Page 1 Original instructions YAMAHA SCARA ROBOT YK-XE Series Installation Manual YK400XE-4 YK510XE-10 / YK610XE-10 / YK710XE-10 EWFV237135 Ver. 1.35 E674...
Page 3 CONTENTS YK-XE Installation Manual Warranty Chapter 1 Introduction 1. Introduction 1.1 Available manuals 1.2 Signal symbols 2. Action when a person is caught by robot 3. Emergency action when a person is caught by robot Chapter 2 Functions 1. Robot manipulator 1.1 Manipulator movement 1.2 Part names 2.
Page 4 CONTENTS YK-XE Installation Manual 6. Attaching the end effector 3-14 6.1 Setting the parameters 3-14 6.1.1 Setting the parameters according to the load 3-14 6.1.2 Relevant parameters 3-14 6.1.3 Confirmation after setting the parameters 3-15 6.2 Acceleration coefficient vs. moment of inertia 3-16 6.2.1 R-axis tolerable moment of inertia and acceleration coefficient 3-16 6.3 Equation for moment of inertia calculation 3-17 6.4 Example of moment of inertia calculation 3-20 6.5 Attaching the end effector 3-22 6.6 Gripping force of end effector...
Page 5 CONTENTS YK-XE Installation Manual 19.How to pass wiring and tubing 3-53 19.1 For user wiring/tubing through spline type 3-53 19.2 For user wiring/tubing through cap type YK510XE YK610XE YK710XE 3-54 20.Tool flange mounting YK510XE YK610XE YK710XE 3-55 21.Attaching cap (for user wiring/tubing through cap type) YK510XE YK610XE YK710XE 3-57 22.Retrofitting the brake release switch...
Page 6 CONTENTS YK-XE Installation Manual 5. Setting the standard coordinates 4-32 5.1 Standard coordinate setting using a standard coordinate setup jig YK400XE 4-33 5.2 Standard coordinate setting using a standard coordinate setup jig YK510XE YK610XE YK710XE 4-34 6. A ffixing the stickers for origin positions, movement directions, and axis names 4-37 Chapter 5 Periodic inspection 1.
Page 7 9. Pollution, salt damage, condensation; 10. Fires or natural disasters such as earthquakes, tsunamis, lightning strikes, wind and flood damage, etc; 11. Breakdown due to causes other than the above that are not the fault or responsibility of YAMAHA; ■...
Page 9 Chapter 1 Introduction Contents Introduction Available manuals Signal symbols Action when a person is caught by robot Emergency action when a person is caught by robot 1-4...
Page 11 YAMAHA experience and achievements in the automation field as well as efforts to streamline our in- house manufacturing systems. The YK-XE series robots have a two-joint manipulator consisting of an X-axis arm and a Y-axis arm, and are further equipped with a vertical axis (Z-axis) and a rotating axis (R-axis) at the tip of the manipulator.
Page 12 CAUTION Use only the lubricants specified by your distributor. "Harmonic" and "Harmonic drive" are the registered trademarks of Harmonic Drive Systems Inc. Signal symbols The following safety alert symbols and signal words are used to provide safety instructions that must be observed and to describe handling precautions, prohibited actions, and compulsory actions.
Page 13 If a person is caught or caught by a robot, a machine such as a frame, release the person by the following methods. ■ Using the Robot Brake Release Switch (YK-XE Series Optional) WARNING The Z-axis will slide down when the brake is released, causing a hazardous situation.
Page 14 Emergency action when a person is caught by robot At this time, our thanks for your purchase of this YAMAHA YK-XE series SCARA robot. NOTE In the RCX340 controller, axis names are called using numeric values, like axis-1, axis-2, axis-3, and so on. In this manual, axis names are called using alphabetic characters, like X-axis, Y-axis, Z-axis, and so on.
Page 15 Robot malfunctions (vibration, noise) may also occur. The origin position of the YK-XE series robots is adjusted to the position as shown below, so the reference or standard coordinates are temporarily set. The customer should set the origin position before any other job. There are 2 types of origin position settings as shown below.
Page 16 Set the standard coordinates while referring to instructions in "5. Setting the standard coordinates" in Chapter 4 of this manual and also to "Setting the Standard coordinates" in the "YAMAHA Robot Controller User's Manual". Robot malfunctions (vibration, noise) may occur if the standard coordinates are not set correctly.
Page 17 Chapter 2 Functions Contents Robot manipulator Manipulator movement Part names Brake release switch Robot controller Robot initialization number list...
Page 19 The YK-XE series robots are available in 4-axis models having an X/Y-axis arm (equivalent to human arm) and a Z/R-axis (equivalent to human wrist). With these 4 axes, the YK-XE series robots can move as shown in the Fig. below. By attaching different types of end effector (gripper) to the end of the arm, a wide range of tasks can be performed with high precision at high speeds.
Page 20 User tubing 2 (φ4 red) stopper User tubing 3 (φ4 blue) X-axis motor M4 ground terminal Z-axis spline X-axis mechanical stopper Standard type Tapped hole for user 23102-FV-01 * YAMAHA Part Nos. PARTS NAME PARTS NO. LABEL,SERIAL NUMBER 90K43-000100 LABEL,DANGER 90K41-001470 LABEL,WARNING 90K41-001460 LABEL,WARNING...
Page 21 User tubing 3 (φ6 blue) Y-axis mechanical View of stopper M4 ground terminal X-axis motor X-axis Tapped hole for user mechanical stopper 23104-FV-00 * YAMAHA Part Nos. PARTS NAME PARTS NO. LABEL,SERIAL NUMBER 90K43-000100 LABEL,DANGER 90K41-001470 LABEL,WARNING 90K41-001460 LABEL,WARNING 90K41-001290...
Page 22 RCX340 Operation manual "Servo operation" - "Motor power and servo on/off" ■ For direct teaching Refer to each Chapter. Robot controller The YK-XE series robot comes supplied with a robot controller RCX340/RCX340XE. For more details, refer to the separate "YAMAHA Robot Controller User's Manual". Robot controller RCX340 23103-FK-00...
