Yamaha YK-X Series User manual

UserʼsManual
Standard & Large model
YK1200X
Clean models
YK500XC/YK600XC/YK700XC/YK800XC/YK1000XC
YAMAHASCARAROBOT
Y K-X Series
Original instructions
Ver. 1.11
EUFR217111
E226

CONTENTS YK-X
User’s Manual
T-1
Warranty
Introduction
Introduction i
Available manuals i
Signal symbols ii
Before using the robot (Be sure to read the following notes.) iii
Chapter 1 Functions
1. Robot manipulator 1-1
1.1 Manipulator movement 1-1
1.2 Part names 1-2
2. Robot controller 1-5
3. Robot initialization number list 1-6
Chapter 2 Installation
1. Robot installation conditions 2-1
1.1 Installation environments 2-1
1.2 Installation base 2-2
2. Installation 2-3
2.1 Unpacking 2-3
2.2 Checking the product 2-4
2.3 Carrying the robot 2-5
2.3.1 YK500XC, YK600XC, YK700XC, YK800XC, YK1000XC 2-5
2.3.2 YK1200X 2-8
2.4 Installing the robot 2-10
3. Protective bonding 2-11
4. Robot cable connection 2-12
5. User wiring and user tubing 2-13
5.1 YK500XC, YK600XC, YK700XC, YK800XC, YK1000XC 2-13
5.2 YK1200X 2-16
6. Attachingtheendeector 2-20
6.1 Accelerationcoecientvs.momentofinertia 2-20

CONTENTS YK-X
User’s Manual
T-3T-2
6.1.1 R-axis tolerable moment of inertia and acceleration coefficient 2-20
6.1.2 Parameter setting according to R-axis moment of inertial of load 2-20
6.1.3 Acceleration coefficient vs. moment of inertia 2-21
6.1.3.1 Acceleration coefficient vs. moment of inertia (YK500XC) 2-21
6.1.3.2 Acceleration coefficient vs. moment of inertia (YK600XC) 2-24
6.1.3.3 Acceleration coefficient vs. moment of inertia (YK700XC) 2-27
6.1.3.4 Acceleration coefficient vs. moment of inertia (YK800XC) 2-30
6.1.3.5 Acceleration coefficient vs. moment of inertia (YK1000XC) 2-33
6.1.3.6 Acceleration coefficient vs. moment of inertia (YK1200X) 2-36
6.2 Equationformomentofinertiacalculation 2-39
6.3 Exampleofmomentofinertiacalculation 2-42
6.4 Attachingtheendeector 2-44
6.5 Grippingforceofendeector 2-47
7. Limiting movement range with X-axis mechanical stoppers 2-48
7.1 Changing the X-axis mechanical stopper position 2-48
8. LimitingthemovementrangewithX-axismechanicalstoppers(YK1200X) 2-50
8.1 Changing the Y-axis mechanical stopper position 2-51
8.2 Overrun amounts during impacts with Y-axis mechanical stopper 2-51
9. LimitingthemovementrangewithZ-axismechanicalstoppers(YK1200X) 2-52
9.1 Installingtheminusdirectionstopper 2-52
9.2 Installingtheplusdirectionstopper 2-54
9.3 OverrunamountsduringimpactswithZ-axisadditionalmechanicalstoppers 2-55
10. Workingenvelopeandmechanicalstopperpositionsformaximumworkingenvelope 2-56
11. Stopping time and stopping distance at emergencystop(YK1200X) 2-65
11.1 StoppingtimeanddistanceafterturningstopsignalON 2-65
11.2Stoppingtimeanddistanceconformedwithcategory0 2-67
Chapter 3 Robot settings
1. Overview 3-1
2. Adjusting the origin 3-2
2.1 Return-to-origin method 3-2
2.1.1 Sensor method (X, Y, and R-axis) 3-2
2.1.2 Mark method (X, Y, and R-axis) 3-3
2.1.3 Stroke end method (Z-axis) 3-3
2.2 Machinereferencevalue 3-4
2.3 Return-to-origin procedures 3-5

