YASKAWA MOTOMAN-MH600, Instructions Manual

Page 1: ...nitial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN XXX INSTRUCTIONS DX200 INSTRUCTIONS DX200 OPERATOR S MANUAL for each purpose DX200 MAIN...

Page 2: ...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 phot...

Page 3: ...ates 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 MANDATOR...

Page 4: ...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 closes the safeguarding View the...

Page 5: ...prior to conducting manipulator teaching If problems are found repair them immediately and be sure that all other necessary processing has been performed Check for problems in manipulator movement Che...

Page 6: ...uipped manipulator Fig Warning Label Location Nameplate WARNING label B WARNING label A WARNING label A Nameplate WARNING Do not enter robot work area WARNING Moving parts may cause injury WARNING Lab...

Page 7: ...ly on the Floor 3 4 3 3 Protection Class 3 5 3 4 Location 3 5 4 Wiring 4 1 4 1 Grounding 4 2 4 2 Manipulator Cable Connection 4 3 4 2 1 Connection to the Manipulator 4 3 4 2 2 Connection to the DX200...

Page 8: ...dule 9 1 9 2 Notes on Maintenance Procedures 9 5 9 2 1 Battery Pack Replacement 9 5 9 3 Grease Replenishment Exchange 9 7 9 3 1 Notes on Grease Replenishment Exchange Procedures 9 7 9 3 2 Grease Reple...

Page 9: ...Bearing 9 20 9 3 9 Grease Replenishment for Tapered Roller Bearing in the Link Part 9 21 9 3 10 Grease Replenishment for Balancer Link Part 9 22 9 4 Notes for Maintenance 9 23 10 Recommended Spare Pa...

Page 10: ...tems Information for the content of optional goods is given separately Manipulator DX200 Programming pendant Manipulator cables 3 cables between the DX200 and the manipulator CAUTION Confirm that the...

Page 11: ...manipulator corresponds to the DX200 The order number is located on a label as shown below Fig 1 1 Location of Order Number Labels THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER ORDE...

Page 12: ...it Be sure the manipulator is lifted in the posture as shown in fig 2 1 Transporting Position Fig 2 1 Transporting Position CAUTION Sling and crane or forklift operations must be performed by authoriz...

Page 13: ...pulator mass Do not use them for anything other than transport ing the manipulator Mount the shipping bolts and brackets for transporting the manipulator Avoid external force on the arm or motor unit...

Page 14: ...erve this warning 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...

Page 15: ...nals 3 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 a...

Page 16: ...There are eight mounting holes on the manipulator base securely fix the manipulator to the baseplate using eight hexagon head screws M24 Tensile strength 1200 N mm2 or more 80 mm long is recommended T...

Page 17: ...and that all cracks etc are repaired A non concrete floor or a floor less than 150 mm thick is insufficient for mounting even if the floor is concrete Fig 3 3 Mounting on the Floor Example for the Fou...

Page 18: ...available as optional 3 4 Location When the manipulator is installed it is necessary to satisfy the undermentioned environmental conditions Ambient temperature 0 to 45 C Humidity 20 to 80 RH non conde...

Page 19: ...lectric shock Before wiring make sure to turn the primary power 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 CA...

Page 20: ...ct the ground line directly to the manipulator Fig 4 1 Grounding Method NOTE Never use this wire sharing with other ground lines or grounding electrodes for other electric power motor power welding de...

Page 21: ...he connector base of the manipulator When connecting adjust the cable connector positions to the main key positions of the manipulator and insert cables in the order of 2BC 3BC and 1BC After inserting...

Page 22: ...n 4 4 HW1483270 HW1483270 Fig 4 2 Manipulator Cables X11 1BC X21 2BC X22 3BC 3BC Power cable X11 1BC X21 2BC X22 3BC Power cable 2BC Encoder cable 1BC Manipulator side DX200 side Manipulator side DX20...

Page 23: ...Connection 4 5 HW1483270 HW1483270 Fig 4 3 a Manipulator Cable Connectors Manipulator Side Fig 4 3 b Manipulator Cable Connection DX200 Side Main key position A A A A FB 3BC 2BC 1BC AIR S1 FB 3BC 2BC...

Page 24: ...B axis 1 40 rad s 80 s T axis 2 83 rad s 162 s Allowable Moment4 4 Refer to chapter 6 Allowable Load for Wrist Axis and Wrist Flange for details on the permissible moment of inertia R axis 3430 N m 3...

Page 25: ...xes 5 3 Manipulator Base Dimensions Fig 5 2 Manipulator Base Dimensions Wrist Upper arm U arm Lower arm L arm Manipulator base Rotary head S head Wrist flange T T B B R R U U L L S S 40 View A A 786 5...