Page 23 Robot initialization number list The YK-XE series robots are initialized for optimum setting (default setting) according to the robot model prior to shipping. The robot controllers do not have to be reinitialized during normal operation. However, if for some reason the controller must be reinitialized, proceed while referring to the robot number shown below.
Page 25 Chapter 3 Installation Contents Robot installation conditions Installation environments Installation base Installation Unpacking Checking the product Moving the robot YK400XE Moving the robot YK510XE YK610XE YK710XE Installing the robot Protective bonding Robot cable connection 3-10 User wiring and user tubing 3-11 Attaching the end effector 3-14...
Page 26 Limiting the movement range with Z-axis mechanical stopper YK510XE YK610XE YK710XE 3-31 Installing the minus direction stopper 3-33 Installing the plus direction stopper 3-35 10. Overrun amounts during impacts with Z-axis additional mechanical stopper 3-36 11. Working envelope 3-37 11.1 Working envelope 3-37 11.2...
Page 27 40μm or less Working space Allow sufficient space margin to perform jobs (teaching, inspection, repair, etc.) For detailed information on how to install the robot controller, refer to the separate "YAMAHA Robot Controller User's Manual". WARNING • Avoid installing the robot in locations where the ambient conditions may exceed the allowable temperature or humidity, or in environments where water, corrosive gases, metallic powder or dust are generated.
Page 28 Installation base Prepare a sufficiently rigid and stable installation base, taking account of the robot weight including the end effector (gripper), workpiece and reaction force while the robot is operating. WARNING • Be sure to install the robot on a horizontal surface with the base mount section facing down. Install the wall- mount or wall-mount inverse model robot with the base mount section facing sideward.
Page 29 The equipment and tools used for moving the robot should be serviced daily. The YK-XE series robot comes packed with a robot controller and accessories, according to the order specifications. Using a carrying cart (dolly) or forklift, move the package to near the installation base. Take sufficient care not to apply shocks to the equipment when unpacking it.
Page 30 After unpacking, check the product configuration and conditions. CAUTION If there is any damage due to transportation or insufficient parts, please notify your distributor immediately. ● Controller : RCX340 Robot : YK-XE series Product configurations Standard Robot manipulator Accessories Warning label (×1)
Page 31 Moving the robot YK400XE WARNING Serious injury may occur if the robot falls and pins someone under it. • Do not allow any part of your body to enter the area beneath the robot during work. • Always wear a helmet, safety shoes and gloves during work. To check the mass of robot, refer to "1.1 Basic specification"...
Page 32 Moving the robot YK510XE YK610XE YK710XE WARNING If the transported robot falls and is laid down, serious injury may result. • Use a hoist and rope that can carry the weight of the robot with sufficient margin. • Be careful not to let the rope come off the hoist. •...
Page 33 Support the robot. Support the robot with 3 rope and non-slip bolts (M8 × 40). Insert the protective material to prevent the arm cover from being damaged. Step 5 Bolt mounting Rope 3 Rope 3 Rope 1 Rope 1 Put the robot cable on Put the robot cable on the Y-axis arm cover.
Page 34 Installing the robot Install the robot securely with the four hex socket head bolts as shown in the Fig. below. The robot can be secured from the upper portion. WARNING When installing the robot, be sure to use the specified size and quantity of bolts that match the depth of tapped holes in the installation base, and securely tighten the bolts to the correct torque.
Page 35 When the end effector uses an electrical device which, if it malfunctions, might make contact with the power supply, the user must provide proper grounding on his own responsibility. The YK-XE series robots do not have a ground terminal for this purpose.
Page 36 Robot cable connection The robot cable is pre-connected to the YK-XE series robot. For details on connections to the robot controller, refer to the Fig. below and the "YAMAHA Robot Controller User's Manual". After making connections, check the operation while referring to the section "Trial Operation" in Chapter "Safety Instructions"...
Page 37 The YK-XE series robots are equipped with user wires and air tubes in the machine harness. The table below shows the number of wires and air tubes available for each robot model.
Page 38 ■ Signal wiring connections in the machine harness YK400XE Connector pins 1 to 10 can be used. Pin 11 is connected to a shield wire and cannot be used as a signal wire. Signal Connector Connection Connector Color Brown Orange Blue Violet User signal line...
Page 39 The operators could trip on these parts and be injured. CAUTION Always use the supplied connectors and pins. Contact faults could occur if other types are used. • YK400XE Connector supplied at shipment YAMAHA’s part number Part name Model number Q’ty Connector SMR-11V-B (Used for both the arm and base.)
Page 40 • YK510XE YK610XE YK710XE Connector supplied at shipment YAMAHA’s part number Part name Model number Q’ty SMR-12V-B(J.S.T. Connector) Connector (Used for both the arm and base.) SMR-09V-B(J.S.T. Connector) KFS-M4870-00 SYM-001T-P0.6 or BYM-001T-P0.6 Pin contact (J.S.T. Connector) To check the operation and signal transmission between the end effector and the controller or peripheral equipment after making connections, refer to the section "4.6.1 Trial Operation"...
Page 41 SCARA R-axis moment of inertia offset Center of gravity of load SCARA R-axis moment of inertia offset [ µm] 23229-FG-01 Options to be attached to and weight to be added to tip mass 1 + 2 Tool flange& Tool flange Through tubing Y arm additional stopper Through tubing...
Page 42 Acceleration coefficient vs. moment of inertia 6.2.1 R-axis tolerable moment of inertia and acceleration coefficient The moment of inertia of a load (end effector and workpiece) that can be attached to the R-axis is limited by the strength of the robot drive unit and residual vibration during positioning. It is therefore necessary to reduce the acceleration coefficient in accordance with the moment of inertia.
Page 43 Equation for moment of inertia calculation Usually the R axis load is not a simple form, and the calculation of the moment of inertia is not easy. As a method, the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated.
Page 44 3) Moment of inertia for cylinder (part 2) The equation for the moment of inertia for a cylinder that has a rotation center such as shown in the Fig. below is given as follows. Moment of inertia for cylinder (part 2) ρπ...
