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PICO User`s Manual

1. cssssssscsssssscsssssecsssssecsssesessscssesssssseesssessesseesseees AVAL Befor unpacki g rorcinoi straie aA aea Aa AA E AE ERATA RTO DRAR E APA S TA EE S 4 1 3 Installation and operating environment Installationen cas acepeasad acenatesnaaesetisaasecndeaaaeacnae Mespenan dlseuts apebacbescasadtescaceedvedsat AB Cableswithg sccsscivsivcssesvecousen E cea vas ceaweaveassep weaves vasscoucanpsyesaesvastocsumesvevecne E E GOMMECHIONS AEE A T E EET AAT Connecting tothe robotssisive niera i aaee E EERE AEEA NERES REE SEESE EREE S 4 4 2 Connecting to the I O connector 4 4 3 Power CONNECTIONS ceceesseeeseeeseeeeseeeeees 4 4 4 Grounding connections cece 4 4 5 Preventing faulty operation due to noise 4 4 6 Other wiring precautions AAT Capea neni cans dbvirensec 44 8 Power Cable specitiCatlons sssivedsasuvspieesviivadvesvaless E A AE AEE EA nah SASAE LAETA TELESNA Connecting toa POs sieer is ie aiaosa aons a essea siise oiea ite ise ieas iS asiaa 4 5 1 Conhecting withra PC interface unitis ir naine En O R E A AE S Power Supply sassis ienien aaa ctieg dasedeccciecteesedeseccauetevetedesezveceresettoectesteasixeosceaseds 5 1 External Wiring diagram csscccssccssccssscsssscssscsssessssessesesseesseessesessssosssessssssssssessees 5 1 CNI DG characteristics snesena esnea aeaee anarias 5 2 To customers only using serial communication ssessessoossessossoossesoosesessessosssesso
2. 800 Deceleration rate 0 gt 0 015 mm per pulse Lead length 12 The input range is from 0 06 to 2013265 91 mm and the default value is 0 06 mm E Speed Description Specifies the movement speed Input range 0 to 240 default 4 Remarks e Motor is 18 75 rotations minute at an input of 1 Input range for movement speed and default values will vary according to the robot 8 3 Point data POINT E Acceleration Description Specifies the amount of acceleration during movement Input range 1 to 255 default 20 Remarks e At an input of 1 motor is 9 75 rotations per second e Input range for acceleration and default values will vary according to the robot Deceleration Description Specifies the amount of deceleration during movement Input range 1 to 255 default 10 Remarks e At an input of 1 motor is 9 75 rotations per second e Input range for deceleration and default values vary according to the robot E Torque Limit Description Specifies the motor excitation current limit value to determine the start of pushing operation Input range 0 to 255 default 0 Note Torque movement is not performed when this value is 0 See the following page for information on how the current limit value for each robot model relates to thrust force when stopped 8 3 Point data Current limit value versus thrust force for each robot model
3. This section explains the basic operation and operation timing chart when positioning 9 3 1 Normal positioning operation Example Moving at a speed of 50 for positioning at a position 245 mm from origin point Precondition Point data has already been created and the data loaded into the controller Position mm Item Command INPOS width mm Acceleration Deceleration Torque distance 245 00 0 06 See the support software manual or teaching box manual for information on how to create point data and how to load data Basic operation 1 Specify the movement point Methods for specifying the point are as follows Point No PNT4 23 PNTS 22 PNT2 2 OFF OFF OFF OFF OFF OFF OFF OFF ON 2 Set the START input signal to ON N caution The START input signal is executed by ON edge detection 3 When a START input signal is normally received the ACK output signal turns ON and the robot starts to move The ROTATE output signal turns ON during robot movement during motor drive 4 An END output signal turns ON when robot movement to the specified movement point ends normally A CAUTION If the ORG input signal stays ON the ACK output signal will stay ON even if movement has completed The END output signal cannot turn ON if the ACK output signal is still ON LYVHD ONIWIL NOILVAAdO ANY NOILVadAdO DIS
4. Cannot perform jog movement Cannot release brake Problems with parallel I O Output signal won t turn ON See 11 3 2 Parallel I O Output signal won t turn OFF ALM signal is off after power is turned on END signal won t turn ON after power is turned on No ACK signal is returned after ORG signal is input END signal won t turn ON after ORG signal is input ORGMON signal won t turn ON after return to origin ACK signal is not returned after START signal is input ROTATE signal won t turn on after START signal is input INPOS signal won t turn OFF after START signal is input END signal won t turn ON after START signal is input ZONE signal won t turn ON ZONE signal stays ON or stays OFF EMGMON signal won t turn ON even if emergency stop is input LOCKMON signal won t turn ON even if interlock is input INPOS signal won t turn ON in servo ON and with robot in stop state Others Alarm is canceled at the same time that it occurs See 11 3 3 Others Servo holding power is weak Robot starts to move at the same time that Lock signal is canceled TROUBLESHOOTING _ 1 6 11 3 Dealing with problems based on trouble symptom Format Symptom Abnormal noise or oscillation occurs Cause Checkpoint Action Cause Shows the cause that made the problem symptom occur Checkpoint Shows a checkpoint for the p
5. Start up and maintenance precautions WARNING When operating the robot only personnel trained in safety and robot operation may operate it WARNING Never allow anyone to enter the robot movement range when the robot controller is turned on Serious accident including fatal injury or death could otherwise result We recommend installing a safety enclosure or fence or a gate interlock using area sensors to keep any person from entering within the movement range of the robot WARNING This robot controller is not designed for explosion proof Do not use it in locations exposed to inflammable gases gasoline or solvent that could cause explosion or fire WARNING Never disassemble or modify the robot controller This may lead to breakdowns malfunction injury or fire When parts used in the robot controller must be replaced or repaired consult our sales office or representative for the correct procedure WARNING When using ferrite cores for noise elimination fit them to the power cable as close to the robot controller as possible to prevent faulty operation or malfunction due to noise 23 2 1 Safety items ABOUT SAFETY 24 WARNING When performing maintenance of the robot controller under instructions from YAMAHA turn off the robot controller and wait for at least 1 minute Some parts in the robot controller may be hot or applied at a high voltage shortly after operation so burns or ele
6. a LYVH D ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E 13 9 3 Positioning operation E Relative movement INC PT to relative movement INC PT The reference position for performing consecutive relative movements is the position calculated lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 14 from the preceding relative position However when an interlock alarm or emergency stop has been triggered during movement the stop position becomes the reference position for performing relative movement after canceling the interlock alarm or emergency stop Movement points are as follows Start position Position 12mm from origin PNT1 Movement amount 150mm INPOS width 36mm PNT2 Movement amount 60mm 1 Moves to PNT1 from start position PNT1 _ gt O 4 gt Movement amount 150mm 2 On entering within the INPOS range of PNT1 the END output signal is used as a trigger to move to PNT2 Movement command input to move to PNT2 PNT1 5 a al INPOS width 36mm PNT2 PNT1 eS e i Movement amount 60mm 9 3 Positioning operation Timing chart PNT 1to5 START ACK l Motor speed i ROTATE l END A CAUTION When the data specified for the second point is defective during continuous operation with movement com mands operation at the 2nd point is not run and the Ist point
7. Lead length 6mm Lead length 12mm t cS oe a ne 150 180 210 240 Current limit Lead length 6mm Lead length 12m 120 150 Current limit The values in the above graph are only reference values and are not a guarantee of the thrust force accuracy while stopped e If the thrust force is too small then the sliding resistance might cause faulty pushing operation so use caution e Set an offset amount and thrust force so that the pushing moment will be smaller than the allowable static load moment of each model Allowable static load moment N m Model my MP MR T4P 6 2 5 7 15 9 T5P 10 9 10 0 29 4 INIOd s 9 8 3 Point data POINT 10 E Torque Distance Description This specifies the torque movement amount in the same direction from the target position Pushing movement amount Moves at pushing speed Moves at normal speed Full pushing End of pushing Target position Pushing movement amount Moves at normal speed Moves at pushing speed Target position End of pushing Full pushing Input range 0 to 4095 pulses default 0 Note e The torque movement amount is ignored when the torque current limit is 0 e The settings for PRM29 Insufficient Torque Alarm PRM30 Position Deviation Alarm PRM36 Max Torque Deviation PRM57 Torque Detecti
8. Tighten the nuts and bolts if loose e Replace the ball screw if defective e Check the usage method and payload etc Misoperation due to noise e Check if the robot and controller are using the same ground point e Check if there are any noise sources in the vicinity of the controller such as welders or discharge machines See 4 4 5 Preventing misoperation due to noise and take countermeasures Position is deviated after return to origin 2 Cause 4 Checkpoint Action Cause 5 Checkpoint Action Defective motor Try using another motor If operation with another motor is okay then replace the defective motor Controller is defective Try using another controller If operation with another motor is okay then replace the defective controller Robot won t move with movement commands Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Cause 4 Checkpoint Action Cause 5 Checkpoint Action Cause 6 Checkpoint Action Alarm has occurred Connect the teaching box or support software and check description on alarm that occurred See 11 2 1 Alarm display and take countermeasures Has set to emergency stop Check emergency stop signal input Cancel emergency stop signal input An interlock is activated Check Lock signal input Cancel Lock signal input Return to origin is incomplete Check if return to orig
9. 30ms 5 4 To customers only using serial communication When using only serial communication the EMG input must be shorted to the LOCK input on the I O connector If the LOCK input is open an interlock occurs If the EMG input is open an emergency stop is triggered so return to origin and point trace are disabled Fig 5 2 5 to 24V External DC power supply PRC 5 5 I O connector signal table 5 5 I O connector signal table In the I O connector provided as a standard feature of the PRC controller one signal is assigned to each terminal on the connector The table below gives the names and descriptions of signals assigned to each terminal and the pin No A detailed explanation is given in 5 5 1 Input signal description and 5 5 2 Output signal description Signal name Description Input output COM T O port common supply voltage 5V to 24V COM T O port common supply voltage 0V START Point start signal PNT1 PNT2 PNT3 Specify point number 1 PNT4 PNT5 LOCK Interlock signal Input INI OJAJA JOJN EMG Emergency stop signal Input ALMCLR Alarm reset signal Input ORG Return to origin start signal Input ACK Response signal to ORG and START Output ROTATE Motor drive status output signal Output ALM Alarm status output signal Output ZONE Position output signal Output END Normal end output signal Output EMGMON Emergency stop status ou
10. Emergency stop input Normally closed contact input External communication Conforms to RS 485 1CH teaching box or PC unction error meno error redenetative unit error over speed att Operating temperature 0 C to 55 C Storage temperature 20 C to 70 C Operating humidity Below 90 RH no condensation Selectable option Teaching box support software 1 Power needed for I O control must be supplied from an I O connector from an I O power supply This is separate from the power required by the controller itself 2 Always install a noise filter on the power line when used with inductive loads such as motors and solenoid valves Misoperation or malfunction may occur if no noise filter is used See 4 4 5 Preventing misoperation due to noise 3 The trace command format for the PRC controller is different from that for the YAMAHA ERCX SRCX DRCX TRCX controllers 4 Optional support software YPB Win for PRC is needed 5 The ORG monitor and LOCK monitor can be changed by parameter setting The ORG monitor is set prior to shipment from the factory 6 One to 16 slave stations can be connected to one master station Basic specifications 10 1 SNOILVO14IDAdS 10 2 External view 10 2 External view Fig 10 1 PRC external view 10 3 Robot No Robots h
11. YAMAHA YAMAHA MOTOR CO LTD YAMAHA SINGLE AXIS ROBOT CONTROLLER Pico type User s Manual enous E82 Ver 1 05 General Contents Chapter 1 INTRODUCTION Chapter 2 ABOUT SAFETY 2 1 2 2 Safety MEMS 226cssis ieceneieccodsvasssensanicetesdedusesegsedsesvesereantceisoatensedeccdesvesesesbensesoreoseustsanessniesss 2 1 ZAM Signal Word Meaning oroe rie asa oetieeiss E EA E caveaveas leased A E aa 2 1 Dod 2s x Safety IMStrUCtlOns ss paos AA E EEEE E TALANA AS OAE EA ASEE ESEE 2 1 Before using the robot controller ssesseseosesessossossosseseesesossessossosoesossesessessossosossossesse 2 5 Chapter 3 OVERVIEW 3 1 3 2 3 3 3 4 3 5 3 6 3 7 CONCEP bissscseseissnssccesasseSeasasssasads A E SERN 3 1 Features os cressscssces ones arrre orkane Eana REA ESNE ESEESE AAEE OUSA EAEE ASKEA a Ca EEEa 3 1 System configurations saa iA a aa aa s sE iaa aeaiaioe 3 2 Connector names and functions sesseseosossossesesseseosecsossossessesessesesseesossessesesseseeseesesees 3 3 Point TUNCUIONR siirsin essor aereos seisoo S oa tose coasedgesotedapeaessatenscebesee 3 3 Communicating with equipment sesesssossossoossoesosssossossoossessosssossosesossessoosesesosssossesee 3 4 Sequence from purchase to operation sssessesessessesossessossossssessesossessossossssessesessessessese 3 4 Chapter 4 INSTALLING THE CONTROLLER 4 1 4 2 4 3 4 4 4 5 Chapter 5 5 6 5 7 Before installing the controller
12. 0 00 mm The PRC controller operates in a range of 134217727 to 134217727 pulses However the absolute position command ABS PT moves the robot so as not to exceed the upper limit value in each direction and does not perform shortcut control When moved in the same rota tion direction with the relative position command INC PT the plus minus sign of the current position is inverted at the point that 134217728 pulses is exceeded Clockwise plus direction Counter Clockwise minus direction 134217727 134217727 134217728 134217728 8 3 Point data POINT Example 1 Target position INC PT OK 134217728 134217728 OK INC PT Example 2 e Target position ABS PT NG ABS PT OK ABS PT 134217728 134217728 8 3 Point data E INPOS width Description Specifies the position for switching the INPOS signal during movement as an amount inversely calculated from the target position Direction of robot movement INPOS width Input range 4 to 134217727 pulses default 4 Remarks 8 Set the INPOS width to a large figure when changing the speed during movement or changing the movement destination By setting a large figure for the INPOS width the END signal during movement can be utilized to change the target position or movement speed O The input range for INPOS width default value and unit used will vary according to the robot Z Example On the T4P 12 Resolution
13. 2 OFF OFF OFF OFF OFF OFF OFF OFF ON 2 Set the START input signal to ON A CAUTION The START input signal is executed by ON edge detection 3 When a START input signal is normally received the ACK output signal turns ON and the robot starts to move The ROTATE output signal turns ON during robot movement during motor drive 4 On reaching the target position the speed reduces to a pushing speed and torque movement starts 5 Torque detection time starts at the point that the torque limit is reached 6 The ROTATE output signal turns OFF at count up 7 The END output signal turns ON when the torque movement ends correctly A CAUTION When the START input signal stays ON the ACK output signal remains ON even if the torque movement is complete When the ACK output signal remains ON the END output signal cannot turn ON LYVHD ONIWIL NOILVNIdO ANY NOILVadAdO DISV4E N 9 4 Torque movement Robot torque movement is any one of the following states Balanced state operation External force and specified torque External force specified torque current ends normally current match so that the robot stops at that position Pushed past target position Specified pushing torque current is larger External force lt specified torque current than external force so robot ended movement at target position Torque distance Dribble External force matched the specified Extern
14. Check Lock signal input Action Cancel Lock signal input ACK signal is not returned after START signal is input Cause 4 Return to origin is incomplete Checkpoint Check if return to origin is complete Action Perform return to origin if not completed Cause 5 Data is not stored in point specified by PNT signal Checkpoint After connecting a teaching box or support software and checking the input status of PNT1 to PNTS on an I O monitor screen check the designated point data Action Select the point No and correct the point data Cause 6 Target point is outside of software limits 11 Checkpoint Check the point data movement setting Action Correct the point data mr 7 ROTATE signal won t turn on after START signal is input Cause 1 The target position is the same as current position or is a position within 4 2 gt pulses of the current position am Checkpoint Check the point data movement amount setting N Action ese T Q INPOS signal won t turn OFF after START signal is input Q Cause 1 The target position is the same as current position or is a position within 4 Z pulses of the current position A Checkpoint Check the point data movement amount setting Action Cause 2 The INPOS width setting is larger than the movement amount due to executing point data Checkpoint Check the point data for the INPOS width setting Action Correct the point data Cause 3 System parameter setting
15. Checkpoint Action Cause 9 Checkpoint Action Cause 10 Checkpoint Action Ball screw abnormality Check for intrusion of foreign objects or breakage warping e Replace ball screw e Check usage method payload etc Levelness of robot installation surface is below tolerance value Measure the levelness of the installation surface If below the tolerance value re machine the installation surface Robot type setting error Refer to the robot No PRM42 and check that the robot type is set correctly If the No does not match the model you are using then perform generation e Reset the speed and acceleration deceleration of the point data Payload exceeded robot allowable payload Refer to payload PRM44 and check that is set correctly e Perform generation according to the actual payload e Reset the speed and acceleration deceleration of the point data Motor is defective Try using another motor If operation with another motor is okay then replace the defective motor Controller is defective Try using another controller If operation with another controller is okay then replace the defective control ler Position deviation occurs 1 Cause 1 Checkpoint Action Cause 2 Checkpoint Action Imperfect tightening of coupling Check the tightened section Tighten if loose Ball screw abnormality Check for excessive play or loose nuts and bolts Tigh
