Yamaha ERCX Series User Manual

Single-axis robot controller
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YAMAHA SINGLE-AXIS ROBOT CONTROLLER
ERCX
E
User's Manual
ENGLISH
YAMAHA MOTOR CO., LTD.
IM Operations
882 Soude, Naka-ku, Hamamatsu, Shizuoka 435-0054.Japan
E63-Ver. 7.08
URL http://www.yamaha-motor.jp/robot/index.html

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  • Page 1 YAMAHA SINGLE-AXIS ROBOT CONTROLLER ERCX User’s Manual ENGLISH YAMAHA MOTOR CO., LTD. IM Operations 882 Soude, Naka-ku, Hamamatsu, Shizuoka 435-0054.Japan E63-Ver. 7.08 URL http://www.yamaha-motor.jp/robot/index.html...
  • Page 3: Table Of Contents

    General Contents Chapter 1 OVERVIEW ......................1-1 Features of the ERCX Series Controller .................. 1-2 Setting Up for Operation ....................... 1-3 External View and Part Names ....................1-4 1-3-1 ERCX controller ............................. 1-4 1-3-2 TPB ................................1-6 System Configuration ......................1-7 1-4-1 System configuration .............................
  • Page 4 I/O Assignment Change Function ..................3-23 3-7-1 Changing the I/O assignment ........................3-23 3-7-2 I/O signal descripion ........................... 3-25 3-7-3 Timing chart ..............................3-28 Chapter 4 BASIC OPERATION OF THE TPB ................. 4-1 Connecting and Disconnecting the TPB ................. 4-2 4-1-1 Connecting the TPB to the ERCX controller ....................
  • Page 5 Robot Language Description ....................8-8 8-4-1 MOVA ................................8-8 8-4-2 MOVI ................................8-8 8-4-3 MOVF ................................8-9 8-4-4 JMP ................................8-9 8-4-5 JMPF ................................8-10 8-4-6 JMPB ................................8-11 8-4-7 L .................................. 8-11 8-4-8 CALL ................................8-12 8-4-9 DO ................................8-12 8-4-10 WAIT ................................
  • Page 6 Chapter 10 OTHER OPERATIONS ..................10-1 10-1 Initialization ........................10-2 10-2 DIO Monitor Display ......................10-4 10-2-1 Display from the monitor menu ........................10-4 10-2-2 Display from the DIO key operation ......................10-5 10-3 System Information Display ....................10-5 10-4 SERVICE mode function ....................... 10-6 10-4-1 Safety settings for SERVICE mode ........................
  • Page 7 Chapter 14 MAINTENANCE AND WARRANTY ..............14-1 14-1 Warranty ..........................14-2 14-2 Replacing the System Backup Battery .................. 14-2 14-3 Replacing the Absolute Battery .................... 14-2 14-4 Updating the System ......................14-3 Chapter 15 SPECIFICATIONS ....................15-1 15-1 ERCX sereis ..........................15-2 15-1-1 Basic specifications ............................. 15-2 15-1-2 Robot number list ............................
  • Page 8 MEMO...
  • Page 9: Chapter 1 Overview

    Chapter 1 OVERVIEW Thank you for purchasing the YAMAHA single-axis robot controller ERCX series (hereafter called "ERCX con- troller" or simply "ERCX" or "this controller"). This manual describes ERCX controller features and operating procedures. When used with a YAMAHA single-axis FLIP-X series robot, the ERCX controller performs positioning and pick- and-place tasks of various mechanical parts and devices.
  • Page 10: Features Of The Ercx Series Controller

    1-1 Features of the ERCX Series Controller Features of the ERCX Series Controller The ERCX series is a high-performance robot controller using a 32-bit RISC chip CPU. When used with a YAMAHA single-axis FLIP-X series robot, the ERCX controller performs posi- tioning tasks of various mechanical parts and devices.
  • Page 11: Setting Up For Operation

    1-2 Setting Up for Operation Setting Up for Operation The chart below illustrates the basic steps to follow from the time of purchase of this controller until it is ready for use. The chapters of this user's manual are organized according to the operation proce- dures, and allow first time users to proceed one step at a time.
  • Page 12: External View And Part Names

    1-3 External View and Part Names External View and Part Names This section explains part names of the ERCX controller and TPB along with their functions. Note that the external view and specifications are subject to change without prior notice to the user. 1-3-1 ERCX controller 1.
  • Page 13 1-3 External View and Part Names Fig. 1-1 Exterior of the ERCX controller Fig. 1-2 Three-side view of the ERCX controller...
  • Page 14: Tpb

    1-3 External View and Part Names 1-3-2 TPB 1. Liquid Crystal Display (LCD) Screen This display has four lines of twenty characters each and is used as a program console. 2. Memory Card Slot An IC memory card can be inserted here. Be careful not to insert the card upside-down. 3.
  • Page 15: System Configuration

    1-4 System Configuration System Configuration 1-4-1 System configuration The ERCX controller can be combined with various peripheral units and optional products to configure a robot system as shown below. Fig.1-5 System configuration diagram TPB programming box IC memory card ERCX Controller Gripper, limit switches, etc.
  • Page 16: Accessories And Options

    1-5 Accessories and Options Accessories and Options 1-5-1 Accessories The ERCX controller comes with the following accessories. After unpacking, check that all items are included. 1. Power connector MC1,5/3-ST-3,5 made by Phoenix Contact 1 piece 2. I/O connector Connector : FCN-361P048-AU made by Fujitsu 1 piece Connector cover...
  • Page 17: Chapter 2 Installation And Connection

    Chapter 2 INSTALLATION AND CONNECTION This chapter contains precautions that should be observed when installing the controller, as well as procedures and precautions for wiring the controller to the robot and to external equipment.
  • Page 18: Installing The Ercx Controller

    2-1 Installing the ERCX Controller Installing the ERCX Controller 2-1-1 Installation method Using the L-shaped brackets attached to the top and bottom of the controller, install the controller from the front or rear position. (See Fig.1-2 Three-side view of the ERCX controller.) 2-1-2 Installation location ■...
  • Page 19: Connecting The Power Supply

    2-2 Connecting the Power Supply Connecting the Power Supply 2-2-1 Power supply ■ Power requirements DC24V ±10% Power supply voltage Power supply current 3 to 4.5A (depends on robot type) ■ Power supply current YMS45 YMS55 Standard model (horizontal use) 4.5A -BK model (equipped with brake for vertical use) 4.5A...
  • Page 20: Connecting The Power Supply

    CAUTION The ERCX series controller does not have a power switch. Be sure to provide a power supply breaker (insulation) of the correct specifications that will turn the power on or off to the entire system including the robot controller.
  • Page 21: Grounding

    2-3 Grounding Grounding The ERCX controller must be grounded to prevent danger to personnel from electrical shocks in case of electrical leakage and prevent equipment malfunctions due to electrical noise. We strongly recommend that Class D (grounding resistance of 100 ohms or less) or higher grounding be provided.
  • Page 22: Connecting To The Robot

    2-5 Connecting to the Robot Connecting to the Robot First make sure that the power to the ERCX controller is turned off, and then connect the robot cable to the robot I/O connector on the front panel of the ERCX controller. Fully insert the robot I/O cable until it clicks in position.
  • Page 23: Connecting To The I/O Connector

    2-6 Connecting to the I/O Connector Connecting to the I/O Connector The I/O connector is used for connecting the ERCX controller to external equipment such as a PLC. When using external equipment for I/O control, connect the wiring to the I/O connector supplied as an accessory and then plug it into the I/O connector on the ERCX controller.
  • Page 24: Connecting The Absolute Battery

    2-7 Connecting the Absolute Battery Connecting the Absolute Battery Connect the absolute battery to the controller as shown below. Use a cable tie and binding strap (supplied) to secure the battery to the side of the controller or at the proper position in the system. A "B1 type"...
  • Page 25: Chapter 3 I/O Interface

    To construct a system utilizing the features of the ERCX series, you must understand the signals assigned to each terminal on the I/O connector and how they work. This chapter 3 covers this fundamental information.
  • Page 26: I/O Signals

    3-1 I/O Signals I/O Signals The standard I/O connector of the ERCX controller has 48 pins, with an individual signal assigned to each pin. The following table shows the pin number as well as the name and description of each signal assigned to each pin.
  • Page 27: Input Signal Description

    3-2 Input Signal Description Input Signal Description Input signals consist of 7 dedicated command inputs, 16 general-purpose inputs, interlock signals and an emergency stop input. * DI15 functions as the SERVICE mode input when the SERVICE mode function is enabled. In this case, 15 general-purpose inputs are available.
  • Page 28 3-2 Input Signal Description ■ Absolute point movement command (ABS-PT) This command moves the robot to an absolute position of a point number specified by DI0 to DI9 along an axis coordinate whose origin is defined as 0, at a speed selected by DI10 or DI11. (See "3-2-2 General-purpose input (DI0 to DI15)").
  • Page 29 3-2 Input Signal Description ■ Return-to-origin command (ORG-S) This command returns the robot to its origin position when the search method is selected as the origin detection method. When the mark method is selected, this command checks the return-to- origin status. NOTE Once return-to-origin is performed after the robot cable and absolute battery are connected, there is no need to repeat it even when the controller is turned off.
  • Page 30: General-Purpose Input (Di0 To Di15)

    3-2 Input Signal Description 3-2-2 General-purpose input (DI0 to DI15) These general-purpose inputs are available to users for handling data input in a program. These inputs are usually connected to sensors or switches. These inputs can also be directly con- nected to a PLC output circuit.
  • Page 31: Service Mode Input (Svce)

    3-2 Input Signal Description 3-2-3 SERVICE mode input (SVCE) When the SERVICE mode function is enabled, DI15 functions as the SERVICE mode input (SVCE). The SERVICE mode input is used to notify the ERCX controller whether the current state is a "SERV- ICE mode state".
  • Page 32: Output Signal Description

