YASKAWA MH180, Operating And Maintenance Manual

Page 1: ...ROBOTICS MH180 YR MH180 A00 Operating and Maintenance Manual...

Page 2: ...le 2014 04 Rev 02 Revision of the quantity of grease 2014 06 Rev 03 Revised version of the original HW1482326 2 2014 08 Rev 04 Revised version of chapter Notes on how to refill grease 2014 09 Rev 05 R...

Page 3: ...4 1 Protection measures 19 4 2 Ambient conditions and installation location 20 4 3 Installation example 21 5 Wiring 23 5 1 Grounding 23 5 2 Cable connections 24 5 2 1 Connecting the robot 25 5 2 2 Con...

Page 4: ...ocedure 70 9 5 4 Gas injecting procedure 71 9 6 Home position calibration 72 9 6 1 Registering all axes at the time 72 9 6 2 Registering individual axes 75 9 6 3 Changing the absolute data 76 9 6 4 Cl...

Page 5: ...t background information and application advice 1 2 Frequently used terms The YASKAWA robot is a product of YASKAWA Electric Corporation GmbH The robot is normally supplied with the robot controller p...

Page 6: ...t system must receive training before they operate the robot For optimal use of our products we recommend our customers to take part in a training session at the YASKAWA Academy For more detailed info...

Page 7: ...holes or similar modifications can damage parts This will be regarded as improper use i e use that deviates from the intended use and will lead to loss of warranty and liability claims as well as los...

Page 8: ...covers or shields removed All protective covers and shields must be mounted before the robot is operated The drawings and figures in this manual are representative illustrations They may differ from t...

Page 9: ...in Menu JOB CONTENT 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 TEST01 TOOL CONTROL GROUP R1 S 0000 NOP SET B000 1 SET B001 0 MOVJ VJ 80 00 MOVJ VJ 80 00 DOUT OT 10 ON TIMER T 3 00 MOV...

Page 10: ...ge View the Robot from the front whenever possible Always follow the prescribed operating procedure see the instructions on robot control as well as the operating instructions on Handling or Universal...

Page 11: ...anufacturer Address YASKAWA ELECTRIC CORPORATION 2 1 KUROSAKISHIROISHI YAHATANISHI KU KITAKYUSHU JAPAN 1 9 Authorized representative Address YASKAWA Europe GmbH Robotics Division Yaskawastr 1 85391 Al...

Page 12: ...1 Checking the scope of delivery The standard delivery includes the following items Fig 2 1 Scope of delivery Programming pendant Assembly instruction Robot controller Cable Robot MOTOMAN MANUAL 1 2...

Page 13: ...te NOTICE Please contact the local YASKAWA branch office if the serial numbers do not match the information on the delivery note S N DX200 YASAKAW XXXXX Part No Power Supply Peak kVA AC XXXXXXXX Avera...

Page 14: ...rces may be exercised on the robot control the robot or other components 3 1 Transporting method CAUTION Damage to persons and damage to property due to external force influences External forces must...

Page 15: ...Transport by crane The robot is equipped with transport securing devices and shipping bolts to reduce external forces to a minimum during transport Using a crane Position of the center of grav ity Wir...

Page 16: ...fixed on a pallet with transport securing devices and shipping bolts Make sure that the forklift and the transportation route have sufficient bearing capacity Always take due care when transporting t...

Page 17: ...are removed After removing the transport securing devices and the shipping bolts keep them at a safe place The transport securing devices and shipping bolts will be required again if the system is tra...

Page 18: ...moved After removing the rubber pads keep them at a safe place The rubber pads will be required again if the system is transported again The robot is furnished with damping material for transportation...

Page 19: ...protective measures can lead to death of people serious bodily harm or material damage Implement the following protection measures Separating protection devices Non contact protection devices Enclosu...

Page 20: ...ons Ambient temperature From 0 C to 45 C Air humidity 20 to 80 relative humidity non condensing Free of corrosive gases liquids or explosive gases No water oil or dust and free from excessive electric...

