YASKAWA MH SIGMA-5 Series, MH505 SIGMA-5, MH95 SIGMA-5 Manual

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YASKAWA MH SIGMA-5 Series, MH505 SIGMA-5, MH95 SIGMA-5 Manual | Manualzz

MH-SERIES

SIGMA-5 POSITIONER MANUAL

MH95, MH185, MH505, MH1605, and MH3105

Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN INSTRUCTIONS

DX100 INSTRUCTIONS

DX100OPERATOR’S MANUAL

DX100 MAINTENANCE MANUAL

The DX100 operator’s manual above corresponds to specific usage.

Be sure to use the appropriate manual.

Part Number: 162068-1CD

Revision: 1

MANUAL NO.

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0

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MANDATORY

General items related to safety are listed in Section 2 of the DX100

Controller Manual . To ensure correct and safe operation, carefully read the DX100 Controller Manual before reading this manual.

CAUTION

• 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 improvements, modifications, or changes in specifications.

• If such a modification is made, the manual number will also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids the products warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the MH-SERIES POSITIONER.

In this manual, the Notes for Safe Operation are classified as “WARNING,”

“CAUTION,” “MANDATORY,” or “PROHIBITED.”

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to 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.

Must never be performed.

PROHIBITED

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

NOTE

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “CAUTION” and “WARNING.” iii

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WARNING

• Before operating the MH-SERIES POSITIONER, check that servo power is turned OFF by pressing the EMERGENCY STOP buttons on the operator station or Programming Pendant (refer to

Figure 1

).

When servo power is turned OFF, the SERVO ON LED on the

Programming Pendant is turned OFF.

Injury or damage to machinery may result if the Emergency Stop circuit cannot stop the positioner during an emergency. The positioner should not be used if the EMERGENCY STOP buttons do not function.

Figure 1: EMERGENCY STOP Button

• Release the EMERGENCY STOP button (refer to

Figure 2 ). Once

this button is released, clear the cell of all items which could interfere with the operation of the positioner then, turn servo power

ON.

Injury may result from unintentional or unexpected positioner motion.

Figure 2 : Release of EMERGENCY STOP Button

TURN

• Observe the following precautions when performing teaching operations within the working envelope of the positioner:

– View the positioner from the front whenever possible.

– Always follow the predetermined operating procedure.

– Ensure that there is a safe place to retreat to in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no person is present in the working envelope of the positioner and that you are in a safe location before:

– Turning on the power for the DX100 controller.

– Moving the positioner with the Programming Pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the working envelope of the positioner during operation. Always press an EMERGENCY STOP button immediately if there is a problem. The EMERGENCY STOP buttons are located on the operator station and on the Programming

Pendant.

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CAUTION

• Perform the following inspection procedures prior to conducting positioner teaching. If problems are found, repair them immediately and be sure that all other necessary processing has been performed.

– Check for problems in positioner movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the Programming Pendant to the hook on the cabinet of the DX100 controller after use.

• The Programming Pendant can be damaged if it is left in the work area, on the floor, or near fixtures.

• Read and understand the Explanation of Warning Labels in the

DX100 Controller Manual before operating the MH-SERIES

POSITIONER.

Definition of Terms Used Often in This Manual

The positioner usually consists of the controller, the Programming

Pendant, and supply cables.

In this manual, the equipment is designated as follows:

Equipment

DX100 controller

DX100 Programming Pendant

Cable between the positioner and the controller

Manual Designation

DX100

Programming Pendant

Power cables v

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MH-SERIES

POSITIONER Table of Contents

1 Introduction ..................................................................................................................................... 1-1

1.1 About this Document ......................................................................................................... 1-1

1.2 System Overview............................................................................................................... 1-2

1.3 System Layout ................................................................................................................... 1-2

1.3.1 System Layout...................................................................................................... 1-4

1.4 Customer Support Information........................................................................................... 1-7

2 Safety.............................................................................................................................................. 2-1

2.1 Introduction ........................................................................................................................ 2-1

