Yamaha RCX240 Bedienungsanleitung

RCX240

EUR6127206

E107

Ver. 2.06

UserʼsManual

YAMAHA4-AXISROBOTCONTROLLER

Introduction 1

Introduction

Our sincere thanks for your purchase of this YAMAHA robot controller.

This manual explains how to install and operate the YAMAHA robot controller. Be sure to read

this manual carefully as well as related manuals and comply with their instructions for using the

YAMAHA robot controller safely and correctly.

Refer to the "Programming Manual" that comes with the robot controller for detailed information on

robot programs.

2Before using the robot controller (Be sure to read the following notes)

Before using the robot controller (Be sure to read the following notes) 3

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

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

Failing to perform these tasks will require absolute reset for setting the origin position each time

the power is turned on or may cause abnormal operation (vibration, noise).

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

Always make a secure connection to the ground terminal on the robot controller to ensure

safety and prevent malfunctions due to noise.

Reference

Refer to "4. Connecting to the power" in Chapter 3, "INSTALLATION".

[2] When connecting the battery cable to the robot controller

The absolute batteries shipped with the controller are unused, and the battery connectors are

left disconnected to prevent discharge. After installing the controller, always be sure to connect

the absolute batteries while referring to "9. Connecting the absolute battery" in Chapter 3 before

connecting the robot cables.

An error (relating to absolute settings) is always issued if the robot controller power is turned

on without connecting the absolute batteries, so the origin position cannot be detected. This

means the robot connected to this controller cannot be used with absolute specifications.

[3] When connecting robot cables to the robot controller

Be sure to keep robot cables separate from the robot controller power connection lines and

other equipment power lines. Using in close contact with lines carrying power may cause

malfunctions or abnormal operation.

Reference

Absolute reset is always required when the robot controller power is ﬁrst

turned on after connecting the robot cable to the robot controller. Perform

absolute reset while referring to "11.9 Absolute reset" in Chapter 4,

"OPERATION".

Absolute reset is also required after the robot cable was disconnected from

the robot controller and then reconnected.

[4] Setting the maximum speed

When operating a ball screw driven robot, the ball screw’s free length will increase as the

movement stroke increases, and the resonant frequency will drop. This may cause the ball screw

to resonate and vibrate severely depending on the motor rotation speed. (The speed at which

resonance occurs is called the critical speed.)

To prevent this resonance, the maximum speed must be reduced depending on the robot

model when the movement stroke increases. Refer to our robot catalog for the maximum speed

settings.

2Before using the robot controller (Be sure to read the following notes)

Before using the robot controller (Be sure to read the following notes) 3

cCAUTION

Continuous operation while the ball screw is resonating may cause the ball

screw to wear out prematurely.

[5] Duty

To achieve maximum service life for the single-axis robots, the robot must be operated

within the allowable duty (50%).

The duty is calculated as follows:

Duty (%) = Operation time

Operation time + Non-operation time ×100

If the robot duty is too high, an error such as "overload" or "overheat" occurs. In this case, increase

the stop time to reduce the duty.

4Overview of the RCX series

Overview of the RCX series

The YAMAHA RCX series robot controllers were developed based on years of YAMAHA experience

and proven achievements in robotics and electronics. These controllers are specifically designed to

operate YAMAHA industrial robots efficiently and accurately.

Despite their compact size, the RCX series controllers operate efficiently as multi-axis controllers

with a variety of functions.

Major features and functions are:

1. Multi-task function

Up to 8 tasks* can be run simultaneously in a specified priority. (Low priority tasks are halted

while high priority tasks are run.)

I/O parallel processing and interrupt processing are also available, so that operational efficiency

of the total robot system including peripheral units is greatly improved.

(*: Refer to the programming manual for more details on multi-tasking.)

2. Robot language

The RCX series controller comes with a BASIC-like high-level robot language that conforms

to the industrial robot programming language SLIM *1. This robot language allows easy

programming even of complex movements such as multi-task operations and uses a compiling

method *2for rapid execution of programs.

(*1: Standard Language for Industrial Manipulators)

(*2: This compiling method checks the syntax in a robot language program, converts it into

intermediate codes, and creates an execution file (object file) before actually performing the

program.)

3. Movement command

• Arch motion

Spatial movement during pick-and-place work can be freely set according to the work

environment. This is effective in reducing cycle time.

• Three-dimensionalCPcontrol

Allows three-dimensional interpolation control of linear and circular movements.

4. Maintenance

Software servo control provides unit standardization. This allows connection to most YAMAHA

robot models and simplifies maintenance.

5. CE marking *

As a YAMAHA robot series product, the RCX series robot controller is designed to conform to

machinery directives, low-voltage directives and EMC (Electromagnetic compatibility) directives.

In this case, the robot controller is set to operate under "SAFE" mode. (* For CE marking

compliance, see the CE marking supplement manual.)

This manual explains how to handle and operate the YAMAHA robot controllers correctly and

effectively, as well as I/O interface connections.

Read this manual carefully before installing and using the robot controller. Also refer to the

separate "Programming Manual" and "Robot User's Manual" as needed.

