Manual

YAMAHA Robot Controller PRCX series

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INTRODUCTIONThis manual has been prepared exclusively for Rankin Corp.

This manual explains the matters related to the CE marking of the YAMAHA robotcontroller PRCX Series.When shipping the YAMAHA robot controller PRCX Series to Europe or when using thisseries in Europe, always read this manual thoroughly and use the controller correctly.

This manual explains only the matters related to CE marking. Refer to the RCX40 Seriesmanuals for details regarding the YAMAHA robot controller’s installation methods.

• Outline of PRCX controllerThe PRCX controller is a product developed for Rankin Corp. The PRCX controllerwas developed based on the RCX40 controller. The motion control and I/O controlsections have been eliminated from the RCX40 controller, and instead a product withinterface for connection to a host computer has been prepared. The Rankin Corp.specifications are applied when connecting the host computer and PRCX controller andactually carrying out robot control and I/O control.

• Scope of YAMAHA MOTOR responsibilityAs explained above, YAMAHA MOTOR provides the PRCX controller only for theservo amplifier functions, and guarantees this product within this range.Note that Rankin Corp. is responsible for installing the host computer connection I/F(bridge board) into the PRCX controller, setting the DIP switches, changing the currentsensor range settings, and disassembling and assembling the PRCX controller for theseoperations. YAMAHA MOTOR provides no guarantee to cover these steps.YAMAHA MOTOR will also not be held liable for any robot runaway or faults thatoccur due to faults in the host computer (software, hardware).

* CONTEC is a trademark of CONTEC CO., LTD.

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Safety precautions (Be sure to read before using)

Before using the YAMAHA robot controller, be sure to read this manual and relatedmanuals, and follow their instructions to use the robot controller safely and correctly.Warning and caution items listed in this manual relate to YAMAHA robot controllers.When this robot controller is used in a robot controller system, please take appropriatesafety measures needed by the user’s individual system.

This manual classifies safety caution items and operating points into the following levels,along with symbols for “WARNING”, “CAUITON” and “NOTE”.

w WARNINGFailure to follow WARNING instructions could result in severe injury or death to theoperator, bystanders or persons inspecting or repairing the robot controller or robot.

c CAUTIONFailure to follow CAUTION instructions may result in injury to the operator, bystanders or personsinspecting or repairing the robot controller or robot, and may damage the robot controller or robot.

n NOTEExplains the key point in the operation in a simple and clear manner.

Note that the items classified into “CAUTION” might result in serious injury dependingon the situation or environmental conditions. So always comply with the CAUTION andWARNING instructions as these are essential for safety.

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[System design safety points]

w WARNING• Refer this manual for details on the operating status of the robot controller and

related RCX40 owner’s manual.Design and configure the system including the robot controller so that it willalways work safely.

• The robot controller has an emergency stop terminal to trigger emergency stop.Using this terminal, prepare a physical interlock circuit so that the systemincluding the robot controller will work safety.

c CAUTIONDo not bundle control lines or communication cables together or in close contact with the robotcontroller main circuit or power lines. As a general rule, separate them by at least 100mm. Noise inthe main circuit or power lines may cause faulty operation or malfunctions.

[Installation safety points]

w WARNING• Securely install the connectors into the robot controller, and when wiring the

connectors, make the crimp, press-contact or solder connections correctly, usingthe tool specified by the manufacturer.

• Always shut off all phases of the power supply externally before startinginstallation or wiring work. Failure to shut off all phases could lead to electricshocks or product damage.

c CAUTION• Use the robot controller within the environment specifications listed in this manual.

Using the controller in an environment outside the specification range could lead to electricshocks, fires, malfunctions, product damage or deteriorated performance.

• Tighten the screws on the robot controller firmly to make secure connections.• 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.• Securely install each connection cable connector into the receptacles or sockets.

Poor connections will cause faulty operation or malfunctions.

[Wiring safety points]

w WARNING• Always shut off all phases of the power supply externally before starting

installation or wiring work. Failure to shut off all phases could lead to electricshocks or product damage.

• Always attach the terminal cover (supplied) before turning on the power to therobot controller after installation and wiring work are complete. Failure to attachthe terminal cover could lead to fire, electrical shock, product damage ormalfunctions.

c CAUTION• Tighten the terminal screws within the specified torque range.

A loose terminal screw could lead to short-circuit, faulty operation or malfunctions.If the terminal screw is too tight, short-circuit, faulty operation or malfunctions could alsooccur due to screw damage.

• Make sure that foreign matter, such as cutting chips or wire scraps, do not enter the robotcontroller.

• Always store the cables connected to the robot controller in a conduit or clamp them securelyin place.If the cables are not stored in a conduit or properly clamped, excessive play or movement, ormistakenly pulling on the cable may damage the connector or cables, and poor cable contactmay lead to faulty operation or malfunctions.

• When disconnecting the cable, detach by holding the connector itself and not by tugging on thecable.Loosen the screws on the connector (if fastened with the screws), and then disconnect thecable.Detaching by pulling on the cable itself may damage the connector or cables, and poor cablecontact may lead to faulty operation or malfunctions.

