YASKAWA MPL160-J00, Operating And Maintenance Manual

Page 1: ...ROBOTICS MPL160 J00 YR MPL0160 J00 Operating and Maintenance Manual...

Page 2: ...However the information given in this publication is checked regularly and any necessary corrections will be made in subsequent editions Subject to technical modifications Created on 2016 08 Revision...

Page 3: ...asures 17 4 2 Ambient conditions and installation location 18 4 3 Installation example 18 5 Wiring 21 5 1 Grounding 21 5 2 Cable connections 22 5 2 1 Connecting the robot 23 5 2 2 Connection of the ro...

Page 4: ...2 Grease filling the wrist axes 62 9 3 3 Refilling the amount of grease in joints 63 9 4 Home position calibration 64 9 4 1 Registering all axes at the time 65 9 4 2 Registering individual axes 68 9 4...

Page 5: ...NOTICE Indicates important background information and application advice 1 2 Frequently used terms The YASKAWA robot is a product of YASKAWA Electric Corporation and is provided by default with the r...

Page 6: ...branch office 1 4 Intended use Typical applications Flange mounting tools Installation of spot welding guns Installation of arc welding equipment Installation of grippers Machining and transporting wo...

Page 7: ...operating instructions Basic Information Installation and Wiring and System Setup In order to illustrate details clearly some drawings are shown with the protective covers or shields removed All prot...

Page 8: ...top button 1 Short Cut Main Menu JOB CONTENT 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 TEST01 TOOL CONTROL GROUP R1 S 0000 NOP SET B000 1 SET B001 0 MOVJ VJ 80 00 MOVJ VJ 80 00 DOUT...

Page 9: ...ing or Universal Application An area must be left clear so that the operator can retreat to it in case of emergency The following inspection procedures must be performed prior to teaching the robot If...

Page 10: ...promptly detect a warning A warning message is output as a dedicated output signal so it is recommended that you monitor it on the system side as a warning signal for the sake of safety Refer to Conc...

Page 11: ...nufacturer Address YASKAWA ELECTRIC CORPORATION 2 1 KUROSAKISHIROISHI YAHATANISHI KU KITAKYUSHU JAPAN 1 10 Authorized representative Address YASKAWA Europe GmbH Robotics Division Yaskawastr 1 85391 Al...

Page 12: ...1 Checking the scope of delivery The standard delivery includes the following items Fig 2 1 Scope of delivery Programming pendant Assembly instruction Robot controller Cable Robot MOTOMAN MANUAL 1 2...

Page 13: ...te NOTICE Please contact the local YASKAWA branch office if the serial numbers do not match the information on the delivery note S N DX200 YASAKAW XXXXX Part No Power Supply Peak kVA AC XXXXXXXX Avera...

Page 14: ...xerted on the robot controller on the robot or on other components 3 1 Transporting method CAUTION Damage to persons and damage to property due to external force influences External forces must not be...

Page 15: ...ift Make sure that the forklift and the transportation route have sufficient bearing capacity Always take due care when transporting the robot 3 2 Shipping brackets and bolts NOTICE Before turning ON...

Page 16: ...Transportation 3 16 The shipping brackets and bolts are painted yellow Fig 3 2 Position of shipping bolts Item Screw type Part A Screw M20 12 9 4 B and C Screw M10 12 9 4 C A B...

Page 17: ...protective measures can lead to death of people serious bodily harm or material damage Implement the following protection measures Separating protection devices Non contact protection devices Enclosu...

Page 18: ...tion example 1 At the first set out anchor the base plate firmly onto the floor 2 The robot base is tapped for 8 mounting holes Fix the robot base with the screws M20 strength class 12 9 Minimum lengt...

Page 19: ...of the robot As a rough standard if there is a concrete thickness floor of 200 mm or more the robot base can be fixed directly to the floor with anchor bolts Before mounting the robot however check th...

Page 20: ...and moments of the robot Direction of move ment Horizontal Vertical Force FH Moment MH Force FV Torque MV Emergency stop Stop category 0 20580 N 39200 Nm 49980 N 62720 Nm Acceleration Decelera tion S...