2.2 General Safeguarding Tips................................................................................................ 2-1

2.3 Mechanical Safety Devices................................................................................................ 2-2

2.4 Installation Safety .............................................................................................................. 2-2

2.5 Programming, Operation, and Maintenance Safety........................................................... 2-3

3 Equipment Description.................................................................................................................... 3-1

3.1 General Information ........................................................................................................... 3-1

3.2 MH-Series SIGMA-5 Positioner Assembly – Type I .......................................................... 3-1

3.2.1 MH-Series SIGMA-5 Positioner Type I – Specifications....................................... 3-2

3.3 MH-Series SIGMA-5 Positioner Assembly – Type II ......................................................... 3-3

3.3.1 MH3105-Series SIGMA-5 Positioner, Type II – Specifications............................. 3-4

3.4 MotoMount™ ..................................................................................................................... 3-5

4 Installation....................................................................................................................................... 4-1

4.1 Materials Required............................................................................................................. 4-1

4.1.1 Customer-Supplied Items ..................................................................................... 4-1

4.1.2 List of Tools .......................................................................................................... 4-1

4.2 Installing the MH-Series SIGMA-5 Positioner – Type I...................................................... 4-2

4.2.1 Site Preparation.................................................................................................... 4-2

4.2.2 Unpacking ............................................................................................................ 4-2

4.2.3 Headstock Assembly Mounting Hole Pattern – MH95/185/505/1605................... 4-3

4.2.4 Column Assembly Mounting – Type I Assembly .................................................. 4-5

4.2.5 Connecting the Cables ......................................................................................... 4-7

4.2.6 Home Position ...................................................................................................... 4-7

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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II ..................................................... 4-8

4.3.1 Site Preparation .................................................................................................... 4-8

4.3.2 Unpacking............................................................................................................. 4-8

4.3.3 Unbolting the Drive Assembly Floor Mounting – Type II....................................... 4-9

4.3.4 Connecting the Cables ....................................................................................... 4-11

4.3.5 Home Position .................................................................................................... 4-11

4.4 Tailstock Column Installation ........................................................................................... 4-12

4.4.1 Type I Installation................................................................................................ 4-12

4.4.2 Type II Installation............................................................................................... 4-13

4.4.3 Leveling the Tailstock ......................................................................................... 4-14

4.4.4 Tooling Fixture Installation (initial) ...................................................................... 4-17

4.4.5 Tooling Fixture Installation (regular) ................................................................... 4-18

4.4.6 Final Alignment Check........................................................................................ 4-18

4.4.7 Tooling Fixture Removal..................................................................................... 4-21

4.5 MotoMount Installation..................................................................................................... 4-22

4.5.1 Preparation ......................................................................................................... 4-22

4.5.2 Unpack and Assemble........................................................................................ 4-22

4.5.3 Securing MotoMount Drive Components onto Faceplate ................................... 4-24

4.5.4 Retrofitting Tailstock Assembly........................................................................... 4-24

4.6 MotoMount HD Adjustments ............................................................................................ 4-25

4.6.1 Allowable Misalignment ...................................................................................... 4-25

4.6.2 Tooling Fixture Installation – MotoMount HD...................................................... 4-26

4.6.3 Tooling Fixture Removal..................................................................................... 4-26

4.6.4 Variable Tooling Size Accommodations ............................................................. 4-27

4.7 Conducting a Safety/Operation Check............................................................................. 4-27

5 Tooling Recommendations ............................................................................................................. 5-1

5.1 Headstock Only – Tooling Recommendations................................................................... 5-1

5.1.1 Customer-supplied Tooling Fixture....................................................................... 5-2

5.2 Headstock/Tailstock with MotoMount ................................................................................ 5-5

5.2.1 Customer-supplied Tooling Fixtures ..................................................................... 5-5

5.2.2 Multiple Tooling Fixtures....................................................................................... 5-5

5.2.3 Specifications........................................................................................................ 5-5

