yamaha scara robot yk-xg - yrg incthe robot operator, a bystander or a person inspecting or...

User’s Manual ENGLISH E

YAMAHA SCARA ROBOT

YK-XG

IM Operations882 Soude, Naka-ku, Hamamatsu, Shizuoka 435-0054.JapanURL http://www.yamaha-motor.jp/robot/index.html

YAMAHA MOTOR CO., LTD.

E047-Ver. 1.00EPF011C100

General Contents

Safety Guide

1. Safety Information 1

2. Essential Caution Items 3

3. Industrial Robot Operating and Maintenance Personnel 11

4. Robot Safety Functions 11

5. Safety Measures for the System 13

6. Trial Operation 13

7. Work Within the Safety Enclosure 14

8. Automatic Operation 15

9. Warranty 15

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 1-4

3. Robot initialization number list 1-5

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 ……………………………………………………………………… 2-6

2.3.1 Moving the YK250XG, YK350XG, YK400XG ……………………………………………………… 2-6

2.3.2 Moving the YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG …… 2-7

2.4 Installing the robot …………………………………………………………………… 2-9

3. Protective bonding 2-10

4. Robot cable connection 2-11

5. User wiring and user tubing 2-12

6. Attaching the end effector 2-15

6.1 R-axis tolerable moment of inertia and acceleration coefficient …………… 2-15

6.1.1 Acceleration coefficient vs. moment of inertia (YK250XG) ……………………………… 2-16



6.1.4 Acceleration coefficient vs. moment of inertia (YK250XG, YK350XG, YK400XG) …… 2-19



6.1.7 Acceleration coefficient vs. moment of inertia (YK600XGH) …………………………… 2-20

6.1.8 Acceleration coefficient vs. moment of inertia (YK700XG, YK800XG) ………………… 2-21

6.1.9 Acceleration coefficient vs. moment of inertia (YK900XG, YK1000XG) ………………… 2-21

6.2 Equation for moment of inertia calculation ……………………………………… 2-22

6.3 Example of moment of inertia calculation ……………………………………… 2-25

6.4 Attaching the end effector ………………………………………………………… 2-27

6.5 Gripping force of end effector ……………………………………………………… 2-30

7. Limiting the movement range with x- and y-axis mechanical stoppers 2-31

7.1 YK250XG, YK350XG, YK400XG ……………………………………………………… 2-31

7.1.1 Installing the X-axis/Y-axis additional mechanical stoppers ……………………………… 2-32

7.1.2 Robot overrun during impacts with X-axis or Y-axis mechanical stopper ……………… 2-34

7.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG … 2-35

7.2.1 Changing the X-axis mechanical stopper position ………………………………………… 2-36

7.2.2 Changing the Y-axis mechanical stopper position ………………………………………… 2-38

7.2.3 Robot overrun during impacts with X-axis or Y-axis mechanical stopper ……………… 2-40

8. Working envelope and mechanical stopper positions for maximum working envelope 2-41

9. Stopping time and stopping distance at emergency stop 2-44

9.1 YK250XG, YK350XG, YK400XG ……………………………………………………… 2-44

9.2 YK500XG, YK600XG …………………………………………………………………… 2-48

9.3 YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ……………………… 2-53

10. Installing the user wiring and tubing newly 2-62

11. Passing the wiring and tubing in the user wiring/ tubing through spline type 2-63

12. Installing the tool flange 2-64

Chapter 3 Robot settings

1. Overview 3-1

2. Absolute reset 3-2

2.1 Absolute reset method ……………………………………………………………… 3-2

2.1.1 Sensor method (X-axis, Y-axis, and R-axis) ……………………………………………………… 3-2

2.1.2 Stroke end method (Z-axis) ………………………………………………………………………… 3-3

2.2 Machine reference …………………………………………………………………… 3-3

2.3 Absolute reset procedures ………………………………………………………… 3-4

2.3.1 Sensor method (X-axis, Y-axis, and R-axis) ……………………………………………………… 3-4

2.3.2 Stroke end method (Z-axis) ………………………………………………………………………… 3-5

3. Setting the soft limits 3-7

3.1 Setting the X-axis and Y-axis soft limits …………………………………………… 3-7

3.2 Setting the Z-axis soft limits ………………………………………………………… 3-8

3.3 Setting the R-axis soft limit …………………………………………………………… 3-8

3.4 Relation between the X, Y and R-axis movement angle, the Z-axis movement distance and the number of pulses …………………… 3-8

4. Setting the standard coordinates 3-9

4.1 Standard coordinate setting using a standard coordinate setup jig ……… 3-10

4.1.1 YK250XG, YK350XG, YK400XG ………………………………………………………………… 3-10

4.1.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG …………… 3-11

5. Affixing the stickers for origin positions, movement directions, and axis names 3-14

Chapter 4 Periodic Inspecition

1. Overview 4-1

2. Daily inspection 4-2

3. Six-month inspection 4-3

4. Consumable parts 4-6

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 Specifications

1. Manipulator 7-1

1.1 Basic specification …………………………………………………………………… 7-1

1.1.1 YK250XG, YK350XG, YK400XG …………………………………………………………………… 7-1

1.1.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG ……………… 7-2

1.2 External view and dimensions ……………………………………………………… 7-4

1.2.1 YK250XG ……………………………………………………………………………………………… 7-4

1.2.2 YK350XG ……………………………………………………………………………………………… 7-8

1.2.3 YK400XG …………………………………………………………………………………………… 7-12

1.2.4 YK500XG …………………………………………………………………………………………… 7-16

1.2.5 YK600XG …………………………………………………………………………………………… 7-18

1.2.6 YK600XGH …………………………………………………………………………………………… 7-20

1.2.7 YK700XG …………………………………………………………………………………………… 7-22

1.2.8 YK800XG …………………………………………………………………………………………… 7-24

1.2.9 YK900XG …………………………………………………………………………………………… 7-26

1.2.10 YK1000XG …………………………………………………………………………………………… 7-28

1.3 Robot inner wiring diagram ………………………………………………………… 7-30

1.4 Wiring table …………………………………………………………………………… 7-31

1.5 Maintenance parts …………………………………………………………………… 7-36

1.5.1 YK250XG, YK350XG, YK400XG Standard type ……………………………………………… 7-36

1.5.2 YK250XG, YK350XG, YK400XG Tool flange mount type …………………………………… 7-38

1.5.3 YK250XG, YK350XG, YK400XG User wiring/tubing through spline type ………………… 7-40

1.5.4 YK250XG, YK350XG, YK400XG User wiring/tubing through spline and tool flange mount type … 7-42

1.5.5 YK500XG, YK600XG Z=200mm stroke type …………………………………………………… 7-44


1.5.7 YK600XGH Z=200mm stroke type ……………………………………………………………… 7-48

1.5.8 YK600XGH Z=400mm stroke type ……………………………………………………………… 7-50



1.5.11 YK900XG, YK1000XG Z=200mm stroke type ………………………………………………… 7-56

1.5.12 YK900XG, YK1000XG Z=400mm stroke type ………………………………………………… 7-58

Safety Guide

Contents

1. Safety Information 1

2. Essential Caution Items 3

3. Industrial Robot Operating and Maintenance Personnel 11

4. Robot Safety Functions 11

5. Safety Measures for the System 13

6. Trial Operation 13

7. Work Within the Safety Enclosure 14

8. Automatic Operation 15

9. Warranty 15

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Safety Guide

1. Safety Information

1. Safety InformationIndustrial 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 WARNINGS, 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 injury to personnel (robot operator or service personnel) including fatal accidents.

Warning information in this manual is shown classified into the following items.

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.

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.

Failure to follow CAUTION instructions may result in injury to the robot operator, a bystander or a person inspecting or repairing the robot, or damage to the robot and/or robot controller.

Explains the key point in the operation in a simple and clear manner.

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Safety Guide

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Refer to the user’s 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 user’s manual (available for an additional fee).

2. Operate or adjust the robot while viewing the CD-ROM version of the user’s 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 user’s manual.

It is not possible to list all safety items in detail 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.For specific safety information and standards, refer to the applicable local regulations and comply with the instructions. This manual and warning labels supplied with or attached to the robot are written in English. Unless the robot operators or service personnel understand English, do not permit them to handle the robot.

* Cautions regarding the official language of EU countriesFor equipment that will be installed in EU countries, the language used for the user’s manuals, CE declarations, and operation screen characters is English only.Warning labels only have pictograms or else include warning messages in English.In the latter case, Japanese messages might be added.

1. Safety Information

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Safety Guide

2. Essential Caution ItemsParticularly 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 instructions 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 “1.2 Part names in Chapter 1” for the locations of warning labels.

• Installasafetyenclosure(protectiveenclosure)tokeepanypersonfromenteringwithin the movement range of the robot and suffering injury due to being struck by moving parts.

• Installasafetyinterlockthattriggersemergencystopwhenthedoororpanelisopened.

• Installsafeguardssothatnoonecanenterinsideexceptfromdoorsorpanelsequipped with safety interlocks.

• ThewarninglabelsshowninFig.1-1aresuppliedwiththerobotandshouldbeaffixed to a conspicuous spot on doors or panels equipped with safety interlocks.

Serious injury or death will result from impact with moving robot.• Keepoutsideofguardduringoperation.• Lockoutpowerbeforeapproachingrobot.

DANGERSerious 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. Essential Caution Items

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(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 “1.2 Part names in Chapter 1” for the locations 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.

Moving parts can pinch or crush hands. Keep hands away from robot arms.

Moving parts can pinch or crush.Keep hands away from robot arms.

WARNING


(3) Follow the instructions on warning labels and in this manual.Warning label 3 (Fig. 1-3) is affixed to the robot. See “1.2 Part names in Chapter 1” for the locations of warning labels.

• Besuretoreadthewarninglabelandthismanualcarefullyandmakeyouthoroughly understand the contents before attempting installation and operation of the robot.

• Beforestartingtherobotoperation,evenafteryouhavereadthroughthismanual,read again the corresponding procedures and cautions in this manual as well as descriptions in this chapter (“Safety Guide”).

• Neverinstall,adjust,inspectorservicetherobotinanymannerthatdoesnotcomply with the instructions in this manual.

Improper installation or operation can result in serious injury or death Read user’s (owner’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



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(4) Do not remove the Z-axis upper-end mechanical stopperWarning label 4 (Fig. 1-4) is affixed to the robot. 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.

Do not remove this part. Damage to the ball screw will result.


(5) Do not use the robot in environments containing inflammable gas, etc.

• Thisrobotwasnotdesignedforoperationinenvironmentswhereinflammableor explosive substances are present.

• Donotusetherobotinenvironmentscontaininginflammablegas,dustorliquids. Explosions or fire could otherwise result.

(6) Do not use the robot in locations possibly subject to electromagnetic interference, etc.

Avoid using the robot in locations subject to electromagnetic interference, electrostatic discharge or radio frequency interference. Malfunction may otherwise occur.

(7) Use caution when releasing the Z-axis (vertical axis) brake.

The Z-axis will slide down when the Z-axis brake is released, causing a hazardous situation.• PresstheemergencystopbuttonandpropuptheZ-axiswithasupportstand

before releasing the brake. • UsecautionnottoletyourbodygetcaughtbetweentheZ-axisand

installation base when releasing the brake to perform direct teach.

(8) Provide safety measures for end effector (gripper, etc.).

• Endeffectorsmustbedesignedandmanufacturedsothattheycause no hazards (for example, loosening of workpiece) even if power (electricity, air pressure, etc.) is shut off or power fluctuations occur.

• Ifthereisapossibledangerthattheobjectgrippedbytheendeffectormayfly off or drop, then provide appropriate safety protection taking into account the object size, weight, temperature and chemical properties.

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(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)

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.• Donotlethandsorfingersgetcaughtandsqueezedbymoving

parts of the Z-axis. • KeeptheusualrobotpositioninmindsothattheZ-axiswillnotinterferewith

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)

When the Z-axis comes to a stop due to obstructions from peripheral equipment, the Z-axis may move suddenly when the obstruction is removed, causing injury such as pinched or crushed hands.• Turnoffthecontrollerandreducetheairpressurebeforeattemptingto

remove the obstruction. • Beforereducingtheairpressure,placeasupportstandundertheZ-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)

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 replacing the pneumatic equipment.

Air or parts may fly outwards if pneumatic equipment is disassembled or parts replaced while air is still supplied.• Doserviceworkafterfirstturningoffthecontrollerandreducingtheairpressure.• Beforereducingtheairpressure,placeasupportstandundertheZ-axis

(2-axis robots with air driven Z-axis) since it will drop under its own weight.


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Safety Guide


(13) Use the following caution items when removing the Z-axis motor.

The Z-axis will drop when the Z-axis motor is removed, possibly resulting ininjury.• TurnoffthecontrollerandsetasupportstandundertheZ-axisbefore

removing the motor. • Usecautionnottoallowhandsorbodytobesqueezedorcrushedby

moving parts on the Z-axis or between the Z-axis and the installation base.

(14) Use the following caution during inspection of controller.

• Whenyouneedtotouchtheterminalsorconnectorsontheoutsideofthecontroller during inspection, always first turn off the controller power switch and also the power source in order to prevent possible electrical shock.

• Nevertouchanyinternalpartsofthecontroller.

For precautions on handling the controller, refer to the “YAMAHA Robot Controller User’s Manual”.

(15) Consult us for corrective action when the robot is damaged or malfunction occurs.

If any part of the robot is damaged or any malfunction occurs, continuous operation 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 robotFlying 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 controller cooling fan.

• Bodilyinjurymayoccurfromcomingintocontactwiththecoolingfanwhileit is rotating.

• Whenremovingthefancoverforinspection,firstturnoffthecontrollerandmake sure the fan has stopped.

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(17) Use caution not to touch the high temperature motor or speed reduction gear casing.

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.

(18) Do not remove, alter or stain the warning labels.

If warning labels are removed or difficult to see, necessary cautions may not be taken, resulting in an accident.• Donotremove,alterorstainthewarninglabelsontherobot.• Donotallowthewarninglabelstobehiddenbythedeviceinstalledtothe

robot by the user. • Provideproperlightingsothatthesymbolsandinstructionsonthewarning

labels can be clearly seen even from the outside of safety enclosure.

(19) Protective bonding

Be sure to ground the robot and controller to prevent electrical.

(20) Be sure to make correct parameter settings.

The robot must be operated with correct tolerable moment of inertia and acceleration coefficients according to the manipulator tip mass and moment of inertia. 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.

(21) Do not use the robot for tasks requiring motor thrust.

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.


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(22) 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 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.

(23) Adjustment and inspection

Do not attempt any installation, adjustment, inspection or maintenance unless it is described in this manual.

(24) Repair and modification

Do not attempt any repair, parts replacement and modification unless described in this manual. These works require technical knowledge and skill, and may also involve work hazards.

(25) Precautions when disposing of the robotWhen disposing of the robot, handle it as industrial waste.

(26) Location for installing the controller and the programming boxThe robot controller and programming box should be installed at a location that is outside the robot movement range yet where it is easy to operate and view the robot performing tasks.

(27) Protect electrical wiring and hydraulic/pneumatic hoses as needed.Install a cover or similar item to protect the electrical wring and hydraulic/pneumatic hoses from possible damage.

(28) Install an operation status light.Install an operation status light (signal light tower, etc.) at an easy-to-see position so the operator will know whether the robot is merely stopped or is in emergency-error stop.

(29) Clean work tools, etc.Work tools such as welding guns and paint nozzles which are mounted in the robot arm will preferably be cleaned automatically.

(30) Provide adequate lighting.Make sure to provide enough lighting to ensure safety during work.

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(31) Draw up “work instructions” and makes sure the operator learns them well.Decide on “work instructions” for the following items in cases where personnel must work within the robot movement range to perform teaching, maintenance or inspection. Make sure the workers know these “work instructions” well.

(1) Robot operating procedures needed for tasks such as startup procedures and handling switches

(2) Robot speeds used during tasks such as teaching

(3) Methods for workers to signal each other when two or more workers perform tasks

(4) Steps that the worker should take when a problem or emergency

(5) Steps to take after the robot has come to a stop when the emergency stop device was triggered, including checks for cancelling the problem or error state and safety checks in order to restart the robot.

(6) In cases other than above, the following actions should be taken as needed to prevent hazardous situations due to sudden or unexpected robot operation or faulty robot operation, as listed below.

1. Show a display on the operator panel

2. Ensure the safety of workers performing tasks within the robot movement range

3. Clearly specify position and posture during work Position and posture where worker can constantly check robot movements and immediately move to avoid trouble if an error/problem occurs

4. Install noise prevention measures

5. Use methods for signaling operators of related equipment

6. Use methods to decide that an error has occurred and identify the type of error

Implement the “work instructions” according to the type of robot, installation location, and type of work task. When drawing up the “work instructions”, make an effort to include opinions from the workers involved, equipment manufacture’s technicians, and workplace safety consultants, etc.

(32) Display a sign on operation panel during workDisplay an easy to understand sign or message on the programming box and operation panel during the job task, to prevent anyone other than the operators for that job task from mistakenly operating a start or selector switch. If needed, take other measures such as locking the cover on the operation panel.

(33) Make daily and periodic inspections.(1) Always make sure that daily and periodic inspections are performed, and make

a pre-work check to ensure there are no problems with the robot or related equipment. If a problem or abnormality is found, then promptly repair it or take other measures as necessary

(2) When you make periodic inspections or repairs, make a record and store it for at least 3 years


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Safety Guide

3. Industrial Robot Operating and Maintenance PersonnelOperators or persons who handle the robot such as for teaching, programming, movement check, inspection, adjustment, and repair must receive appropriate training and also have the skills needed to perform the job correctly and safely. They must read the user’s manual carefully to understand its contents before attempting the robot operation.

Tasks related to industrial robots (teaching, programming, movement check, inspection, adjustment, repair, etc.) must be performed by qualified persons who meet requirements established by local regulations and safety standards for industrial robots.

4. Robot Safety Functions

(1) Overload detection.This function detects an overload applied to the motor and shuts off the servo power. If an overload error occurs, take the following measures.

1. Insert a timer in the program.2. Reduce the acceleration coefficient.

(2) Overheat detectionThis function detects an abnormal temperature rise in the driver inside the controller and shuts off the servo power. If an overheat error occurs, take the following measures.

1. Insert a timer in the program.2. Reduce the acceleration coefficient.

(3) Soft limitsSoft limits can be set on each axis to limit the working envelope in manual operation after return-to-origin and during automatic operation.

Note: The working envelope is the area limited by soft limits.

Soft limits must be set within the movement range (mechanical stopper). If the soft limit is set outside the movement range, the robot axis may collide with the mechanical stopper at high speed, causing the object gripped by the end effector to fly or drop and the robot to malfunction.

3. Industrial Robot Operating and Maintenance Personnel

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(4) Mechanical stoppersIf the servo power is suddenly shut off during high-speed operation by emergency stop or safety functions, these mechanical stoppers prevent the axis from exceeding the movement range. The movement range is the area limited by mechanical stoppers.

• ThemovementrangesoftheX-axisarmcanbelimitedasneededbyuseofmechanical stoppers.

• OntheY-axisarm,mechanicalstoppersarefixedatbothendsofthemaximummovement range.

• TheZ-axishasamechanicalstopperattheupperendandlowerend.• NomechanicalstopperisprovidedontheR-axis.

Axis movement will not stop immediately after the servo power supply is shut off by emergency stop or other safety functions.

(5) Z-axis (vertical axis) brakeAn electromagnetic brake is installed on the Z-axis to prevent the Z-axis from sliding down when servo power is turned off. This brake is working when the controller is off or the Z-axis servo power is off even when the controller is on. The Z-axis brake can be released by means of the programming unit or by a command in the program when the controller is on.

The Z-axis will slide down when the Z-axis brake is released, creating a hazardous situation. • PresstheemergencystopbuttonandproptheZ-axiswithasupportstand

before releasing the brake. • UsecautionnottoletyourbodygetcaughtbetweentheZ-axisand

installation base when releasing the brake to perform direct teach.

4. Robot Safety Functions

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Safety Guide

5. Safety Measures for the SystemSince the robot is commonly used in conjunction with an automated system, dangerous situations are more likely to occur from the automated system than from the robot itself. Accordingly, appropriate safety measures must be taken on the part of the system manufacturer according to the individual system. The system manufacturer should provide a proper instruction manual for safe, correct operation and servicing of the system.

6. Trial OperationAfter making installations, adjustments, inspections, maintenance or repairs to the robot, make a trial run using the following procedures.

(1) If a safety enclosure has not yet been provided right after installation of the robot, rope off or chain off around the movement area of the manipulator in place of the safety enclosure, and observe the following points.

1. Use sturdy, 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 sign to keep the operator or other personnel from entering the

movement range of the manipulator.

(2) Check the following points before turning on the controller.

1. Is the robot securely and correctly installed?2. Are the electrical connections to the robot correct?3. Are items such as air pressure correctly supplied?4. Is the robot correctly connected to peripheral equipment?5. Have safety measures (safety enclosure, etc.) been taken?6. Does the installation environment meet the specified standards?

(3) After the controller is turned on, check the following points from outside the safety enclosure.

1. Does the robot start and stop as intended? Can the operation mode be selected correctly?

2. Does each axis move as intended within the soft limits?3. Does the end effector move as intended?4. Are the signal transmissions to the end effector and peripheral equipment

correct?5. Does emergency stop work?6. Are the teaching and playback functions normal?7. Are the safety enclosure and interlock working as intended?8. Does the robot move correctly during automatic operation?

5. Safety Measures for the System

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7. Work Within the Safety Enclosure(1) When work is required inside the safety enclosure, always turn off the controller

and place a sign indicating that the robot is being adjusted or serviced in order to keep any other person from touching the controller switch or operation panel, except for the following cases.

1)Originpositionsetting(“Chapter5Adjustingtheorigin”intheYK-XG series maintenance manual)

2) Soft limit settings (“3. Setting the soft limits in Chapter 3” of this manual)3) Standard coordinate settings (“4. Setting the standard coordinates in Chapter 3”

of this manual)4) Teaching

For items 1) to 3), follow the precautions and procedure for each section. To perform item 4), refer to the description in (2) below.

(2) Teaching When performing teaching within the safety enclosure, comply with the

instructions listed below.

1) Check or perform the following points from outside the safety enclosure.1. Make sure that no hazards are present within the safety enclosure by a visual

check.2. Check that the programming unit RPB operates correctly.3. Check that no failures are found in the robot.4. Check that emergency stop works correctly.5. Select teaching mode and prohibit automatic operation.

2) Never enter the movement range of the manipulator while within the safety enclosure.

7. Work Within the Safety Enclosure

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Safety Guide

8. Automatic OperationAutomatic operation described here includes all operations in AUTO mode.

(1) Check the following before starting automatic operation.

1. No one is within the safety enclosure.2. The programming unit and tools are in their specified locations.3. The alarm or error lamps on the robot and peripheral equipment do not flash.4. The safety enclosure is securely installed with safety interlocks actuated.

(2) Observe the following during automatic operation or in cases where an error occurs.

1) After automatic operation has started, check the operation status and warning lamp to ensure that the robot is in automatic operation.

2) Never enter the safety enclosure during automatic operation.3) If an error occurs in the robot or peripheral equipment, observe the following

procedure before entering the safety enclosure.1. Press the emergency stop button to set the robot to emergency stop.2. Place a sign on the start switch, indicating that the robot is being inspected

in order to keep any other person from touching the start switch and restarting the robot.

9. WarrantyFor information on the product warranty, please contact your local agent where you purchased your product.

8. Automatic Operation

Contents

Before using the robot (Be sure to read the following notes.) i

Introduction iv

Introduction

Intro

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tion

i

Before using the robot (Be sure to read the following notes.)At this time, our thanks for your purchase of this YAMAHA YK-XG series SCARA robot.

Please be sure to perform the following tasks before using the robot.1.

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.

TheoriginpositionoftheYK-XGseriesrobotsisadjustedtotherobotarmextendedpositionatthefactorypriorto

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 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-XGseriesrobotsonlyrequiretheabsoluteresettobeperformedoncewhentherobotisintroduced.Oncethe

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 "2. Absolute reset" in Chapter 3 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 "4. Setting the standard coordinates" in Chapter 3 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.

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-XGseriesrobotsonlyrequiretheabsoluteresettobeperformedoncewhentherobotisintroduced.Oncethe

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 "2. Absolute reset" in Chapter 3 of this manual and in "Absolute

Reset" of the "YAMAHA Robot Controller User's Manual". Set the origin position with the absolute reset.

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 "5. Affixing stickers for origin positions, movement directions and axis names" in Chapter 3 of this manual.

3.Setting the reference coordinates

Set the reference coordinates while referring to instructions in "4. Setting the reference coordinates" in Chapter 3 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 (RCX240)

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.

Intro

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tion

ii

If the X, Y or R axis rotation angle is small.2.

IftheX,YorRaxisrotationangleissmallerthan5°sothatitalwaysmovesinthesameposition,anoilfilmisdifficult

to be formed on the joint support bearing, possibly leading to damage to the bearing. In this type of operation, add a

movementsothatthejointmovesthrough90°ormore,about5timesaday.

Do not remove the Z-axis upper-end mechanical stopper3.

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.

If the Z-axis spline vibrates.4.

TheZ-axissplineoftheYK250XG,YK350XG,andYK400XGtendstovibrateinaZ-axisoperationspeedrangeof20%to

40%.IftheZ-axissplinevibrates,operateitbeyondthisoperationspeedrange.

If the machine harness projects toward the base rear side.5.

IntheYK250XG,YK350XG,andYK400XG,themachineharnessmayprojecttowardthebaserearsideaccordingtothe

arm position.

The projection amount by arm position is described in "1.2 External view and dimensions" in Chapter 7. So, refer to this

section for further information.

Projection of the machine harness toward the base rear side (Example: YK250XG)

X

Y

θx

θy (CCW is the plus direction.)

→Y+

↓X+

Position where the harness projects toward the base rear side.

23001-F6-00

The positions shown below are reference data. So, if there is an interference object on the base rear side, be sure to keep a sufficient space.

X(mm) Y(mm)|θX(°)| |θX(°)|

0 30 60 90 120 140 0 30 60 90 120 140

θY(°)

-144 65 0 0 0 0 0

θY(°)

-144 155 136 136 136 136 136-120 80 0 0 0 0 0 -120 160 136 136 136 136 136-90 70 0 0 0 0 0 -90 170 136 136 136 136 136-60 50 70 0 0 0 0 -60 165 136 136 136 136 136-30 10 50 0 60 0 0 -30 160 136 136 136 136 1360 0 25 50 0 0 0 0 160 145 135 145 136 136

30 -10 10 20 40 80 100 30 160 160 160 155 145 13660 -50 -15 15 45 95 95 60 165 175 160 165 170 16090 -70 -40 5 20 65 80 90 170 180 185 200 185 190

120 -80 -60 -40 -10 30 65 120 160 165 185 210 230 230144 -65 -100 -70 -40 15 20 144 155 170 190 225 245 280

Ｚ

23002-F6-00

Z(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

-144 350 300 300 300 300 300-120 350 300 300 300 300 300-90 410 300 300 300 300 300-60 420 300 300 300 300 300-30 460 400 300 300 300 3000 460 410 470 370 300 300

30 460 430 410 450 435 44060 420 450 450 455 460 46090 410 410 460 470 480 475

120 350 410 430 450 470 480144 350 390 420 460 470 480

Intro

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iii

Set the tip mass parameter of the YK250XG, YK350XG, and YK400XG.6.

WhentheYK250XG,YK350XG,andYK400XGhasanyoftheespecificationswiththeextensionshaftortoolflange

installed as shown in the Fig. below, set the tip mass parameter as follows.

Tip mass parameter = Actual tip mass + 1 (kg)

Failure to make this setting may shorten the service life of the drive unit.

Setting the tip mass parameter of the YK250XG, YK350XG, and YK400XG

User wiring/tubing through spline type Tool flange mount type User wiring/tubing through spline and tool flange mount type

Extension shaft

Tool flange

Extension shaft

Tool flange

23005-F6-00

Put timer during Z-axis operation of the YK250XG, YK350XG, and YK400XG.7.

If the tip load attached to the spline tip exceeds 3kg, the Z-axis may be overloaded according to the operation pattern.

