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Yamaha RCX222 User Manual

Yamaha RCX222
524 pages
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RCX222
EUR2153130
E99
Ver. 1.30
UserʼsManual
YAMAHA2-AXISROBOTCONTROLLER

Table of Contents

Questions and Answers:

Yamaha RCX222 Specifications

General IconGeneral
Controlled axes4 axes
I/O pointsInput: 32 points, Output: 32 points
Communication interfaceRS-232C
Operating Voltage24 VDC ±10%
Operating Temperature0°C

Summary

Safety Instructions

1. Safety Information

General precautions for safe and correct use of YAMAHA robots and controllers, and warnings about potential hazards.

2. Signal words used in this manual

Explains the meaning of DANGER, WARNING, CAUTION, and NOTE symbols used for safety instructions.

3. Warning labels

Describes warning labels attached to the robot body and controller to alert operators to potential hazards.

3.1.1 Warning label messages on robot and controller

Details specific warning messages and instructions for Danger, Warning, and Caution labels on robots and controllers.

3.2 Warning symbols

Explains warning symbols for electrical shock hazard, high temperature hazard, and general caution.

4. Important precautions for each stage of the robot life cycle

Describes major precautions for using robots and controllers throughout their life cycle.

4.1 Precautions for using robots and controllers

General precautions for safe use, including applications where robots cannot be used and operator qualifications.

4.4 Moving and installation

Precautions for moving and installing robots, including installation environment and moving procedures.

4.4.1 Precautions for robots

Precautions for robots regarding installation environment (magnetic fields, interference, flammable gases) and moving procedures.

4.4.2 Precautions for robot controllers

Precautions for robot controllers concerning installation environment, installation, and connections.

4.5 Safety measures

General safety measures including referring to warning labels, creating work instructions, and taking basic safety actions.

4.5.1 Safety measures

Details safety measures such as referring to manuals, understanding work instructions, and taking basic safety actions.

4.5.2 Installing a safety enclosure

Instructions on installing a safety enclosure to prevent contact with moving parts and potential injuries.

4.6 Operation

General safety measures and checks to ensure safe robot operation.

4.6.1 Trial operation

Procedures for performing trial operation after installation, including safety enclosure requirements and pre-operation checks.

4.6.2 Automatic operation

Checkpoints before starting automatic operation and procedures when errors occur.

4.6.3 Precautions during operation

Precautions during operation, including handling damage, abnormal conditions, and high temperatures.

4.7 Inspection and maintenance

Guidelines for performing daily and periodic inspections, pre-operation checks, and record keeping.

4.7.1 Before inspection and maintenance work

Precautions before starting inspection or maintenance, including not attempting un-described work and contacting distributors.

4.7.2 Precautions during service work

Precautions during service work, such as removing motors, handling magnets, pneumatic equipment, and cooling fans.

5. Emergency action when a person is caught by robot

Describes emergency actions to release the robot axis if a person is caught between the robot and mechanical parts.

7. Using the robot safely

General guidance on safely using the robot.

7.2 Robot protective functions

Describes protective functions for YAMAHA robots, including overload detection, overheat detection, soft limits, and mechanical stoppers.

7.4 Special training for industrial robot operation

Stresses the need for appropriate training and skills for personnel handling robots for tasks like teaching and maintenance.

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

[1] When connecting the power supply to the robot controller

Emphasizes secure connection to the ground terminal for safety and noise prevention.

Chapter 1 USING THE ROBOT SAFELY

Chapter 2 SYSTEM OVERVIEW

4.1 RPB programming box

Describes the RPB as a hand-held device for robot operations, including manual operations, program input, editing, teaching, and parameter settings.

5. Basic sequence from installation to operation

Outlines the basic sequence from installation to actual operation, including wiring, power on, initial settings, data setting, and trial operation.

Chapter 3 INSTALLATION

2. Installing the robot controller

Lists installation conditions and cautions for carrying, connector handling, cable length, panel installation, environmental factors, and fan vents.

2.1 Installation conditions

Lists installation conditions and cautions for carrying, connector handling, cable length, panel installation, environmental factors, and fan vents.

4. Connecting to the power

Provides an example connection diagram for supplying power to the controller, including leakage breaker, noise filter, and contactor.

4.1 Connection example

Provides an example connection diagram for supplying power to the controller, including leakage breaker, noise filter, and contactor.

4.2 Power supply and ground terminals

Details power supply voltage specifications, wire cross-sections, grounding requirements, and tightening torque for terminals.

5. Robot connections

Explains how to connect robot cables to the controller's XM, YM, and ROB I/O connectors, with important warnings.