    3-3 Output Signal Description Output Signal Description The output signals consist of 3 dedicated outputs (READY, BUSY and END) and 13 general-purpose outputs. In this section, terms "ON" and "OFF" mean the output transistors are "on and off". 3-3-1 Dedicated output The dedicated outputs are used for exchanging signals between the ERCX controller and an external device such as a PLC.
  • Page 33: General-Purpose Output (Do0 To Do12)

    3-4 I/O Circuits 3-3-2 General-purpose output (DO0 to DO12) These general-purpose outputs are available to users for freely controlling on/off operation in a pro- gram. These outputs are used in combination with an external 24V power supply, to drive loads such as solenoid valves and LED lamps.
  • Page 34: I/O Circuit And Connection Example

    3-4 I/O Circuits 3-4-2 I/O circuit and connection example When using a separate 24V power supply for I/O control Photocoupler Push-button Input signal NPN transistor Incandescent lamp Output signal Solenoid valve +IN COM Controller side External 24V External 24V power supply power supply for I/O control for controller...
  • Page 35 3-4 I/O Circuits When shared with 24V power supply for controller Photocoupler Push-button Input signal NPN transistor Incandescent lamp Output signal Solenoid valve +IN COM Controller side External 24V power supply for I/O control and controller CAUTION Select a 24V power supply with a sufficient capacity. If the power supply capacity is insufficient, the robot may not operate normally resulting in an unexpected error or alarm.
  • Page 36: I/O Connection Diagram

    3-5 I/O Connection Diagram I/O Connection Diagram 3-5-1 General connections General connections Emergency stop switch EMG1 EMG2 DC24V A13,B13 +IN COM A14,B14 A15,B15 LOCK ORG-S RESET AUTO-R STEP-R ABS-PT INC-PT SERVO DI 0 DI 1 DI 2 DI 3 DI 4 DI 5 DI 6 DI 7...
  • Page 37: Connection To Plc Output Unit

    3-5 I/O Connection Diagram 3-5-2 Connection to PLC output unit Connection to the Mitsubishi © PLC AY51 output unit AY51 type output unit ERCX series controller TB 1 DI 0 DI 1 DI 2 DI 3 DI 4 DI 5...
  • Page 38: Connection To Plc Input Unit

    3-5 I/O Connection Diagram 3-5-3 Connection to PLC input unit Connection to the Mitsubishi © PLC AX41 intput unit AX41 type input unit ERCX series controller TB 1 READY BUSY DO 0 Internal DO 1 circuit DO 2 Photocoupler DO 3...
  • Page 39: I/O Control Timing Charts

    3-6 I/O Control Timing Charts I/O Control Timing Charts The following shows typical timing charts for I/O control. Refer to these diagrams when creating a sequence program. 3-6-1 When turning the power on When emergency stop is triggered: Power supply 300ms or more READY When emergency stop is canceled:...
  • Page 40: When Executing A Dedicated Input Command

    3-6 I/O Control Timing Charts 3-6-2 When executing a dedicated input command ■ The BUSY signal turns on when a dedicated command is received. Whether the received com- mand has ended normally can be checked with the END signal status at the point that the BUSY signal turns off.
  • Page 41 3-6 I/O Control Timing Charts (2)When a command with a short execution time runs and ends normally: (Command execution has already ended and the END signal is on before turning off (contact open) the dedicated command input, as in the examples listed below.) •...
  • Page 42 3-6 I/O Control Timing Charts (3)When a command cannot be executed from the beginning: (Command execution is impossible from the beginning and the END signal does not turn on, as in the examples listed below.) • A movement command (ABS-PT, INC-PT) was executed without return-to-origin being com- pleted.
  • Page 43 3-6 I/O Control Timing Charts (4)When command execution cannot be completed: (Command execution stops before completion and the END signal does not turn on, as in the examples listed below.) • An interlock or emergency stop was triggered during execution of a dedicated command. •...
  • Page 44: When Interlock Signal Is Input

    3-6 I/O Control Timing Charts 3-6-3 When interlock signal is input Interlock LOCK Dedicated command BUSY Differs according to execution command ■ When a interlock signal is input while a dedicated command is being executed, the BUSY signal turns off. The READY and END signals remain unchanged.
  • Page 45: When Emergency Stop Is Input

    3-6 I/O Control Timing Charts 3-6-4 When emergency stop is input Emergency stop Dedicated command BUSY READY 5ms or less 1ms or less ■ The READY signal turns off. The BUSY signal also turns off while a dedicated command is being executed.
  • Page 46: When Executing A Point Movement Command

    3-6 I/O Control Timing Charts 3-6-6 When executing a point movement command ■ When executing a point movement command (ABS-PT, INC-PT), the point data and speed data must first be input before inputting the command. The point data and speed data can be specified with DI0 to DI11. Refer to "3-2-2 General- purpose input (DI0 to DI15)".
  • Page 47: I/O Assignment Change Function

    3-7 I/O Assignment Change Function I/O Assignment Change Function 3-7-1 Changing the I/O assignment The function assigned to each I/O signal can be changed with PRM59 (I/O assignment selection parameter) setting. Refer to the table on next page when you want to change the I/O assignment. After changing the I/O assignment, the ERCX controller must be restarted to enable the changes.
  • Page 48 3-7 I/O Assignment Change Function I/O assignment list Type 0 Type 2 Type 3 (Conven- Type 1 Type (Point number output type) (Point teaching type) tional type) Point Point Teaching Teaching trace trace mode mode mode mode PRM59 Setting − xx20 * xx21 * xx30 *...
  • Page 49: I/O Signal Descripion

    3-7 I/O Assignment Change Function 3-7-2 I/O signal descripion The meaning of each signal is explained below. ■ Point number designation inputs 0 to 5 (PI0 to PI5) These inputs designate the point number of the target position where the robot moves with a point movement command (ABS-PT, INC-PT).
  • Page 50 3-7 I/O Assignment Change Function ■ Point data write command (PSET) Writes the current position data in the specified point number. To use this command, the point number for writing the current position data must first be specified using a PI (point number designation input) input. The PSET is enabled only when return-to-origin has been completed.
  • Page 51 3-7 I/O Assignment Change Function Output example PO No. Point No. CAUTION When using PO as an output signal that indicates the target position's point number for point movement commands (ABS-PT, INC-PT): • If moving the robot to point 0 with at the first point movement command which is executed after turning the controller on, all the PO0 to PO5 signals still remain off (because P0 = 000000 ) even after the robot (binary)
  • Page 52: Timing Chart

    3-7 I/O Assignment Change Function 3-7-3 Timing chart This section shows timing charts for the operations that are added by changing the I/O assignment. ■ Jog movement (JOG+, JOG-) Mode switch input (CHG) Jog movement command (JOG+ / JOG-) BUSY READY Robot movement Robot movement...
  • Page 53 3-7 I/O Assignment Change Function ■ Point data write (PSET) Mode switch input (CHG) Point data write command (PSET) Point number designation inputs 0 to 5* Data retention (PI0 to PI5) BUSY READY Point data write Point data writing 30ms or more 30ms or less 1ms or less 30ms or less *: Point numbers that can be used depend on the I/O assignment type.
  • Page 54 3-7 I/O Assignment Change Function ■ Target position's point number output (PO) (1) Outputting the point number at the timing that movement is normally completed Point movement command Command q Command w (ABS-PT, INC-PT) Target position's point number Point number output q Point number output w outputs 0 to 5* (PO0 to PO5)
  • Page 55 3-7 I/O Assignment Change Function (2) Outputting the point number at the timing that a movement command is received Point movement command Command q Command w (ABS-PT, INC-PT) Target position's point number Point number output q Point number output w outputs 0 to 5* (PO0 to PO5) BUSY...
  • Page 56 3-7 I/O Assignment Change Function (3)Outputting the corresponding point number by the point zone output function Zone outputs (ZONE 0, ZONE 1) are also explained here. m-No. is output as binary value n-No. is output as binary value Target position's point number outputs 0 to 3* (PO0 to PO3) Point output...
  • Page 57 3-7 I/O Assignment Change Function NOTE • When using an optional unit such as a CC-Link, the corresponding point number for the point zone output function is output to both the corresponding parallel I/O (PO0 to PO5) and the serial I/O (PO200 to PO205). •...
  • Page 58 3-7 I/O Assignment Change Function (4)Outputting the corresponding point number by the movement point zone output function Zone outputs (ZONE 0) are also explained here. Target position's point number outputs 0 to 3* (PO0 to PO3) Point output (point 6) Zone output 0 (ZONE 0) *Positive logic P900...
  • Page 59 3-7 I/O Assignment Change Function NOTE • The movement point zone output function is supported only in Ver. 13.64 and later versions. • When using an optional unit such as CC-Link, the corresponding point number for the movement point zone output function is output to the corresponding parallel I/O (PO0 to PO5) and the serial I/O (PO200 to PO205).
  • Page 60 MEMO...
  • Page 61: Chapter 4 Basic Operation Of The Tpb

    Chapter 4 BASIC OPERATION OF THE TPB The TPB is a hand-held, pendant-type programming box that connects to the ERCX controller to edit or run pro- grams for robot operation. The TPB allows interactive user operation on the display screen so that even first-time users can easily operate the robot with the TPB.
  • Page 62: Connecting And Disconnecting The Tpb

    4-1 Connecting and Disconnecting the TPB Connecting and Disconnecting the TPB 4-1-1 Connecting the TPB to the ERCX controller CAUTION Do not modify the TPB cable or use any type of relay unit for connecting the TPB to the ERCX controller. Doing so might cause communication errors or malfunctions.
  • Page 63: Disconnecting The Tpb From The Ercx Controller

    4-1 Connecting and Disconnecting the TPB 4-1-2 Disconnecting the TPB from the ERCX controller The TPB can be disconnected from the controller regardless of whether the power is on or off. There is no problem even when the robot is operating. When the TPB will be left disconnected from the controller for a long period of time, we recommend attaching the RS-232C connector dust cover (supplied) to the TPB connector on the controller.
  • Page 64: Basic Key Operation