In this case, put a timer during operation as shown in the Fig. below to prevent overload of the Z-axis. The reference

timer values are shown below. Furthermore, the maximum payload is 5kg. If the tip load exceeds this maximum payload,

the Z-axis may be overloaded easily. So, do not operate the robot with a tip load exceeding 5kg.

Putting timer during Z-axis operation

Only Z-axis operates

Upper endLower endTotal timer, 0.5 sec.

All axes operate

Timer, 0.5 sec.

Timer, 0.5 sec.

23004-F6-00

Intro

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iv

IntroductionThe YAMAHA YK-XG 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-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 insertion of various parts, application of sealant, and packing operations.

This user's 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 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 YK250XG, YK350XG, YK400XG, 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".

Technical skills are required and substantial risk is involved when performing the adjustment and maintenance work with the covers removed that are not described in this user’s manual. Only authorized engineers who received the robot training course conduced by YAMAHA or its sales representative must carry out such work while referring to the separate maintenance manual.

NOTES

• Thecontentsofthismanualaresubjecttochangewithoutpriornotice.

• InformationfurnishedbyYAMAHAinthismanualisbelievedtobereliable.

However,ifyoufindanypartunclearorinaccurateinthismanual,pleasecontactYAMAHAsales

office or dealer.

YAMAHA MOTOR CO., LTD. IM Operations

Chapter 1 Functions

Contents

1. Robot manipulator 1-1

1.1 Manipulator movement 1-1

1.2 Part names 1-2

2. Robot controller 1-4

3. Robot initialization number list 1-5

1-1

1

Functio

ns

1. Robot manipulator1.1 Manipulator movementTheYK-XGseriesrobotsareavailablein4-axismodelshavinganX/Y-axisarm(equivalenttohumanarm)andaZ/R-axis(equivalenttohumanwrist).Withthese4axes,theYK-XGseriesrobotscanmoveasshownintheFig. below. By attaching different types of end effector (gripper) to the end of the arm, a wide range of tasks can be performed with high precision at high speeds. The (+) and (-) signs show the direction of axis movement when the jog keys on the programming box are pressed (standard setting at the factory).

Manipulator movement

Y-axis(+)

X-axis arm

(-)

(+)

X-axis

(-)Y-axis arm

Z-axis

(-)

(-)

(+)

(+)

R-axis

23101-F9-00

1-2

1

Functio

ns

1.2 Part names

YK250XG, YK350XG, YK400XG

Machine harness

Ball screw

Extension shaft for user wiring and tubing

R-axis motor

R-axis speed reduction gear

Warning label 4

X-axis motor

Y-axis motor

Y-axis armY-axis speed reduction gear

Z-axis motor

Y-axis mechanical stopper

Z-axis spline

X-axis arm

X-axis speed reduction gear

X-axis mechanical stopper

User tubing 1 (φ4 black)

User tubing 2 (φ4 red)

User tubing 3 (φ4 blue)

M4 ground terminal

End effector attachmentEnd effector

attachment

Tapped hole for user

D-sub connector for user wiring

(No.1 to 10)

Serial label




(No.1 to 10)


Tool flange mount typeStandard type

Cross section A-A

User wiring/tubing through spline type

A A

Warning label 1

Warning label 2

Warning label 3

23101-F6-00

1-3

1

Functio

ns

YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG




Machine harness

Eyebolt installation position

D-sub connector for user wiring (No.1 to 20)

Ball screw

R-axis motor

R-axis speed reduction gear

End effector attachment

Z-axis spline

Z-axis motor

Y-axis speed reduction gear

Y-axis arm

Y-axis motor

X-axis arm

Y-axis mechanical stopper

Warning label 3

X-axis motor

Tapped hole and screw for user

X-axis speed reduction gear

X-axis movable mechanical stopper

Warning label 1

Warning label 2 on opposite side




M4 ground terminal

Robot cable


(No.1 to 20)

Serial label

Warninglabel 4

23102-F9-00

1-4

1

Functio

ns

2. Robot controllerThe YK-XG series robot comes supplied with a robot controller RCX240. For more details, refer to the separate "YAMAHA Robot Controller User's Manual".

RPB

MOTOR

XM

YM

ZM

RM

PWR

SRV

SAFETY

RPB

COM

STD.DIO

ROBI/O

ZR

OP.1 OP.3

OP.2 OP.4RGEN

ACIN

N

P

N1

L1

L

N

SEL

BATTZR

XYBATT

ROB

XY

I/O

13 14EXT.E-STOP

ERR

RCX240

Robot controller

RCX240

23101-F0-00

1-5

1

Functio

ns

3. Robot initialization number listThe YK-XG series robots are initialized for optimum setting (default setting) according to the robot model prior to shipping. The robot controllers do not have to be reinitialized during normal operation. However, if for some reason the controller must be reinitialized, proceed while referring to the list below.

• Absoluteresetmustbeperformedafterreinitializingthecontroller.Beforereinitializingthecontroller,readthe descriptions in "2. Absolute reset" in Chapter 3 and make sure you thoroughly understand the procedure. • Whenthecontrollerisinitialized,the"ARMLENGTH"and"OFFSETPULSE"settingsintheaxisparameterswillbe erased, making the standard coordinate settings invalid. (For details on standard coordinates, see "4. Setting the standard coordinates" in Chapter 3.) If you do not want to change the origin position by initializing, make a note of the "ARM LENGTH" and "OFFSET PULSE" settings before initializing, and re-enter their settings after initialization is complete.

Robot initialization number Model name

2135 YK250XG

2136 YK350XG

2137 YK400XG

2117 YK500XG Z200

2118 YK500XG Z300

2119 YK600XG Z200

2120 YK600XG Z300

2121 YK600XGHZ200

2122 YK600XGHZ400

2123 YK700XG Z200

2124 YK700XG Z400

2125 YK800XG Z200

2126 YK800XG Z400

2127 YK900XG Z200

2128 YK900XG Z400

2129 YK1000XG Z200

2130 YK1000XG Z400

Chapter 2 Installation

Contents

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 2-6

2.3.1 Moving the YK250XG, YK350XG, YK400XG 2-6

2.3.2 Moving the YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 2-7

2.4 Installing the robot 2-9

3. Protective bonding 2-10

4. Robot cable connection 2-11

5. User wiring and user tubing 2-12

6. Attaching the end ef fector 2-15

6.1 R-axis tolerable moment of inertia and acceleration coefficient 2-15

6.1.1 Acceleration coefficient vs. moment of inertia (YK250XG) 2-16



6.1.4 Acceleration coefficient vs. moment of inertia (YK250XG, YK350XG, YK400XG) 2-19



6.1.7 Acceleration coefficient vs. moment of inertia (YK600XGH) 2-20

6.1.8 Acceleration coefficient vs. moment of inertia (YK700XG, YK800XG) 2-21

6.1.9 Acceleration coefficient vs. moment of inertia (YK900XG, YK1000XG) 2-21

6.2 Equation for moment of inertia calculation 2-22

6.3 Example of moment of inertia calculation 2-25

6.4 Attaching the end effector 2-27

6.5 Gripping force of end effector 2-30

7. Limiting the movement range with x- and y-axis mechanical stoppers 2-31

7.1 YK250XG, YK350XG, YK400XG 2-31

7.1.1 Installing the X-axis/Y-axis additional mechanical stoppers 2-32

7.1.2 Robot overrun during impacts with X-axis or Y-axis mechanical stopper 2-34

7.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 2-35

7.2.1 Changing the X-axis mechanical stopper position 2-36

7.2.2 Changing the Y-axis mechanical stopper position 2-38

7.2.3 Robot overrun during impacts with X-axis or Y-axis mechanical stopper 2-40

8. Working envelope and mechanical stopper positions for maximum working envelope 2-41

9. Stopping time and stopping distance at emergency stop 2-44

9.1 YK250XG, YK350XG, YK400XG 2-44

9.2 YK500XG, YK600XG 2-48

9.3 YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 2-53

10. Installing the user wiring and tubing newly 2-62

11. Passing the wiring and tubing in the user wiring/tubing through spline type 2-63

12. Installing the tool flange 2-64

2

Installa

tion

2-1

1. Robot installation conditions1.1 Installation environmentsBe sure to install the robot in the following environments.

Setting environments Specifications

Allowable ambient temperature 0 to 40°C

Allowable ambient humidity 35to85%RH(noncondensation)

Altitude 0 to 1000 meters above sea level

Ambient environments Avoid installing near water, cutting water, oil, dust, metallic chips and organic solvent.

Avoid installation near corrosive gas and corrosive materials.

Avoid installation in atmosphere containing inflammable gas, dust or liquid.

Avoidinstallationnearobjectscausingelectromagneticinterference,electrostatic

discharge or radio frequency interference.

Vibration Donotsubjecttoimpactsorvibrations.

Air supply pressure, etc.Below 0.58MPa (6.0kgf/cm2); clean dry air not containing deteriorated compressor oil;

filtration 40μm or less

Working space Allowsufficientspacemargintoperformjobs(teaching,inspection,repair,etc.)

For detailed information on how to install the robot controller, refer to the separate "YAMAHA Robot Controller User's Manual".

• AvOIDINSTALLINGTHEROBOTINLOcATIONSWHERETHEAMBIENTcONDITIONSMAyExcEEDTHEALLOWABLE TEMPERATUREORHUMIDITy,ORINENvIRONMENTSWHEREWATER,cORROSIvEGASES,METALLIcPOWDEROR DUST ARE GENERATED. MALFUNCTION, FAILURE OR SHORT CIRCUITS MAY OTHERWISE RESULT. • THISROBOTWASNOTDESIGNEDFOROPERATIONINENvIRONMENTSWHEREINFLAMMABLEORExPLOSIvE SUBSTANcESAREPRESENT.DONOTUSETHEROBOTINENvIRONMENTScONTAININGINFLAMMABLEGAS,DUST OR LIqUIDS. EXPLOSIONS OR FIRE COULD OTHERWISE RESULT. • AvOIDUSINGTHEROBOTINLOcATIONSSUBjEcTTOELEcTROMAGNETIcINTERFERENcE,ELEcTROSTATIc DISCHARGE OR RADIO FREqUENCY INTERFERENCE. MALFUNCTION MAY OTHERWISE OCCUR. • DONOTUSETHEROBOTINLOcATIONSSUBjEcTTOExcESSIvEvIBRATION.ROBOTINSTALLATIONBOLTSMAy OTHERWISEBEcOMELOOSEcAUSINGTHEMANIPULATORTOFALLOvER.

2

Installa

tion

2-2

1.2 Installation basePrepare a sufficiently rigid and stable installation base, taking account of the robot weight including the end effector (gripper), workpiece and reaction force while the robot is operating.

• INSTALLTHEROBOTONAHORIZONTALSURFAcE,WITHTHEBASEMOUNTSEcTIONFAcINGDOWN.IFINSTALLEDBy OTHER METHODS WITH THE BASE MOUNT SECTION NOT FACING DOWN, GREASE MIGHT LEAK FROM THE REDUCTION GEAR UNIT. • DONOTPLAcETHEROBOTONAMOvINGINSTALLATIONBASE.ExcESSIvELOADSWILLBEAPPLIEDTOTHEROBOT ARMByMOvEMENTOFTHEINSTALLATIONBASE,RESULTINGINDAMAGETOTHEROBOT.

• Themanipulatorpositioningmightdecreaseiftheinstallationsurfaceprecisionisinsufficient. • Iftheinstallationbaseisnotsufficientlyrigidandstableorathinmetallicplateisattachedtotheinstallation base, vibration (resonance) during operation, causing detrimental effects on the manipulator work.

1 Prepare a robot installation base.The maximum reaction force applied to the X-axis and Z-axis of each robot during operation is shown in the Table below. These values are instantaneous force values applied to the robot during operation and do not indicate the load resistant values.

Maximum reaction force during robot operation

Fxmax

Fzmax

Mxmax

Load

23201-F6-00

The flatness of the robot installation base surface must be machined within a precision of ± 0.05mm/500mm.

2 Install the robot on the base.The robot must be installed facing down and in a level position. (Only the ceiling-mount models are installed with the base mount facing up).

3 Tap holes into the installation surface of the base.

For details about machining dimensions and positions, see "1.2 External view and dimensions" in Chapter 7.

4 Securely fix the installation base on the floor.Securely fix the installation base with the anchor bolts so that it does not move.

Robot ModelFxmax Mxmax Fzmax

N kgf Nm kgfm N kgf

YK250XG 686 70 96 9.8 108 11

YK350XG 598 61 96 9.8 108 11

YK400XG 588 60 96 9.8 108 11

YK500XG 1416 144 178 18 134 14

YK600XG 1476 150 178 18 134 14

YK600XGH 2125 217 395 40 205 21

YK700XG 2479 253 395 40 239 24

YK800XG 2561 261 395 40 239 24

YK900XG 2494 254 395 40 165 17

YK1000XG 2427 248 395 40 165 17

2

Installa

tion

2-3

2. Installation2.1 Unpacking

THEROBOTANDcONTROLLERAREHEAvy.TAKESUFFIcIENTcARENOTTODROPTHEMDURINGMOvINGORUNPAcKINGASTHISMAyDAMAGETHEEqUIPMENTORcAUSEBODILyINjURy.

When moving the robot or controller by equipment such as a folklift that require a license, only properly qualified personnel may operate it. The equipment and tools used for moving the robot should be serviced daily.

TheYK-XGseriesrobotcomespackedwitharobotcontrollerandaccessories,accordingtotheorderspecifications. Using a carrying cart (dolly) or forklift, move the package to near the installation base. Take sufficient care not to apply shocks to the equipment when unpacking it.

Packed state


Case

Robot manipulator

23202-F6-00

Packed state


Robot manipulator

Robot controllerand accessories

Arm clamping stay(Used only for transportation.Remove after installation.)

23201-F9-00

2

Installa

tion

2-4

2.2 Checking the productAfter unpacking, check the product configuration and conditions.The following configurations are typical examples, so please check that the product is as specified in your order.

If there is any damage due to transportation or insufficient parts, please notify your YAMAHA sales office or dealer immediately.

●Controller :RCX240Robot :YK250XG,YK350XG,YK400XG

RPBMOTOR

XM

YM

ZM

RM

PWR

SRV

SAFETY

RPB

COM

STD.DIO

ROBI/O

ZR

OP.1OP.3

OP.2OP.4

ACINN

P

N1

L1

L

N

SEL

BATT

ZR

XYBATT

ROB

XY

I/O

ERR

RCX240

A BX YZ R

Product configurations

RPB programming box, etc.

Robot manipulator

CD-ROM User’s Manualor

User's Manual

RCX240 controller

Warning label (×1)

Standard coordinatesetting jig (option)

Origin position stickers

D-sub connector/hood (×2)

Standard

Option

23203-F6-00

2

Installa

tion

2-5

●Controller :RCX240Robot :YK500XG,YK600XG,YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG

RPBMOTOR

XM

YM

ZM

RM

PWR

SRV

SAFETY

RPB

COM

STD.DIO

ROBI/O

ZR

OP.1OP.3

OP.2OP.4

ACINN

P

N1

L1

L

N

SEL

BATT

ZR

XYBATT

ROB

XY

I/O

ERR

RCX240

A BX YZ R

Product configurations

RPB programming box, etc.

Robot manipulatorCD-ROM User’s Manual

orUser's Manual

RCX240 controller

Standard coordinatesetting jig (option)

Standard

Option

Warning label (×1)

Eyebolts (×2)


D-sub connector/hood (×2)

* These washers are used when moving the robot using the eyebolts or when changing the Y-axis mechanical stopper positions.

Washers (×2)

23202-F9-00

2

Installa

tion

2-6

2.3 Moving the robot

SERIOUSINjURyMAyOccURIFTHEROBOTFALLSANDPINSSOMEONEUNDERIT. • DONOTALLOWANyPARTOFyOURBODyTOENTERTHEAREABENEATHTHEROBOTDURINGWORK. • ALWAySWEARAHELMET,SAFETySHOESANDGLOvESDURINGWORK.

To check the mass of each robot, refer to "1.1 Basic specifications" in Chapter 7.

2.3.1 Moving the YK250XG, YK350XG, YK400XG

1 Fold the arms while referring to the Fig. below.

Moving the robot

Support

Robot cable

SupportRobot main body

23204-F6-00

2 Place the robot on the base.One work person holds the support of the robot main body with both hands and other work person holds the robot cable to place the robot on the base.

3 Temporarily secure the robot by tightening the bolts.

For details about tightening torque to secure the robot firmly, see "2.4 Installing the robot".

2

Installa

tion

2-7

2.3.2 Moving the YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

SERIOUSINjURyMAyOccURIFTHEROBOTFALLSANDPINSSOMEONEUNDERIT. • cHEcKTHATTHEREARENOcRAcKSANDcORROSIONONTHEEyEBOLTINSTALLATION.IFFOUND,DONOTUSE EyEBOLTSTOMOvETHEROBOT. • ScREWTHEEyEBOLTSSEcURELyINTOTHETAPPEDHOLESUNTILTHEBEARINGSURFAcEOFEyEBOLTMAKESTIGHT CONTACT WITH THE BEARING SURFACE ON THE ARM. • USEAHOISTANDROPEWITHcARRyINGcAPAcITySTRONGENOUGHTOSUPPORTTHEROBOTWEIGHT. • MAKESURETHEROPESTAySSEcURELyONTHEHOISTHOOK. • REMOvEALLLOADSATTAcHEDTOTHEROBOTMANIPULATOREND.IFANyLOADISSTILLATTAcHED,THEROBOT MAyLOSEBALANcEWHILEBEINGcARRIED,ANDTOPPLEOvERcAUSINGAccIDENTS.

• Whenmovingtherobotbyequipmentsuchascranesthatrequirealicense,onlyproperlyqualifiedpersonnel may operate it. • Theequipmentandtoolsusedformovingtherobotshouldbeserviceddaily.

ThefollowingdescribeshowtocorrectlyandsafelymovetherobotusingtheYK500XGasanexample.MovealsotheYK600XG,YK600XGH,YK700XG,YK800XG,YK900XG,andYK1000XGinthesamemanner.

1 Lower the Z-axis from the origin position.For the YK500XG and YK600XG, lower the Z-axis approximately 24mm from its origin position.

For the YK600XGH, YK700XG, YK800XG, YK900XG, and YK1000XG, lower the Z-axis approximately 33mm from its origin position.

The Z-axis is secured to the base with the arm clamp stay at shipment from the factory.

2 Turn off the controller.

3 Disconnect the robot cable from the controller.

4 Remove the bolts from the upper portion of the X-axis arm.

5 Clamp the arm.Clamp the arm with the arm clamp stay, bolts, and washers (2 washers for YK500XG and YK600XG, 1 washer for YK600XGH, YK700G, YK800XG, YK900XG, and YK1000XG) that come with the robot.

If the arm position shown in the Fig. below cannot be obtained due to the X-axis mechanical stoppers, remove them.

The mechanical stoppers are installed to provide the maximum movement range at shipment from the factory.

6 Tighten two eyebolts.Tighten two eyebolts through washers into the upper portion of the X-axis arm. (The washers are also used when changing the Y-axis mechanical stopper positions. So, if they are used, remove the washers and place them underneath the eyebolts.)

7 Secure the robot cable.Wind the robot cable around the upper portion of the robot base so that it does not hinder the base mount, and then fasten the cable end with adhesive tapes.

2

Installa

tion

2-8

Moving the robot

Pallet(supplied with the robot)

Screw, or boltand nut(4 piecessupplied)

Bolt

Supplied bolt *1

Arm clamp stay (supplied)

Supplied bolt *2

45°or more

Washers (under stay)

Hoist hook

Rope

Eyebolt

Washer

23203-F9-00

8 Pass two ropes through the eyebolts and hang them on the hoist.Use looped ropes with the same length to allow a good lifting balance.

9 Hold the robot and remove the mounting bolts.Slightly lift the hoist so that the tension is lightly applied to each rope to hold the robot. In this state, remove the mounting bolts from the supplied pallet or installation base (if the robot is moved to another installation base).

0 Move the robot.Using caution to keep the balance of the robot and avoid subjecting it to any strong vibrations and shocks, operate the hoist carefully to gently move the robot to the installation base. At this time, the angle between each rope and the arm surface should be kept at 45° or more.

q Temporarily secure the robot to the base by tightening the bolts.

For details about tightening torque to secure the robot firmly, see "2.4 Installing the robot".

w Remove the ropes, eyebolts, washers, and arm clamp stay.

e Screw the bolts into the upper portion of the X-axis.

Always attach these bolts to protect the tapped holes for the eyebolts. Be sure to keep the eyebolts, arm clamp stay, bolts, and pallet since they may be used to move the robot again.

*1:

Robot Model Supplied bolt Tightening torque

YK500XG, YK600XG M16×25 71Nm (720kgfcm)

YK600XGH,YK700XG,YK800XG,

YK900XG, YK1000XGM20×25 71Nm (720kgfcm)

*2:

Robot Model Supplied bolt Tightening torque

All models M4×8, 2 pcs. 4.5Nm (46kgfcm)

2

Installa

tion

2-9

2.4 Installing the robotInstall the robot securely with the four hex socket head bolts as shown in the Fig. below.

WHEN INSTALLING THE ROBOT, BE SURE TO USE THE SPECIFIED SIZE AND qUANTITY OF BOLTS THAT MATCH THE DEPTH OF TAPPED HOLES IN THE INSTALLATION BASE, AND SECURELY TIGHTEN THE BOLTS TO THE CORRECT TORqUE. IF THE BOLTSARENOTTIGHTENEDcORREcTLy,THEROBOTMIGHTFALLOvERDURINGOPERATIONcAUSINGASERIOUSACCIDENT.

Tightening torque

Robot Model Bolts Used Tightening torque

YK250XG, YK350XG, YK400XG M8 37Nm (380kgfcm)

YK500XG, YK600XG M10 71Nm (720kgfcm)

YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG M12 128Nm (1310kgfcm)

Depth of tapped holes in installation base:Iron installation base : Bolt diameter × 1.5 or moreAluminum installation base Bolt diameter × 3 or more

Recommended bolt : JIS B 1176 hex socket head bolt, or equivalent Strength class JIS B 1051 12.9, or equivalent

Installing the robot

Installation base

Hex socket head bolt

23204-F9-00

2

Installa

tion

2-10

3. Protective bonding

• BESURETOGROUNDTHEROBOTANDcONTROLLERTOPREvENTELEcTRIcALSHOcK. • TURNOFFTHEcONTROLLERBEFOREGROUNDINGTHEROBOT.

Provide a terminal marked "PE" for the protective conductor of the entire system and connect it to an external protective conductor. In addition, securely connect the ground terminal on the robot pedestal to the same protective conductor. (See the Fig. below.)

(Symbol　417-IEC-5019）

23201-F0-00Example of grounding

Ground symbol

M4 Ground terminal

YK500XG

23205-F9-00

Use a ground cable with a conductor wire cross section of at least 2.0mm2 and a length within 1 meter.

When the end effector uses an electrical device which, if it malfunctions, might make contact with the power supply, the user must provide proper grounding on his own responsibility. The YK-XG series robots do not have a ground terminal for this purpose.

For details on protective bonding on the robot body to comply with CE Marking, follow the instructions on protective bonding explained in the "YAMAHA Robot Controller User's Manual".

2

Installa

tion

2-11

4. Robot cable connectionThe robot cable is pre-connected to the YK-XG series robot. For details on connections to the robot controller, refer to the Fig. below and the "YAMAHA Robot Controller User's Manual". After making connections, check the operation while referring to the section "6. Trial Operation" in Chapter “Safety Guide” of this manual.

• BEFOREcONNEcTINGTHEcABLES,cHEcKTHATTHEREARENOBENDSORBREAKSINTHEcONNEcTORPINSOF THE ROBOT CABLE AND THAT THE CABLES ARE NOT DAMAGED. BENT OR BROKEN PINS OR CABLE DAMAGE MAY CAUSE MALFUNCTION OF THE ROBOT. • ENSURETHATTHEcONTROLLERISOFFBEFOREcONNEcTINGTHEROBOTcABLETOTHEcONTROLLER. • INTHERcx240cONTROLLER,THEMOTORcONNEcTORSxMANDZM,ANDyMANDRMEAcHHAvEIDENTIcAL SHAPES.INADDITION,THEPIcONNEcTORSxyANDZRHAvEIDENTIcALSHAPES.DONOTcONFUSETHESE CONNECTORS WHEN MAKING CONNECTIONS. WRONG CONNECTIONS MAY RESULT IN MALFUNCTION AND HAZARDOUS SITUATIONS. • IFTHEcONNEcTORINSTALLATIONISINADEqUATEORIFTHEREAREcONTAcTFAILURESINTHEPINS,THEROBOT MAY MALFUNCTION CAUSING A HAZARDOUS SITUATION. RECONFIRM THAT EACH CONNECTOR IS SECURELY INSTALLED BEFORE TURNING ON THE CONTROLLER. • TOATTAcHTHEPIcONNEcTORSEcURELy,TIGHTENTHEScREWSSUPPLIEDWITHTHEROBOT. • TAKEcAUTIONNOTTOAPPLyANExcESSIvELOADTOTHEcONNEcTORSDUETOSTRESSORTENSIONONTHE CABLES. • LAyOUTTHEcABLESSOTHATTHEyDONOTOBSTRUcTTHEMOvEMENTOFTHEMANIPULATOR.DETERMINETHE ROBOT WORK AREA IN WHICH THE ROBOT CABLES WILL NOT INTERFERE WITH THE LOAD OR WORKPIECE PICKED UP ByTHEMANIPULATOR.IFTHEROBOTcABLESINTERFEREWITHTHEMOvABLEPARTSOFTHEROBOT,THEcABLESMAy BEDAMAGEDcAUSINGMALFUNcTIONANDHAZARDOUSSITUATIONS.REFERTO"1.2ExTERNALvIEWAND DIMENSIONS" IN CHAPTER 7. • LAyOUTTHEROBOTcABLESSOASTOKEEPTHEOPERATORORANyOTHERPERSONFROMTRIPPINGONTHEM. BODILyINjURyMAyRESULTIFSOMEONETRIPSONTHEcABLES.

Robot cable connections

Robot cable

Robot side connector

XM

YM

ZM

RM

XY

ZR

Controller side connector

RCX240

XM

YM

ZM

RM

ROB I/O

XY

ROB I/O

ZR

23202-F0-00

2

Installa

tion

2-12

5. User wiring and user tubing

ALWAYS TURN OFF THE CONTROLLER AND SHUT OFF AIR SUPPLY BEFORE ATTEMPTING WIRING AND PIPING WORK. IF AIRORPOWERISSUPPLIEDDURINGTHISWORK,THEMANIPULATORMAyMOvEERRONEOUSLycAUSINGAHAZARDOUS SITUATION.

TheYK-XGseriesrobotsareequippedwithuserwiresandairtubesinthemachineharness.Thetablebelowshows the number of wires and air tubes available for each robot model.

Robot Model User wiring User tubing

YK250XG, YK350XG, YK400XG 10 wires φ4, 3 tubes

YK500XG,YK600XG,YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG 20 wires φ6, 3 tubes

* Robot models for custom specifications may have different wiring or tubing.

The specifications of the user wires and air tubes are shown below. Always observe the specifications.

User Wiring

Rated voltage 30V

Allowable current 1.5A

Nominal cross-section area of conductor 0.2mm2

Shield Yes

User Tubing

Maximum pressure 0.58MPa (6Kgf/cm2)

Outer diameter × inner diameterφ4mm × φ2.5mm

φ6mm × φ4mm

FluidDry clean air not containing deteriorated compressor oil;

filtration 40μm or less

A D-sub connector for user wiring and a bulkhead union for user tubing are provided one each on the arm side and pedestal side. For the locations, refer to "1.2 External view and dimensions" in Chapter 7.

2

Installa

tion

2-13

Signal wiring connections in the machine harness ■

•YK250XG,YK350XG,YK400XG

Connector pins 1 to 10 can be used. Pin 15 is connected to a shield wire and cannot be used as a signal wire.

Signal Connector NO Connection NO Connector Color

User signal line IO

(Arm side)

1 1

IO

(Base side)

Brown

2 2 Red

3 3 Orange

4 4 Blue

5 5 Violet

6 6 Grey

7 7 White

8 8 Brown

9 9 Red

10 10 Orange

11 11

12 12

13 13

14 14

Flame Ground 15 15 Grey

Flame Ground 1 FG Grey

* Robots models with non-standard specifications may have different wiring colors.