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6 Maintenance ................................................................................................................................... 6-1

6.1 Spare Parts........................................................................................................................ 6-1

6.2 Servomotor ........................................................................................................................ 6-1

6.3 Weld Ground Brush Replacement – Type I ....................................................................... 6-2

6.3.1 MH95/185/505/1605 ............................................................................................. 6-2

6.4 Weld Ground Brush Replacement – Type II ...................................................................... 6-5

6.4.1 MH3105 ................................................................................................................ 6-5

6.5 Reset Headstock To Home Position.................................................................................. 6-7

6.5.1 Homing ................................................................................................................. 6-7

6.6 Maintenance Schedule .................................................................................................... 6-11

6.6.1 MH-Series SIGMA-5 Positioner.......................................................................... 6-11

6.6.2 MotoMount ......................................................................................................... 6-11

6.7 Troubleshooting ............................................................................................................... 6-12

6.7.1 MH-Series SIGMA-5 Positioner.......................................................................... 6-12

6.7.2 MotoMount ......................................................................................................... 6-12

A Performance Charts .......................................................................................................................A-1

A.1 MH-Series Positioner Assemblies .....................................................................................A-1

A.1.1 MH95 ...................................................................................................................A-1

A.1.2 MH185 .................................................................................................................A-2

A.1.3 MH505 .................................................................................................................A-3

A.1.4 MH1605 ...............................................................................................................A-4

A.1.5 MH3105 ...............................................................................................................A-5

B Illustrated Parts list .........................................................................................................................B-1

B.1 Introduction .......................................................................................................................B-1

B.1.1 Contents...............................................................................................................B-1

B.1.2 Parts List ..............................................................................................................B-1

B.1.3 Symbols and Abbreviations..................................................................................B-2

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1 Introduction

1 Introduction

1.1 About this Document

1.1

About this Document

This manual provides the following information:

 CHAPTER 1 – INTRODUCTION

Provides general information about the MH-SERIES POSITIONER system and components and customer support contact information.

 CHAPTER 2 – SAFETY

Provides general safety information regarding installation, maintenance, and operation.

 CHAPTER 3 – DESCRIPTION OF EQUIPMENT

Provides a description of the major components.

 CHAPTER 4 – INSTALLATION

This chapter provides installation procedures.

 CHAPTER 5 – TOOLING RECOMMENDATIONS

This chapter provides guidelines for customer-supplied tooling design.

 CHAPTER 6 – MAINTENANCE

This chapter provides preventive maintenance requirements for certain components MH-SERIES POSITIONER.

 APPENDIX A – PERFORMANCE CHARTS

This appendix provides performance charts for each of the MH-SERIES

POSITIONER.

 APPENDIX B – ILLUSTRATED PARTS LIST

This appendix contains the Illustrated Parts List (IPL). The IPL provides detailed views (with part numbers).

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1 Introduction

1.2 System Overview

1.2

System Overview

The MH-SERIES POSITIONER Assembly is available in four basic mechanical configurations:

• The Drive Assembly

• The Drive Assembly with MotoMount

• The Headstock Positioner Assembly

• The Headstock and Tailstock Positioner Assembly

WARNING

Do not use a MotoMount™ with stand-alone headstock (no tailstock) applications. Use of a stand-along application will result in uncontrolled tooling motion.

These assemblies are combined with the appropriate single or multiple external axis control packages to provide a complete positioner kit.

1.3

System Layout

NOTE

The warranty is void if the Yaskawa drive or headstock assembly is integrated with other than a Yaskawa tailstock or MotoMount system.

