YAMAHA MOTOR CO., LTD.

Supplemental manual

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IntroductionThank you very much for your purchase of YAMAHA robot controller.This manual explains how to install and operate the YAMAHA robot controller. Be sure to read this manual carefully as well as the related manuals and comply with their instructions for using the YAMAHA robot controller safely and correctly.

About this manualThis is a supplement manual for robot controller RCX143/144. The separated power inlet and servo output functions are added to the RCX141/142 model. This manual describes these individual functions only.

General Contents

1. Wiringtothepowerconnector 2

2. Partnamesandfunctions 3

3. Controllersystem 4

4. Connectornames 5

5. Connectingtothepower 65.1 AC200to230Vsingle-phasespecifications 6

5.2 Installinganexternalleakagebreaker 7

5.3 Installingacircuitprotector 7

5.4 Installingacurrentcontrolswitch 8

6. Precautionsforcableroutingandinstallation 96.1 Precautionsforinstallation 9

6.2 Methodsofpreventingmalfunctions 9

7. Checkingtherobotcontrolleroperation 117.1 Emergencystopinputsignalconnection 11

8. DedicatedI/Osignaltimingchart 128.1 ControllerpowerON,servoONandemergencystop 12

9. SAFETYI/Ointerfaceoverview 149.1 Power 14

9.2 ConnectorI/Osignals 14

10. Controllerbasicspecifications 1610.1 RCX143/144basicspecifications 16

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1. Wiring to the power connector(1) Preparing the wire

Use the wire size specified below. Strip the cable sheath as shown below, and the wire can then be used as is.

• Wire cross-section 1.25 sq mm (AWG16) or more

8 to 9mm

(2) Connection method

Insert the core wire into the terminal hole of the power connector by using either of the following methods. Make sure the wire does not come loose if pulled.

LN

L1N1

Wire-release lever

When using the supplied wire-release lever

When using a small flat-blade screwdriver

c CAUTION

• Unplug the power connector from the controller before wiring.• Only one wire can be inserted into one wire hole of the power connector.• When inserting the wire into the terminal, be careful not to bring the core wire

braid into contact with other conductive parts.• If for some reason the inserted portion of the wire is frayed, cut off that frayed

portion and restrip the wire. Then reconnect the wire securely.

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2. Part names and functionsRCX144 (Maximum number of axes: 4 axes)

RCX144MOTOR

XM

YM

ZM

RM

PWR

SRV

ERR

SAFETY

MPB

COM

STD.DIO

RGEN

ACIN

P

N

L

N

L1

N1

ROBI/O

XY

ROBI/O

ZR

OP.1 OP.3

OP.2 OP.4

200-230V~50-60Hz

MAX.2500VA

BATT

ZR

XY

MODEL.SER. NO.MANUFACTUREDFACTORY AUTOMATION EQUIPMENT MADE IN JAPAN

注意CAUTION

取扱説明書参照READ INSTRUCTIONMANUAL

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3. Controller systemThe basic block diagram of the RCX robot controller system is shown below.

LNL1N1

AC

IN

RG

EN

AC

/DC

24VA

C/D

C5V,

12V

XM

ZM

RM

YM

MOTOR

ROB I/O XY

ROB I/O ZR

SAFETY

STD.DIO

COM

OP.BOARD

OP.BOARD OP.BOARD

OP.BOARD

CN

2C

N12

HEATSINK

TH

1(F

G)

CN8

CN5

CN9

CN5

CN5CN4

CN2

CN1

CN1

CN1

CN1

CN3

CN1CN3

CN4

CN6

CN7

CN

4C

N11

CN

7C

N3

CN

8C

N1

CN

3C

N3

CN

3C

N3

CN5

CN10CN3 CN7 CN2

CN

4C

N1

CN

1C

N2

CN1

CN2

CN2

CN2

CN2

CN2

MPB

CN9

CN13

CN10

CN10

BA

TT

CN

6X

YC

N8

CN

9

CN

11Z

R

CN

1

D POWER BOARD ASSY

DRIVER2 BOARD ASSY

DRIVER1 BOARD ASSY

CPU BOARD ASSY

POW

ER CPU UNIT1PO

WER CPU UNIT2

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4. Connector namesConnector names, locations and functions are shown below.