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[Start-up and maintenance safety points]

w WARNING• When operating the robot, only personnel trained in safety and robot operation

may operate it.• When operating the robot, only personnel trained in safety and robot operation

may operate it.Never allow anyone to enter the robot movement range when the robot controlleris turned on. Serious accident including fatal injury or death could otherwiseresult.

• This robot controller is not designed for explosion-proof. Do not use it in locationsexposed to inflammable gases, gasoline or solvent that could cause explosion orfire.

• Do not touch any electrical terminal while power is supplied to the robotcontroller. This may cause electrical shocks, faulty operation or malfunctions.

• Always shut off all phases of the power supply externally before cleaning ortightening the terminal screws.Failure to shut off all phases could lead to electric shocks, product damage ormalfunctions.A loose screw could lead to dropping, short circuit or malfunctions.If the screw is too tight, short circuit or malfunctions could also occur due toscrew damage.

• Never disassemble or modify the robot controller.This may lead to breakdowns, malfunctions, injury or fire.

• Never replace the fuse installed in the robot controller even in any case.If the fuse in the power input section of the robot controller has blown, the robotcontroller probably has a problem with its internal circuit. Just replacing the fusecannot solve such a problem. Please consult YAMAHA sales dealer.

• Purpose of fuse :To prevent secondary damage such as smoke generation or ignition, in externaldevices when a major fault such as a short-circuit occurs in the robot controller.

• Always shut off all phases of the power supply externally before installing orremoving an option board.Failure to shut off all phases could lead to breakdowns or malfunctions.

• When using ferrite cores for noise elimination, fit them to the power cable as closeto the robot controller as possible, to prevent faulty operation or malfunctions dueto noise.

• When performing maintenance of the robot controller under instructions fromYAMAHA or YAMAHA sales dealer, turn off the robot controller and wait for at least30 minutes. Some parts in the robot controller may be hot or applied at a highvoltage shortly after operation, so burns or electrical shocks may occur if thoseparts are touched.

[Precautions for disposal]

c CAUTIONWhen disposing of this product, handle it as industrial waste.

May. 2002 First edition

Revision Record

Date of revision Description

This manual does not constitute a concession of rights or a guarantee ofindustrial rights. Please acknowledge that we bear no liability whatsoeverfor conflicts with industrial rights arising from the contents of this manual.

2002 YAMAHA MOTOR CO., LTD.

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Contents

Chapter 1 Safety1. Safety ................................................................................................. 1-1

2. CE Marking ........................................................................................ 1-2

2.1 CE Marking ........................................................................................... 1-22.1.1 Safety Standards ...................................................................................... 1-2

2.1.1.1 Safety precaution for EC directive applicability .......................................... 1-2

2.1.1.2 Applicable directives and standards ........................................................... 1-3

2.1.2 Robots subject to CE marking .................................................................. 1-3

2.1.3 Safety Measures ....................................................................................... 1-3

2.1.3.1 Operating conditions ................................................................................. 1-3

2.1.3.2 Safety measures for SCARA type robots ...................................................... 1-4

2.1.3.3 Safety measures for single-axis robots,

Cartesian robots and pick-and-place robots ............................................... 1-4

2.2 Safety precautions during robot operation ............................................. 1-4

2.3 Safety precautions during maintenance ................................................. 1-4

2.4 Precautions for motor overload ............................................................. 1-5

3. Warning labels and marks .................................................................. 1-6

3.1 Warning labels ...................................................................................... 1-6

3.2 Warning marks ...................................................................................... 1-6

4. Operating environment ...................................................................... 1-7

Chapter 2 System overview1. System overview ................................................................................ 2-1

1.1 Main system configuration .................................................................... 2-1

2. Control system configuration ............................................................. 2-3

2.1 Basic configuration ................................................................................ 2-32.1.1 I/O address settings for CONTEC PCI/ISA/BUS ADAPTER ........................ 2-4

2.2 Power supply and emergency stop system circuit configuration ............. 2-5

3. External Connection Circuits ............................................................. 2-6

3.1 External Circuit Connection 1 ................................................................ 2-63.1.1 Dedicated I/O Connections to External Circuit ......................................... 2-6

4. EMC Countermeasures ....................................................................... 2-7

4.1 Typical component layout for EMC countermeasures ............................ 2-7

5. Precautions for cable connections ..................................................... 2-9

Chapter 3 How to install the CONTEC bridge card1. Open the box of PRCX ....................................................................... 3-1

2. Set the bridge card ............................................................................. 3-4

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Chapter 4 Specifications1. Controller .......................................................................................... 4-1

1.1 Controller basic specifications ............................................................... 4-1

1.2 Robot controller external view .............................................................. 4-2

1.3 Connecting the absolute battery ............................................................ 4-3

1.4 Replacing the absolute battery ............................................................... 4-5

1.5 Connecting a regenerative unit .............................................................. 4-6

Chapter 5 Appendix1. Definition of terms ............................................................................. 5-1

1.1 Definition of terms ................................................................................ 5-1

Chapter 1 Safety

Contents1. Safety ............................................................................................... 1-1