Page 26: ...nsions and P Point Maximum Envelope Fig 5 3 Dimensions and P Point Maximum Envelope P point P point maximum envelope B 0 796 1318 2942 0 1409 1498 2236 2401 1371 215 1849 2565 989 0 2683 922 900 14 R2...

Page 27: ...Angles and Times for S L and U axes Following data on stopping angle and time for each axis measured under the standard of ISO10218 5 5 1 Stop Category 0 Stopping Angles and Times 5 5 1 1 Position 100...

Page 28: ...ing Angles and Times for S L and U axes 5 5 HW1483270 HW1483270 5 5 1 2 Position 66 Fig 5 5 Stop Category 0 Position 66 Stopping Angle and Time for Each axes a S Axis Note L axis takes one pose only f...

Page 29: ...ing Angles and Times for S L and U axes 5 6 HW1483270 HW1483270 5 5 1 3 Position 33 Fig 5 6 Stop Category 0 Position 33 Stopping Angle and Time for Each Axis a S Axis Note L axis takes one pose only f...

Page 30: ...gory 1 Emergency Stop Stopping Angle and Time for Each Axis NOTE Stopping angles and times at stop category 1 are not subjected to the position and the load of the manipulator a S Axis b L Axis c U Ax...

Page 31: ...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 Specifications S axis Operating Range 180...

Page 32: ...fig 6 1 Moment Arm Rating The allowable total moment of inertia is calculated when the moment is at the maximum Contact your YASKAWA representative beforehand when only the moment of inertia is creat...

Page 33: ...the attachment be mounted inside the fitting Fitting depth of inside fitting must be 4 mm or less and outside fitting 8 mm or less Fig 6 2 Wrist Flange NOTE Wash off anti corrosive paint yellow color...

Page 34: ...llowing conditions described in table 7 1 Constraint for Attaching and fig 7 1 Installing Peripheral Equipment should be observed Table 7 1 Constraint for Attaching Application Note A Cable Processing...

Page 35: ...Peripheral Equipment View A Tapped hole M8 2 holes depth 15 pitch 1 5 Tapped hole M8 4 holes depth 15 pitch 1 5 Tapped hole M10 4 holes depth 25 pitch 1 5 Tapped hole M8 4 holes depth 15 pitch 1 5 100...

Page 36: ...able 7 2 Internal User I O Wiring Harness and Air Lines Item Specifications Conditions Internal user I O wiring harness 0 5 mm2 6 wires 0 3 mm2 12 wires See Pin details for internal user I O wiring ha...

Page 37: ...4 10 12 11 9 16 15 14 13 0 5 mm2 x 6 pins 18 17 P 0 3 mm2 x 12 pins Pin details for internal user I O wiring harness on casing side P P P P P 5 6 7 8 4 0 5 mm2 x 6 pins 10 11 12 13 16 15 18 17 14 0 3...

Page 38: ...as a result Refer to 8 9 Overrun Tool Shock Sensor Releasing in DX200 INSTRUCTIONS for releasing the status of this overrun 2 The range of S L and U axes limit switches are set to the maximum operatin...

Page 39: ...axis limit 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 c...

Page 40: ...e 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 to...

Page 41: ...9 20 18 17 0BAT4 0BAT5 0BAT6 PG0V2 PG0V3 PG0V5 PG0V4 PG5V4 PG5V3 PG5V2 BAT4 BAT5 BAT6 PG5V1 PG0V1 PG5V5 0BAT2 0BAT3 BAT2 BAT1 0BAT1 BAT3 OBT BAT BAT OBT 5V FG6 OBT BAT OBT DATA 6 DATA 6 0V OBT 5V FG5...

Page 42: ...CN3 8 CN3 7 MU6 MV6 MW6 ME6 BA6 PE X21 8X6 MU4 MV4 MW4 MW4 ME4 BB4 MV4 ME4 BA4 X22 8X6 BA3 E MU4 BA2 MU3 MU3 MV3 MV3 MW3 MW3 BB1 MU2 MU2 MV2 MV2 MW2 MW2 ME2 ME2 E MU1 MV1 MV1 MU1 MW1 MW1 ME1 ME1 BA1...

Page 43: ...must be performed by specified personnel Failure to observe this caution may result in electric shock or injury For disassembly or repair contact your YASKAWA representative Do not remove the motor an...

Page 44: ...l Check for loose connectors and tighten if necessary 8 Connector Base Manual Check for loose connectors and tighten if necessary 9 Balancer Grease Gun Supply grease See chapter 9 3 10 10 Wire harness...

Page 45: ...Parts and Inspection Numbers 2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor This can cause a motor breakdown Contact your YASKAWA representative...

Page 46: ...Inspection 9 1 Inspection Schedule 9 4 HW1483270 HW1483270 Fig 9 1 Inspection Parts and Inspection Numbers View A 16 17 17 4 5 7 18 1 7 4 6 9 1 10 1 2 11 7 11 14 13 14 15 1 1 1 2 12 8 A A 3BC 2BC 1BC...