•YK500XG,YK600XG,YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG

Connector pins 1 to 20 can be used. Pin 25 is connected to a shield wire and cannot be used as a signal wire.

Signal Connector NO Connection NO Connector Color

User signal lineIO

(Arm side)

1 1

IO

(Base side)

Brown

2 2 Red

3 3 Orange

4 4 Blue

5 5 Violet

6 6 Grey

7 7 White

8 8 Black

9 9 Brown

10 10 Red

11 11 Orange

12 12 Blue

13 13 Brown

14 14 Red

15 15 Orange

16 16 Blue

17 17 Violet

18 18 Grey

19 19 White

20 20 Black

21 21

22 22

23 23

24 24

Flame Ground 25 25 Green

Flame Ground 1 FG Green

* Robots models with non-standard specifications may have different wiring colors.

2

Installa

tion

2-14

As shown in Fig. below, solder the user cable wires to the D-sub connector (supplied with the robot). Reattach the hood to the D-sub connector after soldering, then plug it into the user wiring connector. The connector pinouts as viewed from the solder side are shown below.

13 12 11 10 9 8 7 6 5 4 3 2 1

25 24 23 22 21 20 19 18 17 16 15 14

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25

8 7 6 5 4 3 2 1

15 14 13 12 11 10 9

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

D-sub connector connections and pin assignments

Cable to beprepared by user

SolderingHood

D-sub connector

D-sub connector on arm side(As viewed from solder side)

D-sub connector on base side(As viewed from solder side)


D-sub connector on arm side(As viewed from solder side)

D-sub connector on base side(As viewed from solder side)


23206-F6-00

• THEUSERcABLEWIRESSHOULDHAvEASHIELDWIRE.cONNEcTITTOTHESAMENO.PININTHED-SUB CONNECTOR ON THE ROBOT SIDE, WHICH ALSO CONNECTS TO THE SHIELD WIRE. IF THIS TASK IS OMITTED, NOISE MAY CAUSE MALFUNCTION OF THE ROBOT. • SEcURELyATTAcHTHED-SUBcONNEcTOR(SUPPLIEDWITHTHEROBOT)INTOTHED-SUBcONNEcTORONTHE ROBOT SIDE, BY TIGHTENING THE SCREWS ON THE CONNECTOR HOOD. IF THIS CONNECTOR COMES LOOSE OR COMES OFF, MALFUNCTION MAY RESULT. • AvOIDFASTENINGTHEUSERcABLEORTUBEWITHTHEMAcHINEHARNESS,ASTHISMAyLEADTOHARNESS BREAKAGE AND MALFUNCTION. • MAKESURETHATTHEUSERcABLEATTAcHEDTOTHED-SUBcONNEcTORFORUSERWIRINGANDTHETUBE ATTAcHEDTOTHEBULKHEADUNIONFORUSERTUBINGWILLNOTINTERFEREWITHTHEROBOTMOvEMENT, ENTANGLE AROUND THE ROBOT OR FLAP AROUND DURING OPERATION. WIRING AND TUBING MIGHT THEN BE DAMAGED CAUSING MALFUNCTION OF THE ROBOT. • LAyOUTTHEUSERcABLEATTAcHEDTOTHED-SUBcONNEcTORFORUSERWIRINGANDTHETUBEATTAcHEDTO THEBULKHEADUNIONFORUSERTUBINGSOTHATTHEyDONOTOBSTRUcTTHEMOvEMENTOFTHEOPERATOROR ANyOTHERPERSONS.BODILyINjURyMAyRESULTIFANyONETRIPSONTHEcABLEORAIRTUBE.

• TheD-subconnectorsuppliedwiththerobotshouldbeconnectedtothearmsidebypincontact,andtothe pedestal side by socket contact. Use caution at these points when soldering. • BesuretousetheD-subconnectorandhoodwhicharesuppliedwiththerobot.Usingothertypesmayresultin contact failure.

D-sub connectors (supplied with robot)

Robot Model D-sub connector on arm side D-sub connector on base side Hood

YK250XG, YK350XG, YK400XG DA-15P-NR DA-15S-NR DA-C1-J10R

YK500XG,YK600XG,YK600XGH,YK700XG,

YK800XG, YK900XG, YK1000XGDB-25P-NR DB-25S-NR DB-C2-J9R

Manufacturer:JapanAviationElectronicsIndustry,Limited.

To check the operation and signal transmission between the end effector and the controller or peripheral equipment after making connections, refer to the section "6. Trial Operation" in Chapter “Safety Guide” of this manual.

2

Installa

tion

2-15

6. Attaching the end effector6.1 R-axis tolerable moment of inertia and acceleration coefficientThe moment of inertia of a load (end effector and workpiece) that can be attached to the R-axis is limited by the strength of the robot drive unit and residual vibration during positioning. It is therefore necessary to reduce the acceleration coefficient in accordance with the moment of inertia.

The R-axis tolerable moment of inertia and the acceleration coefficient versus R-axis moment of inertia for each robot model are shown in "6.1.1 to 6.1.9 Acceleration coefficient vs. moment of inertia".The symbols AX, AY, AZ, and ARineachFig.respectivelyindicatetheaccelerationcoefficientsoftheX-axis,Y-axis, Z-axis, and R-axis. The symbol IR (JR) indicates the moment of inertia of the load around the R-axis and the symbol m indicates the tip mass. ItisnecessaryonlyfortheYK250XG,YK350XG,andYK400XGtoreducetheZ-axisaccelerationaccordingtothe moment of inertia around the R-axis so as to ensure the service life of the spline. This is shown in "6.1.4 Accelerationcoefficientvs.momentofinertia(YK250XG,YK350XG,YK400XG)".

Example:YK500XG(Seealso"6.1.5Accelerationcoefficientvs.momentofinertia(YK500XG)".) Assume that the mass of the load installed to the R-axis is 1.5kg and the moment of inertia around the R-axis is 0.1kgm2 (1.0kgfcmsec2). When the tip mass parameter is set to 2kg, the robot can be operated by reducing the X,YandR-axisaccelerationcoefficientsto62%,ascanbeseenfrom"6.1.5Accelerationcoefficientvs.momentofinertia(YK500XG)".Besuretoselectanoptimumtipmassandaccelerationcoefficientparametersthat meet the mass of the load and moment of inertia before using the robot. To make settings for the tip mass and acceleration coefficient, refer to the separate "YAMAHA Robot Controller User's Manual".

Methods for calculating the moment of inertia of the load are shown in "6.2 Equation for moment of inertia calculation" and "6.3 Example of moment of inertia calculation". However, it is not easy to precisely figure out these values. If a calculated value smaller than the actual moment of inertia is set, residual vibrations may occur. If this happens, reduce the acceleration coefficient parameter further.

• Therobotmustbeoperatedwithcorrecttolerablemomentofinertiaandaccelerationcoefficientsaccording to the manipulator tip mass and moment of inertia. 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. • DependingontheZ-axisposition,vibrationmayoccurwhenthex,yorR-axismoves.Ifthishappens,reduce the X, Y or R-axis acceleration to an appropriate level. • Ifthemomentofinertiaistoolarge,vibrationmayoccurontheZ-axisdependingonitsoperationposition.If this happens, reduce the Z-axis acceleration to an appropriate level.

2

Installa

tion

2-16

6.1.1 Acceleration coefficient vs. moment of inertia (YK250XG)

m=1 to 5kg

AX, AY, AR (%)

0.010.1

0.020.2

0.030.3

0.040.4

0.050.5

0

100

80

60

40

20

Ir (kgm2)Jr (kgfcmsec2)0

23207-F6-00

m=1 to 5kg

Ir (kgm2)Jr (kgfcmsec2)

90

0

0.00010.001

0.00020.002

0.00030.003

0.00040.004

0.00090.009

0.00080.008

0.00070.007

0.00060.006

0.00050.005

0.0010.01

100

99

97

98

95

96

93

94

91

92

AX, AY, AR (%)

23208-F6-00

2

Installa

tion

2-17


m=1 to 5kg

AX, AY, AR (%)


0

0

0.020.2

0.040.4

0.030.3

0.050.5

100

80

60

40

20

0.010.1

23201-F7-00

m=1 to 5kg


90

0

0.00010.001

0.00020.002

0.00030.003

0.00040.004

0.00090.009

0.00080.008

0.00070.007

0.00060.006

0.00050.005

0.0010.01

100

91

93

95

97

99

98

96

94

92

AX, AY, AR (%)

23202-F7-00

2

Installa

tion

2-18


m=1 to 5kg

AX, AY, AR (%)


0

0

0.010.1

0.020.2

0.040.4

0.030.3

0.050.5

100

80

60

40

20

23201-F8-00

m=1 to 5kg


90

0

0.00010.001

0.00020.002

0.00030.003

0.00040.004

0.00090.009

0.00080.008

0.00070.007

0.00060.006

0.00050.005

0.0010.01

100

91

93

95

97

99

98

96

94

92

AX, AY, AR (%)

23202-F8-00

2

Installa

tion

2-19

6.1.4 Acceleration coefficient vs. moment of inertia (YK250XG, YK350XG, YK400XG)

m=1 to 5kg


0 0.010.1

0.020.2

0.030.3

0.040.4

0.050.5

0.060.6

AZ (%)

0

20

40

60

80

100

23209-F6-00


m=1 to 10kg


0

0

0.050.5

0.11.0

0.151.5

0.22.0

0.252.5

0.33.0

100

80

60

40

20

AX, AY, AR (%)

0.04 (0.4)

23207-F9-00

2

Installa

tion

2-20


m=1 to 10kg

Ir (kgm2)

Jr (kgfcmsec2)

0

0

0.05

0.5

0.1

1.0

0.15

1.5

0.2

2.0

0.25

2.5

0.3

3.0

100

80

60

40

20

AX, AY, AR (%)

0.03 (0.3)

23201-FA-00

6.1.7 Acceleration coefficient vs. moment of inertia (YK600XGH)

m=1 to 20kg

Ir (kgm2)

Jr (kgfcmsec2)

0

0

0.2

2.0

0.4

4.0

0.6

6.0

0.8

8.0

1.0

10.0

100

80

60

40

20

AX, AY, AR (%)

0.03 (0.3)

23202-FA-00

2

Installa

tion

2-21

6.1.8 Acceleration coefficient vs. moment of inertia (YK700XG, YK800XG)

m=1 to 20kg

Ir (kgm2)

Jr (kgfcmsec2)

0

0

0.2

2.0

0.4

4.0

0.6

6.0

0.8

8.0

1.0

10.0

100

80

60

40

20

AX, AY, AR (%)

0.02 (0.2)

23201-FB-00

6.1.9 Acceleration coefficient vs. moment of inertia (YK900XG, YK1000XG)

m=1 to 20kg

Ir (kgm2)

Jr (kgfcmsec2)

0

0

0.2

2.0

0.4

4.0

0.6

6.0

0.8

8.0

1.0

10.0

100

80

60

40

20

AX, AY, AR (%)

0.07 (0.7)

23201-FD-00

2

Installa

tion

2-22

6.2 Equation for moment of inertia calculationUsually the R axis load is not a simple form, and the calculation of the moment of inertia is not easy. As a method, the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated. The total of the moment of inertia for these factors is then obtained.The objects and equations often used for the calculation of the moment of inertia are shown below. Incidentally, there is the following relation: J (kgfcmsec2) = I (kgm2) × 10.2.

1) Moment of inertia for material particle The equation for the moment of inertia for a material particle that has a rotation center such as shown in the Fig. below is as follows: This is used as an approximate equation when x is larger than the object size.

Moment of inertia for material particle

x

J=Wx2

g(kgfcmsec2)

g : Gravitational acceleration (cm/sec2)

m : Mass of material particle (kg)

... (1)

I= mx2 (kgm2)

W : Weight of material particle (kgf)

23203-F0-00

2) Moment of inertia for cylinder (part 1) The equation for the moment of inertia for a cylinder that has a rotation center such as shown in the Fig. below is given as follows.

Moment of inertia for cylinder (part 1)

D

h

J=ρπD4h

32g

WD2

8g= (kgfcmsec2)

... (2)

I=ρπD4h

32

mD2

8= (kgm2)

ρ : Density (kg/m3, kg/cm3)


m : Mass of cylinder (kg)

W : Weight of cylinder (kgf)

23204-F0-00

2

Installa

tion

2-23

3) Moment of inertia for cylinder (part 2) The equation for the moment of inertia for a cylinder that has a rotation center such as shown in the Fig. below is given as follows.

Moment of inertia for cylinder (part 2)

h

D

2h

... (3)

J=ρπ D2h

16g

W

4g=

D2

4

h2

3( + )

D2

4

h2

3( + )

I=ρπ D2h

16

m

4=

D2

4

h2

3( + )

D2

4

h2

3( + )





(kgfcmsec2)

(kgm2)

23205-F0-00

4) Moment of inertia for prism The equation for the moment of inertia for a prism that has a rotation center as shown in the Fig. below is given as follows.

Moment of inertia for prism

a

c

b

1/2aJ=

ρabc(a2+b2)

12g

W(a2+b2)

12g=

... (4)

I=ρabc(a2+b2)

12

m(a2+b2)

12=

(kgfcmsec2)

(kgm2)



m : Mass of prism (kg)

W : Weight of prism (kgf)

23206-F0-00

5) When the object's center line is offset from the rotation center. The equation for the moment of inertia, when the center of the cylinder is offset by the distance "x" from the rotation center as shown in the Fig. below is given as follows.

When the object’s center line is offset from the rotation center.

D

h

x

Center line

Rotationcenter

J=ρπD4h

32g

WD2

8g=

... (5)

+ρπD2hx2

4g

+Wx2

g

I=ρπD4h

32+

ρπD2hx2

4

mD2

8= mx2+





(kgfcmsec2)

(kgm2)

23207-F0-00

2

Installa

tion

2-24

In the same manner, the moment of inertia of a cylinder as shown in the Fig. below is given by

Moment of inertia of a cylinder

h

D

x

Center line

W

4g=

... (6)

D2

4

h2

3( + )

J=ρπD2h

16g+

D2

4

h2

3( + )

ρπD2h x2

4g

+Wx2

g

I=ρπD2h

16+

D2

4

h2

3( + )

ρπD2h x2

4

=

(kgfcmsec2)

m

4

D2

4

h2

3( + ) + mx2 (kgm2)

23208-F0-00

In the same manner, the moment of inertia of a prism as shown in the Fig. below is given by

Moment of inertia of a prism

a

c

bx

Center line

J=ρabc(a2+ b2)

12g

W(a2+ b2)

12g=

... (7)

+ρabcx2

g

Wx2

g+

I=ρabc(a2+ b2)

12+ ρabcx2=

m(a2+b2)

12

m : Mass of prism (kg)

W : Weight of prism (kgf)

(kgfcmsec2)

+ mx2 (kgm2)

23209-F0-00

2

Installa

tion

2-25

6.3 Example of moment of inertia calculationLet's discuss an example in which the chuck and workpiece are at a position offset by 10cm from the R-axis by the stay, as shown in the Fig. below. The moment of inertia is calculated with the following three factors, assuming that the load material is steel and its density ρ is 0.0078kg/cm3.

Example of moment of inertia calculation

(The chuck and workpiece are at a position offset by 10 cm from the R-axis by the stay.)

10cm

2cm

2cm

R-axis

1cm

1cm

2cm

2cm

4cm

6cm

4cm

Stay

Chuck

Workpiece

23210-F0-00

1. Moment of inertia of the stay

Moment of inertia of the stay

12cm

2cm

2cm

Center line

5cm

R-axis

The weight of the stay (Ws) is given as follows:

Ws = ρabc = 0.0078 × 12 × 2 × 2

= 0.37 (kgf)

The moment of inertia of the stay (Js) is then calculated from Eq. (7).

Js =0.37 × (122+22)

+0.37 × 52

= 0.014 (kgfcmsec2)12 × 980 980

23211-F0-00

2

Installa

tion

2-26

2. Moment of inertia of the chuck

Moment of inertia of the chuck

10cm2cm

6cm

4cm

R-axis

When the chuck form resembles

that shown in figure, the weight

of the chuck (Wc) is

Wc = 0.0078 × 2 × 4 × 6

= 0.37 (kgf)

The moment of inertia of the

chuck (Jc) is then calculated

from Eq. (7).

Jc =0.37 × (22+42)

12 × 980

0.37 × 102 +

980

= 0.038 (kgfcmsec2)

23212-F0-00

3. Moment of inertia of workpiece

Moment of inertia of workpiece

10cm

4cm

R-axis

2cm

Ww =ρπD2h

= 0.0078π × 22 × 4

4 4

= 0.098 (kgf)

The moment of inertia of the

workpiece (Jw) is then calculated

from Eq. (5).

When the workpiece form

resembles that shown in figure, the weight of the

workpiece (Ww) is

Jw =0.097 × 22

+ 0.097 × 102

8 × 980 980

= 0.010 (kgfcmsec2)

23213-F0-00

4. Total weight The total weight (W) is calculated as follows: W = Ws + Wc + Ww = 0.84 (kgf)

5. Total moment of inertia The total moment of inertia (J) is then obtained as follows: J = Js + Jc + Jw = 0.062 (kgfcmsec2)

2

Installa

tion

2-27

6.4 Attaching the end effectorIt is necessary to prepare the user's end effector attaching part to the robot that has adequate strength and rigidity, as well as gripping force to prevent positioning errors.

• BEFOREATTAcHINGTHEENDEFFEcTOR,BESURETOTURNOFFTHEcONTROLLER. • WHENTHEENDEFFEcTORISATTAcHEDUSINGTHESLOTcLAMPING,ALWAySOBSERvETHEcONDITIONSLISTEDIN THE TABLE, "MAXIMUM LOAD APPLIED TO END EFFECTOR ATTACHMENT". IF THESE ARE IGNORED, THE END EFFEcTORMAycOMELOOSEANDFLyOFFDURINGROBOTOPERATION,RESULTINGINANAccIDENTORINjURy. • INcASESWHEREOTHERATTAcHMENTMETHODSAREUSED,BESURETHATTHEENDEFFEcTORWILLNOTcOMEOFF EvENWHENTHELOADSLISTEDINTHETABLE,"MAxIMUMLOADAPPLIEDTOENDEFFEcTORATTAcHMENT"ARE APPLIED.

When checking end effector operation, refer to the section "6. Trial Operation" in Chapter “Safety Guide” of this manual.

The following shows the maximum load that can be applied to the end effector attachment of each robot model.

• THEENDEFFEcTORATTAcHMENTMUSTHAvEADEqUATESTRENGTHTOWITHSTANDTHELOADSLISTEDINTHETABLE BELOW. IF THE STRENGTH IS INSUFFICIENT, THE ATTACHMENT MAY BREAK DURING ROBOT OPERATION AND FRAGMENTSFLyOFF,cAUSINGAccIDENTSORINjURIES. • THEENDEFFEcTORATTAcHMENTMUSTHAvESUFFIcIENTRIGIDITyTOTHELOADSLISTEDINTHETABLEBELOW.IF THISRIGIDITyISINADEqUATE,THEENDEFFEcTORMAyvIBRATEDURINGROBOTOPERATION,cAUSINGADvERSE EFFECTS ON THE WORK.

Maximum load applied to end effector attachment

Robot ModelFXYmax FZmax FRmax MRmax Mmax

N kgf N kgf N kgf Nm kgfm Nm kgfm

YK250XG 125 13 108 11 382 39 18 1.8 29 3.0

YK350XG 88 9 108 11 294 30 18 1.8 25 2.6

YK400XG 75 8 108 11 265 27 18 1.8 23 2.4

YK500XG 173 18 134 14 506 52 24 2.6 15 1.5

YK600XG 173 18 134 14 506 52 24 2.6 15 1.5

YK600XGH 489 49 214 22 696 71 56 5.7 26 2.7

YK700XG 489 49 214 22 696 71 56 5.7 26 2.7

YK800XG 489 49 191 19 696 71 56 5.7 24 2.4

YK900XG 443 46 191 19 696 71 56 5.7 24 2.4

YK1000XG 443 46 191 19 696 71 56 5.7 24 2.4

Maximum load applied to end effector attachment

FRmax

End effector

Stay

FxYmax

Fzmax

MRmax

Mmax

23210-F6-00

2

Installa

tion

2-28

Next, the following shows the recommended end effector attaching method.

Attaching the end effector

Hole diameter

Bolt

Slot

Spline shaft

End effector or stay

23214-F0-00

Attaching the end effector

YK250XG, YK350XG, YK400XG (Tool flange mount type)

Stay

M4 bolt

Tool flange

23211-F6-00

Robot Model Bolts usedNumber

of bolts

Tightening torqueHole diameter

(mm)Nm kgfcm

YK250XG, YK350XG, YK400XG M5 or more 2 or more 9 92 16 +0.018 0

YK250XG, YK350XG, YK400XG (Tool flange mount type) M4 4 4.5 46 -

YK500XG, YK600XG M6 or more 2 or more 15.3 156 20+0.021

0

YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG M8 or more 2 or more 37.0 380 25 +0.021 0

2

Installa

tion

2-29

The following shows the details of the end effector attachment of each robot.

• THETAPPEDHOLE(SHOWNINTHEFIG.ABOvE)PROvIDEDATTHELOWERPORTIONOFTHEENDEFFEcTOR ATTAcHMENTSHOULDBEUSEDONLyFORPREvENTINGTHEENDEFFEcTORFROMcOMINGLOOSE. • DONOTFASTENTHEENDEFFEcTORjUSTByUSINGTHISTAPPEDHOLE.IFTHEENDEFFEcTORISFASTENEDONLy WITH THIS TAPPED HOLE, IT MAY COME LOOSE FROM THE ATTACHMENT DURING ROBOT OPERATION AND FLY OFF, RESULTINGINAccIDENTSORINjURIES.

Details of end effector attachment

Never loosen this bolt.

Spline shaft (hollow diameter φ14)

�20 h7 0-0.021

End effector attachment area

M16×2, depth 20

40

YK500XG, YK600XG

Never loosen this bolt.

Spline shaft (hollow diameter φ18)

45

�25 h7 0-0.021

M20×2.5, depth 20

End effector attachment area

YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

Never loosen this bolt.Never loosen this bolt.

φ16 h7 - 0.0180

φ30 h70

46 4

2

φ55

30

22.6

22.6

22.6

22.6

22.6±0.02

4-φ4.5 through hole

φ4 H7 0+0.012

through hole

90°

Hollow

diameterφ11

7±0.

02

-0.021


Standard type

Tool flange mount type

23212-F6-00

For details about the depth of the tapped hole and recommended bolt, see the Table below.

Depth of tapped holeIronmaterialbase Bolt diameter × 1.5 or more

Aluminum material base Bolt diameter × 3.0 or more

Recommended boltJISB1176Hexsocketheadbolt,orequivalent

(Strengthclass:JISB105112.9,orequivalent)

2

Installa

tion

2-30

6.5 Gripping force of end effectorThe gripping force of the end effector must have a sufficient extra margin of strength versus the workpiece weight and reaction force applied to the workpiece during robot operation. The reaction force applied to the workpiece during operation can be calculated from the acceleration applied to the end effector attachment. The maximum acceleration on the end effector attachment of each robot model is listed in the table below. Whentheworkpiecepositionisoffsettotheendeffectorattachment,theaccelerationsAmaxandAXYmaxbecome larger by an amount equal to the offset versus the arm length. When the R-axis rotates during operation, this acceleration ARmax must be taken into account.

THEGRIPPINGFORcEOFTHEENDEFFEcTORMUSTHAvEASUFFIcIENTExTRAMARGINOFSTRENGTHTOPREvENTTHEWORKPIECE FROM COMING LOOSE AND FLYING OFF DURING ROBOT OPERATION. IF THE GRIPPING FORCE IS TOO WEAK,THEWORKPIEcEMAycOMELOOSEANDFLyOFFcAUSINGAccIDENTSORINjURIES.

Maximum acceleration during robot operation

Robot Model Amax(m/sec2) AXYmax(m/sec2) AZmax(m/sec2) ARmax(rad/sec2)

YK250XG 88 47 23 110

YK350XG 108 35 23 110

YK400XG 98 24 23 110

YK500XG 98 48 57 280

YK600XG 104 41 57 280

YK600XGH 78 60 38 176

YK700XG 96 60 38 176

YK800XG 101 51 38 176

YK900XG 95 51 38 176

YK1000XG 95 51 38 176

Maximum acceleration on end effector attachment

ARmax

Azmax

Amax AXYmax

(centrifugal acceleration) (Tangential acceleration)

23213-F6-00

2

Installa

tion

2-31

7. Limiting the movement range with x- and y-axis mechanical stoppers

ALWAySTURNOFFTHEcONTROLLERBEFOREcHANGINGTHEMOvEMENTRANGEWITHMEcHANIcALSTOPPERS.

When the mechanical stopper positions are changed, the soft limits must be set to a point inside the mechanical stopper positions. (Refer to "3 setting the soft limits" in Chapter 3.)

If the working envelope during robot work is smaller than the maximum working envelope range or if the robot interferes with peripheral units, the movement range is limited. (When the robot is shipped from factory, the movement range is set to the maximum level.) The movement range can be limited by shifting the X-axis and Y-axis mechanical stopper positions. Follow the steps below to limit the movement range.

7.1 YK250XG, YK350XG, YK400XGThe following shows the mechanical stopper positions and movement range.

Mechanical stopper position and maximum movement position

X-axis standard stopper position

Y-axis standard stopper position

X-axis additional stopper

Y-axis additional stopper

142°

146°

119°

127°

23214-F6-00

Asoptionpartsareordered,andthentheyareinstalled,themovementrangesoftheX-axisandY-axiscanbenarrowed.

Note that the stopper position may slightly deviate due to the part machining accuracy and mounting position.

2

Installa

tion

2-32

After changing the mechanical stopper positions, set the soft limits to the values shown below.

Soft limits ■

Standard stopper Additional stopper

Stopper position in X-axis plus or minus direction 142° 119°

Maximum movement position in X-axis plus or minus direction 140° 117°

Stopper position in Y-axis plus or minus direction 146° 127°

Maximum movement position in Y-axis plus or minus direction 144° 125°

Soft limits after setting additional stopper ■

Soft limit (pulses) Movement range

Movement range in X-axis plus direction 425984 117°

Movement range in X-axis minus direction -425984 -117°

Movement range in Y-axis plus direction 455111 125°

Movement range in Y-axis minus direction -455111 -125°

7.1.1 Installing the X-axis/Y-axis additional mechanical stoppersFollowthestepsbelowtoinstalltheX-axis/Y-axisadditionalmechanicalstoppers.Use the bolts and nuts listed below to install optional mechanical stoppers.

No. Part No. Q'ty Remarks

Additional mechanical stopper parts in either one

direction of X-axis plus or minus direction or both

directions (*1)

1 KCY-M2197-000 1 Stopper damper

2 90112-10J055 1 Bolt

3 90189-02J106 1 Nut


direction of Y-axis plus or minus direction or both

directions (*1)

4 KCY-M2197-000 1 Stopper damper

5 90112-10J055 1 Bolt

6 90189-02J106 1 Nut

*1 : The quantity of each part shown above is 1 even when the stopper in either plus or minus direction or the stopper in both

directions is added. (When adding the stopper in both directions, the existing stopper is also used after moving it.)

TheX-axisandY-axismechanicalstopperscanbeindividuallyinstalledintheX-axisandY-axisplusandminus directions. ThefollowingdescribeshowtoinstallthemechanicalstopperusingthestopperintheX-axisplusdirectionasan example. (The stopper in the minus direction can also be installed in the same manner.) Prepare a hex wrench set.

When adding the stopper in one direction of the X-axis or Y-axis, do not remove the standard stopper. If this stopper is removed, the stopper on the opposite side is also lost. (The X-axis standard stopper functions as a stopper in both the plus and minus directions.)


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being adjusted, to keep others from touching the controller switch.

3 Enter the safety enclosure.

4 Remove the bolts and washers.Remove the tapped-hole plug bolts and washers from the X-axis arm.

Removing the tapped-hole plug bolts and washersStep 4

Bolt

Washer23215-F6-00

2

Installa

tion

2-33

5 Sandwich the damper between the bolt and nut to secure the parts.1. Sandwich the damper (1) between the

bolt (2) and nut (3).

At this time, use the bolt and nut listed in

the Table above.