2. CE Marking ....................................................................................... 1-2

2.1 CE Marking .............................................................................................1-22.1.1 Safety Standards .......................................................................................... 1-2

2.1.1.1 Safety precaution for EC directive applicability ............................. 1-22.1.1.2 Applicable directives and standards .............................................. 1-3

2.1.2 Robots subject to CE marking ...................................................................... 1-3

2.1.3 Safety Measures .......................................................................................... 1-32.1.3.1 Operating conditions .................................................................... 1-32.1.3.2 Safety measures for SCARA type robots ......................................... 1-42.1.3.3 Safety measures for single-axis robots,

Cartesian robots and pick-and-place robots .................................. 1-42.2 Safety precautions during robot operation ............................................... 1-4

2.3 Safety precautions during maintenance ...................................................1-4

2.4 Precautions for motor overload ...............................................................1-5

3. Warning labels and marks ................................................................ 1-6

3.1 Warning labels ........................................................................................1-6

3.2 Warning marks ........................................................................................1-6

4. Operating environment .................................................................... 1-7

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Safety

1. Safety

Please observe all safety rules and cautions to use the YAMAHA robot safely and correctly. Also,

please bear in mind that not all safety items can be listed in detail, so that an accurate judgment by the

operator or service personnel is essential to operate the robot and controller safely.

To ensure correct and safe use of YAMAHA industrial robots, carefully read this manualand FOLLOW THE WARNINGS, CAUTIONS AND INSTRUCTIONS in this chapter.Failure to take necessary safety measures or mishandling may result in trouble or damageto the robot and injury to personnel (robot operator or service personnel) including fatalaccidents.

Particularly important safety items and operation points are identified in this manual bythe following symbols.

w WARNINGFailure to follow WARNING instructions could result in severe injury or death to theoperator, bystanders or persons inspecting or repairing the robot controller or robot.

c CAUTIONFailure to follow CAUTION instructions may result in injury to the operator, bystanders or personsinspecting or repairing the robot controller or robot, and may damage the robot controller or robot.

n NOTEExplains the key point in the operation in a simple and clear manner.

To install, operate or adjust the YAMAHA robot or controller safely and correctly, alwaysfollow the instructions explained in this manual by using either of the following methods.

1. Install, operate or adjust the robot or controller while referring to the contents of thismanual.

2. Install, operate or adjust the robot or controller while viewing the contents of the CD-ROM version manual on your computer screen.

3. Install, operate or adjust the robot or controller while referring to a printout of thenecessary pages from the CD-ROM version manual.

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2. CE Marking

2.1 CE MarkingThis section provides a basic description of how YAMAHA robot series products arecompatible with CE marking.■ Differences in main specifications of CE marking compatible controller and standard

controller

Power supply voltage

CE marking compatible controller

Single phase AC 200V only

Standard controller

Single phase AC 200 to 230V

2.1.1 Safety Standards

2.1.1.1 Safety precaution for EC directive applicability

The YAMAHA robot series products (robots and controllers) do not fall under the robotsystems category. We define the YAMAHA robot series products as equipment to beincorporated (built-in equipment) into your system, and declare that our products conformto the EC directives only within the scope of the built-in equipment. This means that useof any single unit of YAMAHA robot series products is not guaranteed to conform to theEC directives, although a CE marking is affixed to each unit of YAMAHA robot seriesproducts. When you ship your finished system to Europe or use it in Europe, you arerequired to verify that your system conforms to the EC directives.

Note : Differences between the YAMAHA robot series products (robots andcontrollers) and robot systems

YAMAHA robot series products (robots and controllers) are componentsused to assemble a robot system and therefore do not constitute a robotsystem.

This is because YAMAHA robot series products do not include “the endeffector(s)”, “equipment, devices or sensors required for the robot to performits tasks”, which are listed in the “Robot System” definition in Clause 3.2.20of the EN775:1992 standard.

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Safety

2. CE Marking

2.1.1.2 Applicable directives and standards

The table below shows directives and related standards applied to make YAMAHA robotscompatible with the CE marking.

EC Directives Related Standards NOTE

Machinery

directives

98/37/EC

Low-voltage directives

73/23/EEC

93/68/EEC

EMC directives

89/336/EEC

92/31/EEC

93/68/EEC

EN292 : Safety of machinery - basic concepts

EN775 : Industrial robots - safety

EN1050 : Safety of machinery - risk assessment

EN60204-1 : Safety of machinery - electrical

equipment of machines

EN55011 : Emission / ISM equipment

EN61000-6-2 : Immunity / Industrial environment

YAMAHA robot series products are built-

in equipment unnecessary to adapt to the

machinery directives. However,

YAMAHA robot series products conform

to the standards on the left regarding the

required items for basic health and safety.

YAMAHA robot series products conform

to the directives and related standards on

the left.

YAMAHA robot series products are tested

according to the directives and related

standards on the left. EMC

countermeasures for a single unit of

YAMAHA robots are described in

Chapter 2.

2.1.2 Robots subject to CE marking

The following robot series products are subject to CE marking.

