YASKAWA MOTOMAN-EPX1750, Instructions Manual

Page 1: ...ial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN EPX1750 EPX2800 INSTRUCTIONS NX100 INSTRUCTIONS NX100 INSTRUCTIONS EPX INSTRUCTION SUPPLEMENTS NX100 OPERATOR S MANUAL FOR PAINTING NX100 MAINTENANCE MANUAL The NX100 operator s manual above corresponds to specific usage Be sure to use the appropriate manual 1 of 66 ...

Page 2: ... property of Yaskawa and may not be sold or redistributed in any way You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files to another website blog cloud storage site or any other means of storing or distributing online content Printed in the United States of America First Printing 2015 Yaskawa America Inc Motoman Robotics Divisio...

Page 3: ...oved for clarity Be sure all covers and shields are replaced before operating this product The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product YASKAWA may modify this model without notice when necessary due to product improvements modifications or changes in specifications If such modification is made the manual number...

Page 4: ...e for providing adequately trained personnel to operate program and maintain the equipment NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE PROGRAM OR REPAIR THE EQUIPMENT We recommend approved Yaskawa training courses for all personnel involved with the operation programming or repair of the equipment This equipment has been tested and found to comply with the limits for a Class A digital device pursua...

Page 5: ...ot avoided could result in death or serious injury to personnel Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to personnel Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury to personnel and damage to equipment It may also be used to alert against unsafe practices Always be sure to fol...

Page 6: ...Release of Emergency Stop Observe the following precautions when performing teaching operations within the P point maximum envelope of the manipulator View the manipulator from the front whenever possible Always follow the predetermined operating procedure Ensure that you have a safe place to retreat in case of emergency Improper or unintended manipulator operation may result in injury Confirm tha...

Page 7: ...heck for problems in manipulator movement Check for damage to insulation and sheathing of external wires Always return the programming pendant to the hook on the NX100 cabinet after use The programming pendant can be damaged if it is left in the P point maximum envelope of the manipulator on the floor or near fixtures Read and understand the Explanation of Warning Labels in the NX100 Instructions ...

Page 8: ...ollow the warnings on the labels Neglect of this warning may cause a serious accident To find these labels please refer the Manipulator Instruction book The following warning labels are attached to the NX100 Always follow the warnings on the labels Neglect of this warning may cause a serious accident To find these labels please refer the Manipulator Instruction book WARNING Do not enter robot work...

Page 9: ...In this manual the equipment is designated as follows Description of the Operation Procedure In the explanation of the operation procedure the expression Select means that the cursor is moved to the object item and the SELECT key is pressed or that the item is directly selected by touching the screen Equipment Manual Designation NX100 controller NX100 NX100 programming pendant Programming pendant ...

Page 10: ...ours for a response to your inquiry Please have the following information ready before you call Customer Support techsupport motoman com Please use e mail for routine inquiries only If you have an urgent or emergency need for service replacement parts or information you must contact Motoman Customer Support at the telephone number shown above System EPX1750 EPX2050 Robots _________________________...

Page 11: ...tion 4 1 4 2 Receiving and Handling 4 2 4 3 Transport 4 3 4 3 1 Transporting Method 4 3 4 3 2 Shipping Bolts and Brackets 4 5 4 4 Installation 4 6 4 4 1 Installation of Safeguarding 4 7 4 4 2 Mounting Procedures for Manipulator Base 4 7 4 4 3 Mounting the Manipulator on the Baseplate 4 8 4 4 4 Mounting Manipulator Directly on the Floor 4 9 4 4 5 Location 4 10 4 4 6 Controller and Programming Penda...

Page 12: ...n 5 5 5 3 Internal Connections 5 5 6 System Configuration 6 1 Manipulator 6 1 6 2 Robot Controller 6 3 6 3 Pneumatic Unit 6 3 6 4 O Ring and X Ring in the Wrist 6 5 7 Basic Specifications 7 1 Basic Specifications 7 1 7 2 Wrist Flange 7 2 7 3 System Application 7 3 8 Frequent Inspections 8 1 Frequent Inspections 8 1 8 2 Daily Inspections 8 3 8 2 1 Manipulator 8 3 8 2 2 Pneumatic Unit 8 4 8 2 3 Safe...

