YASKAWA MOTOMAN-ES165D, Instructions Manual

Page 1: ...SWITCHES Upon receipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOVAN ES165D INSTRUCTIONS DX100 INSTRUCTIO...

Page 2: ...ghted 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...

Page 3: ...l CAUTION Some drawings in this manual are shown with the protective covers or shields removed for clarity Be sure all covers and shields are replaced before operating this product The drawings and ph...

Page 4: ...ible 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 t...

Page 5: ...onnel CAUTION 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...

Page 6: ...of the manipulator Be sure to use a lockout device to the safeguarding when going inside Also display the sign that the operation is being performed inside the safeguarding and make sure no one close...

Page 7: ...arks or brand names for each company or corporation The indications of R and TM are omitted CAUTION Perform the following inspection procedures prior to conducting manipulator teaching If problems are...

Page 8: ...he manipulator Prior to operating the manipulator confirm the contents Figure 3 Warning Label Locations WARNING Label B Nameplate WARNING Label A WARNING Label A WARNING Label B WARNING Do not enter r...

Page 9: ...is not in use In accordance with ANSI RIA R15 06 2012 section 4 2 5 Sources of Energy use lockout tagout procedures during equipment maintenance Refer also to Section 1910 147 29CFR Part 1910 Occupat...

Page 10: ...backup must always be made before any service procedures are done and before any changes are made to options accessories or equipment Any modifications to the controller unit can cause severe personal...

Page 11: ...personnel Summary of Warning Information This manual is provided to help users establish safe conditions for operating the equipment Specific considerations and precautions are also described in the...

Page 12: ...or a response to your inquiry Please have the following information ready before you call Customer Support techsupport motoman com NOTE Please use e mail for routine inquiries only If you have an urge...

Page 13: ...Wiring 4 1 4 1 Grounding 4 1 4 2 Cable Connection 4 2 4 2 1 Connection to the Manipulator 4 2 4 2 2 Connection to the DX100 4 2 5 Basic Specifications 5 1 5 1 Basic Specifications 5 1 5 2 Part Names a...

Page 14: ...1 Grease Replenishment 9 9 9 3 1 2 Grease Exchange 9 9 9 3 2 Grease Replenishment Exchange for L Axis Speed Reducer 9 10 9 3 2 1 Grease Exchange 9 10 9 3 2 2 Grease Exchange 9 11 9 3 3 Grease Replenis...

Page 15: ...ES165D Table of Contents 10 Recommended Spare Parts 10 1 11 Parts List 11 1 11 1 S Axis Unit 11 1 11 2 L Axis Unit 11 3 11 3 URBT Axes Unit 11 5 11 4 U Arm Unit 11 8 11 5 Wrist Unit 11 10 11 6 Balanc...

Page 16: ...items information for the content of optional goods are given separately Manipulator DX100 Programming pendant Manipulator cables 3 cables between the DX100 and the Manipulator CAUTION Confirm that t...

Page 17: ...N O T P M E E S R ON TR IP PE D RE SE T OFF AVERAGE PEAK kVA kA INTERRUPT CURRENT ERDR POWER SUPPLY TYPE DX100 kVA 3PHASE NJ2960 1 60Hz SERIAL No DATE AC220V MADE IN JAPAN 50 60Hz AC200V NJ1529 THE M...

Page 18: ...caution may adversely affect performance NOTE The weight of the manipulator is approximately 1150 kg including the shipping bolts and brackets Use a wire rope strong enough to withstand the weight Shi...

Page 19: ...transport and lift it in the posture as shown in Fig 2 1 Transporting Position Fig 2 1 Transporting Position 1 piece Shipping bolt Electrical tape painted in yellow Rubber plate Details of B part Hoo...

Page 20: ...ts are painted in yellow The B shipping bolt hexagon socket head cap screw is taped in yellow Position Bolt Type Pcs A Hexagon socket head cap screw M20 X 70 mm 12 B Hexagon socket head cap screw M16...

Page 21: ...ng may result in injury or damage Do not start the manipulator or even turn ON the power before it is firmly anchored The manipulator may overturn and cause injury or damage CAUTION Do not install or...

Page 22: ...firmly mounted on a baseplate or foundation strong enough to support the manipulator and withstand reaction forces during acceleration and deceleration Construct a solid foundation with the appropria...

Page 23: ...the hexagon head bolts and anchor bolts firmly so that they will not work loose during the operation Refer to Fig 3 1 Mounting the Manipulator on Baseplate Fig 3 1 Mounting the Manipulator on Basepla...