Robot Name

Single-axis robots

FLIP-X series

Cartesian type robots

XY-X series

SCARA type robots

YK-X series

Pick-and-place type robots

YP-X series

(except some models)

For more details on model numbers and combinations with peripheral units, consultYAMAHA or YAMAHA dealers.

2.1.3 Safety Measures

2.1.3.1 Operating conditions

The following description gives major operating conditions for using YAMAHA robotseries products.

● EMC (Electromagnetic compatibility)YAMAHA robot series products are products for use in an industrial environment. (Referto the definition applicable to the EMC directives: Under “Scope” in the first article of theEN61000-6-2 standard.In order to ensure your product conforms to EMC directives, you must evaluate yourfinished product (entire system) and take necessary countermeasures. EMCcountermeasures for single units of YAMAHA robots are listed in Chapter 2.

● Installation conditions• Since YAMAHA robot series products are built-in equipment, they have a Class I

protective structure against electrical shock. The robot and controller must thereforebe grounded properly to prevent possible electrical shock. For more details, refer toChapter 3 in the RCX40 Series Owner’s Manual and the Robot Owner’s Manual.

• The Robot controller case is not designed as an enclosure that conforms to EN60204-1 standard. Therefore you must provide appropriate protection against the danger ofelectrical shock due to inadvertent contact and external environmental problems (dust,water, etc.)

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2. CE Marking

• Insulation co-ordination is designed to meet the following conditions. (Refer to theIEC60664-1 standard.)

Overvoltage category II

Pollution degree II

Take proper countermeasures as needed if the robot or controller is used in environmentsworse than these levels.

● Explosion-proof• YAMAHA standard robots and robot controllers are not designed to meet explosion-

proof specifications. Do not use the robot and controller in environments containinginflammable gas, gasoline or solvent. Explosions or fire may otherwise result.

2.1.3.2 Safety measures for SCARA type robots

a. Safety measures during transportation

To ensure safety, use the eyebolts that come with the robot. Refer to the Robot Owner'sManual for details.

b. Protective measures against electrical shock

Use the protective ground terminal to ensure safety. Refer to the Robot Owner's Manualfor details.

2.1.3.3 Safety measures for single-axis robots, Cartesian robots and pick-and-place robots

a. Protective measures against electrical shock

Use the protective ground terminal to ensure safety. Refer to the Robot Owner's Manualfor details.

2.2 Safety precautions during robot operationa. The robot must be operated by a person who has received Robot Training from

YAMAHA or an authorized YAMAHA sales representative.

b. During operation of the robot, be sure to stay out of the working area of the manipulator.Install a safeguard to keep anyone away from the working area or provide a gateinterlock using an area sensor that triggers emergency stop when anyone enters theworking area.

2.3 Safety precautions during maintenancea. Never disassemble the robot or controller. In cases where you have to replace or repair

parts used in the robot or controller, first consult with us and follow the owner's weprovide.

b. Always shut off all phases of the power supplied to the controller before servicing therobot or controller. There may be hot sections or sections with a high voltageimmediately after the controller power is turned off. Wait at least 30 minutes afterturning the power off before starting maintenance.

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Safety

2. CE Marking

2.4 Precautions for motor overloadSince abnormal operation of the motor such as “overload” is detected by software, thecontroller parameters must be set correctly to match the motor type used in the robotwhich is connected to the controller.Prior to shipping, the controller parameters are preset to match the robot model to beused. When connecting to the robot to the controller, check the robot model again. If anyabnormality is found during operation, stop the controller and contact us for correctiveaction.

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3. Warning labels and marks

3.1 Warning labelsThe warning labels shown below are affixed to the controller. To use the YAMAHA robotand controller safely and correctly, be sure to observe the instructions and caution on thelabels.

a. “Electric Hazard” label

! C A U T I O N

ELECTRIC HAZARD

■ This label warns you of possible electrical shock. Do not touch the terminal strip andconnectors to avoid electrical shock.

b. “Read Instruction Manual” label

READ INSTRUCTIONMANUAL

■ This label means that important information you must know is described in RCX40owner’s manual.

When in particular connecting a power supply to the robot controller, read this manualcarefully and follow the instructions.

3.2 Warning marksThe following warning marks are shown on the controller. To use the YAMAHA robotand controller safely and correctly, be sure to observe the instructions and caution of themarks.

a. “Electric Hazard” mark

■ This mark warns you of possible electrical shock. Do not touch the terminal block andconnectors to avoid electrical shock.

b. “Read Instruction Manual” mark

!■ This mark indicates that important information you must know is described in RCX40

owner’s manual.

When in particular connecting a power supply to the robot controller, read this manualcarefully and follow the instructions. Connectors have an orientation, so insert eachconnector in the correct direction.

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Safety

4. Operating environment

Operating temperatureThe ambient temperature should be maintained within a range of 0 to 40°C duringoperation. This is the range in which continuous operation of the robot controller isguaranteed according to the initial specifications. If the robot controller is installed in anarrow space, heat generated from the controller itself and from peripheral equipmentmay drive the temperature above the allowable operating temperature range. This mayresult in thermal runaway or malfunctions and may lower component performance alongwith shortening their useful service life. So be sure to install the controller in locationswith a vent having a natural air flow. If this proves insufficient provide forced air-cooling.