Page 45 In the same manner, the moment of inertia of a cylinder as shown in the Fig. below is given by Moment of inertia of a cylinder ρπD ρπD Center line (kgm ) + mx ... (6) 23208-F0-01 In the same manner, the moment of inertia of a prism as shown in the Fig. below is given by Moment of inertia of a prism Center line ρabc(a...
Page 46 Example of moment of inertia calculation Let's discuss an example in which the chuck and workpiece are at a position offset by 10cm from the R-axis by the stay, as shown in the Fig. below. The moment of inertia is calculated with the following three factors, assuming that the load material is steel and its density ρ...
Page 47 Chuck Chuck When the chuck form resembles R-axis that shown in figure, the weight of the chuck (Wc) is Wc = 0.0078 × 2× 4 × 6 =0.37(kg) Moment of inertia Jc = 0.37×(0.02 +0.04 )/12+0.37×0.1 = 0.00376 (kgm Moment of inertia offset Lc = 0.1 (m) 23212-F0-01 Workpiece...
Page 48 Attaching the end effector It is necessary to prepare the user's end effector attaching part to the robot that has adequate strength and rigidity, as well as gripping force to prevent positioning errors. WARNING • Before attaching the end effector, be sure to turn off the controller. •...
Page 49 Next, the following shows the recommended end effector attaching method. Attaching the end effector Hole diameter Bolt Tool flange Slot Bolts Spline shaft End effector or stay Hole diameter, depth Stay YK510XE, YK610XE, YK710XE (In case of tool flange mount type) 23229-F0-00 Tightening torque Robot Model...
Page 50 Gripping force of end effector The gripping force of the end effector must have a sufficient extra margin of strength versus the workpiece weight and reaction force applied to the workpiece during robot operation. The reaction force applied to the workpiece during operation can be calculated from the acceleration applied to the end effector attachment.
Page 51 7. Limiting the movement range with X-axis and Y-axis mechanical stoppers WARNING Always turn off the controller before changing the movement range with mechanical stoppers. CAUTION When the mechanical stopper positions are changed, the soft limits must be set to a point inside the mechanical stopper positions.
Page 52 ■ Soft limits Standard stopper (°) Additional stopper (°) Stopper position in X-axis plus or minus direction Maximum movement position in X-axis plus or 132 (A*) 94 (B*) minus direction YK400XE Stopper position in Y-axis plus or minus direction Maximum movement position in Y-axis plus or 150 (C*) 98 (D*) minus direction...
Page 53 Installing the X-axis/Y-axis additional mechanical stoppers YK400XE Follow the steps below to install the X-axis/Y-axis additional mechanical stoppers. Use the bolts listed below to install optional mechanical stoppers. Part No. Q'ty Remarks KDS-M2137-00 Bolt Additional mechanical stopper parts in either one direction of X-axis plus or minus direction KDS-M2193-00 Stopper (Stopper bolt)
Page 54 Installing the X-axis/Y-axis additional mechanical stoppers YK510XE YK610XE YK710XE Follow the steps below to install the X-axis/Y-axis additional mechanical stoppers. Regarding the bolts provided as optional parts, use them listed below. Even if ether of +/- direction additional mechanical stopper is installed, add 1 kg to the tip weight. Part No.
Page 55 Installing to the standard stopper Stopper Apply adhesive Damper X-axis Collar Bolt M4x10 Apply screw lock Bolt (16Nm) 23246-FV-00 Apply screw lock Installing to the standard stopper Apply adhesive Damper Y-axis Stopper Collar Bolt M4x10 Apply screw lock Bolt (16Nm) Apply screw lock 23213-FV-00 Make sure that the range of motion is limited.
Page 56 8. Robot overrun during impacts with X-axis or Y-axis mechanical stopper The robot may overrun from the mechanical stopper position for some reason, such as deformation of the mechanical stopper during impacts with mechanical stopper. Be aware that the end effector may interfere with the robot main body and peripheral unit or the robot main body may interfere with the peripheral unit due to overrun during impacts with mechanical stopper.
Page 57 9. Limiting the movement range with Z-axis mechanical stopper YK510XE YK610XE YK710XE As option parts are ordered, and then they are installed, the Z-axis movement range can be narrowed by ordering and assembling optional parts. WARNING Before starting the work, thoroughly read "17. Detaching or attaching the covers" in this Chapter. WARNING Always turn off the controller before changing the movement range with mechanical stoppers.
Page 58 After installing the mechanical stoppers, set the soft limits to the values shown below. ■ Soft limits after installing additional stoppers Z=200mm stroke type Soft limit (pulses) Working envelope Working envelope in Z-axis plus direction 1024 (200- (L 200- (L Working envelope in Z-axis minus direction -1024 minimum value = 14　　L...
Page 59 Installing the minus direction stopper Follow the steps below to install the additional mechanical stopper in the Z-axis minus direction. Prepare a hex wrench set. Turn off the controller. Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted, to keep others from touching the controller switch. Enter the safety enclosure.
Page 60 NOTE For details about how to perform the Z-axis return-to-origin, see "2.3 Return-to-origin procedures" in Chapter 4. Make a note of the Z-axis machine reference value. When the machine reference is within the allowable range (between 26 and 74%), proceed to step 18. When the machine reference is beyond the allowable range, proceed to step 13.
Page 61 Installing the plus direction stopper Follow the steps below to install the additional stopper in the Z-axis plus direction. Prepare a hex wrench set. Turn off the controller. Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted, to keep others from touching the controller switch. Enter the safety enclosure.
Page 62 Check that Z-axis stops firmly. Whether or not the Z-axis stops at a position before the stopper by the soft limit must be checked from the outside of the safety enclosure. NOTE The Z-axis may not stop at a position before the stopper due to the stopper part accuracy or position. If this happens, decrease the value while referring to the Table "Soft limits after installing additional stoppers"...
Page 63 11. Working envelope 11.1 Working envelope The working envelope of each robot is shown in "1.3 External view and dimensions" of Chapter 9. ■ Working envelope (angle) of X, Y arm Do not attempt operation outside the working envelope. The working envelope described in this manual is an area with the robot frontal reference when no load is applied. Working envelope YK400XE 150°...