The two major components of a typical headstock and tailstock positioner assembly (MHT) are;

• MHT System Layout Type I (

Fig. 1-1

)

• MHT System Layout Type II (

Fig. 1-2 )

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1 Introduction

1.3 System Layout

Fig. 1-1: MHT System Layout - Type I

DRIVE

ASSEMBLY

AC SERVO

MOTOR

MotoMount™

ASSEMBLY (HS)

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MotoMount™

ASSEMBLY (TS)

STANDARD

TOOL RADIUS

TAILSTOCK

COLUMN

LEVELING

SCREW, TYP

Fig. 1-2: MHT System Layout - Type II

MotoMount™

HEADSTOCK

ASSEMBLY

HOUSING

S TANDARD

TOOL RADIUS

HEADSTOCK

COLUMN

MotoMount™

TAILSTOCK

ASSEMBLY

FORKLIFT

POCKETS

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1 Introduction

1.3 System Layout

1.3.1

System Layout

The modular drive assembly provides precision-controlled rotary motion and can be mounted in any orientation that the welding, material handling, or dispensing application might require. The standard configuration utilizes an AC servo motor, a high ratio gear reducer with integral output bearing, faceplate, and a cast iron housing. It also includes dual integral position switches and weld ground brushes.

1.3.1.1

Drive Assembly with MotoMount

The Drive Assembly combined with the MotoMount compliant tool mounting system provides headstock and tailstock components for applications requiring custom headstock and tailstock supporting structures. MotoMount is a modular accessory for MHT positioners that provides improved repeatability as compared to hard-mounted tooling systems.

Fig. 1-3: Drive Assembly and MotoMount Assembly

MotoMount

Drive Assembly

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1.3 System Layout

1.3.1.2

Headstock Assembly

The Headstock Assembly integrates the drive assembly with a column that is designed to be floor-mounted or mounted to a machine base, as required for use in cantilevered (stand-alone) applications. The standard configuration provides connectors in the column for motor control and safety circuits. Leveling bolts are included. The user must provide suitable anchor bolts.

Fig. 1-4: Headstock Assembly

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1 Introduction

1.3 System Layout

1.3.1.3

Positioner Assembly (headstock and tailstock)

The positioner assembly integrates the headstock with a tailstock column and the MotoMount compliant tool mounting system. This system is designed to be floor-mounted or mounted to a machine base. Span between the headstock and tailstock is determined by the application. The standard configuration provides a 815-mm tooling sweep radius.

NOTE

If integrating the Yaskawa drive or headstock assembly with other than Yaskawa tailstock or the MotoMount system voids the warranty

Fig. 1-5: Positioner Assembly (headstock and tailstock)

TailStock

Assembly

HeadStock

Assembly

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1.4 Customer Support Information

1.4

Customer Support Information

If you need assistance with any aspect of your MH-SERIES POSITIONER system, please contact Yaskawa Motoman Customer Support at the following 24-hour telephone number:

(937) 847-3200

For routine technical inquiries, you can also contact Yaskawa Motoman

Customer Support at the following e-mail address: [email protected]

When using e-mail to contact Yaskawa Motoman Customer Support, please provide a detailed description of your issue, along with complete contact information. Please allow approximately 24 to 36 hours for a response to your inquiry.

NOTE

Please use e-mail for routine inquiries only. If an urgent or emergency need for service, replacement parts, or information, contact Yaskawa Motoman Customer Support at the telephone number shown above.

Please have the following information ready before calling:

• System

• Robots

MH-SERIES POSITIONER

• Software Version Access this information on the

Programming Pendant’s LCD display screen by selecting {MAIN MENU} -

{SYSTEM INFO} - {VERSION}

Located on the robot data plate • Robot Serial Number

• Robot Sales Order Number Located on the DX100 controller data plate

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2 Safety

2 Safety

2.1 Introduction

2.1

Introduction

It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed.

We suggest that you obtain and review a copy of the ANSI/RIA National

Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA

R15.06-1999). You can obtain this document from the Robotic Industries

Association (RIA) at the following address:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: (734) 994-6088

FAX: (734) 994-3338 www.roboticsonline.com

Ultimately, well-trained personnel are the best safeguard against accidents and damage that can result from improper operation of the robot system. The customer is responsible for providing adequately trained personnel to operate, program, and maintain the robot cell. NEVER

ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR

REPAIR THE ROBOT SYSTEM!