Storage temperatureThe controller should be stored in a location at an ambient temperature between -10 and+65°C when not being used. If the robot controller is stored in a location at high or lowtemperatures for extended periods, deterioration of the electronic components may occurand the memory backup time may decrease.

Operating humidityThe ambient humidity of the robot controller should be 35% to 85% RH (no condensation)in order to guarantee continuous operation within the initial specifications. Installing therobot controller inside an air-conditioned or cooled housing is recommended when anambient humidity is higher than 85% or condensation occurs.

Storage humidityThe controller should be stored in a location at an ambient humidity below 95% RH (nocondensation) when not being used. If the robot controller is stored in a location at highhumidity for an extended period of time, rust may form on the electronic components.

Vibration and shockDo not apply excessive shocks or constant vibrations to the robot controller. Install therobot controller in a steady location not subject to vibrations.

Atmosphere (gas, etc.)Do not install the robot controller in locations where conductive dust particles, hydrogensulfide gas or sulfurous acid gas are present. Such an atmosphere may cause the componentsto erode or poor installation. If such dust particles or gases are generated at the currentlocation, then installing the robot controller in an air-conditioned or cooled housing isrecommended.

Installation locationAlways install the robot controller indoors, at a height of less than 1000 meters above sealevel.

Chapter 2 System overview

Contents1. System overview .............................................................................. 2-1

1.1 Main system configuration ......................................................................2-1

2. Control system configuration ........................................................... 2-3

2.1 Basic configuration .................................................................................2-32.1.1 I/O address settings for CONTEC PCI/ISA/BUS ADAPTER ............................ 2-4

2.2 Power supply and emergency stop system circuit configuration .............. 2-5

3. External Connection Circuits ............................................................ 2-6

3.1 External Circuit Connection 1 .................................................................. 2-63.1.1 Dedicated I/O Connections to External Circuit ............................................ 2-6

4. EMC Countermeasures ..................................................................... 2-7

4.1 Typical component layout for EMC countermeasures .............................. 2-7

5. Precautions for cable connections.................................................... 2-9

2-1

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System

overview

1. System overview

The PRCX Series controller is designed for use with a SCARA robot or Cartesian robot using host

computer control, and is used mainly for assembly and pick-and-place applications.

1.1 Main system configuration

Configuration 1: System for controlling one robot

Example : YK400X

All the axes on the robot controller are used as the main robot axes.

Fig. 2-1-1 System for controlling one robot

External emergency stop circuit Emergency stop button( Safety door switch, etc.

PCYAMAHA robot

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Configuration 2: System for controlling one robot and auxiliary axes

Example: SXYx+T9+T9

Axes 1 and 2 on the robot controller are used as the main robot axes andaxes 3 and 4 are used as the main auxiliary axes.

Fig. 2-1-2 System for controlling one robot and auxiliary axes

External emergency stop circuit Emergency stop button( Safety door switch, etc.

YAMAHA robot

PC

1. System overview

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System

overview

2. Control system configuration

2.1 Basic configurationThe basic block diagram of the PRCX robot controller system is shown below.

Fig. 2-2-1

RG

EN

MOTOR

XM

CN5

CN7

CN5

CN1

CN1

CN6

CN2

CN2

CN1CN3

HEATSINK

CN4

CN6

CN7

CN3 CN10 CN7 CN2

TB1

CN

4C

N1

CN

1C

N2

CN

1C

N2

CN

6

CN

8

CN

9

CN

11

CN

5

TH

1(F

G)

CN

11C

N13

CN

4

CN

8C

N12

CN

10

YM

ZM

RM

ROB I/O XY

ROB I/O ZR

SAFETY

HOST I/F

SI

D POWER BOARD ASSY

DRIVER2 BOARD ASSY

DRIVER1 BOARD ASSY

BRIDGE BOARD ASSY

ISA

CONTECBUS ADAPTER

XYZR

BAT

T

AC

IN

POW

ER C

PU U

NIT1

AC

/DC

24V

POW

ER C

PU U

NIT2

5V, 12V

LN

PC

PCI

ExampleBUF-PC(PCI)

DIPSW(Refer to “2.1.1” on page 2-4)

ExampleBUS-PCI(PC)

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2. Control system configuration

2.1.1 I/O address settings for CONTEC PCI/ISA/BUS ADAPTER

1 2 3 4 5 6 7 8 →

ON

DIPSW is mounted on the KX0-M4510-310,BRIDGE BOARD ASSY.

You can set the I/O address bit (A3 to A9 ) to ON or OFF.“ON” means bitAx=0, “OFF” means bitAx=1.The table 1 shows the example of settings.

