YASKAWA MOTOMAN-MPL100, Instructions Manual

Page 1: ...FIELDBUS CABLE Upon receipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN MPL100 INSTRUCTIONS DX100 INSTRUCTIONS DX100 OPERATOR S MANUAL DX100 MAINTENACE MANUAL The DX100 operator s manual above corresponds to specific usage Be sure to use the appropriate manual 1 of 106 ...

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 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 2011 Yaskawa America Inc Motoman Robotics Di...

Page 3: ...al 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 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 improvement...

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 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 pur...

Page 5: ...sonnel 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 practices MANDATORY Always be sure to follow explicitly the items listed under this heading PROHIBITED Must never be performed NOTE To ensure safe and efficient operation at all times be sure to fol...

Page 6: ...mergency Stop TURN 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 Keep in mind the emergency response measures against the manipulator s unexpected motion toward you Ensure that you have a safe place to retreat in ca...

Page 7: ... 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 found repair them immediately and be sure that all other necessary processing has been performed Check for problems in manipulator movement Check for damage to insulation and sheathing of external wires ...

Page 8: ...the manipulator Prior to operating the manipulator confirm the contents Figure 3 Warning Label Locations WARNING label A WARNING label B Nameplate WARNING Moving parts may cause injury WARNING Label A WARNING Label B Nameplate WARNING Do not enter robot work area WARNING Do not enter robot work area MADE IN JAPAN YASKAWA ELECTRIC CORPORATION Kitakyushu 806 0004 Japan 2 1 Kurosakishiroishi Yahatani...

Page 9: ...t 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 Occupational Safety and Health Standards for General Industry OSHA Mechanical Safety Devices The safe operation of this equipment is ultimately the users responsibility The conditions under which the equipm...

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 injury or death as well as damage to the robot Do not make any modifications to the controller unit Making any changes without the written permission from Yaskawa will void the warranty Some operatio...

Page 11: ...fied 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 manual but appear in the form of Dangers Warnings Cautions and Notes It is important that users operate the equipment in accordance with this instruction manual and any additional information whic...

Page 12: ...for 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 urgent or emergency need for service replacement parts or information you must contact YASKAWA Customer Support at the telephone number shown above System MPL100 Robots ___________________________ Primar...

Page 13: ...ing 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 and Working Axes 5 2 5 3 Manipulator Base Dimensions 5 2 5 4 Dimensions and T Point Maximum Envelope 5 3 5 5 Alterable Operating Range 5 4 5 5 1 Components for Altering Operating Range 5 5 5 5 2 Notes on the Mechanical Sto...

Page 14: ... 10 9 3 1 2 Grease Exchange 9 11 9 3 2 Grease Replenishment Exchange for L Axis Speed Reducer 9 12 9 3 2 1 Grease Replenishment 9 13 9 3 2 2 Grease Exchange 9 14 9 3 3 Grease Replenishment Exchange for U Axis Speed Reducer 9 16 9 3 3 1 Grease Replenishment 9 16 9 3 3 2 Grease Exchange 9 17 9 3 4 Grease Replenishment Exchange for T Axis Speed Reducer 9 18 9 3 4 1 Grease Replenishment 9 18 9 3 4 2 G...

Page 15: ... four items information for the content of optional goods are given separately Manipulator DX100 Programming pendant Manipulator cables between the DX100 and the Manipulator CAUTION Confirm that the manipulator and the DX100 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 an...

Page 16: ... CHECK ALL THE DOOR LOCKS NJ3005 1 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 PROGRAMMING PENDANT Y C E G N O T P M E E S R ON TR IPP ED RES ET OFF THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER ORDER NO Check that the manipulator and the DX100 have the same order number Label Enla...

Page 17: ...ransport The system consists of precision components Failure to observe this caution may adversely affect performance NOTE The weight of the manipulator is approximately 1750kg including the shipping bolts and brackets Use a wire rope strong enough to withstand the weight Mount the shipping bolts and brackets for transporting the manipulator Avoid putting external force on the arm or motor unit wh...

Page 18: ...tor should be lifted by a crane with four wire ropes when removing it from the package and moving it Be sure that the manipulator is fixed with the shipping bolts and brackets before transport and lift it in the posture as shown in Fig 2 1 Transporting Position Fig 2 1 Transporting Position 2 5 4 5 18 of 106 ...

Page 19: ...The shipping bolts and brackets are painted yellow Fig 2 2 Shipping Bolts and Brackets Position Screw Type Pcs A Hexagon socket head cap screw M20 8 B and C Hexagon socket head cap screw M10 4 NOTE Before turning ON the power check to be sure that the shipping bolts and brackets are removed The shipping bolts and brackets then must be stored for future use in the event that the manipulator must be...