    4-2 Basic Key Operation Basic Key Operation 1) Selectable menu items are displayed on the 4th line (bottom line) of the TPB screen. [MENU] Example A is the initial screen that allows you select menu to select the following modes. 1 EDIT 1EDIT2OPRT3SYS 4MON 2 OPRT...
  • Page 65: Reading The Screen

    4-3 Reading the Screen Reading the Screen The following explains the basic screen displays and what they mean. 4-3-1 Program execution screen The display method slightly differs depending on the version of TPB. Ver. 12.50 or earlier Ver. 12.51 or later [OPRT-STEP] 100 0:31 [STEP] 100% 062:MOVA 200,100...
  • Page 66: Point Edit Screen (Teaching Playback)

    4-3 Reading the Screen 4-3-3 Point edit screen (teaching playback) [EDIT-PNT-TCH](1)100 P255 = 123.45 [mm] 0.00] 1CHG 2SPD 3S_SET 4next 1. Current mode 2. Speed selection number 3. Speed parameter (%) 4. Edit point number 5. Current position 4-3-4 DIO monitor screen DI 10000000 00000000 10000000 DO 00000000 10100000...
  • Page 67: Hierarchical Menu Structure

    4-4 Hierarchical Menu Structure Hierarchical Menu Structure MOD (Step Edit) INFORMATION INS (Step Insert) (System information) DEL (Step Delete) CHG (Program Change) (Program Edit) MDI (Manual Data Input) CHG (Point Change) CHG (Point Change) SPD (Speed Change) S_SET (Speed Set) EDIT (Point Edit) (Teaching Playback)
  • Page 68: Restricting Key Operation By Access Level

    4-5 Restricting Key Operation by Access Level Restricting Key Operation by Access Level The TPB key operations can be limited by setting the access levels (operation levels). A person not trained in robot operation might accidentally damage the robot system or endanger others by using the TPB incorrectly.
  • Page 69: Changing An Access Level

    4-5 Restricting Key Operation by Access Level Memory card Level Description All operations are permitted. Loading the parameters and all data to the ERCX is prohibited. (Point data or program data can be loaded.) Loading any data to the ERCX is prohibited. (Data can be saved and the memory card formatted.) Use of memory card is prohibited.
  • Page 70 4-5 Restricting Key Operation by Access Level 5) Select the item you want to change. [SYS-SAFE-ACLV] To change the access level for editing, press select menu (EDIT). To change the access level for operation, press (OPRT). 1EDIT2OPRT3SYS 4CARD To change the access level for system-related data, press (SYS).
  • Page 71: Chapter 5 Parameters

    Chapter 5 PARAMETERS The ERCX controller uses a software servo system, so no adjustment of hardware components such as potentiometers or DIP switches are required. Instead, the ERCX controller uses parameters that can be easily set or changed by the TPB or PC (personal computer).
  • Page 72: Setting The Parameters

    5-1 Setting the Parameters Setting the Parameters 1) On the initial screen, press (SYS). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (PRM). [SYS] select menu 1PRM 2B.UP3INIT 3) The current PRM0 (robot type number) setting [SYS-PRM] appears on the screen. Use the STEP STEP DOWN...
  • Page 73: Parameter Description

    5-2 Parameter Description Parameter Description The parameters are described in order below. CAUTION Parameters not displayed on the TPB screen are automatically set or optimized to match the robot type when the robot parameters are initialized. You usually do not have to change these parameter settings. If for some special reason you need to change or check these hidden parameters, use any of the following methods.
  • Page 74 5-2 Parameter Description PRM4: Acceleration This parameter sets the acceleration. The controller will automatically set optimum acceleration according to the robot type and payload. Change this parameter when the acceleration is to be decreased beyond this state. Input range: 1 to 100 (%) Default value: 100 PRM5: Return-to-origin direction...
  • Page 75 5-2 Parameter Description PRM8: No. of conditional input points This parameter specifies the number of effective points for the third data conditional input for executing the JMPF statement of the robot language. For example, when the default setting is selected for this parameter, the four points from DI0 to DI3 are used as the conditional inputs for the JMPF statement.
  • Page 76 5-2 Parameter Description PRM13: Origin detection method This parameter is used to select the origin (reference point) detection method. There are two methods for detecting the origin: search method and mark method. The search method is further divided into the origin sensor method and stroke-end detection method.
  • Page 77 5-2 Parameter Description PRM18: Speed integration gain This sets the speed control gain. Typically, PRM17 and PRM18 should be input at a ratio of 3 : 2. Generally, the larger the gain, the higher the acceleration will be. However, if the gain is set too high, abnormal oscillation or noise might be generated, causing serious problems in the robot and controller.
  • Page 78 5-2 Parameter Description PRM23: Payload-dependent acceleration coefficient The value calculated from PRM0, PRM12 and PRM3 is set automatically for this param- eter. Default value: Depends on robot type. PRM24: Teaching count data (TPB entry) This is entered in the TPB and cannot be used. Default value: 0 PRM25: Not used Default value: 0...
  • Page 79 5-2 Parameter Description PRM31: Open-circuit fault detection level This parameter sets the sensitivity for detecting an open-circuit fault. The upper limit of this parameter is 254. The sensitivity lowers as the parameter value increases. Leave this parameter set to 255 if you want to disable this detection function. Input range: 1 to 255 Default value: 255 (This function is disabled.)
  • Page 80 5-2 Parameter Description PRM34: System mode selection This parameter specifies the system operation mode. When you want to use the ERCX controller in operating specifications that differ from normal mode, for example, to make it compatible with the conventional controllers, change this parameter as explained below. This parameter functions are allocated in bit units.
  • Page 81 5-2 Parameter Description Bit 3: Voltage check setting for system backup battery This selects whether to check the system backup battery voltage when the control- ler servo is turned on. In such cases where you want to operate the robot immediately even when the battery needs to be replaced, you can temporarily disable this voltage check.
  • Page 82 5-2 Parameter Description PRM39: No. of motor poles Default value: Depends on robot type. PRM40: RESET execution condition selection Selects the operation to be executed with the I/O reset command. Input range: 0 to 2 Meaning: 0: Turns on the servo and resets the program. 1: Switches the operation depending on the LOCK signal status.
  • Page 83 5-2 Parameter Description PRM42: I/O point movement command speed 2 This parameter specifies the movement speed (%) at which the robot moves when a point movement command (ABS-PT, INC-PT) is executed. When "type 3" (point teaching type) is selected by the I/O assignment setting, this param- eter specifies the jog speed at which the robot moves at a jog movement command (JOG+, JOG-).
  • Page 84 5-2 Parameter Description PRM44: Maximum speed setting This parameter sets the maximum motor revolution speed. Input range: 1 to 4500 (rpm) Default value: Depends on robot type. CAUTION Changing this parameter carelessly might shorten the robot service life or cause other problems. PRM45: Feed forward gain Default value: Depends on robot type.
  • Page 85 5-2 Parameter Description PRM49: Controller version 1 This parameter reads out the version information (1) on the control software in the con- troller. This is a read-only parameter. PRM50: Deceleration (Available with Ver. 13.33 or later) Use this parameter to reduce only the deceleration. When this parameter is left set to the default value (100), the deceleration is the same as the acceleration.
  • Page 86 5-2 Parameter Description PRM53: Zone output selection (Available with Ver. 13.50 or later) This parameter is used to select the output destination and output logic when the zone output function is enabled. The zone output is used to control the signal output when the robot's current position is within the specified range.
  • Page 87 5-2 Parameter Description Example q PRM53=1 (Zone 0 output enabled, positive logic output) P900=100.00 P901=200.00 100.00 200.00 Current position Example w PRM53=68 (Zone 2 output enabled, negative logic output) P904=100.00 P905=200.00 100.00 200.00 Current position PRM54: Not used (Available with Ver. 13.50 or later) Default value: 0 PRM55: Not used (Available with Ver.
  • Page 88 5-2 Parameter Description PRM59: I/O assignment selection (Available with Ver. 13.57 or later) This parameter selects the function to be assigned to each I/O signal. This parameter setting allows changing the function assigned to each I/O signal. This makes it possible to output the destination point number and perform jog movement. After changing the I/O assignment, the ERCX controller must be restarted to enable the changes.
  • Page 89 5-2 Parameter Description I/O assignment list Type 0 Type 2 Type 3 (Conven- Type Type 1 (Point number output type) (Point teaching type) tional type) Point Point Teaching Teaching trace trace mode mode mode mode PRM59 Setting − xx20 * xx21 * xx30 * xx31 *...
  • Page 90 MEMO...
  • Page 91: Chapter 6 Programming

    Chapter 6 PROGRAMMING In this chapter we will try programming some operations. First, you will learn how to enter a program using the TPB programming box.
  • Page 92: Basic Contents

    Basic Contents 6-1-1 Robot language and point data The ERCX controller uses the YAMAHA robot language that is very similar to BASIC. It allows you to easily create programs for robot operation. In programs created with the YAMAHA robot language, the robot position data (absolute position, amount of movement) are not expressed in terms of direct numeric values.
  • Page 93 6-2 Editing Programs Editing Programs "Program editing" refers to operations such as creating a program right after initialization, creating a new program, changing an existing program, and deleting or copying a program. In this section, you will learn the basic procedures for program editing using the TPB. "Creating a program right after initialization"...
  • Page 94: Editing Programs

    6-2 Editing Programs 6-2-1 Creating programs after initialization 1) On the initial screen, press (EDIT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (PGM). [EDIT] select menu 1PGM 2PNT 3UTL 3) Since no program is registered after initializa- [EDIT] tion, an error message appears on the screen, indicating that no program exists.
  • Page 95 6-2 Editing Programs 7) After selecting the robot language command, [EDIT-PGM] No 0 enter the operand data. When you press , the cursor moves to op- 001:MOVA 0 ,100 erand 1, so enter the data with the number keys. (Do not press at this point.) (point No) 0→999 While pressing...
  • Page 96: Creating A New Program

    6-2 Editing Programs 6-2-2 Creating a new program 1) On the initial screen, press (EDIT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (PGM). [EDIT] select menu 1PGM 2PNT 3UTL 3) The execution program number and step are [EDIT-PGM] No10 displayed on the screen.
  • Page 97: Adding A Step