We recommend approved Motoman training courses for all personnel involved with the operation, programming, or repair of the robot system.

This training is designed to familiarize personnel with the safe and correct operation of the robot system.

2.2

General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot 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 trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation.

Programmers must have the teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot

I/O (Inputs and Outputs).

• The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

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2 Safety

2.3 Mechanical Safety Devices

• In accordance with ANSI/RIA R15.06-1999, 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).

2.3

Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's responsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 safety standards, and other local codes that may pertain to the installation and use of industrial 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 fences and barriers

• Light curtains and/or safety mats

• Door interlocks

• Emergency stop palm buttons located on operator station, robot controller, and programming pendant

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately.

2.4

Installation Safety

Safe installation is essential for protection of people and equipment. The following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, local codes, and ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.

• Identify the work envelope of each robot with floor markings, signs, and barriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entry into the work envelope.

• Eliminate areas where personnel might get trapped between a moving robot and other equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching and maintenance procedures.

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2 Safety

2.5 Programming, Operation, and Maintenance Safety

2.5

Programming, Operation, and Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to program, operate, and maintain the system. All personnel involved with the operation of the equipment must understand potential dangers of operation.

• Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place. Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.

• Do not enter the robot cell while it is in automatic operation. Be sure that only the person holding the programming pendant enters the workcell.

• Check the E-Stop button on the programming pendant for proper operation before programming. The robot must be placed in

Emergency Stop (E-Stop) mode whenever it is not in use.

• Back up all programs and jobs onto suitable media before program changes are made. To avoid loss of information, programs, or jobs, a 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 PART 1, System Section, of the robot controller concurrent I/O program can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to

PART 1, System Section. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require special passwords. Special passwords are for Motoman use only.

YOUR WARRANTY WILL BE VOID if you use these special passwords.

• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O program and modifications to controller parameters for maximum robot performance. Great care must be taken when making these modifications. All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot and other parts of the system. Double-check all modifications under every mode of robot operation to ensure that you have not created hazards or dangerous situations.

• Check and test any new or modified program at low speed for at least one full cycle.

• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

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2 Safety

2.5 Programming, Operation, and Maintenance Safety

• Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual.

• Use proper replacement parts.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot

I/O (Inputs and Outputs).

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3 Equipment Description

3.1 General Information

3 Equipment Description

3.1

General Information

The MH-Series SIGMA-5 Positioner drive assembly consist of an AC servo motor and gear reducer with an integral output bearing mounted in a cast iron housing.Weld ground brushes and position switches are included as standard features. Drive assembly provides programmable motion about the central axis, and endless rotation can be purchased as an option. Holes in the faceplate provide for mounting MotoMount drive components or parts fixtures in stand-alone (cantilevered) applications.

3.2

MH-Series SIGMA-5 Positioner Assembly – Type I

The design of the four available drive assemblies is very similar; size is the primary difference. The flexibility of the Type I drive assembly allows for any mounting orientation including vertical (typical), horizontal, or other.

The Type I drive assembly positioners (

Figure 3-1 ) are available in four

different models:

• MH95

• MH185

• MH505

• MH1605

Fig. 3-6: MH-Series SIGMA-5 Positioner Manual Drive Assembly — Type I

CASTING HOMING PIN

(ZERO ADJ)

HOLE

SERVOMOTOR,

SIGMA-5

IN-POSITION

SWITCH,

2-PLACES

FACEPLATE,

TOOLING

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3 Equipment Description

3.2 MH-Series SIGMA-5 Positioner Assembly – Type I

3.2.1

MH-Series SIGMA-5 Positioner Type I – Specifications

See Table 3-1

for Type I, MH-Series SIGMA-5 Positioner drive assembly specifications.

CAUTION

Operating outside the standard setup, without Yaskawa approval may change

E-Stop performance and void warranty.