Page 64 ■ Z-axis Do not attempt work outside the working envelope. In particular, do not attempt work in the area between the working envelope and mechanical stopper position. Mechanical stoppers are installed at both the upper and lower ends of the movement range. WARNING The robot cable, user wiring or tubing may be damaged if the robot load interferes with them resulting in hazardous robot malfunctions.
Page 65 11.2 Performance area YK-XE series has areas (performance areas) that are advantageous for CP operation. The performance area is from the maximum radius of straight extension of the XY arm to 10mm in front. In areas outside the performance area, vibration may occur during CP operation. If vibrations occur, lower the SCARA MOVE L acceleration coefficient [%] of the robot parameter or all axes of the acceleration coefficient [%] of the axis parameter at the same ratio.
Page 66 12. Stopping time and stopping distance at emergency stop YK400XE When the emergency stop button is pressed during robot operation or the power supply to the controller is turned off, the stopping time and stopping distance or angle of the main 3 axes change depending on the operation speed as shown below.
Page 67 Z-axis stopping time (Emergency stop is activated while the Z-axis operates in the plus direction.) 0.04 1.33kg Z-axis 2.66kg Z-axis 0.03 Z-axis 0.03 0.02 0.02 0.01 0.01 0.00 Operation speed (%) 23222-FV-00 Z-axis stopping distance (Emergency stop is activated while the Z-axis operates in the plus direction.) 1.33kg Z-axis 2.66kg...
Page 68 R-axis stopping time (Emergency stop is activated while the R-axis operates in the plus direction.) 0.12 0.10 0.08 0.06 0.04 1.33kg 0.001 R-axis 0.02 2.66kg 0.002 R-axis 4kg 0.003 R-axis 0.00 Operation speed (%) 23224-FV-00 R-axis stopping angle (Emergency stop is activated while the R-axis operates in the plus direction.) 1.33kg 0.001 R-axis 2.66kg 0.002...
Page 69 13. Stopping time and stopping distance at emergency stop YK510XE The stopping time and stopping distance or angle of the three major axes when the power (main power) supply to the controller is cut off by the emergency stop input during robot operation are shown below. The stopping time and stopping distance (angle) are as follows according to the speed and tip load mass (33%, 66% and 100% of the maximum payload) with the robot arm extended.
Page 70 Z-axis stopping time (Emergency stop is activated while the Z-axis operates in the plus direction.) 0.35 3.33kg Z-axis 6.66kg Z-axis 0.30 10kg Z-axis 0.25 0.20 0.15 0.10 0.05 0.00 Operation speed (%) 23263-FV-00 Z-axis stopping distance (Emergency stop is activated while the Z-axis operates in the plus direction.) 3.33kg Z-axis 6.66kg...
Page 71 14. Stopping time and stopping distance at emergency stop YK610XE The stopping time and stopping distance or angle of the three major axes when the power (main power) supply to the controller is cut off by the emergency stop input during robot operation are shown below. The stopping time and stopping distance (angle) are as follows according to the speed and tip load mass (33%, 66% and 100% of the maximum payload) with the robot arm extended.
Page 72 Z-axis stopping time (Emergency stop is activated while the Z-axis operates in the plus direction.) 0.35 3.33kg Z-axis 6.66kg Z-axis 0.30 10kg Z-axis 0.25 0.20 0.15 0.10 0.05 0.00 Operation speed (%) 23263-FV-00 Z-axis stopping distance (Emergency stop is activated while the Z-axis operates in the plus direction.) 3.33kg Z-axis 6.66kg...
Page 73 15. Stopping time and stopping distance at emergency stop YK710XE The stopping time and stopping distance or angle of the three major axes when the power (main power) supply to the controller is cut off by the emergency stop input during robot operation are shown below. The stopping time and stopping distance (angle) are as follows according to the speed and tip load mass (33%, 66% and 100% of the maximum payload) with the robot arm extended.
Page 74 Z-axis stopping time (Emergency stop is activated while the Z-axis operates in the plus direction.) 0.35 3.33kg Z-axis 6.66kg Z-axis 0.30 10kg Z-axis 0.25 0.20 0.15 0.10 0.05 0.00 Operation speed (%) 23263-FV-00 Z-axis stopping distance (Emergency stop is activated while the Z-axis operates in the plus direction.) 3.33kg Z-axis 6.66kg...
Page 75 16. Installing the user wiring and tubing newly Use the user wiring and tubing in the machine harness as much as possible by considering the durability of the machine harness. If the user wiring and tubing incorporated into the machine are insufficient, add new user wiring and tubing using tie bands.
Page 76 To prevent such troubles, strictly observe this caution. YK400XE Y-axis arm cover (YAMAHA’s part No. KDS-M1314-11) Harness cover (YAMAHA’s part No.KDS-M1312-10) Harness cover mounting bolt Binding head screw M4×10, 3 pcs.
Page 77 YK510XE / YK610XE / YK710XE Y-axis arm cover (YAMAHA’s part No. KFS-M1314-00) Grommet (YAMAHA’s part No. KFS-M1392-00) Harness cover mounting bolt Hex socket head bolt (YAMAHA’s part No. 91312-03010) M3x10 8 pcs.(0.9Nm) Washer (YAMAHA’s part No. 90990-28J204) Harness cover Harness cover Harness cover (YAMAHA’s part No.KFS-M1312-00)
Page 78 Before starting the work, thoroughly read "17. Detaching or attaching the covers" in this Chapter. Extension shafts can be retrofitted to route the user wiring / tubing through the spline. The following optional parts are required. YAMAHA Part Q'ty Remarks...
Page 79 Go out of the safety enclosure. 19. How to pass wiring and tubing 19.1 For user wiring/tubing through spline type Example of how to pass wiring and tubing Clamp with Tie Band Stay Clamp with Tie Band Stay Install the stay Install the stay Attach Tie Band Stay Attach Tie Band Stay...