    6-2 Editing Programs 6-2-3 Adding a step 1) On the initial screen, press (EDIT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (PGM). [EDIT] select menu 1PGM 2PNT 3UTL 3) The execution program number and step are [EDIT-PGM] No10 displayed on the screen. Press (CHG) here.
  • Page 98 6-2 Editing Programs 7) Select or a robot language com- [EDIT-PGM] No10 mand shown on the lower part of each number key. 051:_ To change the robot language menu display, press (next). To go back to the previous menu display, press the key.
  • Page 99: Correcting A Step

    6-2 Editing Programs 6-2-4 Correcting a step 1) Use the same procedure up to step 4 in "6-2-3 Adding a step". 2) Enter the number of the step you want to cor- [EDIT-PGM] rect with the number keys and press No = 10 STEP No = _ (REG.steps) 50...
  • Page 100: Inserting A Step

    6-2 Editing Programs 6-2-5 Inserting a step 1) Use the same procedure up to step 4 in "6-2-3 Adding a step". 2) Enter the number of the step where you want to insert a step with the number keys and press [EDIT-PGM] No = 10 STEP No = _...
  • Page 101: Deleting A Step

    6-2 Editing Programs 6-2-6 Deleting a step 1) Use the same procedure up to step 4 in "6-2-3 Adding a step". 2) Enter the number of the step you want to delete [EDIT-PGM] with the number keys and press No = 10 STEP No = _ (REG steps) 50 3) Press...
  • Page 102: Program Utility

    6-3 Program Utility Program Utility 6-3-1 Copying a program 1) On the initial screen, press (EDIT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (UTL). [EDIT] select menu 1PGM 2PNT 3UTL 3) Press (COPY). [EDIT-UTL] select menu 1COPY2DEL 3LIST 4) Enter the program number you want to copy from with the number keys, and then press [EDIT-UTL-COPY] Copy from No = _...
  • Page 103: Deleting A Program

    6-3 Program Utility 6) If program data is already registered with the [EDIT-UTL-COPY] selected program number, a confirmation mes- sage appears. Copy from No = 0 To overwrite the program, press (yes). No99 overwrite OK ? To cancel, press (no). 1yes 2no 7) When the program has been copied, the screen [EDIT-UTL]...
  • Page 104: Viewing The Program Information

    6-3 Program Utility 6-3-3 Viewing the program information 1) Use the same procedure up to 2 in "6-3-1 Copy- ing a program". 2) Press (LIST). [EDIT-UTL] select menu 1COPY2DEL 3LIST 3) The program numbers are displayed on the [EDIT-UTL-LIST] screen, along with the number of registered steps and the number of available remaining free 678 steps...
  • Page 105: Chapter 7 Editing Point Data

    Chapter 7 EDITING POINT DATA There are three methods to enter point data: manual data input (MDI), teaching playback, and direct teaching. Manual data input allows you to directly enter point data with the TPB number keys. Teaching playback moves the robot in manual operation to a desired position and then obtains that position as point data.
  • Page 106: Manual Data Input

    7-1 Manual Data Input Manual Data Input 1) On the initial screen, press (EDIT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (PNT). [EDIT] select menu 1PGM 2PNT 3UTL 3) Press (MDI). [EDIT-PNT] select menu 1MDI 2TCH 3DTCH4DEL 4) The currently selected point data in the execu- [EDIT-PNT-MDI] tion program appears on the screen.
  • Page 107: Teaching Playback

    7-2 Teaching Playback Teaching Playback 1) On the initial screen, press (EDIT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (PNT). [EDIT] select menu 1PGM 2PNT 3UTL 3) Press (TCH). [EDIT-PNT] select menu 1MDI 2TCH 3DTCH4DEL 4) The currently selected point data in the execu- [EDIT-PNT-TCH](1) 50 tion program appears on the screen.
  • Page 108 7-2 Teaching Playback 6) Move the robot to the teaching position with [EDIT-PNT-TCH](1) 50 – keys. Each time the – key is pressed, the robot moves a certain P500 = 19.27 [mm] amount in the direction indicated by the key 0.00] and then stops.
  • Page 109: Direct Teaching

    7-3 Direct Teaching Direct Teaching 1) On the initial screen, press (EDIT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (PNT). [EDIT] select menu 1PGM 2PNT 3UTL 3) Press (DTCH). [EDIT-PNT] select menu 1MDI 2TCH 3DTCH4DEL 4) Following the message, press the emergency [EDIT-PNT-DTCH] stop button on the TPB.
  • Page 110 7-3 Direct Teaching 7) Move the robot to the teaching position by hand. [EDIT-PNT-DTCH] P500 = 19.27 [mm] 0.00] 1CHG 2DO 3BRK 8) Press to input the current position as point [EDIT-PNT-DTCH] data. P500 = 167.24 [mm] Use the same procedure to input all other nec- essary point data, and then press the key.
  • Page 111: Manual Control Of General-Purpose Output

    7-4 Manual Control of General-Purpose Output Manual Control of General-Purpose Output When performing teaching playback or direct teaching with systems that use a general-purpose output through the I/O interface to operate a gripper or other tools, you may want to check the position of workpiece by actually moving it.
  • Page 112: Manual Release Of Holding Brake

    7-5 Manual Release of Holding Brake Manual Release of Holding Brake The holding brake on the vertical type robot can be released. Since the movable part will drop when the brake is released, attaching a stopper to protect the tool tip from being damaged is recommended. 1) Use the same procedure up to step 4 in "7-3 Direct Teaching".
  • Page 113: Deleting Point Data

    7-6 Deleting Point Data Deleting Point Data 1) Use the same procedure up to step 2 in "7-1 Manual Data Input". 2) Press (DEL). [EDIT-PNT] select menu 1MDI 2TCH 3DTCH4DEL 3) Enter the point number at the start to delete [EDIT-PNT-DEL] point data with the number keys and press DEL range P_...
  • Page 114: Tracing Points (Moving To A Registered Data Point)

    7-7 Tracing Points (Moving to a registered data point) Tracing Points (Moving to a registered data point) The robot can be moved to the position specified by a registered data point. You can check the input point data by actually moving the robot. 1) Use the same procedure up to step 5 in "7-2 Teaching Playback".
  • Page 115: Chapter 8 Robot Language

    This chapter explains the robot language. It describes what kind of commands are available and what they mean. The ERCX series uses the YAMAHA robot language. This is an easy-to-learn BASIC-like programming language. Even a first-time user can easily create programs to control complex robot and peripheral device movements.
  • Page 116: Robot Language Table

    8-1 Robot Language Table Robot Language Table Instruction Description and Format Applicable version Moves to point data position. MOVA MOVA <point number>, <maximum. speed> Moves from current position by amount of point data. MOVI MOVI <point number>, <maximum. speed> Moves until specified DI input is received. MOVF MOVF <point number>, <DI number>, <DI status>...
  • Page 117: Robot Language Syntax Rules

    8-2 Robot Language Syntax Rules Robot Language Syntax Rules 8-2-1 Command statement format The robot language command statement format for the ERCX controller is as follows. When creating a program using the TPB, each command statement can be automatically entered in this format, so you do not have to be aware of this format while creating the program.
  • Page 118: Variables

    8-2 Robot Language Syntax Rules 8-2-2 Variables Variable are used in a program to hold data. The following variables can be used with the ERCX controller. ■ Point variable P A point variable can contain a point number. It is used in movement commands such as MOVA and MOVI statements instead of specifying the point number directly.
  • Page 119: Program Function

    8-3 Program Function Program Function 8-3-1 Multi-task function A multi-task function allows simultaneous executing two or more programs (tasks). The ERCX con- troller can execute a maximum of 4 programs at the same time. Since the multi-task function simultaneously executes two or more programs, the following process- ing can be performed.
  • Page 120: Limitless Movement Function

    8-3 Program Function 8-3-2 Limitless movement function The limitless movement function allows multiple turns in the same direction along the robot axis. The ERCX controller incorporates the soft limit function that prohibits any robot motion which exceeds the soft limits specified by the parameters. This soft limit function is very useful for linear movement type robots such as FLIP-X series.
  • Page 121 8-3 Program Function ■ When the position data unit parameter is set to 3: When this parameter is set to 3, the current position is expressed in degrees (°) from 0 to 359.99 as a basic cycle. Therefore, even if the robot moves to the 360° point, that position sets to 0° (=360°) so that the robot can rotate continuously in the same direction.
  • Page 122: Robot Language Description

    8-4 Robot Language Description Robot Language Description 8-4-1 MOVA Function: Moves to a point specified by a point number (Moves to an absolute position relative to the origin point). Format: MOVA <point number>, <maximum speed> Example: MOVA 51, 80 Moves to P51 at speed 80. Explanation: This command moves the robot to a position on the absolute coordinates whose origin position is defined as 0.
  • Page 123: Movf

    8-4 Robot Language Description 8-4-3 MOVF Function: Moves until a specified DI number input is received. Format: MOVF <point number> <DI number> <DI status> Example: MOVF 1, 2, 1 The robot moves toward P1 and stops when DI2 turns on. Program ex- ecution then proceeds to the next step.
  • Page 124: Jmpf

    8-4 Robot Language Description 8-4-5 JMPF Function: If the conditional jump input matches the setting value, program execu- tion jumps to a specified label in a specified program. Format: JMPF <label number>, <program number>, <input condition value> Example: JMPF 12, 3, 5 If the conditional jump input is 5, program execution jumps to label 12 in program 3.
  • Page 125: Jmpb

    8-4 Robot Language Description 8-4-6 JMPB Function: Jumps to a specified label when a specified general-purpose input or memory input is ON or OFF. Format: JMPB <label number>, <DI or MI number>, <input status> Example: JMPB 12, 8, 1 Jumps to label 12 when DI8 input is ON. If DI8 is OFF, the program execution proceeds to the next step.
  • Page 126: Call