CONTENTS YK-X
User’s Manual
T-3T-2
2.3.1 Sensor method (X, Y, and R-axis) 3-5
2.3.2 Mark method (X, Y, and R-axis) 3-6
2.3.2.1 Absolute reset in servo on state (re-reset) 3-7
2.3.2.2 Absolute reset in servo off state (re-reset) 3-10
2.3.2.3 Absolute reset in servo on state (new reset) 3-13
2.3.2.4 Absolute reset in servo off state (new reset) 3-16
2.3.3 Stroke end method (Z-axis) 3-22
2.4 Changingtheoriginpositionandadjustingthemachinereferencevalue 3-24
2.4.1 Sensor method (YK500XC, YK600XC, YK700XC, YK800XC, YK1000XC, YK1200X) 3-24
2.4.2 Mark method 3-31
2.5 Adjustingthemachinereferencevalueofthestrokeendmethod(Z-axis) 3-32
3. Setting the soft limits 3-35
3.1 SettingtheXandY-axissoftlimits 3-35
3.2 SettingtheZ-axissoftlimits 3-36
3.3 SettingtheR-axissoftlimit 3-36
3.4 RelationbetweentheX,Y,andR-axismovementangle,theZ-axismovementdistanceandthe
 numberofpulses 3-36
4. Setting the standard coordinates 3-37
5. Axingthestickersfororiginpositions,movementdirections,andaxisnames 3-38
6. Detachingorattachingthecovers 3-40
7. Adjusting the timing belt tension 3-45
7.1 YK500XC, YK600XC 3-46
7.2 YK700XC,YK800XC,YK1000XC 3-49
7.3 YK1200X 3-52
Chapter 4 Periodic inspection
1. Overview 4-1
2. Daily inspection 4-2
3. Six-month inspection 4-3
4. OriginsensorofX,YandR-axis 4-6
5. ApplyingthegreaseforYK1200XZ-axis 4-7

CONTENTS YK-X
User’s Manual
T-5T-4
Chapter 5 Harmonic drive replacement period
1. Overview 5-1
2. Replacement period 5-1
3. Cautions on replacement of the harmonic drive 5-2
4. Replacement procedure for harmonic drive 5-3
4.1 YK500XC, YK600XC 5-3
4.1.1 Replacing the X-axis harmonic drive 5-3
4.1.2 Replacing the Y-axis harmonic drive 5-9
4.1.3 Replacing the R-axis harmonic drive 5-14
4.2 YK700XC, YK800XC, YK1000XC 5-21
4.2.1 Replacing the X-axis harmonic drive 5-21
4.2.2 Replacing the Y-axis harmonic drive 5-27
4.2.3 Replacing the R-axis harmonic drive 5-31
4.3 YK1200X 5-38
Chapter 6 Replacing the bellows
1. YK500XC,YK600XC 6-2
2. YK700XC,YK800XC,YK1000XC 6-4
Chapter7 ReplacingthegreaseforRVspeedreductiongears(YK1200X)
1. Replacement period 7-1
2. Recommended grease 7-1
3. Replacement procedure 7-1
3.1 ReplacingtheX-axisgrease(productsmanufacturedfromOctober2009onward) 7-2
3.2 ReplacingtheY-axisgrease(productsmanufacturedfromOctober2009onward) 7-4
Chapter 8 Increasing the robot operating speed
1. Increasing the robot operating speed 8-1
1.1 Increasing speed by arch motion 8-1
1.2 Increasing the speed with the WEIGHT statement 8-3
1.3 Increasing the speed by the tolerance parameter 8-4
1.4 Increasing the speed by the OUT valid position parameter 8-5

CONTENTS YK-X
User’s Manual
T-5T-4
Chapter9 TorquelimitdesignatedZ-axispushingaction(YK1200X)
1. Torque limit designated Z-axis pushing action 9-1
Chapter10Specications
1. Manipulator 10-1
1.1 Basicspecication 10-1
1.2 Regarding the noise level 10-4
1.3 External view and dimensions 10-5
1.3.1 YK500XC 10-5
1.3.2 YK600XC 10-7
1.3.3 YK700XC 10-9
1.3.4 YK800XC 10-11
1.3.5 YK1000XC 10-13
1.3.6 YK1200X 10-15
1.4 Robotinnerwiringdiagram 10-19
1.5 Wiring table 10-20
Declarationofincorporationofpartlycompletedmachinery