Page 80 19.2 For user wiring/tubing through cap type YK510XE YK610XE YK710XE Example of how to pass wiring and tubing Attach Tie Band Stay Attach Tie Band Stay Apply 2 g of silicon grease Apply 2 g of silicon grease (Shin-Etsu Chemical G501, etc.) (Shin-Etsu Chemical G501, etc.) to the wires and tubes for sliding.
Page 81 20. Tool flange mounting YK510XE YK610XE YK710XE You can add a tool flange later. The following optional parts are required. Replacement parts Part No. Q'ty Remarks KBF-M1790-00 Tool flange 91312-06025 Bolt 92A08-05308 Set screw Tools(Torque wrench, etc.) CAUTION Use a torque driver and torque wrench that have been calibrated precisely. Name Part No.
Page 82 Step 4 Installing the Tool Flange Turn off the controller. Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted, to keep others from touching the controller switch. Enter the safety enclosure. Width across flats Installing the Tool Flange.
Page 83 21. Attaching cap (for user wiring/tubing through cap type) YK510XE YK610XE YK710XE The cap (KFS-M1318-00 COVER, 8) can be retrofitted to route the user wires / tubes. Turn off the controller. Step 5 Remove the sticker. Place a sign indicating the robot is Sticker Sticker being adjusted...
Page 84 22. Retrofitting the brake release switch The brake release switch can be retrofitted. The following optional parts are required. without without with with Grommet Grommet Grommet Grommet with with without without Grommet Grommet Grommet Grommet YK400XE YK510XE YK610XE YK710XE ■ Replacement parts YK400XE YK510XE...
Page 85 22.1 Mounting procedure Turn off the controller. Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being adjusted, to keep others from touching the controller switch. Enter the safety enclosure. Remove the Y-axis arm cover and Base rear cover. Remove the cover while referring to "17.
Page 86 Put the wires in the base and reattach the rear cover. YK400XE YK510XE YK610XE YK710XE Store the wires in the space in front of the X motor. Store the signal wire to the left back side of the X motor and the power wire to the right back side when viewed from the base wiring side.
Page 87 Insert the brake body into the hole of the harness stay from the outside, and fix it with washers and nuts from the opposite side. Tighten the nut with plier so that it will not come loose. YK510XE YK610XE YK710XE YK400XE washer washer...
Page 88 Put the wires in the base and reattach the rear cover. YK400XE YK510XE YK610XE YK710XE Store the wires under the harness stay Store the wires in the space next to the switch. Attach the Y-axis arm cover to the Y-axis arm. Check the operation of the Z-axis brake switch.
Page 89 23. Permissible spline load Due to the strength factors of the spline, and the X,Y,Z,R axes, do not apply loads which exceed those shown below during an all-axis servo hold status, or during ultra-slow-speed operations. "F " includes the load of the tip load's weight. Permissible spline loads 23245-FV-00 YK400XE...
Page 91 Chapter 4 Robot settings Contents Overview Adjusting the origin Return-to-origin method 2.1.1 Stroke end method YK400XE 2.1.2 Mark method YK400XE 2.1.3 Sensor method (X-axis, Y-axis) Machine reference Return-to-origin procedures 2.3.1 Stroke end method YK400XE 2.3.2 Sensor method (X-axis, Y-axis) Adjusting the machine reference value 2.4.1 Stroke end method YK400XE 2.4.2 Mark method...
Page 93 Overview Various settings have been completely made at the factory or by your distributor before shipment, including the origin position setting. If the operating conditions are changed and the robot needs to be set again, then follow the procedures described in this chapter. The following describes the safety precautions to be observed when making various settings.
Page 94 Adjusting the origin The YK-XE series robots use an absolute type position detector. The origin position (zero pulse point) can be determined by return-to-origin. Once return-to-origin is performed, you do not have to repeat return-to-origin when turning the power on next time. However, return-to-origin is required if any of the following cases occur.
Page 95 2.1.1 Stroke end method YK400XE In the stroke end method, return-to-origin is performed at a position slightly backed off from the stroke end, after the axis whose return-to-origin is performed contacts the mechanical stopper and stroke end is detected. WARNING Serious injury might occur from physical contact with the robot during operation.
Page 96 2.1.2 Mark method YK400XE In the mark method, the robot is moved to a position beforehand where the return-to-origin is performed and this position is determined to the return-to-origin position. There are two kinds of methods to move the robot to a position where the return-to-origin is performed as described below.
Page 97 Machine reference The position detector of the YK-XE series uses a resolver that has five positions where the return-to-origin can be performed per motor revolution. (YK510XE, YK610XE, YK710 has four X axes) The machine reference means the position relationship of the position where the robot detects the origin signal to the position where the reset can be performed soon after detection (see the Fig.
Page 98 • When pressing the key on the execution confirmation screen, the execution of the return-to-origin is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 99 • When pressing the key on the execution confirmation screen, the execution of the return-to-origin is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 100 Perform the return-to-origin. Step 6 Return-to-origin The return-to-origin execution confirmation screen pops up. Check that there are no obstacles within the movement range, and then press . To cancel the return-to-origin, press . After the return-to-origin has been completed, press to return to the "ORIGIN RTN (TRQ/SENS)"...
Page 101 Stroke end method YK400XE The return-to-origin of the YK-XE series uses the stroke end method. The machine reference value was adjusted correctly at shipment. So, the readjustment is not needed during normal operation. However, if the machine reference value exceeds the return-to-origin tolerance range (25 to 75%) for some reason, follow the steps below to readjust the machine reference value.
Page 102 Replace the bolts one-by-one and take great care so that the speed reduction gear and arm do not deviate. Bolt M3 x 35, (YAMAHA’s part No. 91312-03035) 12 pcs. Secure the speed reduction gear. Secure the speed reduction gear while referring to “ Replacing the X-axis harmonic drive” in Chapter 5 of the Maintenance Manual.
Page 103 ■ Changing the Z-axis and R-axis reference values Remove the cover. Step 9 Removing the cover Remove the cover while referring to "17. Detaching or attaching the covers" in Chapter 3. bolt 23301-FV-00 washer Y-axis arm cover Z-axis motor R-axis motor WARNING If the pulley comes off from the belt, the Z-axis may drop.