    8-4 Robot Language Description 8-4-8 CALL Function: Calls and executes another program. Format: CALL <program number>, <number of times> Example: CALL 5, 2 Calls program 5 and executes it twice. Program execution then proceeds to the next step. Explanation: When repeating the same operation a number of times, the CALL state- ment is used as needed to call and execute the subroutine defined as a separate program.
  • Page 127: Wait

    8-4 Robot Language Description 8-4-10 WAIT Function: Waits until a specified general-purpose input or memory input changes to a specified state. Format: WAIT <DI or MI number>, <input status> Example: WAIT 5, 1 Waits until DI5 turns on. Explanation: This command adjusts the timing according to the general-purpose in- put or memory input state.
  • Page 128 8-4 Robot Language Description 8-4-12 P Function: Sets a point variable P. Format: <point number> Example: Sets a point variable P to 200. Explanation: The point variable can contain a point number as a variable, which can be from 0 to 999. By using a movement command such as MOVA with a P+ or P- statement, the number of steps required to create a repeating program can be reduced.
  • Page 129: Srvo

    8-4 Robot Language Description 8-4-15 SRVO Function: Turns the servo on and off. Format: SRVO <servo status> Example: SRVO This turns the servo on. SRVO This turns the servo off. Explanation: This command is used to prevent an overload on the motor that may occur if the robot is locked mechanically after positioning is completed.
  • Page 130: Orgn

    8-4 Robot Language Description 8-4-17 ORGN Function: Performs return-to-origin when the search method is selected as the ori- gin detection method, or checks whether return-to-origin has been per- formed when the mark method is selected. Format: ORGN Example: ORGN Performs return-to-origin when the search method is selected as the ori- gin detection method, or checks whether return-to-origin has been per- formed when the mark method is selected.
  • Page 131: Ton

    8-4 Robot Language Description 8-4-18 TON Function: Executes a specified task. Format: <task number>, <program number>, <start type> Example: 1,2,0 Newly executes program 2 as task 1. Explanation: This command starts multiple tasks and can be used to control the I/O signals in parallel with the axis movement and perform different process- ing for each axis.
  • Page 132: Jmpp

    8-4 Robot Language Description 8-4-20 JMPP Function: Jumps to a specified label when the axis position relation meets the speci- fied conditions. Format: JMPP <label number>, <axis position condition> Example: JMPP Jumps to label 3 if the X-axis position is smaller than the point specified with the point variable P.
  • Page 133: Mat

    You do not have to enter any data in p253 and p254 (when pallet number is 0). • The matrix definition contents are shared with each task. • Because only a single-axis robot is controlled with the ERCX series, the actual movement is linear even if a 2-dimensional matrix is de- fined.
  • Page 134: Msel

    8-4 Robot Language Description 8-4-22 MSEL Function: Specifies a matrix where the robot moves with a MOVM statement. Format: MSEL <pallet number> Example: MSEL Points where the robot moves with a MOVM statement are calculated based on matrix data of pallet number 0. Explanation: This command selects a matrix and is always used with a MOVM state- ment as a pair.
  • Page 135: Movm

    • The MOVM statement performs calculation on the assumption that the robot operates on the Cartesian coordinate system. • Because only a single-axis robot is controlled with the ERCX series, the actual movement is linear even if a 2-dimensional matrix is de- fined.
  • Page 136: Jmpc

    8-4 Robot Language Description 8-4-24 JMPC Function: Jumps to a specified label when the counter array variable C matches a specified value. Format: JMPC <label number>, <counter value> Example: JMPC 5, 100 Jumps to label 5 when the counter array variable C is 100. Program execution proceeds to the next step except when the counter array vari- able C is 100.
  • Page 137: Csel

    8-4 Robot Language Description 8-4-26 CSEL Function: Specifies an array element of the counter array variable C to be used. Format: CSEL <array element number> Example: CSEL The counter array variable of element number 1 is used in the subse- quent steps.
  • Page 138 8-4 Robot Language Description 8-4-28 C+ Function: Adds a specified value to the counter array variable C. Format: [<addition value>] Example: Adds 100 to the counter array variable C. (C←C+100) Adds 1 to the counter array variable C. (C←C+1) Explanation: This command adds a specified value to the counter array variable C specified with the CSEL statement.
  • Page 139 8-4 Robot Language Description 8-4-31 D+ Function: Adds a specified value to the counter variable D. Format: [<addition value>] Example: Adds 100 to the counter variable D. (D←D+100) Adds 1 to the counter variable D. (D←D+1) Explanation: This command adds a specified value to the counter variable D. The addition value can be set to any value from 1 to 65535.
  • Page 140: Shft

    8-4 Robot Language Description 8-4-33 SHFT Function: Shifts the position data. Format: SHFT <point number> Example: SHFT Shifts the coordinates on which the subsequent movement commands are executed, by a data amount defined by point 10. Explanation: This command shifts position data in the subsequent movement com- mands to be executed, by coordinates equal to the specified point data.
  • Page 141: Sample Programs

    8-5 Sample Programs Sample Programs 8-5-1 Moving between two points Program Comment [NO0] 001: L ; Label definition 002: MOVA ; Moves to P1 003: MOVA ; Moves to P2 004: TIMR ; Delays for one second 005: JMP : Returns to L0 8-5-2 Moving at an equal pitch 50mm 50mm...
  • Page 142 8-5 Sample Programs 8-5-3 Positioning 2 points and sending job commands to a PLC at each position Job 1 Job 2 Point Position at which job 1 is complete Position at which job 2 is complete General-purpose input Job 1 completion 1: Complete 0: Not complete Job 2 completion 1: Complete 0: Not complete General-purpose output Job 1 command 1: Output...
  • Page 143 8-5 Sample Programs 8-5-4 Robot stands by at P0, and moves to P1 and then to P2 to pick and place a workpiece X-axis Upper end limit switch (DI0) AC servo Air cylinder Lower end limit (DO0) switch (DI1) Air chuck (DO1) Workpiece detection sensor (DI2)
  • Page 144: Picking Up 3 Kinds Of Workpieces Flowing On The Front Conveyor And Placing Them On The Next Conveyors While Sorting

    8-5-5 Picking up 3 kinds of workpieces flowing on the front conveyor and placing them on the next conveyors while sorting [TOP VIEW] Front conveyor Workpiece Next conveyors YAMAHA single-axis robot [SIDE VIEW] Upper end limit AC servo switch (DI0) Air cylinder (DO0)
  • Page 145 8-5 Sample Programs Program Comment [NO1] <<Main routine>> 001: L ; Label definition 002: JMPB ; Jumps to L2 when workpiece A is detected 003: JMPB ; Jumps to L3 when workpiece B is detected 004: JMPB ; Jumps to L4 when workpiece C is detected 005: JMP ;...
  • Page 146: Switching The Program From I/O

    8-5 Sample Programs 8-5-6 Switching the program from I/O The ERCX series controller does not accept dedicated command inputs for program switching. To switch the program through the I/O, use the program selection signal as a conditional jump input as explained below.
  • Page 147 8-5 Sample Programs Program Comment [NO0] ; Label definition 001: L ; Waits for confirmation ON of the selected program 002: WAIT Handshaking ; Program selection start turns on 003: DO ; Waits for confirmation OFF of the selected program 004: WAIT ;...
  • Page 148: Axis Movement And I/O Multi-Task

    8-5 Sample Programs 8-5-7 Axis movement and I/O multi-task The robot moves between two points and performs multi-task I/O operation in asynchronous mode. General-purpose input/output Job status detection Job owner's output Program Comment [NO0] 001: TON ; Starts program NO1 as task 1 002: L ;...
  • Page 149 8-5 Sample Programs 8-5-8 Turning ON general-purpose outputs during robot movement after a certain time has elapsed 3 sec. 3 sec. 3 sec. DO0=1 DO1=1 DO2=1 Point Start position Target position Program Comment [NO0] 001: L ; Label definition 002: MOVA ;...
  • Page 150 8-5 Sample Programs 8-5-9 Turning ON a general-purpose output during robot movement when it has passed a specified position DO0=1 DO0=0 Point Start position Target position Position at DO0=1 Position at DO0=0 ■ When P1 is nearer to the plus side than P0: Program Comment [NO0]...
  • Page 151: Limitless Movement At Same Pitch

    8-5 Sample Programs 8-5-10 Limitless movement at same pitch The robot moves continuously in the same direction at the same pitch (e.g. 150mm) for cycle con- veyor applications. 150mm ■ Make the following settings in advance to enable the limitless movement function. •...
  • Page 152: Limitless Rotation

    8-5 Sample Programs 8-5-11 Limitless rotation The robot moves continuously in the same direction for index table applications. ■ Make the following setting in advance to enable the limitless movement function. • Set the position data unit parameter (PRM21) to 3. ■...
  • Page 153: Chapter 9 Operating The Robot

    Chapter 9 OPERATING THE ROBOT This chapter describes how to actually operate the robot. If the program has already been completed, you will be able to operate the robot by the time you finish reading this chapter. There are two types of robot operation: step and automatic. In step operation, the program is executed one step at a time, with a step being carried out each time the RUN key on the TPB is pressed.
  • Page 154: Performing Return-To-Origin

    9-1 Performing Return-to-Origin Performing Return-to-Origin There are two methods for detecting the origin position (reference point): search method and mark method. The search method is further divided into the origin sensor method and stroke-end detection method. In the mark method, you can move the robot to a desired position (mark position) and set it as the particular coordinate position to determine a reference point.
  • Page 155 9-1 Performing Return-to-Origin CAUTION When the SERVICE mode function is enabled, the following safety control will function. (See "10-4 SERVICE mode function".) • Return-to-origin movement speed is limited to 10mm/s or less (10deg/s for rotary robots) in "SERVICE mode state" when the robot movement speed limit is enabled. •...
  • Page 156: Return-To-Origin By The Mark Method