Page 21: ...that they will not work loose during operation see figure Mounting of the robot on the base plate Fig 4 1 Mounting the robot on the base plate NOTICE YASKAWA Europe recommends to use the robot only w...

Page 22: ...obot Force and Torque Direction of move ment Horizontal Vertical Force FH Moment MH Force FV Torque MV Emergency stop Stop category 0 24000 N 37630 Nm 15680 N 49000 Nm Acceleration Decelera tion Stop...

Page 23: ...ounding Follow the applicable electrical installation standards and wiring regulations for earthing The cable cross section must be 6 mm or more With regard to the direct connection of the earthing ca...

Page 24: ...ase and on the robot controller see the following chapter on robot connection and robot controller connection Fig 5 2 Robot cable Robot control side Encoder cable 1BC Robot side Power cable 2BC DX200...

Page 25: ...er cable 2BC 2 Connect the encoder cable 1BC to the connector plate of the robot 3 Connect the power cable 2BC to the connector plate of the robot Make sure that you hear each locking clip snap into p...

Page 26: ...order 1 Connect the encoder cable 1BC X11 at 1BC connection to the robot controller 2 Connect the power cable 2BC X21 at 2BC connection to the robot controller Make sure that you hear the locking clip...

Page 27: ...PROGRAMMING PENDANT PROPERLY CHECK ALL THE DOOR LOCKS NJ3005 1 kVA kVA ERDR Average Peak NJ3053 1 Kammerfeldstr 1 D 85391 Allershausen 2 1 Kurosaki Shiroishi Yahatanishi Ku Kitakyushu City Fukuoka 80...

Page 28: ...axes 54 Wrist axes 67 Maximum speed S axis 2 18 rad s 125 s L axis 2 01 rad s 115 s U axis 2 18 rad s 125 s R axis 3 18 rad s 182 s B axis 3 05 rad s 175 s T axis 4 63 rad s 265 s Allowed moment Nm 3...

Page 29: ...1 Parts and work axis label Fig 6 1 Part names and working axes 6 2 Robot base dimension Fig 6 2 Robot base dimensions 2 holes 20 H7 Mating surfaces 8 mounting holes 22 All dimensions in mm T T B B R...

Page 30: ...Technical data 6 30 6 3 Dimensions and defined working area Fig 6 3 Dimensions and defined work area P point Working area defined with point P All dimensions in mm 2 1 1 2...

Page 31: ...he s axis may be changed depending on the type of application If any modification is necessary please contact the local YASKAWA branch office The mechanical stop can only be adjusted in 60 steps Item...

Page 32: ...rking Area To change the working area of S axis the following components are required see the following figure Fig 6 4 Components of the S axis limit 4 M16 x 35 screws strength category 12 9 and 4 M16...

Page 33: ...e set both the pulse limit and the angle of the mechanical S axis limit Fig 6 5 Adjustable angle for the S axis limit Degree 15 30 45 60 75 90 Number of pulses 0 28672 57344 86016 114688 143360 172032...

Page 34: ...an angle of 135 The model shown at an angle of 150 Screw The model shown at an angle of 105 The model shown at an angle of 120 Screw The model shown at an angle of 75 The model shown at an angle of 9...

Page 35: ...crew The model shown at an angle of 45 The model shown at an angle of 60 Screw The model shown at an angle of 15 The model shown at an angle of 30 Screw The model shown at an angle of 0 1 1 2 3 1 3 2...

Page 36: ...The actual overrun distances and overrun times may differ due to internal and external influence on the braking torque According to the mode robot application and number of triggered safety stops wit...

Page 37: ...Technical data 6 37 6 5 1 Stop category 0 6 5 1 1 Stop position S axis 100 deflection 66 deflection 33 deflection deg deg s deg s sec deg s deg s sec deg deg deg s deg s sec...

Page 38: ...Technical data 6 38 6 5 1 2 Stop position L axis 100 deflection 66 deflection 33 deflection deg deg s deg s sec deg s deg s sec deg deg deg s deg s sec...

Page 39: ...Technical data 6 39 6 5 1 3 Stop position U axis 100 deflection 66 deflection 33 deflection deg deg s deg s sec deg s deg s sec deg deg deg s deg s sec...