Table 1 DIPSW settings for CONTEC bridge card

IO ADDRESS

(PCI/ISA:word)

DIPSW

definition

0x200

0x300

0x310

0x318

0x320

0x328

0x3f8

1

WORD

ON

ON

ON

ON

ON

ON

ON

2

A3

ON

ON

ON

OFF

ON

OFF

OFF

3

A4

ON

ON

OFF

OFF

ON

ON

OFF

4

A5

ON

ON

ON

ON

OFF

OFF

OFF

5

A6

ON

ON

ON

ON

ON

ON

OFF

6

A7

ON

ON

ON

ON

ON

ON

OFF

7

A8

ON

OFF

OFF

OFF

OFF

OFF

OFF

8

A9

OFF

OFF

OFF

OFF

OFF

OFF

OFF

Fig. 2-1-1 KX0-M4510-310 BRIDGE BOARD ASSY

Servo card connector

Contec bridge card slot

1 2 3 4 5 6 7 8 →

ON

n NOTE1. A3 to A9 :

I/O address bit2. DIPSW BIT1 :

word access for PCI/ISA

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2

System

overview

2.2 Power supply and emergency stop system circuit configurationThe control system’s power supply system and emergency stop system circuit block dia-gram are shown below.

Fig. 2-2-2

*1) The input power and each control power areinsulated by the insulated transformer.

*2) The 0V line for the 3.6VDC, 5VDC, 12VDCand 24VDC is not connected to the protectiveearth.

2. Control system configuration

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3. External Connection Circuits

c CAUTIONUltimately, safety measures must betaken following the Safety Standardsrelated to the user’s devices.

3.1 External Circuit Connection 1An example of the external connection circuit is explained below. An example of thecircuit is shown below.

Fig. 2-3-1 Example of external connection circuit 1

EMG RDY

AC200V

AC IN

L

N

XM/YM ZM/RM

ControlPower

MotorPower

ROB I/OXY/ZR

KA2RELAY

GND24

EMG24VEMG24V

SAFETY

1413 Emergency button

Robot

HOST I/F

Hostcomputer

*1

3.1.1 Dedicated I/O Connections to External Circuit

The following dedicated I/O is available for the circuit shown in Fig. 2-3-1.

ExplanationInput

Emergency stop readyThis is an input signal for the robot controller to turn on the servo motors connected to it.

n NOTE*1 Do not connect anything to pins 1

to 12 and pin 15.

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2

System

overview

c CAUTIONThe following description and circuitsare typical countermeasures usedwhen the robot and controller aretested under YAMAHA installationconditions. When the robot andcontroller are used while installed inyour system, the actual test resultsmay differ depending on installationconditions.

4. EMC Countermeasures

To conform to EMC directives, implement the appropriate EMC countermeasures for your finished

product (entire system). The following description and circuits are typical EMC countermeasures for a

single unit of YAMAHA robot, just for your reference.

4.1 Typical component layout for EMC countermeasuresFig. 2-4-1 shows a typical component layout for EMC countermeasures when the PRCXcontroller is used in combination with a YAMAHA cartesian robot, SCARA type robot orpick-and-place robot. Fig. 2-4-2 shows a typical component layout for EMCcountermeasures when the PRCX controller is used in combination with a YAMAHAsingle-axis robot.In Figs. 2-4-1 and 2-4-2, the layout key points are as follows.

• Power cable

Connect a lightning surge absorber to the power input cable. Then pass the cable(including the ground wire) through ferrite cores.

• Motor cable

Pass each motor cable through ferrite cores on the controller side.

• Feedback cable

Pass each feedback cable through ferrite cores on the controller side.

• SAFETY cable

Pass SAFETY cable through ferrite cores on the controller side.

• Host I/F cable

Pass the Host I/F cable through ferrite cores on the controller side.

• Precautions for handling ferrite cores fitted onto cables other than the power cable.

Place the ferrite cores on the controller side as close to the controller connectors aspossible. Likewise, place the ferrite cores on the robot side as close to each unit aspossible.

2-8

Sys

tem

ove

rvie

w

2

4. EMC Countermeasures

c CAUTIONThe ferrite cores on the controllerside should be placed as close to thecontroller body as possible. Theferrite cores on the robot side shouldbe placed as close to the robot body aspossible.

Power

200Vandearth

PRCX

Robot series Cartesian Scara P&P

LN

XMYMZMRM

MotorRGEN

RGU-2

XYZR

ROBI/O

ACIN

Ferrite core

Lightning surge absorber

external Connection circuits

PC

SAFETY

HOST I/F

Battery

Fig. 2-4-1 EMC countermeasures for PRCX-E and Cartesian, SCARA or pick-and-place robot

RGU-2

external Connection circuits

PC

SAFETY

HOST I/F

Battery

Power

200Vandearth

PRCX

Single axis robot

Single axis robot

Single axis robot

Single axis robot

LN

ACIN

Motor

XYZR

XMYMZMRM

RGEN

ROBI/O

Ferrite core

Lightning surge absorber

Fig. 2-4-2 EMC countermeasures for PRCX-E and single-axis robot

Meaning of each symbol

: Ferrite core

Lightning surge absorber:

2-9

2

System

overview

5. Precautions for cable connections

Various cables are used to connect the robot controller to peripheral devices. Follow theprecautions below when making cable connections.

q Keep the Safety cables, robot cables and power cable separate from each other. Neverbundle them together.

w Keep the Host I/F cable, robot cables and power cable separate from each other. Neverbundle them together.

e Keep robot cables separate from the power cable. Never bundle them together.

r Keep robot cables separate from other equipment power lines. Never bundle themtogether.