16. OFF OFF OFF ON OFF OFF ON OFF Point Nos specified with PNTI through 5 are only valid for movement with a START input signal These are not used for movement via communication LOCK Interlock Pin No A9 oJ NOTE This serves as an operation stop signal while still in servo on The interlock is triggered when the contacts open B contact If the LOCK input signal turns OFF contacts open while the robot is moving the robot will decelerate and stop Movement commands are not accepted while the robot is moving Serial communication at this time results in a command error and there is no ACK reply to execution of START e After decelerating the stop position becomes the target position e After decelerating and stopping the interlock condition is canceled by signal ON contact closed e Canceling the interlock input edge detection of Active to Non Active also cancels the interlock command set by serial communication e Interlock is triggered when a logic OR condition from both the I O port and serial communication is met e If the power is turned on with the interlock triggered then the unit starts up in emergency stop e Reset is not performed after power is turned on if the LOCK input signal is OFF contacts open when restarted E EMG Emergency stop Pin No A10 W NOTE This is the emergency stop signal Emergency stop is triggered when the contacts are op
17. a host device such as a PLC When the DO3 output function was set in DI4MON the host PLC or other device can check the LOCKMON output signal and determine if there is an interlock state or not 7 3 Parameter description PRM24 Motor Direction Description Sets the motor rotation direction for moving the linear robot in the plus direction see below Input range O default CW Clockwise CCW Counterclockwise Remarks Motor Motor shaft Clockwise Note F Changing only this parameter will invert the origin position Return to origin direction Return to origin direction When only PRM24 was changed SAJ LAWVaAVd 3 7 3 Parameter description PRM28 Position Limit Alarm Description This parameter specifies whether to permit or protect inverting the plus minus sign of the absolute position counter except for zero point in a rotary robot If this parameter is set to Permit an A11 Position Limit Exceeded alarm is issued during servo on when the plus minus sign for the current position is inverted except for zero point and the servo turns off If this parameter is set to Protected no alarm is issued even when the plus minus sign in coor dinates is inverted Input range 0 default Permit 1 Protected Remarks The PRC controller operates in a range from 134217727 to 134217727 pulses However the absolute positi
18. after running a movement command through the parallel I O port when the point data target position has exceeded the lower software limit value Running move ment instructions from a serial I O will cause a command error When using the software limit functions on a linear robot to avoid striking the mechanical stopper stroke end set PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Enable and set the values for PRM61 Upper Soft Limit and PRM62 Lower Soft Limit When using a rotary robot in unlimited rotation mode PRM28 Position Limit Alarm must be set to Protected and PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Disabled Sada LAWVaAVd 7 3 Parameter description PARAMETERS N PRM36 Max Torque Deviation Description This parameter sets the movement amount to be detected as excessive deviation when the robot is pulled forward or is pushed back torque movement Input range 1 to 65535 pulses default 533 Note e This parameter is enabled only when PRM30 is 0 However the movement amount is not detected if set to a distance longer than the robot stroke Also might not be detected depending on the robot position Example When detected Pushed back movement Maximum amount of pushing deviation When not detected Pushed back movement Maximum amount of pushing deviation The input range for maximum pushing deviation prev
19. an alarm occurs the LED on the front panel flashes or lights up accord ing to the alarm information Description This lists the alarm information Cause Shows the cause of the alarm Action Shows the corrective action to take to cancel or avoid the alarm Alarms that have Restart appearing behind the alarm name require that the controller be restarted in order to cancel the alarm OINILOOHSATENOAL 11 2 Checking the alarm and countermeasure TROUBLESHOOTING nu Alarm message list A01 Encoder Wire Broken REBOOT LED flash count 1 time Description Encoder wire broken or disconnected Encoder wire is broken or miswired Check the encoder wire connection Misoperation or malfunction caused due to noise Make a check for ambient noise See 4 4 5 Preventing misoperation due to noise and take proper measures A02 Power Supply Voltage High LED flash count 2 times Description Power supply voltage exceeded its rated specifications Excessive supply voltage on the 24 V power line or a wrong connection Check the power supply connection and setting A03 Power Supply Voltage Low LED flash count 2 times Description Power supply voltage dropped below its rated specifications This is detected during servo on and initializing operation Not detected during servo off emergency stop or during alarm Controller drive power is insufficient Check the ca
20. chain is connected between three or more PRC units The following is an example for connecting four PRC units in a daisy chain A CAUTION Always shut off the power supply during this task 1 Set the addresses on DPRC PRC PRC and PRC A CAUTION When connecting multiple PRC units in a daisy chain always set a different address for each PRC unit 2 Remove the covers from the PRC PRC PRC and PRC 3 Check that DIP switches 1 and 2 for the PRC and PRC are both set to ON If not both set to ON then set so that both of them are ON Switches 1 and 2 are both set to ON prior to shipment at the factory Svima y PRC Syama y PRC 1 l 4 A caution Always set the communication speed DIP switch 3 to the same setting as the PC side support software side If these have different settings then communication is disabled If different settings are used for communication speed on the support software PC side among the PRC connected by daisy chain then communication with those PRC is impossible NOILVOINAWWOD TVIAAS 6 6 Setting for a daisy chain between PRC units 4 Check that DIP switches 1 and 2 for the PRC and PRC are both set to OFF If not both set to ON then set so that both of them are OFF Switches and 2 are both set to ON prior to shipment at the factory Gvam y PRC A CAUTI ON aaaaaaaaaaaaaaaamamammmms Always set the communication speed DIP switch 3 to the same setting as
21. controller status e A monitor signal is output in EMG input port status regardless of the controller status E ORGMON Return to origin end monitor Pin No B9 This monitors the normal end of return to origin operation Turns on when return to origin is completed NOTE Turns off return to origin was run again after return to origin ended Turns on at the point that return to origin is again completed A CAUTION O Either interlock monitor LOCKMON or return to origin end monitor ORGMON can be selected The return to origin end monitor is enabled valid by factory setting prior to shipment If you wish to use LOCKMON this can be changed with the parameter However ORGMON and LOCKMON cannot both be used at the same time m LOCKM ON Interlock monitor Pin No B9 This monitors the interlock status A CAUTION O Either interlock monitor LOCKMON or return to origin end monitor ORGMON can be selected The return to origin end monitor is enabled valid by factory setting prior to shipment If you wish to use LOCKMON this can be changed with the parameter However ORGMON and LOCKMON cannot both be used at the same time 5 5 I O connector signal table E INPOS Pin B10 This outputs the INPOS status The INPOS in position status is the state when the robot axis has entered the positioning com pletion range Turns on in INPOS status The INPOS output signal turns on when the robot enters within the INPO
22. forward or is pushed back to the maximum deviation during torque movement When this parameter is set to Permit and the robot is pushed back to a value exceeding that set in PRM27 Max Position Deviation during normal robot movement or hold operation or when pushed back to a value exceeding that set in PRM36 Max Torque Deviation during torque move ment an A05 Servo Error alarm is issued and the servo turns off When set to Protected no alarm is issued even when the robot is pulled forward or is pushed back Input range 0 Permit Alarm will be issued 1 default Protected Note e Even when an A05 Servo Error alarm has occurred other movement commands can be run after turning the servo on by inputting an alarm clear ALMCLR signal See 11 Troubleshoot ing for more information on alarms e PRM27 Max Position Deviation is a write protected parameter PRM31 Upper Soft Limit Function Description This parameter specifies whether to permit or protect the upper software limit function The software limits determine the robot movement range that is permitted by software setting When the upper software limit function is enabled movement to a position that might exceed the upper software limit value is determined as an error prior to movement However if the current position has already exceeded the upper software limit value then the robot can still move to wards the allowable movement rang
23. function is enabled movement to a position that might exceed this lower limit value is determined as an error prior to movement However if the current position has already exceeded the lower software limit value then the robot can still move towards the allow able movement range Input range 134217727 to 134217727 pulses default 134217727 Note e When using the software limit functions on a linear robot to avoid striking the mechanical stopper stroke end set PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Enable and set the values for PRM61 Upper Soft Limit and PRM62 Lower Soft Limit When using a rotary robot in unlimited rotation mode PRM28 Position Limit Alarm must be set to Protected and PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Disabled On linear robots if the PRM69 Origin Preset parameter is set so large that the plus minus sign is inverted at a location within the movement range the software upper limit value be comes smaller than the software lower limit value This state is always treated as being outside the software limits when the software limit functions are enabled so the robot cannot move Remarks e The input range for the lower software limit value default value and unit used will vary ac cording to the robot Example On the T4P 12 PARAMETERS N Resolution 800 Deceleration rate 0 lt gt 0 0
24. output signal turns ON during robot movement during motor drive 4 The ZONE output signal turns ON when the robot enters the zone output signal designated area 5 The ZONE output signal turns OFF when the robot leaves the zone output signal designated area 6 The END output signal turns ON when the robot normally completes movement to the desig nated movement point A CAUTION When the START input signal stays ON the ACK output signal remains ON even if the movement is complete When the ACK output signal remains ON the END output signal cannot turn ON LYVHD ONIWIL NOILVAAdO ANY NOILVadAdO DISV4E A CAUTION The ZONE output position is inaccurate if return to origin is incomplete Always use the ZONE output signal after performing return to origin 3 1 9 5 Zone output operation Timing Chart PNT 1 to5 ACK Motor speed ROTATE END oo pii i L INPOS width INPOS ZONE 1 i G Li H H ZONE output range The ZONE output signal can determine and output the current position when the robot has changed to the interlock state emergency stop state or alarm state However the previous output status is maintained when a broken wire detection or CPU error alarm has occurred A CAUTION Always turn the START input signal OFF at the point that the ACK output signal has turned ON lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun
25. payload is higher than the allowable robot payload Correct the payload weight Robot won t move with return to origin command Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Alarm has occurred Connect the teaching box or support software and check description on alarm See 11 2 1 Alarm display and take countermeasures Has set to emergency stop Check emergency stop signal input Cancel emergency stop signal input An interlock is activated Check Lock signal input Cancel Lock signal input that occurred ONILOOHSATENOAL Alarm occurs during return to origin Cause 1 Checkpoint Action Cause 2 Checkpoint Action Encoder cable or motor cable are broken or disconnected Check the encoder cable and motor cable connections If broken then replace the cable The return to origin method PRM63 parameter is not set correctly Check if the setting matches the robot type Edge or Sensor Reset the parameter 1 9 11 3 Dealing with problems based on trouble symptom Position is deviated after return to origin TROUBLESHOOTING 1 10 Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Imperfect coupling tightening Check the tightened section Tighten if loose Ball screw abnormality Check for excessive play or loose nuts and bolts
26. precautions and also read the following caution points Fig 4 1 Controller installation diagram l 50mm or more Allow a space of at least 50 mm on the upper and lower sides of the controller so that there are no obstructions to the flow of air from equipment emitting heat Install a fan to circulate the air if heat tends to accumulate above the controller When two or more controllers are used install at least a space of 10 mm between the evanaga M evanana M controllers 10mm or more wr ad 50mm or more YATIOULNOD AHL ONITIVISNI 30mm or more CAUTION Do not apply impact or loads to the connectors on the front or bottom of the controller This may damage the PC boards inside the controller CAUTION Allow extra slack when routing the cables and do not place a load on the connector by pulling on the cables CAUTION Avoid installing the controller in locations where oil or water might get on it If installation in such locations is unavoidable then use a water proof box with cleaning unit to house the controller CAUTION Install the controller in a stable level location Do not install facing any direction other than specified Also avoid installing in locations with large amounts of vibration Pp PP Pp CAUTION Avoid installing in locations where ambient temperatures are high 3 4 3 Wiring 4 3 Wiring 4 3 1 Cable wiring Fig 4 2 External wiring connection layou
27. the PC side support software side If these have different settings then communication is disabled If different settings are used for communication speed on the support software PC side among the PRC connected by daisy chain then communication with those PRC is impossible 5 Reattach the covers to the MPRC PRC PRC and PRC 6 Connect the MPRC PRC PRC and PRC with link cables The CN5 CN6 connectors are functionally the same Either one can be used SERIAL COMMUNICATION 7 1 How to set the parameters See the support software manual or teaching box manual for information on how to set the parameters 7 2 Cautions when setting the parameters Some parameters are input in millimeter units Parameters input in millimeters are recognized as multiples of the distance mm that the robot moves per pulse according to the screw lead length So the input parameter settings might sometimes be rewritten during storing of the data Example When 13 mm was input into Upper Zone Range PRMS9 limit for a robot lead length of 12 mm 13 12 x 800 866 6 867 Movement amount lead length x encoder division 800 pulses setting value pulses 867 800 x 12 13 005 13 01 Movement pulse amount encoder division 800 pulses x lead length setting value mm The input value in this case is 13 mm but the value is stored as 13 01 mm Parameters that are input in millimet
28. the controller Otherwise electrical shock might occur N caution Always provide ground connections CN4 signal table Signal name Description Controller drive power supply 24V Controller drive power supply 0V Frame ground Fig 4 3 CN4 pinout controller side Connector pin No 4 4 4 Grounding connections The controller uses PWM for controlling the transistors in the main circuit If the ground wiring is not correct or inadequate then transistor switching noise will occur The controller also has internal electronic circuits such as a CPU so wiring and other measures to prevent external noise are required Be sure the wiring and grounding connections are sufficient to prevent trouble such as from circuit noise Make a reliable grounding connection for Type III ground ground resistance of 100 ohms or less Motor frame grounds Always provide a robot and controller ground at one point Cable grounds If motor wiring is routed through a metal conduit or metal box then always be sure to ground these metal portions Provide a ground at one point 4 4 5 Preventing faulty operation due to noise Evaluate the following points to prevent faulty operation or malfunctions from noise 1 Noise filters If using with parts having an inductive load such as motors and solenoid valves then always install a noise filter in the power line Faulty operation or malfunctions might occur if you fail to use a no
29. the wiring Cause 3 T O flat cable is miswired Checkpoint Check if connection to wrong Pin No was made Action Correct the miswiring Cause 4 Controller is defective Checkpoint Try using another controller Action If operation with another motor is okay then replace the defective controller Output signal won t turn OFF Cause 1 T O flat cable is shorted to COM Checkpoint Use a tester or multimeter to find if the I O flat cable and COM are shorted Action Correct the miswiring short Cause 2 T O flat cable is miswired Checkpoint Check if connection to wrong Pin No was made Action Correct the miswiring Cause 3 Controller is defective Checkpoint Try using another controller Action If operation with another motor is okay then replace the defective controller ALM signal is OFF after power is turned on Cause 1 Alarm has occurred 5 Checkpoint Connect the teaching box or support software and check description on alarm Cc that occurred lee Action See 11 2 1 Alarm display and take countermeasures am N ALM signal is OFF after power is turned on 5 Cause 2 Drive power to the controller is not supplied O Checkpoint Check the connection at the controller power input connector and also if power is being supplied through the power cable Z Action Supply drive power to the controller O n13 11 3 Dealing with problems based on troubl