2. Secure the parts to the arm by tightening

the nut to the specified torque (16Nm

(163kgfcm)).

Installing the additional partsStep 5

* Do not remove the standard stopper.

Stopper damper (1)

Bolt (2)

Nut (3)

Stopper damper (4)

Bolt (5)

Nut (6)

23216-F6-00

• Whenaddingthestopperinonedirectionofthe X-axis, do not remove the standard stopper. If this stopper is removed, the stopper on the opposite side is also lost. • Wheninstallingtheadditionalstopperinboth directions of the X-axis, remove the standard stopper.

6 Install the bolt and washer in the blank tapped hole in the standard stopper.To protect the blank tapered hole in the standard stopper, tighten the bolt and washer to the specified torque (16Nm (163kgfcm)).

Installing the standard stopperStep 6

Y-axis plus direction additional stopper

X-axis plus direction additional stopper

X-axis standard stopper

Y-axis standard stopper

Minus direction Plus direction

23217-F6-00

7 Check that the movement range is limited.

8 Go out of the safety enclosure.

9 Turn on the controller.Check that no one is inside the safety enclosure, and then turn on the controller.

0 Set the X-axis soft limits in the plus direction.When the stopper is installed in the minus direction, set the soft limits in the minus direction.

Whether or not the X-axis stops at a position before the stopper limited by the soft limit must be checked from the outside of the safety enclosure.

q Check that the X-axis stops firmly.Whether or not the X-axis stops at a position before the stopper limited by the maximum soft limit must be checked from the outside of the safety enclosure.

The X-axis may not stop at a position before the stopper due to the stopper part accuracy or position. If this happens, decrease the value while referring to the Table "■Soft limits" described previously.

2

Installa

tion

2-34

Installing the additional stoppers in both the plus and minus directions ■

Install the additional stoppers in both the plus and minus directions while referring to the Fig. below.

Installing the additional stoppers in both the plus and minus directions

Y-axis plus direction additional stopper

X-axis plus direction additional stopper

X-axis minus direction additional stopper(Move the standard stopper to this position and secure it.)

Use the bolt * and washer to protect the tapped hole.

Y-axis minus direction additional stopper(Move the standard stopper to this position and secure it.)

Use the bolt * and washer to protect the tapped hole.

* Tightening torque: 16Nm (163kgfcm)

23218-F6-00

7.1.2 Robot overrun during impacts with X-axis or Y-axis mechanical stopperA urethane damper is installed to absorb the shock when an impact occurs with the mechanical stopper, so a certain amount of overrun occurs when the robot strikes the mechanical stopper. Use caution and take overrun into account since the end effector may interfere with the robot body and peripheral equipment or the robot body may interfere with the peripheral equipment.Maximum overrun amounts are listed below (for normal operation, maximum payload, maximum speed).

X-axis Y-axis

8° 4°

Note:Here,°(deg.)istheoverrunangleattheX-axisandY-axisjoints.

• Ifthex-axisory-axismechanicalstopperisdeformedordamagedduetoanimpactonthestopper,please contact our sales office or dealer. Continued use of the deformed or damaged stopper is very dangerous, and so it must be replaced. • Whentherobotstrikesthex-axisory-axismechanicalstopperoranotherobject,orwhentheR-axiscollides with an object, the speed reduction gears are locked while being meshed if the collision impact is large. If this happens, please contact our sales office or dealer.

2

Installa

tion

2-35

7.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XGThe following shows the movement ranges.

Stopper position in plus direction

* Values in parentheses apply to the YK600XGH, YK700XG, YK800XG, YK900XG, and YK1000XG.

132° 87°

12°

43°

107° (121°)147° (152°)

23208-F9-00

Stopper position in minus direction

* Values in parentheses apply to the YK600XGH, YK700XG, YK800XG, YK900XG, and YK1000XG.

102° (114°)

87°132°

12° 43°

147° (152°)

23209-F9-00

2

Installa

tion

2-36

TheX-axisstopperpositioncanbechangedbyshiftingtheexistingstopperposition. The Y-axis stopper position can be changed by installing the supplied parts. The following describes the necessary procedures.

Note that the mechanical stopper position may slightly deviate due to the part machining accuracy.

Additionally, set the soft limits to the values shown below after the mechanical stopper position has been changed.

Soft limits ■


X-axis stopper position Soft limit (pulses) Working envelope

±12° ±32768 ±9°

±43° ±145635 ±40°

±87° ±305834 ±84°

±132° (maximum movement range position) ±473315 ±130°

YK500XG, YK600XG

Y-axis stopper position Soft limit (pulses) Working envelope


+107° +378652 +104°

-102° -360448 -99°


Y-axis stopper position Soft limit (pulses) Working envelope


+121° +429264 +118°

-114° -415061 -111°

7.2.1 Changing the X-axis mechanical stopper positionTheX-axismechanicalstopperpositioncanbechangedbyshiftingtheexistingstopperposition.Followthesteps below to change the position.

ThefollowingdescribeshowtochangetheX-axismechanicalstopperpositionfromthemaximummovementrangeposition(132°)tothe87°-position.Prepare a hex wrench set.


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being adjusted, to keep others from touching the controller switch.


4 Remove the screw plug, mechanical stopper bolt, and washer.Remove the screw plug, X-axis mechanical stopper bolt, and washer as shown in the Fig. on the right.

Removing the screw plug, X-axis mechanical stopper bolt, and washerStep 4

Screw plug X-axis mechanicalstopper bolt

Washer

23210-F9-00

2

Installa

tion

2-37

5 Move the mechanical stopper bolt and washer.Move the X-axis mechanical stopper bolt and washer to a position you want to narrow the movement range.

[Number of washers]

YK500XG, YK600XG 1 pc.


YK900XG, YK1000XG2 pcs.

Moving the mechanical stopper bolt and washerStep 5

X-axis mechanicalstopper bolt

Washer

23211-F9-00

6 Tighten the mechanical stopper bolt and washer.The specified tightening torque is shown in the Table on the right.

Installing the mechanical stopper and washerStep 6-7

X-axis mechanicalstopper bolt

Washer

Screw plug

23212-F9-00

7 Install the screw plug.Install the screw plug that has been removed at the position where the X-axis mechanical stopper has been installed before moving.

8 Check that the movement range is limited.Check that the movement range is limited by the mechanical stopper that has been moved.



q Set the soft limits.

Whether or not the X-axis stops at a position before the stopper limited by the soft limit must be checked from the outside of the safety enclosure.

w Check that the X-axis stops firmly.Check that the X-axis stops at a position before the stopper limited by the soft limit.

The X-axis may not stop at a position before the stopper due to the stopper part accuracy or position. If this happens, decrease the value while referring to the Table "■Soft limits" described previously.

Robot modelBolt

size

Tightening

torque (kgfcm)

Tightening

torque (Nm)

YK500XG, YK600XG M8 380 37.2

YK600XGH,YK700XG,

YK800XG, YK900XG,

YK1000XG

M10 459 45.0

*BesuretousetheboltssuppliedbyYAMAHA.

2

Installa

tion

2-38

7.2.2 Changing the Y-axis mechanical stopper positionThe Y-axis mechanical stopper position is changed by installing the supplied parts.

Supplied parts ■

YK500XG, YK600XG



direction of Y-axis plus or minus direction (*1)

1 KBF-M1123-001 1 Washer (supplied)

2 91312-08016 1 Bolt (supplied)

*1 : Since the X-axis has two stoppers as standard, no additional stopper will be needed for changing the X-axis stopper position.

To change the Y-axis stopper position in the plus or minus direction or even in both directions, use one each of the above

stopper parts. (When the stopper in both directions is added, the existing stopper is also used after moving it.)

*2 : Washers are also used when moving the robot using the eyebolts. After having moved the robot, use the washers to change

the stopper position.

Ifthewashersareneededagaintomovetherobotusingtheeyebolts,removethewashersfromthestopperandthenplace

them underneath the eyebolts.




direction of Y-axis plus or minus direction (*1)

1 KBP-M1123-001 2 Washer (supplied)

2 90112-10J025 1 Bolt (supplied)

*1 : Since the X-axis has two stoppers as standard, no additional stopper will be needed for changing the X-axis stopper position.

To change the Y-axis stopper position in the plus or minus direction or even in both directions, use one each of the above

stopper parts. (When the stopper in both directions is added, the existing stopper is also used after moving it.)

*2 : Washers are also used when moving the robot using the eyebolts. After having moved the robot, use the washers to change

the stopper position.

Ifthewashersareneededagaintomovetherobotusingtheeyebolts,removethewashersfromthestopperandthenplace

them underneath the eyebolts.

Changing in plus or minus direction (one direction only) ■

The Y-axis mechanical stopper position can be

changed in either plus or minus direction (one

direction only) using the supplied washers and bolt.

1 Remove the tapped-hole plug screw.

Removing the tapped-hole plug screwStep 1

Tapped-hole plug screw

Standard stopper

23213-F9-00

Do not remove the standard stopper. If this stopper is removed, the stopper on the opposite side is also lost.

2 Install the washer (1) and bolt (2).[Number of washers]




Installing the washer and bolt (1)Step 2

Washer (1)

Bolt (2)

23214-F9-00

2

Installa

tion

2-39

3 Tighten to the specified torque.The specified tightening torque is shown in the Table on the right.

Installing the washer and bolt (2)Step 3

Standard stopper after moved.

23215-F9-00

Changing in both directions ■

(plus and minus directions)

When changing the Y-axis mechanical stopper position

in both directions, use also the standard stopper after

removing it.

1 Remove the tapped-hole plug screw.

2 Remove the standard stopper.

Removing the tapped-hole plug screw and standard stopperStep 1-2


Standard stopper

23216-F9-00

3 Move the tapped-hole plug screw.

4 Move the standard stopper.Install the washer and bolt.

[Number of washers]




5 Tighten to the specified torque.The specified tightening torque is shown in the Table on the right.

Changing the tapped-hole plug screw and standard stopper positionStep 3-5


Washer

Bolt

Standard stopper after moved.

23217-F9-00

Robot modelBolt

size

Tightening

torque (kgfcm)

Tightening

torque (Nm)

YK500XG, YK600XG M8 380 37.2

YK600XGH,YK700XG,

YK800XG, YK900XG,

YK1000XG

M10 459 45.0


Robot modelBolt

size

Tightening

torque (kgfcm)

Tightening

torque (Nm)

YK500XG, YK600XG M8 380 37.2

YK600XGH,YK700XG,

YK800XG, YK900XG,

YK1000XG

M10 459 45.0


2

Installa

tion

2-40

7.2.3 Robot overrun during impacts with X-axis or Y-axis mechanical stopperA urethane damper is installed to absorb the shock when an impact occurs with the mechanical stopper, so a certain amount of overrun occurs when the robot strikes the mechanical stopper. Use caution and take overrun into account since the end effector may interfere with the robot body and peripheral equipment or the robot body may interfere with the peripheral equipment.Maximum overrun amounts are listed below (for normal operation, maximum payload, maximum speed).

Robot model X-axis Y-axis

YK500XG, YK600XG 9° 16°

YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG 9° 16°


• Ifthex-axisory-axismechanicalstopperisdeformedordamagedduetoanimpactonthestopper,please contact our sales office or dealer. Continued use of the deformed or damaged stopper is very dangerous, and so it must be replaced. • Whentherobotstrikesthex-axisory-axismechanicalstopperoranotherobject,orwhentheR-axiscollides with an object, the speed reduction gears are locked while being meshed if the collision impact is large. If this happens, please contact our sales office or dealer.

2

Installa

tion

2-41

8. Working envelope and mechanical stopper positions for maximum working envelope

Working envelope of each robot and mechanical stopper positions for the maximum working envelope are shown in "1.2 External view and dimensions" in Chapter 7. Here, those are described using the YK500XG as an example. Other robot models are the same.

X and Y axes ■

1.Donotattemptoperationoutsidetheworkingenvelope.OntheYK-XGseries,theorigincanbesetatadiscreteposition.The working envelope described in this manual is an area with the robot frontal reference when no load is applied.

2. Interference positions where a load may touch the robot within the working envelope and their radii are shown in the figure.

• Becarefulnottoallowtherobotloadtointerferewithanypartoftherobot. • TheZ-axissplinemaytouchthebaseorthey-axisarmmaytouchthewireharnessbeforetherobotstrikesthe X-axis or Y-axis mechanical stoppers, so use caution.

Interference positions and radii in working envelope

145˚

R500R

105 (a)

130˚

260 16

5

R178

R71 (d)

145˚

130˚

R300

R25R25 (c)

114˚

288100

114˚

R55

(b)

Working envelope

Interference position(a) Base front panel(b) Base side panel(c) Base rear panel(d) Base corners

23218-F9-00

3. Interference positions where a load might touch the robot within the maximum movement range and their radii are shown in the figure.

The Zaxis spline may touch the base or the Y-axis arm may touch the wire harness before the robot strikes the X-axis or Y-axis mechanical stoppers, so use caution.

2

Installa

tion

2-42

Interference positions and radii in working envelope

113˚

260

132˚

147˚

R500R

82 (a)

R64 (d)

R171 132˚

147˚

R300

R25R25 (c)

113˚

100288

R55 (b)

165

Interference position(a) Base front panel(b) Base side panel(c) Base rear panel(d) Base corners

Maximum movement rangeX-axis mechanical stopper: 132°Y-axis mechanical stopper: 147°*Do not operate the robot in an area outside the working envelope.

23219-F9-00

Z-axis ■

Do not attempt work outside the working envelope. In particular, do not attempt work in the area between the working

envelope and mechanical stopper position. Mechanical stoppers are installed at both the upper and lower ends of the

movement range.

THE ROBOT CABLE, USER WIRING OR TUBING MAY BE DAMAGED IF THE ROBOT LOAD INTERFERES WITH THEM RESULTING IN HAZARDOUS ROBOT MALFUNCTIONS. DO NOT OPERATE AT POINTS WHERE THE LOAD MAY INTERFERE WITH THE ROBOT CABLE, USER WIRING OR TUBING.

Z-axis mechanical stopper position

Z300mm stroke 775

Z200mm stroke 675

137.6 ± 2

0

200

300

1010

Z-axis lower end mechanical stopper position

8

0

Z-axis upper end mechanical stopper position 8mm rise during Z-axis return-to-origin

23220-F9-00

2

Installa

tion

2-43

R-axis ■

The R-axis has no mechanical stoppers.

Since the R-axis has no mechanical stoppers, make certain that the end effector wiring and tubing do not become entangled during operation.

Robot overrun during impacts with mechanical stopper ■

A urethane damper is installed to absorb the shock when an impact occurs with the mechanical stopper, so a certain

amount of overrun occurs when the robot strikes the mechanical stopper. Use caution and take overrun into account

since the end effector may interfere with the robot body and peripheral equipment or the robot body may interfere with

the peripheral equipment. Maximum overrun amounts are listed below (for normal operation, maximum payload,

maximum speed).

Robot model X-axis Y-axisZ-axis

Upper end Lower end

YK250XG, YK350XG, YK400XG 8° 4° 1mm 1mm

YK500XG, YK600XG 9° 12° 5mm 5mm

YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG 9° 12° 5mm 5mm


• Ifthex-axis,y-axisorZ-axismechanicalstopperisdeformedordamagedbyimpacts,pleasecontactour sales office or dealer. Using the deformed or damaged mechanical stopper is dangerous, so it must be replaced. • Whentherobotstrikesthex-axisory-axismechanicalstopperoranotherobject,orwhentheR-axiscollides with an object, speed reduction gears are locked while being meshed if the collision impact is large. If this happens, please contact our sales office or dealer. • AftertherobotstrikestheZ-axismechanicalstopper,thestopperpositionmayshift,andsocheckthestopper position. If shifted, move the stopper to the correct position and refasten it securely by following the assembly procedure.

2

Installa

tion

2-44

9. Stopping time and stopping distance at emergency stopWhen the emergency stop button is pressed during robot operation or the power supply to the controller is turned off, the stopping time and stopping distance or angle of the main 3 axes change depending on the operation speed as shown below. The following figures show typical time and distance or angle needed for each axis to come to a stop after a stop signal is initiated when the robot arms are fully extended while 3 types of tip mass (33%, 66% and 100% of maximum payload) are loaded.

9.1 YK250XG, YK350XG, YK400XG

XY-axis stopping time for YK250XG

Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0 10 20 30 40 50 60 70 80 90 100

1.6kg XY-axis3.3kg XY-axis

5kg XY-axis

23219-F6-00

XY-arm stopping rotation angle for YK250XG

Operation speed (%)

XY-

axis

sto

ppin

g ro

tatio

n an

gle

(°)

0

10

20

30

40

50

60

70

0 10 20 30 40 50 60 70 80 90 100

3.3kg X-axis

3.3kg Y-axis

5kg X-axis

5kg Y-axis

1.6kg X-axis

1.6kg Y-axis

23220-F6-00

2

Installa

tion

2-45


0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

5kg

1.6kg3.3kg

23203-F7-00


0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

XY-

axis

sto

ppin

g ro

tatio

n an

gle

(°)

3.3kg X-axis

3.3kg Y-axis

5kg X-axis

5kg Y-axis

1.6kg X-axis

1.6kg Y-axis

23204-F7-00

2

Installa

tion

2-46


Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

0

0.1

0.2

0.3

0.4

0.5

0.6

0 10 20 30 40 50 60 70 80 90 100

5kg

1.6kg3.3kg

23203-F8-00


0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

XY-

axis

sto

ppin

g ro

tatio

n an

gle

(°) 3.3kg X-axis

3.3kg Y-axis

5kg X-axis

5kg Y-axis

1.6kg X-axis

1.6kg Y-axis

23204-F8-00

2

Installa

tion

2-47

Z-axis stopping time for YK250XG, YK350XG and YK400XG

Operation speed (%)

Z-

axis

sto

ppin

g tim

e (s

ec.)

0

0.01

0.02

0.03

0.04

0.05

0.06

0 10 20 30 40 50 60 70 80 90 100

5kg

1.6kg3.3kg

23221-F6-00

Z-axis stopping distance for YK250XG, YK350XG and YK400XG

0

2

4

6

8

10

12

14

16

18

20

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

5kg

1.6kg

3.3kg

23222-F6-00

2

Installa

tion

2-48

9.2 YK500XG, YK600XG


Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 10 20 30 40 50 60 70 80 90 100

3.3kg XY-axis6.6kg XY-axis10kg XY-axis

23221-F9-00


Operation speed (%)

XY-

arm

sto

ppin

g ro

tatio

n an

gle

(°)

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

0 10 20 30 40 50 60 70 80 90 100

6.6kg X-axis

6.6kg Y-axis

10kg X-axis

10kg Y-axis

3.3kg X-axis

3.3kg Y-axis

23222-F9-00

2

Installa

tion

2-49


Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

3.3kg XY-axis6.6kg XY-axis10kg XY-axis

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 10 20 30 40 50 60 70 80 90 100

23203-FA-00


Operation speed (%)

XY-

arm

sto

ppin

g ro

tatio

n an

gle

(°)

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

0 10 20 30 40 50 60 70 80 90 100

6.6kg X-axis

6.6kg Y-axis

10kg X-axis

10kg Y-axis

3.3kg X-axis

3.3kg Y-axis

23204-FA-00

2

Installa

tion

2-50

Z-axis stopping time for YK500XG Z200

Operation speed (%)

Z-

axis

sto

ppin

g tim

e (s

ec.)

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 10 20 30 40 50 60 70 80 90 100

10kg

3.3kg6.6kg

23223-F9-00

Z-axis stopping distance for YK500XG Z200

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

0

10

20

30

40

50

60

70

0 10 20 30 40 50 60 70 80 90 100

10kg

3.3kg

6.6kg

23224-F9-00

2

Installa

tion

2-51


Operation speed (%)

Z-

axis

sto

ppin

g tim

e (s

ec.)

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 10 20 30 40 50 60 70 80 90 100

10kg

3.3kg6.6kg

23205-FA-00


Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

0

10

20

30

40

50

60

70

0 10 20 30 40 50 60 70 80 90 100

10kg

3.3kg

6.6kg

23206-FA-00

2

Installa

tion

2-52

Stopping time for YK500XG Z300 and YK600XG Z300

Operation speed (%)

Z-

axis

sto

ppin

g tim

e (s

ec.)

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 10 20 30 40 50 60 70 80 90 100

10kg Z-axis

3.3kg Z-axis6.6kg Z-axis

23225-F9-00

Stopping distance for YK500XG Z300 and YK600XG Z300

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

0

10

20

30

40

50

60

70

0 10 20 30 40 50 60 70 80 90 100

10kg

3.3kg

6.6kg

23226-F9-00

2

Installa

tion

2-53

9.3 YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

XY-axis stopping time for YK600XGH

0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

20kg XY-axis


23207-FA-00

XY-arm stopping rotation angle for YK600XGH

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

Operation speed (%)

XY-

arm

sto

ppin

g ro

tatio

n an

gle

(°)

6.6kg X-axis

6.6kg Y-axis

13.2kg X-axis

13.2kg Y-axis

20kg X-axis

20kg Y-axis

23208-FA-00

2

Installa

tion

2-54


Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

20kg XY-axis


0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

0 10 20 30 40 50 60 70 80 90 100

23202-FB-00


Operation speed (%)

XY-

arm

sto

ppin

g ro

tatio

n an

gle

(°)

20kg Y-axis

6.6kg X-axis

6.6kg Y-axis

13.2kg X-axis

13.2kg Y-axis

20kg X-axis

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

0 10 20 30 40 50 60 70 80 90 100

23203-FB-00

2

Installa

tion

2-55


0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

20kg XY-axis


23201-FC-00


Operation speed (%)

XY-

arm

sto

ppin

g ro

tatio

n an

gle

(°)

6.6kg X-axis

6.6kg Y-axis

13.2kg X-axis

13.2kg Y-axis

20kg X-axis

20kg Y-axis

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

0 10 20 30 40 50 60 70 80 90 100

23202-FC-00

2

Installa

tion

2-56


0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

20kg XY-axis


23202-FD-00


Operation speed (%)

XY-

arm

sto

ppin

g ro

tatio

n an

gle

(°)

6.6kg X-axis

6.6kg Y-axis

13.2kg X-axis

13.2kg Y-axis

20kg X-axis

20kg Y-axis

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

0 10 20 30 40 50 60 70 80 90 100

23203-FD-00

2

Installa

tion

2-57


0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

XY-

axis

sto

ppin

g tim

e (s

ec.)

6.6kg XY-axis

13.2kg XY-axis

20kg XY-axis

23201-FE-00


Operation speed (%)

XY-

arm

sto

ppin

g ro

tatio

n an

gle

(°)

6.6kg X-axis

6.6kg Y-axis

13.2kg X-axis

13.2kg Y-axis

20kg X-axis

20kg Y-axis

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

0 10 20 30 40 50 60 70 80 90 100

23202-FE-00

2

Installa

tion

2-58

Z-axis stopping time for YK600XGH Z400

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

Z-a

xis

stop

ping

tim

e (s

ec.)

20kg

6.6kg13.2kg

23209-FA-00

Z-axis stopping distance for YK600XGH Z400

0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

20kg

6.6kg13.2kg

23210-FA-00

2

Installa

tion

2-59


0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

Z-a

xis

stop

ping

tim

e (s

ec.)

6.6kg13.2kg20kg

23204-FB-00


0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

6.6kg

13.2kg20kg

23205-FB-00

2

Installa

tion

2-60


0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

Z-a

xis

stop

ping

tim

e (s

ec.)

6.6kg Z-axis13.2kg Z-axis20kg Z-axis

23206-FB-00


0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70 80 90 100

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

6.6kg13.2kg

20kg

23207-FB-00

2

Installa

tion

2-61

Z-axis stopping time for YK600XGH Z200, YK800XG, YK900XG and YK1000XG

0 10 20 30 40 50 60 70 80 90 1000

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

Operation speed (%)

Z-a

xis

stop

ping

tim

e (s

ec.)

6.6kg13.2kg20kg

23211-FA-00

Z-axis stopping distance for YK600XGH Z200, YK800XG, YK900XG and YK1000XG

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

Operation speed (%)

Z-a

xis

stop

ping

dis

tanc

e (m

m)

6.6kg13.2kg20kg

23212-FA-00

2

Installa

tion

2-62

10. Installing the user wiring and tubing newlyUse the user wiring and tubing in the machine harness as much as possible by considering the durability of the machine harness. If the user wiring and tubing incorporated into the machine are insufficient, add new user wiring and tubing using cable ties. The following shows the outside diameters and quantities that can be added by considering the durability of the machine harness.

Installing the user wiring and tubing newly

Clamp the user wiring and tubing with minimal cable tie quantity so that the additional signal lines and tubes do not deviate.If the clamp is too strong, the machine harness may have faulty wiring.

φ D

φ d

Machine harness

Signal line

Air tube

Cable tie

23223-F6-00

Robot modelSignal line outside diameter

φ D (mm) × quantity

Tube outside diameter

φ d (mm) × quantity

YK250XG, YK350XG, YK400XG φ6 × 1 pc. φ4 × 3 pcs.

YK500XG,YK600XG,YK600XGH,YK700XG,

YK800XG, YK900XG, YK1000XGφ10 × 1 pc. φ6 × 3 pcs.

2

Installa

tion

2-63

11. Passing the wiring and tubing in the user wiring/tubing through spline type

In the YK250XG, YK350XG, and YK400XG with the user wiring/tubing through spline type, the user wiring and tubing can be passed through the spline. The following Fig. shows a reference example. The wiring at the top end of the spline can be detached or attached easily when replacing the spline, R-axis speed reduction unit, or R-axis motor. Use an appropriate connector that passes through the spline with an inside diameter of φ11.

Passing the wiring and tubing through the spline

Clamp using nylon clamp, etc.

Stay

Extension shaft

Clamp using nylon clamp, etc.

Stay

Junkosha’s mechatro flat tubeMF1-06-working length (cm)-10 × 0.10.1sq wire materials (10 pcs.) are included in the air tube (outside diameter �6 × �4 air tube)

Outside diameter �4 × inside diameter �2.5Air tube

Clamp on the hand side.

User wiring

User tubing

φ11

Z-axis moves up Z-axis moves down

M3 bolt

23224-F6-00

2

Installa

tion

2-64

12. Installing the tool flangeThe tool flange can be retrofitted. The following option parts are needed.


1 KCY-M1790-000 1 Tool flange

2 91312-05014 2 Bolt

3 92A08-05308 1 Set screw

When the tool flange is installed, set the tip mass parameter as follows. Tip mass parameter = Actual tip mass + 1 (kg) Failure to make this setting may shorten the service life of the drive unit.


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being adjusted, to keep others from operating the controller and operation panel.


4 Remove the Y-axis arm cover.

5 Remove the bolt, and then the stopper.

Removing the stopperStep 5

Stopper Bolt

Urethane damper

23225-F6-00

6 Install the tool flange.Align the orientation of the tapped hole for the tool flange set screw with that of the width across flat part of the spline, and then insert the tool flange all the way inside.

Installing the tool flangeStep 6

Tool flange (1)

Tapped hole for set screw

Width across flat part

23226-F6-00

7 Install the tool flange with the bolt (2).Secure that tool flange after it has been inserted all the way inside. • Tightening torque: 9Nm (92kgfcm)

Installing the tool flangeStep 7

Set screw (3)

Bolt (2)

23227-F6-00

8 Tighten the set screw (3).• Tightening torque: 3.5Nm (36kgfcm)


Chapter 3 Robot settings

Contents

1. Overview 3-1

2. Absolute reset 3-2

2.1 Absolute reset method 3-2

2.1.1 Sensor method (X-axis, Y-axis, and R-axis) 3-2

2.1.2 Stroke end method (Z-axis) 3-3

2.2 Machine reference 3-3

2.3 Absolute reset procedures 3-4

2.3.1 Sensor method (X-axis, Y-axis, and R-axis) 3-4

2.3.2 Stroke end method (Z-axis) 3-5

3. Setting the soft limits 3-7

3.1 Setting the X-axis and Y-axis soft limits 3-7

3.2 Setting the Z-axis soft limits 3-8

3.3 Setting the R-axis soft limit 3-8

3.4 Relation between the X, Y and R-axis movement angle, the Z-axis movement distance and the number of pulses 3-8

4. Setting the standard coordinates 3-9

4.1 Standard coordinate setting using a standard coordinate setup jig 3-10

4.1.1 YK250XG, YK350XG, YK400XG 3-10

4.1.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 3-11

5. Affixing the stickers for origin positions, movement directions, and axis names 3-14

3

Rob

ot se

ttings

3-1

1. OverviewVarious settings have been completely made at the factory or by the sales representative before shipment, including the origin position setting. If the operating conditions are changed and the robot needs to be set again, then follow the procedures described in this chapter.