Page 13: ...ed Reducers 9 7 9 2 3 Tightening Bolts 9 8 9 2 4 Wrist Speed Reducer and Bearing 9 9 9 2 5 Air Sealings for Internal Air Pressure 9 10 9 3 Maintenance and Inspection of the Pneumatic Unit 9 12 9 3 1 Solenoid Valve 9 12 9 3 2 Pressure Reducing Valve 9 12 9 4 Inspection of Explosion Proof Devices 9 13 9 4 1 Pressure Switch 9 13 9 4 2 Master Valve 9 13 9 4 3 Pressurized Anti Explosion Barrier 9 13 10...

Page 14: ...s may cause a serious accident When on standby the manipulator can be moved by an external signal To avoid these accidents caused by a lack of information put up a board or indicator lamp to show the robot operation status Action to be taken in case of a failure or an accident Appoint a person to be contacted and the action to be taken in case of a failure or an accident Safety standards and the s...

Page 15: ... stop the manipulator and turn OFF the main power supply to the NX100 Brake release Option A braking system is provided on each axis of the manipulator to hold the arm in its position when a failure or fault occurs When the brake is activated the manipulator cannot be moved manually even if the power is OFF To change the posture of the manipulator after a failure or fault the brake can be released...

Page 16: ...Mutual FM Research Approval Guide They have the construction of protection as follows Method of Protection The pressurized explosion proof method prevents explosive gas from entering the manipulator by supplying a protective gas such as clean air or an inert gas to keep the internal air pressure constant The Intrinsic safety explosion proof method prevents explosive gas from igniting by electric s...

Page 17: ...rator through the operation procedures Large capacity backup as a standard A large capacity drive for PC cards is provided as a standard feature of backup unit and enables data to be transmitted easily High reliability The built in microcomputer continuously checks the I O data and the manipulator motion to ensure high reliability Can detect power supply faults and software faults with its self di...

Page 18: ...N OFF Gun tilt switching Pressurized explo sion proof enclosure Required pressure 0 35 MPa to 0 65 MPa Capacity For turning the spray ON OFF 30 N min For switching the tilt of the gun 30 N min For the pressurized explosion proof 30 N min usually 1000 N min when purging Dryness Freezing at 18 C Use dry air for the pressurized explosion proof construction 3 Grounding Grounding resistance 100 ohm or ...

Page 19: ... 0 to 45 C 90 RH Pneumatic unit not explosion proof 0 to 45 C 85 RH Programming pendant not explosion proof 0 to 40 C 85 RH Programming pendant explosion proof Option 0 to 40 C 85 RH Conveyor speed detector not explosion proof 0 to 50 C 90 RH Conveyor speed detector explosion proof 0 to 50 C 90 RH Conveyor switch explosion proof 0 to 50 C 90 RH Workpiece supplier explosion proof 0 to 50 C 85 RH Co...

Page 20: ...ed 2 Clean working place that is clearly defined and free of obstacles 3 Appointment of personnel in charge 4 Company working regulations for safe operation 4 1 Preparation Before installing the MOTOMAN do the following 1 Confirm the installation layout and the dimensions of each device to ensure the transportation route and the installation space 2 Check if the transportation route can support th...

Page 21: ...er Number Labels Confirm that the manipulator and the NX100 have the same order number Special care must be taken when more than one manipulator is to be installed If the numbers do not match manipulators may not perform as expected and cause injury or damage CAUTION ORDER No Label Enlarged View a NX100 Front View b Manipulator Side View THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NU...

Page 22: ... to observe this caution may adversely affect performance The mass of the manipulator is approximately 900 kg including the shipping bolts and brackets Use a wire rope strong enough to withstand the mass The attached eyebolts are designed to support the manipulator mass Never use them for anything other than transporting the manipulator Mount the shipping bolts and brackets before transporting the...