General contents i

General contents General contents

Introduction 1

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

Overview of the RCX series 4

General contents i

Chapter 1 USING THE ROBOT SAFELY

1. Safety information 1-1

2. Particularly important cautions 1-2

2.1 System design safety points 1-2

2.2 Installation safety points 1-3

2.3 Wiring safety points 1-4

2.4 Start-up and maintenance safety points 1-5

2.5 Safety precautions during robot operation 1-7

2.6 Precautions for disposal 1-7

3. Safety measures for robots 1-8

3.1 Safety measures for SCARA type robots 1-8

3.2

Safety measures for single-axis robots, Cartesian robots,

and pick & place robots 1-8

4. Motor overload precautions 1-8

5. Warning labels and marks 1-8

5.1 Warning labels 1-8

5.2 Warning marks 1-9

Industrial robot operating and maintenance personnel

1-9

7. Make daily and periodic inspections 1-9

8. Freeing a person caught by the robot 1-10

9. Warranty 1-12

10. Operating environment 1-13

Chapter 2 SYSTEM OVERVIEW

1. System overview 2-1

ii General contents

General contents iii

1.1 Main system configuration 2-1

1.2 Axis definition for the RCX240 2-3

2. External view and control system 2-4

2.1 RCX240 external view 2-4

2.2 Controller system 2-4

3. Optional devices 2-5

3.1 RPB programming box 2-5

3.2 Expansion I/O board 2-5

3.3 Regenerative unit 2-5

4. Basic sequence from installation to operation 2-6

4.1 When using absolute type axes only 2-6

4.2 When using incremental type axes only 2-7

4.3 When using both absolute and incremental type axes 2-8

Chapter 3 INSTALLATION

1. Unpacking 3-1

1.1 Packing box 3-1

1.2 Unpacking 3-1

2. Installing the robot controller 3-2

2.1 Installation conditions 3-2

2.2 Installation methods 3-3

3. Connector names 3-6

4. Connecting to the power 3-7

4.1 Power supply connection example 3-7

4.2 Power supply and ground terminals 3-8

4.3 AC power connector wiring 3-9

4.4

Considering power capacity and generated heat amount

3-10

4.5 Installing an external leakage breaker 3-12

4.6 Installing a circuit protector 3-12

4.7 Installing an electromagnetic contactor 3-13

4.8 Installing a noise filter 3-13

4.9 Installing a surge absorber 3-14

5. Connecting the robot cables 3-15

6. Connecting the RPB programming box 3-16

7. I/O connections 3-17

8. Connecting a host computer 3-18

ii General contents

General contents iii

9. Connecting the absolute battery 3-19

10. Replacing the absolute battery 3-21

11. Connecting a regenerative unit 3-22

12.

Precautions for cable routing and installation

3-23

12.1 Wiring methods 3-23

12.2 Precautions for installation 3-25

12.3 Methods of preventing malfunctions 3-25

13. Checking the robot controller operation 3-26

13.1 Cable connection 3-26

13.2 Emergency stop input signal connection 3-27

13.3 Operation check 3-28

Chapter 4 OPERATION

1. Operation overview 4-1

2. The RCX robot controller 4-2

2.1 Part names 4-2

2.2 Main functions 4-2

3. RPB programming box 4-3

3.1 Part names 4-3

3.2 Main functions 4-3

3.3 Connection to the robot controller 4-5

3.4 Changing the RPB screen settings 4-6

4. Turning power on and off 4-7

5. Operation keys 4-9

5.1 RPB screen 4-9

5.2 Operation key layout 4-11

5.3 Basic key operation 4-12

5.4 Function keys 4-13

5.5 Control keys 4-15

5.6 Data keys 4-17

5.7 Other keys 4-17

6. Emergency stop 4-18

6.1 Emergency stop reset 4-19

7. Mode configuration 4-21

7.1 Basic operation modes 4-21

iv General contents

General contents v

7.2 Other operation modes 4-22

7.3 Mode hierarchy 4-23

8. "SERVICE" mode 4-28

8.1 Operation device 4-28

8.2 Prohibition of "AUTO" mode operation 4-28

8.3 Hold-to-Run function 4-28

8.4 Limitations on robot operating speed 4-29

9. "AUTO" mode 4-30

9.1 Automatic operation 4-33

9.2 Stopping the program 4-34

9.3 Resetting the program 4-35

9.4 Switching task display 4-37

9.5 Switching the program 4-38

9.6 Changing the automatic movement speed 4-39

9.7 Executing the point trace 4-40

9.7.1 PTP motion mode 4-42

9.7.2 ARCH motion mode 4-45

9.7.3 Linear interpolation motion mode 4-49

9.8 Direct command execution 4-52

9.9 Break point 4-53

9.9.1 Setting break points 4-53

9.9.2 Deleting break points 4-54

9.10 Executing a step 4-55

9.11 Skipping a step 4-56

9.12 Executing the next step 4-56

10. "PROGRAM" mode 4-57

10.1 Scrolling a program listing 4-58

10.2 Program editing 4-59

10.2.1 Cursor movement 4-61

10.2.2 Insert/Overwrite mode switching 4-62

10.2.3 Inserting a line 4-63

10.2.4 Deleting a character 4-63

10.2.5 Deleting a line 4-64

10.2.6 User function key display 4-64

10.2.7 Quitting program editing 4-65

10.2.8 Copying or cutting lines 4-65

10.2.9 Backspace 4-67

10.2.10 Line jump 4-67

10.2.11 Searching a character string 4-68

10.3 Directory 4-70

10.3.1 Cursor movement 4-72

10.3.2 Registering a new program name 4-72

10.3.3 Directory information display 4-73

10.3.4 Copying a program 4-74

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