30. 06 35 35 0 00 Command See the support software manual or teaching box manual for information on how to create point data and how to load data PNT1 PNT2 lt INPOS width 30 0mm gt Be 1st movement 2nd movement Basic operation 1 Specify the movement point Methods for specifying the point are as follows Point No PNT4 2 PNT3 22 PNT2 2 PNT1 2 OFF OFF OFF OFF OFF OFF OFF ON OFF OnE ON OFF Specify PNT1 here 2 Set the START input signal to ON A CAUTION The START input signal is executed by ON edge detection 3 When the START input signal is normally received the ACK output signal turns ON and the robot starts to move Turn the START input signal OFF when the ACK output signal has turned ON The ROTATE output signal turns ON during robot movement during motor drive 4 Specify the next movement point position Specify PNT2 here 5 The END output signal turns ON when entering within the INPOS range of PNT1 Continuous movement to the next point can be performed by using this signal as a trigger 6 Turn the START input signal ON using the END output signal as a trigger A CAUTION The START input signal is run by ON edge detection 7 When a START input signal is normally received the ACK output signal turns ON and the robot starts to move The ROTATE output signal turns ON during robot movement du
31. 15 mm per pulse Lead length 12 U The input range is from 2013265 91 to 2013265 91 mm 14 7 3 Parameter description PRM63 Origin Method Description Specifies the origin point detection method during return to origin Input range 1 Sensor 3 default Edge Note e The return to origin method varies according to the robot Linear robots generally use the Edge detection method that utilizes a mechanical stopper stroke end Even if the return to origin method is changed the return to origin status is the same until you perform return to origin again Be sure to perform return to origin after changing the return to origin method e Please note YAMAHA can accept no liability for problems resulting from changing this pa rameter without consulting us in advance mJ PRM69 Origin Preset Description This is a default value for the position when return to origin is completed Input range 134217727 to 134217727 pulses default 0 Note This parameter does not perform any movement SaaLAWVaAVd This is enabled after return to origin is complete When using the software limit functions the amount specified with this parameter must be added to PRM61 Upper Soft Limit and PRM62 Lower Soft Limit When using the zone function it is not necessary to add the amount specified with this param eter to PRM59 Upper Zone Range and PRM60 Lower Zone Range On linear robots
32. 2 Safety instructions To use the YAMAHA robot safely and correctly be sure to follow the safety rules and instructions described in this manual or shown on warning labels Failure to follow the necessary safety instruc tions or incorrect handling could result in death or serious injury to the user persons installing operating servicing or adjusting the robot as well as malfunction and damage to the robot and or robot controller General precautions WARNING Do not use in explosive atmosphere Personal injury or fire may result WARNING Never touch this robot controller while power is being supplied to it Electrical shock may result WARNING Do not perform work such as wiring maintenance and inspection while power is being supplied to the robot controller Always turn the power off and then wait for at least 1 minute before beginning the work to avoid electrical shock gt WARNING When moving installing wiring operating servicing or inspecting the robot controller only a person with required expertise may perform the work Electrical shock injury or fire may result CAUTION Always use the controller and robot within the specifications listed in this manual to avoid electrical shock injury or damage CAUTION Do not use the controller and robot if they are damaged as personal injury or fire may result CAUTION Use the controller and robot in a specified combination An incorrect combina
33. D 4 8 ACK output signal ON 2 Arrived within INPOS range before EMG input 3 EMG signal ON EMG signal OFF When emergency stop is triggered the INPOS output signal turns OFF regardless of whether the robot has already entered within INPOS range or not The END output signal during emergency stop maintains the signal state it had just prior to emergency stop The END output signal does not change even if emergency stop is canceled After the robot stops due to an alarm or emergency stop the stop position will be the reference position for performing relative movement A CAUTION Always turn the START input signal OFF at the point that the ACK output signal has turned ON CAUTION The ALMCLR input signal does not use edge detection Always turn the signal off after ALMCLR input LYVH D ONIWIL NOILVUAdO ANY NOILVasAdO DISV4E 17 9 3 Positioning operation lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 518 9 3 6 Canceling an interlock during movement When an interlock is activated during robot movement the robot decelerates and stops but the servo does not turn off The robot does not move when an interlock has been activated even if a movement command is run The robot will not continue movement even if the interlock is canceled Timing chart PNT 1 to5 Motor speed ROTATE l ACK output signal ON Arriv
34. IMPLIED WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU OF ALL EXPRESSED OR IMPLIED WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR WARRANTIES ARIS ING FROM A COURSE OF DEALING OR USAGE OF TRADE YAMAHA MOTOR CO LTD SOLE LIABILITY SHALL BE FOR THE DELIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO LTD SHALL NOT BE LIABLE FOR ANY CON SEQUENTIAL DAMAGES WHETHER ARISING FROM CONTRACT WARRANTY NEGLI GENCE OR STRICT LIABILITY YAMAHA MOTOR CO LTD MAKES NO WARRANTY WHATSOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO LTD 12 3 Disposal When disposing of this controller handle it as industrial waste MEMO Revision record Manual version Issue date Description Ver 1 02 Nov 2003 English manual Ver 1 02 is based on Japanese manual Ver 1 02 Ver 1 03 Oct 2005 English manual Ver 1 03 is based on Japanese manual Ver 1 03 Ver 1 04 Aug 2006 English manual Ver 1 04 is based on Japanese manual Ver 1 05 Ver 1 05 Jan 2007 English manual Ver 1 05 is based on Japanese manual Ver 1 06 User s Manual PICO Series YAMAHA PRC1 PRC2 Jan 2007 Ver 1 05 This manual is based on Ver 1 06 of Japanese manual YAMAHA MOTOR CO LTD IM Operations All rights reserved No part of this publication may be reproduced in an
35. MCLR signal is left still input then the next alarm that occurs will be cleared right away A CAUTION If the robot is a vertical installation type then brake release will be delayed for a certain time after the servo turns on Do not run a movement command until at least 50 ms have elapsed after servo on INVHO ONIWIL NOILVAAdO ANY NOILVadAdO DISV4E S lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 9 2 Performing return to origin 0 6 9 2 Performing return to origin This section explains the basic operation and operating timing charts for return to origin When power to the controller is turned on the robot is not set at the origin return to origin incomplete As long as return to origin is incomplete the robot will not move even if a movement command is issued Robot movement by the jog keys is also impossible Always be sure to complete return to origin before attempting robot movement 9 2 1 Normal return to origin Basic operation 1 Set the return to origin ORG signal from OFF to ON A CAUTION Return to origin is performed when the ON edge is detected 2 When the ORG input signal turns on normally the ACK output signal turns ON and the robot moves in return to origin direction 3 When return to origin ends normally the END output signal turns ON If the return to origin complete ORGMON output signal is enabled it turns ON when the re
36. O N lt ca 932 SPECIFICATIONS 10 1 Basic specifications Specification item a PRC1 PRC2 Controllable robot T4P Dimensions W42 5xH102xD81mm Weight 0 4kg Controller only Power input DC24V 10 1 2 Power capacity Max 1 6Arms 2 7Arms Number of control axes 1 axis Control method Software servo Position detection method Encoder Position setting units mm or pulses Axis control Operation method PTP operation point trace method 3 Speed setting 0 to 240 in 1 increment 100 1875rpm Acceleration deceleration setting 1 to 255 in 1 increment 100 6123rad s Servo adjustment Adjustable by parameter setting gain adjustment LPF adjustment Pulse resolution 800 P R Number of points 32 points Memory Point input method Teaching box TP 2 or PC 4 specifications Origin detection method Stroke end or sensor Point teaching method Manual input teaching input direct teaching Dedicated 10 8 points e Start input START e Instruction position number input 5 bit binary e Interlock LOCK e Emergency stop EMG e Alarm clear e Return to origin input ORG e ACK Parallel I O signal e Motor drive status output ROTATE e Alarm output ALM External e Zone output ZONE VO e END interface e EMG monitor e Return to origin input monitor ORG monitor Interlock monitor LOCK monitor 5 e In POSITION target point arrival check Serial I O signal Serial interface I O RS 485 6 Power DC 5 to 24V Brake output Available
37. ON when inside the zone range If using the zone function set both PRM59 and PRM60 However the zone function is disa bled when PRM59 and PRM60 are the same value On linear robots if the PRM69 Origin Preset parameter is set so large that the plus minus sign is inverted at a location within the movement range the zone upper limit becomes smaller than the zone lower limit This state is always treated as being outside the zone range Remarks e This parameter can be used to check whether or not the axis is within the specified range 7 regardless of whether the robot is moving or stopped The input range for the zone upper limit default value and unit used will vary according to the robot Ss Example On the T4P 12 S Resolution 800 zZ Deceleration rate 0 gt 0 015 mm per pulse m Lead length 12 P rz N The input range is from 2013265 91 to 2013265 91 mm and the default value is 0 00 mm 11 7 3 Parameter description PRM60 Lower Zone Range Description This parameter specifies the lower limit value for switching a zone output signal in absolute coordinates Input range 134217727 to 134217727 pulses default 0 Note e Specified value is contained in the zone range e Zone output signal is ON when inside the zone range e If using the zone function set both PRM59 and PRM60 However the zone function is disa bled when PRM59 and PRM60 are the same value e On line
38. S range That INPOS output signal turns off when the next movement command is run NOTE e The INPOS signal is off when the servo is off e Turns on when return to origin ends correctly e Determines the INPOS width for the target position during torque movement e When the movement command is less than 4 motor pulses the motor signal remains on 5 6 I O cable specifications The I O cable is used to connect the PRC controller to an external control device such as a PLC To operate the controller from an external device via I O control first perform the necessary wiring connections of the I O flat cable supplied with the PRC controller and then connect it to the PRC controller I O flat cable KX1 M5163 200 B1 A1 Cable mark red SNOILVOISIDAdS JDVANALNI O I N Z p lt Q kalal ou N kla Q S a bla Z O 5 8 5 7 Connecting to a PLC using 24V DC power supply 5 7 Connecting to a PLC using 24V DC power supply 5 7 1 Connecting to a Mitsubishi PLC model AY50 output unit AY50 output unit PRC controller Surge killer Photocoupler ica ALMCLR ORG COM COM i i External DC 24V power supply 5 7 2 Connecting to a Mitsubishi PLC model AX40 input unit PRC controller AX40 input unit ACK ROTATE ALM ZONE END EMG MON ORG MON INPOS Chapter 6 SERIAL COMMUNICATION 6 1 Overview In t
39. V4E 9 3 Positioning operation Timing chart PNT 1 to 5 l START f ACK i Motor speed ROTATE END An END output signal turns ON when the robot enters within the INPOS range A CAUTION Always turn the START input signal OFF at the point that the ACK output signal has turned on See the next section 9 3 2 START signal AC characteristics for information on START signal minimum hold time etc 9 3 2 START signal AC characteristics The timing chart for executing commands with the START signal is shown below The START signal minimum hold time is also shown in the table below Always refer to this table when making signal setups me DS PNT 1to5 ORG i ACK Point data hold time START signal hold time START signal setup time ACK signal response delay time ACK signal response delay time lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 10 9 3 Positioning operation 9 3 3 Positioning with a short movement time Timing chart Motor speed ROTATE Hold PNT1 to 5 for at least 2 ms 2 After setting PNT1 to 5 wait at least 1 ms and then set the START signal to ON 3 After setting the START signal to ON set a hold state for 1 ms or more 9 After setting the START signal to ON the PRC unit sets the ACK output signal to ON within 1 ms This is not set to ON if an error occu
40. WOD 1IVI NIS 6 3 6 6 Setting for a daisy chain between PRC units SERIAL COMMUNICATION 6 6 Setting for a daisy chain between PRC units 6 6 1 When using two PRC units in a daisy chain Here is how to make the setting when the daisy chain is connected between two PRC units A CAUTION Always shut off the power supply during this task 1 Set the addresses on the DPRC and PRC A CAUTION When connecting multiple PRC units in a daisy chain always set a different address for each PRC unit 2 Remove the covers from the PRC and PRC 3 Check that DIP switches 1 and 2 are both set to ON If not both set to ON then set so that both of them are ON Switches 1 and 2 are both set to ON prior to shipment at the factory PRC A CAUTI ON Pe Always set the communication speed DIP switch 3 to the same setting as the PC side support software side If these have different settings then communication is disabled If different settings are used for communication speed on the support software PC side among the PRC connected by daisy chain then communication with those PRC is impossible 4 Reattach the covers to the PRC and PRC 5 Connect the PRC and PRC with a link cable The CN5 CN6 connectors are functionally the same Either one can be used YAMAHA PRC PRC 6 6 Setting for a daisy chain between PRC units 6 6 2 When using three or more PRC units in a daisy chain Here is how to make the setting when the daisy
41. act to the controller Install in a stable location having little vibration If installing at a location near a source of vibration install a shock absorber at the base so that the vibration is not applied directly to the controller Atmosphere gas dust etc Absolutely never use in locations having corrosive gas Long term use in such environments will cause connection problems in electrical contacts such as in connectors and lead to equipment breakdowns Do not use in locations having explosive or combustible gases Using in such environments may lead to accidents involving fire or explosions Do not use in locations with excessive dust or oil mist The dust or oil mist may attach to the equipment causing insulation deterioration or electrical leakage from conductive components which might damage the controller Noise When located near large sources of noise the noise might enter the line signal or power supply circuit through induction and cause faulty operation or malfunction If there is a possibility of external noise penetration then install a noise filter have the line wiring checked and take meas ures to prevent noise generation 4 2 Installation 4 2 Installation Prepare a location beforehand taking the various conditions for system layout into account and where it will be easy to service the equipment Be sure to read the cautions listed in 4 1 3 Installation and operating environment and 4 4 6 Other wiring
42. al force lt specified torque current pushing torque current but the torque current exceeded the external force so the robot gradually moved in that same direction Pushed back Moves External force matched specified torque External force gt specified torque current rearward after balancing current but the torque current was less than the external force so the robot moved in the reverse direction During torque movement the particular state such as normal end pushing past target position or dribble can be found by checking for one of 3 signals ROTATE END INPOS However this is only when the INPOS width setting is less than 4 pulses ROTATE END INPOS Start movement gt gt ON OFF ON OFF gt gt Ends normally OFF ON gt Ineffective ON ON gt Dribble then ineffective lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 22 9 4 Torque movement Timing Chart PNT 1105 START ACK JAE rT i ae a pare Motor speed fo it fii EE iN pete Torque detection time ROTATE INPOS END i i mi Starts decelerating towards target position Torque distance is added to target position 2 Reduces to torque movement speed Starts torque movement 4 Reaches specified torque current Balanced state Target position torque distance After the pushing conditions are set up the INPOS output
43. ar robots if the PRM69 Origin Preset parameter is set so large that the plus minus sign is inverted at a location within the movement range the zone upper limit becomes smaller than the zone lower limit This state is always treated as being outside the zone range Remarks e This parameter can be used to check whether or not the axis is within the specified range regardless of whether the robot is moving or stopped e The input range for the zone lower limit default value and unit used will vary according to the robot Example On the T4P 12 Resolution 800 Deceleration rate 0 lt gt 0 015 mm per pulse Lead length 12 PARAMETERS N The input range is from 2013265 91 to 2013265 91 mm and the default value is 0 00 mm 712 7 3 Parameter description PRM61 Upper Soft Limit Description This parameter specifies the upper software limit value in absolute coordinates The software limits determine the robot movement range that is permitted by software setting When the upper software limit function is enabled movement to a position that might exceed this upper limit value is determined as an error prior to movement However if the current position has already exceeded the upper software limit value then the robot can still move towards the allow able movement range Input range 134217727 to 134217727 pulses default 134217727 Note e When using the software limit funct
44. ave a number established to identify them according to model lead and installation layout Refer to the following table when initializing parameters or checking robot settings PL TAP 06 T4P 12 T5P 06 T5P 12 Horizontal installation 2 3 4 6 Vertical installation 5 7 SPECIFICATIONS Troubleshooting 11 1 When problems occur When contacting us after problems occur please provide information in as much detail as possible about the following items ee e Controller type e Controller serial No e Robot type e Robot serial No e When purchased e Usage period circumstance of use e Circumstances of problem that occurred What condition e What was done that made the problem occur What happened e Symptoms of the problem How often e How often does the problem occur 11 2 Checking the alarm and countermeasure This controller has an LED to show the alarm status and for checking if trouble has occurred The nature of the trouble can be found by the number of times the LED flashes or the alarm code by communicating with the device How to find the trouble and deal with it when an alarm occurs are described below Consult with us if the trouble is not corrected 11 2 1 Alarm display The alarm information cause and countermeasure are explained in the alarm code sequence Format Alarm code Alarm name A06 OVERLOAD LED flash count Description LED flash count When