Page 20: ...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 operate the manipulator that is damaged or lacks parts Failure to observe this caution may cause injury or damage Before turning ON the power check to be sure that the shipping bolts and brackets expl...

Page 21: ...rmly 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 forces of the manipulator referring to Table 3 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop and Table 3 2 Endurance Torque in Operation A b...

Page 22: ...he baseplate The manipulator base is tapped for eight mounting holes securely fix the manipulator base to the baseplate with eight hexagon socket head cap screws M20 80 mm long is recommended Tighten the hexagon socket head cap screws 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...

Page 23: ...nvironmental conditions Ambient temperature 0 to 45 C Humidity 20 to 80 RH non condensing Free from dust soot or water Free from corrosive gas or liquid or explosive gas or liquid Free from excessive vibration Vibration acceleration 4 9 m s2 0 5 G or less Free from large electrical noise plasma Flatness for installation 0 5 mm or less 23 of 106 ...

Page 24: ...ure 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 shock DO NOT cover the cable with heat insulating material and avoid multiple cabling when laying manipulator cables from the manipulator to the DX100 Failure to observe this caution may result in burn ...

Page 25: ...ecting two cables to the manipulator verify the numbers on both manipulator cables and the connectors on the 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 then 1BC After inserting the cables depress the lever until it clicks 4 2 2 Connection to the DX100 Before connecting...

Page 26: ...9 1CD HW0485652 MPL100 Fig 4 2 Manipulator Cables Power Cable Power Cable DX100 side Encoder Cable Manipulator side DX100 side DX100 side Manipulator side Manipulator side X11 1BC X11 1BC 1BC 2BC X21 2BC 3BC 3BC X22 3BC X22 2BC X21 26 of 106 ...

Page 27: ...tion Fig 4 3 a Manipulator Cable Connectors Manipulator Side YR MPL0100 A00 Fig 4 3 b Manipulator Cable Connectors Manipulator Side YR MPL0100 A04 A Connector Details Manipulator Side Key positions A Connector Details Manipulator Side Key positions 27 of 106 ...

Page 28: ...4 Wiring 4 2 Cable Connection 4 5 157569 1CD HW0485652 MPL100 Fig 4 3 c Manipulator Cable Connection DX100 Side X22 X21 X11 28 of 106 ...

Page 29: ...xis 2 44 rad s 140 s U Axis 2 44 rad s 140 s T Axis 5 32 rad s 305 s T Axis Allowable Inertia GD2 4 3 80 kg m2 Approx Mass 1700 kg Ambient Conditions Temperature 0 to 45 C Humidity 20 to 80 RH non condensing Vibration Acceleration 4 9 m s2 0 5G or less Others Free from corrosive gas or liquid or explosive gas or liquid Free from exposure to dust soot or oil Free from excessive electrical noise pla...

Page 30: ...Axes 5 3 Manipulator Base Dimensions Fig 5 2 Manipulator Base Dimensions T T U U L L S S Lower arm L arm Base Upper arm U arm Wrist Wrist flange Rotary head S head 40 540 540 A 710 350 879 519 640 640 Units mm View A 360 0 1 320 0 1 360 0 1 0 021 0 20 dia hole 2 places 12 dia hole 0 018 0 22 dia hole 8 places 220 0 1 220 0 1 300 0 1 320 0 1 30 of 106 ...

Page 31: ...ons and T Point Maximum Envelope Fig 5 3 Dimensions and P Point Maximum Envelope YR MPL0100 A00 A04 625 616 15 5 2529 R1124 2776 614 2162 1300 1300 1600 1600 2363 2624 1241 45 9 0 120 R 6 9 7 R1037 R3159 2204 300 250 1400 0 820 3159 1037 880 1250 270 0 T Point point maximum envelope T P point Units mm 31 of 106 ...

Page 32: ...ions as shown in Table 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 Specifications S Axis Operating Range 180 standard 165 150 135 120 105 90 75 60 45 30 15 NOTE When altering the operating range to 15 or 165 please contact your YASKAWA representative 32 of...

Page 33: ...xis Stopper referring to the following list 1 Pin drawing No HW0407007 1 1 pin 2 Stopper drawing No HW0307574 1 1 stopper 3 Hexagon head screw M20 length 70 mm tensile strength 1200 N mm2 or more 3 screws 4 Flat washer M20 3 flat washers Fig 5 4 Components of S Axis Stopper A A Stopper HW0307574 1 Pin HW0407007 1 Section A A Hexagon head screw M20 length 70 mm tensile strength 1200 N mm2 or more 3...

