Omron SCARA YRC Series Supporting Supplement Manual
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Omron SCARA YRC Series Supporting Supplement Manual

Omron SCARA YRC Series Supporting Supplement Manual

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Cat. No. I154E-EN-02
SCARA Robots
ZX-T Series
YRC Series
CE marking
SUPPORTING
SUPPLEMENT MANUAL

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Summary of Contents for Omron SCARA YRC Series

  • Page 1 Cat. No. I154E-EN-02 SCARA Robots ZX-T Series YRC Series CE marking SUPPORTING SUPPLEMENT MANUAL...

  • Page 3: Table Of Contents

    General Contents Introduction Safety Guide 1. Safety information 2. Particularly important cautions System design safety points …………………………………………………………… 2 Installation safety points ………………………………………………………………… 2 Wiring safety points ……………………………………………………………………… 3 Start-up and maintenance safety points …………………………………………… 3 Safety precautions during robot operation ………………………………………… 4 Precautions for disposal …………………………………………………………………...
  • Page 4 1.2.1 Basic configuration ………………………………………………………………………………… 2-2 1.2.2 Power supply and emergency stop system circuit configuration ………………………… 2-3 Programming box (PB) ……………………………………………………………… 2-4 1.3.1 Part names and functions ………………………………………………………………………… 2-4 1.3.2 PB connector ………………………………………………………………………………………… 2-5 SERVICE mode ………………………………………………………………………… 2-6 1.4.1 What is SERVICE mode? …………………………………………………………………………… 2-6 1.4.2 Flow for enabling the SERVICE mode functions ………………………………………………...
  • Page 5 Introduction Thanks for purchasing the OMRON robot controller YRC. This manual describes the CE marking for the YRC. When shipping the YRC to Europe or when using it in Europe, always read this manual thoroughly to use the controller correctly.
  • Page 7 Safety Guide Contents Safety information Particularly important cautions System design safety points Installation safety points Wiring safety points Start-up and maintenance safety points Safety precautions during robot operation Precautions for disposal Safety measures for robots Safety measures for SCARA type robots Motor overload precautions Warning labels and marks Warning labels...

  • Page 9: Safety Information

    Warnings and cautions listed in this manual relate to OMRON robot controllers. To ensure safety of the user's final system that includes OMRON robots and controllers, please take appropriate safety measures as required by the user's individual system.

  • Page 10: Particularly Important Cautions

    Particularly important cautions for handling and operating the robot and controller are described below. Additional cautions are also described in each chapter. Be sure to comply with those instructions to ensure safety. System design safety points DANGER • OMRON ROBOT CONTROLLERS AND ROBOTS ARE DESIGNED AND MANUFACTURED FOR GENERAL-PURPOSE INDUSTRIAL EQUIPMENT. THEY SHOULD NOT BE USED IN THE FOLLOWING APPLICATIONS: • MEDICAL EQUIPMENT OR SYSTEMS WHICH WILL AFFECT HUMAN LIFE • EQUIPMENT DESIGNED TO CARRY OR TRANSPORT PERSONS • EQUIPMENT OR SYSTEMS WHICH WILL SERIOUSLY AFFECT SOCIETY OR PUBLIC POLICY...

  • Page 11: Wiring Safety Points

    Wiring safety points WARNING • ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE STARTING INSTALLATION OR WIRING WORK. FAILURE TO SHUT OFF ALL PHASES MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE. CAUTION • Make sure that no foreign matter such as cutting chips or wire scraps enter the robot controller. Malfunctions, breakdown or fire may result if they have entered. • Always store the cables connected to the robot controller in a conduit or clamp them securely in place. If the cables are not stored in a conduit or properly clamped, excessive play or movement or mistakenly pulling on the cable may damage the connector or cables, and poor cable contact may cause equipment malfunctions. • Do not modify the cables and do not place any heavy object on them. Handle them carefully to avoid damage. Damaged cables may cause malfunction or electrical shock.