45. ble then no reply is issued to the ACK output signal e Always turn the ORG signal OFF if there is no ACK reply within the specified time 5 5 2 Output signal description To find more information on the timing chart see 9 Basic operation and timing chart E ACK Pin No B3 This is a reply signal to the start command START and return to origin command ORG No reply is made to commands that cannot be executed NOTE e ACK reply is not made if data for the specified point No is not registered ACK reply is not made if the movement command is outside the software limits E ROTATE motor drive Pin No B4 Outputs the motor drive status Turns on during motor drive Turns off during stop W NOTE p The ROTATE signal is output in response to execution of the START or ORG command This is always off during servo off e This is off while an interlock is triggered Turns off when pushing operation ends normally Pushing operation turns off when not an ALM on reaching the target position When the movement command is less than 4 motor pulses the motor signal stays off SNOILVOISIDAdS JDVAANALNI O I E ALM Alarm output Pin No B5 This is output when an alarm occurs This is off during alarm status B contact 5 5 5 I O connector signal table N Z p lt Z Q Lhd ou N Lela Q S o thd Z O 5 6 E ZONE Zone output Pin No B6 Ou
46. c controller To control the robot from external equipment via the I O port connect the I O flat cable supplied with controller to the controller after making the necessary wiring to the I O flat cable For information on the meaning and operation of signals assigned to each terminal on the connector see chapter 5 I O Interface specifications WARNING Turn off the power before making these connections Otherwise equipment breakdowns might result 2 4 4 Connections a Lel mal l a _ Z O Q Lll IT 9 Z N Z 1 6 4 4 3 Power connections The power supplied to the equipment shall be as follows Model No Power supply voltage Power supply current PRC 1 1 6Arms DC24V 10 2 7Arms A CAUTION This is power required by the controller itself Power needed for I O control must be supplied to the I O connector section See chapter 5 I O Interface specifications for details Use the supplied power cable to connect the power supply to the connector CN4 Be careful not to make a wrong connection The wrong connection may cause a major hazard such as fire There is no power switch on the PRC controller Always install a suitable power breaker insulation for the entire equipment Use a power supply heavily insulated on the primary and secondary sides WARNING Always set the power breaker for the entire equipment to OFF before doing any installation wiring on
47. ctrical shock may occur if those parts are touched A CAUTION Make sure that the power supply voltage is within the specification range Using a voltage outside the specifica tion range may cause breakdown or malfunction Disposal precautions A CAUTION When disposing of this product handle it as industrial waste 2 2 Before using the robot controller 2 2 Before using the robot controller Please be sure to perform the following tasks before using the robot controller Failing to perform these tasks may cause abnormal operation vibration unusual noise 1 When connecting the power supply to the robot controller Always make a secure connection to the ground terminal on the robot controller to ensure safety and prevent malfunction due to noise See chapter 4 Installing the controller 2 When connecting robot cables to the robot controller Be sure to keep robot cables separate from the robot controller power connection lines and other equipment power lines Using in close contact with lines carrying power may cause malfunction or abnormal operation ALJAVS LNOPV MEMO 2 6 OVERVIEW 3 1 Concept This PRC series robot controller was created to combine the latest in control technology with design technology for high performance precision compact motors with the goal of producing a new type of intelligent robot controller that is easy to use and low in cost 3 2 Features Fig 3 1 App
48. d lower limits are the same value Check the Upper and Lower Zone Range values PRM59 PRM60 Reset the Upper and Lower Zone Range to the correct values PRM59 PRM60 Respective large and small values in zone range upper and lower limit values are now reversed Check the Upper and Lower Zone Range values PRM59 PRM60 Reset the Upper and Lower Zone Range to the correct values PRM59 PRM60 ZONE signal stays ON or stays OFF Cause 1 Checkpoint Action CPU error or encoder broken cable alarm occurring Connect the teaching box or support software and check description on alarm that occurred See 11 2 1 Alarm display and take countermeasures EMGMON signal won t turn ON even if emergency stop is input Cause 1 Checkpoint Action System parameter settings are incorrect Perform generation LOCKMON signal won t turn ON even if Lock is input Cause 1 Checkpoint Action The DO3 output function PRM19 is not set to 2 DIAMON Check the DO3 output function PRM19 value Set the DO3 output function PRM19 to 2 DI4MON 11 3 Dealing with problems based on trouble symptom INPOS signal won t turn ON in servo ON and with robot in stop state Cause 1 System parameter settings are incorrect Checkpoint Action Perform generation 11 3 3 Others Alarm is canceled at the same time that it occurs Cause 1 ALMCLR signal
49. e Input range 0 default Enable 1 Disabled Note e No ACK signal is issued after running a movement command from the parallel I O when the point data target position has exceeded the upper software limit value Running a movement command through the serial I O port will cause a command error When using the software limit functions on a linear robot to avoid striking the mechanical stopper stroke end set PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Enable and set the values for PRM61 Upper Soft Limit and PRM62 Lower Soft Limit When using a rotary robot in unlimited rotation mode PRM28 Position Limit Alarm must be set to Protected and PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Disabled 7 3 Parameter description PRM32 Lower Soft Limit Function Description This parameter specifies whether to permit or protect the lower software limit function The software limits determine the robot movement range that is permitted by software setting When the lower software limit function is enabled movement to a position that might exceed the lower software limit value is determined as an error prior to movement However if the current position has already exceeded the lower software limit value then the robot can still move to wards the allowable movement range Input range 0 default Enable 1 Disabled Note e No ACK signal is issued
50. e symptom END signal won t turn ON after power is turned on TROUBLESHOOTING n 14 Cause 1 Alarm has occurred Checkpoint Connect the teaching box or support software and check description on alarm that occurred Action See 11 2 1 Alarm display and take countermeasures Cause 2 Has set to emergency stop Checkpoint Check emergency stop signal input Action Cancel emergency stop signal input Cause 3 An interlock is activated Checkpoint Check Lock signal input Action Cancel Lock signal input Cause 4 System parameter settings are incorrect Checkpoint Action Perform generation No ACK signal is returned after ORG signal is input Cause 1 Alarm has occurred Checkpoint Connect the teaching box or support software and check description on alarm that occurred Action See 11 2 1 Alarm display and take countermeasures Cause 2 Has set to emergency stop Checkpoint Check emergency stop signal input Action Cancel emergency stop signal input Cause 3 An interlock is activated Checkpoint Check Lock signal input Action Cancel Lock signal input Cause 4 System parameter settings are incorrect Checkpoint Action Perform generation END signal won t turn ON after ORG signal is input Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Cause 4 Checkpoint Action Cause 5 Checkpoin
51. e then brake release will be delayed for a certain time after the servo turns on Do not run a movement command until at least 50 ms have elapsed after servo on LYVH D ONIWIL NOILVNIdO ANY NOILVasAdO DISVE BASIC OPERATION AND OPERATION TIMING CHART 9 1 3 When interlock LOCK was activated during power on Initialization is not performed if the interlock LOCK signal was input during power on Initializa tion will automatically start when the LOCK input signal is cancelled When the interlock LOCK signal was input during power on the EMGMON output signal turns on When the EMGMON output signal is ON during power on close the contacts for the EMG input signal and LOCK input signal Timing chart Power o ALM Pes Lock EMGMON Initialization END Seve ON INPOS 1 2000ms or more A CAUTION If the robot is a vertical installation type then brake release will be delayed for a certain time after the servo turns on Do not issue a movement command for 50ms after servo on 9 1 4 Alarm status cancelable alarm See 11 Troubleshooting for detailed information on alarms The END output signal does not change when an alarm occurs Timing chart Power EMG LOCK ALMCLR Initialization Servo ON r i I I 2000ms or mor e A CAUTION The ALMCLR input signal does not use edge detection Always turn the signal off after ALMCLR input If the AL
52. ecssscsseccsecssssessscessessessssessees 11 1 11 2 1 Alarm display ssciesscsiesssssssssstvesssscasvessssessestescessasseascncensbasvessesdessessossaaadutacsieevassaess oasssavesuasvedagussteatons 11 2 2 Alarms not requiring restart 11 3 Dealing with problems based on trouble symptom ccsccsscsssecsesccssecessscssseesees 11 6 11 3 1 Robot operation 113 2 Parallel O anann a TEIS ONES a a EE WOR ENEON AE AEE N EE Chapter 12 MAINTENANCE AND WARRANTY 121 Maintenance iccccscccececcseccecescceecsscectecccescdtssoteschsseucestbeciacevettesccevereesectusehasciecsuievecessseseses 12 1 12 2 Warranty caccseccsivessncesicass Gussdascounss danvosodbeaposscsuedansossnsscdensescsesvosoesceadassooasssasoseaseeseses sane 12 2 12 3 Disposals s asee ccauesets S EEan Ea a Sias E EEES S Sa EES 12 2 MEMO Chapter 1 INTRODUCTION At this time our sincere thanks for your purchase of the YAMAHA PRC series robot controller This manual de scribes installation and operation methods for use with the YAMAHA PRC series robot controller Read this manual and related equipment manuals carefully to make sure that operation is both correct and safe when using the YAMAHA PRC series robot controller After reading this manual store it carefully and make sure it is always available to the end user Use any of the following approaches for installing operating and adjusting this YAMAHA robot controller and keep it available for quick use when needed 1 Keep this man
53. ected Front view Single axis robot T4P T5P fA ol CN4 Bottom view TP 2 ee Power supply 3 4 Connector names and functions 3 4 Connector names and functions Fig 3 3 Parts name cns f OM cne l e CNS Cc SYAMANA F Front view PWR PWR ewy TT PIN 2 ALM Rotary switch cni lt COM CN1 CN6 CN2 CN2 CN3 CN3 MdAIAYIAO W CN4 E Connector names and indicators Connector name or indicator Purpose Function Lights up when power is turned on ALM Lights up or flashes if an alarm is issued Rotary switch Use to make the controller address setting COM Connector for RS 485 communication CN1 I O port Signal input output connector CN5 CN6 Communication connector Use these connectors to control two or more robots from one PC CN2 Encoder Connector for motor feedback and sensor signals CN3 Motor Connector for driving the motor CN4 Power 3 5 Point function Connector for supplying power to the controller Point positions and operating types can be assigned to a maximum of 32 points The assigned point positions and operating types are stored in the nonvolatile memory inside the controller Th
54. ed within INPOS range before LOCK input 3 LOCK signal ON LOCK signal OFF 9 3 Positioning operation INPOS and END timing chart INPOS END INPOS END 4 ACK output signal ON 2 Arrived within INPOS range before LOCK input 3 LOCK signal ON LOCK signal OFF When an interlock is activated the INPOS output signal turns ON regardless of whether the robot has already entered within INPOS range or not The END output signal during interlock maintains the signal state it had just prior to interlock The END output signal does not change even if the interlock is canceled After the robot stops due to an interlock the stop position will be the reference position for performing relative movement A CAUTION Always turn the START input signal OFF at the point that the ACK output signal has turned on LYVHO ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E 19 9 3 Positioning operation 9 3 7 Cases where movement commands cannot be run Timing chart PNT 1 to 5 l START l ACK Motor speed i ROTATE END The following cases do not permit movement commands to be run 1 No data is stored registered in the designated point No 2 When the specified target position is outside the software limits software limit over 3 When an interlock an alarm or emergency stop has occurred A command error is issued if the ACK output signal does not turn ON within 1 ms after
55. en operation so far is normal After power is on the END output signal is a way to check if the servo turned on or not Timing chart Power Pil AM EMG ae Lock Initialization 7 END i Servo on INPOS j S 2000ms or more INVHO ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E A CAUTION If the robot is a vertical installation type then brake release will be delayed for a certain time after the servo turns on Do not run a movement command until at least 50 ms have elapsed after servo on W NOTE p About initialization After turning the power on the PRC controller runs the motor within a defined range maximum of 8 degree mechanical angle in order to initialize for position detection A maximum of 2 000 ms 2 seconds is required for this operation lt I Q 9 z Z Q lt a kala ou O m Z lt Z z lt a Ld ou O lt N lt ca 02 9 1 2 When emergency stop was triggered during power on Initialization is not performed if the emergency stop EMG signal was input during power on Ini tialization will automatically start when the EMG input signal is cancelled When the EMGMON output signal is on during power on close the contacts for the EMG input signal and LOCK input signal Timing chart Power i l l AM BE EMG Lock EMGMON Initialization END Servo ON l INPOS S 2000ms or more A CAUTION If the robot is a vertical installation typ
56. ence position A CAUTION lt Always set the START input signal to OFF at the point that the ACK output signal has turned ON Z lt a LLJ on O N lt aa 28 9 4 Torque movement 9 4 6 When alarm or EMG were input during torque movement When an alarm or EMG emergency stop were input during torque movement the robot is held at the position where these were input and the servos are in free state after stopping Timing chart Before the end of torque movement PNT 1 to5 START ACK Motor speed l ROTATE INPOS END EMG MON Starts decelerating towards target position 2 Reduces to torque movement speed 3 Starts torque movement 4 Reaches specified torque current During torque movement when the INPOS output signal turns ON with the robot already within INPOS range prior to an emergency stop the INPOS output signal will turn OFF if an alarm or EMG signal is input e When an alarm or EMG signal is input before the torque detection time elapses after starting torque movement the robot stops with the END output signal still turned OFF and the servo turns off e Even if the emergency stop is canceled the END output signal maintains the same state it had during the emergency stop At this point the INPOS output signal turns ON e When performing relative movement after stopped with an alarm or EMG input the stop posi tion becomes the reference posi
57. ened B contact The controller then sets to servo off When the EMG input signal turns OFF contacts open during robot movement the robot imme diately stops The movement command is not accepted during emergency stop Serial communication at this time results in a command error and there is no ACK reply to execution of START When emergency stop is canceled in a state with no ALM issued the servo turns on automatically When the EMG signal is canceled by serial communication edge detection of Active to Non Active the EMG command set by serial communication is also canceled e Emergency stop is triggered when OR conditions are met by serial communication input and the I O entry port 5 5 I O connector signal table ALMCLR Alarm clear Pin No B1 This is the alarm clear signal This only clears alarms that can be reset Resettable alarms are cleared on detecting the rise OFF to ON of the ALM CLR signal See 11 Troubleshooting for more information on alarms NOTE If an alarm cannot be cleared try turning the power off and then back on again A CAUTION This is not edge detection e Avoid trying to input other signals while the alarm clear signal is input E ORG Return to origin input Pin No B2 This is a signal for executing return to origin Return to origin is performed at the rise OFF to ON of the ORG signal W NOTE e If executing this command is already impossi
58. ent might generate heat that raises the surrounding temperature and eventually causes the equipment to malfunction run out of control or degrade the performance specifications Carefully consider the installation location and keep the controller ambient temperature to below 55 C To ensure reliability and a long service life using the controller in surroundings at a temperature below 40 C is recommended Even in cases where heat convection or heat radiation is likely to increase temperature you should always keep the controller ambient temperature within 55 C E Storage temperature Store in a location not exposed to direct sunlight and within a fixed temperature range 20 C to 65 C If storing the controller for long periods of time 3 years or more then consult with us before hand Capacity of the electrolytic condensers will drop after extended periods of storage and lead to equipment breakdowns 4 1 Before installing the controller a kla ol a Z O Q Lalal I U Z N Z 4 2 E Ambient operating humidity Operate within a specified humidity and temperature range Controller 0 C to 55 C within 90 RH no condensation Robot 0 C to 40 C within 90 RH no condensation Storage humidity Store in a location not exposed to direct sunlight and within a specified humidity and temperature range within 90 RH no condensation Vibration and impact Do not apply strong shock or imp
59. er units are shown to 2 decimal places and the third decimal point value is rounded off Example 250 005 mm is rounded off to 250 01 mm Sada LAWVaAVd 7 3 Parameter description PARAMETERS N 7 3 Parameter description This manual basically does not list write protected parameters Consult with YAMAHA when changing of parameters is required for running special applications Write protected parameters PRMO to 18 PRM20 to 23 PRM25 PRM33 to 35 PRM38 PRM39 PRM41 to 44 PRM48 to 54 PRM64 PRM68 PRM26 PRM2 PRM37 PRM40 PRM45 to 47 PRM65 to 67 PRM70 PRM71 System related parameters Robot type dependent parameters PRM19 DO3 Output Function Description Sets the function of the DO3 output signal When ORGMON was set a return to origin status which is off if incomplete or on if complete is output to the ORGMON output signal pin No B9 When DI4MON was set the signal input set in PRM13 which is normally an interlock LOCK is directly output to the LOCKMON output signal pin No B9 Input range 0 DI4MON 3 default ORGMON Remarks e The robot must be returned to origin before robot movement is attempted When the DO3 output function was set in ORGMON and point trace movement failed a check can be made of ORGMON signal status to determine if the problem is failure to return to origin e The interlock input signal LOCK is usually input to the controller from
