YASKAWA Motoman-MPL300 II, Instructions Manual

Page 1: ...e product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN MPL300 II INSTRUCTIONS DX200 INSTRUCTIONS DX200 OPERATOR S MANUAL for each purpose DX200 MAINTENANCE MANUAL The DX200 operator s manual above corresponds to specific usage Be sure to use the appropriate manual 1 of 100 ...

Page 2: ...pyrighted 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 2014 Yaskawa America Inc Motoman Robotic...

Page 3: ...anual 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 improvem...

Page 4: ...personnel 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 ...

Page 5: ...oint maximum envelope 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 closes the safeguarding View the manipulator from the front whenever possible Always follow the predetermined operating procedure Keep in mind the emergency response measures against t...

Page 6: ... 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 Always return the programming pendant to the hook on the cabinet of the DX200 after use The programming pendant can b...

Page 7: ...g the L axis of the balancer equipped manipulator Fig Warning Label Locations Nameplate WARNING Do not enter robot work area WARNING Moving parts may cause injury WARNING Label B WARNING Label A release the brake Failure to observe Do not remove the motor and do not this caution may result in injury from unexpected turning of the manipulator arm Please contact your Yaskawa representive DANGER WARN...

Page 8: ...rding Tips All operators programmers maintenance personnel supervisors and anyone working near the system must become familiar with the operation of this equipment All personnel involved with the operation of the equipment must understand potential dangers of operation General safeguarding tips are as follows Improper operation can result in personal injury and or damage to the equipment Only trai...

Page 9: ...R15 06 2012 safety standards and other local codes that may pertain to the installation and use of this equipment Additional safety measures for personnel and equipment may be required depending on system installation operation and or location The following safety equipment is provided as standard Safety barriers Door interlocks Emergency stop palm buttons located on operator station Check all saf...

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 operati...

Page 11: ...lified 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 wh...

Page 12: ...o 36 hours 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 Customer Support at the telephone number shown above System MPL300 II Primary Application _______________...

Page 13: ... and Fixture on the Baseplate 3 3 3 3 Protection Class 3 4 3 4 Location 3 4 4 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 DX200 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 Stopping Angle...

Page 14: ...9 1 9 1 Inspection Schedule 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 Replenishment Exchange for S Axis Speed Reducer and Gear 9 8 9 3 2 1 Grease Replenishment 9 8 9 3 2 2 Grease Exchange 9 9 9 3 3 Grease Replenishment Exchange for L Axis Speed Reducer...

Page 15: ...0 II 9 3 8 Notes for Maintenance 9 20 9 3 8 1 Battery Pack Connection 9 20 10 Recommended Spare Parts 10 1 11 Parts List 11 1 11 1 S Axis Unit 11 1 11 2 L Axis Unit 11 4 11 3 U Axis Unit 11 8 11 4 Wrist Unit 11 10 11 5 Balancer Unit 11 13 15 of 100 ...

Page 16: ...cludes the following four items information for the content of optional goods are given separately Manipulator DX200 Programming pendant Manipulator cables CAUTION Confirm that the manipulator and the DX200 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 ...

Page 17: ... the 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 ORDER NO Check that the manipulator and the DX200 have the same order number Label Enlarged View b Manipulator Side View a DX200 Front View 17 of 100 ...

Page 18: ...e this caution may adversely affect performance NOTE The weight of the manipulator is approximately 1865kg including the shipping bolts and brackets Use a wire rope strong enough to withstand the weight Shipping bolts and brackets are designed to support the manipulator weight Do not use them for anything other than transporting the manipulator Mount the shipping bolts and brackets for transportin...

Page 19: ...re 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 Axis Angle Pulse Factory setting for angle and pulse of each axis S L U T 0 0 94720 52622 2 5 4 5 19 of 100 ...

Page 20: ... 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 4 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 b...

Page 21: ... include but not be limited to safeguarding devices barriers interlock barriers perimeter guarding awareness barriers and awareness signals WARNING Install the safeguarding Failure to observe this warning may result in injury or damage Install the manipulator in a location where the tool or the workpiece held by its fully extended arm will not reach the wall safeguarding or controller Failure to o...

Page 22: ...ing installation if the flatness is not right the manipulator shape may be deformed and its functional ability may be compromised The flatness for baseplate must be kept at 0 5 mm or less Fix the manipulator base as described in section 3 2 1 Mounting the Manipulator and Fixture on the Baseplate Fig 3 1 Manipulator Repulsion Force and Torque Table 3 1 Manipulator Repulsion Force and Torque Horizon...