Page 40: ...ergency stop in category 1 are not subjected to the robot position and the load Stop of category1 doesn t depend on the robot position and the load 6 5 2 1 Stop position S axis 100 deflection 66 defle...

Page 41: ...p position L axis 100 deflection 66 deflection 33 deflection deg sec deg s deg s deg deg s deg s sec deg deg s deg s sec 1 0 0 9 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0 40 40 35 30 25 20 20 15 10 5 0 60 8...

Page 42: ...Technical data 6 42 6 5 2 3 Stop position U axis 100 deflection 66 deflection 33 deflection deg sec deg s deg s deg deg s deg s sec deg deg s deg s sec...

Page 43: ...seen at all times the tool may only be flange mounted with the inner diameter Fitting depth of inside fittings must be 8 mm NOTICE Before mounting a tool remove anticorrosive coating on the flange Th...

Page 44: ...centroidal distance of the load mass within the specifications refer to the following figure Hand loads Fig 7 2 Hand loads The peripheral devices are mounted on the upper arm of the U axis and the ro...

Page 45: ...x 14 4 threaded holes M12 x 24 2 threaded holes M5 x 9 4 threaded holes M20 x 39 2 threaded holes M6 x 11 4 threaded holes M6 x 11 A1 A2 and A3 Wiring and valve load 30 kg maximum Not more than 49 Nm...

Page 46: ...xis varies and depends on the permissible torque Contact your YASKAWA branch office in a timely manner if you have questions regarding the calculation of the load or centroidal distance Example In the...

Page 47: ...owing figure Wiring must be performed by the user The following requirements must be met The current carrying capacity per single conductor cross section 2 00 mm 0 75 mm 0 50 mm and 0 20 mm must not e...

Page 48: ...th individual wires The internal connections of the robot are shown in the following diagrams Connection diagram A and Connection diagram B used not used Connector plug for the internal cable feedthro...

Page 49: ...BAT P BAT12 0BT 5 0BAT21 0BT 0BT BAT P 1 3 2 0BAT11 BAT11 0BAT12 6 PG5V3 BAT1 BAT2 0BAT1 PG0V1 PG5V1 1 No 19CN 1 2 4 3 13 14 15 16 7 9 10 11 12 8 PG0V4 PG0V5 PG5V5 PG0V6 PG5V6 PG5V4 No 18CN P L P P OB...

Page 50: ...MV2 MV2 MW2 MW2 F 2 F 6 F 1 F 5 F 7 F 8 E 5 E 6 E 1 E 2 E 7 SM YB YB SM SM YB C No 9CN 9CN A B MW1 MU1 MV1 1 D 2 BA1 ME1 BB1 E 8 MU1 MV1 MV1 MW1 MU1 MU2 MU2 MW1 10CN A No 10CN MU2 2 C 1 D BB2 MW2 BA2...

Page 51: ...ing maintenance and inspection measures Turn OFF the main power supply Put up the required warning sign e g Do not turn the power on Install a switch on guard as prescribed If you have any questions r...

Page 52: ...MONITORING TIME DATA EDIT DISPLAY UTILITY Main Menu ShortCut CONTROL POWER TIME 1998 07 06 10 00 2385 42 02 SERVO POWER TIME 1998 07 06 10 30 36000 00 00 PLAYBACK TIME 1998 10 22 11 12 2210 00 20 MOV...

Page 53: ...Maintenance and inspection 9 53 1 Trained staff 2 YASKAWA trained staff 3 YASKAWA personnel...

Page 54: ...scharge 2 5 Fastening bolts of the base plate Using a correspond ing tool tighten loose screws replace if necessary 6 Fixing screws of the cover Using a correspond ing tool tighten loose screws replac...

Page 55: ...attery alarm appears or after the robot has been operated for 36000 hours the battery must be exchanged 12 S L U R B and T axes gear Grease gun Check for malfunctions replace if necessary The grease5...

Page 56: ...or conduction with multimeter connect the battery to BAT and OBT of the plug connections of the respective motor Then remove the connectors of the encoders of the respective motor if this is not obser...