5.1 Connecting the robot cables

Details connecting robot cables to controller connectors and emphasizes checking for damage and proper grounding.

6. Connecting the RPB programming box

Explains how to connect the RPB to the controller's RPB connector and the importance of using a terminator if the RPB is not connected.

9. Connecting the absolute battery

Guides on connecting absolute batteries to the BAT A or BAT B connector for data retention, explaining backup time with one or two batteries.

13. Checking the robot controller operation

Explains how to check controller operation after making connections, using a special connector and applicable robot.

13.1 Cable connection

Details the cable connections required before checking controller operation, including power supply, robot cable, RPB, and safety connector.

13.2 Operation check

Describes how to check controller operation after turning on power, distinguishing between normal and abnormal operation based on LED indicators.

Chapter 4 OPERATION

3. RPB programming box

Describes the RPB programming box, its part names, main functions, connection to the controller, and screen settings adjustment.

3.3 Connection to the robot controller

Details connecting the RPB programming box to the controller's RPB connector and securing the cable.

4. Turning power on and off

Explains how to turn the robot controller power on and off, assuming external circuits are correctly connected.

6. Emergency stop

Explains how to press the emergency stop button on the RPB to immediately stop robot operation and displays the resulting screen message.

6.1 Emergency stop reset

Guides on how to reset the emergency stop status to return to normal operation, including canceling the flag and turning on motor power.

6.2 Overload error reset

Explains how to reset overload errors to restore robot operation, including the requirement for software version 9.36 onwards.

7. Mode configuration

Describes the robot operation modes: SERVICE, AUTO, PROGRAM, MANUAL, and SYSTEM, and how to select them.

7.1 Basic operation modes

Classifies robot operation into five basic modes: SERVICE, AUTO, PROGRAM, MANUAL, and SYSTEM, and how to select them.

8. "SERVICE" mode

Explains that SERVICE mode is used for safe maintenance work within the safety enclosure, with specific limitations on operation and speed.

9. "AUTO" mode

Explains that AUTO mode executes robot language programs and related tasks, showing the initial AUTO mode screen.

9.1 Automatic operation

Details continuous program command execution during automatic operation, emphasizing prerequisites like return-to-origin and debugging.

10. "PROGRAM" mode

Explains how to edit, delete, and manage robot language programs in PROGRAM mode, showing the initial screen.

10.2 Program editing

Details how to enter program editing mode, move the cursor, enter commands, and finish editing.

Chapter 5 PARALLEL I/O INTERFACE

1.4 Connecting the power supply

Explains connecting a 24V DC power supply to the DIO option board's power connector.

Chapter 6 SAFETY I/O INTERFACE

1. SAFETY I/O interface overview

Explains the robot controller's SAFETY I/O interfaces for compatibility and describes I/O terminals and connection methods.

1.4 Emergency stop input signal connections

Illustrates emergency stop input signal connections for standard RPB and RPB-E with external circuits.

Chapter 7 RS-232C INTERFACE

Chapter 9 TROUBLESHOOTING

1. Error Messages

Lists robot controller error messages classified by group number, detailing code, meaning/cause, and action.

1.1 Robot controller error messages

Lists robot controller error messages classified by group number, detailing code, meaning/cause, and action.

[ 2] Robot operating area errors

Details errors related to robot operating area, such as over soft limit, missing standard coordinates, and failed calibrations.

[ 5] Robot language syntax (compiling) errors

Lists syntax errors encountered during robot language compiling, such as syntax errors, data errors, and illegal commands.

[ 6] Robot language execution errors

Details execution errors in robot language, including illegal commands, task errors, and path errors.

[ 9] Memory errors

Lists errors related to memory issues, such as program destroyed, point data destroyed, and memory full.

[10] System setting or hardware errors

Covers errors related to system settings or hardware, like robot disconnected and driver unit version mismatches.

[12] I/O and option board errors

Lists errors related to I/O and option boards, such as communication errors and hardware failures.

[13] RPB errors

Details errors specific to the RPB, including communication errors, parity errors, and version mismatches.

[17] Motor control errors

Lists errors related to motor control, including watchdog errors, over current, over load, and servo errors.

[21] Major software errors

Lists major software errors such as system errors and watchdog errors.

[22] Major hardware errors

Lists major hardware errors like AC power low, DC24V power low, and abnormal voltage/temperature.

2. Troubleshooting

Provides guidance on troubleshooting common issues, including symptoms, causes, check items, and corrective actions.

2.2 Acquiring error information

Explains methods for acquiring error information from the RPB or via RS-232C connection to a PC.

2.3 Troubleshooting checkpoints

Provides a table of common symptoms, possible causes, check items, and corrective actions for installation, power supply, and robot operation issues.

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