60. es Description Motor rotation speed exceeded the maximum value Problems during use Correct the payload as well as speed settings in the point data Motor defective Replace the motor Parameter error Perform generation Controller defective Replace the controller if problems frequently occur A08 Over Regenerator Voltage LED flash count 5 times Description Motor regenerative voltage exceeded the maximum value Problems during use Lower the robot operating duty ONILOOHSATENOAL Parameter error Perform generation Controller defective Replace the controller if problems frequently occur 1 2 11 2 Checking the alarm and countermeasure TROUBLESHOOTING 14 A09 Origin Motion Failed LED flash count 6 times Description Return to origin operation does not end normally Parameter error Perform generation Controller defective Replace the controller if problems frequently occur A10 Deviation Counter Overflow LED flash count 7 times Description Deviation from current position to target position exceeded 134127727 pulses Problems during use Correct the Position in the point data A11 Position Limit Exceeded LED flash count 7 times Description Plus minus sign on absolute position counter inverts when the Position Limit Alarm PRM28 is 0 Permit Problems during use Set the Position Limit Alarm PRM28 to 1 Protected when using the
61. ese can be run by sending operating signals from CN1 making motion control with a PLC easier No special controller is required so system costs can be kept low Use the teaching box TP 2 or support software YPB Win installed on a PC to edit point TP 2 and YPB Win are options See the TP 2 manual or support software manual for the operation method 3 3 3 6 Communicating with equipment gt Oo kalal gt O 34 3 6 Communicating with equipment In the Pico series data can be sent over the RS 485 line Here one PC is connected to one PRC unit using support software instead of a teaching box to perform on line operations such as editing of parameters and point data and robot control Different addresses can be set for multiple PRC units and a daisy chain formed via the CN5 and CN6 connectors so that up to a maximum of 16 PRC units can be connected to one PC to allow editing parameters and point data and operating the robot with support software 3 7 Sequence from purchase to operation The basic sequence from purchase to actual operation is shown below Operation procedures are shown in detail in each section See the support software manual or teaching box manual for information on how to operate creating point data and loading data etc What to do Setup Install the controller Wiring Make connections to power supply ground terminal and peripheral equipment Power ON Turn on power to the co
62. et position Moves at speed specified in Moves at speed specified in 2nd point data 1st point data 8 2 5 Additional movement The INPOS signal and ZONE signal can be used during movement to consecutively move to the next point INPOS signal ON a Q 1st movement command 2nd movement command Note e When an additional movement by INC PT is performed during ABS PT the robot moves by relative movement to the target position of the absolute position movement command instead of moving from the position at that time the command was received 8 3 Point data 8 3 Point data One point is comprised of the following elements Position INPOS width Torque distance Command Acceleration Deceleration Torque limit mm mm mm ABS PT 12 00 0 06 0 0 00 8 3 1 Cautions on setting the speed acceleration and deceleration The upper limit that can be entered for Speed Acceleration and Deceleration point data de pends on the payload The payload is preset to the robot maximum payload when shipped from the factory Before setting the Speed Acceleration and Deceleration perform a generation to match the customer s payload See the support software manual or teaching box manual for information on how to perform generation 8 3 2 Cautions on setting the position INPOS width and Torque distance When the 3 point data items Posi
63. eter description PRM57 Torque Detection Time Description This specifies the time for deciding the end of pushing operation after reaching the torque current limit during torque movement Input range 1 to 255 x10 ms default 15 Note When the current falls below the torque current limit due to dribble workpiece gradually moves in pushing direction during the pushing decision time the time count is reset and starts counting again after reaching the specified current level Torque Distance Movement Speed enn Torque Speed ia Torque Limit al Pushing decision count gt Pushing decision recount Current position Target position PARAMETERS N PRM58 Torque Speed Description Specifies the speed during torque movement Input range 1 to 20 default 2 Remarks e Motor is 18 75 rotations minute at an input of 1 e Movement speed for an input of 1 depends on the robot deceleration rate and the lead length Example On the T4P 12 Deceleration rate 0 Lead length 7 10 lt gt Movement speed is 225 mm min for an input of 1 7 3 Parameter description PRM59 Upper Zone Range Description This parameter specifies the upper limit value for switching a zone output signal in absolute coordinates Input range 134217727 to 134217727 pulses default 0 Note Specified value is contained in the zone range Zone output signal is
64. he Pico series support software via RS 485 communication is used instead of a teaching box In this arrangement one PC is connected to one PRC unit to perform on line operations such as editing parameters and point data or operating the robot Different addresses can also be set in multiple PRC units and by then forming a daisy chain through the CN5 CN6 connectors one PC can be connected to a maximum of 16 PRC units and on line operations such as editing parameters and point data or operating the robot can be performed 6 2 Serial communication specifications Communication method RS 485 2 wire half duplex polling method Baud rate 9600 bps or 38400 bps DSW1 3 Synchronization method Start stop synchronization Data bit 8 bits Stop bit 1 bit Parity check Yes Parity setting Even Address 0 to 15 RSW1 Cable length 100 meters maximum total extension A CAUTION The internal circuits on the PRC unit and the ground GND on the input to the power supply and the commu nication line ground GND are not insulated 6 3 Serial communication cable specifications 6 3 1 When connecting to external devices such as PCs Connect the RS485 adapter HA 2 KX1 M4400 000 to the COM port on the PRC unit Also con nect the external devices such as a PC with an RS232C communication cable KX1 M538F 000 Fig 6 1 RS485 adapter HA 2 RS232C communication cable with cable pt d D Sub 9
65. if the PRM69 Origin Preset parameter is set so large that the plus minus sign is inverted at a location within the movement range the software upper limit value be comes smaller than the software lower limit value This state is always treated as being outside the software limits when the software limit functions are enabled so the robot cannot move Remarks e Use when collectively shifting the teaching point positions e The origin preset input range and unit used will vary according to the robot Example On the T4P 12 Resolution 800 Deceleration rate 0 c gt 0 015 mm per pulse Lead length 12 The input range is from 2013265 91 to 2013265 91 mm 715 7 3 Parameter description Distance from origin 100mm Origin Target position Mechanical deviation Installation shift 1 1 Origin Target position PARAMETERS Origin preset e Distance from preset origin 100mm eee Zone output range ween Software limit range If this software limit value is not changed this position is then used as the software limit range So when using the origin preset parameter change the software limit by adding the origin preset value to it 716 8 1 Overview On the PRC a total of 32 points can be specified from PNTO to 31 This point data can be entered by one of 3 different methods manual data in teaching playback and direct teachi
66. in is complete Perform return to origin if not completed Target point is outside of software limits e Check movement amount of designated point data e Check the upper and lower soft limit PRM61 PRM62 settings Reset the point data movement amount as well as upper and lower soft limits PRM61 PRM62 to their correct settings Movement amount specified in absolute position movement command from current position to target position exceeded 134217727 pulses Check the movement amount of the designated point data Reset the point data 11 3 Dealing with problems based on trouble symptom Robot stopps during movement Cause 1 Alarm has occurred Checkpoint Connect the teaching box or support software and check description on alarm that occurred Action See 11 2 1 Alarm display and take countermeasures Cause 2 Has set to emergency stop Checkpoint Check emergency stop signal input Action Cancel emergency stop signal input Cause 3 An interlock is activated Checkpoint Check Lock signal input Action Cancel Lock signal input Robot won t perform torque movement Cause 1 Position robot arrive at by torque movement is outside the software limit range Checkpoint Check the point data or the software limit settings Action Reset the point data or the software limit Robot stops during torque movement Cause 1 Alarm has occurred Checkpoint Connect
67. input of the START signal The END output signal pulse falls at the point that no ACK output signal rise is detected inside the PRC controller A CAUTION The END output signal does not turn ON during a command error so check that the ACK output signal is not ON even after 1 ms or more after the START input signal turns ON and then always set the START input signal to OFF lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 20 9 4 Torque movement 9 4 Torque movement This section explains the basic operating methods and the operation timing charts for torque move ment 9 4 1 Normal torque movement Example Moving at a speed of 100 towards a position 150 mm from the origin point In this example the current limit is set at 150 during torque movement and the torque distance is 15 mm Precondition Point data has already been created and the data loaded into the controller Position INPOS width Torque distance mm mm mm 150 00 0 06 150 15 00 Item Command Acceleration Deceleration Torque limit See the support software manual or teaching box manual for information on how to create point data and how to load data N caution Set the INPOS range to a value smaller than the torque distance Basic operation 1 Specify the movement point Methods for specifying the point are as follows Point No PNT4 23 PNT3 22 PNT2
68. ions on a linear robot to avoid striking the mechanical stopper stroke end set PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Enable and set the values for PRM61 Upper Soft Limit and PRM62 Lower Soft Limit When using a rotary robot in unlimited rotation mode PRM28 Position Limit Alarm must be set to Protected and PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit 7 Function to Disabled On linear robots if the PRM69 Origin Preset parameter is set so large that the plus minus sign is inverted at a location within the movement range the software upper limit value be comes smaller than the software lower limit value This state is always treated as being outside the software limits when the software limit functions are enabled so the robot cannot move Remarks The input range for the upper software limit value default value and unit used will vary ac cording to the robot Example On the T4P 12 SaaLAWVaAVd Resolution 800 Deceleration rate 0 gt 0 015 mm per pulse Lead length 12 U The input range is from 2013265 91 to 2013265 91 mm 713 7 3 Parameter description PRM62 Lower Soft Limit Description This parameter specifies the lower software limit value in absolute coordinates The software limits determine the robot movement range that is permitted by software setting When the lower software limit
69. ious setting and units vary according to the robot Example On the T4P 12 Resolution 800 Deceleration rate 0 gt 0 015 mm per pulse Lead length 12 The input range is from 0 02 to 983 03 mm and the default value is 8 00 mm PRM55 Slowdown Adjust Function Description Selects whether to use or not use the deceleration curve compensation function Input range 0 default Disabled 1 Enable Note The deceleration compensation coefficient is set with PRM56 7 3 Parameter description PRM56 Slowdown Adjust Coefficient Description This parameter is for compensating the deceleration curve so that there is a gentle deceleration just before stopping This function is for ensuring a soft landing when stopping Input range 1 to 255 default 1 Movement start position Target position Speed Deceleration distance I 1 T pl a Sisa T 1 mJ As the deceleration compensation coefficient gets larger the deceleration distance and decelera tion time get longer Remarks At a speed of 160 deceleration of 20 and lead of 12mm Slowdown Adjust Coefficient Deceleration distance mm Deceleration time s Not used 20 40 Z caution Sada LAWVaAVd The above are only reference values Actual values may vary according to load conditions and movement range 9 7 3 Param
70. is left turned ON Checkpoint Check the ALMCLR signal input state Action Set the ALMCLR signal to OFF Servo holding power is weak Cause 1 Robot settings are incorrect Checkpoint Check the robot No PRM42 Action Perform generation Robot starts to move at the same time that Lock signal is canceled Cause 1 System parameter settings are incorrect Checkpoint Action Perform generation wl 7 OINILOOHSATENOAL MEMO 1 18 Chapter 12 MAINTENANCE AND WARRANTY 12 1 Maintenance Check the surrounding area environment periodically also clean away dust and tighten the various screws nuts and bolts Also please note the following items 1 Contact YAMAHA when repairs are required 2 The controller frame reaches high temperature so use caution during maintenance and inspections 3 The electrolytic capacitors in the controller will deteriorate over time so replacing them with new capacitors about every 5 years at 40 C is recommended as pre ventive maintenance 21 ALNVadvM ANY JIDNVNALNIVW 12 2 Warranty MAINTENANCE AND WARRANTY 12 2 Warranty The YAMAHA robot and or related product you have purchased are warranted against the defects or malfunctions as described below Warranty description If a failure or breakdown occurs due to defects in materials or workmanship in the genuine parts constituting this YAMAHA robot and or related product within the warra
71. ise filter Fig 4 4 Noise filter installation diagram YATIOULNOD AHL ONITIVISNI AC input line DC24V supply line Noise filter 24V supply Noise filter 2 PRC Noise filter Always install a noise filter in AC power input lines of 24V power supply units Noise filter 2 If the power line from the 24V power supply unit to the controller is long or if using with a component that is a large inductive load and the noise environment is bad then installing a noise filter in the 24V power supply line is recommended lt Recommended noise filter gt NEC Tokin GT2000 Series TDK Corporation ZAG 11S Series 2 Others e Install the noise filters controller and host controller in close proximity to each other e Always install a surge protector when using coils such as relays electromagnetic contacts inductive motors or brake solenoids etc Do not run power supply motor lines and signal lines bundled together in the same duct e Do not bundle noise filters in the primary cable with the secondary cable Do not use a long ground line 4 4 Connections 4 4 6 Other wiring precautions a Lel mal l a _ Z O Q Lll IT 9 Z N Z 8 Miswiring A miswiring in the controller or robot might damage the equipment so take adequate care to ensure that the wiring was performed correctly Fuses The controller contains fuses These fuses are for the purpose of preventing seco
72. lication example M4AIAYIAO e Semiconductor manufacturing serial I O RS 485 equipment VJ e Cylinder e General industrial machine Position command by Ka Start command by parallel I O or PRC e Position data stored beforehand in the controller via a serial I O can be started and run by a Start command and specifying a point No from a parallel I O An ordinary parallel I O can control operation so hardware costs are kept low e Has a thrust force control function and teaching function e Speed can be changed from any position during movement e Current flow in motor is regulated according to the motor load so a minimum of heat is emitted and operation is highly efficient A special feature is that the motor yields large torque in the low speed range compared to other motors so system size is kept compact e In house technique gives motor a holding torque when stopped so there is no tiny vibration as found in conventional servos e Controller has internal holding brake control and regenerative control functions 3 1 3 3 System configuration z Z me gt O 3 3 System configuration The PRC series controller is made up of the following major components Fig 3 2 System layout External control PLC etc CN6 cns f SVAMANA fA Multi dro Front view multiple units can be conn
73. limited rotation mode PRM28 Position Limit Alarm must be set to Protected and PRM31 Upper Soft Limit Function and PRM32 Lower Soft Limit Function to Disabled e PRM28 Position Limit Alarm is enabled after completing return to origin SaaLAWVAVd PRM29 Insufficient Torque Alarm Description Specifies whether to permit or protect an alarm output when torque movement is ineffective ro bot moved a specified pushing distance without reaching a specified torque current limit during torque movement with the torque current limit specified as 1 or more by point setting When this parameter is set to Permit and pushing operation was ineffective then the A12 Torque Motion Failed occurs and the servo turns off When set to Protected then no alarm occurs even when pushing operation was ineffective Input range 0 Permit Alarm will be issued 1 default Protected Note Even when the A12 Torque Motion Failed has occurred other movement commands can be run after turning the servo on by inputting an alarm clear ALMCLR signal See 11 Troubleshooting for more information on alarms 7 3 Parameter description PARAMETERS N PRM30 Position Deviation Alarm Description This parameter specifies whether to permit or protect an alarm output when the robot is pushed back to the maximum position deviation during normal robot movement or during hold operation or when the robot is pulled