Page 24: ...ilure to observe this warning may result in fire or electric shock CAUTION Wiring must be performed by authorized or certified personnel Failure to observe this caution may result in fire or electric...

Page 25: ...on to the Manipulator Before connecting three cables to the manipulator verify the numbers on both manipulator cables and the connectors on the connector base of the manipulator When connecting adjust...

Page 26: ...49 ES165D Fig 4 2 Manipulator Cables X21 X22 3BC 3BC 2BC 1BC X11 X11 1BC 1BC 2BC 2BC X21 X22 3BC The Manipulator Side The DX100 Side The Manipulator Side The DX100 Side The Manipulator Side The DX100...

Page 27: ...Cable Connection Fig 4 3 a Manipulator Cable Connectors Manipulator Side Fig 4 3 b Manipulator Cable Connection DX100 Side 1BC 3BC S1 AIR A 2BC 3BC molex molex molex 1BC 2BC Connector Details Manipul...

Page 28: ...20 T Axis wrist twist 360 360 200 200 Maximum Speed S Axis 1 92 rad s 110 s L Axis 1 92 rad s 110 s U Axis 1 92 rad s 110 s R Axis 3 05 rad s 175 s B Axis 2 62 rad s 150 s T Axis 4 19 rad s 240 s Allo...

Page 29: ...ensions Fig 5 2 Manipulator Base Dimensions T T B B R R U U L L S S 350 0 1 290 0 1 290 0 1 640 290 0 1 893 290 0 1 540 290 0 1 290 0 1 540 640 735 353 0 1 40 A View A 22 dia 8 holes For fixing the ma...

Page 30: ...and P Point Maximum Envelope 491 294 18 0 18 0 3050 1 4 2 5 495 348 1024 650 0 322 16 R 7 2 9 R2651 2651 491 1961 4612 225 1225 76 285 25 4 2 153 250 5 0 650 1150 60 729 727 582 701 524 0 A 945 40 220...

Page 31: ...e 5 2 S Axis Operating Range If alteration is necessary contact your YASKAWA representative in advance The interval between stoppers must be 60 or more Table 5 2 S Axis Operating Range Item Specificat...

Page 32: ...ying the angle of S axis 1 Pin drawing No HW0402104 1 1 pin 2 Stopper drawing No HW0302424 2 1 stopper 3 Hexagon socket head cap screw M20 length 45 mm 3 screws tightening torque 402 N m 4 Flat washer...

Page 33: ...5 3 The settable angle for S Axis Stopper Confirm to stabilize both sides of the protrusion with the hexagon socket head cap screws as in Fig 5 5 Properly Mounted Image on account of the limitation o...

Page 34: ...ramming pendant The limitation to the pulse Pulse Soft Limit 1st Axis SICxG400 The limitation to the pulse Pulse Soft Limit 1st Axis SICxG408 Refer to section 5 5 Alterable Operating Range Degree 0 15...

Page 35: ...60 75 90 105 120 135 150 165 180 180 165 150 135 120 105 90 75 60 45 30 15 0 15 30 45 60 75 90 105 120 135 150 165 180 Settable angle Non settable angle The Angle of S Axis Stopper for Direction The...

Page 36: ...165D Fig 5 6 a The Properly Mounted Models for S Axis Stopper The stopper is reversible Either side of the stopper can be used Installation at 180 Hexagon head screws Installation at 165 The stopper i...

Page 37: ...5 6 b The Properly Mounted Models for S Axis Stopper The stopper is reversible Either side of the stopper can be used Hexagon head screws Hexagon head screws Installation at 150 Installation at 135 Th...

Page 38: ...5 6 c The Properly Mounted Models for S Axis Stopper The stopper is reversible Either side of the stopper can be used Hexagon head screws Installation at 120 The stopper is irreversible Only this side...

Page 39: ...Range Fig 5 6 d The Properly Mounted Models for S Axis Stopper The stopper is reversible Either side of the stopper can be used Hexagon head screws Installation at 90 Installation at 75 Hexagon head s...

Page 40: ...5 6 e The Properly Mounted Models for S Axis Stopper The stopper is reversible Either side of the stopper can be used Hexagon head screws Installation at 60 The stopper is irreversible Only this side...

Page 41: ...nted Models for S Axis Stopper The stopper is reversible Either side of the stopper can be used Installation at 30 The stopper is irreversible Only this side of the stopper can be used at this angle H...

Page 42: ...WA representative for further information or assistance When the volume load is small refer to the moment arm rating shown in Fig 6 1 Moment Arm Rating The allowable total moment of inertia is calcula...