Warranty
Ver.1.03_201802
Warranty
For information on the warranty period and terms, please contact our distributor where you purchased the
product.
■This warranty does not cover any failure caused by:
1. Installation, wiring, connection to other control devices, operating methods, inspection or maintenance that does not
comply with industry standards or instructions specified in the YAMAHA manual;
2. Usage that exceeded the specifications or standard performance shown in the YAMAHA manual;
3. Product usage other than intended by YAMAHA;
4. Storage, operating conditions and utilities that are outside the range specified in the manual;
5. Damage due to improper shipping or shipping methods;
6. Accident or collision damage;
7. Installation of other than genuine YAMAHA parts and/or accessories;
8. Modification to original parts or modifications not conforming to standard specifications designated by YAMAHA,
including customizing performed by YAMAHA in compliance with distributor or customer requests;
9. Pollution, salt damage, condensation;
10. Fires or natural disasters such as earthquakes, tsunamis, lightning strikes, wind and flood damage, etc;
11. Breakdown due to causes other than the above that are not the fault or responsibility of YAMAHA;
■The following cases are not covered under the warranty:
1. Products whose serial number or production date (month & year) cannot be verified.
2. Changes in software or internal data such as programs, points, calibration, or registered models that were created or
changed by the customer.
3. Products whose trouble cannot be reproduced or identified by YAMAHA.
4. Products utilized, for example, in radiological equipment, biological test equipment applications or for other purposes
whose warranty repairs are judged as hazardous by YAMAHA.
THE WARRANTY STATED HEREIN PROVIDED BY YAMAHA ONLY COVERS DEFECTS IN PRODUCTS
AND PARTS SOLD BY YAMAHA TO DISTRIBUTORS UNDER THIS AGREEMENT. ANY AND ALL OTHER
WARRANTIES OR LIABILITIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXPRESSLY
DISCLAIMED BY YAMAHA. MOREOVER, YAMAHA SHALL NOT BE HELD RESPONSIBLE FOR CONSEQUENT
OR INDIRECT DAMAGES IN ANY MANNER RELATING TO THE PRODUCT.
This manual does not serve as a guarantee of any industrial property rights or any other rights and
does not grant a license in any form. Please acknowledge that we bear no liability whatsoever for
any problems involving industrial property rights which may arise from the contents of this manual.
Warranty

Contents
Introduction i
Available manuals i
Signal symbols ii
Before using the robot (Be sure to read the following notes.) iii
Introduction

Introduction
i
Introduction
The YAMAHA YK-X series robots are SCARA type industrial robots developed based on years of YAMAHA
experience and achievements in the automation field as well as efforts to streamline our in-house
manufacturing systems.
The YK-X 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-X series robots can be used for a wide range of assembly applications such as installation and insertion
of various parts, application of sealant, and packing operations.
This user's manual describes the safety measures, handling, adjustment and maintenance of YK-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 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.
This manual describes the following robot models.
Standard & Large model YK1200X
Clean room model YK500XC, YK600XC, YK700XC, YK800XC, YK1000XC
For details about actual robot operation and programming, refer to the "YAMAHA Robot Controller User's
Manual".
wWARNING
The adjustment and maintenance work with the cover removed needs the special knowledge and skill. If
unskilled work person performs such work, this may involve risk.
Only qualified personnel are allowed to carry out such work while referring to the separate Maintenance Manual
after reading "4.1.2 Qualification of operators/workers" of "Safety Instructions".
"Harmonic" and "Harmonic drive" are the registered trademarks of Harmonic Drive Systems Inc.
Available manuals
The following manuals are included in the disk that comes supplied with the YAMAHA robot or controller.
Safety instructions
Describes safe and correct operating method for controller and robot.
User's manual (this manual)
Describes the installation, maintenance procedures for the robot.
Use any of the following approaches to this manual when installing, operating and adjusting the YAMAHA
robot and/or controller so that you can quickly refer to this manual when needed.
1. Keep the printed version of this manual (available for an additional fee) handy for ready reference.
2. View the disk version of this manual on your personal computer screen.
3. Print out the necessary pages of this manual from the disk and keep them handy for ready reference.
nNOTE
Manuals are available by downloading from our website (Member Site). Registering is required for accessing
the member site:
https://www2.yamaha-motor.co.jp/Robot/Member/loginagain/lang_div/en

Introduction
ii
This user's manual describes the safety measures, handling, adjustment and maintenance of YK-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 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.
For details about actual robot operation and programming, refer to the "YAMAHA Robot Controller User's
Manual".
wWARNING
The adjustment and maintenance work with the cover removed needs the special knowledge and skill.
If unskilled work person performs such work, this may involve risk.Read "2. Qualification of operators/workers" in
section 4.1 of the Safety Instructions and allow only qualified engineers to perform this work while referring to the
separate Maintenance Manual.
• Place a conspicuous sign indicating the robot is being adjusted, to prevent others from touching the controller
switch, programming box (PBX) or operation panel.
• If a safety enclosure has not yet been provided right after installation of the robot, rope off or chain off the
movement range around the manipulator in place of a safety enclosure, and observe the following points.
1. Use 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 conspicuous sign prohibiting the operator or other personnel from entering the movement range of
the manipulator.
• To check the operation after setting, refer to “4.6.1 Trial run” in the chapter “Safety precautions” in the separate
Safety Manual.
cCAUTION
Use only the lubricants specified by your distributor .
Signal symbols
The following safety alert symbols and signal words are used to provide safety instructions that must be
observed and to describe handling precautions, prohibited actions, and compulsory actions. Make sure to
understand the meaning of each symbol and signal word and then read this manual.
wDANGER
This indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.
wWARNING
This indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
cCAUTION
This indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury, or
damage to the equipment.
nNOTE
This indicates a supplementary explanation in the operation.