    9-1 Performing Return-to-Origin 9-1-2 Return-to-origin by the mark method When the mark method is selected as the origin detection method (PRM13=2), perform return-to- origin with the procedure below. 1) Press (OPRT) on the initial screen. [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (ORG).
  • Page 157 9-1 Performing Return-to-Origin 7) When you press after moving the robot to the mark position by the teaching playback [ORG-MARK-TCH] method or direct teaching method, the screen changes to allow entering the coordinate val- input mark position ues for the mark position. While checking the robot stays at the mark po- sition, use the number keys to enter the coordi- ][mm]...
  • Page 158: Using Step Operation

    9-2 Using Step Operation Using Step Operation The following procedure explains how to perform step operation. In the case of a multi-task program, only the task currently selected is executed in step operation. 1) On the initial screen, press (OPRT). [MENU] select menu 1EDIT2OPRT3SYS 4MON...
  • Page 159 9-2 Using Step Operation 7) The screen returns to step 5. Pressing [OPRT-STEP] 50 0:10 this point executes the first step. 001:MOVA 999,50 0.00] 1SPD 2RSET3CHG 4next 8) This screen is displayed while the program is [OPRT-STEP] being executed. running ... 9) Pressing during execution brings the ro- STOP...
  • Page 160 9-2 Using Step Operation 14)The screen returns to step 5, and the process is [OPRT-STEP] 50 0:10 repeated from that point. 001:MOVA 999,50 250.00] 1SPD 2RSET3CHG 4next CAUTION When the SERVICE mode function is enabled, the following safety control will function. (See "10-4 SERVICE mode function".) •...
  • Page 161: Using Automatic Operation

    9-3 Using Automatic Operation Using Automatic Operation The following procedure explains how to perform automatic operation. All the tasks started in a multi-task program are executed by automatic operation. 1) On the initial screen, press (OPRT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press (AUTO).
  • Page 162 9-3 Using Automatic Operation 8) This is the screen displayed while the program [OPRT-AUTO] is being executed. running ... 9) Pressing during execution brings the ro- STOP [OPRT-AUTO] bot to a halt and displays the message "stop key". Press the key to display the step where execution was interrupted.
  • Page 163: Switching The Execution Program

    9-4 Switching the Execution Program Switching the Execution Program The following procedure explains how to switch the program in automatic operation. Use the same procedure in step operation. The program selected by this procedure will be the lead program to which the execution sequence always returns after program reset.
  • Page 164: Emergency Stop Function

    9-5 Emergency Stop Function Emergency Stop Function There are two ways to trigger emergency stop on the ERCX controller. One way is by using the push- button on the TPB. The other is to use the I/O emergency stop input. In either case for safety reasons, a contact B (normally closed) input is used (when the contact is opened, emergency stop is triggered).
  • Page 165 9-5 Emergency Stop Function 3) After the emergency stop is released, a mes- sage appears asking whether to turn the servo [OPRT-STEP] 100 0: 7 To turn the servo on, press (yes). servo on ready ? To leave the servo off , press (no).
  • Page 166: Displaying The Memory I/O Status

    9-6 Displaying the Memory I/O Status Displaying the Memory I/O Status The memory I/O status can be displayed on the screen. 1) On the initial screen, press (OPRT). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Press (STEP) or (AUTO). [OPRT] The STEP or AUTO mode screen appears. The select menu following steps are explained using the STEP mode screen.
  • Page 167: Displaying The Variables

    9-7 Displaying the Variables Displaying the Variables The values of point data variable "P", counter array variable "C" and counter variable "D" can be displayed on the TPB screen. This monitor function can be used when the ERCX controller version is 13.23 or later and the TPB version is 12.18 or later.
  • Page 168 MEMO...
  • Page 169: Chapter 10 Other Operations

    Chapter 10 OTHER OPERATIONS The TPB has many convenient functions in addition to those already covered. For example, memories can be initialized, and options such as memory cards can be used. This chapter will describe these additional functions...
  • Page 170: Initialization

    10-1 Initialization 10-1 Initialization Initializing the programs and points erases all the program data and point data currently stored in the controller. Initializing the parameters resets the parameters to their initial values. 1) On the initial screen, press (SYS). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Next, press...
  • Page 171 10-1 Initialization 6) A confirmation message appears after select- [SYS-INIT-PRM] ing the lead length. robot type : 90 Make sure the lead length is correct and press (yes). lead : 6.0 [mm] To select another lead length, press (no). 1yes 2no 7) Next, enter the robot stroke length.
  • Page 172: Dio Monitor Display

    10-2 DIO Monitor Display 10-2 DIO Monitor Display Data indicating whether the I/O signals are on or off can be displayed on the screen. The operation procedure is explained below. 10-2-1 Display from the monitor menu 1) On the initial screen, press (MON).
  • Page 173: Display From The Dio Key Operation

    10-2 DIO Monitor Display 10-2-2 Display from the DIO key operation 1) Hold down the key. [OPRT-AUTO] running... 2) The ON/OFF status of I/O signals is displayed DI 10000000 00000000 as long as the key is held down. For information about what the display shows, 10000000 refer to "4-3-4 DIO monitor screen".
  • Page 174: Service Mode Function

    10-4 SERVICE mode function 10-4 SERVICE mode function The SERVICE mode function is explained in this section. The robot operator or others sometimes need to enter the hazardous area in the robot safety enclosure and move the robot to perform maintenance or adjustment while using the TPB. This situation is referred to as "SERVICE mode state"...
  • Page 175: Safety Settings For Service Mode

    10-4 SERVICE mode function 10-4-1 Safety settings for SERVICE mode Safety controls that work in "SERVICE mode state" are explained in detail below. ■ Limiting command input from any device other than TPB When the operator is working within the robot safety enclosure using the TPB, permitting any command input from devices (such as via I/O) other than the TPB is very hazardous to the TPB operator.
  • Page 176 10-4 SERVICE mode function ■ Prohibiting the automatic operation and step operation Running an automatic operation or step operation while an operator is working within the robot safety enclosure is very dangerous to that operator. (For example, when the operator is in the safety enclosure, a hazardous situation may occur if someone runs a robot program without letting the operator know about it.) To avoid this kind of hazard, automatic operation and step operation are basically prohibited in "SERVICE mode state".
  • Page 177: Enabling/Disabling The Service Mode Function

    10-4 SERVICE mode function 10-4-2 Enabling/disabling the SERVICE mode function To enable or disable the SERVICE mode function, follow these steps. 1) On the initial screen, press (SYS). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Press (next) to change the menu display [SYS] and then press (SAFE).
  • Page 178 10-4 SERVICE mode function 7) When writing is complete, the screen returns [SYS-SAFE-SVCE-SET] to step 6. SERVICE mode = 1 0:Invalid 1:Valid NOTE The password is identical to the ERCX controller's version number. For example, if the controller version is 13.13, enter 13.13 as the password.
  • Page 179: Setting The Service Mode Functions

    10-4 SERVICE mode function 10-4-3 Setting the SERVICE mode functions 1) On the initial screen, press (SYS). [MENU] select menu 1EDIT2OPRT3SYS 4MON 2) Press (next) to change the menu display [SYS] and then press (SAFE). select menu 1SAFE2OPT 3UTL 4next 3) The password request screen appears.
  • Page 180 10-4 SERVICE mode function 7) When the setting has been changed, the memory [SYS-SAFE-SVCE-DEV] write screen appears. To save the change permanently (retain the data = 1 change even after the controller power is turned PB/DI valid off), press (SAVE). To save the change temporarily (retain the 1SAVE2CHG 3CANCEL change until the power is turned off), press...
  • Page 181: System Utilities

    10-5 System utilities 10-5 System utilities 10-5-1 Viewing hidden parameters Parameters hidden in the normal state can be viewed. Use extra caution to avoid accidentally changing the parameters when these hidden parameters are displayed. 1) On the initial screen, press (SYS).
  • Page 182: Using A Memory Card

    10-6 Using a Memory Card 10-6 Using a Memory Card A memory card can be used with the TPB to back up the data in the ERCX controller. Refer to "16-2-1 Memory card" for the procedure for handling a memory card and for the number of data that can be stored.
  • Page 183 10-6 Using a Memory Card 7) The saved status of data on the memory card can be checked by pressing (ID) in step 6. [SYS-B.UP-ID] To check the saved status in AREA 3 onward, AREA 0 : 00.01.01 press to scroll the screen. To return STEP STEP DOWN...
  • Page 184: Loading Data From A Memory Card

    10-6 Using a Memory Card 10-6-2 Loading data from a memory card 1) Insert the memory card into the TPB. 2) On the initial screen, press (SYS). [MENU] select menu 1EDIT2OPRT3SYS 4MON 3) Next, press (B.UP). [SYS] select menu 1PRM 2B.UP3INIT 4) Press (LOAD).
  • Page 185 10-6 Using a Memory Card 7) When the load area was selected in step 5, the [SYS-B.UP-LOAD]AREA3 data load screen appears. Select the data to be loaded. Select menu To load the program data, press (PGM). To load the point data, press (PNT).
  • Page 186: Formatting A Memory Card

    10-6 Using a Memory Card 10-6-3 Formatting a memory card 1) Insert the memory card into the TPB. 2) On the initial screen, press (SYS). [MENU] select menu 1EDIT2OPRT3SYS 4MON 3) Next, press (B.UP). [SYS] select menu 1PRM 2B.UP3INIT 4) Press (FMT).
  • Page 187: Viewing The Id Number For Memory Card Data

    10-6 Using a Memory Card 10-6-4 Viewing the ID number for memory card data 1) Insert the memory card into the TPB. 2) On the initial screen, press (SYS). [MENU] select menu 1EDIT2OPRT3SYS 4MON 3) Next, press (B.UP). [SYS] select menu 1PRM 2B.UP3INIT 4) Press (ID).
  • Page 188: Duty (Load Factor) Monitor

    10-7 Duty (load factor) monitor 10-7 Duty (load factor) monitor The ERCX controller has a duty (load factor) monitor to allow you to operate the robot under the most optimal conditions. The duty monitor checks the robot's motor load factor and displays it in percent (%) versus the motor rating.
  • Page 189 10-7 Duty (load factor) monitor [Method 2] 1) Add the robot language command "DUTY 1" to the beginning of the interval in a program in which you want to measure the duty and also add the robot language command "DUTY 0"...
  • Page 190: Measuring The Duty (Load Factor)