Page 43: ...is and Wrist Flange 6 1 Allowable Wrist Load Fig 6 1 Moment Arm Rating 1400 1200 1000 800 800 1000 40kg 60kg 80kg 1000 600 130kg 400 100kg 800 LB mm 600 400 LT mm 200 200 400 600 LT mm 165kg P point T...

Page 44: ...identify the alignment marks Fitting depth of inside and outside must be 8 mm or less Fig 6 2 Wrist Flange 8 8 P C D 125 P C D 92 Units mm 9 dia 2 holes depth 8 mm 10 dia 2 holes depth 8 mm Alignment...

Page 45: ...to attach or install peripheral equipment Refer to Table 7 1 Conditions for Installation Fig 7 1 Installing Peripheral Equipment 120 40 255 133 120 255 153 40 255 40 30 117 73 50 120 133 120 255 40 1...

Page 46: ...mounted on the upper arm as shown in Fig 7 2 Connectors for Internal User I O Wiring Harness and Air Line The connector pins and the terminals are assigned as shown in Fig 7 2 Connectors for Internal...

Page 47: ...with cap Prepare pin connector JL05 6A18 1P Connector for internal user I O wiring harness Casing JL05 2A22 14SC socket connector with cap Prepare pin connector JL05 6A22 14P JL05 2A20 29SC socket con...

Page 48: ...1 2 5 4 3 P P 8 7 11 10 9 P 6 13 14 15 16 17 18 12 6 10 3 8 5 1 2 7 4 9 14 16 12 11 15 13 1 2 P P 10 15 9 2 1 4 7 5 8 3 9 6 2 1 5 4 6 3 0 3mm2 12 pins 0 75mm2 6 pins 0 2mm2 4 pins 1 25mm2 4 pins 0 75m...

Page 49: ...efer to section 8 9 Overrun Tool Shock Sensor Releasing in DX100 INSTRUCTIONS for releasing the status of this overrun 2 The range of S L and U axes limit switches are set to the maximum operating ran...

Page 50: ...switch S axis operation range can be set to those ranges mentioned in Table 5 2 S Axis Operating Range 8 1 3 2 L Axis Operation Range By the L axis limit switch the L axis operation range can be set...

Page 51: ...ce Angle L and U axes interference limit switches are designed to check the interference angle of L and U axes As shown in Fig 8 3 LU Axes Interference Angle the operation range of U axis can be set t...

Page 52: ...ternal Connection Diagram Fig 8 4 Locations and Numbers of Connectors Table 8 1 List of Connector Types Name Type of Connector Connector Base Connector for internal user I O wiring harness JL05 2A28 2...

Page 53: ...FG2 SPG 2 CN1 7 CN1 6 CN1 8 SPG 3 SPG 3 FG3 CN2 3 CN2 2 CN2 1 P P P P P P SPG 4 SPG 4 FG4 CN2 7 CN2 6 CN2 8 SPG 5 SPG 5 SPG 6 FG5 CN3 6 CN3 3 CN3 2 CN3 1 PG No 7CN 20 29 1 10 BAT 0V OBT 5V FG6 BAT OBT...

Page 54: ...ME1 ME1 ME1 CN6 2 CN2 6 CN2 5 BB1 MU2 MU2 BA1 CN6 1 MW1 CN2 2 CN3 3 CN3 1 CN3 2 CN3 5 MV2 MV2 MV2 MW2 CN3 7 CN2 8 CN3 4 CN3 8 MW2 ME2 ME2 ME2 MW2 CN3 6 CN4 1 CN4 2 CN6 4 MU3 MU3 BB2 CN4 7 CN4 5 CN4 6...

Page 55: ...ay result in electric shock or injury For disassembly or repair contact your YASKAWA representative Do not remove the motor and do not release the brake Failure to observe these safety precautions may...

Page 56: ...connectors and tighten if necessary 8 Connector base Manual Check for loose connectors 9 Balancer Grease Gun Supply grease See Chap section 9 3 5 10 Wire harness in manipulator SLU axis wires RBT axis...

Page 57: ...leakage indicates the possibility that grease has seeped into the motor This can cause a motor breakdown Contact your YASKAWA representative 3 When checking for conduction with multimeter connect the...

Page 58: ...nspection Schedule 9 4 155976 1CD HW0485249 ES165D Fig 9 1 Inspection Items U AXIS 2 4 12 9 T AXIS B AXIS R AXIS S AXIS 1 1 15 16 5 1 1 1 14 13 7 10 8 11 2 L AXIS 1 7 2 4 7 Check that no grease is lea...