Page 21: ...s and wiring regulations for earthing The cable cross section must be 6 mm or more For information on connecting the earthing cable directly see Fig 5 1 Earthing connection NOTICE Note on the earthing...

Page 22: ...he robot base and on the robot controller see the following chapter on robot connection and robot controller connection Fig 5 3 Robot cable Robot control side Encoder cable 1BC Robot side Power cable...

Page 23: ...er cable 2BC 2 Connect the encoder cable 1BC to the connector plate of the robot 3 Connect the power cable 2BC to the connector plate of the robot Make sure that you hear each locking clip snap into p...

Page 24: ...order 1 Connect the encoder cable 1BC X11 at X 1 connection to the robot controller 2 Connect the power cable 2BC X21 at X 2 connection to the robot controller Make sure that you hear the locking clip...

Page 25: ...PROGRAMMING PENDANT PROPERLY CHECK ALL THE DOOR LOCKS NJ3005 1 kVA kVA ERDR Average Peak NJ3053 1 Kammerfeldstr 1 D 85391 Allershausen 2 1 Kurosaki Shiroishi Yahatanishi Ku Kitakyushu City Fukuoka 80...

Page 26: ...60 360 Protection class IP Main axes 54 Wrist axes 67 Maximum speed S axis 2 44 rad s 140 s L axis 2 44 rad s 140 s U axis 2 44 rad s 140 s R axis B axis T axis 5 32 rad s 305 s Allowed moment Nm 3 3...

Page 27: ...nsion Fig 6 2 Robot base dimensions Upper arm U arm Rotating head of S axis Wrist flange Robot base Lower arm L arm 2 holes 20 H7 Borehole 12 H7 8 mounting holes 22 All dimensions in mm T U L S S L U...

Page 28: ...ions and defined work area P point Working area defined with point P T point All dimensions in mm R 6 9 7 1300 1300 1600 1600 R3 159 R1037 0 270 1250 880 1037 3159 0 1400 250 300 1 5 5 2529 R1 124 277...

Page 29: ...may be changed depending on the type of application If any modification is necessary please contact the local YASKAWA branch office The mechanical stop can only be adjusted in 60 steps Item Specificat...

Page 30: ...Working Area To change the working area of S axis the following components are required see the following figure Fig 6 4 Components of the S axis limit 3 screws M20 x 70 strength category 12 9 and 3...

Page 31: ...ng table 6 4 3 Adjusting the S Axis Pulse Limit Check whether both sides are stabilized with screws as shown in the following diagram Fig 6 5 Mounted correctly with regard to the force limitation of t...

Page 32: ...both the pulse limit and the angle of the mechanical S axis limit Fig 6 6 Adjustable angle for the S axis limit Degree 15 30 45 60 75 90 Number of pulses 0 29089 58179 87268 116357 145446 174536 Degre...

Page 33: ...imitation The limit can be used on both sides Screw 2 1 2 1 180 165 1 2 1 2 150 135 1 2 1 2 120 105 1 2 1 2 90 75 1 2 1 2 60 45 1 2 2 1 30 15 165 2 1 150 165 150 2 1 135 120 135 2 1 120 1 2 105 90 105...

Page 34: ...times may differ due to internal and external influence on the braking torque According to the mode robot application and number of triggered safety stops with stop category 0 a different brake wear...

Page 35: ...Technical data 6 35 6 5 1 Stop category 0 6 5 1 1 Stop position S axis 100 deflection 66 deflection 33 deflection deg deg s deg s sec deg deg s deg s sec deg deg s deg s sec...

Page 36: ...Technical data 6 36 6 5 1 2 Stop position L axis 100 deflection deg deg s deg s sec...

Page 37: ...Technical data 6 37 6 5 1 3 Stop position U axis 100 deflection deg deg s deg s sec...

Page 38: ...38 6 5 2 Stop category 1 6 5 2 1 Stop position S axis 100 deflection 6 5 2 2 Stop position L axis 100 deflection 6 5 2 3 Stop position U axis 100 deflection deg deg s deg s sec deg deg s deg s sec deg...