Page 104 YK510XE YK610XE YK710XE Step 11 Removing the plate To adjust the Z-axis reference value, Z-axis motor loosen the bolts at 3 locations. Z-axis fixing plate R-axis motor To adjust the R-axis reference value, loosen the bolts at 3 locations. R-axis fixing plate 23401-FV-01 Shift the engagement between the motor pulley and belt tooth.
Page 105 2.4.2 Mark method YK400XE The absolute reset in the mark method is classified into four groups according to the conditions as shown in the flowchart below. Since each operating procedure varies, refer to relevant portion. ■ Absolute reset flowchart The origin is performed at the same The origin is performed at a position position as the previous absolute reset different from the previous absolute...
Page 106 • When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 107 Select an axis whose absolute reset is performed. Use the cursor keys ( ) to select an axis number whose absolute reset is performed, and then press The execution confirmation screen will pop up. Perform the step movement. Press the jog key to perform the step movement of the robot until the origin position marks are matched with each other.
Page 108 • When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 109 Move the arm to the position where the origin position marks are matched with each other. Press the emergency stop button on the PBX to put the robot in the emergency stop state. WARNING Be sure to press the emergency stop button and move the robot in the state where the servo on cannot be operated from the outside.
Page 110 Select an axis whose absolute reset is performed. Use the cursor keys ( ) to select an axis number whose absolute reset is performed, and then press The execution confirmation screen will pop up. CAUTION • There are multiple discrete positions where the absolute reset can be performed. Move the robot step-by-step while referring to the PBX screen.
Page 111 • When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 112 Affix the origin position stickers. After the robot has been moved to the all axes "0" pulse position, press the emergency stop button and affix the origin position stickers to legible positions. After that, these origin position stickers are used to perform the absolute reset again at the same position.
Page 113 • When pressing the key on the execution confirmation screen, the execution of the absolute reset is canceled. • For details about how to operate the robot controller, see the "YAMAHA Robot Controller User's Manual". Turn on the controller. Check that no one is inside the safety enclosure, and then turn on the controller.
Page 114 Affix the origin position stickers. After the robot has been moved to the all-axis 0 pulse position, press the emergency stop switch and affix the origin position stickers supplied with the robot to easy-to-identify positions near the R-axis rotation part so that they can be used when the absolute reset is performed again at the same position.
Page 115 2.4.3 Sensor method (X-axis, Y-axis) ■ Adjusting the X-axis machine reference CAUTION • The origin position may change due to machine reference adjustment. If it occurs, you must set point data again. • When the return-to-origin direction is reversed, the origin position may not be the base front. When using the standard soft limit, the axis may collide with the mechanical stopper.
Page 116 Loosen the hex nut. Step 8-10 Adjusting the X-axis machine reference value Using the wrench, loosen the hex nut that secures the X-axis origin sensor. 23307-FV-00 X-axis origin sensor CAUTION It is enough to loosen the nut. Do not remove the nut completely.
Page 117 ■ Adjusting the Y-axis machine reference CAUTION The origin position may change due to machine reference adjustment. If it occurs, you must set point data again. Follow the steps below to adjust the Y-axis machine reference value. Prepare a wrench for a width across flat of 13 mm. Turn on the controller.
Page 118 Loosen the hex nut. Using the wrench, loosen the hex nut that secures the Y-axis origin sensor. Step 8-10 Adjusting the Y-axis machine reference value 23308-FV-02 CAUTION It is enough to loosen the nut. Do not remove the nut completely. Hex nut Move the Y-axis origin sensor as follows.
Page 119 3. Changing the origin position of X/Y-axis YK510XE YK610XE YK710XE The origin position of X-axis and Y-axis can be changed by 90 degrees clockwise and counterclockwise from the front position of the X-axis and Y-axis arm base by attaching a bolt to the origin position change dog as shown in the figure below.
Page 120 Step 4 Installing the dog Remove the bolts(M3x6) For X-axis For Y-axis bolts(bolt)(M8x8) Remove the origin dog (bolt) attached to arm X from the through hole from which the Y arm bolt has been removed. Remove the origin dog (bolt) 23457-FV-00 Install the origin position change dog.
Page 121 Attach the bolts to the origin position change dog. Step 6 Bolt Installation Rotate the arm and move the bolt over the sensor For the distance between the bolt For the distance between the bolt and the sensor Keep to 0.5mm and the sensor Keep to 0.5mm Bolt Bolt...
Page 122 Press the emergency stop button on the PBX to put the robot in the emergency stop status. NOTE For details about emergency stop and how to cancel the emergency stop, see the "YAMAHA Robot Controller User's Manual". Place a sign indicating the robot is being adjusted.
Page 123 Setting the Z-axis soft limits CAUTION Set the Z-axis soft limits from outside the safety enclosure. The Z-axis has mechanical stoppers fixed at the upper and lower ends of the Z-axis movement range. When the actual working range of the robot is smaller than the maximum working envelope or the manipulator interferes with the peripheral equipment, reduce the Z-axis plus (+) soft limit [pulses] to narrow the working envelope.
Page 124 Setting the standard coordinates CAUTION If the standard coordinate settings are incorrect, the acceleration cannot be optimized to match the arm position. This results in too short a service life, damage to the drive unit, or residual vibration during positioning. In addition, the cartesian coordinate accuracy will be impaired.
Page 125 Press the emergency stop button on the PBX to put the robot in the emergency stop status. NOTE For details about emergency stop and how to cancel the emergency stop, see the "YAMAHA Robot Controller User's Manual". Place a sign indicating the robot is being adjusted.
Page 126 Press the emergency stop button on the PBX to put the robot in the emergency stop status. NOTE For details about emergency stop and how to cancel the emergency stop, see the "YAMAHA Robot Controller User's Manual". Place a sign indicating the robot is being adjusted.
Page 127 Insert the shaft. Step 5-6 Attaching the Y-axis reference coordinate jig 1. Make the adjustment so that the X-axis arm and Y-axis arm are aligned on an almost straight line. 2. Adjust the arm positions so that the shaft enters the slot in the Y-axis arm and the hole in the X-axis arm without prying, and then insert the shaft.