Page 23: ...manipulator with a wire rope using the attached eyebolts Make sure to fix the manipulator with shipping bolts and brackets before transport and lift it in the posture as shown in Fig 4 2 Transport Using a Crane Fig 4 2 Transport Using a Crane before shipment Fixed to the manipulater Shipping bolt and bracket before shipment Fixed to the manipulater Eyebolt M20 23 of 66 ...

Page 24: ... 4 3 Transport Using a Forklift 4 3 2 Shipping Bolts and Brackets The manipulator is provided with shipping bolts and brackets at positions as shown in the figures in Fig 4 2 Transport Using a Crane to protect its driving units from various external force during transport The shipping brackets are painted yellow Before turning ON the power check to be sure that the shipping bolts and brackets have...

Page 25: ...ipulator or even turn ON the power before it is firmly anchored The manipulator may overturn and cause injury or damage Do not install or operate a manipulator that is damaged or lacks parts Failure to observe this caution may cause injury or damage Do not install the paint gun and the gun brackets until the manipulator is firmly anchored Any contact to the unstable manipulator may cause injury or...

Page 26: ...imeter guarding awareness barriers and awareness signals 4 4 2 Mounting Procedures for Manipulator Base The manipulator should be firmly mounted on a baseplate or foundation strong enough to support the manipulator and withstand repulsion forces during acceleration and deceleration Construct a solid foundation with the appropriate thickness to withstand maximum repulsion force of the manipulator R...

Page 27: ...rrect relative position The thickness of the baseplate is 40 mm or more and an M16 size or larger anchor bolt is recommended Fix the manipulator base to the baseplate with the hexagon socket head cap screws M16 8 screws length of 70 mm or more is recommended using mounting holes on the manipulator base Tighten the hexagon socket head cap screws and anchor bolts securely so that they will not work ...

Page 28: ...kness to withstand maximum repulsion forces of the manipulator As a rough standard when there is a concrete thickness floor of 150 mm or more the manipulator base can be fixed directly on the floor with M16 anchor bolts Make the floor surface even and repair all the cracks A non concrete floor or a concrete floor less than 150 mm thick is insufficient to install the manipulator directly Fig 4 5 Mo...

Page 29: ...m space of 60 cm around the controller for maintenance When the suffi cient space is not available provide equipment for maintenance such as a drawing out system An exhaust fan is provided on the back of the controller Keep enough space behind the controller so that air can be exhausted properly Do not install the controller and programming pendant close to any noise source such as the power suppl...

Page 30: ...wer supply OFF and put up a warning sign ex DO NOT TURN THE POWER ON Failure to observe this warning may result in fire or electric shock Wiring must be performed by authorized or certified personnel Failure to observe this caution may result in fire or electric shock Do not cover the cable with heat insulating material and avoid multiple cabling Failure to observe this caution may result in burn ...

Page 31: ... connectors named 1BC 1 2 3 4 5 6 7 and 2BC 1 3 4 6 3BC 1 2 and 3 on both cables and manipulator Then connect each connector of cables to same named connector of Manipulator Fix the plate of cables 6 bolts M6 4 bolts 12 mm long and 2 bolts 20 mm long recommended with spring washers and washers The air hose for the pressure switch the intrinsically safe cable and the crimped terminals should be pre...

Page 32: ...5 Connection 5 2 Cable Connection 5 3 154771 1CD HW1480052 Fig 5 3 Manipulator Cable Connection 32 of 66 ...

Page 33: ...ig 5 4 Metal Pipe Construction Example Construct the signal cable and the peripheral device coupling cable as mention above The metal pipe must have enough strength For the explosion proof approved parts use neither sealing fitting nor sealing compound other than the above mentioned model Manufacturer Cooper Industrial Inc or equivalent NOTE 33 of 66 ...

Page 34: ...al connections and Fig 5 5 c Intrinsically Safe Circuit Diagram shows the Intrinsically Safe Circuit Diagram Use Connection Type Power supply cable Power source to from controller CVV 3 5SQ 4C Intrinsically safe signal line cable Manipulator to from controller CVV 1 25SQ 2Cx2 Cable for conveyor speed detection device To from controller CVV SB 1 25SQ 3C Cable for optional equipment To from controll...