  • Page 12: Safety Precautions During Robot Operation

    • DO NOT DISASSEMBLE OR MODIFY ANY PART IN THE ROBOT CONTROLLER AND PROGRAMMING BOX. DO NOT OPEN ANY COVER. FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE ELECTRICAL SHOCK, BREAKDOWN, MALFUNCTION, INJURY, OR FIRE. • IF A COMPONENT USED IN THE ROBOT OR CONTROLLER NEEDS TO BE REPLACED OR REPAIRED, ALWAYS FOLLOW THE INSTRUCTIONS FROM OMRON. INSPECTION AND MAINTENANCE OF THE CONTROLLER OR ROBOT BY ANY PERSON WHO DOES NOT HAVE THE REQUIRED KNOWLEDGE AND EXPERTISE IS DANGEROUS AND MUST BE AVOIDED. • WHEN PERFORMING MAINTENANCE OR INSPECTION OF THE ROBOT CONTROLLER UNDER OUR INSTRUCTIONS, WAIT AT LEAST 30 MINUTES FOR THE YRC SERIES AFTER TURNING THE POWER OFF. SOME COMPONENTS IN THE ROBOT CONTROLLER MAY BE HOT OR STILL RETAIN A HIGH VOLTAGE SHORTLY AFTER OPERATION, SO BURNS OR ELECTRICAL SHOCK MAY OCCUR IF THOSE PARTS ARE TOUCHED. • DURING STARTUP OR MAINTENANCE WORK, DISPLAY AN EASY TO UNDERSTAND SIGN OR MESSAGE ON THE PROGRAMMING UNIT OR OPERATION PANEL TO PREVENT ANYONE OTHER THAN PERSONNEL FOR THAT WORK FROM MISTAKENLY OPERATING A START OR SELECTOR SWITCH. IF NEEDED, TAKE OTHER MEASURES SUCH AS LOCKING THE COVER ON THE OPERATION PANEL. • DECIDE ON "WORK INSTRUCTIONS" IN CASES WHERE PERSONNEL MUST WORK WITHIN THE ROBOT'S WORKING ENVELOPE TO PERFORM STARTUP OR MAINTENANCE WORK. MAKE SURE THE WORKERS KNOW THESE "WORK INSTRUCTIONS" WELL. CAUTION • When using ferrite cores for noise elimination, fit them to the power cable as close to the robot controller and/or the robot as possible, to prevent malfunctions due to noise. • Back up the robot controller internal data in an external storage device. The robot controller internal data (programs, point data, etc.) may be lost or deleted for unexpected reasons. Always make a backup of the internal data.

  • Page 13: Safety Measures For Robots

    Warning labels and marks Warning labels The warning labels shown below are affixed to the controller. To use the OMRON robot and controller safely and correctly, be sure to observe the instructions and caution on the labels. "Read Instruction Manual" label...

  • Page 14: Warning Marks

    Warning marks The following warning marks are shown on the controller. To use the OMRON robot and controller safely and correctly, be sure to observe the instructions and caution of the marks. "Electric Hazard" mark This mark indicates that a high voltage is present.
  • Page 15 Chapter 1 CE MARKING Contents CE Marking Safety standards Cautions regarding compliance with EC Directives Applicable EC Directives and their related standards Robots subject to CE Marking Cautions regarding the official language of EU countries Usage conditions...

  • Page 17: Safety Standards

    EC Directives. ● Differences between OMRON robots (robot and controller) and robot systems A OMRON robot (robot and controller) is just one component in a robot system, and is not, in itself, a robot system. This is because a OMRON robot does not include the "end effector(s)" or "any equipment, devices, or sensors required for the robot to perform its tasks", as defined in "Industrial Robot system" of the ISO 10218-1: 2011...

  • Page 18: Applicable Ec Directives And Their Related Standards

    Applicable EC Directives and their related standards The tables below show directives and related standards applied to OMRON robots. YRC robot controller ■ EC Directive Related Standards EN ISO12100 : Safety of machinery - General principles for design - Risk assessment and risk reduction Machinery Directive EN ISO10218-1 : Robots and robotic devices - Safety requirements for industrial robots - Part 1: Robots 2006/42/EC EN60204-1 : Safety of machinery - Electrical equipment of machines - Part 1: General requirements EN 55011 : Industrial, scientific and medical equipment - Radio-frequency disturbance characteristics - EMC Directive...

  • Page 19: Usage Conditions

    OMRON robot series products are designed for use in industrial environments. (Applicable definition relating to the EMC Directive: Refer to the EN61000-6-2 Standard, Clause 1 "Scope".) In order to conform to the EMC Directive, the customer must evaluate the finished product (entire system) and take necessary countermeasures. Refer to EMC countermeasures for single units of OMRON robots, which are described in the next chapter in this manual. ● Installation conditions • Protective structure OMRON robots are classified as built-in equipment and have a "Class I"...
  • Page 21 Chapter 2 YRC series Contents System overview System overview 1.1.1 Main system configuration Control system configuration 1.2.1 Basic configuration 1.2.2 Power supply and emergency stop system circuit configuration Programming box (PB) 1.3.1 Part names and functions 1.3.2 PB connector SERVICE mode 1.4.1 What is SERVICE mode? 1.4.2...

  • Page 23: System Overview

    YRC robot controller ■ Example: R6YXG500 All the axes on the robot controller are used as the main robot axes. System for controlling one robot OMRON robot External device (PLC etc.) External emergency stop circuit Emergency stop button Safety relay...