Page 34: ...s e g 15 165 install the stopper referring to Table 5 3 Settable Angle for S Axis Stopper To ensure the stopper strength make sure to fix both sides of the protrusion with screws DO NOT fix only one side of the protrusion See Fig 5 5 Properly Mounted Image As in the figures Fig 5 6 a Properly Mounted Models for S Axis Stopper to Fig 5 6 m Properly Mounted Models for S Axis Stopper the S axis mecha...

Page 35: ...rogramming pendant Pulse limit positive direction of the S axis SICxG400 Pulse limit negative direction of the S axis SICxG408 MPL100 Degree Number of Pulse 0 0 15 1 1 Refer to section 5 5 Alterable Operating Range 29089 30 58179 45 87268 60 116357 75 145446 90 174536 105 203625 120 232714 135 261804 150 290893 165 1 319982 180 349071 NOTE Adjust both of the pulse limit and the angle of the S axis...

Page 36: ...stalling two mechanical stoppers on the S axis The vertical axis of the table shows the angles in the positive direction and the horizontal axis of the table shows the angles in the negative direction For example if one stopper is to be installed at a 180 degree angle in the positive direction the other one can be installed within the range of 105 degree angles since more than 60 degrees of interv...

Page 37: ...Stopper 165 Installation at 180 Installation at 165 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 180 37 of 106 ...

Page 38: ...35 150 Hexagon head screw M20 3 screws length 70 mm with three washers M20 Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is reversible Either side of the stopper can be used Installation at 150 The stopper is irreversible Only this side of the stopper can be used at this angle Installation at 135 38 of 106 ...

Page 39: ...05 Installation at 120 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 105 Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is irreversible Only this side of the stopper can be used at this angle 120 39 of 106 ...

Page 40: ...s Stopper 7 5 9 0 Installation at 90 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 75 Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is reversible Either side of the stopper can be used 40 of 106 ...

Page 41: ...4 5 6 0 Installation at 60 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is irreversible Only this side of the stopper can be used at this angle Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 45 41 of 106 ...

Page 42: ...1 5 3 0 Installation at 30 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is irreversible Only this side of the stopper can be used at this angle Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 15 42 of 106 ...

Page 43: ...ations 5 5 Alterable Operating Range Fig 5 6 g Properly Mounted Models for S Axis Stopper The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 0 43 of 106 ...

Page 44: ... Stopper 165 180 Installation at 180 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is reversible Either side of the stopper can be used Installation at 165 44 of 106 ...

Page 45: ...50 135 Installation at 150 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is irreversible Only this side of the stopper can be used at this angle Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 135 45 of 106 ...

Page 46: ...05 120 Installation at 120 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is irreversible Only this side of the stopper can be used at this angle Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 105 46 of 106 ...

Page 47: ...s Stopper 9 0 7 5 Installation at 90 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 75 The stopper is reversible Either side of the stopper can be used 47 of 106 ...

Page 48: ...6 0 4 5 Installation at 60 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is irreversible Only this side of the stopper can be used at this angle Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 45 48 of 106 ...

Page 49: ...1 5 3 0 Installation at 15 The stopper is reversible Either side of the stopper can be used Hexagon head screw M20 3 screws length 70 mm with three washers M20 The stopper is irreversible Only this side of the stopper can be used at this angle Hexagon head screw M20 3 screws length 70 mm with three washers M20 Installation at 30 49 of 106 ...

Page 50: ...tal Inertia 2 When the inertia of the volume load on the flange is small the eccentricity of load center measured from T axis flange rotation center is in the range shown in Fig 6 1 Moment Arm Rating for MPL100 When the inertia of the volume load on the flange Ji is large use the following formula to calculate the eccentricity LT Table 6 1 Allowable Total Inertia T Axis Total Moment of Inertia GD2...

Page 51: ...t Flange 6 1 Allowable Wrist Load Fig 6 1 Moment Arm Rating for MPL100 Center of T axis flange rotation 900 800 700 600 500400 300 200100 100 200 300 400 500 600 700 800900 100 200 300 400 500 600 700 800 900 1000 1100 LB mm LB 1000 1000 LT mm LT W 100 kg W 80 kg 51 of 106 ...

Page 52: ...g in order to identify the alignment marks Fitting depth shall be 8 mm or less When the outside fitting is used the depth of outside fitting must be 8 mm or less Fig 6 2 Wrist Flange NOTE Wash off anti corrosive paint yellow on the wrist flange surface with thinner or light oil before mounting the tools Tappled hole M10 10 places depth 16 10 dia hole 2 places depth 8 0 015 0 Units mm 63 dia 0 030 ...

Page 53: ...MOTOMAN MPL100 in the full range of motion However minor tilting may occur due to the posture and load conditions When the manipulator will be used in applications in which the levelness of the wrist flange is important first evaluate and check tilting with the actual posture and load conditions Fig 6 3 Tilting of Wrist Flange T point maximum envelope Mounting surface T point Tilting of wrist flan...