Page 39: ...NOTICE Before mounting a tool remove anticorrosive coating on the flange Thinner or light fuel oil are the most suitable for this purpose Fig 7 1 Wrist flange 7 2 Maximum load of the S axis For perip...

Page 40: ...WLT J Total moment of inertia GD2 4 of the T axis kgm Ji Inertia of the volume load on flange kgm W Payload kg LT Eccentricity mm Fig 7 2 Moment of arm rating In order to facilitate the user s system...

Page 41: ...ent mounts Tab 7 1 Installation Conditions View A 6 threaded holes M6 x 15 Section B B 2 threaded holes M6 x 15 All dimensions in mm Application Notice Wiring and valve load Up to 160 kg for attaching...

Page 42: ...xis varies and depends on the permissible torque Contact your YASKAWA branch office in a timely manner if you have questions regarding the calculation of the load or centroidal distance Example In the...

Page 43: ...ose must not exceed 600 kPA the inner diameter of the air hose is 7 5 Fig 8 1 Plug for internal cables and compressed air routing Air inlet A B C D and E with cap Connector for the internal cable bush...

Page 44: ...pipe for the field bus cable inner diameter 12 mm 12 mm will be connected over a connection inthere the cable is lead Step 2 Remove the connection from the field bus cable pipe Pull the field bus cabl...

Page 45: ...2 A sufficient clearance must be maintained between the protective cover and the internal cables etc The ratio of the total cross section the internal cables and the protective cover may not exceed 3...

Page 46: ...BAT OBT No 6CN OBAT2 PG5V2 BAT2 PG0V2 2 3 4 1 L No 2CN 1 9 6 5 4 2 0V BAT OBT 5V L AXIS PG DATA 3 DATA 3 2 OBAT3 PG0V3 PG5V3 4 3 BAT3 No 7CN 1 U OBT 5 4 9 10 BAT 5V 0V OBT FG3 No 3CN 1 2 6 BAT PG U AX...

Page 47: ...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...

Page 48: ...ing maintenance and inspection measures Turn OFF the main power supply Put up the required warning sign e g Do not turn the power on Install a switch on guard as prescribed If you have any questions r...

Page 49: ...UTILITY Main Menu ShortCut CONTROL POWER TIME 1998 07 06 10 00 2385 42 02 SERVO POWER TIME 1998 07 06 10 30 36000 00 00 PLAYBACK TIME 1998 10 22 11 12 2210 00 20 MOVING TIME 1998 10 22 15 30 1875 15...

Page 50: ...obot Visual inspection Dirty working area has to be cleaned Please control the robot for damage and external cracks 4 Motors for L and U axes Visual inspection Check for grease leakage2 5 Fastening bo...

Page 51: ...attery unit in robot If a battery alarm appears or after the robot has been operated for 36 000 hours the battery must be replaced 13 S L U and T axes gear Grease gun Check for faults replace if neces...

Page 52: ...AWA branch office 3 When checking for conduction with multimeter connect the battery to BAT and OBT of connectors on the motor side for each axis Now remove the connectors of the encoders of the respe...

Page 53: ...Maintenance and inspection 9 53 Fig 9 2 Inspection intervals The numbers in the above figure are equal to the numbers in the table of Inspection intervals A...

Page 54: ...9 4 Battery unit location top view The battery units are installed as shown in picture The location of the battery unit If battery alarm occuring in the robot controller battery pack has to be changed...

Page 55: ...e plug from circuit board 4 Connect the new battery pack to the unoccupied connector on the board Fig 9 6 Battery pack connections 5 Remove the old battery pack from the battery holder 6 Mount the new...

Page 56: ...d NOTICE Make sure that no wires are pinched when you install the battery pack and the cover plate again 8 Please apply Teroson Plast sealing compound material no 143813 to thread part of screws Excha...

Page 57: ...attery unit connector diagram for R B and T axes Motor Battery unit Motor power connector Plug for backup Encoder connector Encoder Warning label Motor cable Power connector Battery unit Wiring harnes...

Page 58: ...to the grease outlet If this instruction is not followed the motor will be damaged Avoid air getting into the gear Insert grease with a grease gun If an automatic lubricating pump is used the grease s...