Page 128 Enter the axis parameter "OFFSET Step 11 Entering the “Offset pulse” values PULSE". Enter the values shown on the right in the axis YX-axis position pulse value X-axis position pulse value in step 7 (counterclockwise) in step 7 (clockwise) parameter "OFFSET PULSE". - 327680 23304-FK-00 Y-axis position pulse value...
Page 129 6. Affixing the stickers for origin positions, movement directions, and axis names The robot comes packed with stickers showing origin positions, movement directions and axis names. Using the following procedure, attach these stickers in conspicuous points on the robot after changing the origin position and installing peripheral equipment.
Page 130 Sticker affixing positions (example) 23305-FV-01 4-38...
Page 131 Chapter 5 Periodic inspection Contents Overview List of inspection items...
Page 133 • Do not attempt to weld, heat up, drill holes or cut this container. This might cause the container to explode and the remaining materials inside it to ignite. CAUTION Unless grease specified by YAMAHA is used, the service life of the ball screw and ball spline will shorten.
Page 134 Engineers who have the qualification in conformity with "2. Qualification of operators/workers" in section 4.1 of the Safety Guide must perform the inspection items requiring the cover removal while referring to the separate YK-XE Series Maintenance Manual. CAUTION The Z-axis will slide down when the brake is released with the brake release switch (optional for YE-XE) or the programming box, causing a hazardous situation.
Page 135 Location Contents Daily 6-month Cleaning Adjustment Replacement Functional check of Z-axis • Drop amount from the Z-axis rest state is 3 mm brake (*4) or less. Functional check of Brake • Check that the Z-axis moves when pressing the release switch (optional to switch and does not move when releasing the YK-XE) and Brake release switch.
Page 137 Chapter 6 Harmonic drive replacement period Contents Overview Replacement period...
Page 139 Overview The YK-XE series robots uses a harmonic drive as the speed reduction gear for the X and Y axes. Harmonic drives need to be replaced after specified operation hours have elapsed. Use the guideline explained below to determine the replacement period and replace the harmonic drive periodically. Since the YK-XE series robots listed below use long-life harmonic grease, it is not necessary to replace the harmonic grease.
Page 140 : Operation time per day : Operation days per year For example, when the robot is used under the following conditions, the replacement period for the X-axis harmonic drive of the YK-XE series robots can be calculated as follows. : 10 : 0.25 θ...
Page 141 Chapter 7 Increasing the robot operating speed Contents Increasing the robot operating speed Increasing speed by arch motion Increasing the speed with the WEIGHTG statement Increasing the speed by the tolerance parameter Increasing the speed by the OUT effective position parameter...
Page 143 Increasing the robot operating speed The robot operating speed can be increased by the following methods. Use these methods as needed when programming. Increasing speed by arch motion [Also refer to:] Programming manual (MOVE Arch motion setting) Gate motion From point P1 to P4 via P2 and P3: MOVE P, P2 MOVE P, P3 MOVE P, P4...
Page 144 Increasing the speed with the WEIGHTG statement [Also refer to:] Robot controller user’s manual (Robot parameters Tip weight) Programming manual (WEIGHTG) [Example] From P1 when chuck is open: WEIGHTG 5000 ..Changes the tip weight parameter to 5kg(5000g) (no workpiece). MOVE P, P2, A3=0 DO3 (0) = 1 ....Chuck closes.
Page 145 Increasing the speed by the tolerance parameter [Also refer to:] Robot controller user’s manual (Axis parameters Tolerance) Programming manual (TOLE) Increasing the speed by the tolerance parameter 23605-F0 [Example] From P1 to P3 via P2 TOLE (1) = 2048 ... X-axis tolerance (pulses) : Increases the tolerance. TOLE (2) = 2048 ...
Page 146 Increasing the speed by the OUT effective position parameter [Also refer to:] Robot controller user’s manual (Axis parameters Out valid position) Programming manual (OUTPOS) [Example] From P1 when chuck is open: OUTPOS (1) = 10000... X-axis OUT effective position (pulses) : Increases the OUT effective position. OUTPOS (2) = 10000...
Page 147 Chapter 8 Torque limit designated Z-axis pushing action Contents Torque limit designated Z-axis pushing action...
Page 149 Torque limit designated Z-axis pushing action You can use the PUSH statement in a program to apply a Z-axis pushing action (in the direction of gravity). The table below shows the torque limit value (%) and speed limit value (%) for the motor rated torque at the tip load weights.
Page 150 Tip Load Weight (kg) Torque Limit Value (%) Pushing Force (N) Speed Limit Value (%) 10 to 100 80 to 285 10 to 100 75 to 280 10 to 100 70 to 275 10 to 100 65 to 270 10 to 100 65 to 265 10 to 100 60 to 255...
Page 151 Chapter 9 Specifications Contents Manipulator Basic specification Regarding the noise level External view and dimensions Robot inner wiring diagram 9-11 Wiring table 9-13...
Page 153 Manipulator Basic specification YK400XE-4 YK510XE-10 YK610XE-10 YK710XE-10 225mm 235mm 335mm 435mm Arm length X-axis Rotation ±132° ±134° angle 175mm 275mm Arm length Axis Y-axis Rotation specifications ±150° ±152° angle 150mm 200mm Z-axis Stroke Rotation ±360° R-axis angle 200W 400W X-axis Y-axis Motor 100W...
Page 154 External view and dimensions YK400XE 188(Base size) 6 H7 +0.012 +0.012 6-φ9 φ6 H7 +0.012 ±0.05 M8 bolt for installation, 4 bolts used Maximum 350 during arm rotation (123.5) 62.5 Maximum 530 during arm rotation 187.8 Z-axis upper end mechanical 174.8 stopper position 174.3 10mm rise during return-to-origin...
Page 155 YK400XE φ27 4-M3x0.5 through-hole (No phase relation to R-axis origin.) As this hole is intended for the wiring/tubing clamp, do not attach a large load to it. Option User wiring/tubing through Standard type spline type Working envelope X-axis mechanical stopper position : 134° Y-axis mechanical stopper position : 154°...