The following describes the safety precautions to be observed when making various settings.

• Readandunderstandthecontentsofthischaptercompletelybeforeattemptingtosettherobot. • Placeaconspicuoussignindicatingtherobotisbeingadjusted,topreventothersfromtouchingthecontroller switch, programming box or operation panel. • Ifasafetyenclosurehasnotyetbeenprovidedrightafterinstallationoftherobot,ropeofforchainoffthe movement area 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 area of the manipulator. • Tochecktheoperationafterthesettingshavebeenmade,refertothesection"6.TrialOperation"inchapter “Safety Guide” of this manual.

3

Rob

ot se

ttings

3-2

2. Absolute resetAll models of the YK-XG series robots use an absolute type position detector. The origin position (zero pulse point) can be determined by absolute reset. Once absolute reset is performed, you do not have to repeat absolute reset when turning the power on next time. However, absolute reset is required if any of the following cases occur. The robot is shipped from the factory in condition "3." (below), so please perform absolute reset after installing the robot. For more details on absolute reset, refer to "Absolute Reset" in Chapter 4 of the "YAMAHA Robot Controller User's Manual".

1. Absolute-related error occurred on the axis.

2. Power drop was detected in the absolute battery for the driver installed inside the robot controller.

3. Cable connecting the robot unit to the controller was disconnected. (This is the status when shipped from the factory.)

4. Robot generation was changed.

5. Parameters were initialized.

6. Axis parameters "Origin shift", "Origin method", "Origin direction" or "Motor direction" were changed.

7. Motor was replaced. (Motor wiring connector was removed.)

8. Data in the ALL data file (extension: ALL) or parameter file (extension: PRM) was written into the controller by way of the RS-232C.

The following sections explain how to perform absolute reset.

• Ifanyoftheabovecasesoccurafterinstallingtherobot,absoluteresetmustbeperformedagain.Toperform absolute reset, move the robot arms back to their origin positions where the robot does not interfere with peripheral equipment after the setup is complete. • Afterperformingabsolutereset,movetherobottoaknownpointtocheckwhethertheoriginpositionis correctly set. When doing this check, move the robot at the slowest possible speed. • Thestandardcoordinateandpointdatamustberesetwhentheoriginpositionischanged. • Makepointdatasettingafterchangingtheoriginposition.Afterchangingtheoriginposition,donotusethe previous point data.

TherearethreeabsoluteresetmethodsfortheYK-XGseries:thesensormethod,markmethod,andstrokeendmethod.TheX-axis,Y-axis,andR-axisusethesensormethodastheinitialsetting,whiletheZ-axisusesthestroke end method.

2.1 Absolute reset method

2.1.1 Sensor method (X-axis, Y-axis, and R-axis)In the sensor method, the target axis is automatically operated for the absolute reset, and the absolute reset is performed at the position where the proximity sensor provided on the target axis detects the detection area (dog). The absolute reset in the sensor method can be executed with the programming box (RPB), RS-232C communication, and dedicated input.

SERIOUSINjURyMIGHTOccURFROMPHySIcALcONTAcTWITHTHEROBOTDURINGOPERATION.NEvERENTERWITHINTHEROBOTMOvEMENTRANGEDURINGABSOLUTERESET.

The origin cannot be detected in any axis which is not positioned on the plus side from the origin (see the Fig. stated in step 6 of "2.3.1 Sensor method (X-axis, Y-axis, and R-axis)" in this chapter) before starting the return-to-

origin operation. (Factory setting at shipment.) In this case, press the key to interrupt the return-to-origin

operation, move the target axis to the plus side of the origin, and reperform the origin return operation. If the return-to-origin operation is not interrupted, the robot will continue the operation and may collide with the mechanical stopper or a peripheral device. Since a mechanical stopper is not provided in the R-axis, the wiring and piping installed on the end effecter may be wound up by the operation.

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2.1.2 Stroke end method (Z-axis)In the stroke end method, absolute reset is performed at a position slightly backed off from the stroke end, after the Z-axis contacts the mechanical stopper and stroke end is detected.


2.2 Machine referenceTheYK-XGseriespositiondetectorsareresolversthathavefourpositionswhereabsoluteresetcanbeperformed per motor revolution. If the sensor method is used for the absolute reset, the origin position will be set at the positions where absolute reset can be performed soon after the origin sensor reacts to the dog (the origin signal is detected). The machine reference means the position relationship of the position where the robot detects the origin signal to the position where the absolute reset can be performed soon after detection (see the Fig. below). The machine reference is expressed with the ratio of interval A to interval B shown in the Fig. below. Interval A is the minimum distance between the positions where absolute reset can be performed and interval B is the distance between the position where the origin signal is detected and the position where absoluteresetcanbeperformedsoonaftertheoriginsignaldetection.Themachinereferencevalue(unit:%)isdisplayed on the optional RPB screen.

Machine reference value = B/A × 100(%)

The machine reference must be adjusted within a specified range to keep the repeatability precision of the absolute reset position (The machine reference is factory-adjusted prior to shipping). If the origin position is changed, the machine reference must be readjusted. For information on how to adjust the machine reference, refer to Chapter 5, "Adjusting the origin”, in the YK-XG series maintenance manual. When the temperature of the robot joint sections is high immediately after the robot has been operated, the machine reference value might be outside the specified range (40 to 60%). When checking or adjusting the machine reference value, always make sure that the temperature of the robot joint sections has returned to room temperature. Recommended machine reference value: 40 to 60%

Machine referenceOrigin signal detection

Origin signal

Resolver

Positions where absolutereset can be performed

One motor revolution

BA

ON

OFF

23301-F0-00

Machine reference display on RPB screen

RPB

* In the screen illustration below, a section of the screen shown by the marks is omitted.

R-axis X-axis Y-axis Z-axis

ＭＡＮＵＡＬ　　　　　　　　　　　　　　　　　　　　５０％　　　　［Ｓ０Ｈ０］

　Ｍａｃｈｉｎｅ　ｒｅｆｅｒｅｎｃｅ（％）　　Ｍ１＝　　　　　　　５１　Ｍ２＝　　　　　　　５７　Ｍ３＝　　　　　　　５１　Ｍ４＝　　　　　　　５２　

　ＰＯＩＮＴ　　　　　　　　　　　ＯＲＩＧＩＮ　　ＶＥＬ＋　　　　ＶＥＬ－

24301-F0-00

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2.3 Absolute reset procedures

2.3.1 Sensor method (X-axis, Y-axis, and R-axis)


The operation procedure using the RPB is described below.

• Toreturntothepreviousoperationstep,pressthe key.

• Fordetailsabouthowtooperatetherobotcontroller,seethe"YAMAHARobotControllerUser'sManual".


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being adjusted, to keep others from operating the controller or operation panel.

3 Enter the manual mode using the RPB screen.

4 Select "RST.ABS".Press the ( + ) key to select

"RST.ABS".

5 Select an axis for absolute reset. (X-axis: M1, Y-axis: M2, R-axis: M4)To select the X-axis, press the (M1) key.

To perform the absolute reset of all axes,

press the ( + ) key to select

"ALL".

ＭＡＮＵＡＬ＞ＲＳＴ．ＡＢＳ　　　　　　　　　　　　５０％［ＭＧ］［Ｓ０Ｈ０Ｊ］　　　Ｐｒｅｓｓ　Ｆ．ｋｅｙ　ｔｏ　ｇｅｔ　ａｘｉｓ　ｆｏｒ　ＡＢＳＲＳＴ　Ｍ１＝　ＮＧ　／　Ｓｅｎｓｏｒ　　　　　Ｍ５＝　ｎｏ　ａｘｉｓ　Ｍ２＝　ＮＧ　／　Ｓｅｎｓｏｒ　　　　　Ｍ６＝　ｎｏ　ａｘｉｓ　Ｍ３＝　ＮＧ　／　ＴＯＲＱＵＥ　Ｍ４＝　ＯＫ　／　Ｓｅｎｓｏｒ

　Ｍ１　　　　　　Ｍ２　　　　　　Ｍ３　　　　　　Ｍ４　　　　　　Ｍ５　

－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－

X-axisY-axis

R-axis

Absolute reset mode screenStep 3-5

24302-F0-00

The Z-axis of the stroke end method first rises during the absolute reset of all axes (default setting). Be careful that your fingers do not get pinched or crushed by any sudden movement.

6 Check the axis position.Check that the absolute reset axis must be positioned at the plus side of the origin. (See the Fig. on the right.) If it is not at the plus side, then press the jog key to move the target axis to the plus side.

Absolute reset possible rangeStep 6

Return-to-origin isimpossible from this area.

Origin position at shipment

Return-to-origin direction

Plus sideMinus side

23302-F0-00

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7 Perform the absolute reset.The message "Reset ABS OK?" appears on the RPB screen.

ＭＡＮＵＡＬ＞ＲＳＴ．ＡＢＳ＞Ｍ１　　　　　　　　　５０％［ＭＧ］［Ｓ０Ｈ０Ｊ］　　　Ｓｔａｒｔｉｎｇ　ｏｒｉｇｉｎ　ｓｅａｒｃｈ

　Ｒｅｓｅｔ　ＡＢＳ　ＯＫ？　　　　　　　　　　　ＹＥＳ　　　　　ＮＯ

－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－

Performing the absolute reset of the X-axisStep 7-8

24303-F0-00

8 Press the (Yes) key.

Check that there are no obstacles in the robot movement range, and then press the

key (YES).

To cancel the absolute reset, press the

(NO) key.

9 Check the machine reference value.After the absolute reset has been completed, check that the machine reference value displayed on the RPB is between 40 and 60 (recommended range). (For YK250XG, YK350XG, and YK400XG, the recommended range is between 30 and 70.) If the machine reference value is outside the recommended range, then the next absolute reset may not be properly performed. In this case, make the necessary adjustments while referring to Chapter 5, "Adjusting the origin”, in the YK-XG series maintenance manual

2.3.2 Stroke end method (Z-axis)

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The operation procedure using the RPB is described below.

• Toreturntothepreviousoperationstep,pressthe key.

• Fordetailsabouthowtooperatetherobotcontroller,seethe"YAMAHARobotControllerUser'sManual".



3 Enter the manual mode using the RPB screen.

4 Select "RST.ABS".Press the ( + ) key to select

"RST.ABS".

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5 Select "M3" that corresponds to the Z-axis.Press the (M3) key.

ＭＡＮＵＡＬ＞ＲＳＴ．ＡＢＳ　　　　　　　　　　　　５０％［ＭＧ］［Ｓ０Ｈ０Ｊ］　　　Ｐｒｅｓｓ　Ｆ．ｋｅｙ　ｔｏ　ｇｅｔ　ａｘｉｓ　ｆｏｒ　ＡＢＳＲＳＴ　Ｍ１＝　ＮＧ　／　Ｓｅｎｓｏｒ　　　　　Ｍ５＝　ｎｏ　ａｘｉｓ　Ｍ２＝　ＮＧ　／　Ｓｅｎｓｏｒ　　　　　Ｍ６＝　ｎｏ　ａｘｉｓ　Ｍ３＝　ＮＧ　／　ＴＯＲＱＵＥ　Ｍ４＝　ＯＫ　／　Ｓｅｎｓｏｒ

　Ｍ１　　　　　　Ｍ２　　　　　　Ｍ３　　　　　　Ｍ４　　　　　　Ｍ５　

－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－

Z-axis

Absolute reset mode screenStep 3-5

24304-F0-00

6 Perform the absolute reset.The message "Reset ABS OK?" appears on the RPB screen.

ＭＡＮＵＡＬ＞ＲＳＴ．ＡＢＳ＞Ｍ３　　　　　　　　　５０％［ＭＧ］［Ｓ０Ｈ０Ｊ］　　　Ｓｔａｒｔｉｎｇ　ｏｒｉｇｉｎ　ｓｅａｒｃｈ

　Ｒｅｓｅｔ　ＡＢＳ　ＯＫ？　　　　　　　　　　　ＹＥＳ　　　　　ＮＯ

－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－

Performing the absolute reset of the Z-axisStep 6

24305-F0-00

7 Press the (YES) key.

Check that there are no obstacles in the robot movement range, and then press the

key (YES).

To cancel the absolute reset, press the

(NO) key.

8 Check the machine reference value.After the absolute reset has been completed, check that the machine reference value displayed on the RPB is within the absolute reset tolerance range (25 to 75). (For YK250XG, YK350XG, and YK400XG, the recommended range is between 30 and 70.)

ＭＡＮＵＡＬ＞ＲＳＴ．ＡＢＳ　　　　　　　　　　　　５０％［ＭＧ］［Ｓ０Ｈ０Ｊ］　　Ｍａｃｈｉｎｅ　ｒｅｆｅｒｅｎｃｅ　（％）　　　　　　　　　　　　　　　　　　　　　　　　　　　Ｍ３＝　　　　　　　４９　

　Ｍ１　　　　　　Ｍ２　　　　　　Ｍ３　　　　　　Ｍ４　　　　　　Ｍ５

－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－

Machine reference valueStep 8

24306-F0-00

When adjusting the machine reference value, be sure to check the adjustment machine reference value.

Machine reference value checking procedure ■

1. Press the key.

2. Press the key to enter the manual mode.

3. Press the key ( + ) to select "RST.ABS".

4. After the Z-axis absolute reset is complete, press the ( + ) key to display the

adjustment machine reference value (%).

If the machine reference value is outside the absolute reset tolerance range, then the next absolute reset may not be properly performed. In this case, make the necessary adjustments while referring to Chapter 5, "Adjusting the origin”, in the YK-XG series maintenance manual.

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3. Setting the soft limitsIn the YK-XG Series, the working envelope during manual and automatic operation can be limited by setting the plus soft limit [pulse] and minus soft limit [pulse] on each axis. The origin point (0 [pulse] )is used as the reference to set the soft limits. The working envelope can be limited by specifying the number of pulses from the 0 pulse position.

When performing actual checks of the soft limit settings, operate the robot manually from outside the safety enclosure.

Refer to the "YAMAHA Robot Controller User's Manual" for further details. Also refer to "1.2 External view and dimensions" in Chapter 7 for the working envelope area.

3.1 Setting the X-axis and Y-axis soft limitsThe soft limits must be set within the movement range limited by the mechanical stoppers as explained in "7. LimitingthemovementrangewithX-andY-axismechanicalstoppers"inChapter2orwithintherangewherethe manipulator does not interfere with the peripheral equipment (but within maximum working envelope). Similarly, set the soft limits when the origin position has been changed. Likewise, in models where the mechanical stopper position cannot be changed, reduce the soft limits to narrow the working envelope when the actual working envelope of the robot is small or the manipulator interferes with the peripheral equipment. Follow the steps below to set the soft limits.


2 Press the emergency stop button.Press the emergency stop button on the RPB to put the robot in the emergency stop status.

For details about emergency stop and how to cancel the emergency stop, see the "YAMAHA Robot Controller User's Manual".


4 Enter the safety enclosure while holding the RPB.

5 Move the X-axis and Y-axis arms by hand.Move the X-axis and Y-axis to the mechanical stopper positions or to the point where interference with the peripheral equipment occurs.

6 Note the pulse values.Read the X-axis and Y-axis plus (+) and minus (-) direction pulses displayed on the RPB in step 6 and note them.

• Beforecancellingtheemergencystop,checkfromoutsidethesafetyenclosurethatnooneisinsidethesafety enclosure. • Setthesoftlimitsfromoutsidethesafetyenclosure.

7 Set the soft limits.Set the soft limits to within the figure for the X-axis and Y-axis encoder pulses that you have noted in step 7.

For details about how to set the soft limits, see the "YAMAHA Robot Controller User's Manual".

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The origin position factory-adjusted at shipment is not completely aligned with the front face position of the robot. When installing the robot, be sure to set the soft limits with the number of pulses from the origin position (0 pulse position).

3.2 Setting the Z-axis soft limits

Set the Z-axis soft limits from outside the safety enclosure.

The Z-axis has mechanical stoppers fixed at the upper and lower ends of the Z-axis movement range. When the actual working range of the robot is smaller than the maximum working envelope or the manipulator interferes with the peripheral equipment, reduce the Z-axis plus (+) soft limit [pulses] to narrow the working envelope.

3.3 Setting the R-axis soft limit

Set the R-axis soft limits from outside the safety enclosure or after the emergency stop button has been pressed in the same manner as the X-axis and Y-axis soft limits.

The R-axis has no mechanical stoppers. When the actual working range of the R-axis is small or it interferes with the peripheral equipment, reduce the R axis plus (+) soft limit [pulse] and minus (-) soft limit [pulses] to narrow the working envelope.

Overloads may occur if the soft limit is almost near the encoder pulse at the mechanical stopper and the operating point is used at the edge of the movement range. Set the soft limit to the inner side of the mechanical stopper with an ample safety margin.

3.4 Relation between the X, Y and R-axis movement angle, the Z-axis movement distance and the number of pulsesThetablesbelowareforcalculatingresolverpulseswithrespecttotheX,YandR-axismovementanglesandto the Z-axis movement distance for each robot. Use these figures as a guide to set the soft limits.

X, Y and R-axis speed reduction ratio and Z-axis ball screw lead for each robot

Robot Model X-axis Y-axis Z-axis R-axis

YK250XG, YK350XG, YK400XG 80 80 12mm 50

YK500XG, YK600XG 80 80 20mm 30

YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG 80 80 20mm 30

Operation angle/distance vs. number of resolver pulses X, Y and R-axis speed reduction ratio Z-axis

Speed ratio Number of resolver pulses per turn (360 degrees) Lead Number of resolver pulses per lead movement

30 491520 10mm 16384

50 819200 12mm 16384

80 1310720 20mm 16384

100 1638400 30mm 16384

105 1720320

121 1982464

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4. Setting the standard coordinates

If the standard coordinate settings are incorrect, the acceleration cannot be optimized to match the arm position. This results in too short a service life, damage to the drive unit, or residual vibration during positioning. In addition, the cartesian coordinate accuracy will be impaired.

Setting the standard coordinates enables the following operations and functions.

1. Optimizes acceleration according to arm position during automatic operation.

2. Allows moving robot arm tip at right angles.

3. Allows using shift coordinates.

4. Enables commands such as linear interpolation and arm switching.

The procedure for setting standard coordinates and cautions are shown below.


2 Check that the soft limits are correctly set.If not correctly set, adjust the soft limits while referring to "3. Setting the soft limits".


4 Enter the safety enclosure while holding the RPB.At this time, stay outside the robot movement range.

Never enter the robot movement range.

5 Set the standard coordinates.See "Setting the standard coordinates" stated in the "YAMAHA Robot Controller User's Manual".

The next section, "4.1 Standard coordinate setting using a standard coordinate setup jig (option)", describes how to set the standard coordinates more accurately using an optional setup jig.

6 Check that the standard coordinates are set correctly.1. Check that the robot arm tip can move at right angles in the manual operation (cartesian

coordinates).

2. Check that the values nearly equal to the X-axis and Y-axis arm lengths are entered in "Arm length"

of the axis parameters.

If points 1 and 2 shown above are not satisfied, the standard coordinate settings are incorrect. So, make the standard coordinate settings again.

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4.1 Standard coordinate setting using a standard coordinate setup jigUse a standard coordinate setup jig (option) to set the standard coordinates more accurately.The following describes how to set the standard coordinates using the standard coordinate setup jig.

4.1.1 YK250XG, YK350XG, YK400XG

Standard coordinate setup jig (option)

Part No. Name Q'ty

1 KCY-M1577-000 Pin 1

2 91312-04065 Bolt 1


2 Put the robot in the emergency stop status.Press the emergency stop button on the RPB to put the robot in the emergency stop status.




5 Remove the plug bolt.Put the robot in the arm posture as shown in the Fig. on the right, and then remove the plug bolt.

Removing the plug boltStep 5

Plug bolt

Enlarged hole

Hole23301-F6-00

6 Insert the pin (1).1. Make the X-axis arm almost in alignment

with the Y-axis arm.

2. Adjust the arm positions so that the pin

can be inserted into the enlarged hole in

the Y-axis arm and the hole in the X-axis

arm without jamming, and then insert the

pin into the holes.Y-axis position pulse valueStep 6-8

Bolt (2)

Pin (1)

23302-F6-00

7 Secure the pin (1) with the bolt (2).Tighten the bolt so that the pin does not move.

8 Make a note of the Y-axis position pulse value.1. Enter "MANUAL>POINT" mode.

2. Lightly apply a clockwise torque to the

Y-axis while holding the X-axis arm.

3. Make a note of the Y-axis position pulse

value displayed on [POS] when the

torque is unloaded.

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4. Lightly apply a counterclockwise torque

to the Y-axis while holding the X-axis arm.



torque is unloaded.

9 Determine the + direction of the X-axis.Move the X-axis arm in the direction that you want to set as the + direction of the X-axis. At this time, make a note of the X-axis position pulse value displayed on [POS].

X-axis + directionStep 9

+Y direction

+X direction23303-F6-00

0 Enter the "11. Arm length [mm]" values.Enter the following values in M1 and M2 for "11. Arm length [mm]" of axis parameters.

M1 (X-axis arm length) M2 (Y-axis arm length)

YK250XG 100.00 150.00

YK350XG 200.00 150.00

YK400XG 250.00 150.00

q Enter the "12. Offset pulse" values.Enter the values shown on the right in "12. Offset pulse" of axis parameters.

Entering the “12. Offset pulse” valuesStep 11

Note) Round off the decimal part of the M2 value.

M1= X-axis position pulse value you have made a note of in step 10

2M2=

+Y-axis position pulse value you have made a note of in step 8 (clockwise)

Y-axis position pulse value you have made a note of in step 8 (counterclockwise)

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w Reattach the plug bolt.1. Remove the pin and bolt.

2. Reattach the plug bolt.

4.1.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

Standard coordinate setup jig (option)

Part No. Name Q'ty

1 KBP-M1562-002 Sleeve 1

2 KBP-M1577-001 Pin 1

391312-04025 Bolt (YK500XG, YK600XG) 2

91312-04030 Bolt(YK600XGH,YK700XG,YK800XG,YK900XG,YK1000XG) 2

4 91312-04045 Bolt 1


2 Put the robot in the emergency stop status.Press the emergency stop button on the RPB to put the robot in the emergency stop status.


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5 Remove the bolt.Put the robot in the arm posture as shown in the Fig. on the right, and then remove the plug bolt.

Removing the boltStep 5

Bolt

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6 Secure the sleeve (1) with the bolt (3).Position the robot arms so that you can easily insert the sleeve into the hole, and then insert the sleeve into the hole. After that, secure the sleeve with the bolt (3). Tighten the bolt just enough to hold the sleeve. Securing the sleeveStep 6

Bolt

Sleeve

Hole

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7 Remove the cover and plate.Make the X-axis arm almost in alignment with the Y-axis arm, and then remove the cover and plate.

Removing the cover and plateStep 7

Bolt

Plate

Cover

Bolt

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8 Secure the pin (2) with the bolt (4).1. Adjust the arm positions so that the pin

can be inserted into the enlarged hole in

the Y-axis arm and the sleeve without

jamming, and then insert the pin.

2. Secure the pin with the bolt. Tighten the

bolt so that the pin does not move.

Y-axis position pulse valueStep 8-9

Y-axis arm

Bolt

Pin

Sleeve

X-axis arm

Elongated hole

Clockwise

Counterclockwise

23304-F9-00

9 Make a note of the Y-axis position pulse value.1. Enter "MANUAL>POINT" mode.

2. Lightly apply a clockwise torque to the

Y-axis while holding the X-axis arm.



torque is unloaded.

4. Lightly apply a counterclockwise torque

to the Y-axis while holding the X-axis arm.



torque is unloaded.

0 Determine the + direction of the X-axis.Move the X-axis arm in the direction that you want to set as the + direction of the X-axis. At this time, make a note of the X-axis position pulse value displayed on [POS].

X-axis + directionStep 10

+Y direction

+X direction23305-F9-00

q Enter the "11. Arm length [mm]" values.Enter the following values in M1 and M2 for "11. Arm length [mm]" of axis parameters.

M1 (X-axis arm length) M2 (Y-axis arm length)

YK500XG 200.00 300.00

YK600XG 300.00 300.00

YK600XGH 200.00 400.00

YK700XG 300.00 400.00

YK800XG 400.00 400.00

YK900XG 500.00 400.00

YK1000XG 600.00 400.00

w Enter the "12. Offset pulse" values.Enter the values shown on the right in "12. Offset pulse" of axis parameters.

Entering the “12. Offset pulse” valuesStep 12

Note) Round off the decimal part of the M2 value.

M1= X-axis position pulse value you have made a note of in step 10

2M2=

+Y-axis position pulse value you have made a note of in step 9 (clockwise)

Y-axis position pulse value you have made a note of in step 9 (counterclockwise)

23306-F9-00

e Return the cover and plate to their original positions.1. Remove the pin, bolt, and sleeve.

2. Reattach the cover, plate, and bolt

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5. Affixing the stickers for origin positions, movement directions, and axis names

The robot comes packed with stickers showing origin positions, movement directions and axis names. Using the following procedure, attach these stickers in conspicuous points on the robot after changing the origin position and installing peripheral equipment.

A BX YZ R

Origin position stickers, direction of movement and axis name stickers

Direction of movement andaxis name stickers


23305-F6-00

AFFIxTHEORIGINPOSITIONSTIcKERSPREcISELyONTHEORIGINPOSITIONS.ALIGNTHEDIREcTIONOFMOvEMENTSTIcKERSWITHTHEjOGDIREcTIONANDAFFIxTHEMcORREcTLy.AFFIxEAcHAxISNAMESTIcKERONTHECORRECT AXIS. AFFIXING THE STICKER AT A WRONG LOCATION MAY CAUSE FAULTY OPERATION AND HAZARDOUS SITUATIONS.


2 Move the robot to the 0 pulse position.

For details about how to move the axes to their "0" pulse positions, see "Chapter 4 Point trace function" in the "YAMAHA Robot Controller User's Manual".




6 Affix the stickers.Being careful not to move the origin positions, affix the stickers at legible points on matching sides of components such as the robot arm of each axis, base, and end effector. Affix stickers nearby showing the axis name and movement direction. Use a cloth moistened with alcohol to remove grease from the surface where you will affix the stickers. After the surface is dry, affix the stickers securely.

3

Rob

ot se

ttings

3-15

Sticker affixing positions

End effector End effector

R- +

-+

Z

Y- +

X- +

23306-F6-00

Chapter 4 Periodic Inspecition

Contents

1. Overview 4-1

2. Daily inspection 4-2

3. Six-month inspection 4-3

4. Consumable parts 4-6

4

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1. OverviewDaily and periodic inspection of the YAMAHA robot is essential in order to ensure safe and efficient operation. This chapter describes the periodic inspection items and procedures for the YAMAHA YK-XG series robots.

Periodic inspection includes:

•Dailyinspection

•6-monthinspection

Make sure that you thoroughly understand details of the inspection and follow the procedures and precautions explained in this chapter.

• WHENyOUNEEDTOTOUcHTHETERMINALSORcONNEcTORSONTHEOUTSIDEOFTHEcONTROLLERDURING INSPECTION, ALWAYS FIRST TURN OFF THE CONTROLLER POWER SWITCH AND ALSO THE POWER SOURCE IN ORDER TOPREvENTPOSSIBLEELEcTRIcALSHOcK. • NEvERTOUcHANyINTERNALPARTSOFTHEcONTROLLER.

• PeriodicinspectionmustbeperformedbyorinthepresenceofpersonnelwhohavereceivedtheRobot Training given by YAMAHA or YAMAHA dealers. • Donotattemptanyinspection,adjustment,repairandpartsreplacementnotdescribedinthismanual.This work requires specialized technical knowledge and skill, and may also involve work hazards. • Wheninspectionisrequiredinsidethesafetyenclosure,alwaysturnoffthecontrollerandalsotheexternal switch board. • Iftheinspectionormaintenanceprocedurecallsforoperationoftherobot,stayoutsidethesafetyenclosure. • Placeasignindicatingtherobotisbeinginspected,tokeepothersfromoperatingthecontrollerswitch, programming box or operation panel. • UseonlythelubricantsspecifiedbyyAMAHAoryAMAHAdealers. • Tochecktheoperationafterinspection,referto"6.TrialOperation"inchapter“SafetyGuide”ofthismanual.