Page 54: ... system applications The following conditions shall be observed to attach or install peripheral equipment Refer to Table 7 1 Conditions for Installation Fig 7 1 Installing Peripheral Equipment Tapped hole M6 6 places depth 15 View A Units mm Section B B Tapped hole M6 2 places depth 15 20 122 20 20 53 dia 177 5 122 5 30 53 B B A Table 7 1 Conditions for Installation Application Note Cable Processi...

Page 55: ...ig 7 2 a Connectors for Internal User I O Wiring Harness and Air Line YR MPL0100 A00 and Fig 7 2 b Connectors for Internal User I O Wiring Harness and Air Line YR MPL0100 A04 The connector pins 1 to 23 are assigned as shown in Fig 7 2 d Details of the Connector Pin Numbers Wiring must be performed by users The allowable current for internal user I O wiring harness 2 0 A or less for each wire The t...

Page 56: ... C B A E D B A Connector base View B View A Connector for the internal user I O wiring harness base side JL05 2A24 28PC with a cap Prepare connector JL05 6A24 28S Connector for the internal user I O wiring harness wrist side JL05 2A24 28SC with a cap Prepare connector JL05 6A24 28P Exhaust port A B C D E F PT3 8 with a pipe plug 6 places Air inlet A B C D E F PT3 8 with a pipe plug 6 places 56 of ...

Page 57: ...nd pull the cable on the wrist C B A E D C B A E D B A View B Connector for the internal user I O wiring harness base side JL05 2A24 28PC with a cap Prepare connector JL05 6A24 28S Connector for the internal user I O wiring harness wrist side JL05 2A24 28SC with a cap Prepare connector JL05 6A24 28P Tube for field bus cable inside dia 12 Tube for field bus cable inside dia 12 Exhaust port A B C D ...

Page 58: ... for a field bus cable inside dia 12 mm is connected by a union in which the cable runs See the step 1 on the left 2 Remove the union from the tube for a field bus cable See the step 2 on the left 3 Pull the field bus cable fixed to the cable until it reaches the union See the step 3 on the left 4 Cut the cable from the field bus cable See the step 4 on the left 5 Remove the union fix the cable to...

Page 59: ...f the Connector Pin Numbers The same numbered pins 1 to 23 of the two connectors are connected with a single lead wire of 0 5 mm2 1 2 4 3 1 2 5 7 6 4 3 21 16 23 18 19 20 17 22 14 13 11 12 10 12 11 9 10 15 17 16 14 13 15 20 21 22 19 23 18 8 5 7 8 9 6 Pins used Internal user I O wiring harness 23 wires size 0 5 mm2 59 of 106 ...

Page 60: ...rotective springs etc Also clearance of 10 mm or more is needed between the hollow part and the protective material Ratio of the cross section of the wiring harness etc to the protective material 30 or less Since sufficient clearance is also needed between the protective material and the wiring harness etc make sure that the ratio of the total cross section of the wiring harness etc to the cross s...

Page 61: ...hes are optional For the S L and U axes with limit switches specifications the limit switches are located on the S axis L axis and U axis respectively For the location refer to Fig 8 1 Location of Limit Switches Fig 8 1 Location of Limit Switches L and U axes interference limit switch optional L axis overrun limit switch optional S axis overrun limit switch optional A 61 of 106 ...

Page 62: ...f connectors see Fig 8 2 a Locations and Numbers of Connectors YR MPL0100 A00 and Fig 8 2 b Locations and Numbers of Connectors YR MPL0100 A04 Diagrams for internal connections of the manipulator are shown in Fig 8 3 a Internal Connection Diagram and Fig 8 3 b Internal Connection Diagram Fig 8 2 a Locations and Numbers of Connectors YR MPL0100 A00 Connector for internal user I O wiring harness Enl...

Page 63: ...ng harness Enlarged View B Connector for internal user I O wiring harness Enlarged View A A A 1BC 2BC 3BC B Table 8 1 List of Connector Types Name Type of Connector Connector for the internal user I O wiring harness on the connector base JL05 2A24 28PC JL05 6A24 28S Optional Connector for the internal user I O wiring harness on the wrist base JL05 2A24 28SC JL05 6A24 28P Optional 63 of 106 ...