RCX144MOTOR

XM

YM

ZM

RM

PWR

SRV

ERR

SAFETY

MPB

COM

STD.DIO

RGEN

P

N

ROBI/O

XY

ROBI/O

ZR

OP.1 OP.3

OP.2 OP.4

200-230V~50-60Hz

MAX.2500VA

BATT

ZR

XY

MODEL.SER. NO.MANUFACTUREDFACTORY AUTOMATION EQUIPMENT MADE IN JAPAN

注意CAUTION

取扱説明書参照READ INSTRUCTIONMANUAL

ACIN

L

N

L1

N1

COM

MPB

SAFETY

XM

YM

ZM

RM

OP.1 OP.3

OP.2 OP.4

RGEN

ACIN

ROBI/O XY

ROBI/O ZR

STD.DIO

BATT

Connector name Function

XM/YM/ZM/RM Connectors for servomotor drive.

ROB I/O [XY/ZR] Connectors for servomotor feedback and sensor signals.

SAFETYInput/output connector for safety function such as emergency stop.

MPB Connector for MPB.

COM RS-232C interface connector.

STD.DIO Connector for dedicated input/output and standard general-purpose input/output.

OP.1-4 Connectors attached to optional expansion I/O boards. (OP.2 and OP.4 cannot be used with RCX142-T.)

BATT [XY/ZR] Battery connector for absolute backup.

REGN [P/ /N] Connector for regenerative unit. (Cannot be connected to RCX142-T.)

AC IN [L/N/ ] Terminal connector for power cable.

w WARNINGTO pReveNT eleCTRICAl shOCks, NeveR TOUCh The RGeN ANd AC IN TeRmINAls WheN pOWeR Is sUpplIed TO The RObOT CONTROlleR.

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5. Connecting to the powerAttach the power connector to the power cable and insert it into the "AC IN" connector on the front panel of the controller as shown below.

5.1 AC200 to 230V single-phase specificationsTerminal name Wiring Remarks

L1 200-230V LivePower supply for control

0.75mm2 or largerN1 200-230V

Neutral (ground side)

L 200-230V Live Power supply for motor 2.0mm2 or largerN 200-230V

Neutral (ground side)

Ground

wiring example

EXTERNALCIRCUIT

DO27

L

N

L1

N1

RCX144

c CAUTIONbefore connecting the power cable, be sure to check that the power supply voltage matches the power specifications of your controller.

w WARNING

• TO pReveNT eleCTRICAl shOCks OR fAUlTy OpeRATION CAUsed by NOIse, The eARTh TeRmINAl (pROTeCTIve CONdUCTOR) mUsT be GROUNded pROpeRly.

• TO pReveNT eleCTRICAl shOCks, NeveR TOUCh The AC IN TeRmINAls WheN pOWeR Is sUpplIed TO The RObOT CONTROlleR.

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5.2 Installing an external leakage breakerSince the robot controller drives the motors by PWM control of IGBT, leakage current flows at high frequencies. This might cause the external leakage breaker to malfunction.When installing an external leakage current breaker, it is important to choose the optimum sensitivity current rating (IΔn). (Check the leakage breaker manufacturer's data sheets to select the optimum product compatible with inverters.)

Leakage current

L/N (RCX144) 4mA (Max)

L1/N1 2.5mA (Max)

c CAUTION

1. leak current was measured with a leak tester with a low-pass filter turned on (100hz). • leak tester: hioki electric 3283

2. When using two or more controllers, sum the leakage current of each controller.

3. make sure that the controller is securely grounded.4. stray capacitance between the cable and fG may vary depending on the

cable installation condition, causing the leakage current to fluctuate.