74. movement is run up until its end If there is no ACK output signal reply to the START signal to the 2nd point then you must install some means such as an interlock See 9 3 7 When running the movement command is impossible for more information A CAUTION Always turn the START input signal OFF at the point that the ACK output signal has turned ON INVHO ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E 15 9 3 Positioning operation lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca gt 16 9 3 5 Canceling an emergency stop alarm during movement When an EMG emergency stop or alarm state occurs during robot movement the servo automati cally turns off During an EMG or alarm state the robot does not move even if a movement command is issued When the EMG or alarm state is canceled the servo automatically turns on The robot performs no steps to enable movement Timing chart Motor speed ROTATE INPOS EMG ALM EMGMON ACK output signal ON 2 Arrived within INPOS range before EMG input 3 EMG signal ON EMG signal OFF A CAUTION If the robot is a vertical installation type then brake release will be delayed for a certain time after the servo turns on Do not run a movement command until at least 50 ms have elapsed after servo on 9 3 Positioning operation INPOS and END timing chart INPOS END INPOS EN
75. n torque distance When the robot has moved past the target position during torque movement it then stops at the target position torque distance so the INPOS output signal will turn ON e Pushing conditions are not satisfied when the robot has pushed past the target position so the END output signal does not turn ON e When then END output signal turns OFF while the ROTATE signal is OFF this state means the robot has pushed past the target position A CAUTION Always set the START input signal to OFF at the point that the ACK output signal has turned ON 9 4 Torque movement 9 4 5 When held in position at interlock during torque movement Timing chart Before the end of torque movement When an interlock LOCK is input during torque movement the position during input is held PNT1to5 i ae NS eae Motor speed i i i i i i if i i i i ioi i i gt Torque detection time ROTATE Starts decelerating towards target position 2 Reduces to torque movement speed 3 Starts torque movement 4 Reaches specified torque current During torque movement when the INPOS output signal turns ON with the robot already within INPOS range prior to an interlock state the INPOS output signal will stay ON even if a LOCK signal is input When the LOCK input is entered before the torque detection time elapses after starting torque movement position hold is performed with the END output signal still
76. nced state Restarts operation Target position torque distance After the pushing conditions are set up the INPOS output signal turns ON when the robot enters within INPOS range before the torque detection time elapses The INPOS output signal remains ON even when the robot further moves in the same direction after the torque move ment is complete After the pushing conditions are set up the END output signal is ON after the torque detection time elapses regardless of the ROTATE signal state A CAUTION Always set the START input signal to OFF at the point that the ACK output signal has turned ON 9 4 Torque movement 9 4 3 When the robot moves in reverse direction after torque movement When the robot has moved in the reverse direction after torque movement an alarm is issued on returning a certain amount from the balanced position specified by parameter PRM36 Max Torque Deviation and the robot stops Timing Chart PNT 1 to5 ae d H iid d I Parameter specified Motor speed i amount P H 0O OO ROTATE Starts decelerating towards target position 2 Reduces to torque movement speed 6 Starts torque movement 4 Reaches specified torque current Balanced state Restarts operation After the pushing conditions are setup the INPOS output signal turns ON when the robot enters within INPOS range before the torque detection time elapses After the pushing conditions are
77. nd deceleration s ssssssssssisrssisistsrertsistsssseserisnssesesests 8 3 8 3 2 Cautions on setting the position INPOS width and Torque distance c cccceeceseeseeeeseeeeeeseeeesenes 8 3 8 3 3 Point data table information cccccceeeeseseteesceeseseseseseseenetecscsssesssssensesesesessseseseseneesesesesssenenenenees 8 4 POWEL OMN sccsecseersscscessceesscesscesseeessesees 9 1 1 Normal operation at power on 9 1 2 When emergency stop was triggered during pOWer ON cceecceccceees eens eects eseeeeecseeeceeseeeeseseeseeeeeens 9 3 9 1 3 When interlock LOCK was activated during pOWEI ON cc ccccecscesesceeescseeseseeesceeseseeeseeseeaeeeees 9 1 4 Alarm status cancelable alarm Performing return to origin sesessessossossesessesossossossossessesesessossessossessssessesessessessessssesse 9 2 4 Normal ireturin t0 Origin snarar iaeaea roa ARAE EE NAE REK RA REATARD 9 2 2 ORG signal AC characteristics 9 2 3 Return to origin operation error Positioning operation 000 9 3 1 Normal positioning operation 9 3 2 START signal AC characteristics z 9 3 3 Positioning witha shortmovement ime sursson renani aE EAEE DER ARO 9 11 9 3 4 When movementisCOntinN GUS sasiet na ai ia a Ei E E raa Ea aE 9 12 9 3 5 Canceling an emergency stop alarm during movement ssssssessssssessretsieistrisstnssisisirisrenrresrersretse 9 16 9 3 6 Canceling an interl
78. ndary damage if the controller is damaged due to a short circuit in the power supply or motor They are not in tended to protect the controller itself 3 Emergency stop circuit Always install an external emergency stop circuit to instantly stop operation and shut down the power 4 4 7 Cables Use the following cable sizes and wire types Cable No Cable 1 I O flat cable Standard item 1 27mm pitch flat cable AWG28 Cable length 2m Cable 2 Encoder cable Standard item Twisted pairshielded cable 10m 5m 3 5m Cable 3 Motor cable Standard item AWG22 10m 5m 3 5m Cable 4 Power supply cable Standard item AWG20 2m Ground cable Not supplied AWG20 or thicker wire Cable5 Link cable Optional items Twisted pairshielded cable 4 4 8 Power cable specifications Power cable KX1 M532A 000 Pin No Signal name Al B3 a q B1 See 4 4 3 Power connections for power supply connections 4 5 Connecting to a PC 4 5 Connecting to a PC Parameter settings and the controller status can be loaded from a PC interface unit sold separately 4 5 1 Connecting with a PC interface unit Fig 4 5 Wiring diagram RS485 adapter HA 2 RS232C communication cable with cable es io PT D Sub 9 pin female D Sub 9 pin female D Sub 9 pin male D Sub 9 pin male connector connec
79. ng Manual data in is a method for directly specifying numeric data for a target position Teaching playback is a method for specifying a target position by actually moving the robot in jog to the position Direct teaching is a method for specifying a target position by moving the robot manually to the actual position by your hand See the support software manual or teaching box manual for information on how to set the parameters 8 2 Point trace movement Point trace movement is achieved by specifying a point number from the parallel I O and running a command described for the point data 8 2 1 Absolute position movement Absolute position movement is an action to move to a specified point The point specified here is the position relative to the origin Origin Target position Moves to a specified position relative to the origin 8 2 2 Relative position movement Relative position movement is an action to move from the current position by an amount specified in the point data Current position Target position Moves by an amount specified in the point data INIOd 8 2 Point trace movement POINT 8 2 3 Torque movement Torque movement is utilized for pushing or press fitting a workpiece by regulating the motor torque i A Press fitting 8 2 4 Changing speed during movement The speed during movement to a target position can be changed by using two point data items Final targ
80. ntroller Data setting Create point data and load the data into the controller Operation Operate the robot INSTALLING THE CONTROLLER 4 1 Before installing the controller 4 1 1 Before unpacking This product is a precision instrument so take plenty of care when unpacking In the unlikely event you find large scratches damage or dents on the package promptly contact us without opening the package 4 1 2 Unpacking Be careful not to apply shock or impact to the controller unit when opening the package After open ing the package check the accessory items using the list below PRC main unit 1 Power cable 1 Motor cable 1 Standard items Encoder cable 1 I O flat cable 1 User s Manual CD ROM version 1 1 1 RS485 conversion adapter with cable HA 2 RS232C communication cable tional items OP Link cable Support software installation disk A CAUTION Be careful not to drop the package and or its contents when opening it Dropping it may cause injury as well as scratch and damage the equipment So take adequate precautions during handling YATIOULNOD AHL DNITIVLSNI 4 1 3 Installation and operating environment Using this controller under the wrong operating conditions will cause accidents due to equipment breakdowns Use while observing the following points E Ambient operating temperature If installed in a cramped or narrow location the controller itself and peripheral equipm
81. nts or omissions are noticed 1 NOILINGOULNI MEMO 2 ABOUT SAFETY 2 1 Safety items Before using this YAMAHA robot controller be sure to read this manual and related equipment manuals carefully and follow their instructions to ensure adequate safety and correct handling of the PRC controller and robot Warning and caution items listed in this manual relate to this YAMAHA PRC series robot controller When this robot controller is used in a robot controller system please take appropriate safety meas ures needed by the user s individual system 2 1 1 Signal word meaning To use the YAMAHA robot and controller safely and correctly always comply with the safety rules and instructions described in this manual or shown on warning labels This manual classifies safety caution items into the following alert levels using the signal words WARNING and CAUTION WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ALdJAVS LNOPV A CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or may damage the robot controller or peripheral equipment Note that the items classified into CAUTION might result in serious injury depending on the situation or environmental conditions Always comply with the CAUTION and WARNING instructions as these are essential for safety 2 1
82. nty period then YAMAHA will repair or replace those parts free of charge here after called warranty repair Warranty Period The warranty period ends when any of the following applies 1 After 18 months one and a half year have elapsed from the date of shipment 2 After one year has elapsed from the date of installation 3 After 2 400 hours of operation Exceptions to the Warranty This warranty will not apply in the following cases 1 Fatigue arising due to the passage of time natural wear and tear occurring during operation natural fading of painted or plated surfaces deterioration of parts subject to wear etc 2 Minor natural phenomena that do not affect the capabilities of the robot and or related product noise from computers motors etc 3 Programs point data and other internal data that were changed or created by the user Failures resulting from the following causes are not covered by warranty repair 1 Damage due to earthquakes storms floods thunderbolt fire or any other natural or man made disasters 2 Troubles caused by procedures prohibited in this manual 3 Modifications to the robot and or related product not approved by YAMAHA or YAMAHA sales representatives 4 Use of any other than genuine parts and specified grease and lubricants 5 Incorrect or inadequate maintenance and inspection 6 Repairs by other than authorized dealers YAMAHA MOTOR CO LTD MAKES NO OTHER EXPRESS OR
83. ock during movement cece ects ee ee ceseseeeeeseescseeeceesecsesesecsesesseseeeeseeesaeategs 9 18 9 3 7 Cases where movement Commands Cannot be run cccccccecesseeseeseseseseseseeeeesescsesssesesesenseseseseassesees 9 20 TOrQUe MOVEMENT reirse aien aE A EA 9 21 941 Normal torque movement ra aiaeei n E EENE E E E 9 21 9 4 2 When the robot moves in same direction dribble after torque movement ends cceeeeeeee 9 24 9 4 3 When the robot moves in reverse direction after torque movement sss sssssssesisteresisisisresesistsnsreres 9 25 9 4 4 When the robot has pushed past target position cece ccc cscs eens cs ceeeecseeeceeseeeeseeesseeseeseseeaeees 9 26 9 4 5 When held in position at interlock during torque movement cece eecee es eteeseeeetseeeeseeeeeseees 9 27 9 4 6 When alarm or EMG were input during torque Movement cece ese ee ee ceees cess ceeeeeecseeeesenecseneees 9 29 ZONE OUtPUt operation siss aa ea e as e a aaa Ea aaisa 9 31 9 5 Normal Zone output operation an iae eon o e EEEE N E O ATEA 9 31 10 1 Basic specifications ssiri eseina resan eiaa ae scedechdageanccrasencessedecegev sseneteqcceaees 10 1 10 2 External View sisiane esseni essas aas ess aaao sisis is 10 2 Chapter 11 11 1 When problems OCCU i 0c0 ccuceesectccetescerececeseicecteceedcesencvsscrnenececei etesedsisecsededzesseeeses 11 1 11 2 Checking the alarm and countermeasure scsscccs
84. oller in an environment outside the specification range could lead to electric shock fire malfunction product damage or deteriorated performance CAUTION Tighten the screws on the robot controller firmly to make secure connections CAUTION Never directly touch the conductive sections or electronic parts other than the rotary switches and DIP switches on the outside panel of the robot controller CAUTION Securely install each connection cable connector into the receptacles or sockets Poor connections will cause faulty operation or malfunction Pe o ae e CAUTION Provide clearance between this controller and the inner surface of the control board or other equipment according to the distance specified in this manual Insufficient clearance may cause faulty operation or malfunction Wiring precautions WARNING Always shut off the power supply externally before starting installation or wiring work Failure to shut off the power could lead to electric shock or product damage WARNING Always make a secure connection to the ground terminals on the controller and robot to prevent electrical shock gt FP gt gt AN 2 1 Safety items WARNING Use caution to prevent damage to the cables Do not apply excessive stress to the cables place a heavy object on them or allow them to be pinched Electrical shock may result WARNING When making connections to the power cable follow the wiring diagram
85. on Time and PRM58 Torque Speed are utilized for torque movement e The speed at the start of pushing operation changes smoothly to the steady torque movement speed Remarks e Input range for torque movement amount and default values vary according to the robot Example On the T4P 12 Resolution 800 Deceleration rate 0 gt 0 015 mm per pulse Lead length 12 The input range is from 0 00 to 61 43 mm and the default value is 0 00 mm BASIC OPERATION AND OPERATION TIMING CHART This chapter explains basic operating methods and the operation timing charts The signal level is defined as Hi high when the photocoupler is ON and as Lo low when the photocoupler is OFF 9 1 Power on The basic operation and operation timing charts for operation when power is turned on are shown here Please note that these operation timing charts are only for showing general operation and are not actual examples 9 1 1 Normal operation at power on Basic operation Precondition Installation and wiring of the controller and robot must already be complete 1 Turn on power to the controller 2 When the power is turned on the robot performs initialization and the servo automatically turns on However this does not happen if emergency stop or an interlock were triggered exter nally 3 The END output signal turns on after initialization is complete When the END output signal turns on th
86. on command ABS PT moves the robot so as not to exceed the upper limit value in verted at the point that 134217728 pulses is exceeded Counterclockwise minus direction PARAMETERS ABS PT 134217727 134217728 134217728 Example 1 e Target position INC PT n When PRM28 is set to Protected 4 INC PT i 134217728 134217728 each direction and does not perform shortcut control When moved in the same rotation direction with the relative position command INC PT the plus minus sign of the current position is in Clockwise plus direction 134217727 When PRM28 is set to Protected INC PT OK gt OK INC PT 7 3 Parameter description NG ABS PT OK ABS PT 134217728 134217728 Example 2 e Target position ABS PT Note e When an A11 Position Limit Exceeded alarm is issued the servo turns on by input of an ALMCLR signal and other movement commands can be run See 11 Troubleshooting for detailed information on alarms mJ e On linear robots if the PRM69 Origin Preset parameter is set so large that the plus minus sign is inverted at a location within the movement range the software upper limit value be comes smaller than the software lower limit value This state is always treated as being outside the software limits when the software limit functions are enabled so the robot cannot move e When using a rotary robot in un
87. or instruction listed in this manual to avoid electrical shock or fire CAUTION Use caution not to allow foreign matter such as cutting chips and wire scraps to enter the robot controller Electrical shock or fire may result CAUTION Always store the cables connected to the robot controller in a conduit or clamp them securely in place If the cables are not stored in a conduit or properly clamped excessive play or movement or mistakenly pulling on the cable may damage the connector or cables and poor cable contact may lead to faulty operation or malfunction ALdJAVS LNOPV CAUTION When disconnecting the cable detach by holding the connector itself and not by tugging on the cable Loosen the screws on the connector if fastened with the screws and then disconnect the cable Detaching by pulling on the cable itself may damage the connector or cables and poor cable contact may lead to faulty operation or malfunction CAUTION Do not measure the insulation resistance withstand voltage and noise immunity to avoid damage to the robot controller CAUTION When making wiring connections follow the electrical installation technical standards or instruction listed in this manual Incorrect wiring may result in fire or damage by fire CAUTION This robot controller does not have an over current protective function Make correct wiring securely so the power line is not shorted Incorrect wiring may cause damage to the controller or motor
88. otary SWITCH sccccceccccesceceaeesecensecesecsecersestecencsesteesacenescescerseetecceeesurecteeesses 6 2 Setting the DIP Switch sisisi isisisi ioien eiss iseis 6 3 Setting for a daisy chain between PRC units scsccssssscsseseecssccsesssesseessesseeseseeseesees 6 4 6 6 1 When using two PRC units in a daisy Chain ccceceeceeccee cesses cenececeeesesesecsesesseseeessessssesesseseeesaeees 6 4 6 6 2 When using three or more PRC units in a daisy Chain c ccccceseseeceseescseeecseeeescseescseeesseesseseceeaeees 6 5 How to set the parameters ccssssoccesesecsssececcessecescceseccsseesscceseseeceersosecetoeeacessece 7 1 Cautions when setting the parameters ccsscsscccsscscssecsssessesseeesssesessscsssessesseeeses 7 1 Parameter description sssini issan aessa uesia 7 2 OVENI EW ssa Sores cag as suas Gas siant Sene not ea Cebe NOES vas cocu cad evauee kt ae of dauas cans CE ESCASAS OCSE s ESCin set Point trace MOVE Ie Ibs oiaeie asec ed eeseaisc caters cst eat nc ee eneae nd sede steeri essercene 8 2 1 Absolute position movement 8 2 2 Relative position movement 8 213 Torge MOVEMENT esetrae aa Ea EERE ENEEK O AERE esutedanse weds dveas ieeseed susan sav EONA E 8 2 4 Changing speed d ring MovemeNt esnash eioi o EE E a E n A 8 2 82 5 SAMMitOMAl AMOVEMENE es eneee rra reita E PE REPA PREEN aA N E EARNE SEERA REA AEE 8 2 POE Eir A E TE T S 8 3 8 3 1 Cautions on setting the speed acceleration a
