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

MEMO

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

MEMO

1-1
CHAPTER 1 Using the Robot Safely
1Safety 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 WARN-
INGS, 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 in-
jury 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, a bystander or a person inspecting or repairing the robot.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to
the robot operator, a bystander or a person inspecting or repairing the robot.
!
CAUTION
Failure to follow CAUTION instructions may result in injury to the robot opera-
tor, a bystander or a person 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 in-
struction manual (available for an additional fee).
2. Operate or adjust the robot while viewing the CD-ROM version of the in-
struction 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 detail all safety items 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 Eng-
lish, do not permit him to handle the robot.

1-2
CHAPTER 1 Using the Robot Safely
2 Essential Caution Items
Particularly important cautions for handling or operating the robot are described
below. In addition, safety information about installation, operation, inspection
and maintenance is provided in each chapter. Be sure to comply with these in-
structions to ensure safe use of the robot.
(1) Observe the following cautions during automatic operation.
Warning labels 1 (Fig. 1-1) are affixed to the robot. See Fig. 2-2 for the loca-
tions of warning labels.
•Install a safeguard enclosure (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 shown in Fig. 1-1 are supplied with the robot and should
be affixed to a conspicuous spot 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.
DANGER
Serious injury or death
will result from impact
with moving robot.
•Keep outside of guard
during operation.
• Lock out power before
approaching robot.
■Fig. 1-1 Warning label 1
(2) Use caution to prevent hands or fingers from being pinched or
crushed.
Warning labels 2 (Fig. 1-2) are affixed to the robot. See Fig. 2-2 for the loca-
tions of warning labels. Be careful not to let hands or fingers be pinched or
crushed by the moving parts of the robot during transportation or teaching.
WARNING
Moving parts can pinch or crush hands. Keep hands away from robot arms.

1-3
CHAPTER 1 Using the Robot Safely
Moving parts can
pinch or crush.
Keep hands away
from robot arms.
WARNING
■Fig. 1-2 Warning label 2
(3) Follow the instructions on warning labels and in this manual.
Warning label 3 (Fig. 1-3) is affixed to the robot. See Fig. 2-2 for the loca-
tions of warning labels.
•Be sure to read the warning label and this manual carefully and make you
thoroughly understand the contents before attempting installation and op-
eration of the robot.
•Before starting the robot operation, even after you have read through this
manual, read again the corresponding procedures and cautions in this manual
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
Improper installation or operation can result in serious injury or death.
Read user's manual and all warning labels before installation or 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 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.
!
CAUTION
Do not remove this part. Damage to the ball screw will result.
■Fig. 1-4 Warning label 4

1-4
CHAPTER 1 Using the Robot Safely
(5) Do not use the robot in environments containing inflammable
gas, etc.
WARNING
•This robot was not designed for operation in environments where inflamma-
ble or explosive substances are present.
•Do not use the robot in environments containing inflammable gas, dust or
liquids. Explosions or fire could otherwise result.
(6) Do not use the robot in locations possibly subject to electro-
magnetic interference, etc.
WARNING
Avoid using the robot in locations subject to electromagnetic interference, elec-
trostatic discharge or radio frequency interference. Malfunction may otherwise
occur.
(7) Use caution when releasing the Z-axis (vertical axis) brake.
WARNING
The Z-axis will slide down when the Z-axis brake is released, causing a hazard-
ous situation.
•Press the emergency stop button and prop up the Z-axis with a support stand
before releasing the brake.
•Use caution not to let your body get caught between the Z-axis and installa-
tion base when releasing the brake to perform direct teach.
(8) Provide safety measures for end effector (gripper, etc.).
WARNING
•End effectors must be designed and manufactured so that they cause no
hazards (for example, loosening of workpiece) 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.