Page 47: ...2 Remove the plate fixing screws and the plate from the connector base and pull the battery pack out to replace with a new battery pack 3 Remove the battery pack from the battery holder 4 Connect the...

Page 48: ...d Inspection 9 2 Notes on Maintenance Procedures 9 6 HW1483270 HW1483270 6 Mount the new battery pack to the holder 7 Reinstall the plate NOTE Do not allow plate to pinch the cables when reinstalling...

Page 49: ...exhaust port grease will 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 e...

Page 50: ...lug Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the plug with a tightening torque of 24 5 N m 2 5 kgf m 6 Remove the grease zerk from the grease inlet...

Page 51: ...to discharge excess grease 6 Wipe the discharged grease with a cloth and reinstall the plug Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the plug with...

Page 52: ...th 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 4 9 N m 0 5 kgf m 6 Remove the grease zerk...

Page 53: ...grease can be distinguished from the old grease by color 5 Move the L and U axes for a few minutes to discharge excess grease 6 Wipe the discharged grease with a cloth and reinstall the plug Before i...

Page 54: ...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 24 5 N m 2 5 kgf m 6 Remove the grease zerk from...

Page 55: ...harge excess grease 6 Wipe the discharged grease with a cloth 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 tight...

Page 56: ...stall 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 4 9 N m 0 5 kgf m 6 Remove the grease zerk from the gr...

Page 57: ...ischarge excess grease 6 Wipe the discharged grease with a cloth 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 ti...

Page 58: ...cloth 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 4 9 N m 0 5 kgf m 6 Remove the grease ze...

Page 59: ...to discharge excess grease 6 Wipe the discharged grease with a cloth and reinstall the plug Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the plug with...

Page 60: ...loth 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 3 9 N m 0 4 kgf m 6 Remove the grease zer...

Page 61: ...to discharge excess grease 6 Wipe the discharged grease with a cloth and reinstall the plug Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the plug with...

Page 62: ...grease 2 Amount of grease approx 19 cc 4 Reinstall the plug into the exhaust port Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the plug with a tighten...

Page 63: ...port of each link Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the plug with a tightening torque of 4 9 N m 0 5 kgf m 5 Remove the grease zerk from th...

Page 64: ...f grease approx 5cc 10cc for the 1st supply 5 Remove the grease zerk from the grease inlet and reinstall the plug Tighten the plug with a tightening torque of 4 9 N m 0 5 kgf m Apply ThreeBond 1206C t...

Page 65: ...the motor and battery pack 4 Reinstall the attached cap to the battery backup connector of the motor Fig 9 13 Battery Pack Connection for Motor NOTE When performing maintenance such as replacement of...

Page 66: ...S KAWA representative Table 10 1 Spare Parts for the MOTOMAN MH600 Sheet 1 of 2 Rank Parts No Name Type Manufacturer Qty Qty per Unit Remarks A 1 Battery Pack HW9470917 A YASKAWA Electric Corporation...

Page 67: ...R1 YASKAWA Electric Corporation 1 1 C 14 AC SERVOMOTORs for L and U axes HW0389687 A SGMRV 55ANA YR1 YASKAWA Electric Corporation 1 2 C 15 AC SERVOMOTORs for R B and T axes HW0388669 A SGMRV 30ANA YR1...

Page 68: ...1006 1007 1008 1009 1010 1012 1011 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1037 1040 1041 1042 1043 1044...

Page 69: ...n socket head cap screws 17 1019 2H 12 Conical spring washer 17 1020 HW0307574 1 Stopper 1 1021 M20X45 Hexagon head screw 3 1022 M20 Washer 3 1023 HW0101152 2 Gear case 1 1024 6828ZZ Bearing 1 1025 AR...

Page 70: ...l 1 1052 HW0307565 3 Shaft 1 1053 M8X115 Hexagon socket head cap screws 1 1054 2H 8 Conical spring washer 1 1055 IRTW 72 Retaining ring 2 1056 ISTW 35 Retaining ring 2 1057 CIMR35 1 Shim 2 1058 6207ZZ...

Page 71: ...1 2022 2015 2014 2022 2024 2025 2023 2027 2026 2001 2002 2010 2005 2029 2028 2011 2012 2021 2020 2017 2019 2018 2013 2033 2032 2034 2004 2004 2004 2036 2035 2038 2037 2039 2040 2041 2050 2049 2041 204...

Page 72: ...0 HW9482506 N Bolt 2 2021 HW1401163 A Gear 2 2022 ISTW 12 Retaining ring 2 2023 HW1302251 1 Shaft 1 2024 M12X35 Hexagon socket head cap screws 21 2025 2H 12 Conical spring washer 21 2026 M16X100 Hexag...

