Yamaha YK-XR Series User manual

Ver.1.09
EWFK155120
E66
Ver. 1.20
YAMAHASCARAROBOT
InstallationManual
YK-XR Series
YK400XR

CONTENTS YK-XR
Installation Manual
T-1
Safety Instructions
1. Safety Information S-1
2. Signal words used in this manual S-2
3. Warning labels S-3
3.1 Warning labels S-3
3.1.1 Warning label messages on robot and controller S-3
3.1.2 Supplied warning labels S-8
3.2 Warning symbols S-9
4. Important precautions for each stage of the robot life cycle S-10
4.1 Precautions for using robots and controllers S-10
4.2 Essential precautions for the linear conveyor module S-11
4.3 Design S-12
4.3.1 Precautions for robots S-12
4.3.2 Precautions for robot controllers S-12
4.4 Moving and installation S-13
4.4.1 Precautions for robots S-13
4.4.2 Precautions for robot controllers S-14
4.5 Safety measures S-16
4.5.1 Safety measures S-16
4.5.2 Installing a safety enclosure S-17
4.6 Operation S-18
4.6.1 Trial operation S-18
4.6.2 Automatic operation S-20
4.6.3 Precautions during operation S-20
4.7 Inspection and maintenance S-22
4.7.1 Before inspection and maintenance work S-22
4.7.2 Precautions during service work S-23
4.8 Disposal S-24
5. Emergency action when a person is caught by robot S-25
6. Cautionsregardingstrongmagneticelds S-25
7. Using the robot safely S-26
7.1 Movement range S-26
7.2 Robot protective functions S-27
7.3 Residual risk S-28
7.4 Special training for industrial robot operation S-28

CONTENTS YK-XR
Installation Manual
T-2
T-3
Warranty
Introduction
Before using the robot (Be sure to read the following notes.) i
Introduction iv
Chapter 1 Functions
1. Robot manipulator 1-1
1.1 Manipulator movement 1-1
1.2 Part names 1-2
2. Robot controller 1-3
3. Robot initialization number list 1-4
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 Moving the robot 2-5
2.4 Installing the robot 2-6
3. Protective bonding 2-7
4. Robot cable connection 2-8
5. User wiring and user tubing 2-9
6. Attaching the end effector 2-11
6.1 Accelerationcoefcientvs.momentofinertia 2-11
6.1.1 R-axis tolerable moment of inertia and acceleration coefficient 2-11
6.1.2 Parameter setting according to R-axis moment of inertial of load 2-11
6.2 Equation for moment of inertia calculation 2-12
6.3 Example of moment of inertia calculation 2-15
6.4 Attaching the end effector 2-17
6.5 Gripping force of end effector 2-19

T-2
CONTENTS YK-XR
Installation Manual
T-3
7. Limiting the movement range with X-axis and Y-axis mechanical stoppers 2-20
7.1 Installing the X-axis/Y-axis additional mechanical stoppers 2-21
7.2 Robot overrun during impacts with X-axis or Y-axis mechanical stopper 2-23
8. Working envelope 2-24
9. Stopping time and stopping distance at emergency stop 2-27
10. Installing the user wiring and tubing newly 2-30
11. Passing the wiring and tubing in the user wiring/tubing through spline type 2-31
12. Detaching or attaching the covers 2-32
Chapter 3 Robot settings
1. Overview 3-1
2. Adjusting the origin 3-2
2.1 Return-to-origin method 3-3
2.1.1 Stroke end method 3-3
2.1.2 Mark method 3-4
2.1.3 Sensor method (X-axis, Y-axis) 3-4
2.2 Machine reference 3-5
2.3 Return-to-origin procedures 3-6
2.3.1 Stroke end method 3-6
2.3.2 Sensor method (X-axis, Y-axis) 3-7
2.4 Adjusting the machine reference value 3-9
2.4.1 Stroke end method 3-9
2.4.2 Mark method 3-13
2.4.2.1 Absolute reset in servo on state (re-reset) 3-14
2.4.2.2 Absolute reset in servo off state (re-reset) 3-16
2.4.2.3 Absolute reset in servo on state (new reset) 3-19
2.4.2.4 Absolute reset in servo off state (new reset) 3-21
2.4.3 Sensor method (X-axis, Y-axis) 3-23
3. Setting the soft limits 3-27
3.1 Setting the X-axis and Y-axis soft limits 3-27
3.2 Setting the Z-axis soft limits 3-28
3.3 Setting the R-axis soft limits 3-28
3.4
Relation between the X, Y, and R-axis movement angle, the Z-axis movement distance and the number of pulses 3-28
4. Setting the standard coordinates 3-29
4.1 Standard coordinate setting using a standard coordinate setup jig 3-30