Page 156 YK510XE User wiring connector (Numbers 1 to 12 are usable.) J.S.T. Connector 6 blue) SM connector: SMR-12V-B User plumbing 3 φ (Base size) Pin: SYM-001T-P0.6 is attached. 6 red) User plumbing 2 φ Use AP-K2N for the 6 H7 0.012 crimping machine.
Page 157 YK510XE 4-M3x0.5 through-hole (No phase relation to R-axis origin.) 45.5 φ As this hole is intended for the wiring/tubing clamp, do not attach a large load to it. View of B View of D Optional User wiring/tubing through cap type Base mounting surface Base mounting surface Standard type...
Page 158 YK610XE User wiring connector (Numbers 1 to 12 are usable.) J.S.T. Connector 6 blue) User plumbing 3 176(Base size) φ SM connector: SMR-12V-B 6 red) User plumbing 2 φ Pin: SYM-001T-P0.6 is 6 H7 0.012 6 black) attached. User plumbing 1 φ...
Page 159 YK610XE 4-M3x0.5 through-hole (No phase relation to R-axis origin.) As this hole is intended for the φ 45.5 wiring/tubing clamp, do not attach a large load to it. View of B View of D Optional User wiring/tubing through cap type Base mounting surface Base mounting surface Optional...
Page 160 YK710XE User wiring connector (Numbers 1 to 12 are usable.) J.S.T. Connector 176(Base size) (45) 6 blue) SM connector: SMR-12V-B User plumbing 3 φ Pin: SYM-001T-P0.6 is 6 red) User plumbing 2 φ 0.012 6 H7 attached. 6 black) User plumbing 1 φ...
Page 161 YK710XE 45.5 4-M3x0.5 through-hole (No phase relation to R-axis origin.) As this hole is intended for the wiring/tubing clamp, do not attach a large load to it. View of B View of D Optional User wiring/tubing through cap type Base mounting surface Base mounting surface Option User wiring/tubing through...
Page 162 Robot inner wiring diagram YK400XE Standard type Robot inner wiring diagram Machine harness Z-axis resolver Y-axis resolver R-axis resolver Connector for user wiring Z-axis motor Y-axis motor R-axis motor User tubing RORG X-axis origin sensor Round terminal YORG YORG Z-axis brake X-axis arm X-axis motor X-axis resolver...
Page 163 YK510XE YK610XE YK710XE Standard type Robot inner wiring diagram Machine harness Connector for user wiring User tubing RORG Z-axis resolver Y-axis resolver R-axis resolver Z-axis motor Y-axis motor R-axis motor X-axis origin sensor YORG YORG Z-axis brake Round terminal X-axis arm X-axis motor X-axis resolver Y-axis arm...
Page 164 YK410XE YK510XE YK610XE YK710XE Option: Z-axis brake release switch type (Only the parts that differ from the standard type are shown) Robot inner wiring diagram Machine harness RORG RORG Z-axis brake Z-axis brake release switch Arm side intermediate cable RORG RORG RORG ZORG...
Page 165 Wiring table Robot cable wiring table Signal Connector Connection Connector Color/Number Wire Resolver Orange-1-Red 0.15sq Orange-1-Black Twisted pair Gray-1-Red 0.15sq Gray-1-Black Twisted pair Sky blue-2-Red 0.15sq Sky blue-2-Black Twisted pair Gray 0.3sq Resolver Orange-2-Red 0.15sq Orange-2-Black Twisted pair Bright green-2-Red 0.15sq Bright green-2-Black Twisted pair...
Page 166 Signal Connector Connection Connector Color/Number Wire Resolver Orange-1-Red 0.15sq Orange-1-Black Twisted pair Gray-1-Red 0.15sq Gray-1-Black Twisted pair Sky blue-2-Red 0.15sq Sky blue-2-Black Twisted pair Gray 0.3sq Brake Pink-1-Red 0.15sq MB– Pink-1-Black Twisted pair Sky blue-1-Red 0.15sq Sky blue-1-Black Twisted pair Resolver Orange-2-Red 0.15sq...
Page 167 Machine harness wiring table YK400XE Signal Connector Connection Connector Color Wire Y-axis Resolver Brown 0.2mm Twisted pair White 0.2mm Twisted pair White Orange 0.2mm Twisted pair White Gray Shield Z-axis Resolver Brown 0.2mm Twisted pair Black 0.2mm Twisted pair Black Orange 0.2mm Twisted pair...
Page 168 Machine harness wiring table YK510XE YK610XE YK710XE Signal Connector Connection Connector Color Wire Y-axis Resolve Brown 0.2mm White Twisted pair 0.2mm White Twisted pair Orange 0.2mm Twisted pair White Gray Shield Z-axis Resolver Brown 0.2mm Black Twisted pair 0.2mm Twisted pair Black Orange 0.2mm...
Page 169 Motor wiring table Signal Color Connection Remarks Connector Motor X,Y,Z,RM White Black Green/Yellow Motor Round terminal Cable wiring table (Motor Robot cable) YK400XE Signal Connection Wire Connector 0.3sq Blue Orange Bright green Brown X,Y,Z,RP Gray Drain wire Cable wiring table (Motor Robot cable) YK510XE YK610XE YK710XE...
Page 170 Brake release switch Arm side intermediate cable wiring diagram Connector Signal Connection Wire Connector 0.2sg Black Brake MB+ White RORG Brake MB+ 0.2sgWhite Brake MB- Black Brake release switch Base side intermediate cable wiring diagram Connector Signal Connection Wire Connector 0.2sg White RORG ZORG...
Page 172 YAMAHA MOTOR CO., LTD. The contents of this manual are subject to change without prior notice. Information furnished by YAMAHA in this manual is believed to be reliable. However, no responsibility is assumed for possible inaccuracies or omissions.
Page 174 Robotics Operations 127 Toyooka, Kita-ku, Hamamatsu, Shizuoka, 433-8103, Japan https://global.yamaha-motor.com/business/robot/ YAMAHA MOTOR CO., LTD.

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