Page 59: ...numbers in the above table correspond to the numbers in Table 9 1 Inspection Items Table 9 2 Inspection Parts and Grease Used No Grease Used Inspected Parts 12 13 14 15 16 Molywhite RE No 00 Speed Re...

Page 60: ...e installed in the position shown in Fig 9 2 a Battery Location Back View and Fig 9 2 b Battery Location Top View If a battery alarm occurs in the DX100 replace the battery in accordance with the foll...

Page 61: ...m the battery holder 4 Connect the new battery pack to the unoccupied connector on the board 5 Remove the old battery pack from the board 6 Mount the new battery pack to the holder 7 Reinstall the pla...

Page 62: ...ll leak inside a motor or an oil seal of a speed reducer will come off which may result in damage to the motor Make sure to remove the plug screw Do not install a joint a hose etc to the grease exhaus...

Page 63: ...en tighten the plug with a tightening torque of 5 N m 0 51 kgf m 9 3 1 2 Grease Exchange Refer to Fig 9 4 S Axis Speed Reducer Diagram 1 Remove the hexagon socket head plugs PT3 8 from the exhaust por...

Page 64: ...e manipulator 4 Inject grease through the grease inlet using a grease gun Grease type Molywhite RE No 00 Amount of grease 280 cc 560 cc for 1st supply Air supply pressure of grease pump 0 3 MPa or les...

Page 65: ...rease approx 1400 cc Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 5 The grease exchange is completed when new grease appears in the grease exhaust port The ne...

Page 66: ...e inlet using a grease gun Grease type Molywhite RE No 00 Amount of grease 280 cc 560 cc for 1st supply Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 5 Move th...

Page 67: ...MPa or less Grease injection rate 8 g s or less 5 The grease exchange is complete when new grease appears in the grease exhaust port The new grease can be distinguished from the old grease by color 6...

Page 68: ...ort R and B axes speed reducer Hexagon socket head plug PT1 8 A R axis speed reducer B axis speed reducer Grease Inlet B and T axes speed reducer Hexagon socket head plug PT1 8 T axis speed reducer Gr...

Page 69: ...fer to Fig 9 7 U Arm Diagram 1 Remove the hexagon socket head plug PT1 8 from the grease exhaust port 2 Install a grease zerk A PT1 8 to the grease inlet The grease zerk is delivered with the manipula...

Page 70: ...e grease zerk from the grease inlet and reinstall the plug Before installing the plug apply Three Bond 1206C on the thread part of the plug then tighten the plug with a tightening torque of 5 N m 0 51...

Page 71: ...grease exchange is completed when new grease appears in the grease exhaust port The new grease can be distinguished from the old grease by color 5 Move the R B T Axes for a few minutes to discharge e...

Page 72: ...to Fig 9 7 U Arm Diagram 1 Remove the hexagon socket head plug PT1 8 from the grease exhaust port 2 Install a grease zerk A PT1 8 to the grease inlet The grease zerk is delivered with the manipulator...

Page 73: ...hange is completed when new grease appears in the grease exhaust port The new grease can be distinguished from the old grease by color 5 Move the T Axis for a few minutes to discharge excess grease 6...

Page 74: ...connection and using a grease gun 3 Reinstall the plugs PT1 8 of connection and Before installing the plug apply Three Bond 1206C on the thread part of the plug then tighten the plug with a tightening...

Page 75: ...s connected after the maintenance check and remove the battery packs Install the caps attached to the battery backup connectors of the motors Fig 9 9 Battery Pack Connection NOTE When performing maint...

Page 76: ...16 kg for all axes speed reducers and wrist units A 2 Grease Alvania EP Grease 2 Showa Oil Co Ltd 16 kg for balancer joint part A 3 Liquid Seal Three Bond 1206C Three Bond Co Ltd 1 1 A 4 Battery Pack...

Page 77: ...SGDR EFBA02A YASKAWA 1 1 C 22 Limit switch set for S axis HW0371747 A YASKAWA 1 1 Treatment of A01 lead terminal is done C 23 Limit switch set for L axis HW0374590 A YASKAWA 1 1 Treatment of A01 lead...

Page 78: ...65D 11 Parts List 11 1 S Axis Unit Fig 11 1 S Axis Unit 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1013 1014 1015 1016 1017 1020 1021 1023 1024 1018 1019 1025 1026 1027 1028 1029 1030 1031...

Page 79: ...1014 HW9404486 1 Shaft 1 1015 MSTH12 30 Pin 1 1016 MSTH12 40 Pin 2 1017 MSTH6 20 Pin 2 1018 KQ2L10 01S Union 1 1019 NB 1075 Tube 1 1020 PT3 8 Plug 1 1021 G415 O ring 1 1022 G105 O ring 1 1023 M6X16 S...