For precautions on handling the controller, refer to the "YAMAHA Robot Controller User's Manual".

4

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2. Daily inspectionThe following is an inspection list that must be performed every day before and after operating the robot.

Inspection to be performed with the controller turned off ■


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being inspected, to keep others from operating the controller switch.

3 Perform the daily inspection.Enter the safety enclosure and check the following points.

Checkpoint Procedure

Machine harness

Robot cable

User cable and wiring

Checkforscratches,dentsandexcessivebendandkinks.(Ifthemachine

harnessorrobotcableisdamaged,contactYAMAHAdealer.)

Regulator,joints,airtube,

solenoid valve, air cylinder

Check air pressure.

Check for air leaks.

Check drain.

Check air filter for clogging or damage.

Robot exterior Checkfordamage.(Ifadamageisfound,contactYAMAHAdealer.)

Inspection to be performed with the controller turned on ■


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being inspected, to keep others from operating the controller, programming box or operation panel.

3 Perform the daily inspection.Check the following points from outside the safety enclosure.


Safety enclosure

Check if the safety enclosure is in place.

Check if emergency stop is triggered when the door is opened.

Check if warning labels are affixed at the entrance and clearly visible.

Emergency stop device Press the emergency stop button to check if it works.

Robot movementCheckforabnormalmovementandexcessivevibrationandnoise.(Ifany

abnormalsymptomisfound,contactYAMAHAdealer.)

Z-axis brake operation *

Check if the brake works to stop the Z-axis from dropping more than 3mm from

thestationarypoint.(Ifanyabnormaloperationisfound,contactYAMAHA

dealer.)

* Visually check the Z-axis movement when you press the emergency stop button from outside the safety enclosure and

also when you turn off the controller.

Adjustment and parts replacement ■

• Afterinspection,ifyounoticeanyadjustmentorpartsreplacementisneeded,firstturnoffthecontrollerand then enter the safety enclosure to perform the necessary work. To perform the inspection after the adjustment and parts replacement work, follow the steps stated in ■ Inspection to be performed with the controller turned off and ■ Inspection to be performed with the controller turned on described above. • Ifrepairorpartsreplacementisrequiredfortherobotorcontroller,pleasecontactyouryAMAHAdealer.This work requires specialized technical knowledge and skill, so do not attempt it by yourself.

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3. Six-month inspectionTake the following precautions when performing 6-month inspection.

THE Z-AXIS WILL SLIDE DOWN WHEN THE Z-AXIS BRAKE IS RELEASED, CAUSING A HAZARDOUS SITUATION. DO NOT RELEASE THE BRAKE WHEN LUBRICATING THE Z-AXIS PARTS.

When lubricating the ball screw and spline shaft, observe the following precautions.

PRECAUTIONS WHEN HANDLING GREASE: • INFLAMMATIONMAyOccURIFTHISGETSINTHEEyES. BEFORE HANDLING THE GREASE, WEAR YOUR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES. • INFLAMMATIONMAyOccURIFTHEGREASEcOMESINTOcONTAcTWITHSKIN.BESURETOWEARPROTEcTIvE GLOvESTOPREvENTcONTAcTWITHSKIN. • DONOTTAKEORALLyOREAT.(EATINGWILLcAUSEDIARRHEAANDvOMITING.) • HANDSANDFINGERSMIGHTBEcUTWHENOPENINGTHEcONTAINER,SOUSEPROTEcTIvEGLOvES. • KEEPOUTOFTHEREAcHOFcHILDREN. • DONOTHEATTHEGREASEORPLAcENEARANOPENFLAMESINcETHIScOULDLEADTOSPARKSANDFIRES. EMERGENCY TREATMENT: • IFTHISGREASEGETSINTHEEyES,WASHLIBERALLyWITHPUREWATERFORABOUT15MINUTESANDcONSULTA PHYSICIAN FOR TREATMENT. • IFTHISGREASEcOMESINcONTAcTWITHTHESKIN,WASHAWAycOMPLETELyWITHSOAPANDWATER. • IFTAKENINTERNALLy,DONOTINDUcEvOMITINGBUTPROMPTLycONSULTAPHySIcIANFORTREATMENT. DISPOSING OF GREASE AND THE CONTAINER: • PROPERDISPOSALIScOMPULSORyUNDERFEDERAL,STATEANDLOcALREGULATIONS.TAKEAPPROPRIATE MEASURES IN COMPLIANCE WITH LEGAL REGULATIONS. • DONOTPRESSURIZETHEEMPTycONTAINER.PRESSURIZINGMAycAUSETHEcONTAINERTORUPTURE. • DONOTATTEMPTTOWELD,HEATUP,DRILLHOLESORcUTTHIScONTAINER.THISMIGHTcAUSETHEcONTAINERTO EXPLODE AND THE REMAINING MATERIALS INSIDE IT TO IGNITE.

Unless grease specified by YAMAHA is used, the service life of the ball screw and ball spline will shorten.

4

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Inspection to be performed with the controller turned off ■


2 Place a sign indicating the robot is being adjusted.Place a sign showing that the robot is being inspected, to keep others from operating the controller switch.

3 Perform the daily inspection.Enter the safety enclosure and check the following points.


Manipulatorboltsandscrews(Onlyformajor

bolts and screws exposed externally)Check for looseness and tighten if necessary. (See the Table below.)

Detection areas of the origin sensors of the

X-axis, Y-axis, and R-axisClean if it is dirty.

ControllerCheck for looseness at each terminal and connector on the panel. (See

4 in Chapter 2.)

Grease lubrication of Z-axis spline

LubricatetheZ-axissplineshaftafterremovingtheoldgrease.The

specifiedgreaseisAlvaniaS2(SHOWASHELLSEKIYUKK).(Seethe

Fig. below.)

Z-axis ball spline, ball screw Checkforbacklash.(Ifanyabnormalityisfound,contactYAMAHAdealer.)

Bolt tightening torque

Bolt size Tightening torque (kgfcm) Tightening torque (Nm)

M3 button head bolt 14 1.4

M4 set screw 20 2.0

M3 20 2.0

M4 46 4.5

M5 92 9.0

M6 156 15.3

M8 380 37

M10 459 45.0

M12 1310 128

M14 2090 205

Applying the grease


Lower the spline and apply grease to the groove.

23401-F9-00

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Applying the grease


Lower the spline and apply grease to the groove.

23401-F6-00

Inspection to be performed with the controller turned on ■

• THEROBOTcONTROLLERMUSTBEINSTALLEDOUTSIDETHESAFETyENcLOSURE,TOPREvENTAHAZARDOUS SITUATION IN WHICH YOU OR ANYONE ENTER THE SAFETY ENCLOSURE TO INSPECT THE CONTROLLER WHILE IT IS TURNED ON. • BODILyINjURyMAyOccURFROMcOMINGINTOcONTAcTWITHTHEFANWHILEITISROTATING. • WHENREMOvINGTHEFANcOvERFORINSPEcTION,FIRSTTURNOFFTHEcONTROLLERANDMAKESURETHEFAN HAS STOPPED.


2 Place a sign indicating the robot is being adjusted.Place a sign indicating the robot is being inspected, to keep others from operating the controller, programming box or operation panel.

3 Perform the daily inspection.Check the following points from outside the safety enclosure.


Cooling fan at rear of controller

• Checkifthefanrotatesnormally.

• Checkifobjectsblockingthefanarelocatedandremoveifanyarefound.

• Checkforabnormalnoisefromtherotatingfan.Ifabnormalnoiseisheard,

visuallycheckandremovethecause.Ifnocauseisfound,contactYAMAHA

dealer.

• Checkfordustonthefancover.Removeandcleanifnecessary.

Adjustment and parts replacement ■

• Afterinspection,ifyounoticeanyadjustmentorpartsreplacementisneeded,firstturnoffthecontrollerand then enter the safety enclosure to perform the necessary work. o perform the inspection after the adjustment and parts replacement work, follow the steps stated in “■ Inspection to be performed with the controller turned off” and “■ Inspection to be performed with the controller turned on” described above. • Ifrepairorpartsreplacementisrequiredfortherobotorcontroller,pleasecontactyouryAMAHAdealer.This work requires specialized technical knowledge and skill, so do not attempt it by yourself.

4

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4. Consumable par ts

For details about consumable part locations, see "1.5 Maintenance parts" in Chapter 7.

Robot model Consumable part Q'ty Remarks

YK250XG, YK350XG, YK400XG KCY-M4843-001 1 Machine harness

YK500XG,YK600XG,YK600XGH KBF-M4843-003 1 Machine harness

YK700XG, YK800XG KBP-M4843-001 1 Machine harness

YK900XG, YK1000XG KBP-M4843-101 1 Machine harness

Chapter 5 Harmonic drive replacement period

Contents

1. Overview 5-1

2. Replacement period 5-2

5

Ha

rmonic d

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5-1

1. OverviewThe YK-XG series robots listed below use a harmonic drive as the speed reduction gear for the X, Y and R axes. Harmonic drives need to be replaced after specified operation hours have elapsed. Use the guideline explained below to determine the replacement period and replace the harmonic drive periodically. Since the YK-XG series robots listed below use long-life harmonic grease, it is not necessary to replace the harmonic grease. Only authorized engineers who received the robot training course conduced by YAMAHA or its sales representative must replace the harmonic drive while referring to the separate YK-XG series maintenance manual.

Applicable models: YK250XG, YK350XG, YK400XG, YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

5

Ha

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5-2

2. Replacement periodThe harmonic drive replacement period is determined by the total number of turns of the wave generator used in the harmonic drive. It is recommended to replace the harmonic drive when the total number of turns has reached 8.4×108 (at ambient operating temperatures of 0°C to +40°C). This means that the replacement period will differ depending on the following operating conditions. If the robot operation duty ratio is high or the robot is operated in environments at higher temperatures, the harmonic drive should be replaced earlier.

Replacement period = 8.4×108/(n×60×h×D×N×θ) years where n : Number of axis movements per minute θ : Average turn per axis movement N : Speed reduction ratio h : Operation time per day D : Operation days per year

For example, when the robot is used under the following conditions, the replacement period for the X-axisharmonicdriveoftheYK500XGcanbecalculatedasfollows.

n : 10

θ : 0.25

N : 80

h : 24 hours per day

D : 240 days per year

Replacement period = 8.4×108/(n×60×h×D×N×θ) = 8.4×108/(10×60×24×240×80×0.25) = 12.2 years

Harmonic drive speed reduction ratio

Robot model X-axis Y-axis R-axis

YK500XG, YK600XG 80 80 30

YK250XG,YK350XG,YK400XG,YK600XGH,YK700XG,YK800XG,

YK900XG, YK1000XG80 80 50

Chapter 6 Increasing the robot operating speed

Contents

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

6

Increasing the robot operating speed

6-1

1. Increasing the robot operating speedThe robot operating speed can be increased by the following methods. Use these methods as needed when programming.

1.1 Increasing speed by arch motion[Also refer to:] Robot controller user’s manual ("Axis parameters" – "Arch position" in Chapter 4) Programming manual (ARCH statement in "11. Command statements".)

Gate motion1.

From point P1 to P4 via P2 and P3:

MOVE P, P2

MOVE P, P3

MOVE P, P4

Gate motion

Z=0P2

P1

P3

P4

23601-F0

Arch motion: Using default arch position: (2000 pulses)2.

From point P1 to P2:

MOVE P, P2, Z=0

"Axis parameters" – "Arch position"

M1(X-axisarchposition)=2000pulses

M2 (Y-axis arch position) = 2000 pulses

M3 (Z-axis arch position) = 2000 pulses

M4 (R-axis arch position) = 2000 pulses

Arch motion:

Using default arch position: (2000 pulses)

Z=0

M1, M2, M4

P1

M3

P2

23602-F0

WhentheZ-axismovesupwardfromP1andenterstheM3archpositionrange(2000pulsespriortoZ=0),theX,YandR

axes begin to move. When these 3 axes enter the M1, M2 and M4 arch position range (2000 pulses prior to P2), the Zaxis

movesdownwardtoP2.Comparedwith"1.Gatemotion",thisarchmotionshortensthecycletimeapproximately20%

by moving the robot arm along an arc.

6


6-2

Arch motion: Making the arch position value larger3.

In "2. Arch motion", making the arch position value larger can further shorten the cycle time. Since the robot arm moves

along a larger arc, use caution to avoid obstacles if they are located near the arm movement path. The arch position

parameter can be set for each axis.

Arch motion: changing the arch positions in the program4.

[Example]

From point P1 to P2 and then to P3:

ARCH(1)=10000...X-axisarchposition(pulses)

ARCH (2) = 20000 ... Y-axis arch position (pulses)

ARCH (3) = 20000 ... Z-axis arch position (pulses)

ARCH (4) = 20000 ... R-axis arch position (pulses)

MOVE P, P2, Z=0

ARCH (1) = 2000

ARCH (2) = 2000

ARCH (3) = 2000

ARCH (4) = 2000

MOVE P, P3, Z=100

Since the arch positions can be changed in the program, optimizing the arch positions can further shorten the cycle time.

Arch motion

Z=0

P1 P2 P3

Z=100

Arch position: large

Arch position: small

23603-F0

Arch position can be set for each axis.

If the same arch position value (pulses) is used for all axes, you can write as "ARCH 2000".

6


6-3

1.2 Increasing the speed with the WEIGHT statement[Also refer to:] Robot controller user’s manual ("Robot parameters" – "Axis tip weight" in Chapter 4) Programming manual (WEIGHT statement in "11. Command statements".)

[Example]

From P1 when chuck is open:

WEIGHT 5 ...............Changes the axis tip weight parameter to 5kg (no workpiece).

MOVE P, P2, Z=0

DO3 (0) = 1 ............Chuck closes.

WEIGHT 10 .............Changes the axis tip weight parameter to 10kg (with workpiece).

MOVE P, P3, Z=0

In the above program, the acceleration can be set to a higher level by reducing the axis tip weight parameter to 5kg

while the chuck does not grip any workpiece, and then set to a lower level by changing the axis tip weight parameter to

10kg. Compared to programs using an axis tip weight parameter left set at 10kg, this method shortens the cycle time

since the acceleration is increased.

Increasing the speed with the WEIGHT statement

P1

Z=0

Chuck opens.

Chuck 5kg

Workpiece 5kg

P3P2

Chuck closes.

No workpiece Chuck is gripping workpiece.

23604-F0

6


6-4

1.3 Increasing the speed by the tolerance parameter[Also refer to:] Robot controller user’s manual ("Axis parameters" – "Tolerance" in Chapter 4) Programming manual (TOLE statement in "11. Command statements".)

Increasing the speed by the tolerance parameter

P1

P2

P3

23605-F0

[Example]

From P1 to P3 via P2

TOLE(1)=2048...X-axistolerance(pulses):Increasesthetolerance.

TOLE (2) = 2048 ... Y-axis tolerance (pulses)

TOLE (3) = 2048 ... Z-axis tolerance (pulses)

TOLE (4) = 2048 ... R-axis tolerance (pulses)

MOVE P, P2

TOLE (1) = 80 ....... Returns the tolerance to the default value.

TOLE (2) = 80

TOLE (3) = 80

TOLE (4) = 80

MOVE, P, P3

When P2 is an escape point and does not need to be accurately positioned, setting the tolerance parameter to a larger

value allows the robot arm to pass through P2 quickly. The larger the tolerance value for the positioning time, the shorter

the cycle time will be. The maximum value of the tolerance parameter is 2048 (pulses) and the default is 80 (pulses).

Tolerance can be set for each axis. If the same tolerance is used for all axes, you can write as "TOLE 2048".

If the same tolerance is used for all axes, you can write as "TOLE 80".

6


6-5

1.4 Increasing the speed by the OUT effective position parameter[Also refer to:] Robot controller user’s manual ("Axis parameters" – "Out effective Position" in Chapter 4) Programming manual (OUTPOS statement in "11. Command statements".)

[Example]

From P1 when chuck is open:

OUTPOS(1)=10000...X-axisOUTeffectiveposition(pulses):IncreasestheOUTeffectiveposition.

OUTPOS (2) = 10000... Y-axis OUT effective position (pulses)

OUTPOS (3) = 10000... Z-axis OUT effective position (pulses)

OUTPOS (4) = 10000... R-axis OUT effective position (pulses)

MOVE P, P2, Z=0

DO3 (0) = 1 ................ Chuck closes.

OUTPOS (1) = 2000..... Returns the OUT effective position to the default value.

OUTPOS (2) = 2000

OUTPOS (3) = 2000

OUTPOS (4) = 2000

Increasing the speed by the OUT effective position parameter

P1 P2

Chuck closed.

Chuck starts closing.

OUT effective position

23606-F0

WhenalloftheX,Y,ZandRaxesentertheOUTeffectiveposition(10000pulsespriortoP2),thechuckstartsclosing.

By setting the OUT effective position larger, the chuck starts closing while the robot arm is still moving at an earlier

point, so that the chuck can grip the workpiece more quickly. The default value of the OUT effective position is 2000

(pulses).

[Reference]

RelationbetweenX,Y,R-axisrotatingangle,Z-axismovementdistanceandpulsevalues

Thearchposition,toleranceandOUTeffectivepositionparametersaresetinpulses.FortherelationbetweenX,Y,

R-axisrotatingangle,Z-axismovementdistanceandpulsevalues,referto"3.4RelationbetweentheX,YandR-axis

movement angle, the Z-axis movement distance and the number of pulses" in Chapter 3.

The OUT effective position can be set for each axis. If the same OUT effective position is used for all axes, you can write as "OUTPOS 10000".

If the same OUT effective position is used for all axes, you can write as "OUTPOS 2000".

Chapter 7 Specifications

Contents

1. Manipulator 7-1

1.1 Basic specification 7-1

1.1.1 YK250XG, YK350XG, YK400XG 7-1

1.1.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG 7-2

1.2 External view and dimensions 7-4

1.2.1 YK250XG 7-4

1.2.2 YK350XG 7-8

1.2.3 YK400XG 7-12

1.2.4 YK500XG 7-16

1.2.5 YK600XG 7-18

1.2.6 YK600XGH 7-20

1.2.7 YK700XG 7-22

1.2.8 YK800XG 7-24

1.2.9 YK900XG 7-26

1.2.10 YK1000XG 7-28

1.3 Robot inner wiring diagram 7-30

1.4 Wiring table 7-31

1.5 Maintenance parts 7-36

1.5.1 YK250XG, YK350XG, YK400XG Standard type 7-36

1.5.2 YK250XG, YK350XG, YK400XG Tool flange mount type 7-38

1.5.3 YK250XG, YK350XG, YK400XG User wiring/tubing through spline type 7-40

1.5.4 YK250XG, YK350XG, YK400XG User wiring/tubing through spline and tool flange mount type 7-42

1.5.5 YK500XG, YK600XG Z=200mm stroke type 7-44


1.5.7 YK600XGH Z=200mm stroke type 7-48

1.5.8 YK600XGH Z=400mm stroke type 7-50





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1. Manipulator1.1 Basic specification

1.1.1 YK250XG, YK350XG, YK400XG

Robot model YK250XG YK350XG YK400XG

Axis

specifications

X-axisArm length 100mm 200mm 250mm

Rotation angle ±140°

Y-axisArm length 150mm


Z-axis Stroke 150mm

R-axis Rotation angle ±360°

Motor

X-axis 200W

Y-axis 150W

Z-axis 50W

R-axis 100W

Maximum speed

XY resultant 4.5m/s 5.6m/s 6.1m/s

Z-axis 1.1m/s

R-axis 1020°/s

Repeatability (*1)

XY-axes ±0.01mm

Z-axis ±0.01mm

R-axis ±0.004°

Payload Standard specifications 5kg, Option specifications 4kg (*3)

R-axis tolerable moment of inertia (*2) 0.05kgm2 (0.5kgfcms2)

User wiring 10 cables

User tubing φ4×3

Travel limit 1.Soft limit 2.Mechanical stopper (XYZ-axes)

Robot cable 3.5m (option: 5m, 10m)

Weight 18.5kg 19kg 19.5kg

*1 At constant ambient temperature (XY)

*2 There are limits to acceleration coefficient settings.

*3 Option specifications … Tool flange mount type


* The Z-axis spline may vibrate in a Z-axis operation speed range of 20% to 40% depending on the arm position or

Z-axisposition.IftheZ-axissplinevibrates,operateitbeyondthisoperationspeedrange.

Noise level

Maximum sound pressure level of the robot (when there is 10dB or

larger difference from the back ground sound pressure level)

Position where the maximum sound pressure

is measured

76.2dB1.25m apart from the front of the robot base,

1.6m height from the floor surface.

Note:Thenoiselevelcanbehigherwhentherobotissetnearbytheobjectsthatcausesoundreflection.

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1.1.2 YK500XG, YK600XG, YK600XGH, YK700XG, YK800XG, YK900XG, YK1000XG

Robot model YK500XG YK600XG

Axis

specifications

X-axisArm length 200mm 300mm




Z-axis Stroke 200, 300mm


Motor

X-axis 400W

Y-axis 200W

Z-axis 200W

R-axis 200W

Maximum speed

XY resultant 7.6m/s 8.4m/s

Z-axis2.3m/s (200mm stroke Z-axis)

1.7m/s (300mm stroke Z-axis)

R-axis 1700°/s

Repeatability *1

XY-axes ±0.01mm

Z-axis ±0.01mm

R-axis ±0.004°

Payload 10kg

R-axis tolerable moment of inertia *2 0.30kgm2 (3.0kgfcms2)


User tubing φ6×3



Weight 30kg 31kg



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Robot model YK600XGH YK700XG YK800XG YK900XG YK1000XG

Axis

specifications

X-axisArm length 200mm 300mm 400mm 500mm 600mm




Z-axis Stroke 200, 400mm


Motor

X-axis 750W

Y-axis 400W

Z-axis 400W

R-axis 200W

Maximum speed

XY resultant 7.7m/s 8.4m/s 9.2m/s 9.9m/s 10.6m/s

Z-axis2.3m/s (200mm stroke Z-axis)

1.7m/s (400mm stroke Z-axis)

R-axis 920°/s

Repeatability *1

XY-axes ±0.02mm

Z-axis ±0.01mm

R-axis ±0.004°

Payload 20kg

R-axis tolerable moment of inertia *2 1.0kgm2 (10.0kgfcms2)


User tubing φ6×3



Weight 48kg, 50kg 50kg, 52kg 52kg, 54kg 54kg, 56kg 56kg, 58kg



Noise level

Maximum sound pressure level of the robot (when there is 10dB or

larger difference from the back ground sound pressure level)

Position where the maximum sound pressure

is measured

78.4dB1m apart from the back of the robot,

1.6m height from the floor surface.

Note:Thenoiselevelcanbehigherwhentherobotissetnearbytheobjectsthatcausesoundreflection.

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1.2 External view and dimensions

1.2.1 YK250XG

0

138.5 ±2183187

230235264283

4

150

0

167174202222246

4

φ 16 h7 -0.0180

φ 35

3012

11.5


User toolinstallation range

Z-axis lower endmechanical stopper position

B B

A A

1010

50 70 20

3939

01245617995

2686

28

D-sub connector for user wiring (No. 1 to 10 usable)




M4 ground terminal

Cross section B-B

Wid

th a

cros

s fla

t 15

Hollow

diam

eter φ

11

Cross section A-A

Scale 1:1

The weight of the tool attached here should be added to the tip mass.

Tapped hole for user wiring 6-M3 × 0.5 Depth 6

140

6060

104

142

93

62

8850

30

138 (Base size)

4-φ9M8 bolt for installation, 4 bolts used

90




D-sub connector for user wiring (No. 1 to 10 usable)129Maximum 280 during arm rotation

620Maximum 660during arm rotation

428

468

10015056

661

613

42 57

47

138.5 ±2

780.5

150

150

5

φ 27

11.5

↓F

0

Standard type

Option: User wiring/tubing through spline type

23701-F6

7

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7-5

0

134.5 ±2

149

181

150

15.5

D

7.8

7.8

7.8 7.8

View of F

4-M3 × 0.5 through-hole (No phase relation to R-axis origin.)

As this hole is intended for the wiring/tubing clamp, do not attach a large load to it.

φ 30 h7 - 0.0210

φ 55

2

446

φ 35

Detailed drawing D

Scale 2:3

↑E

22.6

22.6

22.6

22.6

22.6±0.02

4-φ4.5 through-hole

φ 4 H7 0+ 0.012through-hole

90°

Hollow diameter φ11

7 ±0.02

View of E

YK250XG


D

↓F

0

134.5 ±2149181

780.5

150

15.5

φ 27

150 5




23702-F6

7

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7-6

YK250XG

Working envelope

Standard type Tool flange mount type

• Note that the robot cannot be used at a position where the base flange, robot cable, spline, and tool flange interfere with each other in the working envelope shown above.• X-axis mechanical stopper position : 142°• Y-axis mechanical stopper position : 146°

144°

144°

140°

140°

227

36°36°

148

R 250

R150

R 91

140°

140°

144°

144°

226

33°33°

R 250

R150

164

84

R 30

164

R 91

23703-F6

Option

X-axis additional stopperThe X-axis mechanical stopper position can be changed to the 119°-position.

(Working envelope: 117°)

Y-axis additional stopperThe Y-axis mechanical stopper position can be changed to the 127°-position.


Z-axis upper end additional stopperThe Z-axis origin position can be lowered 12mm, 15mm, 18mm, etc.

(at intervals of 3mm).

Z-axis lower end additional stopperThe lower end stopper position can be raised 17mm or more

(within 4mm of the working envelope).