Page 23: ...anipulator base securely fix the manipulator to the baseplate using eight hexagon head screws M20 Tensile strength 1200 N mm2 or more 80 mm long is recommended Tighten the bolts with a tightening torque of 402 N m 41 kgf m Tighten the hexagon head screws and anchor bolts firmly so that they will not be loosened during the operation Fig 3 2 Mounting the Manipulator on Baseplate Hexagon socket head ...

Page 24: ...Location When installing a manipulator it is necessary to satisfy the following environmental 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 installati...

Page 25: ...ay 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 DX200 Failure to observe this caution may result in burn caused by cable heat emission...

Page 26: ...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 then 1BC After inserting the cables depress the lever until it clicks 4 2 2 Connection to the DX200 Before connecting cables to the DX200 verify the numbers on both manipulator cables and the connectors on the DX200 When co...

Page 27: ...CD HW1482991 4 Wiring 4 2 Cable Connection MPL300 II Fig 4 3 a Manipulator Cable Connectors Manipulator Side Fig 4 3 b Manipulator Cable Connection DX200 Side Key positions S1 2BC 1BC FB C D E A B X21 X11 27 of 100 ...

Page 28: ...the manipulator IP54 or equivalent Wrist axis only IP67 or equivalent Ambient Conditions Temperature 0 to 45 C Humidity 20 to 80 RH non condensing Vibration 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 plasma Power Requirements 8 0 kVA Noise4 70dB 1 SI units are used in this tab...

Page 29: ... Axes 5 3 Manipulator Base Dimensions Fig 5 2 Manipulator Base Dimensions S S Lower arm L arm Base Upper arm U arm Wrist Wrist flange Rotary head S head T T U U L L 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 29 of 100 ...

Page 30: ...5 4 Dimensions and T Point Maximum Envelope Fig 5 3 Dimensions and T Point Maximum Envelope point maximum envelope T Units mm T Point P point 625 616 16 2529 R1124 2776 614 2162 1300 1300 1600 1600 2363 2624 1241 45 9 0 F R1037 R3159 2204 300 250 1400 0 820 3159 1037 R 6 9 7 880 1250 270 0 120 30 of 100 ...

Page 31: ...㻿㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻜㻌㻝㻜㻜㻑 㻸㼛㼍㼐㻝㻜㻜㻑 㻸㼛㼍㼐㻢㻢㻑 㻸㼛㼍㼐㻟㻟㻑 㻜 㻡 㻝㻜 㻝㻡 㻞㻜 㻞㻡 㻟㻜 㻟㻡 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼍㼚㼓㼘㼑㼇㼐㼑㼓㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌㼛㼒㻌㻿㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻜㻌㻝㻜㻜㻑㻌 㻸㼛㼍㼐㻝㻜㻜㻑 㻸㼛㼍㼐㻢㻢㻑 㻸㼛㼍㼐㻟㻟㻑 㻜 㻡 㻝㻜 㻝㻡 㻞㻜 㻞㻡 㻟㻜 㻟㻡 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼍㼚㼓㼘㼑㼇㼐㼑㼓㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌㼛㼒㻌㻸㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻜㻌㻝㻜㻜㻑 㻸㼛㼍㼐㻝㻜㻜㻑 㻸㼛㼍㼐㻢㻢㻑 㻸㼛㼍㼐㻟㻟㻑 㻜㻚㻜 㻜㻚㻝 㻜㻚㻞 㻜㻚㻟 㻜㻚㻠 㻜㻚㻡 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼠㼕㼙㼑㼇㼟㼑㼏㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚...

Page 32: ... takes one pose only for this structure a S Axis 㻜㻚㻜 㻜㻚㻝 㻜㻚㻞 㻜㻚㻟 㻜㻚㻠 㻜㻚㻡 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼠㼕㼙㼑㼇㼟㼑㼏㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌㼛㼒㻌㻿㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻜㻌㻢㻢㻑 㻸㼛㼍㼐㻝㻜㻜㻑 㻸㼛㼍㼐㻢㻢㻑 㻸㼛㼍㼐㻟㻟㻑 㻜 㻡 㻝㻜 㻝㻡 㻞㻜 㻞㻡 㻟㻜 㻟㻡 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼍㼚㼓㼘㼑㼇㼐㼑㼓㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌㼛㼒㻌㻿㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻜㻌㻢㻢㻑 㻸㼛㼍㼐㻝㻜㻜㻑 㻸㼛㼍㼐㻢㻢㻑 㻸㼛㼍㼐㻟㻟㻑 a S Axis 㻜㻚㻜 㻜㻚㻝 㻜㻚㻞 㻜㻚㻟 㻜㻚㻠 㻜㻚㻡 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼠㼕㼙㼑㼇㼟㼑㼏㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜...