Page 57: ...Maintenance and inspection 9 57 Fig 9 2 Inspection intervals...

Page 58: ...robot controller to the main power supply see Fig 9 4 Main power switch in switch off position 2 Remove the fixing screws from the cover plate 3 Carefully pull out the battery pack from the base NOTIC...

Page 59: ...efore having installed new battery pack 7 Please remove old battery pack plug from circuit board NOTICE Make sure that no wires are pinched when you install the battery pack and the cover plate again...

Page 60: ...attery unit connector diagram for R B and T axes Motor Battery unit Motor power connector Plug for backup Encoder connector Encoder Warning label Motor cable Power connector Battery unit Wiring harnes...

Page 61: ...sappearance of the encoder absolute data When performing maintenance such as replacement of a wire harness in the robot the encoder connector may be necessary to be removed In this case be sure to con...

Page 62: ...nstall a joint hose etc to the grease outlet If this instruction is not followed the motor will be damaged Avoid air getting into the gear Insert grease with a grease gun If an automatic lubricating p...

Page 63: ...nting the plug apply to thread part Tightening torque of sealing plug Designation Tightening torque Nm PT 3 8 23 PT 1 4 12 PT 1 8 5 PT 1 16 4 Example Amount of grease Axis types Refill grease Replace...

Page 64: ...tenance and inspection 9 64 9 4 1 Grease filling the main axes Figures the main axes S axis gear L axis gear U axis gear Grease outlet opening Grease inlet opening PT3 8 PT1 4 PT1 8 PT3 8 PT1 8 PT3 8...

Page 65: ...wrist axes 9 4 3 Grease replenishment for balancer link part Figures the wrist axes R axis gear B and T axis gear R B and T axes pinion Grease outlet opening Grease inlet opening Figure the axes Greas...

Page 66: ...e possibility of suffocation exists Therefore adequate ventilation is required during work Before you carry out the gas pressure inspection of the balancer unit or discharge of the gas i e filling che...

Page 67: ...5 2 Gas pressure inspection NOTICE Personal injury or damage to property The operation of the robot with an incorrect gas pressure in the compensating cylinder can lead to failure or breakage Run the...

Page 68: ...o Digital pressure gauge FRDSG 1 170839 Tapered roller bearing 168211 Rapid action coupling T2 770 G1 8 Valve 168213 Valve tool 168214 Thermometer to measure the surface level of the compensating cyli...

Page 69: ...n the needle valve of the gas filling device and then check that the pressure indicated on the digital pressure gauge is satisfying the value shown in table 9 5 2 2 Adequate gas pressure on page 68 De...

Page 70: ...Remove the quick connector and mount the cover then tighten the screw with flange by using a tightening torque shown in table 9 5 2 2 Adequate gas pressure 8 Turn on the power to the robot controller...

Page 71: ...er than the adequate pressure shown in table Tab 9 2 7 Slowly open the needle valve of the gas filling device 8 Release the gate valve of the gas filling device to inject gas until the gas pressure in...

Page 72: ...ition of the absolute encoder must match it Although this operation is performed prior to shipment at the factory the following cases require this operation to be performed again Change in the combina...

Page 73: ...POSITIONING window appears 3 Select DISPLAY under the menu or select PAGE to display the selection window for the control group or press PAGE The pull down menu appears 4 Select the desired control g...

Page 74: ...inspection 9 74 6 Select SELECT ALL AXES A confirmation dialog box is displayed 7 Select YES Displayed position data of all axes are registered as home position When NO is selected the registration w...

Page 75: ...module to be calibrated e g R1 ROBOT Perform steps 3 and 4 which have been described in Registering All Axes at One Time to select the desired control group 4 Select the axis to be registered A confi...

Page 76: ...t ROBOT from the main menu 2 Select HOME POSITION 3 Select the desired control group Perform steps 3 and 4 which have been described in chapter Registering All Axes at One Time to select the desired c...

Page 77: ...have been described in Registering All Axes at One Time to display the HOME POSITIONING window and select the desired control group 3 Select DATA under the menu The pull down menu appears 4 Select CLE...