1-5
CHAPTER 1 Using the Robot Safely
(9) Be cautious of possible Z-axis movement when the controller is
turned off or emergency stop is triggered. (2-axis robots with
air-driven Z-axis)
WARNING
The Z-axis moves up when the power to the controller or PLC is turned off, the
program is reset, emergency stop is triggered, or air is supplied to the solenoid
valve for the Z-axis air cylinder.
•Do not let hands or fingers get caught and squeezed by moving parts of the
Z-axis.
•Keep the usual robot position in mind so that the Z-axis will not interfere with
obstacles during raising of the Z-axis, except in case of emergency stop.
(10)Use the following caution items when the Z-axis is interfering
with peripheral equipment. (2-axis robots with air driven Z-axis)
WARNING
When the Z-axis comes to a stop due to obstructions from peripheral equip-
ment, the Z-axis may move suddenly when the obstruction is removed, causing
injury such as pinched or crushed hands.
•Turn off the controller and reduce the air pressure before attempting to re-
move the obstruction.
•Before reducing the air pressure, place a support stand under the Z-axis
because it will drop under its own weight.
(11) Use caution on Z-axis movement when air supply is stopped. (2-
axis robots with air-driven Z-axis)
WARNING
The Z-axis may suddenly drop when the air pressure to the Z-axis air cylinder
solenoid valve is reduced, creating a hazardous situation.
Turn off the controller and place a prop or support under the Z-axis before
cutting off the air supply.
(12)Use the following caution items when disassembling or replac-
ing the pneumatic equipment.
WARNING
Air or parts may fly outwards if pneumatic equipment is disassembled or parts
replaced while air is still supplied.
•Do service work after first turning off the controller and reducing the air pres-
sure.
•Before reducing the air pressure, place a support stand under the Z-axis (2-
axis robots with air driven Z-axis) since it will drop under its own weight.

1-6
CHAPTER 1 Using the Robot Safely
(13) Use the following caution items when removing the Z-axis mo-
tor.
WARNING
The Z-axis will drop when the Z-axis motor is removed, possibly resulting in
injury.
•Turn off the controller and set a support stand under the Z-axis before re-
moving the motor.
•Use caution not to allow hands or body to be squeezed or crushed by moving
parts on the Z-axis or between the Z-axis and the installation base.
(14) Use the following caution during inspection of controller.
WARNING
•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.
For precautions on handling the controller, refer to the "YAMAHA Robot Con-
troller User's Manual".
(15) Consult us for corrective action when the robot is damaged or
malfunction occurs.
WARNING
If any part of the robot is damaged or any malfunction occurs, continuous op-
eration may be very dangerous. Please consult YAMAHA dealer for corrective
action.
If the following damages or troubles exist These dangers can happen
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
(16) Use caution not to touch the high temperature motor or speed
reduction gear casing.
WARNING
The motor and speed reduction gear casing are extremely hot after automatic
operation, so burns may occur if these are touched. Before touching these
parts during inspections or servicing, turn off the controller, wait for a while and
check that the temperature has cooled.

1-7
CHAPTER 1 Using the Robot Safely
(17)Do not remove, alter or stain the warning labels.
WARNING
If warning labels are removed or difficult to see, necessary cautions may not be
taken, resulting in an accident.
•Do not remove, alter or stain the warning labels on the robot.
•Do not allow the warning labels to be hidden by the device installed to the
robot by the user.
•Provide proper lighting so that the symbols and instructions on the warning
labels can be clearly seen even from the outside of safeguard enclosure.
(18)Protective bonding
WARNING
Be sure to ground the robot and controller to prevent electrical shock.
(19)Be sure to make correct parameter settings.
!
CAUTION
The robot must be operated with correct tolerable moment of inertia and accel-
eration coefficients according to the manipulator tip mass and moment of iner-
tia. If this is not observed, premature end to the life of the drive units, damage to
the robot parts or residual vibration during positioning may result.
(20)Do not use the robot for tasks requiring motor thrust.
!
CAUTION
Avoid using the YK-XG series robots for tasks which make use of motor thrust
(press-fitting, burr removal, etc.). These tasks may cause malfunctions of the
robot.
(21)If the X, Y or R axis rotation angle is small
!
CAUTION
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.

1-8
CHAPTER 1 Using the Robot Safely
3Special Training for Industrial Robot Opera-
tion
Companies or factories using industrial robots must make sure that every person,
who handles the robot such as for teaching, programming, movement check, in-
spection, adjustment and repair, has received appropriate training and also has
the skills needed to perform the job correctly and safely.
Since the YK-XG series robots fall under the industrial robot category, the user
must observe local regulations and safety standards for industrial robots, and
provide special training for every person involved in robot-related tasks (teach-
ing, programming, movement check, inspection, adjustment, repair, etc.).