Page 64: ...o 7CN P P P L 1 4 3 2 PG0V2 BAT2 PG5V2 OBAT2 No 17CN OBT BAT 10 FG2 DATA 2 DATA 2 DATA 1 DATA 1 2 FG1 0V 5V OBT OBT BAT 4 5 9 10 BAT 6 PG P P P No 6CN 6CN 1 S OBAT1 PG5V1 PG0V1 BAT1 2 3 4 1 No 16CN X No 20CN 1BC 10PX4 4 2 3 1 24V 0V 24V 0V 0V 0V 24V 24V CN1 9 CN1 5 CN1 4 CN1 10 P P CN1 10 CN1 9 0V 24V 24V 0V CN1 4 CN1 5 PG0V6 PG5V6 9 11 10 16 15 14 13 12 1 4 2 3 PG0V2 PG0V3 PG5V2 3 5 4 7 8 PG5V3 6...

Page 65: ...E3 ME3 ME3 BB6 ME3 MW3 MV3 MV3 MW3 MW3 MW3 MU3 MV3 MU3 MV3 MU3 MU3 E BA6 BB1 AC1 AC2 CN5 3 CN5 4 4BC CN 5 1 CN 5 2 CN 4 4 CN 4 5 CN 4 6 CN 4 1 CN 4 2 CN 4 3 24 28 MU6 ME6 ME6 MU6 MV6 MV6 MW6 MW6 BA3 CN 6 3 4BC 1 11 20 19 14 15 18 17 16 12 13 9 10 3 4 8 7 6 5 2 1 E 10 19 20 14 15 16 17 18 12 13 11 6 9 8 7 5 4 3 2 23 22 23 21 22 21 SP1 SP2 11 19 20 14 16 17 18 15 13 12 10 7 8 9 6 2 5 4 3 1 10 19 20 ...

Page 66: ...d by service company personnel Only specified personnel shall perform the inspection work WARNING 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 CAUTION Maintenance and inspection must be performed by specified personnel Failure to observe this ca...

Page 67: ...r axes which are used very frequently in handling applications etc it is recommended that inspections be conducted at intervals of 1 2 of the schedule indicated in Table 9 1 Inspection Items From the standpoint of the preventive maintenance it is recommended that the following parts be replaced at the secondary inspection 18000 H Speed reducers for the S L U and T axes Cross roller bearing for the...

Page 68: ...unting bolts Spanner Wrench Tighten loose bolts Replace if necessary 6 Connector base Manual Check for loose connectors and tighten if necessary 7 LU axis connectors Manual Check for loose connectors and tighten if necessary 8 Connectors in S head Manual Check for loose connectors 9 L axis balancer Grease Gun Visual Supply grease Check for loose screw nuts and shafts and tighten if necessary 10 Wi...

Page 69: ...Replenish grease5 5000H cycle See section 9 3 2 Grease Replenishment Exchange for L Axis Speed Reducer and section 9 3 3 Grease Replenishment Exchange for U Axis Speed Reducer Exchange grease5 9000H cycle See section 9 3 2 and section 9 3 3 15 T axis speed reducer Grease Gun Check for malfunction Replace if necessary Replenish grease5 5000H cycle See section 9 3 4 Grease Replenishment Exchange for...

Page 70: ...When checking for conduction with multimeter connect the battery to BAT and OBT of connectors on the motor side for each axis and then remove connectors on detector side for each axis from the motor Otherwise the home position may be lost Refer to section 9 3 6 Grease Replenishment for Links 4 Wire harness in manipulator to be replaced at 18000H inspection 5 For the grease refer to Table 9 2 Inspe...

Page 71: ...n 9 1 Inspection Schedule 9 6 157569 1CD HW0485652 MPL100 Fig 9 1 Inspection Items A View A U axis L axis T axis S axis A 16 11 14 7 2 4 14 7 2 4 8 2 12 6 1 13 10 1 1 1 16 11 16 11 16 11 16 11 16 11 16 11 15 16 11 5 2 9 71 of 106 ...

Page 72: ...cation Back View YR MPL0100 A04 and Fig 9 2 c Battery Location Top View If the battery alarm occurs in the DX100 replace the battery in accordance with the following procedure Fig 9 2 a Battery Location Back View YR MPL0100 A00 Fig 9 2 b Battery Location Back View YR MPL0100 A04 Table 9 2 Inspection Parts and Grease Used No Grease Used Inspected Parts 13 14 15 Molywhite RE No 00 Speed reducers for...

Page 73: ...pull the battery pack out to replace it with the new one 3 Remove the battery pack from 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 Battery pack Board New battery pack HW0470360 A Battery pack before replacement See the step 5 See the step 4 Connector Board NOTE Remove the old battery pack after connecting ...

Page 74: ...ase is added without removing the plug screw from the grease 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 etc to the grease exhaust port Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal Make su...

Page 75: ...supply Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 4 Move the S axis for a few minutes to discharge excess grease 5 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 tightening torque of 24 5 N m 2 5 kgf m Grease inlet Hexagon socket ...