Page 78: ...xis keys and perform the position confirmation For performing the position confirmation refer to chapter Procedure after the Alarm Playback and test runs will not function unless CONFIRM POSITION is p...

Page 79: ...ith a robot that has no brake it is possible to enable playback without position checking after the alarm occurs However as a rule always perform CONFIRM POSITION Under the above special conditions th...

Page 80: ...ears The Message Available to move to and modify specified point shown 3 Press the page key PAGE or select PAGE to display the selection window for the control group The group axes by which the second...

Page 81: ...ion if the PG system is found to be the cause of the alarm perform the necessary operation such as replacing the PG system etc The robot current position data when turning main power supply ON and OFF...

Page 82: ...g operations or if the following events occur Replacement of motors Replacement of Encoders Discharging the battery of the robot The home position data is stored by the backup battery In the case of a...

Page 83: ...hen the de vice is on LED CHG Charge Lights up when the power cable is inserted and when the battery is being charged LED BAT Battery Lights up when the battery must be charged The devices runtime wit...

Page 84: ...emely dirty conditions Strong movements or vibrations Strong magnetic fields For cleaning use a clean and dry cloth Never use liquids or aggressive cleaning agents The device must not be used in a pot...

Page 85: ...bot to home position as otherwise errors might occur if axes are coupled 3 Insert the CF data transmission card of the reset to zero device in the opening of the programming pendant Fig 9 8 Inserting...

Page 86: ...annex 1 Drive the axis in position so that the marking on the screw in point of the reset sensor coincides with the corresponding alignment marking The markings differ depending on the type of robot...

Page 87: ...ogramming pendant 12 Press Zeroing on the screen A window with a warning message opens If you have followed all the previously described steps then you fulfilled all the points stated on the list and...

Page 88: ...ing pendant 23 Press FWD to move the TCP in the second home position 24 Check if the second home position deviates from your required position 25 Press MAIN MENU CONFIRM POSITION DATA A message Home p...

Page 89: ...the sensor for de formations Carry out a new reset Switch to TEACH mode Again execute zeroing The mode switch on the pro gramming pendant is in the Play Mode position when starting the reset Switch t...

Page 90: ...reset again Alarm Sensor amp battery The battery of the amplifier is empty Replace the battery Alarm Sensor amp write error EEPROM Amplifier EEPROM writing er ror Contact the local YASKAWA branch off...

Page 91: ...e to an er ror Confirm the error message and eliminate the error Repeat the reset from the begin ning Finished Error occur Operator stop The reset is ended with the Stop switch Repeat the reset from t...

Page 92: ...Battery pack Robot 128708 Battery pack Controller 155543 Wire harness HW1171456 A 164778 Power input module HW1371448 A 164779 Wrist unit HW1171565 A 164791 Balancer unit HW1382567 A 164777 Battery bo...

Page 93: ...SF22B E 169501 General I O board PNP Type JANCD YIO22 E 164762 Power ON unit Cat 4 JZRCR YPU52 1 164764 Axis board SRDA EAXA21A 170650 Converter module SRDA COA30A21B E 164767 Capacitor module 12A Typ...

Page 94: ...1 S axis drive 1002 1031 1032 1027 1028 1004 1024 1025 1005 1029 1030 1006 1008 1042 1043 1015 1003 1001 1012 1013 1016 1018 1019 1014 1011 1020 1021 1017 1010 1033 1047 1026 1034 1009 1022 1023 1007...

Page 95: ...3 8 Sealing plug 1 1016 G415 O ring 1 1017 G130 O ring 1 1018 M12 x 50 Screw 16 1019 SW2H 12 Washer 16 1020 M8 x 45 Screw 1 1021 2L 8 Washer 1 1022 M6 x 16 Screw 6 1023 2L 6 Washer 6 1024 M16 x 55 Scr...

Page 96: ...sts 11 96 Tab 11 1 Parts list S axis drive 1042 M16 x 35 Screw 4 1043 2H 16 Washer 4 1044 HW0402104 1 Pin 1 1045 HW1404681 1 Shaft 2 1046 M6 x 30 Screw 2 1047 HW1405024 1 Gasket 1 No DWG no Designatio...