Page 33: ...U Axis 㻜㻚㻜 㻜㻚㻞 㻜㻚㻠 㻜㻚㻢 㻜㻚㻤 㻝㻚㻜 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼠㼕㼙㼑㼇㼟㼑㼏㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌㼛㼒㻌㻿㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻝 㻜 㻝㻜 㻞㻜 㻟㻜 㻠㻜 㻡㻜 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼍㼚㼓㼘㼑㼇㼐㼑㼓㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌㼛㼒㻌㻿㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻝㻌 㻜㻚㻜 㻜㻚㻝 㻜㻚㻞 㻜㻚㻟 㻜㻚㻠 㻜㻚㻡 㻜㻚㻢 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼠㼕㼙㼑㼇㼟㼑㼏㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌㼛㼒㻌㻸㻙㼍㼤㼕㼟㻌㼏㼍㼠㼑㼓㼛㼞㼥㻝 㻜 㻝㻜 㻞㻜 㻟㻜 㻠㻜 㻡㻜 㻜 㻟㻜 㻢㻜 㻥㻜 㻝㻞㻜 㻿㼠㼛㼜㼜㼕㼚㼓㻌㼍㼚㼓㼘㼑㼇㼐㼑㼓㼉 㻿㼜㼑㼑㼐㼇㼐㼑㼓㻛㼟㼉 㻿㼠㼛㼜㻌㼜㼛㼟㼕㼠㼕㼛㼚㻌...

Page 34: ...itions 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 34 ...

Page 35: ...er referring to the following list 1 Pin drawing No HW0407007 1 1 pin 2 Stopper drawing No HW0307574 1 1 stopper 3 Hexagon socket head cap screw M20 length 70 mm tensile strength 1200 N mm2 or more 3 screws 4 Flat washer M20 3 flat washers Fig 5 8 Components of S Axis Stopper Stopper HW0307574 1 Pin HW0407007 1 Section A A Hexagon socket head cap screw M20 length 70 mm tensile strength 1200 N mm2 ...

Page 36: ...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 9 Properly Mounted Image As in the figures Fig 5 10 a Properly Mounted Models for S Axis Stopper to Fig 5 10 m Properly Mounted Models for S Axis Stopper the S axis mec...

Page 37: ...modifying the range of motion of S Axis Pulse limit positive direction of the S axis S1CxG400 Pulse limit negative direction of the S axis S1CxG408 MPL300 II Degree Number of Pulse 0 0 15 1 1 Refer to section 5 6 Alterable Operating Range 34092 30 68183 45 102275 60 136367 75 170458 90 204550 105 238642 120 272733 135 306825 150 340917 165 1 375008 180 409100 NOTE Adjust both of the pulse limit an...

Page 38: ...installing 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 inte...

Page 39: ...is 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 39 of 100 ...

Page 40: ... 135 150 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 40 of 100 ...

Page 41: ... 105 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 41 of 100 ...

Page 42: ...xis 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 42 of 100 ...

Page 43: ...r 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 43 of 100 ...

Page 44: ...r 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 44 of 100 ...

Page 45: ...6 Alterable Operating Range MPL300 II Fig 5 10 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 45 of 100 ...

Page 46: ...is 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 46 of 100 ...

Page 47: ... 150 135 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 47 of 100 ...

Page 48: ... 105 120 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 48 of 100 ...

Page 49: ...xis 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 49 of 100 ...

Page 50: ...r 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 50 of 100 ...

Page 51: ...r 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 51 of 100 ...

Page 52: ... T axis flange rotation center is in the range shown in Fig 6 1 Moment Arm Rating for MPL300 II When the inertia of the volume load on the flange Ji is large use the following formula to calculate the eccentricity LT Fig 6 1 Moment Arm Rating for MPL300 II Table 6 1 Allowable Total Inertia T Axis Total Moment of Inertia GD2 4 kg m2 140 kg m2 J Ji WL 2 T J Ji W LT Total inertia GD2 4 of the T axis ...

Page 53: ...ing 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 03...

Page 54: ...MOTOMAN MPL300 II 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 Tilting of wrist flange T ...