Other option

Referencecoordinatesettingjig

7

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7-7

YK250XG

Projection of the machine harness toward the base rear side


X

Y

θx


→Y+

↓X+


Z

X(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

-144 65 0 0 0 0 0-120 80 0 0 0 0 0-90 70 0 0 0 0 0-60 50 70 0 0 0 0-30 10 50 0 60 0 00 0 25 50 0 0 0

30 -10 10 20 40 80 10060 -50 -15 15 45 95 9590 -70 -40 5 20 65 80

120 -80 -60 -40 -10 30 65144 -65 -100 -70 -40 15 20

Y(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

-144 155 136 136 136 136 136-120 160 136 136 136 136 136-90 170 136 136 136 136 136-60 165 136 136 136 136 136-30 160 136 136 136 136 1360 160 145 135 145 136 136

30 160 160 160 155 145 13660 165 175 160 165 170 16090 170 180 185 200 185 190

120 160 165 185 210 230 230144 155 170 190 225 245 280

Z(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

-144 350 300 300 300 300 300-120 350 300 300 300 300 300-90 410 300 300 300 300 300-60 420 300 300 300 300 300-30 460 400 300 300 300 3000 460 410 470 370 300 300

30 460 430 410 450 435 44060 420 450 450 455 460 46090 410 410 460 470 480 475

120 350 410 430 450 470 480144 350 390 420 460 470 480

23704-F6

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7-8

1.2.2 YK350XG

Standard type

Cross section B-B

Cross section A-A

Scale 1 : 1


0

138.5±2

183187230235264283

613

661

4

150

0

167174202222246

428

468


4

φ 16 h7 -0.0180

φ 35

42

3012

150

47

129Maximum 330 during arm rotation200

11.5

56

57



B B

A A

93

30 62

50 88

138 (Base size)

104 60

60

140

142

9010

10

50 70 20

3939



01245617995

26

86

28





M4 ground terminal





Wid

th a

cros

s fla

t 15

Hollow

diam

eter φ

11



0

138.5 ±2

780.5

150

150

5

φ 27

11.5

↓F

23701-F7

7

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7-9



D

0

134.5 ±2149181

780.5

150

15.5

150 5

φ 27↓F

View of F

0

134.5 ±2149

181

0

150

15.5

D

7.8

7.8

7.8 7.8



Detailed drawing D

Scale 2 : 3

View of E

φ30 h7-0.0210

φ 55

2

446

φ 35

↑E

22.6

22.6

22.6

22.6

22.6 ±0.0290

°


7 ±0.02

0+ 0.012

through-holeφ4 H7


YK350XG



23702-F7

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7-10

YK350XG

Working envelope

Standard type Tool flange mount type


140°

140°

303

116°

116°

144°

144°

148R

190

R150

R 350

R 118 140°

140°144°

144°

116°

116°

303R 350

R118

164

R150

R19

0

23703-F7

Option









Other option


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7-11

YK350XG



X

Y

θx


→Y+

↓X+


Z

X(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

-144 0 0 0 0 0 0-120 0 0 0 0 0 0-90 40 0 0 0 0 0-60 40 30 0 0 0 0-30 30 25 0 0 0 00 0 0 0 30 65 60

30 -30 -10 0 30 60 6060 -40 -25 0 5 30 5090 -40 -60 -60 -50 20 25

120 0 -90 -60 -80 0 -70144 0 -100 -60 -125 -80 -70

Y(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

-144 136 136 136 136 136 136-120 136 136 136 136 136 136-90 136 136 136 136 136 136-60 136 136 136 136 136 136-30 136 136 136 136 136 1360 136 136 136 136 136 136

30 136 136 140 150 140 13660 136 136 150 170 170 21090 136 140 165 180 225 240

120 136 136 160 225 260 270144 136 136 170 220 265 330

Z(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

-144 400 400 400 400 400 400-120 400 400 400 400 400 400-90 400 400 400 400 400 400-60 400 400 400 400 400 400-30 400 400 400 400 400 4000 400 400 400 400 470 400

30 400 400 430 450 460 48060 400 400 450 450 490 50090 400 400 440 480 520 520

120 400 430 440 500 520 500144 400 400 430 500 510 500

23704-F7

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7-12

1.2.3 YK400XG

Standard type

Cross section B-B

Cross section A-A

Scale 1 : 1



0

138.5 ±2

183187230235264283

613

661

4

150

0

167174202222246

428

468


4

φ16 h7 -0.0180

φ 35

42

3012

150

47

129Maximum 380 during arm rotation250

11.5

56

57


B B

A A

93

30 62

50 88

138 (Base size)

104 60

60

140

142

9010

10

50 70 20

3939





Wid

th a

cros

s fla

t 15

Hollow

diam

eter φ

11

01245617995

26

86

28





M4 ground terminal




0

138.5 ±2

780.5

150

150

5

φ 27

11.5

↓F


23701-F8

7

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7-13

YK400XG


0134.5 ±2

149181

780.5

150

150 5

φ 27

15.5

↓F

D

View of F

0

134.5 ±2

149

181

0

150

15.5

D

7.8

7.8

7.8 7.8



Detailed drawing D

Scale 2 : 3 View of E

φ 30 h7 -0.0210

φ 55

2

446

φ 35

↑E

22.6

22.6

22.6

22.6

22.6 ±0.02

90°


7 ±0.02

0+ 0.012

through-holeφ4 H7





23702-F8

7

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7-14

YK400XG

Working envelope


Standard/Tool flange mount type144°

144° 140°

140°

131° 131° 342

R 400

R150148

R18

0

R 156

23703-F8

Option









Other option


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7-15

YK400XG



XY

θx


→Y+

↓X+


Z

X(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

θY<0 0 0 0 0 0 00 0 0 0 0 0 0

30 0 0 0 35 35 -6060 0 0 0 -25 40 -7090 0 0 -25 -25 -40 -70

120 0 0 -25 -30 -40 -70144 0 0 -50 -65 -30 -60

Y(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

θY<0 136 136 136 136 136 1360 136 136 136 136 136 136

30 136 136 136 136 136 14060 136 136 136 136 136 15090 136 136 140 165 180 190

120 136 136 140 180 220 270144 136 136 145 205 260 380

Z(mm)|θX(°)|

0 30 60 90 120 140

θY(°)

θY<0 300 300 300 300 300 3000 300 300 300 300 300 300

30 300 300 300 440 410 47060 300 300 350 430 470 47090 300 300 430 465 500 500

120 300 300 430 460 480 530144 300 300 425 470 470 500

23704-F8

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7-16

1.2.4 YK500XG

60 140

40 120

200300 19471

120

200 (Base size)

150

178

7979

100




User tubing 3 (φ6 blue)4-φ11 M10 bolt for installation, 4 bolts used

0

158.5

187

259

373

652(Maximum 660 during arm rotation)

89

81

Flat surface has no phase relation to R-axis origin.

0-0.021

φ50

φ20h7

Z200mm stroke

Z300mm stroke

11354

675

775

0

137.6±2

204

253

283

351

213242

User toolinstallation range 8m

m ris

e dur

ingZ-

axis

retur

n-to-

origi

n

1440

71AA A

200

Z-ax

is st

roke

300

Z-ax

is s

troke

10

10


Cross section A-AWidt

h ac

ross

flat 1

9 Hollow diameter φ14

3210

4040

4-M4x0.7 through-hole for tool attachmentFour M4x10L binding screws are supplied.Do not screw the screws in deeper than 10mm from bottom surface of arm.The weight of the tool attached here should be added to the tip mass.

M16x2 Depth 20 (Bottom of spline)

23701-F9

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7-17

Working envelope of left-handed system

130°

130°

145°

260

50144

165

R300

R178

R25R300

R500114°

145°

130° 130°

165

260

50

144R30

0

R25

R500

R178

114°

Working envelope of right-handed system

X-axis mechanical stopper position: 132°Y-axis mechanical stopper position: 147°

R300

39 40M4 ground terminal

D-sub connector for user wiring(No. 1 to 20 usable)

015274767

04046




YK500XG

23702-F9

7

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7-18

1.2.5 YK600XG

60 140

40 120

300300 19471

120

200 (Base size)

178

7979

100


150




4-φ11 M10 bolt for installation, 4 bolts used

Z200mm stroke

Z300mm stroke

11354

675

775

137.6±2

204213

242253

283

351

0


10

10

200

Z-ax

is s

troke

300

Z-ax

is s

troke


0-0.021

8mm

rise d

uring

Z-ax

is re

turn-

to-or

igin

AA4014

φ20h7

φ50

71

89

81

0

158.5

187

259

373

652

Maximum 660 during arm rotation


Widt

h ac

ross

flat 1

9


Cross section A-A

4040

3210


M16x2 Depth 20 (Bottom of spline)

23701-FA

7

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7-19

M4 ground terminal

01527

4767


46

040

39 40X-axis mechanical stopper position: 132°Y-axis mechanical stopper position: 147°



130°

220

130°145°

135

135°

R600

R300

R180

R300

130°

145°

135

220

130°

135°

R600

R300

R30

0

R180




YK600XG

23702-FA

7

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7-20

1.2.6 YK600XGH

75

200400

50 145

170

22080

245 (Base size)12

0


220

9999

189

161





Z400mm stroke

Z200mm stroke

0

208.7±2273

278319.5333.5

368

440

790

990

63 128

200

Z-ax

is s

troke

400

Z-ax

is s

troke

12

12

Flat surface has no phase relation to R-axis origin.6mm

rise d

uring

Z-ax

is re

turn-

to-or

igin

AUser toolinstallation range 0

-0.021φ25h7

φ55

4514

AA



0

219

254.5

339.5

476

711

9886

99

Cross section A-A

Wid

th a

cros

s fla

t 24


15 36

4848


M20x2.5 Depth 20 (Bottom of spline)

23703-FA

7

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7-21

53


M4 ground terminal

01934475474

21

25 46

R40

0

R248

R600

R400

400

97°

100

130°

130°

150°


150°

130°

130°

100

97°

400

R400

R600

R248R

400






YK600XGH

23704-FA

7

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7-22

1.2.7 YK700XG

75

300400

50 145

170

22080

245 (Base size)

189 99

99

220

120

161



0

219254.5

339.5

476

711

Z400mm stroke

Z200mm stroke

63 128

208.7±2273

278319.5333.5

368440

790

990

12

1240

0 Z-

axis

stro

ke

6mm

rise d

uring

Z-ax

is re

turn-

to-or

igin

200

Z-ax

is s

troke

0



45

0-0.021


14

A AA

98

99

86

Cross section A-A


Wid

th a

cros

s fla

t 24

4848

15 36





φ25h7

φ55



23701-FB

7

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7-23



R700

R400

R205

R400

R400

124°

150° 130°

30020

2

140

100

R30

130°


100

140

202

300

130°

150°

124°

130°

R400R400

R30R205

R400

R700

54

0

74

473419

25


21

53

46M4 ground terminal




YK700XG

23702-FB

7

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7-24

1.2.8 YK800XG

220

161

80 400 400


75

50 145

170

245 (Base size)12

0 189 99

99

220

Z200mm stroke

Z400mm stroke

333.5

440

790

990

368

319.5278273

208.7±2

63 128


200

Z-ax

is s

troke

6mm

rise d

uring

Z-ax

is re

turn-

to-or

igin

400

Z-ax

is s

troke

12

0

12

AAUser toolinstallation range

45


0-0.021

14

Cross section A-A

Wid

th a

cros

s fla

t 24



219

476

339.5

711

254.5

0

99

9886

48

15

48

36





φ25h7

φ55



23701-FC

7

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7-25



019

54

M4 ground terminal

3447

74

25


46

21

53

141°

130°130° 15

0°

R400 R3

0

R207

R400

R800

250

202

140100

100

140

202

250

R800

R400

R207

R30 R400

150°

130°130°

141°





YK800XG

23702-FC

7

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7-26

1.2.9 YK900XG

AA

99

161

220

99

189

245 (Base size)

220

170

14550

75


80 500400

120

Z200mm stroke

Z400mm stroke

333.5368

990

0

273278

319.5

790

440

208.7±2

12400

Z-ax

is s

troke

6mm

rise d

uring

Z-ax

is re

turn-

to-or

igin

12

200

Z-ax

is s

troke

A 45 User toolinstallation range


14

0-0.021


9886

99


0

254.5

711

339.5

476

219

Cross section A-A

Wid

th a

cros

s fla

t 24


36

48

15

48

12863





φ25h7

φ55



23701-FD

7

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7-27

74

53

21

4734

M4 ground terminal46

54


25

190



Working envelope of left-handed systemR900

R252

R400

R400

150°

130°130°

150°

150°13

0°

130°

150°

R400

R900

R252

R400




YK900XG

23702-FD

7

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7-28

1.2.10 YK1000XG

A

48

15

48

36

12400

Z-ax

is s

troke

12

200

Z-ax

is s

troke



Wid

th a

cros

s fla

t 24

Cross section A-A

333.5368

0

273278

319.5

790

440

208.7±2

45


14

0-0.021

6mm

rise d

uring

Z-ax

is re

turn-

to-or

igin


99

9886

A A

Z200mm stroke

Z400mm stroke

990

12863


0

254.5

711

339.5

476

219

161

22080


120

600400

99

75

50 145

170

245 (Base size)

189 99

220





φ25h7

φ55



23701-FE

7

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7-29

54

M4 ground terminal

3447

74

019

46

21

25

53





150°

130°

150°

R400

R1000

R400

R323

R1000

R400

R323

R400

150°

130°

130°

150°

130°




YK1000XG

23702-FE

7

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7-30

1.3 Robot inner wiring diagram

X-axis resolver

FG

RORGRORG

XORG YM

ZMZM

RMRM

XMXM

YPYP

IOZP

RPRP

YORG YORG

ZORG

ZBK ZBK

X-axis motor

XPXP

XORG

X-axis origin sensor

FG

YM

ZP

FG

XM

YM

XY

ZM

RM

ZR

Y-axis resolver

Y-axis motor

Z-axis brake

Z-axis motor

Z-axis resolver

R-axis resolver

R-axis motor

Y-axis origin sensor R-axis

origin sensor

ZBKZBK

ZM ZM

ZP ZP

RPRP

RM RM

RORG RORG

YP YP

YMYM

YORGYORG

IO

User IO connector

User tubing

Round terminal M4 ground terminal

Round terminal

User IO connector

User tubingMachine harness

X-axis arm

Y-axis arm

Robot inner wiring diagram

YK500XG

Robot cable

23706-F9

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7-31

1.4 Wiring table

Robot cable wiring table

Signal Connector No. Connection No. Connector Color/Number Wire

Resolver S2

XP

1 1

XY

Orange-1-Red 0.15sq

S4 2 2 Orange-1-Black Twisted pair

S1 3 3 Gray-1-Red 0.15sq

S3 4 4 Gray-1-Black Twisted pair

R1 5 5 Sky blue-2-Red 0.15sq

R2 6 6 Sky blue-2-Black Twisted pair

DG 7 7 Gray 0.3sq

Resolver S2

YP

1 19 Orange-2-Red 0.15sq


S1 3 21 Bright green-2-Red 0.15sq

S3 4 22 Bright green-2-Black Twisted pair

R1 5 23 Pink-2-Red 0.15sq

R2 6 24 Pink-2-Black Twisted pair

DG 7 25 Gray 0.3sq

FG

FG

1 18 Gray-2-Red 0.15sq

36 Gray-2-Black 0.15sq

HLIM 10 Gray 0.3sq

GND24 11

HLIM 28 Gray 0.3sq

GND24 29

Origin Sensor GND

XORG

3 13 Sky blue-3-Red 0.15sq

ORG 2 12 Sky blue-3-Black Twisted pair

24V 1 9 Pink-3-Red 0.15sq

Origin Sensor 24V

YORG

1 27 Pink-3-Black Twisted pair

ORG 2 30 Bright green-1-Red 0.15sq

GND 3 31 Bright green-1-Black Twisted pair

U

XM

1 2

XM

Black 0.75sq

V 2 3 Red 0.75sq

W 3 4 White 0.75sq

FG Round terminal 1 Gray 0.75sq

U

YM

1 2

YM

Yellow 0.75sq

V 2 3 Brown 0.75sq

W 3 4 Blue 0.75sq

7

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7-32

Signal Connector No. Connection No. Connector Color/Number Wire

Resolver S2

ZP

1 1

ZR

Orange-1-Red 0.15sq


S1 3 3 Gray-1-Red 0.15sq

S3 4 4 Gray-1-Black Twisted pair

R1 5 5 Sky blue-2-Red 0.15sq

R2 6 6 Sky blue-2-Black Twisted pair

DG 7 7 Gray 0.3sq

Brake MB+

ZBK

1 14 Pink-1-Red 0.15sq

MB– 2 16 Pink-1-Black Twisted pair

15 Sky blue-1-Red 0.15sq

17 Sky blue-1-Black Twisted pair

Resolver S2

RP

1 19 Orange-2-Red 0.15sq


S1 3 21 Bright green-2-Red 0.15sq

S3 4 22 Bright green-2-Black Twisted pair

R1 5 23 Pink-2-Red 0.15sq

R2 6 24 Pink-2-Black Twisted pair

DG 7 25 Gray 0.3sq

FG

FG

1 18 Gray-2-Red 0.15sq

36 Gray-2-Black 0.15sq

HLIM 10 Gray 0.3sq

GND24 11

HLIM 28 Gray 0.3sq

GND24 29

Origin Sensor 24V

ZORG

3 13 Sky blue-3-Red 0.15sq

ORG 2 12 Sky blue-3-Black Twisted pair

GND 1 9 Pink-3-Red 0.15sq

Origin Sensor 24V

RORG

1 27 Pink-3-Black Twisted pair

ORG 2 30 Bright green-1-Red 0.15sq

GND 3 31 Bright green-1-Black Twisted pair

U

ZM

1 2

ZM

Black 0.75sq

V 2 3 Red 0.75sq

W 3 4 White 0.75sq

FG Round terminal 1 Gray 0.75sq

U

RM

1 2

RM

Yellow 0.75sq

V 2 3 Brown 0.75sq

W 3 4 Blue 0.75sq

7

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7-33

Machine harness wiring table (YK250XG, YK350XG, YK400XG)Y-axis arm side Base side

Signal Connector No. Connection No. Connector Color Wire

Y-axis Resolver S2

YP

1 1

YP

Brown 0.2mm2

S4 2 2 White Twisted pair

S1 3 3 Red 0.2mm2


R1 5 5 Orange 0.2mm2

R2 6 6 White Twisted pair

DG 7 7 Gray Shield

Z-axis Resolver S2

ZP

1 1

ZP

Brown 0.2mm2

S4 2 2 Black Twisted pair

S1 3 3 Red 0.2mm2



R2 6 6 Black Twisted pair

DG 7 7 Gray Shield

R-axis Resolver S2

RP

1 1

RP

Brown 0.2mm2

S4 2 2 Gray Twisted pair

S1 3 3 Red 0.2mm2



R2 6 6 Gray Twisted pair

DG 7 7 Gray Shield

Y-axis motor U

YM

1 1

YM

Brown

0.75mm2V 2 2 Red

W 3 3 Orange

Z-axis motor U

ZM

1 1

ZM

Blue

0.75mm2V 2 2 Purple

W 3 3 Gray

R-axis motor U

RM

1 1

RM

Black

0.75mm2V 2 2 Blue

W 3 3 Red

Z-axis brake 1ZBK

1 1ZBK

Purple0.3mm2

Z-axis brake 2 2 2 Gray

User signal lineIO

1 1

IO

Brown

0.2mm2

2 2 Red

3 3 Orange

4 4 Blue

5 5 Purple

6 6 Gray

7 7 White

8 8 Brown

0.2mm2

9 9 Red

10 10 Orange

11 11

12 12

13 13

14 14

Frame ground 15 15 Gray Shield

Frame ground 1 FG Gray Shield

Origin Sensor 24V

YORG

1 1

YORG

White

0.2mm2ORG 2 2 Purple

GND 3 3 Gray

Origin Sensor 24V

RORG

1 1

RORG

White

0.2mm2ORG 2 2 Blue

GND 3 3 Gray

Round terminal Round terminal Yellow/Green 0.75sq

Round terminal Round terminal Blue 0.75sq

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Machine harness wiring table (YK500XG, YK600XG, YK600XGH, YK700XG,YK800XG, YK900XG, YK1000XG)Y-axis arm side Base side

Signal Connector No. Connection No. Connector Color Wire

Y-axis Resolver S2

YP

1 1

YP

Brown 0.2mm2


S1 3 3 Red 0.2mm2



R2 6 6 White Twisted pair

DG 7 7 Green Shield

Z-axis Resolver S2

ZP

1 1

ZP

Brown 0.2mm2


S1 3 3 Red 0.2mm2



R2 6 6 Black Twisted pair

DG 7 7 Green Shield

R-axis Resolver S2

RP

1 1

RP

Brown 0.2mm2


S1 3 3 Red 0.2mm2



R2 6 6 Gray Twisted pair

DG 7 7 Green Shield

Y-axis motor U

YM

1 1

YM

Brown

0.75mm2V 2 2 Red

W 3 3 Orange

Z-axis motor U

ZM

1 1

ZM

Blue

0.75mm2V 2 2 Purple

W 3 3 Gray

R-axis motor U

RM

1 1

RM

Black

0.75mm2V 2 2 White

W 3 3 Brown

Z-axis brake 1ZBK

1 1ZBK

White0.3mm2

Z-axis brake 2 2 2 Black

User signal lineIO

1 1

IO

Brown

0.2mm2

2 2 Red

3 3 Orange

4 4 Blue

5 5 Purple

6 6 Gray

7 7 White

8 8 Black

9 9 Brown

10 10 Red

11 11 Orange

12 12 Blue

13 13 Brown

0.2mm2

14 14 Red

15 15 Orange

16 16 Blue

17 17 Purple

18 18 Gray

19 19 White

20 20 Black

21 21 Brown

22 22 Red

23 23 Orange

24 24 Blue

Frame ground 25 25 Green Shield

Frame ground 1 FG Green Shield

Origin Sensor 24V

YORG

1 1

YORG

Brown

0.2mm2ORG 2 2 Red

GND 3 3 Orange

Origin Sensor 24V

RORG

1 1

RORG

Brown

0.2mm2ORG 2 2 Blue

GND 3 3 Orange

Round terminal Round terminal Yellow/Green 0.75sq

Round terminal Round terminal Black 0.75sq

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Motor wiring table

Signal Color Connection No. Connector

Resolver S2 Blue 1

XP, YP, ZP, RP

S4 Blue/Black 2

S1 Brown 3

S3 Brown/Black 4

R1 Red 5

R2 Black 6

SHIELD Black 7

Motor U Red 1

XM, YM, ZM, RMV White 2

W Black 3

PE Yellow/Green 1 Round terminal

Brake BK Yellow 1 ZBK

(Z-axis motor only)BK Blue 2

Origin sensor wiring tabl

Signal Color Connection No. Connector

+24V Brown 1

XORG, YORG, RORGORG Black 2

0V Blue 3

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1.5 Maintenance parts

1.5.1 YK250XG, YK350XG, YK400XG Standard type

No. Part No. Part name Q’ty RemarksRecommended

replacement timing

X-axis

X1 KCY-M2110-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

X2 98502-03030 SCREWPANHEAD(+) 1 LowerdogofspeedreductionunitX3 91312-03030 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltX4 95302-04600 NUTHEXAGON 1 Nut for dogX5 92903-03600 WASHER,PLAIN 16 Washer for speed reduction unit mounting boltX6 91312-03018 BOLTHEX.SOCKETHEAD 16 Speed reduction unit mounting boltX7 KN4-M257K-000 ORING,1 1 Upper O-ring of speed reduction unitX8 KCY-M4880-000 MOTOR ASSY.,1 1 MotorX9 KN3-M2143-000 ORING.,2 1 O-ring for motor flange rabbet

X10 91312-05014 BOLTHEX.SOCKETHEAD 4 Motor mounting boltX11 KCY-M4850-600 PROXIMITYSW.ASSY. 1 SensorX12 KCY-M2197-000 DAMPER,2 1 Mechanical stopper damperX13 90112-10J055 BOLT,HEX.SOCKETHEAD 1 Mechanical stopper boltX14 90189-02J106 NUT,HEXAGON 1 Nut for mechanical stopper bolt

Y-axis

Y1 KCY-M2510-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

Y2 KN4-M1896-000 ORING,2 1 LowerO-ringofspeedreductionunitY3 91312-03025 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltY4 98502-03030 SCREWPANHEAD(+) 1 Upper dog of speed reduction unitY5 95302-04700 NUTHEXAGON 1 Nut for dogY6 92903-03600 WASHER,PLAIN 16 Washer for speed reduction unit mounting boltY7 91312-03022 BOLT,HEX.SOCKETHEAD 16 Speed reduction unit mounting boltY8 KCY-M4881-000 MOTOR ASSY.,2 1 MotorY9 91312-04008 BOLTHEX.SOCKETHEAD 2 Motor mounting bolt

Y10 KN3-M257K-000 ORING,1 1 O-ring for motor flange rabbetY11 KCY-M2197-000 DAMPER,2 1 Mechanical stopper damperY12 90189-02J106 NUT,HEXAGON 1 Mechanical stopper boltY13 90112-10J055 BOLT,HEX.SOCKETHEAD 1 Nut for mechanical stopper boltY14 KCY-M4850-100 PROXIMITYSW.ASSY 1 SensorY15 KCY-M1314-001 COVER,4 1 Y-axis coverY16 92903-03200 WASHERPLAIN 4 Washer for Y-axis cover screwY17 98902-03006 SCREWBINDINGHEAD 4 Y-axis cover screwY18 98902-03016 SCREW,BINDINGHEAD 4 Y-axis cover screwY19 KCY-M1321-000 LABEL 1 LabelontopofY-axiscover

Z-axis

Z1 KCY-M4882-000 MOTOR ASSY.,3 1 MotorZ2 91312-04012 BOLT,HEX.SOCKETHEAD 2 Motor mounting boltZ3 KCY-M1753-000 COUPLING 1 CouplingZ4 KCY-M1750-000 SCREW,BALL 1 Ball screwZ5 91312-03014 BOLTHEX.SOCKETHEAD 4 Ball screw mounting boltZ6 90933-02J608 BEARING 1 Ball screw support bearingZ7 KCY-M1788-000 DAMPER,1 1 LowerenddamperZ8 90933-01J002 BEARING 2 Upper bearing of ball spline shaftZ9 KN3-M1788-000 DAMPER,1 1 Upper end damper

Z10 91312-05016 BOLTHEX.SOCKETHEAD 1 Upper end stopper mounting boltZ11 KCY-M1780-001 STOPPER,1 1 Upper end stopper

R-axis

R1 KCY-M1821-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

R2 KN3-M1895-000 ORING 1 LowerO-ringofspeedreductionunitR3 91312-03022 BOLT,HEX.SOCKETHEAD 8 Speed reduction unit mounting boltR4 90990-17J034 O-RING 1 O-ring for input part of speed reduction unitR5 92903-03600 WASHER,PLAIN 12 Washer for speed reduction unit mounting boltR6 91312-03014 BOLT,HEX.SOCKETHEAD 12 Speed reduction unit mounting boltR7 KCY-M1888-000 DOG,R 1 Upper dog of speed reduction unitR8 90990-28J064 WASHER,PLAIN 1 Washer for upper dog of speed reduction unitR9 KCY-M4883-000 MOTOR ASSY.,3 1 Motor

R10 91312-05016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltR11 KN3-M2144-000 ORING,3 1 LowerO-ringofmotorR12 KCY-M4850-400 PROXIMITYSW.ASSY 1 SensorR13 KCY-M1840-000 SPLINE,BALL 1 Ball splineR14 90990-17J032 O-RING 1 Upper O-ring of ball spline nut (outside)R15 KN5-M181H-000 ORING,4 1 Upper O-ring of ball spline nut (inside)R16 90990-36J002 WASHER,SEAL 4 Seal washer for ball spline nut mounting boltR17 91312-04012 BOLT,HEX.SOCKETHEAD 4 Ball spline nut mounting boltR18 KCY-M1886-000 SEAL 1 End face seal inside speed reduction unit

Cables

C1 KCY-M4843-001 HARNESS,MACHINE2 1 Machine harness

C2KBF-M6211-004

CABLE,ROBOT1 Robot cable (3.5 m)

KBF-M6211-104 1 Robot cable (5 m)KBF-M6211-204 1 Robot cable (10 m)

C3 K58-M4872-101 CONNECTORE/L2 1 D-sub connector on base sideC4 KN0-M4839-001 PANEL,CONECTOR 1 HoodforD-subconnectoronbasesideC5 KN3-M2296-000 BOLT 2 D-sub connector on base side mounting boltC6 92903-03100 WASHERSPRING 2 D-sub connector on base side mounting spring washerC7 95302-03600 NUTHEXAGON 2 D-sub connector on base side mounting nutC8 K58-M4871-101 CONNECTORE/L1 1 D-sub connector on Y-axis arm sideC9 K58-M4839-001 PANEL,CONNECTOR 1 HoodforD-subconnectoronY-axisarmside

C10 KN3-M2296-000 BOLT 2 D-sub connector on Y-axis arm side mounting boltC11 92903-03100 WASHERSPRING 2 D-sub connector on Y-axis arm side mounting spring washerC12 95302-03600 NUTHEXAGON 2 D-sub connector on Y-axis arm side mounting nut

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Standard type

X1

X2

X3X4

X5, X6 (inside)

X7 (inside)

X8 to X10 (inside)X11 (inside)

X12

X13

X14

Y1

Y2 (inside)

Y3

Y4Y5

Y6, Y7 (inside)

Y8 to Y10 (inside)

Y11

Y12Y13

Y14 (inside)

Y15Y16, Y17

Y18

Y19

Z1, Z2 (inside)

Z3 (inside)

Z4 (inside)

Z5 (inside)

Z6 (inside)

Z7 (inside)

Z8 (inside)

Z9

Z10Z11

R1R2 (inside)

R3

R4 (inside)

R5, R6 (inside)

R7,R8

R9 (inside)

R10 (inside)

R11 (inside)

R12 (inside)

R13

R14, R15 (inside)R16 R17

R18 (inside)

C1

C2

C3 to C7

C8 to C12

23711-F6

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7-38

1.5.2 YK250XG, YK350XG, YK400XG Tool flange mount type


replacement timing

X-axis




Y-axis



Y10 KN3-M257K-000 ORING,1 1 O-ring for motor flange rabbetY11 KCY-M2197-000 DAMPER,2 1 Mechanical stopper damperY12 90189-02J106 NUT,HEXAGON 1 Mechanical stopper boltY13 90112-10J055 BOLT,HEX.SOCKETHEAD 1 Nut for mechanical stopper boltY14 KCY-M4850-100 PROXIMITYSW.ASSY 1 SensorY15 KCY-M1314-001 COVER,4 1 Y-axis coverY16 92903-03200 WASHERPLAIN 4 Washer for Y-axis cover screwY17 98902-03006 SCREWBINDINGHEAD 4 Y-axis cover screwY18 98902-03016 SCREW,BINDINGHEAD 4 Y-axis cover screwY19 KCY-M1321-000 LABEL 1 LabelontopofY-axiscover

Z-axis


Z10 91312-05016 BOLTHEX.SOCKETHEAD 1 Upper end stopper mounting boltZ11 KCY-M1790-000 SHAFT 1 Tool flangeZ12 91312-05014 BOLTHEX.SOCKETHEAD 2 Tool flange mounting boltZ13 92A08-05308 SCREW,SET 1 Tool flange mounting set screw

R-axis



R10 91312-05016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltR11 KN3-M2144-000 ORING,3 1 LowerO-ringofmotorR12 KCY-M4850-400 PROXIMITYSW.ASSY 1 SensorR13 KCY-M1840-000 SPLINE,BALL 1 Ball splineR14 90990-17J032 O-RING 1 Upper O-ring of ball spline nut (outside)R15 KN5-M181H-000 ORING,4 1 Upper O-ring of ball spline nut (inside)R16 90990-36J002 WASHER,SEAL 4 Seal washer for ball spline nut mounting boltR17 91312-04012 BOLT,HEX.SOCKETHEAD 4 Ball spline nut mounting boltR18 KCY-M1886-000 SEAL 1 End face seal inside speed reduction unit

Cables


C2KBF-M6211-004





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7-39


(Only the pars different from those of the standard type are shown.)