Page 97: ...2029 2032 2031 1008 2027 2009 2026 2025 2022 2028 2028 2016 2011 2010 2004 2045 2047 2046 2044 2028 2053 2007 2021 2060 2061 2056 2057 2018 2073 2073 2066 2067 2064 2072 2071 2054 2017 2026 2025 2063...

Page 98: ...2L 8 Washer 36 2027 PT3 8 Sealing plug 1 2028 PT1 8 Sealing plug 7 2029 M12 x 30 Screw 23 2030 2H 12 Washer 23 2031 M16 x 35 Screw 6 2032 2H 16 Washer 6 2033 M12 x 75 Screw 25 2034 2H 12 Washer 25 20...

Page 99: ...M4 x 6 Screw 2 2068 2L 4 Washer 2 2069 HW1304369 A Cover 1 2070 M6 x 16 Screw 3 2071 2H 6 Washer 3 2072 M6 Washer 3 2073 M5 x 10 Screw 2 2074 2L 5 Washer 2 2075 HW1406698 1 Cover 1 2076 M6 x 16 Screw...

Page 100: ...3002 HW0402406 1 Sleeve 1 3031 3013 3015 3030 3001 3028 3005 3004 3002 3008 3009 3003 3007 3025 3026 3014 3024 3016 3019 3020 3021 3022 3023 3027 3010 3011 R axis B axis T axis 3029 3017 3018 3012 300...

Page 101: ...3017 M12 x 55 Screw 16 3018 2H 12 Washer 16 3019 M10 x 25 Screw 18 3020 2L 10 Washer 18 3021 M16 x 35 Screw 6 3022 2H 16 Washer 6 3023 HW0481083 A Screw 1 3024 ISTW 12 Circlip 1 3025 HW1303890 1 Gear...

Page 102: ...ip 1 4005 AC2847F3 NOK Oil seal 1 4006 NK25 20R Bearing 1 4007 WR20 Terminal 1 4008 LRT202526 Bearing 1 4009 HW0386260 A Gear 1 4010 HR32017XJ Bearing 1 4011 AC3842 F1 FKM Oil seal 1 3012 4027 4027 40...

Page 103: ...1 4020 HW0303951 1 Gear 1 4021 M8 x 20 Screw 1 4022 2L 8 Washer 1 4023 M4 x 6 Screw 1 4024 M8 x 20 Screw 6 4025 2L 8 Washer 6 4026 PT1 8 Sealing plug 1 4027 HR32006XJ Bearing 2 4028 M8 x 95 Screw 16 4...

Page 104: ...908DB Bearing 1 5010 HW0401511 1 Holder 1 5029 4012 5016 5087 5017 5018 5040 5041 5024 5026 5025 5046 5034 5035 5042 5089 5045 5092 5093 5057 5061 5065 5043 5044 5095 5050 5047 5004 5094 5023 5027 502...

Page 105: ...618 1 Housing 1 5029 M6 x 15 Screw 5 5030 HW0301224 1 Gear 1 5031 HW0301225 1 Gear 1 5032 HW0401514 1 Nut 2 5033 M5 x 7 Screw 4 5034 M8 x 20 Screw 3 5035 2L 8 Washer 3 5036 HW9403617 1 Housing 1 5037...

Page 106: ...x 20 Screw 16 5079 2HL 8 Washer 16 5080 HW9403623 Adjusting washer 1 5084 M4 x 16 Screw 4 5085 M4 x 8 Screw 8 5086 2L 4 Washer 12 5087 HW0301231 1 Gear 1 5088 HW0301230 1 Gear 1 5089 HW0301226 1 Gear...

Page 107: ...Parts lists 11 107...

Page 108: ...yin 972 3 9004114 NL YASKAWA Benelux B V Son 31 40 2895500 PL YASKAWA Polska Sp z o o Wroc aw 48 71 7928670 RUS YASKAWA Nordic AB Moskva 46 480 417 800 SE YASKAWA Nordic AB Tors s 46 480 417 800 SI YA...