5.3 Installing a circuit protectorAn inrush current, which might be from several to nearly 20 times higher than the rated current, flows at the instant that the controller is turned on or the robot motors start to operate. When installing an external circuit protector for the robot controller, select a circuit protector that provides optimum operating characteristics.To ensure proper operation, we recommend using a medium to slow response circuit protector with an inertial delay function. (Refer to the circuit protector manufacturer's data sheets for making the selection.)

Example

Rated current Operating characteristics

RCX144 (L/N only) 20ASlow type with inertia delay 300% 2 sec.

1000% 0.01 sec.

5. Connecting to the power

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5.4 Installing a current control switchWhen controlling the power on/off of the robot controller from an external device such as a PLC, a current control switch (contactor, breaker, etc.) may be used. In this case, the current control switch usually creates a large on/off surge current. To minimize this on/off surge current, surge killers must be installed for surge absorption. Connect a surge killer in parallel with and close to each contact of the current control switch.

Recommended surge killer: Okaya Electric XE1201, XE1202, RE1202 or equivalent

Example

: Surge killer

Controller

: Contactor

AC IN

L1

N1

FG

L

NAC200V

NoiseFilter(Required)

5. Connecting to the power

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6. Precautions for cable routing and installation6.1 Precautions for installationThis robot controller is not designed with an explosion-proof, dust-proof or drip-proof structure. Do not install it in the following locations or environments.

(1) where exposed to flammable gases or liquids.

(2) where conductive debris such as metal cutting chips are spread.

(3) where to corrosive gases such as acid gases and alkaline gases.

(4) where exposed to cutting oil, grinding fluids and machining mist.

(5) near sources of electrical noise, such as large inverters, high-power high-frequency generators, large switching equipment, and welding machines.

6.2 Methods of preventing malfunctionsTo prevent malfunctions due to noise, take into account the following points.

1) Place a noise filter and ferrite core at a point near the robot controller. Do not bundle the primary wiring and secondary wiring of the noise filter together.

Bad example

L1

N1

L

N

• Primary wiring and secondary wiring of the noise filter are bundled together.

• Ground wire is bundled with primary wiring of the noise filter.

Noise filterRobot

controllerPrimary wiring Secondary wiring

Ground wire

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2) Always attach a surge absorber to the coil of inductive loads (inductive motor, solenoid valve, brake solenoid and relay) located near the robot controller.

Example of surge absorber

•For inductive motor

A: Surge killer (Okaya Electric Industries CRE-50500, 3CRE-50500 or equivalent)

Single-phasemotorA

3-phasemotor

A

•For solenoid valve, solenoid

B: Diode, varistor, CR elements

DC type

C: Varistor, CR elements

AC type

B C

6. Precautions for cable routing and installation

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7. Checking the robot controller operation7.1 Emergency stop input signal connection

c CAUTION

• external emergency stop and the mpb emergency stop button are disabled when pin 13 and pin 14 are directly shorted to each other on the sAfeTy connector. make connections to ensure the system including the robot controller will always operate safely.

• In order to make "mp ReAdy" work, 24v is required. with this wiring, the parameter "Watch on sTd dId 24v" is kept in "vAlId" status. (It is impossible to change it to "INvAlId" while 24v is provided.)

GNDGND

24V

13

14

131211

14

234

MPB

EMG 24VN.COM D1P.COM D1P.COM (STD DI0)

N.COM (STD DI0)

MP Ready

AC 200V

AC 200V

L

N

L1

N2

24V

MPB connector

RCX143/RCX144

SAFETYconnector

SAFETYconnector (supplied) Needs to be controlled

by an external circuit.

Emergency stop button

Motor powersupply

relay coil

Motor powersupply circuit

Power supply control circuit

• The emergency stop button on the MPB is connected to the controller through the SAFETY connector.