89. pacity of the power supply If insufficient replace it with a power supply having larger capacity A04 Initial Motion Failed REBOOT LED flash count 3 times Description Initialization did not finish within 5 5 seconds Motor wire is broken or connected wrong Check the motor wire connection Encoder wire is broken or miswired Check the encoder wire connection Controller drive power supply has insufficient capacity Check the power supply capacity If insufficient replace it with a power supply having large capacity Motor defective Replace the motor Electromagnetic brake or wire is broken Operate the brake and check if the brake can be released Abnormal resistance in mechanical sliding part Check if the robot moving parts are working sluggishly If sluggish then readjust the mechanical alignment Payload too heavy Do not place a load during initialization Parameter error Perform generation if the PRM25 parameter Initial Motion Bump is not set to 0 Permit Controller defective Replace the controller if problems frequently occur 11 2 Checking the alarm and countermeasure A05 Servo Error LED flash count 4 times Description In the case that PRM30 Position Deviation Alarm is 0 Permit Normal movement amount or movement in reverse direction of command exceeded the value of PRM27 Max Position Deviation e Movement amount to direction in re
90. pin female D Sub 9 pin female D Sub 9 pin male D Sub 9 pin ma connector connector connector connector E RS485 adapter HA 2 KX1 M4400 000 This is an adapter unit for converting the RS 485 interface to the RS232C interface E RS232C communication cable KX1 M538F 000 This is a shielded straight cable terminated with a 9 pin female connector at both ends I NOILVOINAWWOD TVIAAS 6 3 Serial communication cable specifications SERIAL COMMUNICATION s62 6 3 2 Connecting PRC units in a daisy chain Make a daisy chain between PRC units by connecting the CN5 CN6 connectors with a link cable KX1 M5361 000 The CN5 CN6 connectors are functionally the same Fig 6 2 Link cable 6 4 Setting the rotary switch Specify the PRC unit address 0 to 15 with the hexadecimal 0 to F rotary switch Fig 6 3 Use a small flat blade screwdriver to align the arrow with the desired address e An address 0 is set at the factory prior to shipment e After changing the address always turn the power off and then back on again The previous settings are used until you turn the power off and then on again e When connecting multiple PRC units in a daisy chain using the CN5 CN6 connectors always set a different address for each PRC unit 6 5 Setting the DIP switch 6 5 Setting the DIP swi
91. r if problems frequently occur 11 2 2 Alarms not requiring restart Alarms not requiring re startup can be reset by setting the alarm clear signal ALMCLR to ON When the alarm is canceled the alarm signal ALM turns ON normal controller status and the servo is on After checking this always turn off the alarm clear signal ALMCLR If the alarm clear signal ALMCLR is always on then alarms will be mistakenly cleared as soon as they occur See 9 1 4 Alarm status cancelable alarm for more information OINILOOHSATENOAL 15 11 3 Dealing with problems based on trouble symptom 11 3 Dealing with problems based on trouble symptom This section explains causes checkpoints and action to take for the following problem symptoms If problem symptoms occur that are not covered in the table below then consult with YAMAHA Problem Symptom Refer to Problems with robot operation No servo lock on robot even if power is turned on See 11 3 1 Robot operation Abnormal noise or oscillation occurs Position deviation occurs Robot speed is abnormally slow Robot won t move with return to origin command Alarm occurs during return to origin Position is deviated after return to origin Robot won t move with movement commands Robot stops during movement Robot won t perform torque movement Robot stops during torque movement Torque movement ends while in progress
92. ring motor drive 9 3 Positioning operation 8 An END output signal turns ON when robot movement to the specified movement point ends normally A CAUTION If the START input signal is left ON the ACK output signal will stay ON even if movement has been completed The END output signal will not turn ON if the ACK output signal is still ON Relative movement INC PT during continuous operation The movement position concept for relative movement INC PT during continuous operation is described below using a simple example E Absolute movement ABS PT to relative movement INC PT The reference position for performing consecutive absolute movement and relative movement is the position specified by the preceding absolute movement However when an interlock alarm or emergency stop has been triggered during movement the stop position becomes the reference position for performing relative movement after canceling the interlock alarm or emergency stop Movement points are as follows Start position Position 12mm from origin PNT1 Movement amount 150mm INPOS width 36mm PNT2 Movement amount 60mm 1 Moves to PNT 1 from start position PNT1 2 On entering within the INPOS range of PNT1 the END output signal is used as a trigger to move to PNT2 Movement command input to move to PNT2 PNT1 INPOS width 36mm e PNT2 PNT1 ees e Movement amount 60mm gt j
93. roblem symptom Action Shows an action or countermeasure for resolving the problem 11 3 1 Robot operation No servo lock on robot even if power is turned on Cause 1 Alarm has occurred Checkpoint Connect the teaching box or support software and check description on alarm that occurred Action See 11 2 1 Alarm display and take countermeasures Cause 2 Has set to emergency stop Checkpoint Check emergency stop signal input Action Cancel emergency stop signal input Cause 3 An interlock is activated Checkpoint Check Lock signal input Action Cancel Lock signal input Abnormal noise or oscillation occurs 1 Cause 1 Imperfect alignment Checkpoint Check if robot moving parts work smoothly Action Adjust the parts alignment Cause 2 Imperfect coupling tightening Checkpoint Check the tightened section Action Tighten if loose Cause 3 Cover setscrews are loose Checkpoint Check the tightened section Action Tighten if loose Cause 4 Guide problem Checkpoint Check for intrusion of foreign objects or breakage warping Action Replace the guide rail e Check the usage method amount of tool offset etc ONILOOHSATENOAL 1 7 ee 11 3 Dealing with problems based on trouble symptom Abnormal noise or oscillation occurs 2 TROUBLESHOOTING e 1 0 Cause 5 Checkpoint Action Cause 6 Checkpoint Action Cause 7 Checkpoint Action Cause 8
94. rs After determining that the ACK output signal has ended set the START input signal to OFF After the START input signal turns OFF the PRC unit turns the ACK output signal OFF within 30 ms if it was ON When the movement time is short the END output signal turn OFF in synchronization with the ACK output signal The ROTATE output signal does not change if the movement distance was less than 4 motor pulses Similarly the ROTATE output signal does not change if the same position as the current position was specified A CAUTION Always turn the START input signal OFF at the point that the ACK output signal has turned ON See 9 3 2 START signal AC characteristics for information on START signal minimum hold time etc INVHO ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E 11 9 3 Positioning operation BASIC OPERATION AND OPERATION TIMING CHART 12 9 3 4 When movement is continuous By setting the INPOS width of the first command larger the END signal during movement can be used to execute the next movement Example Moving to a position 245 mm from origin point In this example the movement speed is set to 100 at startup and then switched to a speed of 50 during movement Precondition Point data has already been created and the data loaded into the controller Position INPOS width Acceleration Deceleration Torque limit Torque distance mm mm mm ABS PT 120 0 30 0 35 35 0 00 ABS PT 245 0 0
95. s are incorrect Checkpoint Action Perform generation n 15 11 3 Dealing with problems based on trouble symptom END signal won t turn ON after START signal is input TROUBLESHOOTING 1 16 Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Cause 4 Checkpoint Action Cause 5 Checkpoint Action Cause 6 Checkpoint Action ORG or START signal has turned ON and still stays ON Check the ORG or START signal input state Always set the ORG and START signals to OFF when the ACK signal is ON or expected time is elapsed Alarm occurred during operation Connect the teaching box or support software and check description on alarm that occurred See 11 2 1 Alarm display and take countermeasures Has set to emergency stop during operation Check emergency stop signal input Cancel emergency stop signal input An interlock was activated during operation Check Lock signal input Cancel Lock signal input Torque movement was completed without arriving at current limit robot has moved past the target position during torque movement Check the point data torque limit settings and torque distance settings Correct the point data System parameter settings are incorrect Perform generation ZONE signal won t turn ON Cause 1 Checkpoint Action Cause 2 Checkpoint Action Zone range upper an
96. set up the INPOS output signal turns OFF when the robot has moved in reverse and deviated from the INPOS range before returning to the movement amount specified by parameter When entering INPOS range the INPOS output signal is also OFF when the robot has re turned by an amount of movement specified by parameter e After pushing conditions are set up the END output signal is ON after the torque detection time elapses regardless of the ROTATE signal state e The END output signal state does not change even if an ALM alarm is issued See 11 Troubleshooting for detailed information on alarms e The state of the INPOS output signal depends on whether the balanced point with the reverse direction force is within or outside the INPOS range LYVH D ONIWIL NOILV8AdO ANY NOILVasAdO DISV4E A CAUTION Always set the START input signal to OFF at the point that the ACK output signal has turned ON 29 9 4 Torque movement lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 26 9 4 4 When the robot has pushed past target position When the robot has moved past the target position during torque movement it then stops at the target position torque distance Timing Chart PNT 1to5 i i Motor speed ROTATE Starts decelerating towards target position 2 Reduces to torque movement speed 3 Torque movement is complete Target positio
97. signal input Cancel emergency stop signal input An interlock is activated Check Lock signal input Cancel Lock signal input Return to origin is incomplete Check if return to origin is complete Perform return to origin if not completed Operation specified for jog movement has exceeded the software limits Check the current position and jog movement speed as well as the movement direction Change the jog movement speed setting as well as the movement direction Cannot release brake Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Brake cable is defective Check if brake cable requires replacement Replace the defective cable Defective motor Try using another motor If operation with another motor is okay then replace the defective motor Controller is defective Try using another controller If operation with another motor is okay then replace the defective controller 11 3 Dealing with problems based on trouble symptom 11 3 2 Parallel I O Output signal won t turn ON Cause 1 Drive power for I O signal is not supplied Checkpoint Check if drive power for I O signal is being supplied to COM COM of I O flat cable Action Supply drive power for I O signal Cause 2 I O flat cable is broken or disconnected Checkpoint Check the power to the I O flat cable with a tester or multimeter etc Action Correct
98. signal turns ON when the robot enters within INPOS range before the torque detection time elapses The INPOS output signal remains ON even after the torque detection time elapses After the pushing conditions are set up the END output signal is ON after the torque detection time elapses regardless of the ROTATE and INPOS signal states A CAUTION After reaching the specified current if the current value falls below the specified value during torque detection such as when workpiece has moved by torque control then the count starts again after once again reaching the specified current A CAUTION Set the INPOS range to a value smaller than the torque distance A CAUTION Always set the START input signal to OFF at the point that the ACK output signal has turned ON INVHO ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E 23 9 4 Torque movement lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca s24 9 4 2 When the robot moves in same direction dribble after torque movement ends When the robot has moved in the same direction after torque movement ends it stops at the point the specified torque distance is reached Timing Chart PNT1to5 i iii NOIA Motor speed ROTATE Starts decelerating towards target position 2 Reduces to torque movement speed gt Starts torque movement 4 Reaches specified torque current Bala
99. sssesoesse 5 2 I O connector signal table csccssscesccesecssocsesescescceesscessoessceesccessecsscessoesseoarenases 5 3 5 5 1 Input signal description popi siror oyren aa E EAREN EEEE EE A E E AREE ENE A 5 3 5 5 2 Output signal description seori DE siro Nir n a EAEE EE EOT OEO ELEA 5 5 VO cable specificatiOnSuissii reiasa nan ae reese ian esasi iaaea eaaa 5 7 Connecting to a PLC using 24V DC power supply ssessessssssossessosssessosssessossoossessosesesseseo 5 8 5 7 1 Connecting to a Mitsubishi PLC model AY50 output unit s ssssssssssissssissststssssesistsrentresisrsntnenisrsnesenees 5 8 5 7 2 Connecting to a Mitsubishi PLC model AX40 input unit cee eee cece cs cere eens ceeeeeeceeecseneeeens 5 8 SERIAL COMMUNICATION ivrcacsscccsoconncossoescsncccsccccccuseeactseceensrstsnnnsoosososnsde OAM 6 1 6 2 6 3 6 4 6 5 6 6 Chapter 7 7 1 7 2 7 3 Chapter 8 8 1 8 2 8 3 9 1 9 2 9 3 9 4 9 5 OVERVIEW E ETT E 6 1 Serial communication specifications e sessossesessesossessossossssossessesessossoseossssessesessessese 6 1 Serial communication cable specifications eseeesseseseeesoeseseseeoesesersesesessesesoserseseseseese 6 1 6 3 1 When connecting to external devices such as PCS s ssesssssssssssssssssssssssiersieisietsssrtssrstnintsesnssnrernesrnes 6 1 6 3 2 Connecting PRC units in a daisy Chain gess essesssras irar EE et ON s oA EA pEr E a EENE o ia 6 2 Setting the r
100. t PRC Connection to LEAS ono other PRC controller Link cable 5 1 0 flat cable 1 Connection to PLC h Link cable 5 LES TS LE 1 gt Power a Nes supply Noise filter Power cable 4 ome j i Motor cable 3 Power input line Encoder cable 2 a Lel mal l a _ Z O Q Lll IT 9 Z lt N Z Install the cables as shown above 4 4 Connections 4 4 Connections 4 4 1 Connecting to the robot Connect the robot cables to the connectors CN2 and CN3 on the bottom of the controller as shown WARNING Turn off the power before making these connections Otherwise equipment breakdowns might result Robot encoder connector CN2 signal table Signal name Description Encoder A phase output Signal name Description Encoder power supply 5V Encoder A phase inverted output Encoder power supply OV Encoder B phase output Frame ground Encoder B phase inverted output Sensor power supply 24V Not used Sensor signal O O lolo S gt Not used Sensor power supply OV Robot motor connector CN3 signal table Signal name Description Motor A phase Motor A phase inverted Motor B phase Motor B phase inverted Brake signal Brake signal YATIOULNOD AHL ONITIVISNI 4 4 2 Connecting to the I O connector Connect external equipment such as the PLC programmable logi
101. t Action ORG or START signal has turned ON and still stays ON Check the ORG or START signal input state Always set the ORG and START signal to OFF when the ACK signal is ON or expected time is elapsed Alarm has occurred Connect the teaching box or support software and check description on alarm that occurred See 11 2 1 Alarm display and take countermeasures Has set to emergency stop during origin point Check emergency stop signal input Cancel emergency stop signal input An interlock was activated during return to origin Check Lock signal input Cancel Lock signal input System parameter settings are incorrect Perform generation 11 3 Dealing with problems based on trouble symptom ORGMON signal won t turn ON after return to origin Cause 1 The DO3 output function PRM19 is not set to 3 ORGMON Checkpoint Check the DO3 output function PRM19 value Action Set the DO3 output function PRM19 to 3 ORGMON ACK signal is not returned after START signal is input Cause 1 Alarm has occurred Checkpoint Connect the teaching box or support software and check description on alarm that occurred Action See 11 2 1 Alarm display and take countermeasures Cause 2 Has set to emergency stop Checkpoint Check emergency stop signal input Action Cancel emergency stop signal input Cause 3 An interlock is activated Checkpoint
102. tch The DIP switch settings need to be changed in some cases when connecting multiple PRC units in a daisy chain The DIP switch is located next to the COM port inside the PRC unit Meaning ON OFF Internal termination resistance Enable Disable Internal termination resistance Enable Disable Communication speed 9600 bps 38400 bps Reserved e These are all set to ON at the factory prior to shipment e If you changed the DIP switch settings always be sure to turn the power off and then on again The previous settings are used unless you turn the power off and then on again Internal termination resistance gt Termination resistance and 2 see above must be the same setting gt When connecting multiple PRC units in a daisy chain using the CN5 CN6 connectors always activate the termination resistance on devices at both ends of the daisy chain Deactivate dis able the termination resistance on the other devices gt When using the PRC as single units no daisy chain use with termination resistance 1 and 2 activated enabled Communication speed gt Always set the communication speed at the same setting as used on the PC support software side Communication exchange is impossible if these are at different settings A CAUTION To change the DIP switch setting you need to remove the PRC unit cover At that time be careful not to touch anything other than the DIP switches NOILVOINAW