  • Page 24: Control System Configuration

    Control system configuration 1.2.1 Basic configuration The basic block diagram of the YRC robot controller system is shown below. YRC basic block diagram ■ Basic block diagram DRIVER POWER CN10 MOTOR HEATSINK DRIVER 2 CN14 CN12 ROB I/O XY BATT XY DRIVER 1 ROB I/O ZR BATT ZR...

  • Page 25: Power Supply And Emergency Stop System Circuit Configuration

    1.2.2 Power supply and emergency stop system circuit configuration The control system's power supply system and emergency stop system circuit block diagram are shown below. Power supply and emergency stop circuit block diagram Emergency stop button BATTERY Selector switch +3.6V CONTROL CIRCU IT BLOCK...

  • Page 26: Programming Box (Pb)

    Programming box (PB) The programming box (PB) is a hand-held unit specifically designed to connect to the controller, in order to perform various operations. The PB allows all operations including manual operation of the robot, programming and editing, teaching, and parameter setting. 1.3.1 Part names and functions The PB has an emergency stop button and an enable switch.

  • Page 27: Pb Connector

    1.3.2 PB connector The PB has an emergency stop button and an enable switch. The contact outputs of these can be used to connect to the emergency stop circuit of the entire equipment via the SAFETY connector on the controller. This section describes signal connections. CAUTION • Do not change or modify the cable and connector. Along with the input/output signals for the programming box, the PB connector includes signals used to configure an external safety circuit, and so changing or modifying the cable and connector is very dangerous. • Always configure an external safety circuit by using the SAFETY connector. Although the PB has an emergency stop button and an enable switch, they do not function independently because the controller is designed on the assumption that an external safety circuit is configured.

  • Page 28: Service Mode

    SERVICE mode This section describes SERVICE mode. 1.4.1 What is SERVICE mode? SERVICE mode is used to perform work using the PB within the safety enclosure of the robot system. This mode is enabled only when the controller is set to SAFE mode. The CE marking compliant controllers are set to SAFE mode at the time when they are shipped. CAUTION The CE marking compliant controllers are always set to SAFE mode. Basic operation mode Basic operation modes "SERVICE" mode "DI/DO "AUTO" "MANUAL" "PROGRAM" "SYSTEM" "UTILITY" monitor" mode mode mode mode mode mode SERVICE mode includes AUTO and MANUAL modes in the basic operation mode, and is selected by opening (turning OFF) the DI02 contact (SERVICE mode input). Normal mode is maintained as long as the DI02 contact is closed (ON). If a serial I/O option board is installed, SERVICE mode is entered when either one of SI02 or DI02 is open (OFF). (Normal mode is entered only when both SI02 and DI02 contacts are closed.) When the DI02 contact is open (OFF), the controller is in SERVICE mode with the operation level, operating speed limit, and exclusive control of the operating devices specified by the SERVICE mode parameters. The following functions can be selected in SERVICE mode.

  • Page 29: Flow For Enabling The Service Mode Functions

    1.4.2 Flow for enabling the SERVICE mode functions • Controller is set to SAFE mode. • SERVICE mode parameters have been set. ↓ • Open (turn OFF) the DI02 contact. (If a serial I/O option board is installed, SERVICE mode is entered when either one of SI02 or DI02 is open (OFF).) ↓ • Controller enters SERVICE mode with the operation level, operating speed limit, and exclusive control of the operation devices specified by the SERVICE mode parameters. Refer to the next section for the SERVICE mode parameter settings. 1.4.3 SERVICE mode parameter settings There are the following three parameters for SERVICE mode. 1. SERVICE mode level 2. Operating speed limit during SERVICE mode 3. Operation device control during SERVICE mode These parameter settings determine the operation level, operating speed limit, and exclusive control of the operation devices during SERVICE mode.
  • Page 30 SERVICE mode level The SERVICE mode level can be selected to enable or disable the Hold-to-Run function and to permit or prohibit the operation in AUTO mode. The Hold-to-Run function allows the robot to move (including program execution) only during the time that the PB operation key is kept pressed. Description Setting Hold-to-Run function AUTO mode operation Level 0 Disabled Permitted Level 1 Enabled Permitted Level 2 Disabled Prohibited Level 3 Enabled Prohibited * Default setting Limitations on operating speed during SERVICE mode The maximum robot operating speed can be specified. Setting Description <3%...

  • Page 31: Emc Countermeasure Examples

    CAUTION The following description and circuits are typical countermeasures used when the robot and controller are tested under OMRON installation conditions. When the robot and controller are used while installed in the customer's system, the actual test results may differ depending on installation conditions.