Page 76: ...aust port The new grease can be distinguished from the old grease by color 5 Move the S axis for a few minutes 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 a tightening torque of 24 5 N m 2 5 kgf m 7 Remove the grease zerk from the grease inlet ...

Page 77: ...ase Replenishment Exchange for L Axis Speed Reducer Fig 9 5 a L Axis Speed Reducer Diagram Fig 9 5 b L Axis Grease Replenishment Grease inlet Hexagon socket head plug Section A A L axis speed reducer Grease exhaust port Hexagon socket head plug A A 225 mm Grease zerk A PT1 8 Joint PT1 8 Hose for grease replenishment 77 of 106 ...

Page 78: ...grease hose as shown in Fig 9 5 b L Axis Grease Replenishment and inject grease 5 Move the L axis for a few minutes 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 a tightening torque of 24 5 N m 2 5 kgf m 7 Remove the grease zerk from the grease i...

Page 79: ...rox 1800 cc Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less CAUTION If the L arm is tilted at 80 degrees or more the link C interferes with the plug for air exhaust Do not tilt the L arm over 80 degrees when verifying the manipulator operation 80 9 0 170 Plug for air exhaust Link C Plug for air exhaust Link C Link C NOTE If grease is injected with the plug on...

Page 80: ...nstall 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 7 Remove the 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 4 9 N m 0 5 kgf m NOTE If the plu...

Page 81: ...h the grease inlet using a grease gun Grease type Molywhite RE No 00 Amount of grease 320 cc 640 cc for 1st supply Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 4 Move the U axis for a few minutes to discharge excess grease Grease inlet Hexagon socket head plug Grease exhaust port Hexagon socket head plug U axis speed reducer NOTE If grease is injected with...

Page 82: ...grease exhaust port The new grease can be distinguished from the old grease by color 5 Move the U axis for a few minutes 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 a tightening torque of 24 5 N m 2 5 kgf m 7 Remove the grease zerk from the gre...

Page 83: ... supply Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 4 Move the T axis for a few minutes to discharge excess grease 5 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 tightening torque of 4 9 N m 0 5 kgf m Grease inlet Hexagon socket ...

Page 84: ... few minutes 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 a tightening torque of 4 9 N m 0 5 kgf m 7 Remove the grease zerk from the grease inlet and reinstall the plug Before installing the plug apply Three Bond 1206C on the thread part of the ...

Page 85: ...f grease approx 60 cc Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 3 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 tightening torque of 4 9 N m 0 5 kgf m 4 Remove the grease zerk from the grease inlet and reinstall the plug Before installing the plug ap...

Page 86: ...ort Hexagon socket head plug PT1 8 3 Link Exhaust port Hexagon socket head plug PT1 8 4 Link Exhaust port Hexagon socket head plug PT1 8 10 Link Grease inlet Hexagon socket head plug PT1 8 10 Link Grease inlet Hexagon socket head plug PT1 8 7 Link Exhaust port Hexagon socket head plug PT1 8 8 Link Exhaust port Hexagon socket head plug PT1 8 5 Link Exhaust port Hexagon socket head plug PT1 8 2 Link...

Page 87: ...c 24 cc for 1st supply Amount of grease for links 7 8 3 cc 6 cc for 1st supply Amount of grease for links 10 11 5 cc 10 cc for 1st supply Air supply pressure of grease pump 0 3 MPa or less Grease injection rate 8 g s or less 3 Reinstall the plug into the exhaust 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 tightenin...

Page 88: ... encoder Under this condition remove the encoder connector and carry out the maintenance checks 3 Confirm all connectors connected after the maintenance check and remove the battery packs Install the caps attached to the battery backup connectors of the motors NOTE When performing maintenance such as replacement of a wire harness in the manipulator the encoder connector may be necessary to be remo...

Page 89: ... on Grease Replenishment Exchange Procedures Fig 9 10 Battery Pack Connection Motor Motor power connector Connector for motor encoder Battery pack HW9470932 A Battery backup connector a Crimped contact pin pin b Crimped contact pin socket b a a b 0BT BAT BAT 0BT 89 of 106 ...

Page 90: ...e Manufacturer Qty Qty per Unit Remarks A 1 Grease Molywhite RE No 00 YASKAWA Electric Corporation 16kg For speed reducers A 2 Grease Alvania EP Grease 2 Showa Shell Sekiyu K K 16kg For links and bearings A 3 Battery Pack HW0470360 A YASKAWA Electric Corporation 1 1 A 4 Battery Pack HW9470932 A YASKAWA Electric Corporation 1 1 For replacement of wire harness in manipulator A 5 Liquid Gasket Three ...