Z11

Z12

Z13

23712-F6

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7-40

1.5.3 YK250XG, YK350XG, YK400XG User wiring/tubing through spline type


replacement timing

X-axis




Y-axis



Y10 KN3-M257K-000 ORING,1 1 O-ring for motor flange rabbetY11 KCY-M2197-000 DAMPER,2 1 Mechanical stopper damperY12 90189-02J106 NUT,HEXAGON 1 Mechanical stopper boltY13 90112-10J055 BOLT,HEX.SOCKETHEAD 1 Nut for mechanical stopper boltY14 KCY-M4850-100 PROXIMITYSW.ASSY 1 SensorY15 KCY-M1314-001 COVER,4 1 Y-axis coverY16 92903-03200 WASHERPLAIN 4 Washer for Y-axis cover screwY17 98902-03006 SCREWBINDINGHEAD 4 Y-axis cover screwY18 98902-03016 SCREW,BINDINGHEAD 4 Y-axis cover screw

Z-axis


Z10 91312-05016 BOLTHEX.SOCKETHEAD 1 Upper end stopper mounting boltZ11 KCY-M1780-001 STOPPER,1 1 Upper end stopper

R-axis



R10 91312-05016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltR11 KN3-M2144-000 ORING,3 1 LowerO-ringofmotorR12 KCY-M4850-400 PROXIMITYSW.ASSY 1 SensorR13 KCY-M1840-000 SPLINE,BALL 1 Ball splineR14 90990-17J032 O-RING 1 Upper O-ring of ball spline nut (outside)R15 KN5-M181H-000 ORING,4 1 Upper O-ring of ball spline nut (inside)R16 90990-36J002 WASHER,SEAL 4 Seal washer for ball spline nut mounting boltR17 91312-04012 BOLT,HEX.SOCKETHEAD 4 Ball spline nut mounting boltR18 KCY-M1886-000 SEAL 1 End face seal inside speed reduction unitR19 KCY-M1872-000 SHAFT 1 Spline extension shaftR20 91312-03010 BOLT,HEX.SOCKETHEAD 4 Spline extension shaft mounting bolt

Cables


C2KBF-M6211-004





7

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7-41



R19

R20 (inside)

23713-F6

7

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7-42

1.5.4 YK250XG, YK350XG, YK400XG User wiring/tubing through spline and tool flange mount type


replacement timing

X-axis




Y-axis



Y10 KN3-M257K-000 ORING,1 1 O-ring for motor flange rabbetY11 KCY-M2197-000 DAMPER,2 1 Mechanical stopper damperY12 90189-02J106 NUT,HEXAGON 1 Mechanical stopper boltY13 90112-10J055 BOLT,HEX.SOCKETHEAD 1 Nut for mechanical stopper boltY14 KCY-M4850-100 PROXIMITYSW.ASSY 1 SensorY15 KCY-M1314-001 COVER,4 1 Y-axis coverY16 92903-03200 WASHERPLAIN 4 Washer for Y-axis cover screwY17 98902-03006 SCREWBINDINGHEAD 4 Y-axis cover screwY18 98902-03016 SCREW,BINDINGHEAD 4 Y-axis cover screw

Z-axis


Z10 91312-05016 BOLTHEX.SOCKETHEAD 1 Upper end stopper mounting boltZ11 KCY-M1790-000 SHAFT 1 Tool flangeZ12 91312-05014 BOLTHEX.SOCKETHEAD 2 Tool flange mounting boltZ13 92A08-05308 SCREW,SET 1 Tool flange mounting set screw

R-axis



R10 91312-05016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltR11 KN3-M2144-000 ORING,3 1 LowerO-ringofmotorR12 KCY-M4850-400 PROXIMITYSW.ASSY 1 SensorR13 KCY-M1840-000 SPLINE,BALL 1 Ball splineR14 90990-17J032 O-RING 1 Upper O-ring of ball spline nut (outside)R15 KN5-M181H-000 ORING,4 1 Upper O-ring of ball spline nut (inside)R16 90990-36J002 WASHER,SEAL 4 Seal washer for ball spline nut mounting boltR17 91312-04012 BOLT,HEX.SOCKETHEAD 4 Ball spline nut mounting boltR18 KCY-M1886-000 SEAL 1 End face seal inside speed reduction unitR19 KCY-M1872-000 SHAFT 1 Spline extension shaftR20 91312-03010 BOLT,HEX.SOCKETHEAD 4 Spline extension shaft mounting bolt

Cables


C2KBF-M6211-004





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7-43

User wiring/tubing through spline and tool flange mount type


R19

R20 (inside)

Z11

Z12

Z13

23714-F6

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1.5.5 YK500XG, YK600XG Z=200mm stroke type


replacement timing

X-axis

X1 KBF-M2110-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

X2 91312-04030 BOLTHEX.SOCKETHEAD 11 Speed reduction unit mounting boltX3 95302-05600 NUTHEXAGON 1 Nut for dogX4 98502-04030 SCREWPANHEAD(+) 1 LowerdogofspeedreductionunitX5 91312-04020 BOLTHEX.SOCKETHEAD 16 Speed reduction unit mounting boltX6 92903-04600 WASHERPLAIN 16 Washer for speed reduction unit mounting boltX7 KN4-M2143-000 ORING,1 1 Upper O-ring of speed reduction unitX8 90K94-8417FX MOTOR ASSY.,1 1 MotorX9 91312-06016 BOLTHEX.SOCKETHEAD 4 Motor mounting bolt

X10 90990-17J030 O-RING 1 Upper O-ring for motor flange rabbetX11 KN3-M4850-401 PROXIMITYSW.ASSY 1 SensorX12 KBF-M2193-001 STOPPER 1 Stopper blockX13 91312-06030 BOLTHEX.SOCKETHEAD 2 Bolt for stopper blockX14 KN3-M2596-002 DAMPER 2 Damper for stopper blockX15 91312-08016 BOLTHEX.SOCKETHEAD 2 Stopper boltX16 90990-28J091 WASHER,PLAIN 2 Washer for stopper boltX17 KBF-M1535-000 PLATE,2 2 X-axis arm end cap

Y-axis

Y1 KBF-M2510-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

Y2 KN4-M257K-000 ORING,1 1 LowerO-ringofspeedreductionunitY3 91312-03030 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltY4 95302-04600 NUTHEXAGON 1 Nut for dogY5 91312-03016 BOLT,HEX.SOCKETHEAD 16 Speed reduction unit mounting boltY6 98502-03030 SCREWPANHEAD(+) 1 Upper dog of speed reduction unitY7 KBF-M2511-000 TUBE 1 Coil tube of speed reduction unitY8 90K94-6217FY MOTOR ASSY.,2 1 MotorY9 KN3-M2143-000 ORING.,2 1 O-ring for motor flange rabbet

Y10 91312-05012 BOLTHEX.SOCKETHEAD 4 Motor mounting boltY11 KBF-M2587-001 STOPPER,1 1 Stopper blockY12 KN3-M2596-002 DAMPER 2 Damper for stopper blockY13 91312-05025 BOLTHEX.SOCKETHEAD 2 Bolt for stopper blockY14 91312-08016 BOLTHEX.SOCKETHEAD 1 For stopper boltY15 90990-28J091 WASHER,PLAIN 1 Washer for stopper boltY16 KBF-M1534-000 PLATE,1 2 Y-axis arm end cap Y17 KBF-M1314-001 COVER,4 1 Y-axis arm upper resin cover (Z-axis 200mm)Y18 92012-03008 BOLT,BUTTONHEAD 4 Mounting bolt for rear of Y-axis arm upper resin cover (Z-axis 200mm)Y19 91312-03020 BOLTHEX.SOCKETHEAD 2 Mounting bolt for front of Y-axis arm upper resin coverY20 KN3-M4850-301 PROXIMITYSW.ASSY 1 SensorY21 KBF-M1316-000 COVER,6 1 Y-axis motor resin cover

Z-axis

Z1 KBF-M4882-001 MOTOR ASSY.,3 1 Motor

These parts need to be replaced as a set.

Z2 KBP-M1750-001 SCREW,BALL 1 Ball screw (Z-axis 200mm)Z3 KBP-M1778-001 SLEEVE,LOCK 1 Nylon nutZ4 KBP-M1753-003 FLANGE 1 Motor and ball screw shaft connection flangeZ5 KBP-M1788-001 DAMPER,1 1 LowerenddamperZ6 91312-05014 BOLTHEX.SOCKETHEAD 4 Ball screw nut mounting boltZ7 91312-03020 BOLT,HEX.SOCKETHEAD 10 Motor and ball screw shaft connection flange mounting boltZ8 91312-05012 BOLTHEX.SOCKETHEAD 2 Motor mounting boltZ9 91312-05016 BOLTHEX.SOCKETHEAD 2 Motor mounting bolt

Z10 KBF-M1315-000 COVER,5 1 Z-axis motor coverZ11 KBF-M1780-001 STOPPER,1 1 Upper end stopperZ12 91312-06018 BOLTHEX.SOCKETHEAD 1 Upper end stopper mounting boltZ13 KBF-M1789-001 DAMPER,2 1 Upper end stopper damper

R-axis

R1 KBF-M1821-100 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

R2 KN4-M1896-000 ORING,2 1 LowerO-ringofspeedreductionunitR3 91312-03025 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltR4 95302-04600 NUTHEXAGON 1 Nut for upper dog of speed reduction unitR5 98502-03030 SCREWPANHEAD(+) 1 For upper dog of speed reduction unitR6 91312-03014 BOLT,HEX.SOCKETHEAD 16 Speed reduction unit mounting boltR7 90990-17J034 O-RING 1 O-ring for input part of speed reduction unitR8 KBF-M1840-002 SPLINE,BALL 1 Ball spline (Z-axis 200mm)R9 KBF-M1871-000 SHAFT,1 1 Upper collar of ball spline nut

R10 91312-04010 BOLTHEX.SOCKETHEAD 6 Ball spline nut mounting boltR11 90990-17J031 O-RING 1 Upper O-ring of ball spline R12 KBF-M4883-001 MOTOR ASSY.,4 1 MotorR13 91312-05014 BOLTHEX.SOCKETHEAD 4 Motor boltR14 90990-17J032 O-RING 1 LowerO-ringofmotorR15 KBF-M1886-000 SEAL 1 End face seal inside speed reduction unitR16 90933-01J003 BEARING 2 Upper bearing of ball splineR17 KN3-M4850-501 PROXIMITYSW.,ASSY. 1 Sensor

Cables

C1 KBF-M4843-003 HARNESS,MACHINE2 1 Machine harness

C2KBF-M6211-004



C3 KN0-M4872-002 CONNCTORE/L2 1 D-sub connector on base sideC4 KN0-M4839-001 PANEL,CONECTOR 1 HoodforD-subconnectoronbasesideC5 KN3-M2296-000 BOLT 2 D-sub connector on base side mounting boltC6 92903-03100 WASHERSPRING 2 D-sub connector on base side mounting spring washerC7 95302-03600 NUTHEXAGON 2 D-sub connector on base side mounting nutC8 KN0-M4871-002 CONNCTORE/L1 1 D-sub connector on Y-axis arm sideC9 KN0-M4839-001 PANEL,CONECTOR 1 HoodforD-subconnectoronY-axisarmside


7

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Z=200mm stroke type

Y11

Y12

Y13

Y17 Y18

Y19

Z10

Z11

Z12Z13

R1R2 (inside)

R4

R5

R6 (inside)

R7 (inside)

R8

R9 (inside)

R10R11 (inside)

R12 (inside)

R13 (inside)

R14 (inside)

R15 (inside)

R16 (inside)

R17 (inside)

X1

X2

X5,X6 (inside)

X7 (inside)

X10 (inside)

X15

X16

X17

C2

C3 to C7

X4

X8 (inside)

X9 (inside)

X11 (inside)

X12

X13

Y2 (inside)

X3X14

Y1

Y3

Y4

Y5 (inside)

Y6

Y7 (inside)

Y8 (inside)

Y14Y15

Y16

Y20 (inside)

Y9 (inside)

Y10 (inside)

Y21

C8 to C12

Z1 to Z9 (inside)C1

R3

23704-F9

7

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7-46



replacement timing

X-axis

X1 KBF-M2110-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

X2 91312-04030 BOLTHEX.SOCKETHEAD 11 Speed reduction unit mounting boltX3 95302-05600 NUTHEXAGON 1 Nut for dogX4 98502-04030 SCREWPANHEAD(+) 1 LowerdogofspeedreductionunitX5 91312-04020 BOLTHEX.SOCKETHEAD 16 Speed reduction unit mounting boltX6 92903-04600 WASHERPLAIN 16 Washer for speed reduction unit mounting boltX7 KN4-M2143-000 ORING,1 1 Upper O-ring of speed reduction unitX8 90K94-8417FX MOTOR ASSY.,1 1 MotorX9 91312-06016 BOLTHEX.SOCKETHEAD 4 Motor mounting bolt

X10 90990-17J030 O-RING 1 Upper O-ring for motor flange rabbetX11 KN3-M4850-401 PROXIMITYSW.ASSY 1 SensorX12 KBF-M2193-001 STOPPER 1 Stopper blockX13 91312-06030 BOLTHEX.SOCKETHEAD 2 Bolt for stopper blockX14 KN3-M2596-002 DAMPER 2 Damper for stopper blockX15 91312-08016 BOLTHEX.SOCKETHEAD 2 Stopper boltX16 90990-28J091 WASHER,PLAIN 2 Washer for stopper boltX17 KBF-M1535-000 PLATE,2 2 X-axis arm end cap

Y-axis

Y1 KBF-M2510-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

Y2 KN4-M257K-000 ORING,1 1 LowerO-ringofspeedreductionunitY3 91312-03030 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltY4 95302-04600 NUTHEXAGON 1 Nut for dogY5 91312-03016 BOLT,HEX.SOCKETHEAD 16 Speed reduction unit mounting boltY6 98502-03030 SCREWPANHEAD(+) 1 Upper dog of speed reduction unitY7 KBF-M2511-000 TUBE 1 Coil tube of speed reduction unitY8 90K94-6217FY MOTOR ASSY.,2 1 MotorY9 KN3-M2143-000 ORING.,2 1 O-ring for motor flange rabbet

Y10 91312-05012 BOLTHEX.SOCKETHEAD 4 Motor mounting boltY11 KBF-M2587-001 STOPPER,1 1 Stopper blockY12 KN3-M2596-002 DAMPER 2 Damper for stopper blockY13 91312-05025 BOLTHEX.SOCKETHEAD 2 Bolt for stopper blockY14 91312-08016 BOLTHEX.SOCKETHEAD 1 For stopper boltY15 90990-28J091 WASHER,PLAIN 1 Washer for stopper boltY16 KBF-M1534-000 PLATE,1 2 Y-axis arm end cap Y17 KBF-M1314-101 COVER,4 1 Y-axis arm upper resin cover (Z-axis 300mm)Y18 92012-03008 BOLT,BUTTONHEAD 6 Mounting bolt for rear of Y-axis arm upper resin cover (Z-axis 300mm)Y19 91312-03020 BOLTHEX.SOCKETHEAD 2 Mounting bolt for front of Y-axis arm upper resin coverY20 KN3-M4850-301 PROXIMITYSW.ASSY 1 SensorY21 KBF-M1316-000 COVER,6 1 Y-axis motor resin cover

Z-axis

Z1 KBF-M4882-001 MOTOR ASSY.,3 1 Motor



Z10 KBF-M1315-000 COVER,5 1 Z-axis motor coverZ11 KBF-M1780-001 STOPPER,1 1 Upper end stopperZ12 91312-06018 BOLTHEX.SOCKETHEAD 1 Upper end stopper mounting boltZ13 KBF-M1789-001 DAMPER,2 1 Upper end stopper damper

R-axis

R1 KBF-M1821-100 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

R2 KN4-M1896-000 ORING,2 1 LowerO-ringofspeedreductionunitR3 91312-03025 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltR4 95302-04600 NUTHEXAGON 1 Nut for upper dog of speed reduction unitR5 98502-03030 SCREWPANHEAD(+) 1 For upper dog of speed reduction unitR6 91312-03014 BOLT,HEX.SOCKETHEAD 16 Speed reduction unit mounting boltR7 90990-17J034 O-RING 1 O-ring for input part of speed reduction unitR8 KBF-M1840-102 SPLINE,BALL 1 Ball spline (Z-axis 300mm)R9 KBF-M1871-000 SHAFT,1 1 Upper collar of ball spline nut

R10 91312-04010 BOLTHEX.SOCKETHEAD 6 Ball spline nut mounting boltR11 90990-17J031 O-RING 1 Upper O-ring of ball spline R12 KBF-M4883-001 MOTOR ASSY.,4 1 MotorR13 91312-05014 BOLTHEX.SOCKETHEAD 4 Motor boltR14 90990-17J032 O-RING 1 LowerO-ringofmotorR15 KBF-M1886-000 SEAL 1 End face seal inside speed reduction unitR16 90933-01J003 BEARING 2 Upper bearing of ball splineR17 KN3-M4850-501 PROXIMITYSW.,ASSY. 1 Sensor

Cables

C1 KBF-M4843-003 HARNESS,MACHINE2 1 Machine harness

C2KBF-M6211-004





7

Spe

cific

atio

ns

7-47

Z=300mm stroke type

(Only the pars different from those of the Z=200mm stroke type are shown.)

Y17 Y18

Z1 to Z9 (inside)

R8

23705-F9

7

Spe

cific

atio

ns

7-48

1.5.7 YK600XGH Z=200mm stroke type


replacement timing

X-axis

X1 KBP-M2110-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

X2 95302-06600 NUTHEXAGON 1 Nut for dogX3 98502-05040 SCREWPANHEAD(+) 1 LowerdogofspeedreductionunitX4 91312-05040 BOLTHEX.SOCKETHEAD 27 Speed reduction unit mounting boltX5 KN5-M2159-000 0RING.,1 1 Upper O-ring of speed reduction unitX6 90K94-8E173X MOTOR ASSY.,1 1 MotorX7 91312-05016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltX8 90990-17J035 O-RING 1 Upper O-ring of motorX9 KN3-M4850-501 PROXIMITYSW.,ASSY. 1 Sensor

X10 KBP-M2193-001 STOPPER 1 Stopper blockX11 91312-08040 BOLTHEX.SOCKETHEAD 2 Stopper block mounting boltX12 KN5-M2196-001 DAMPER 2 Damper for stopper blockX13 90112-10J030 BOLTHEX.S.H 2 Stopper boltX14 90990-28J093 WASHER,PLAIN 4 Washer for stopper boltX15 KBP-M1535-000 PLATE,2 2 X-axis arm end cap

Y-axis

Y1 KBP-M2510-000 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

Y2 KN4-M2143-000 ORING,1 1 LowerO-ringofspeedreductionunitY3 91312-04030 BOLTHEX.SOCKETHEAD 11 Speed reduction unit mounting boltY4 95302-05600 NUTHEXAGON 1 Nut for dogY5 98502-04030 SCREWPANHEAD(+) 1 Upper dog of speed reduction unitY6 92903-04600 WASHERPLAIN 16 Washer for speed reduction unit mounting boltY7 91312-04020 BOLTHEX.SOCKETHEAD 16 Speed reduction unit mounting boltY8 KBP-M2511-000 TUBE 1 Coil tube of speed reduction unitY9 90K94-8417FY MOTOR ASSY.,2 1 Motor

Y10 91312-06016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltY11 90990-17J030 O-RING 1 LowerO-ringofmotorY12 KN3-M4850-501 PROXIMITYSW.,ASSY. 1 SensorY13 KBP-M1314-002 COVER,4 1 Y-axis arm upper resin cover (Z-axis 200mm)

Y14 92012-03008 BOLT,BUTTONHEAD 6Mounting bolt for rear of Y-axis arm upper resin cover (Z-axis 200mm)

Y15 91312-03016 BOLT,HEX.SOCKETHEAD 2Mounting bolt for front of Y-axis arm upper resin cover (Z-axis 200mm)

Y16 KBP-M2587-000 STOPPER,1 1 Stopper blockY17 KN5-M2196-001 DAMPER 2 Damper for stopper blockY18 91312-08035 BOLTHEX.SOCKETHEAD 2 Stopper block mounting boltY19 90112-10J025 BOLTHEX.S.H. 2 Stopper boltY20 90990-28J093 WASHER,PLAIN 4 Washer for stopper boltY21 KBP-M1316-000 COVER,6 1 Upper cover of Y-axis motorY22 KBF-M1535-000 PLATE,2 2 Y-axis arm end cap

Z-axis

Z1 KBP-M4882-000 MOTOR ASSY.,3 1 Motor



Z10 KBP-M1315-000 COVER,5 1 Z-axis motor coverZ11 KBP-M1780-001 STOPPER,1 1 Upper end stopperZ12 91312-06020 BOLTHEX.SOCKETHEAD 1 Upper end stopper mounting boltZ13 KBP-M1789-000 DAMPER,2 1 Upper end stopper damper

R-axis

R1 KBP-M1821-011 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in Chapter 5.

R2 KN3-M2159-000 ORING.,1 1 LowerO-ringofspeedreductionunitR3 91312-03025 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltR4 91312-03030 BOLT,HEX.SOCKETHEAD 1 Dog mounting boltR5 KBP-M1888-000 DOG,R 1 Upper dog of speed reduction unitR6 91312-03016 BOLT,HEX.SOCKETHEAD 16 Speed reduction unit mounting boltR7 90990-17J037 O-RING 1 O-ring for input part of speed reduction unitR8 KBP-M4883-000 MOTOR ASSY.,4 1 MotorR9 90990-17J038 O-RING 1 LowerO-ringofmotor

R10 91312-06016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltR11 KN3-M4850-901 PROXIMITYSW.ASSY 1 SensorR12 KBP-M1840-001 SPLINE,BALL 1 Ball spline (Z-axis 200mm)R13 91312-05014 BOLTHEX.SOCKETHEAD 6 Ball spline nut mounting boltR14 90990-17J036 O-RING 1 Upper O-ring of ball spline nutR15 KBP-M1886-000 SEAL 1 End face seal inside speed reduction unitR16 90933-01J022 BEARING 2 Upper O-ring of ball spline nut

Cables

C1 KBF-M4843-003 HARNESS,MACHINE2 1 Machineharness(YK600XGH)

C2KBF-M6211-004





7

Spe

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7-49

YK600XGH Z=200mm stroke type

Y13

Y15

Z11Z13

R1

R3

R4

R5

R7 (inside)

R8 (inside)

R11 (inside)

R12R14 (inside)

R16 (inside)

Y2 (inside)

Y7 (inside)

Y9 (inside)

Y10 (inside)

Y11 (inside)

Y14

Y16

Y17

Y18

Y22

Z1 to Z9 (inside)

Z10

Z12

R9 (inside)

R10 (inside)

R13

R15 (inside)

C8 to C12

X1

X2X3

X4

X5 (inside)

X6 (inside)

X7 (inside)

X8 (inside)

X9 (inside)

X10

X11

X12

X13

X14

X15

Y1

Y3

Y3

Y5

Y6 (inside)

Y12 (inside)

Y19Y20

Y21

C1

C2

C3 to C7

Y8 (inside)

R2 (inside)

R6 (inside)

23705-FA

7

Spe

cific

atio

ns

7-50

1.5.8 YK600XGH Z=400mm stroke type


replacement timing

X-axis




Y-axis







Z-axis





R-axis

R1 KBP-M1821-011 HARMONICDRIVEASSY. 1 Speed reduction unitSee section 1 in

Chapter 5.R2 KN3-M2159-000 ORING.,1 1 LowerO-ringofspeedreductionunitR3 91312-03025 BOLT,HEX.SOCKETHEAD 11 Speed reduction unit mounting boltR4 91312-03030 BOLT,HEX.SOCKETHEAD 1 Dog mounting boltR5 KBP-M1888-000 DOG,R 1 Upper dog of speed reduction unitR6 91312-03016 BOLT,HEX.SOCKETHEAD 16 Speed reduction unit mounting boltR7 90990-17J037 O-RING 1 O-ring for input part of speed reduction unitR8 KBP-M4883-000 MOTOR ASSY.,4 1 MotorR9 90990-17J038 O-RING 1 LowerO-ringofmotor

R10 91312-06016 BOLTHEX.SOCKETHEAD 4 Motor mounting boltR11 KN3-M4850-901 PROXIMITYSW.ASSY 1 SensorR12 KBP-M1840-101 SPLINE,BALL 1 Ball spline (Z-axis 400mm)R13 91312-05014 BOLTHEX.SOCKETHEAD 6 Ball spline nut mounting boltR14 90990-17J036 O-RING 1 Upper O-ring of ball spline nutR15 KBP-M1886-000 SEAL 1 End face seal inside speed reduction unitR16 90933-01J022 BEARING 2 Upper bearing of ball spline

Cables

C1 KBF-M4843-003 HARNESS,MACHINE2 1 Machineharness(YK600XGH)

C2KBF-M6211-004





7

Spe

cific

atio

ns

7-51

YK600XGH Z=400mm stroke type

(Only the parts different from those of the YK600XGH Z=200mm stroke type are shown.)

Y13Y14

Y15

Z1 to 9 (inside)

R12

23706-FA

7

Spe

cific

atio

ns

7-52



replacement timing

X-axis




Y-axis







Z-axis





R-axis




Cables

C1 KBP-M4843-001 HARNESS,MACHINE2 1 Machine harness (YK700XG, YK800XG)

C2KBF-M6211-004





7

Spe

cific

atio

ns

7-53

YK700XG, YK800XG Z=200mm stroke type


C1

23703-FB

7

Spe

cific

atio

ns

7-54



replacement timing

X-axis




Y-axis







Z-axis





R-axis




Cables


C2KBF-M6211-004





7

Spe

cific

atio

ns

7-55



C1

Y14Y13

Y15

R12

Z1 to Z9 (inside)

23704-FB

7

Spe

cific

atio

ns

7-56



replacement timing

X-axis




Y-axis







Z-axis





R-axis




Cables


C2KBF-M6211-004





7

Spe

cific

atio

ns

7-57



C1

23703-FD

7

Spe

cific

atio

ns

7-58



replacement timing

X-axis




Y-axis







Z-axis





R-axis




Cables


C2KBF-M6211-004





7

Spe

cific

atio

ns

7-59



C1

Y14Y13

Y15

R12

Z1 to Z9 (inside)

23704-FD

SCARA Robot

© YAMAHA MOTOR CO., LTD. IM Operations

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.

User’s Manual

Dec. 2011Ver. 1.00This manual is based on Ver. 1.00 of Japanese manual.

Revision record

Manual version Issue date Description

Ver. 1.00 Dec. 2011 First edition

yamaha scara robot yk-xg - yrg incthe robot operator, a bystander or a person inspecting or...

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