    10-7 Duty (load factor) monitor 10-7-1 Measuring the duty (load factor) NOTE The duty monitor function can be used when the controller version is 13.50 or later and the TPB version is 12.60 or later. 1) Press (MON) on the TPB initial screen [MENU] while moving the robot with a point move- ment command (ABS-PT, INC-PT) or a...
  • Page 191: Chapter 11 Communication With Pc

    Chapter 11 COMMUNICATION WITH PC The ERCX controller allows you to edit the program data and point data or control the robot operation using a PC (personal computer) by RS-232C communication instead of using the TPB. This chapter describes how to set the communication parameters required to communicate between the PC and the ERCX controller, and also explains the communication command specifications.
  • Page 192: Communication Parameter Specifications

    11-1 Communication Parameter Specifications 11-1 Communication Parameter Specifications The communication parameters on the PC should be set as follows. For the setting procedure, refer to the computer operation manual. ■ Baud rate 9600 bps ■ Data bit length 8 bits ■...
  • Page 193: Communication Cable Specifications

    11-2 Communication Cable Specifications 11-2 Communication Cable Specifications CAUTION Pins 10, 12, 18 and 21 of the controller's connector are specifically used for TPB connection. To avoid possible accidents do not connect other inputs to these pins. When using optional POPCOM software, make connections while referring to the POPCOM operation manual since it shows the different connection specifications.
  • Page 194: Communication Command Specifications

    Items in [ ] (brackets) can be omitted. ■ The character codes used in the ERCX series, are the JIS8 unit system codes (ASCII codes with katakana characters added). Input characters can be upper case or lower case. ■ One or more space must be inserted between the operation code and the operand.
  • Page 195: Communication Command List

    11-4 Communication Command List 11-4 Communication Command List 1. Robot movement Operation code Operand 1 Operand 2 Operand 3 Command details Returns to origin ORGN RESET Resets program Starts automatic operation SRUN Starts step operation SRVO Turns servo off Turns servo on X+/X- Performs jog movement (inching) along X-axis XINC/...
  • Page 196 11-4 Communication Command List 2. Data handling Operation code Operand 1 Operand 2 Operand 3 Command details ?POS Reads current position Reads current program number ?SNO Reads current step number ?TNO Reads current task number ?PNO Reads current point number ?STP program number Reads total number of steps in specified...
  • Page 197 11-4 Communication Command List 3. Utility Operation code Operand 1 Operand 2 Operand 3 Command details INIT Initializes program data Initializes point data robot number Initializes robot parameters CLOCK Initializes timer that measures total operation time Initializes alarm history Initializes error history program number Switches program number to be run SWITSK...
  • Page 198: Communication Command Description

    11-5 Communication Command Description 11-5 Communication Command Description 11-5-1 Robot movements (1)@ORG @ORGN This commands performs return-to-origin when the search method is selected as the origin detec- tion method and outputs the machine reference value when return-to-origin is completed nor- mally.
  • Page 199 11-5 Communication Command Description (2)@RESET This returns the program execution step to the first step of the program selected with the '@SWI' statement, and turns all general-purpose outputs (DO0 to DO12) and memory output off. The "current position in the program" used as a reference for the relative movement command (MOVI) is initialized to the current position of the robot, and the point variable P is also cleared to 0.
  • Page 200 11-5 Communication Command Description (5)@SRVO <servo status> Turns the servo on or off. Servo status : Specify 1 to turn the servo on or 0 to turn it off. Transmission example : @SRVO 0 c/r l/f ......Turns the servo off. Response example : OK c/r l/f (6)@X+, (@X-)
  • Page 201 11-5 Communication Command Description (9)@MOVA <point number>,<speed> Moves the robot to a position specified by a point number at a specified speed. Point number : This is a number assigned to each point (position data) and can be from 0 to 999 (a total of 1,000 points). Data for the point numbers can be edited with the @WRITE PNT statement.
  • Page 202 11-5 Communication Command Description (11)@MOVF <point number>,<DI number>,<DI status> This command moves the robot toward a position specified by a point number until a specified DI input condition is met. When the DI condition is met, the robot stops and the command termi- nates.
  • Page 203 11-5 Communication Command Description (15)@P <point number> Sets the point variable P. Point number : This can be any value from 0 to 999. Transmission example : @P 100 c/r l/f ....... Set the point variable P to 100. Response example : OK c/r l/f CAUTION The contents of the point variable P are held even when the ERCX is turned off.
  • Page 204 11-5 Communication Command Description (18)@MOVM <pallet work position>,<speed> Moves the robot to a specified pallet work position at a specified speed. This command is available with controller version 13.23 or later. Pallet work position : The pallet work position is a number used to identify each point on a matrix, and can be from 1 to 65025 (=255 ×...
  • Page 205 11-5 Communication Command Description (21)@CSEL <array element number> Specifies an array element for the counter array variable C to be used. This command is available with controller version 13.23 or later. Array element number : This is a number used to designate an array element for the counter array variable C, and can be from 0 to 31.
  • Page 206 11-5 Communication Command Description (26)@D+ [<addition value>] Adds a specified value to the counter variable D. This command is available with controller version 13.23 or later. Addition value : This can be any value from 1 to 65535. If this value is omitted, then 1 is added to the counter variable.
  • Page 207: Data Handling

    11-5 Communication Command Description 11-5-2 Data handling (1)@?POS Reads the current position. Transmission example : @?POS c/r l/f Response example : 321.05 c/r l/f OK c/r l/f (2)@?NO Reads the current program number. In multi-task operation, this command reads the program information on the task currently selected.
  • Page 208 11-5 Communication Command Description (6)@?STP <program number> Reads the total number of steps in the specified program. Program number : This is a number used to identify each program and can be 0 to 99 (a total of 100). Transmission example : @?STP 10 c/r l/f ......
  • Page 209 11-5 Communication Command Description (11) @?ALM <history number>[,<display count>] Displays a specified number of past alarms, starting from a specified history number. A maximum of 100 past alarms can be displayed. This alarm history shows the time (total elapsed time from controller start-up) that each alarm occurred and a description of the alarm.
  • Page 210 11-5 Communication Command Description (14)@?ORG Reads whether or not return-to-origin has been completed. Transmission example : @?ORG c/r l/f Response example 1 : 0 c/r l/f .......... Return-to-origin not com- OK c/r l/f pleted. Response example 2 : 1 c/r l/f .......... Return-to-origin completed. OK c/r l/f (15)@?MODE Reads the robot status.
  • Page 211 11-5 Communication Command Description (18)@?DO <general-purpose output or memory output number> Reads the status of a general-purpose output or memory output. Output number : Specify one of the general-purpose outputs 0 to 12 (13 points) or one of the memory outputs 100 to 131 (32 points). Transmission example : @?DO 2 c/r l/f Response example 1...
  • Page 212 11-5 Communication Command Description (20-1) @?P <point number> Reads the data of a specified point. Point number : This is a number used to identify each point data and can be from 0 to 999. Transmission example : @?P 254 c/r l/f ......Reads the data of point 254. Response example 1 : -0.05 c/r l/f OK c/r l/f...
  • Page 213 11-5 Communication Command Description (21-2) @READ PGM Reads all of the program data. Transmission example : @READ PGM c/r l/f Response example : NO0 c/r l/f MOVA 0,100 c/r l/f JMPF 0,31,13 c/r l/f NO31 c/r l/f STOP c/r l/f ^Z (=1AH) OK c/r l/f (21-3) @READ PNT...
  • Page 214 11-5 Communication Command Description (21-5) @READ ALL Reads all data (parameters, programs, points) at one time. Each data group (parameters, pro- grams, points) is separated by an empty line (a carriage return only). Transmission example : @READ ALL c/r l/f Response example : PRM0=20 c/r l/f PRM1=350 c/r l/f...
  • Page 215 11-5 Communication Command Description (21-8) @READ INF Reads the status of the registered programs. The registered program numbers and number of steps are displayed. Transmission example : @READ INF c/r l/f Response example : NO0- 43 steps c/r l/f NO1- 52 steps c/r l/f NO31- 21 steps c/r l/f ^Z (=1AH) OK c/r l/f...
  • Page 216 11-5 Communication Command Description (22-3) @WRITE PRM Writes the parameter data. The controller will transmit READY when this command is received. Confirm that READY is received and then transmit the parameter data. Always transmit ^Z (=1AH) at the end of the data. Transmission example : Send Receive...
  • Page 217 11-5 Communication Command Description (23)@?ERR <history number>[,<display count>] Displays a specified number of past errors, starting from a specified history number. A maximum of 100 past errors can be displayed. This error history shows the time (total elapsed time from controller start-up) that each error occurred and a description of the error.
  • Page 218 11-5 Communication Command Description (26)@?CSEL Reads the currently specified element number of the counter array variable C. In multi-task opera- tion, this command reads the program information on the task currently selected. This command is available with controller version 13.23 or later. Transmission example : @?CSEL c/r l/f Response example...
  • Page 219: Utilities

    11-5 Communication Command Description 11-5-3 Utilities (1-1) @INIT PGM Initializes all program data. Transmission example : @INIT PGM c/r l/f Response example : OK c/r l/f (1-2) @INIT PNT Initializes all point data. Transmission example : @INIT PNT c/r l/f Response example : OK c/r l/f (1-3) @INIT PRM <robot number>...
  • Page 220 11-5 Communication Command Description (2)@SWI <program number> This command switches the execution program number. When a program is reset, program execu- tion will always return to the first step of the program selected here. The program is reset when the @SWI command is executed.
  • Page 221 11-5 Communication Command Description (5)@SDEL <program number>,<step number> Deletes a specified step. Program number : This is a number used to identify each program and can be from 0 to 99. Step number : This is a number used to identify each step and can be from 1 to 255.
  • Page 222 11-5 Communication Command Description (8)@DEL <program number> Deletes a program. Program number : This is a number used to identify each program and can be from 0 to 99. Transmission example : @DEL 10 c/r l/f ......Deletes program No. 10. Response example 1 : OK c/r l/f Response example 2...
  • Page 223: Chapter 12 Message Tables