Page 73: ...erweight 1 2048 M16X60 Hexagon socket head cap screws 15 2049 2H 16 Conical spring washer 15 2050 HW0405126 1 Weight 4 2051 M16X60 Hexagon socket head cap screws 18 2052 2H 16 Conical spring washer 18...

Page 74: ...lancer Unit 1002 2041 3001 3003 3002 3004 3005 3006 3007 3008 3009 3010 3012 3011 3015 3014 3016 3013 3013 3012 3017 3018 3018 3019 3020 3021 3022 3023 3024 3025 3026 3028 3027 3029 3025 3026 3028 302...

Page 75: ...cap screws 8 3016 2H 10 Conical spring washer 8 3017 HW0303581 1 Rod 1 3018 M6X8 Magic screw 2 3019 HW0481741 A Spring 1 3020 HW0481740 A Spring 1 3021 HW0306033 1 Flange 1 3022 HW0401112 1 Flange 1 3...

Page 76: ...006 4008 4007 4010 4009 2051 4011 4011 4011 4011 4002 4003 4004 4005 4006 4012 4010 4009 4008 4007 4013 4014 4015 4016 4017 4018 4011 4020 4019 4011 4014 4021 4016 4022 4024 4023 4025 4017 4026 4028 4...

Page 77: ...90 O ring 2 4018 HW0402979 3 B support 1 4019 M8X20 Hexagon socket head cap screws 8 4020 2H 8 Conical spring washer 8 4021 HW0402981 1 Collar 1 4022 HW0402980 2 Plate 1 4023 M8X25 Hexagon socket head...

Page 78: ...B and T Axes Unit R AXIS T AXIS B AXIS 5001 4001 5016 5007 5009 5008 5010 5009 5026 5025 5012 5013 5010 5015 5009 5017 5019 5017 5019 5011 5010 5014 5003 5001 5008 5001 5005 5004 5005 5002 5005 5011...

Page 79: ...Needle bearing 3 5010 AR68 Retaining ring 3 5011 WR50 Cerclip 3 5012 HW1302254 1 Gear 1 5013 HW1302310 1 Gear 1 5014 HW0302985 B Gear 1 5015 RTW72 Retaining ring 3 5016 HW0402951 1 Collar 2 5017 M8X3...

Page 80: ...Unit Fig 11 6 U Axis Unit 6001 6002 6003 6004 6005 6009 6010 6011 6012 6013 6014 6015 6016 7043 6017 6018 6019 6020 6047 6021 6022 6023 6025 6033 6029 6030 6031 6032 6033 6048 6034 6035 6036 6037 603...

Page 81: ...2H 12 Conical spring washer 16 6024 HW1405948 8 20 Pin 1 6025 G170 O ring 1 6029 HR32924J Bearing 1 6030 SC115X145X14 FKM Oil seal 1 6031 SC75X100X13 FKM Oil seal 1 6032 M10X40 Hexagon socket head cap...

Page 82: ...xis Unit Fig 11 7 R Axis Unit 7001 7002 7003 7005 7006 7010 7011 7012 7014 7015 7016 7017 7021 7022 7046 7047 7025 7026 7027 7048 7049 7028 7029 7032 7032 7033 7034 7035 7036 7035 7040 7038 7039 7037...

Page 83: ...7 2H 5 Conical spring washer 6 7028 M5X14 Hexagon socket head cap screws 8 7029 2H 5 Conical spring washer 8 7030 M5X14 Hexagon socket head cap screws 8 7031 2H 5 Conical spring washer 8 7032 6905DDU...

Page 84: ...33 8034 8035 8036 8037 8038 8039 8113 8119 8112 8111 8114 8115 8040 8041 8042 8122 8123 8043 8044 8045 8051 8052 8053 8051 8052 8061 8062 8063 8055 8064 8065 8066 8068 8069 8070 8071 8072 8073 8023 80...

Page 85: ...22 HW0302600 1 Gear 1 8023 M3X16 Hexagon socket head cap screws 8 8024 2H 3 Conical spring washer 8 8025 6911 Bearing 1 8026 RTW80 Retaining ring 1 8027 HW0302599 1 Gear 1 8028 AE3290E3 Oil seal 1 802...

Page 86: ...6 Conical spring washer 6 8089 PT1 8 STAINLESS Plug 1 8090 HW0402968 Shim 8096 HW0302594 1 Gear 1 8097 HW0381033 B Speed reducer 1 8098 HW0302457 1 Cover 1 8099 STW 45 Retaining ring C type 1 8100 60...

Page 87: ...70 HW1483270 8120 HW0402957 1 Plate 1 8121 PT1 16 STAINLESS Plug 1 8122 M12X35 Hexagon socket head cap screws 12 8123 2H 12 Conical spring washer 12 8124 2H 12 Conical spring washer 9 Table 11 8 Wrist...

Page 88: ...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 22F One Corpora...