Page 35: ...5 Connection 5 3 Internal Connections 5 6 154771 1CD HW1480052 EPX1750 EPX2050 Fig 5 5 a Internal Connection Diagram 35 of 66 ...

Page 36: ...5 7 154771 1CD HW1480052 5 Connection 5 3 Internal Connections EPX1750 EPX2050 Fig 5 5 b Internal Connection Diagram 36 of 66 ...

Page 37: ...5 Connection 5 3 Internal Connections 5 8 154771 1CD HW1480052 Fig 5 5 c Intrinsically Safe Circuit Diagram 37 of 66 ...

Page 38: ...cally articulated operation mode with 6 degrees of freedom on the manipulator base The motion of the manipulator is made by six axis The three main axes are used for positioning the spray gun the S axis which turns the arm the L axis which moves the arm left and right and the U axis which moves the arm up and down The three wrist axis are used for changing the direction of the spray gun the R B an...

Page 39: ...6 System Configuration 6 1 Manipulator 6 2 154771 1CD HW1480052 Fig 6 1 System Configuration Fig 6 2 Dimensions and P point Maximum Envelope 39 of 66 ...

Page 40: ...t Air Circuit and Fig 6 4 Pneumatic Unit External View Set the air pressure so that the pressure shown on the pressure gauge of each pressure reducing valve will be within the pressure ranges shown in Fig 6 3 Pneumatic Unit Air Circuit The power supply of the robot controller is 200 220 VAC Be sure to turn OFF the primary power supply of the controller before starting maintenance Failure to observ...

Page 41: ...requested to strictly observe that the supply air is between 0 35 MPa to 0 65 MPa The pressurized explosion proof will not operate properly without the required amount of air pressure if air pressure is low If increase the air pressure the pneumatics equipment for the pressurized explosion proof system will be caused for equipment damage CAUTION 41 of 66 ...

Page 42: ...he O ring and X ring in the wrist Contact your Yaskawa representative to replace the ring When the wrist is cleaned two or three times a week with the recovered thinner the O rings may become deformed which causes malfunctions Contact your Yaskawa representative for more information about the O ring made of special material option 42 of 66 ...

Page 43: ... of Motion S axis turning 90 L axis lower arm 100 50 U axis upper arm 6 163 5 163 R axis wrist roll 360 B axis wrist pitch yaw 360 T axis wrist twist 360 Maximum Speed 2 m s Allowable Moment R axis 45 8 N m 4 67 kgf m B axis 33 8 N m 3 45 kgf m T axis 10 8 N m 1 1 kgf m Allowable Moment of Inertia GD2 4 R axis 1 45 kg m2 B axis 0 79 kg m2 T axis 0 1 kg m2 Approx Mass 530 kg 540 kg Ambient Conditio...

Page 44: ...ons 7 2 Wrist Flange 7 2 154771 1CD HW1480052 7 2 Wrist Flange The wrist flange dimensions are shown in Fig 7 1 Wrist Flange Fitting depth of inside and outside fittings must be 7 mm or less Fig 7 1 Wrist Flange 44 of 66 ...

Page 45: ... 7 3 System Application The device required for the system application can be mounted on the horizontal arm Observe the following restriction Maximum allowable load 15 kg Mounting Position Refer to Fig 7 2 Device Mounting Position Fig 7 2 Device Mounting Position 45 of 66 ...

Page 46: ...ion does not change Do not enter the robot working envelope 2 Noise and vibration during operation No abnormal noise and vibration during robot operation Do not enter the robot working envelope 3 Tubes No severe wear and tear on paint and air supply tubes Use a pair of protective glasses to protect your eyes against paint or thinner that is being removed Make sure that the air tube is firmly inser...