Page 91: ...tion 1 3 C 14 AC Servomotor for T axis SGMRV 13ANA YR1 HW0388666 A YASKAWA Electric Corporation 1 1 C 15 Wire Harness in Manipulator HW0174949 A A00 HW0174949 B A04 YASKAWA Electric Corporation 1 1 C 16 Wire Harness in Manipulator HW0374305 A A00 HW0373017 A A04 YASKAWA Electric Corporation 1 1 Table 10 1 Spare Parts for the YR MPL0100 A00 A04 Sheet 2 of 2 Rank Parts No Name Type Manufacturer Qty ...

Page 92: ...002 1078 1011 1012 1013 1079 1077 1021 1022 1023 1024 1025 1037 1038 1040 1017 1014 1015 1003 1004 1035 1030 1033 1026 1058 1059 1060 1061 1058 1062 1061 1059 1063 1048 1049 1050 1048 1051 1052 1053 1044 1045 1041 1042 1043 1066 1046 1047 1054 1055 1056 1057 1064 1065 1067 1069 1070 1072 1071 1080 1082 1081 1068 1076 1075 1036 1027 1019 1020 1034 92 of 106 ...

Page 93: ...1022 HW0414514 1 Shaft 1 1023 HW0307565 3 Shaft 1 1024 M8X115 Socket screw 1 1025 2H 8 Spring washer 1 1026 HW0407007 1 Pin 1 1027 HW0403903 1 Plate 1 1028 M20X70 12 9 Bolt 3 1029 M20 Washer 3 1030 HW0402102 1 Stopper 1 1031 M8X40 Socket screw 1 1032 2H 8 Spring washer 1 1033 HW9404486 1 Shaft 1 1034 M5X16 GT SA Bolt 8 1035 S180 O ring 1 1036 MSTM6 20 Pin 2 1037 M12X40 Socket screw 4 1038 2H 12 Sp...

Page 94: ...1063 HW9405051 1 Cover 1 1064 2H 5 Spring washer 7 1065 M5X16 Socket screw 7 1066 M12X20 Socket screw 1 1067 PT3 8 DACROTIZED coating Plug 1 1068 HW0314644 A Cover 1 1069 M8X25 STAINLESS Socket screw 2 1070 2H 8 STAINLESS Spring washer 2 1071 HW0471083 A Fan 1 1072 A 33C Fan cover 1 1075 TA1 S10 Clamp 4 1076 M5X10 Round head screw 4 1077 HW0308464 1 Flange 1 1078 TC8511013 Oil seal 1 1079 HW030846...

Page 95: ...11 2069 2069 2081 2081 2068 2068 2052 2052 2048 2072 2053 2048 2002 2054 2029 2030 2033 2035 2046 2070 2083 2047 2042 2036 2075 2082 2036 2029 2030 2045 2045 2045 2067 2076 2077 2078 2055 2057 2003 2008 2076 2077 2031 2035 2058 2043 2056 2041 2041 2039 2040 2045 5004 2071 2073 2074 2045 2059 2085 2086 2025 2086 2025 95 of 106 ...

Page 96: ...0 2032 2035 2037 2007 2012 2021 2014 2015 2016 2009 2028 2039 2040 2031 2080 2035 2026 2030 2022 2004 2023 2045 2002 2013 2018 2018 2017 2087 2014 2015 2016 2021 2006 2022 2001 2005 2034 2035 2031 2035 2038 2040 2027 2030 2019 2087 2094 2045 2045 2045 2045 2094 2045 2092 2086 2045 2025 2045 2095 2095 2093 2045 2092 2093 96 of 106 ...

Page 97: ...6 HW9482306 F Shaft 2 2017 HW9481363 A Bolt 1 2018 ISTW 12 Stopper 2 2019 G270 O ring 2 2020 GS310 O ring 1 2021 Y507212 5 Oil seal 2 2022 VB 265 280 7 Oil seal 2 2023 M8X25 Socket screw 12 2025 2H 8 Spring washer 20 2026 M10X60 Socket screw 18 2027 M10X50 Socket screw 18 2028 M10X45 Socket screw 1 2029 M10X25 Socket screw 2 2030 2H 10 Spring washer 38 2031 M12X75 Socket screw 33 2032 M12X55 Socke...

Page 98: ...B60787 Oil seal 1 2072 WR60 Clip 1 2073 VB75956 Oil seal 1 2074 AR 85 Clip 1 2075 NA6912 Needle bearing 1 2076 AG3512E1 Oil seal 2 2077 HR32011XJ Bearing 2 2078 G85 O ring 1 2079 KE901107 Oil seal 2 2080 M10X45 Socket screw 9 2081 M10X50 Socket screw 18 2082 G75 O ring 1 2083 HW0484003 A Bearing 1 2085 2H 6 Spring washer 1 2086 2H 10 Spring washer 27 2087 HW0408806 2 Washer 2 2092 POC6 01 1 TSH6 0...