Page 55: ...rs 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 Proces...

Page 56: ...s mounted on the upper arm as shown in Fig 7 2 a Connectors for Internal User I O Wiring Harness and Air Line The connector pins 1 to 23 are assigned as shown in Fig 7 2 c 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 total current value for pins 1 to 23 must be 44 A or less The maxi...

Page 57: ... for a field bus cable inside dia 12 mm is connected by a union in the Z part of the S head Connector for the internal user I O wiring harness base side JL05 2A24 28PC with a cap Prepare connector JL05 6A24 28S Air inlet A B C D E PT3 8 with a pipe plug 5 places View A Connector base E D C B S1 2BC 1BC FB C D E A B A C B A E D B A View B Connector for the internal user I O wiring harness wrist sid...

Page 58: ... 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 the field bus cable and run it through the manipulator See the step 5 on th...

Page 59: ...of 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 100 ...

Page 60: ...h protective 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 cros...

Page 61: ...ptional 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 S1 2BC 1BC FB C D E A B 61 of 100 ...

Page 62: ... BAT PG U AXIS DATA 6 DATA 6 OBAT6 PG0V6 PG5V6 BAT6 No 8CN 2 3 4 1 T No 4CN 5 4 9 10 1 2 6 OBT FG6 5V BAT 0V OBT BAT T AXIS PG CN1 1 SPG 1 CN1 2 SPG 1 P CN1 1 CN1 2 SPG 1 SPG 1 CN1 3 FG1 CN1 3 FG1 CN1 8 FG2 CN1 7 CN1 6 SPG 2 SPG 2 CN1 8 FG2 CN1 7 CN1 6 P SPG 2 SPG 2 CN2 3 CN2 2 CN2 1 SPG 3 SPG 3 FG3 CN2 3 CN2 2 CN2 1 P SPG 3 SPG 3 FG3 CN3 8 CN3 7 CN3 6 SPG 6 SPG 6 FG6 CN3 8 CN3 7 CN3 6 P SPG 6 SPG...

Page 63: ...11 D 8 D 7 B 9 D 3 D 4 D 5 D 6 D 2 D 1 MU2 MU2 MV2 MV2 MW2 MW2 ME2 ME2 BA1 BA2 F 8 F 7 F 2 F 1 F 5 F 6 F 3 B 5 B 4 F 4 E MU1 MV1 MU1 MW1 MW1 MV1 ME1 ME1 2BC 8X5 E 8 E 7 E 2 E 5 E 6 E 1 E 4 E 3 C D B A No 15CN MU3 MW3 ME3 MV3 C D B No 13CN A MW6 ME6 MV6 MU6 SM T AXIS SM U AXIS MU2 ME2 MW2 MV2 D C B No 11CN A MV1 MW1 MU1 ME1 BB1 BA1 B C D No 9CN A 2 1 SM L AXIS SM YB S AXIS E B 3 C 4 C 6 C 2 C 5 A 3...

Page 64: ...ion may 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 result in death or serious injury from unexpected turning of the manipulator s arm WARNING Before maintenance or inspection be sure to turn the main power supply OFF and put up a warning sign ex...

Page 65: ... 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 Wire harness in manipulator Wires for S L and U axes Wires for T axis Multimeter Visual Check for conduction between the main connector of base and int...

Page 66: ...sibility 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 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 7 Grease Replenishment...

Page 67: ... 9 Maintenance and Inspection 9 1 Inspection Schedule MPL300 II Fig 9 1 Inspection Items U axis L axis T axis S axis 14 7 2 4 14 7 2 4 8 2 13 10 1 1 1 16 11 16 11 16 11 16 11 16 11 16 11 16 11 15 16 11 2 9 A 12 6 1 5 67 of 100 ...

Page 68: ...Fig 9 2 b Battery Location Top View If the battery alarm occurs in the DX200 replace the battery in accordance with the following procedure Fig 9 2 a Battery Location Back View Fig 9 2 b Battery Location Top View Fig 9 3 Battery Connection Plate Connector base Base Plate mounting screw M4 S1 2BC 1BC FB C D E A B Battery pack Board New battery pack HW0470360 A Battery pack before replacement See th...

Page 69: ...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 6 Mount the new battery pack to the holder 7 Reinstall the plate NOTE Remove the old battery pack after connecting the new one so that the encoder absolute data does not disappear NOTE Do not allow the plate to pi...

Page 70: ...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 sure to use a grease pump to inject grease Set air supply press...

