautions ......................... 5-10
5-2-1 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG... 5-12
CHAPTER 6 Increasing the robot operating speed
1Increasing the robot operating speed ..........................................................6-1
CHAPTER 7 Specifications
1 Manipulator ..................................................................................................7-1
1-1 Basic specification ..................................................................................................... 7-1
1-2 Robot inner wiring diagram ....................................................................................... 7-2
1-3 Wiring table ............................................................................................................... 7-3

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