Page 47: ...of the photoelectric intru sion detecting switch Dried paint 1 The manipulator stops when the photoelectric switch is turned OFF 2 Remove the dried paint on the light beam detector 3 Operation of limit switch Dried paint 1 Normal operation of the limit switch 2 Remove the dried paint on the limit switch Options 1 Operation of the gun tilt switching The gun tilt changes correctly when air is suppli...

Page 48: ...s of the motor on each axis when the air is supplied in the manipulator to form the anti explosion barrier The actual amount of air leakage is not important if a fault in the internal air pressure does not occur However if internal air pressure faults occur frequently check if the pressure of the air source and the pressure setting of the pressure reducing valve are correct and if excessive air is...

Page 49: ... to be within the specified range 8 2 3 Safety Devices Emergency Stop Button and Safety Plug Before operating the manipulator check the following to make sure that the emergency stop button and the safety plug operate correctly The manipulator stops immediately when the emergency stop button is pressed The manipulator stops immediately when the safety plug is pulled out Inspect the manipulator whi...

Page 50: ...witches for positioning workpieces starting the robot and return the robot to home operate correctly Remove any dried paint that may obstruct the robot motion 8 2 4 Options Gun Tilt Switching Check if the gun changes its tilt smoothly when compressed air is supplied If excessive shock is applied on both ends reduce the pressure supplied to the actuator Shear Pin Disconnect the air supply tube and ...

Page 51: ...ilure to observe these safety precautions may result in death or serious injury from unexpected turning of the manipulator s arm Before maintenance or inspection be sure to turn the main power supply OFF and put up a warning sign ex DO NOT TURN THE POWER ON Failure to observe this warning may result in electric shock or injury The battery pack must be connected before removing detection connector ...

Page 52: ...e inspection interval must be based on the servo power supply ON time Maintenance and Inspection Item Schedule Operation Inspection Charge 1000H Cycle 6000H Cycle 12000H Cycle 24000H Cycle 36000H Cycle Specified Personnel Licensee Service Company Inspection replacement and grease replenishment replacement of bearing speed reducers and gears a Refer to Section 9 2 Gear inside the wires Replenish gr...

Page 53: ... Check for the wears on the protective spring Motor Connector Check if the connectors are securely inserted Insert the connector securely if it is loose Battery in manipulator Replacement of the battery Replace Replace the battery when the battery alarm is displayed on the XRC Overhaul Contact your Yaskawa repre sentative a When replenishing or replacing the grease be careful not to let any grease...

Page 54: ...h or replace the grease for the following 1 Gears on the wrist and the end of the U arm 2 RV speed reducers for the S L and U axis Gears Remove the cover and the plug Inject Alvania EP grease 2 by using a grease gun to the gear teeth See Fig 9 1 Injecting Grease at Wrist and End of U arm PX2850 A10 and Fig 9 2 Injecting Grease at R B T axis Gear Fig 9 1 Injecting Grease at Wrist and End of U arm P...

Page 55: ...e 2 Inject grease into the Si Li Ui grease inlet with the injecting pressure of 0 3 Mpa or less and injecting speed of 8 0 g s or less Ass for L and U axis before injecting If grease is added without removing the plug the internal pressure will be higher and may damage it It is absolutely necessary to remove the plug When injecting grease into the L axis speed reducer grease may come out from the ...

Page 56: ... excessive grease 5 Wipe the exhaust ports with a cloth and reinstall plugs in the So Lo Uo exhaust port Apply three Bond 4501 on screwed parts Reinstall the cover on the L axis motor side Fig 9 3 S axis RV Speed Reducer Fig 9 4 L Axis RV Speed Reducer Grease type Molywhite RE No 00 Amount of grease S axis 1700 cc L axis 2000 cc U axis 900 cc If the plug So Lo Uo is installed while the grease is b...

Page 57: ... Reducer 9 2 2 Lubricating Oil Replacement R B and T Axis Speed Reducers Contact your Yaskawa representative because motors and drive shafts for the R B and T axis need to be removed to replace the lubricating oil Recommend lubricating oil Renolin PG220 made by Fuchs Lubricants Co Viscosity ISO VG200 57 of 66 ...