  • Page 32: Countermeasure Components

    2.1.2 Countermeasure components Surge absorber ■ The YRC can be used without an external surge absorber. However, to further enhance surge resistance, install a surge absorber on the AC power line. A recommended surge absorber is shown below. ● Recommended surge absorber Manufacturer : SOSHIN ELECTRIC CO., LTD. Type No. : LT-C12G801WS Dimensional outline Status indicator Green : Normal : Abnormal ±1.0 Wire (line) Wire (earth) (Black) (Green/Yellow) 22.5...
  • Page 33 Noise filter ■ Always install an external noise filter on the AC power line. A recommended noise filter is shown below. ● Recommended noise filter Manufacturer : SOSHIN ELECTRIC CO., LTD. Type No. : NF2020A-UP Dimensional outline 85±1 40±1 (71.6) (28.8) 70±0.5 R2.25, Length: 6 6-M4 φ4.5 Part name Note...
  • Page 34 Ferrite core ■ Install ferrite cores according to the customer's final product (entire system). Recommended ferrite cores are shown below. ● Recommended ferrite core 1 Manufacturer : TDK Type No. : ZCAT3035-1330 Dimensional outline 39.0±1 30.0±1 13.0±1 34.0±1 unit: mm ● Recommended ferrite core 2 Manufacturer : TDK Type No. : ZCAT2132-1130 Dimensional outline 36.0±1 20.5±1 32.0±1 11.0±1 unit: mm...
  • Page 35 ● Recommended ferrite core 4 Manufacturer : Takeuchi Kogyo Co., Ltd. Type No. : TFT-274015S Dimensional outline (90.1) 43.8 40.0 φ43.8 φ27.4 Ferrite Plastic case Clamped state unit: mm ● Recommended ferrite core 5 Manufacturer : Takeuchi Kogyo Co., Ltd. Type No. : SFT-72SNB-026K Dimensional outline (61.3) 29.4 29.4 φ12.2 25.0 Ferrite Plastic case Clamped state unit: mm...

  • Page 36: External Safety Circuit Examples

    External safety circuit examples This section describes category-specific safety circuit configuration examples using the PB. Customers should install the appropriate safety measures for their system by referring to the circuit example for each controller, in order to use the robots more safely. Performance level To comply with the machinery directives, the "performance level (PL)" required of the safety circuit must be evaluated.

  • Page 37: Circuit Examples For The Yrc

    Circuit examples for the YRC The following shows category-specific safety circuit configuration examples for the YRC. Customers should install the appropriate safety measures for their system by referring to these safety circuit configuration examples in order to use the robots more safely. The example shown here provide the following input/output signals.
  • Page 38 Reference: Connection diagram without enable switch (category B) Controller Safety circuit (PNP speci cations) Emergency stop External emergency circuit SAFETY AUTO SERVICE Maintenance switch SERVICE(DI02) P.COMDI P.COM MPRDY MPRDY Status N.COM N.COMDI E-STOP24V Internal+24V E-STOPRDY E-STOP Status +24V STD.DIO +24V_GND COMMON CPU_OK (contact A (normally open)) +24V...

  • Page 39: Category 4

    *1: Wiring to check whether the controller is normal when using an alarm to shut o the main power Parts list Circuit No. Part name Type No. Manufacturer Reset switch A22 series OMRON Key selector switch A22 TK series OMRON Safety door switch D4 series OMRON Emergency stop switch...

  • Page 40: Category 3

    *1: Wiring to check whether the controller is normal when using an alarm to shut o the main power Parts list Circuit No. Part name Type No. Manufacturer Reset switch A22 series OMRON Key selector switch A22 TK series OMRON Safety door switch D4 series OMRON Emergency stop switch...

  • Page 41: Category 2

    *1: Wiring to check whether the controller is normal when using an alarm to shut o the main power Parts list Circuit No. Part name Type No. Manufacturer Reset switch A22 series OMRON Key selector switch A22 TK series OMRON Safety door switch D4 series OMRON Emergency stop switch...

  • Page 42: Overview Of Circuit Operation

    3.2.4 Overview of circuit operation This section describes an overview of the circuit operation for each safety circuit configuration example shown in the previous sections. During AUTO mode The main power is supplied only when the enable switch is disabled, the controller is in a normal state (MPRDY is ON) with no internal alarms occurring, and also all the following conditions are met: Conditions • Maintenance mode switch is in AUTO (M1: open, M2: closed)
  • Page 43 Revision history A manual revision code appears as a suffix to the catalog number on the front cover manual. Cat. No. I156E-EN-01 Revision code The following table outlines the changes made to the manual during each revision. Revision code Date Description August 2010 Original production December 2012 Minor changes...
  • Page 44 Authorized Distributor: Cat. No. I154E-EN-02 Note: Specifications subject to change without notice. Printed in Europe...

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