Page 71: ...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 6 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 th...

Page 72: ...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 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 t...

Page 73: ...nishment 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 73 of 100 ...

Page 74: ...he 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 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 to...

Page 75: ...e 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 and reinstall the plug Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the p...

Page 76: ...l 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 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 Grease inlet Hexagon...

Page 77: ... 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 and reinstall the plug Before installing the plug apply Three Bond 1206C on the thread part of the plug Then tighten the pl...

Page 78: ...ir 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 head plug...

Page 79: ...utes 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 plug The...

Page 80: ... 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 apply Thre...

Page 81: ...gon 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 A A 1BC A 4BC 2BC 3BC F E B C A Link Grease inlet Hexagon socket head plug PT1 8 10 Link Exhaust port Hexagon socket head plug PT1 8 10 Link Exhaust port Hexagon soc...

Page 82: ...or 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 tightening torque ...

Page 83: ...rs connected after the maintenance check and remove the battery packs Install the caps attached to the battery backup connectors of the motors Fig 9 10 Battery Pack Connection NOTE When performing maintenance such as replacement of a wire harness in the manipulator the encoder connector may be necessary to be removed In this case be sure to connect the battery pack to the battery backup connector ...

Page 84: ... 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 Bond 1206C ThreeBond Co Ltd 1 1 B 6 Replacement Kit for S Axis Speed Reducer Y005C MPL0300J00S YASKAWA Electric C...

Page 85: ...025 A YASKAWA Electric Corporation 1 1 C 14 Wire Harness in Manipulator HW1372054 A YASKAWA Electric Corporation 1 1 C 15 Board SGDR EFBA02A YASKAWA Electric Corporation 1 1 Table 10 1 Spare Parts for the YR MPL0300 J00 Sheet 2 of 2 Rank Parts No Name Type Manufacturer Qty Qty per Unit Remarks 85 of 100 ...

Page 86: ...1029 1031 1032 1039 1001 1002 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 1036 1027 1019 1020 1034 86 of 100 ...

Page 87: ... 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 S...

Page 88: ...7 1057 M5X16 Socket screw 7 1058 IRTW 72 Ring 2 1059 ISTW 35 Ring 2 1060 CIMR35 1 Shim 2 1061 6207ZZ Bearing 2 1062 HW9381477 A Gear 1 1063 HW9405051 1 Cover 1 1064 2H 5 Spring washer 7 1065 M5X16 Socket screw 7 1066 M12X20 Socket screw 1 1067 PT3 8 STAINLESS Plug 1 1077 HW0308464 1 Flange 1 1078 TC8511013 Oil seal 1 1079 HW0308465 1 Shaft 1 Table 11 1 S Axis Unit Sheet 2 of 2 No DWG No Name Pcs 8...

Page 89: ...011 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 89 of 100 ...

Page 90: ...40 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 2086 2045 2025 2045 2095 2095 2045 2092 2093 2092 2093 90 of 100 ...

Page 91: ...9482306 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 Socket sc...

Page 92: ... Bearing 2 2070 AG3217A4 Oil seal 1 2071 VB60787 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 ...

Page 93: ...11 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 3037 3005 3005 3005 3005 3005 2003 3027 3027 3005 3005 93 of 100 ...

Page 94: ... 1 3016 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...

Page 95: ...4 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 95 of 100 ...

Page 96: ... 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 STAINLESS Plug 7 4025 LP M5 Plug 1 4026 HW0314598 1 Guide 1 4027 HW0314599 2 Gear 1 4028 HW0314600 1 Gear 1 4029 HW0314601 1 M base 1 4030 HW0314602 1 Flange A 1 4031 HW0314603 1 Flange B ...

Page 97: ...048 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 97 of 100 ...

Page 98: ...11 5Balancer Unit 11 13 173124 1CD HW1482991 MPL300 II 11 5 Balancer Unit Fig 11 5 Balancer Unit 5001 5002 5017 5003 5004 5005 5006 5007 5008 5009 5010 5011 5012 5012 5013 5014 5015 5016 5003 5018 5019 5020 98 of 100 ...

Page 99: ... 5005 HW0306033 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 STAINLESS Plug 3 5015 M10X40 Socket screw 8 5016 2H 10 Spring washer 8 5017 HW0481742 A Coil spring 1 5018 M8X16 Socket screw 3 5019 2H 8 Spring washer 3 5020...

Page 100: ...HOUGANG 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 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 Ra...