Chapter 3

How to install the CONTEC bridge card

Contents1. Open the box of PRCX ..................................................................... 3-1

2. Set the bridge card ........................................................................... 3-4

3-1

3

Ho

w to

install th

e Co

ntec b

ridg

e card

1. Open the box of PRCX

Remove the RGU-2 and battery unit

Remove the battery(pull out)

Remove the battery bracket

Remove the RGU-2 braket

3-2

1. Open the box of PRCX

Ho

w t

o in

stal

l th

e C

on

tec

bri

dg

e ca

rd

3

Remove the front and rear panels

Remove the fan connector

3-3

1. Open the box of PRCX

3

Ho

w to

install th

e Co

ntec b

ridg

e card

Remove the heat sink

Remove the power connector

3-4

Ho

w t

o in

stal

l th

e C

on

tec

bri

dg

e ca

rd

3

2. Set the bridge card

Remove the bridge board

KXO-M4510-310

KXO-M4510-310

Example : BUS-PCI (PC)

3-5

2. Set the bridge card

3

Ho

w to

install th

e Co

ntec b

ridg

e card

Set Contec card to the bridge

Set them to the servo board

\

Insert the panel to the slit

3-6

2. Set the bridge card

Ho

w t

o in

stal

l th

e C

on

tec

bri

dg

e ca

rd

3

Fix the bridge board

Chapter 4 Specifications

Contents1. Controller ......................................................................................... 4-1

1.1 Controller basic specifications ..............................................................4-1

1.2 Robot controller external view ..............................................................4-2

1.3 Connecting the absolute battery ............................................................4-3

1.4 Replacing the absolute battery ..............................................................4-5

1.5 Connecting a regenerative unit ............................................................. 4-6

4-1

4

Sp

ecification

s

1. Controller

1.1 Controller basic specifications

Item Specifications

Applicable robots

Maximum power consumption

Dimensions

Weight

Power supply voltage

No. of axes

Drive method

Position detection method

Control method

Coordinate system

Speed setting

Acceleration/deceleration

setting

Program language

Multitask

Sequence program

Memory size

Program

Point

Teaching

Memory backup

SAFETY Emergency stop input

Break output

Operating temperature

Storage temperature

Operating humidity

CE Marking

Basic specifications

Axis control

Programming

External I/O

PC communications

General specifications

YAMAHA Cartesian robots, SCARA robots, single axis robot, pick & place robot

2500VA

W180 × H250 × D235 (main unit)

6.5kg (main unit)

Single phase AC 200V ±10%, 50/60Hz

4 axes maximum (simultaneous control: 4 axes)

AC full digital servo

Resolver

Follows Rankin Corp. specifications.

Follows Rankin Corp. specifications.

Lithium battery (service life about 4 years at 0 to 40°C)

Relay contact

Relay contact

0 to 40°C

-10 to 65°C

35 to 85% RH (no condensation)

Refer to this manual

PRCX

ISA

ISA

PC side

BUF-PC (PCI)

BUS-PC (PC) E

CARD NAME

CONTEC PART No.

BUF-PCI (PC)

BUF-PC (E)

PRCX side

BUS-PCI (PC)

BUS-PAC (PC) E

PC

PCI

ISA

c CAUTION• Specifications and appearance

are subject to change withoutprior notice.

n NOTEContact CONTEC for details on thecommunication I/F hardware usedbetween the PRCX controller and PC.

1. Controller

4-2

Sp

ecif

icat

ion

s

4

1.2 Robot controller external view

Fig. 1-2-1 Standard PRCX-E

PRCXMOTOR

XM

YM

ZM

RM

PWR

SRV

ERR

SAFETY

HOST I/F

BATT

RGEN

ACIN

X

Y

Z

R

P

N

L

N

ROBI/O

XY

ROBI/O

ZR250

10

180

235

17 139.5 15.5 15.5

204

15.5

5.5

44.8

30

80.5

100 27.6 180

Fig. 1-2-2 PRCX-E with RGU-2 option installed

PRCXMOTOR

XM

YM

ZM

RM

PWR

SRV

ERR

SAFETY

BATT

RGEN

ACIN

X

Y

Z

R

P

N

L

N

ROBI/O

XY

ROBI/O

ZR

P

N

RGEN

RGU-2

YAMAHA MOTOR CO.,LTD.

HOST I/F

235

17 139.5 15.5 15.5

204

15.5

250

10

180 4085.5

44.8 100 27.6 180

1. Controller

4-3

4

Sp

ecification

s

1.3 Connecting the absolute batteryThe absolute batteries are fully charged at factory prior to shipping. However, the batteryconnectors are left disconnected to prevent discharge.After installing the controller, always be sure to connect the absolute battery as shown inthis manual, before connecting the robot cable.

Connecting the absolute battery

For standard controller:

1) Connect the absolute battery connectors to the “BATT X, Y, Z and R” connectors onthe front right of the controller as shown below.