Page 58: ...nipulator 9 8 154771 1CD HW0485080 9 2 3 Tightening Bolts Tighten the bolts shown in Fig 9 6 Manipulator Base Box Fixing Bolts to Fig 9 8 Terminal Box in Manipulator Base Box Fig 9 6 Manipulator Base Box Fixing Bolts Fig 9 7 Wrist Fixing Bolts 58 of 66 ...

Page 59: ...othly or not If the wrist does not move smoothly contact your Yaskawa representative Removing and disassembling the wrist to find the faulty axis will be needed for repair or replacement of the bearing the speed reducer or the sealing compounds To remove the wrist from the U arm firmly hold the wrist and remove the fixing bolt If not the wrist may fall down when the fixing bolt is removed CAUTION ...

Page 60: ...the cable inlet in the motor case and check the packing where the cover is attached Excessive oil in the air that is used for the internal air pressure can damage the packing which results in air leakage Replace the packing if air leakage is found Refer to Fig 9 9 S and L axis Motor Packings and Fig 9 10 R B and T axis Motor Packing for more information on the packing on each axis motor Fig 9 9 S ...

Page 61: ... 11 154771 1CD HW0485080 Manipulator Base Box Cover Packing Remove the two covers on the back side of the manipulator base box and check the rubber packing Refer to Fig 9 11 Manipulator Base Box Rubber Packing Fig 9 11 Manipulator Base Box Rubber Packing 61 of 66 ...

Page 62: ...ing ON the power to the NX100 and if it ends approximately 8 5 minutes later 9 3 2 Pressure Reducing Valve Measure the air pressure for the pneumatic unit with a pressure gauge Remove the test plug or the relief valve on the pneumatic unit and connect the gauge The air pressure must always be from 0 02 MPa 0 2 kg cm2 to 0 04 MPa 0 4 kg cm2 under normal conditions and from 0 3 MPa 3 0 kg cm2 to 0 4...

Page 63: ...r valve during the air purge 9 4 3 Pressurized Anti Explosion Barrier While the air is being supplied from the pneumatic unit check if the air purge starts a few seconds after the power to the NX100 is turned ON and if it ends approximately 8 5 minutes later Also check the following a The alarm AIR PRESSURE ERROR occurs immediately after the air supply from the pneumatic unit is stopped and the po...

Page 64: ...er Unit Remarks A 1 Sealing compound DB 1600 Diabond Industries Co Ltd 200ml For packing A 2 Seal tape TB 4501 Three Bond Co Ltd For plug seal A 3 Grease Alvania EP grease 2 Showa Oil Co Ltd 16 kg For bevel gear in wrist and R B and T axes scissors gear A 4 Grease VIGO grease RE No 0 Yaskawa 16 kg For RV speed reducer A 5 Lubricating oi Renolin PG220 Fuchs Lubricants Co 10l Alpha Getriebebau speed...

Page 65: ...rnal Cable HW0373190 A Yaskawa 1 1 For L axis motor C 18 Internal Cable HW0373191 A Yaskawa 1 1 For L axis encoder C 19 Internal Cable HW0272858 A Yaskawa 1 1 For R B and T axis C 20 Internal Cable HW0373189 A Yaskawa 1 1 For U axis 21 Internal Cable HW0472242 A Yaskawa 1 1 Battery Cable Fig 10 1 Spare Parts for MOTOMAN EPX1750 EPX2050 Rank Part No Name Type Manufacturer Qty Qty per Unit Remarks 6...

Page 66: ... 2858 Fax 86 10 6788 2878 YASKAWA SHOUGANG ROBOT Co Ltd 426 Udyog Vihar Phase IV Gurgaon Haryana India Fax 91 124 475 8542 Phone 91 124 475 8500 YASKAWA India Private Ltd Robotics Division YASKAWA Electric China Co Ltd 22 F One Corporate Avenue No 222 Hubin Road Huangpu District Shanghai 200021 China Phone 86 21 5385 2200 Fax 㧗86 21 5385 3299 YASKAWA Electric Thailand Co Ltd 252 125 126 27th Floor...