Page 59: ...eeze out the excess fat all taxes must be brought to operating temperature In a operating JOB or a special moving JOBs about 20 minutes at 100 speed 5 Wipe away excess grease with a cloth 6 Remove the...

Page 60: ...he axes Amount of grease S axis gear Replenishment 2100 cm approx 1827 g Exchange 10400 cm approx 9048 g1 1 The grease exchange is complete when new grease appears from the exhaust port The new grease...

Page 61: ...Maintenance and inspection 9 61 Air outlet cap Joint 80 9 0 170 1 1 2 2 2 1 2...

Page 62: ...rist axes Grease filling the wrist axes Figure the axes Amount of grease BT axis gear Replenishment 180 cm approx 156 g Exchange 900 cm approx 783 g1 U axis cross roller bearing Replenishment 60 cm ap...

Page 63: ...nts 1 2 3 6 6 cm approx 5 g Amount of grease for joints 4 5 9 12 cm approx 10 g Amount of grease for joints 7 8 3 cm approx 2 5 g Amount of grease for joints 10 11 5 cm approx 4 5 g 10 5 1 6 2 5 2 3 6...

Page 64: ...setting the home position the position of the absolute encoder must match it Although this operation is performed prior to shipment at the factory the following cases require this operation to be perf...

Page 65: ...Maintenance and inspection 9 65 9 4 1 Registering all axes at the time 1 Select ROBOT from the main menu The sub menu choices appear 2 Select HOME POSITION The HOME POSITIONING window appears...

Page 66: ...3 can also be performed by selecting the PAGE button In this case a selection box appears 4 Select the sub assembly to calibrate e g R1 ROBOT Select the control group for HOME POSITIONING The control...

Page 67: ...inspection 9 67 6 Select SELECT ALL AXES A confirmation dialog box is displayed 7 Select YES Displayed position data of all axes are registered as home position When NO is selected the registration w...

Page 68: ...ibrated e g R1 ROBOT Perform steps 3 and 4 as described in section 9 4 1 Registering all axes at the time to select the desired control group 4 Move the cursor to the axis you want to register and sel...

Page 69: ...The sub menu choices appear 2 Select HOME POSITION 3 select the sub assembly components to be calibrated Carry out steps 3 and 4 as described in section 9 4 1 Registering all axes at the time on page...

Page 70: ...choices appear 2 Select HOME POSITION Carry out steps 3 and 4 as described in section 9 4 1 Registering all axes at the time on page 65 to select the desired control group 3 Select DATA from the main...

Page 71: ...or in the PG system The robot was moved after the power supply was turned OFF If the alarm OUTSIDE THE RANGE ABSOLUTE DATA appears automatic mode is not possible The home position must be checked If t...

Page 72: ...9 5 2 Procedure for the second home position setting on page 73 Alarm message If the alarm occurs again the error may be in the PG system Check the pulse generating system Once you have set the fault...

Page 73: ...absolute data Use the following steps to set the specified point NOTICE If 2 or more Robots or stations are controlled by one controller the second home position must be set for each robot or station...

Page 74: ...anger of crushing Irregularities in the PG system may lead to an alarm and the robot may perform unexpected movements If the OUT OF RANGE ABSO DATA alarm occurs Reset the alarm the SERVO power ON Then...

Page 75: ...o you intend to specify second home position 4 Press FWD TCP moves to the second home position The robot moving speed is set as selected manual speed 5 Select DATA in the menu 6 Select CONFIRM POSITIO...

Page 76: ...0 2 E146745 20 kg A Sealing compound Teroson Plast 143813 200 ml A Battery unit Robot 128708 1 1 A Battery unit Control 155543 1 1 B S axis gear HW0281280 A E112628 1 1 B Pinion HW0307565 3 1 1 B L an...

Page 77: ...29 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 10...

Page 78: ...8 Washer 1 1026 HW0407007 1 Pin 1 1027 HW0403903 1 Metal sheet 1 1028 M20 x 70 12 9 Screw 3 1029 M20 Washer 3 1030 HW0402102 1 Stop 1 1031 M8 x 40 Screw 1 1032 2H 8 Washer 1 1033 HW9404486 1 Shaft 1...