    Chapter 12 MESSAGE TABLES This section lists all of the messages that are displayed on the TPB or sent to the PC (personal computer) to inform the operator of an error in operation or a current status. For a list of the alarm messages displayed if any trouble occurs, refer to "13-2 Alarm and Countermeasures".
  • Page 224: Error Messages

    12-1 Error Messages 12-1 Error Messages 12-1-1 Error message specifications The error message transmission format is as follows. <Error No.> : <Error message> c/r l/f The length of the <error message> character string is 17 characters. (Spaces are added until the message contains 17 characters.) Thus, the character string length containing the c/r l/f will be 22 characters.
  • Page 225: Operation Error Message

    12-1 Error Messages 12-1-3 Operation error message Message soft limit over Error No. Cause Executing the command will move the robot to a position that exceeds the soft limit set by parameter. Action Review the point data or soft limit parameter. Message running Error No.
  • Page 226: Program Error Message

    12-1 Error Messages 12-1-4 Program error message Message stack overflow q Seven or more successive CALL statements were used within a CALL statement. w In the program called as a subroutine by a CALL statement, a jump was made to Error No.
  • Page 227: System Error Message

    12-1 Error Messages 12-1-5 System error message Message system error Error No. An unexpected error occurred. Cause Action Contact YAMAHA and describe the problem. Message illegal opecode Error No. Cause There is an error in a registered program. Action Check the program.
  • Page 228: Tpb Error Messages

    SIO error 1. Parity error in data received from controller. Cause 2. TPB was connected when dedicated command input was on. 1. Contact YAMAHA for consultation. Action 2. Turn all dedicated command inputs off before connecting the TPB. Message bad format Cause The memory card is not formatted.
  • Page 229: Stop Messages

    12-3 Stop Messages 12-3 Stop Messages 12-3-1 Message specifications The stop message transmission format is as follows. <Stop No.> : <Stop message> c/r l/f The length of the <stop message> character string is 17 characters. (Spaces are added until the mes- sage contains 17 characters.) Thus, the character string length containing the c/r l/f will be 22 charac- ters.
  • Page 230: Displaying The Error History

    12-4 Displaying the Error History 12-4 Displaying the Error History A history of past errors can be displayed. Up to 100 errors can be stored in the controller. This function is available when the controller version is 13.50 or later and the TPB version is 12.18 or later.
  • Page 231 12-4 Displaying the Error History 5) History numbers, time that errors occurred 00:00101,05:11:12,CM (total elapsed time from controller start-up) and error descriptions are displayed. One 01:00096,18:10:02,PI screen displays the past 4 errors in the order from the most recent error. 02:00080,10:07:33,CM Pressing the keys displays the...
  • Page 232 MEMO...
  • Page 233: Chapter 13 Troubleshooting

    Chapter 13 TROUBLESHOOTING This chapter explains how to take corrective action when a problem or breakdown occurs, by categorizing it into one of two cases depending on whether or not an alarm is output from the controller.
  • Page 234: If A Trouble Occurs

    13-1 If A Trouble Occurs 13-1 If A Trouble Occurs If trouble or breakdown occurs, contact YAMAHA or your YAMAHA dealer, providing us with the following information in as much detail as possible. Item Description (example) What you were using ・Controller model name...
  • Page 235: Alarm And Countermeasures

    13-2 Alarm and Countermeasures 13-2 Alarm and Countermeasures If the READY singal is turned off except in cases of emergency stop, then an alarm has probably been issued. The status LED on the front panel of the controller lights up in red. 13-2-1 Alarm specifications ■...
  • Page 236: Alarm Message List

    13-2 Alarm and Countermeasures 13-2-2 Alarm message list Alarm No. Alarm Message Meaning Possible Cause Action OVER LOAD Excessive load Improper operation Lower the operation duty on the robot on motor or reduce the acceleration parameter, or correct the payload parameter. Motor failure If the motor armature resistance is too low or the motor movement is...
  • Page 237 13-2 Alarm and Countermeasures Alarm No. Alarm Message Meaning Possible Cause Action P.E. COUNTER Overflow in Mechanical lock Check whether robot moving parts are OVER position deviation locked. counter Motor wire is broken or connected Check the motor wire and resolver wrong.
  • Page 238 13-2 Alarm and Countermeasures Alarm No. Alarm Message Meaning Possible Cause Action ABNORMAL Excessive voltage Rise in regenerative absorption Lower the operation duty on the VOLTAGE (higher than resistor temperature (above robot, or install a cooling fan. 30V) generated 120°C). Incorrect power supply voltage Check the power supply voltage.
  • Page 239: Troubleshooting For Specific Symptom

    13-3 Troubleshooting for Specific Symptom 13-3 Troubleshooting for Specific Symptom If any problems develop while the controller is being used, check the items below for the appropriate way to handle them. If the problem cannot be corrected using the steps listed below, please contact our sales office or sales representative right away.
  • Page 240 13-3 Troubleshooting for Specific Symptom Symptom Possible Cause Items to Check Action Abnormal noise Coupling is not • Check the coupling bolts. • Tighten if loose. or vibration securely tightened. occurs. A screw on the • Check the screws used to secure the •...
  • Page 241: Relating To The I/O

    13-3 Troubleshooting for Specific Symptom Symptom Possible Cause Items to Check Action Robot starts Motor and/or • Check the motor wire and resolver • Correct the connections. moving at high resolver are signal wire connections. speed when the miswired. power is turned Parameter error •...
  • Page 242: Other

    13-3 Troubleshooting for Specific Symptom 13-3-3 Other Symptom Possible Cause Items to Check Action An error • Check the signal input (by using a PLC • Always turn off dedicated command A dedicated I/O occurs when monitor, etc.). input signals when connecting the TPB command input is the TPB is to the controller.
  • Page 243: Displaying The Alarm History

    13-4 Displaying the Alarm History 13-4 Displaying the Alarm History A history of past alarms can be displayed. Up to 100 alarms can be stored in the controller. This function is available with TPB version 12.18 or later. 1) On the initial screen, press (SYS).
  • Page 244 13-4 Displaying the Alarm History 5) History numbers, time that alarms occurred 00:00101,05:11:12,X0 (total elapsed time from controller start-up) and alarm descriptions are displayed. One 01:00096,18:10:02,X0 screen displays the past 4 alarms in the order 02:00080,10:07:33,X0 from the most recent alarm. Pressing the keys displays the –...
  • Page 245: Chapter 14 Maintenance And Warranty

    Chapter 14 MAINTENANCE AND WARRANTY For safety purposes, always turn the power off before starting robot maintenance, cleaning or repairs, etc.
  • Page 246: Warranty

    14-1 Warranty 14-1 Warranty For information on the product warranty, please contact your local agent where you purchased your product. 14-2 Replacing the System Backup Battery If an alarm is issued indicating that the system backup battery voltage is low, replace the battery using the procedure listed below.
  • Page 247: Updating The System

    14-4 Updating the System 14-4 Updating the System YAMAHA may request, on occasion, that you update the system in your equipment. The following steps describe how to update the system. Before updating the system, you must set up a system that allows communications between the controller and a PC (personal computer).
  • Page 248 MEMO...
  • Page 249: Chapter 15 Specifications

    Chapter 15 SPECIFICATIONS...
  • Page 250: Ercx Sereis

    15-1 ERCX sereis 15-1 ERCX sereis 15-1-1 Basic specifications Model ERCX Specification item Applicable motor capacitance DC24V, 30W or less Basic W30 × H250 × D157mm External dimensions specifi- Weight 0.9kg cations Power supply voltage DC24V±10%, 3A to 4.5A (Depends on robot type) No.
  • Page 251: Robot Number List

    15-1 ERCX sereis 15-1-2 Robot number list Each robot model has an identification number as listed in the table below. After you initialize the parameters, enter the correct robot number that matches the robot model actually connected to the controller. Single-axis robot YMS45 YMS55...
  • Page 252: Tpb

    15-2 TPB 15-2 TPB 15-2-1 Basic specifications Model Specification item W107 × H235 × D47mm External dimensions Weight 590g Basic Power consumption 5 V, 200 mA max. specifications Power supply DC12V (supplied form the controller) Cable length Standard 3.5m Serial interface RS-232C, one channel, for communications with controller Liquid crystal, 20 characters ×...
  • Page 253: Chapter 16 Appendix

    Chapter 16 APPENDIX...
  • Page 254: Operation When Not Using Absolute Function

    16-1 Operation When Not Using Absolute Function 16-1 Operation When Not Using Absolute Function An absolute backup function is standard on the ERCX controllers. This means return-to-origin is unnecessary each time the controller is turned on. In some cases, however, the absolute function is not needed because the customer is accustomed to always performing return-to-origin when the power is turned on.
  • Page 255: How To Handle Options

    16-2 How to Handle Options 16-2 How to Handle Options 16-2-1 Memory card A memory card (option) can be used with the TPB to back up the ERCX controller data. ■ Using the memory card 1. Insert the memory card into the TPB as shown in Fig. 16-1. 2.
  • Page 256 16-2 How to Handle Options ■ Data size that can be saved Data size that can be saved on one memory card is as follows: Memory card Save format capacity Ver. 1.52 or later Ver. 2.04 to 2.18 Ver. 12.12 or later Standard Cannot be used.
  • Page 257: Handling The I/O Checker

    16-2 How to Handle Options 16-2-2 Handling the I/O Checker This device connects to the I/O connector of the ERCX controller and is used for pseudo-input (emulation) by means of switches and for input/output monitoring by LED display. ■ Connecting the I/O checker 1.
  • Page 258: Popcom Communication Cable

    16-2 How to Handle Options 16-2-3 POPCOM communication cable This cable is used to operate the ERCX controller from POPCOM software which runs on a PC and allows easy and efficient robot programming and operation. This POPCOM cable is different from typical communication cables, so do not use it for other pur- pose.
  • Page 259 MEMO...
  • Page 260 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.

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