Fig. 1-3-1

R

Z

Y

X

R

Z

Y

X

-

For controller equipped with regenerative unit:

1) Pass the absolute battery cords along the groove of the stay so that they come out ofthe front of the controller.

Fig. 1-3-2

-

w WARNINGDo not modify the wiring orattempt to extend it. This couldcause equipment malfunctionsand breakdowns.

n NOTEThe PRCX controller batteryspecifications are the same as theRCX40 controller. Thus, the drawingsfrom the RCX40 Controller Owner’sManual have been used.

1. Controller

4-4

Sp

ecif

icat

ion

s

4

2) Connect the absolute battery connectors to the “BATT X, Y, Z and R” connectors onthe front right of the controller as shown below.

Fig. 1-3-3

* A return-to-origin incomplete alarm is issued if the absolute battery is disconnectedwhile the controller power is turned off. When shipped to the customer, the absolutebattery is not connected to the controller, so an alarm is always issued when the poweris first turned on. Please note beforehand that this is not an error.

* The battery must be charged if the controller is being used for the first time or thebackup time was exceeded while the controller power was off. The battery isautomatically charged when power is supplied to the controller. Keep power suppliedfor longer than needed to charge the battery by referring to the table below.

Battery type (B3) *1)

3.6V/2000mAh

(KS4-M53G0-100)

Hours until full charge *2)

48h

Backup time *3)

340h

*1) Yamaha exclusive battery name*2) At ambient temperature of 20°C*3) After power is off with the absolute battery fully charged.

1. Controller

4-5

4

Sp

ecification

s

1.4 Replacing the absolute batteryThe absolute battery will wear down and must be replaced as needed. For example, replacethe battery when its service life has expired or when problems with backing up data occureven when the battery charge time was long enough.Though battery wear depends on the number of charges and the ambient temperature, thebattery should generally be replaced one and a half years after being connected to thecontroller.Always charge the new battery after it is installed.The battery is automatically charged when power is supplied to the controller. Keep powersupplied for a time longer than necessary for charging by referring to the table below.

Battery type (B3) *1)

3.6V/2000mAh

(KS4-M53G0-100)

Hours until full charge *2)

48h

Backup time *3)

340h

*1) Yamaha exclusive battery name*2) At ambient temperature of 20°C*3) After power is off with the absolute battery fully charged.

Replacing the absolute battery1) Unfasten the tie strap on the battery holder.

2) Unplug the connector for the absolute battery to be replaced, and then remove theabsolute battery by pulling it towards you as seen from the front of the battery label.

Fig. 1-4-1

2

1

3) Insert the new battery slowly into the battery holder.After inserting, check that the battery is securely installed in position by the holderhook.

Fig. 1-4-2

2

1

4) Fasten the absolute battery cord with the tie strap band on the battery holder.

c CAUTIONUse caution to prevent fingers orwiring cords from being pinchedwhen inserting the absolute batteryinto the battery holder.

n NOTEThe PRCX controller batteryspecifications are the same as theRCX40 controller. Thus, the drawingsfrom the RCX40 Controller Owner’sManual have been used.

1. Controller

4-6

Sp

ecif

icat

ion

s

4

1.5 Connecting a regenerative unitWhen a regenerative unit (RGU-2) is required, connect between the RGEN connector onthe front panel of the controller and the RGEN connector on the RGU-2 regenerative unit,by using the cable that comes with the regenerative unit.

Fig. 1-5-1

Connector (RGEN)

w WARNING•The power to the controller

must be off when connectingthe generative unit to therobot controller.

•To prevent electrical shocks,never touch the RGENterminals when power issupplied to the robotcontroller.

n NOTECheck the cable and connectors forbent pins, kinks, and other damagebefore connecting.

c CAUTIONAlways securely connect the cable.Poor connection or contact failuremay cause malfunction.

n NOTEThe PRCX controller batteryspecifications are the same as theRCX40 controller. Thus, the drawingsfrom the RCX40 Controller Owner’sManual have been used.

Chapter 5 Appendix

Contents1. Definition of terms ........................................................................... 5-1

1.1 Definition of terms ................................................................................ 5-1

5-1

5

Ap

pen

dix

1. Definition of terms

1.1 Definition of terms

1. CE Directives

These are product directives requiring conformance to certain standards regardinghealth, safety and environmental factors such as for electrical machinery safety, EMCregulations, and low voltage regulations before the product can be distributed withinthe unified European marketplace.

2. CE Marking

Product directives regarding electrical machinery safety, EMC, and low voltages relatingto health, safety and environmental factors must be complied with before the productcan be distributed within the unified European marketplace. A “CE” mark is requiredby law on products conforming to these directives.

3. EMC Directive

These are directives for products that emit electromagnetic waves or whose functionmay be affected by externally generated electromagnetic waves.

4. Machinery Directive

These are safety directives for machine products ranging from ordinary householdproducts such as washing machines, to industrial machinery such as machine tools,robots and construction machinery whose moving parts represent a potential hazard.

5. Low Voltage DirectiveThese are directives for electrical products driven by AC voltages from 50 to 1,000V,and DC voltages from 75 to 1,500V.