Page 80: ...it Fig 11 2 L Axis Unit 2001 2002 2003 2005 2006 2009 2019 2019 2009 2010 2011 2012 2012 2017 2017 2018 2018 2019 2019 2005 2007 2020 26 2020 26 2031 2032 2037 2038 2045 6004 2046 1008 2031 2032 2034...

Page 81: ...2 Shim 2 2022 HW9405195 3 Shim 1 2023 HW9405195 4 Shim 1 2024 HW9405195 5 Shim 1 2025 HW9405195 6 Shim 1 2026 HW9405195 7 Shim 1 2027 GT SA M12X35 Socket screw 4 2031 M10X50 Socket screw 18 2032 2L 1...

Page 82: ...3006 3007 3008 3011 3012 3013 3014 3015 3016 3019 3020 3021 3022 3023 3024 3024 3024 3025 3026 3027 3028 3027 3028 3035 4009 3036 3041 3042 3045 3046 3009 3027 3028 3030 3029 3039 3040 3010 3037 3038...

Page 83: ...10 O ring 1 3017 G270 O ring 1 3018 HW0401506 1 Plate 3 3019 HW0401507 1 Plate 1 3020 ISTW 36 Stopper 1 3021 IRTW 55 Stopper 1 3022 HW0402885 1 Cover 1 3023 MSTM8 20 Pin 1 3024 PT1 8 Plug 5 3025 TSH6...

Page 84: ...5249 ES165D 3046 2L 6 Spring washer 4 3047 HW9481343 A Shaft 1 3048 HW9482451 A Gear 1 3049 ISTW 12 Stopper 1 3050 SGMRV 13ANA YR2 Motor 2 2006 HW0100472 1 L arm 1 4009 HW0100172 2 U arm 1 Table 11 3...

Page 85: ...ts List 11 4 U Arm Unit 11 4 U Arm Unit Fig 11 4 U Arm Unit 4001 4030 4003 4004 4006 4006 4005 4007 4008 4009 4010 4011 4012 4013 4014 4015 4016 4017 4018 4019 4020 4021 4022 4023 4024 4025 4024 4025...

Page 86: ...arm 1 4010 HW0312106 1 Shaft 1 4011 HW0302261 A Shaft 1 4012 HW0302262 B Shaft 1 4013 HW0303948 1 Gear 1 4014 HW0303950 1 Gear 1 4015 HW0303951 1 Gear 1 4016 HW0100173 1 Housing 1 4017 HW0401508 1 Pla...

Page 87: ...03 5004 5006 5014 5015 5022 5023 5041 5045 5046 5090 5089 5024 28 5090 5005 5011 5063 66 4010 5073 5074 5100 5071 5072 5078 5094 5035 5068 5067 5007 5007 5012 5016 5017 5018 5019 5062 5039 5040 5045 5...

Page 88: ...23 1 Gear 1 5017 HW0301224 1 Gear 1 5018 HW0301225 1 Gear 1 5019 HW0301226 1 Gear 1 5020 HW0301227 1 Gear 1 5021 HW0301231 1 Gear 1 5022 HW0401509 1 Housing 1 5023 HW0401510 1 B nut 1 5024 HW0401516 1...

Page 89: ...8 2H 12 Spring washer 8 5069 M8X85 Socket screw 6 5070 2L 8 Spring washer 6 5071 M8X40 Socket screw 14 5072 2L 8 Spring washer 14 5073 M8X20 Socket screw 19 5074 2L 8 Spring washer 19 5075 M8X15 Socke...

Page 90: ...nit 11 13 155976 1CD HW0485249 ES165D 11 6 Balancer Unit Fig 11 6 Balancer Unit 2004 2008 2014 2015 2016 2013 2029 2030 6001 6002 6003 6004 6005 6006 6007 6008 6009 6010 6011 6017 6012 6012 6013 6014...

Page 91: ...lange 1 6008 HW0303581 1 Rod 1 6009 HW9405057 1 Clevis 1 6010 FD3187A0 Dust seal 1 6011 EZ2228B0 Cap 1 6012 IRTW 75 Stopper 2 6013 M6X8 Magic screw 2 6014 PT1 8 Stainless Plug 3 6015 M10X40 Socket scr...

Page 92: ...China Co Ltd 22F One Corporate Avenue No 222 Hubin Road Huangpu District Shanghai 200021 China Phone 86 21 5385 2200 Fax 86 21 5385 3299 YASKAWA Electric Thailand Co Ltd 59 1st 5th Floor Flourish Buil...