103. ten the nuts and bolts if loose e Replace the ball screw if defective e Check the usage method and payload etc 11 3 Dealing with problems based on trouble symptom Position deviation occurs 2 Cause 3 Checkpoint Action Cause 4 Checkpoint Action Cause 5 Checkpoint Action Cause 6 Checkpoint Action Robot installation is defective Check the installation bolts on the mount base Tighten if loose Misoperation due to noise e Check if the robot and controller are using the same ground point e Check if there are any noise sources in the vicinity of the controller such as welders or discharge machines See 4 4 5 Preventing misoperation due to noise and take countermeasures Defective motor Try using another motor If operation with another motor is okay then replace the defective motor Controller is defective Try using another controller If operation with another controller is okay then replace the defective control ler Robot speed is abnormally slow Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Imperfect alignment Check if robot moving parts work smoothly Adjust the moving part alignment Speed and acceleration deceleration of point data is set too low Check the point data setting Reset the speed and acceleration deceleration of the point data Load on the robot is too large Check if the
104. the teaching box or support software and check description on alarm that occurred Action See 11 2 1 Alarm display and take countermeasures Cause 2 Emergency stop signal was input during operation Checkpoint Check emergency stop signal input Action Cancel emergency stop signal input Cause 3 A Lock signal was activated during operation Checkpoint Check Lock signal input Action Cancel Lock signal input Torque movement ends while in progress 7 Cause 1 Torque current limit value for point data is extremely low Q Checkpoint Check the setting for the torque current limit ow Action Reset the point data mm N Cause 2 Load on the robot is too large T Checkpoint Check if the payload is higher than the allowable robot payload Q Action Correct the payload Q Cause 3 Abnormal sliding movement resistance Z Checkpoint Check if robot movement sections work smoothly O Action Adjust the alignment u 11 11 3 Dealing with problems based on trouble symptom Cannot perform jog movement TROUBLESHOOTING e wl 2 Cause 1 Checkpoint Action Cause 2 Checkpoint Action Cause 3 Checkpoint Action Cause 4 Checkpoint Action Cause 5 Checkpoint Action Alarm has occurred Connect the teaching box or support software and check description on alarm that occurred See 11 2 1 Alarm display and take countermeasures Has set to emergency stop Check emergency stop
105. tion INPOS width Torque Distance are displayed in millimeters each piece of data is treated as a multiple of the distance mm that the lead length moves per pulse So these input data values might sometimes be rewritten during storing of data Example When a movement amount of 250mm was entered for a robot with a 12mm lead length 250 12 x 800 16666 6 166667 INIOd Movement amount lead length x encoder division 800 pulses movement pulse amount 16667 800 x 12 250 005 250 01 Movement pulse amount encoder division 800 pulses x lead length movement amount mm In this case the value entered was 250mm but is stored as a value of 250 01mm When the 3 point data items Position INPOS width and Torque Distance are displayed in millimeters each piece of data is shown to 2 decimal places and the third decimal point value is rounded off Example 250 005 mm is rounded off to 250 01 mm 8 3 8 3 Point data 8 3 3 Point data table information E Command Description Specifies the type of movement Input range ABS PT Absolute position movement from origin INC PT Relative position movement from current position Remarks ABS PT Origin Target position Distance from origin 150mm INC PT Current position Target position POINT Distance from current position 100mm 24 8 3 Point data E Posi
106. tion A CAUTION Always set the START input signal to OFF at the point that the ACK output signal has turned ON INVHO ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E A CAUTION The ALMCLR input signal does not use edge detection Always turn the signal off after ALMCLR input 29 9 4 Torque movement After completing torque movement PNT 1 to5 l START ACK EMG i Motor speed f ROTATE INPOS END EMG MON Starts decelerating towards target position Torque distance is added to target position 2 Reduces to torque movement speed Starts torque movement 4 Reaches specified torque current When the robot enters within INPOS range before torque movement is complete the INPOS output signal turns ON at that point The INPOS output signal will turn OFF if an alarm or EMG signal is input after torque move ment is complete e When an alarm or EMG signal is input before the torque detection time elapses after starting torque movement the robot stops with the END output signal still turned ON and the servo turns off e Even if the emergency stop is canceled the END output signal maintains the same state it had during the emergency stop At this point the INPOS output signal turns ON e When performing relative movement after stopped with an alarm or EMG input the stop posi tion becomes the reference position A CAUTION Always set the START input signal to OFF at the point that the ACK o
107. tion Description Specifies the movement destination position movement amount Input range 134217727 to 134217727 pulses default 0 Note The current position after movement is the movement amount 1 pulse So when acquiring current position information and setting a new movement destination by absolute position movement the range might be deviated by 1 pulse During operation by continuous relative position movement the target position stored inside the controller functions as the reference position so there is no deviation When using the zone function set the zone range upper limit to a point which is 1 pulse wider and the zone range lower limit to a point which is 1 pulse wider The amount of relative movement from the current position cannot exceed a movement of 134217727 pulses In such a case prepare 2 points and avoid the problem by additional movement by the INPOS signal If the PRM69 Origin Preset parameter is set so large that the plus minus sign is inverted at a location within the movement range absolute movement to a position of 134217728 pulses cannot be performed Remarks e The input range for movement amount default value and unit used will vary according to the robot pz Example On the T4P 12 Resolution 800 zZ Deceleration rate 0 gt 0 015 mm per pulse Lead length 12 The input range is from 2013265 91 to 2013265 91 mm and the default value is
108. tion may cause fire or operation failure gt P amp 2 1 2 1 Safety items ABOUT SAFETY 22 N caution The robot controller and robot become hot during operation Be careful to avoid burns Design precautions WARNING For details on the operating status of the robot controller refer to this manual and related equipment manuals Design and configure the system including the robot controller so that it will always work safely WARNING The robot controller has an emergency stop terminal to trigger emergency stop Using this terminal prepare a physical interlock circuit so that the system including the robot controller will work safely A CAUTION Do not bundle control lines or communication cables together or in close contact with the robot controller main circuit or power lines Noise in the main circuit or power lines may cause faulty operation or malfunction Installing precautions WARNING Securely install the connectors into the robot controller and when wiring the connectors make the crimp press contact or solder connections correctly using the tool specified by the manu facturer WARNING Always shut off the power supply externally before starting installation or wiring work Failure to shut off the power could lead to electric shock or product damage gt CAUTION Use the robot controller within the environment specifications listed in this manual Using the contr
109. tor connector connector e Point data creation e Point run function e Teaching function e Data save into file and load from file e I O monitor function Support software is not supplied with this PRC unit YATIOULNOD AHL ONITIVISNI The communication connector on the controller side should be plugged into the COM port MEMO 10 Chapter 5 I O INTERFACE SPECIFICATIONS 5 1 Power supply Beside the power supply required by the PRC controller itself power must be supplied to the I O connector for external I O control Supply power from the external power supply to COM and COM on the I O connector 5 2 External wiring diagram Fig 5 1 External wiring diagram User device Controller Input supply OPTICAL voltage ENCORDER 24V START2 COM START External RNT sensor PNT2 PNT3 PNT4 PNT5 LOCK EMG ALMCLR Twisted pair shielded cable ORG ACK ROTATE ALM ZONE END EMGMON ORGMON LOCKMON INPOS COM 5 1 SNOILVOIHIOJdS JDVANALNI O I 5 3 CN1 DC characteristics I O INTERFACE SPECIFICATIONS 2 5 3 CN1 DC characteristics Circuit Specifications COM 4 7kQ Input signal e DC 5V to 24V 10 e Response time 1ms Output signal e DC 30V 30mA or less e Response time ON 1ms OFF
110. tput for prespecified coordinate range on deciding current position Turns on when within the prespecified range NOTE This is output regardless of whether return to origin is complete so use after finishing return to origin The PRC controller sets the robot position as 0 where the servo turns on when power is turned on A CAUTION There is no fixed output when a disconnected wire is detected or CPU alarm occurs regardless of the controller status so use caution E END Pin No B7 This is output when the executed signal START ORG ends normally No reply is made to movement by serial communication Turns off at the point that an execution signal was received W NOTE Turns on when power is turned on or restarted when initialization ends normally During positioning the END signal turns on under the condition that the ACK signal is off and also that the INPOS signal is on e Maintains the immediately prior status when stopped due to interlock ALM or EMG e Turns on when pushing operation ends normally during torque movement e Remains off when pushing is ineffective E EMGMON EMG monitor Pin No B8 Monitors the emergency stop status via both serial communication and EMG input This is on in emergency stop and is off when emergency stop is canceled NOTE e The monitor signal is output during emergency stop by serial communication input when a command other than an ALM was issued to check the
111. tput signal Output ORGMON Return to origin completion output signal LOCKMON 2 Interlock status output signal INPOS Positioning completion output signal Output Output 1 For information on how to designate the point data see 8 Point 2 This is set to ORGMON at the factory To use in LOCKMON change the parameter 5 5 1 Input signal description SNOILVOISIDAdS JDVANALNI O I To find more information on the timing chart see 9 Basic operation and timing chart The term ON indicates closed contacts while the term OFF indicates open contacts E START Start command Pin No A3 This is a run signal for the movement command The movement command set in the point No is run at the rise OFF to ON of the start signal NOTE e There is no reply to the ACK output signal if executing the command is already impossible e Always turn the start signal off if there is no ACK response within the specified time 53 5 5 I O connector signal table E PNT 1 to 5 Point signal designation command Pin No A4 to 8 N Z p lt Q kalal ou N kla Q S a bla Z O 5 4 sO NOTE Specifies the point No The point No is specified with a binary input as shown in the table below Points can be specified from 0 to 31 lt Point No setting example gt Point No PNT4 28 PNT3 22 PNT2 2 PNT1 2 OFF OFF OFF OFF
112. turn to origin opera tion is completed A CAUTION If the ORG input signal stays ON the ACK output signal will stay ON even if return to origin has completed The END output signal cannot turn ON if the ACK output signal is still ON Timing chart ORG ACK k END ORGMON ROTATE A CAUTION Always turn the ORG input signal OFF at the point that the ACK output signal has turned on See the next section 9 2 2 ORG signal AC characteristics for information such as the ORG signal minimum hold time 9 2 Performing return to origin 9 2 2 ORG signal AC characteristics The timing chart for executing commands with the ORG signal is shown below The ORG signal minimum hold time is also shown in the table below Always refer to this table when making signal setups Symbol ORG signal hold time tEL ACK signal response delay time ACK signal response delay time LYVH D ONIWIL NOILV8AdO ANY NOILVasAdO DISVE lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca s8 9 2 Performing return to origin 9 2 3 Return to origin operation error The END signal does not turn ON if an interlock signal or EMG signal was input or an alarm oc curred during return to origin operation Timing chart When an interlock signal is input during return to origin operation ORGMON ROTATE 9 3 Positioning operation 9 3 Positioning operation
113. turned OFF Even if the interlock is canceled the END output signal and INPOS output signal maintain the same state they had during the interlock When performing relative movement after stopped with LOCK the stop position becomes the reference position A CAUTION Always set the START input signal to OFF at the point that the ACK output signal has turned ON INVHO ONIWIL NOILVNIdO ANY NOILVasAdO DISV4E 27 9 4 Torque movement After completing torque movement PNT 1 to5 l START l ACK LOCK i Motor speed ROTATE i INPOS END Starts decelerating towards target position Torque distance is added to target position 2 Reduces to torque movement speed 5 Starts torque movement lt 4 Reaches specified torque current am 7 When the robot enters within INPOS range before torque movement is complete the INPOS Z output signal turns ON at that point z The INPOS output signal stays ON even if the LOCK input is entered after torque movement is complete p Z e When the LOCK input is entered when the torque detection time has elapsed after starting le torque movement position hold is performed with the END output signal still turned OFF z Even if the interlock is canceled the END output signal and INPOS output signal maintain the pe same state they had during the interlock S e When performing relative movement after stopped with LOCK the stop position becomes the refer
114. ual near the machine for the required installation operation and adjust ments 2 Make the required installation operation and adjustments while viewing the CD ROM version of the manual on a PC 3 Make the required installation operation and adjustments after extracting the neces sary portions of the manual beforehand from the CD ROM and making a printout Refer to the individual instruction manual for information on the robot unit support software and teaching box The YAMAHA robot controllers and robots are manufactured as a standard piece of industrial equip ment The following points must therefore be kept in mind during use The YAMAHA robot controllers and robots e Cannot be used with devices such as medical treatment equipment that are critical to human life e Cannot be used in or with equipment exerting major effects either socially or publicly e Cannot be used in environments where it will be subject to vibrations such as on ships or in vehicles e Cannot be modified or altered in any manner Before using this robot controller for example before installing making wiring connections oper ating servicing or inspecting read this manual carefully to ensure safe and correct use After gain ing thorough understanding of the equipment safety information and precautions use this robot controller Every effort was made to ensure that this manual is accurate and complete However please contact us if any errors mispri
115. unlimited rotation function When the Origin Preset PRM69 is different from the value already set set a value that does not invert the plus minus sign within the operating range A12 Torque Motion Failed LED flash count 8 times Description Robot moved up to the torque movement amount position by pushing opera tion when the Insufficient Torque Alarm PRM29 was 0 Permit Could not obtain balance versus robot pushing thrust If not wishing to issue an alarm for pushing operation error set the Insufficient Torque Alarm PRM29 to 1 Protected A16 Memory Error REBOOT LED flash count lights up Description Error occurred in memory inside the controller Misoperation or malfunction caused due to noise Make a check for ambient noise See 4 4 5 Preventing misoperation due to noise and take proper measures Controller defective Replace the controller if problems frequently occur 11 2 Checking the alarm and countermeasure Alarms not shown on alarm code A CPU HALT LED flash count lights up Description The CPU in the controller won t operate correctly Drop in power supply voltage Check if the power supply voltage is within the rated specifications Misoperation or malfunction caused due to noise Make a check for ambient noise See 4 4 5 Preventing misoperation due to noise and take proper measures Controller defective Replace the controlle
116. utput signal has turned ON lt I Q 9 z Z lt a kla ou O m Z lt Z lt a Lid oun O N lt ca 30 9 5 Zone output operation 9 5 Zone output operation This section explains the basic operation and operation timing charts for zone output operation 9 5 1 Normal zone output operation Example A position is set 12 mm from the origin point During movement to a position 245 mm from origin point a zone signal is output when the robot enters a position in an area from 120 mm to 150 mm from the origin point Precondition Point data has already been created and the data loaded into the controller PRM59 Upper Zone Range mm 150 PRM60 Lower Zone Range mm 120 Position INPOS width mm mm 245 00 0 06 0 0 00 Torque distance Item Command mm Acceleration Deceleration Torque limit See the support software manual or teaching box manual for information on how to create point data and how to load data Basic operation 1 Specify the movement point Methods for specifying the point are as follows Point No PNT4 2 PNT3 2 PNT2 2 OFF OFF OFF OFF OFF OFF OFF OFF ON 2 Set the START input signal to ON A CAUTION The START input signal is executed by ON edge detection 3 When the START input signal turns ON normally the ACK output signal turns ON and the robot starts to move The ROTATE
117. verse of command during torque move ment exceeded the value of PRM36 Max Torque Deviation Problems during use To permit just the push back during pushing movement set the Max Torque Deviation PRM36 to a figure larger than the effective robot stroke Detected excessive vibration such as overshoot during Lower the speed and acceleration deceleration values in the point movement data Motor defective Replace the motor Electromagnetic brake or wire is broken Operate the brake and check if the brake can be released Abnormal resistance in mechanical sliding parts Check if the robot moving parts are working sluggishly If sluggish then readjust the mechanical alignment Parameter error Perform generation Controller defective Replace the controller if problems frequently occur A06 Overload LED flash count 4 times Description Overload on motor Problems during use Correct the payload as well as speed settings in the point data Motor defective Replace the motor Electromagnetic brake or wire is broken Operate the brake and check if the brake can be released Abnormal resistance in mechanical sliding parts Check if the robot moving parts are working sluggishly If sluggish then readjust the mechanical alignment Parameter error Perform generation Controller defective Replace the controller if problems frequently occur A07 Over Speed LED flash count 4 tim
118. y 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 If you find any part unclear in this manual please contact YAMAHA or YAMAHA sales representatives

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