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8. Dedicated I/O signal timing chart8.1 Controller power ON, servo ON and emergency stop

c CAUTIONIt will take about 3 seconds for the controller to issue the CpU_Ok output after the power is turned on.

onCPU_OK output: DO(01)a off

onServo-ON output: DO(02)a off onAlarm output: DO(03)a off

onEmergency stop input

off

onServo ON input: DI(01) off

MP READY

a)a')b) c) d) e) f ) g) h) i ) j )

Initial servo-on processing when power is turned on.

a) CPU_OK output turns on.

a') MP READY output turns on.

b) When not in emergency stop, servo-ON output turns on after servo-ON processing.

Shifting to emergency stop

c) Emergency stop input turns off.

d) Alarm output turns on and servo-ON output turns off, MP READY turns off.

Shifting from emergency stop to servo-ON

e) Emergency stop input turns on.

f) Emergency stop input turns on, MP READY turns on.

g) Servo-ON input turns on.

h) Alarm output turns off.

i) Servo-ON output turns on.

j) Servo-ON input turns off after checking for servo-ON output.

* If the emergency stop input contacts are open or a major error (malfunction) occurs when the controller power is turned on, the servo remains off. Likewise, if SAFE mode or serial I/O setting is enabled, the controller starts up with the servo turned off.

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* When processing with dedicated inputs, use I/O signals to perform handshake processing. If handshake processing is impossible, hold the signal for a minimum of 100ms.

* Supply motor power immediately when "MP READY" is turned on.

8. Dedicated I/O signal timing char

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9. SAFETY I/O interface overviewThe robot controller is provided with SAFETY I/O interfaces for compatibility with the system used by the customer. A description of the I/O terminals and connection methods are explained below.Connect the I/O terminals correctly for effective operation.The SAFETY I/O interface contains an emergency stop input and one dedicated input point.The input signal is from hereon referred to as DI and the output signal as DO.

Specifications Connector name Connector model No. Wire material

SAFETYEmergency stop input : 1 point Dedicated input : 1 point

SAFETY D-SUB15 (male) 0.3mm2 or more

9.1 PowerThe emergency stop input utilizes internal power for emergency stop.The dedicated input uti l izes external 24V power connected via the standard I/O interface.

9.2 Connector I/O signalsPIN I/O No. Name Remarks

1 DI02 SERVICE mode NPN/PNP specs conform to STD. DIO settings. Common terminal: P. COM / N. COM2 MP READY* Motor power ready

3 EMGIN1 Emergency stop input 1

4 EMGIN2 Emergency stop input 2

5 EMGIN3 Emergency stop input 3

Usable only when enable switch compatible programming unit is used. (MPB-E2)

6 EMGIN4 Emergency stop input 4

7 LCKIN1 Enable switch input 1

8 LCKIN2 Enable switch input 2

9 LCKIN3 Enable switch input 3

10 LCKIN4 Enable switch input 4

11 P.COM DC+24V (P.COMDI) Internally connected with P. COMDI terminal of STD. DIO.

12 N.COM GND (N.COMDI) Internally connected with N. COMDI terminal of STD. DIO.

13 EMG 24V Emergency stop input power

14 EMG RDY Emergency stop READY signal

15 Reserved Do not use.

* MP READY This is an pulsed output for the external circuit, used to turn ON the motor power supply.

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■ NPN specification

Photocoupler(PS2801 or equivalent)

NPN Darlington transistor(2SD2195 or equivalent)

External powersupplyDC24V

Controller side

DC24V

MP READY

GND

■ PNP specification

PNP Darlington transistor(2SB1580 or equivalent)

External powersupplyDC24V

Controller side

DC24V

GND

Photocoupler(PS2801 or equivalent)

MP READY

c CAUTION

• On the sAfeTy connector supplied with the controller, pin 3 is shorted to pin 13, and pin 4 is shorted to pin 14. Use these pins to make an interlock circuit to ensure the system including the robot controller operates safely.

• do not connect an external dC 24v to emG 24.• do not connect any external signals to the reserved terminals.