CONTENTS YK-XR
Installation Manual
T-4
5. Afxingthestickersfororiginpositions,movementdirections,andaxisnames 3-32
Chapter 4 Periodic inspecition
1. Overview 4-1
2. List of inspection items 4-2
Chapter 5 Harmonic drive replacement period
1. Overview 5-1
2. Replacement period 5-2
Chapter 6 Increasing the robot operating speed
1. Increasing the robot operating speed 6-1
1.1 Increasing speed by arch motion 6-1
1.2 Increasing the speed with the WEIGHT statement 6-3
1.3 Increasing the speed by the tolerance parameter 6-4
1.4 Increasing the speed by the OUT effective position parameter 6-5
Chapter 7 Torque limit designated Z-axis pushing action
1. Torque limit designated Z-axis pushing action 7-1
Chapter 8 Specications
1. Manipulator 8-1
1.1 Basicspecication 8-1
1.2 External view and dimensions 8-2
1.3 Robot inner wiring diagram 8-4
1.4 Wiring table 8-5

Contents
1. Safety Information S-1
2. Signal words used in this manual S-2
3. Warning labels S-3
3.1 Warning labels S-3
3.1.1 Warning label messages on robot and controller S-3
3.1.2 Supplied warning labels S-8
3.2 Warning symbols S-9
4. Important precautions for each stage of the robot life cycle S-10
4.1 Precautions for using robots and controllers S-10
4.2 Essential precautions for the linear conveyor module S-11
4.3 Design S-12
4.3.1 Precautions for robots S-12
4.3.2 Precautions for robot controllers S-12
4.4 Moving and installation S-13
4.4.1 Precautions for robots S-13
4.4.2 Precautions for robot controllers S-14
4.5 Safety measures S-16
4.5.1 Safety measures S-16
4.5.2 Installing a safety enclosure S-17
4.6 Operation S-18
4.6.1 Trial operation S-18
4.6.2 Automatic operation S-20
4.6.3 Precautions during operation S-20
4.7 Inspection and maintenance S-22
4.7.1 Before inspection and maintenance work S-22
4.7.2 Precautions during service work S-23
4.8 Disposal S-24
5. Emergency action when a person is caught by robot S-25
6. Cautions regarding strong magnetic fields S-25
7. Using the robot safely S-26
7.1 Movement range S-26
7.2 Robot protective functions S-27
7.3 Residual risk S-28
7.4 Special training for industrial robot operation S-28
Safety Instructions

Safety Instructions
S-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 safe and correct use of YAMAHA industrial robots and con-
trollers*, carefully read and comply with the safety instructions and precautions in this "Safety Instructions"
guide. Failure to take necessary safety measures or incorrect handling may result in trouble or damage to the
robot and controller, and also may cause personal injury (to installation personnel, robot operator or service
personnel) including fatal accidents.
* The descriptions about the controller stated in this manual also include the contents of the robot driver.
Before using this product, read this manual and related manuals and take safety precautions to ensure cor-
rect handling.
The precautions listed in this manual relate to this product. To ensure safety of the user’s final system that in-
cludes YAMAHA robots, please take appropriate safety measures as required by the user’s individual system.
To use YAMAHA robots and controllers safely and correctly, always comply with the safety rules and instruc-
tions.
• Forspecificsafetyinformationandstandards,refertotheapplicablelocalregulationsandcomplywith
the instructions.
• WarninglabelsattachedtotherobotsarewritteninEnglish,Japanese,ChineseandKorean.Thismanual
 isavailableinEnglishorJapanese(orsomepartsinChinese).Unlesstherobotoperatorsorservice 
personnel understand these languages, do not permit them to handle the robot.
• CautionsregardingtheofficiallanguageofEUcountries
 ForequipmentthatwillbeinstalledinEUcountries,thelanguageusedforthemanuals,warninglabels,
 operationscreencharacters,andCEdeclarationsisEnglishonly.
 WarninglabelsonlyhavepictogramsorelseincludewarningmessagesinEnglish.Inthelattercase, 
 messagesinJapaneseorotherlanguagesmightbeadded.
It is not possible to list all safety items in detail within the limited space of this manual. So please note that
it is essential that the user have a full knowledge of safety and also make correct judgments on safety proce-
dures.
Refer to the manual by any of the following methods when installing, operating or adjusting the robot
and controller.
1. Install, operate or adjust the robot and controller while referring to the printed version of the
manual (available for an additional fee).
2. Install, operate or adjust the robot and controller while viewing the disc version of the manual
on your computer screen.
3. Install, operate or adjust the robot and controller while referring to a printout of the necessary
pages from the disc version of the manual.

Safety Instructions
S-2
2. Signal words used in this manual
This manual uses the following safety alert symbols and signal words to provide safety instructions that must
be observed and to describe handling precautions, prohibited actions, and compulsory actions. Make sure
you 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
Explains the key point in the operation in a simple and clear manner.