Page 99: ...0 3011 3012 3013 3014 3015 3020 3021 3028 3031 3041 3034 3036 3038 3039 3016 3017 3018 3002 3003 3004 3005 3001 3004 3017 3018 3023 3023 3023 3030 3032 3032 3030 3032 3024 3033 3027 3024 3033 3033 3022 3022 3023 3030 3032 3035 3019 3021 3009 2002 2054 3009 3030 3032 3029 3029 3028 3032 3031 3034 3005 3005 3005 3005 3005 3005 3005 3005 3005 2003 3027 3027 3005 3005 99 of 106 ...

Page 100: ...6 HW0400012 Shim 3017 AG3512E1 Oil seal 2 3018 HR32011XJ Bearing 2 3019 M12X45 Socket screw 10 3020 M12X75 Socket screw 1 3021 2H 12 Spring washer 11 3022 HW0406922 1 B cover 3 3023 HW0406923 1 Pup washer 5 3024 HW0307641 1 Shaft 2 3027 HW0484003 A Bearing 3 3028 M10X30 Socket screw 8 3029 2H 10 Spring washer 8 3030 M10X25 Socket screw 5 3031 M10X50 Socket screw 8 3032 2H 10 Spring washer 13 3033 ...

Page 101: ... 4014 4013 4013 4017 4018 4017 4011 4012 4019 4020 4019 4005 4020 4004 4004 4008 4009 4003 4007 4024 4024 4006 4023 4022 4024 4024 4018 3037 4002 4026 4040 4030 4031 4055 4054 4051 4050 4043 4042 4041 4035 4049 4027 4039 4053 4036 4028 4034 4052 4001 4045 4029 4037 4032 4045 4044 4046 4038 4033 4038 4024 4024 4049 4056 4048 4047 101 of 106 ...

Page 102: ...016 HW9404383 1 B cover 1 4017 M8X65 Socket screw 8 4018 2H 8 Spring washer 8 4019 M10X25 Socket screw 2 4020 2H 10 Spring washer 2 4021 M8X25 GT SA Bolt 3 4022 M8X30 GT SA Bolt 3 4023 M6X20 GT SA Bolt 3 4024 PT1 8 Plug 7 4025 LP M5 Plug 1 4026 HW0314598 1 Guide 1 4027 HW0314599 1 Gear 1 4028 HW0314600 1 Gear 1 4029 HW0314601 1 M base 1 4030 HW0314602 1 Flange A 1 4031 HW0314603 1 Flange B 1 4032 ...

Page 103: ...8 2H 10 Spring washer 8 4049 M4X10 GT SA Bolt 8 4050 M8X80 Socket screw 30 4051 2H 8 Spring washer 30 4052 M6X20 Socket screw 1 4053 2H 6 Spring washer 1 4054 M10X20 Socket screw 9 4055 2H 10 Spring washer 9 4056 MSTH8 20 Pin 1 3037 HW0308095 1 Link E 1 3039 HW0101148 1 U arm 1 Table 11 4 Wrist Unit Sheet 2 of 2 No DWG No Name Pcs 103 of 106 ...

Page 104: ...st 11 5 Balancer Unit 11 13 157569 1CD HW0485652 MPL100 11 5 Balancer Unit Fig 11 5 Balancer Unit 5002 5017 5003 5004 5005 5006 5007 5008 5009 5010 5011 5018 5019 5012 5012 5013 5014 5015 5016 5003 5020 104 of 106 ...

Page 105: ...033 1 Flange 1 5006 HW0200420 1 Flange 1 5007 HW0401112 1 Flange 1 5008 HW0303581 1 Rod 1 5009 HW9405057 1 Clevis 1 5010 FD3187A0 Dust seal 1 5011 EZ2228B0 Cap 1 5012 IRTW 75 Stopper 2 5013 M6X8 Magic screw set screw 2 5014 PT1 8 Plug 3 5015 M10X40 Socket screw 8 5016 2H 10 Spring washer 8 5017 HW0481741 A Coil spring 1 5018 M8X16 Socket screw 3 5019 2H 8 Spring washer 3 5020 M5X10 Socket screw 2 ...

Page 106: ...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 Corporate Avenue No 222 Hubin Road Huangpu District Shanghai 200021 China Phone 86 21 5385 2200 Fax 㸩86 21 5385 3299 YASKAWA Electric Thailand Co Ltd 59 1st 5th Floor Flourish Building Soi Ratchadapisek 18 Ratchadapisek Road Huaykwang Bangkok 10310 THAIL...