Introduction
iii
Before using the robot (Be sure to read the following notes.)
At this time, our thanks for your purchase of this YAMAHA YK-X series SCARA robot.
nNOTE
In the RCX340 controller, axis names are called using numeric values, like axis-1, axis-2, axis-3, and so on. In this
manual, axis names are called using alphabetic characters, like X-axis, Y-axis, Z-axis, and so on. So, read this
manual while referring to the robot external view and axis name correspondence table shown below.
Robot external view and axis name correspondence table
Y-axis
(axis -2)
(+)
X-axis arm
(arm -1)
(-)
Y-axis arm
(arm -2)
Z-axis
(axis -3)
(-)
(+)
(-) (+)
R-axis
(axis -4)
(+)
X-axis
(axis -1)
(-)
63001-FR-00
RCX340 controller axis name Axis name in this manual
Axis 1 X-axis
Axis 2 Y-axis
Axis 3 Z-axis
Axis 4 R-axis

Introduction
iv
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-X series robots is adjusted to the robot arm extended position at the factory prior to
shipment, so the reference or standard coordinates 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 peripheral equipment during the next return-to-origin.)
[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
Return-to-origin
The YK-X series robots only require the return-to-origin to be performed once when the robot is introduced. Once the
return-to-origin is performed, you do not need to reperform it when the power is turned on next time. Set the origin
position while referring to return-to-origin methods in "2. Adjusting the origin" in Chapter 3 of this manual and in
"Return-to-origin" of the "YAMAHA Robot Controller User's Manual". In this case, setting the standard coordinates is
not necessary.
cCAUTION
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.Return-to-origin
The YK-X series robots only require the return-to-origin to be performed once when the robot is introduced. Once the
return-to-origin is performed, you do not need to reperform it when the power is turned on next time. Set the origin
position while referring to return-to-origin methods in "2. Adjusting the origin" in Chapter 3 of this manual and in
"Return-to-origin" of the "YAMAHA Robot Controller User's Manual". Set the origin position with the return-to-origin.
cCAUTION
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 return-to-origin is complete, and immediately affix the origin point sticker according to
instructions in "5. Affixing the stickers for origin positions, movement directions, and axis names" in Chapter 3 of this
manual.
3.Setting the standard coordinates
Set the standard coordinates while referring to instructions in "4. Setting the standard coordinates" in Chapter 3 of
this manual and also to "Setting the standard coordinates" in the "YAMAHA Robot Controller User's Manual". Robot
malfunctions (vibration, noise) may occur if the standard 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.)
Examples of error messages issued when the robot and controller are connected.
17.410 : ABS. battery error
17.411 : ABS. encoder error
17.412 : ABS. count error
17.413 : ABS. overflow error
17.414 : ABS. mixing error 1
etc.

Introduction
v
2. Repetitive positioning accuracy
Accuracies under the following conditions are not guaranteed in "Repetitive positioning accuracy".
[1] Factors related to absolute accuracy
• If the accuracy between the coordinate positions (command positions) inside the robot controller and the real
space positions (moving positions) is required.
[2] Motion pattern factors
• If a motion approaching to the teaching point from a different direction is included during repetitive operation.
• If the power is turned off or the robot is stopped before completing the motion or the moving speed is changed
even when approaching to the teaching point from the same direction.
• If the robot is moved to the teaching point using a hand system different from the hand system (right-handed or
left-handed system) used for the teaching.
[3] Temperature factors
• If the ambient temperature environment changes significantly.
• If the temperature of the robot main body changes.
[4] Load variation factors
•
If load conditions vary during operation (the load varies depending on whether or not the workpiece is present, etc.).
3. 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 moves in almost the same position, an oil film is difficult
to be formed on the joint support bearing, 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.

Chapter 1 Functions
Contents
1. Robot manipulator 1-1
1.1 Manipulator movement 1-1
1.2 Part names 1-2
2. Robot controller 1-5
3. Robot initialization number list 1-6