9. SAFETY I/O interface overview

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10. Controller basic specifications10.1 RCX143/144 basic specifications

c CAUTIONspecifications and appearance are subject to change without prior notice.

Item Specifications

Basic specifications

Applicable robotsYAMAHA Cartesian robots, SCARA robots (except YK120X and YK150X), single-axis robots, P&P robots

Maximum power consumption 2500VA (L/N) 250VA (L1/N1)

Dimensions W180 × H250 × D235 (main unit)

Weight 6.5kg (main unit)

Power supply voltage Single phase AC 200 to 230V ±10%, 50/60Hz

Axis control

No. of axes 4 axes maximum (simultaneous control: 4 axes)

Drive method AC full digital servo

Position detection method Resolver

Control methodPTP motion (point to point), ARCH motion, linear interpolation, circular interpolation

Coordinate systems Joint coordinates, Cartesian coordinates

Position display units Pulses, mm (millimeters), deg (degrees)

Speed setting 1-100%, 1% increments (setting possible during program execution)

Acceleration/deceleration setting

Automatic acceleration setting by robot model and tip weight parameterSetting by accel coefficient and decel. rate parameters (1% steps)(Can be changed by programming.)Zone control(Optimum speed setting matching SCARA robot arm position)

Programming

Program language YAMAHA BASIC conforming to JIS B8439 (SLIM language)

Multitask 8 tasks maximum

Sequence program 1 program

Memory size364KB (Total of program and point data) (Available size for program when maximum number of points is used: 84KB)

Program

100 programs (maximum number of programs)9999 lines (maximum lines per program)98KB (maximum capacity per program, maximum capacity per object program)

Point 10000 points (maximum number of points)

TeachingMDI (coordinate data input), direct teaching, teaching playback, offline teaching (data input from external unit)

Memory backup Lithium battery (service life about 4 years at 0 to 40°C)

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Item Specifications

External I/O

STD.DIOI/O input

General-purpose 16 points, dedicated 9 points (NPN/PNP specifications selectable)

I/O output General-purpose 8 points, dedicated 11 points

SAFETY

Emergency stop input Relay contact

Service mode input 1 point (NPN/PNP specifications conform to STD.DIO setting.)

MP READY output 1 point

Break output Relay contact

Origin sensor input Connectable to DC24V B-contact (normally closed) sensor

External communicationsRS-232C : 1 channel (D-SUB 9-pin female connector)RS-422 : 1 channel (for MPB only)

General specifications

Operating temperature 0 to 40°C

Storage temperature -10 to 65°C

Operating humidity 35 to 85% RH (no condensation)

Noise immunity Conforms to IEC61000-4-4 Level 3

Protective structure IP10

Options

Parallel DIO boardGeneral-purpose input 24 points/board, output 16 points/board (4 boards maximum, compatible with NPN/PNP specifications)

CC-Link boardDedicated input 11 points, dedicated output 11 pointsGeneral-purpose input 96 points, general-purpose output 96 points

DeviceNet boardDedicated input 11 points, dedicated output 11 pointsGeneral-purpose input 96 points, general-purpose output 96 points

Profibus boardDedicated input 11 points, dedicated output 11 pointsGeneral-purpose input 96 points, general-purpose output 96 points

Ethernet board Conforms to IEEE802.3, 10Mbps (10BASE-T)

Programming unit MPB, MPB-E2

Absolute battery B3 (2000mAh), (replacement guideline: approx. 1.5 years)

PC software VIP

10. Controller basic specifications

Supplemental manual

Apr. 2007Ver. 1.02 This manual is based on Ver. 1.00 of Japanese manual.

© YAMAHA MOTOR CO., LTD. IM Company

Robot Controller

All rights reserved. No part of this publication may be reproduced in any form without the permission of YAMAHA MOTOR CO., LTD.Information furnished by YAMAHA in this manual is believed to be reliable. However, no responsibility is assumed for possible inaccuracies or omissions. If you find any part unclear in this manual, please contact YAMAHA or YAMAHA sales representatives.