Page 79: ...2 1061 6207ZZ Bearing 2 1062 HW0307656 1 Pinion 1 1063 HW9405051 1 Cover 1 1064 2H 5 Washer 7 1065 M5 x 16 Screw 7 1066 M12 x 20 Screw 1 1067 PT3 8 Set screw 1 1068 HW0314644 A Cover 1 1069 M8 x 25 S...

Page 80: ...1 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 203...

Page 81: ...ler bearing 1 2013 1011 2020 2008 2010 2019 2001 2011 2040 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 2...

Page 82: ...0 GS310 O ring 1 2021 Y507212 5 Oil seal 2 2022 VB 265 280 7 Oil seal 2 2023 M8 x 25 Screw 12 2025 2H 8 Washer 20 2026 M10 x 60 Screw 18 2027 M10 x 50 Screw 18 2028 M10 x 45 Screw 1 2029 M10 x 25 Scre...

Page 83: ...7A4 Oil seal 1 2071 VB60787 Oil seal 1 2072 WR60 Circlip 1 2073 VB75956 Oil seal 1 2074 AR 85 Retaining ring 1 2075 NA6912 Bearing 1 2076 AG3512E1 Oil seal 2 2077 HR32011XJ Bearing 2 2078 G85 O ring 1...

Page 84: ...w 1 3034 3037 3030 3032 3022 3009 3023 3005 3001 3006 3006 3007 3008 3010 3010 3011 3012 3013 3014 3015 3020 3021 3028 3031 3041 3034 3036 3038 3039 3016 3017 3018 3002 3003 3004 3005 3001 3004 3017 3...

Page 85: ...crew 1 3021 2H 12 Washer 11 3022 HW0406922 1 Cover 3 3023 HW0406923 1 Washer 5 3024 HW0307641 1 Shaft 2 3027 HW0484003 A Bearing 3 3028 M10 x 30 Screw 8 3029 2H 10 Washer 8 3030 M10 x 25 Screw 5 3031...

Page 86: ...9 4025 4021 4016 4015 4015 4010 4014 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 403...

Page 87: ...10 Washer 2 4021 M8 x 25 Screw 3 4022 M8 x 30 Screw 3 4023 M6 x 20 Screw 3 4024 PT1 8 Set screw 7 4025 LP M5 Set screw 1 4026 HW0314598 1 Pipe 1 4027 HW0314599 1 Pinion 1 4028 HW0314600 1 Pinion 1 402...

Page 88: ...4047 M10 x 20 Screw 8 4048 2H 10 Washer 8 4049 M4 X 10 Screw 8 4050 M8 x 80 Screw 30 4051 2H 8 Washer 30 4052 M6X20 Screw 1 4053 2H 6 Washer 1 4054 M10X20 Screw 9 4055 2H 10 Washer 9 4056 MSTH8 20 Pi...

Page 89: ...DWG no Description Pcs 5001 HW0481740 A Spring 1 5002 HW0481741 A Spring 1 5003 SOB607440 Sleeve 2 5004 HW0100477 1 Housing 1 5005 HW0306033 1 Flange 1 5001 5002 5017 5003 5004 5005 5006 5007 5008 50...

Page 90: ...81 1 Pipe 1 5009 HW9405057 1 Fork head 1 5010 FD3187A0 Dust seal 1 5011 EZ2228B0 Cap 1 5012 IRTW 75 Stop 2 5013 M6 x 8 Screw 2 5014 PT1 8 Set screw 3 5015 M10 x 40 Screw 8 5016 2H 10 Washer 8 5017 HW0...

Page 91: ...Parts lists 11 91...

Page 92: ...i stanbul 90 216 5273450 ZA YASKAWA Southern Africa PTY Ltd Johannesburg 27 11 6083182 BG ARAMET ROBOTICS Ltd Yambol 359 885 317 294 Kammarton Bulgaria Ltd Sofia 359 02 926 6060 CH Messer Eutectic Cas...