Table 3-1: MH-Series SIGMA-5 Positioner Type I Specifications

SERIES COMPONENT

Drive Assy PN

Axis Type*

Rated Load

Max MHT Load @ CG Off

Center

Headstock Speed

180 Degree Sweep Time

Rated CG Off Center

Rated CG Overhang

Load @ 500 mm CG

Overhang

Rated Inertia

Rated Holding Torque

Rated Weld Current (Std/

Optional)

Allowable Thrust

Motor Power

Motor PN, YEC* rpm sec mm mm kgf

MH95 kgf

158238-1

Rotation

95 kgf@mm 550@30 kg*m2

Nm

Amps kgf kW

23.8

1.56

152

500

75

20

156

400/800

12.4

2.72

152

250

75

MH185

158238-2

Rotation

185

550@50

47

268

400/800

Motor Speed*

Rated Acceleration Time*

Motor PN, Motoman

Reducer

Total Reduction Ratio*

Repeatability

Tail Stock Through Hole

Drive Assy Weight rpm sec

R mm/mm mm kgf/lbs

9.8

3.36

152

331

168

MH505

158482-1

Rotation

505

1075@80

105

746

800/1200

10.8

3.28

152

0

500

MH1605

161825-1

Rotation

1605

3000@95

678

2826

800/1600

400

0.450

400

0.450

800

1.300

2000

3.7

SGMRV-05ANA-

YR11

SGMRV-05ANA-

YR11

SGMRV-13ANA-

YR11

SGMRV-37ANA-

YR11

2500

0.3

156009-1

2000

0.3

156009-1

1500

0.3

156009-3

2000

0.5

156009-6

RV-20E-105-1B RV-20E-161-1B RV-80E-153-1B RV-320E-185

105 161 153 185

0.00003

0.00004

0.00003

0.00003

45

59.5/131

45

59.5/131

45

99.5/219

45

358/789

* External axis default settings

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POSITIONER

3 Equipment Description

3.3 MH-Series SIGMA-5 Positioner Assembly – Type II

3.3

MH-Series SIGMA-5 Positioner Assembly – Type II

The MH3105 head stock utilizes a Type II drive assembly similar to that used in the MSR505, MSR1005, and MotoSweep O 20/50 products.

Fig. 3-7: MH3105 Series SIGMA-5 Positioner Drive Assembly - Type II

FACEPLATE

HOUSING

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3.3 MH-Series SIGMA-5 Positioner Assembly – Type II

3.3.1

MH3105-Series SIGMA-5 Positioner, Type II

Specifications

CAUTION

Operating outside the standard setup, without Yaskawa approval may change

E-Stop performance and void warranty.

See Table 3-2

for Type II, MH-Series SIGMA-5 Positioner drive assembly specifications.

Table 3-2: MH-Series SIGMA-5 Positioner Type II Specifications

SERIES COMPONENT

Drive Assy PN

Axis Type*

Rated Load

Max MHT Load @ CG Off Center

Headstock Speed

180 Degree Sweep Time

Rated CG Off Center

Rated CG Overhang

Load @ 500 mm CG Overhang

Rated Inertia

Rated Holding Torque

Rated Weld Current

Allowable Thrust

Motor Power

Motor PN, YEC*

Motor Speed*

Rated Acceleration Time*

Motor PN, Motoman

Reducer

Total Reduction Ratio*

Repeatability

Repeatability w/MotoMount

E-Stop Response

E-Stop Response

Face Plate Through Hole

Tail Stock Through Hole

Drive Assy Weight

R mm/mm mm/mm sec deg mm mm kgf/lbs mm mm kgf kg*m2

Nm

Amps kgf

Kw

MH 3105

162733-3

Rotation

3105 kgf kgf@mm 6300@90 rpm 6.7

sec 4.95

152

58

1400

3058

4622

1200 rpm sec

3000

4.4

SGMRV-44ANA-YR11

2000

0.3

156009-7

RV-320C

11575/39 (296.795)

0.00004

0.000055

TBD

TBD

110

45

918/2022

* External axis default settings

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3.4 * MotoMount™

3.4

*MotoMount™

MotoMount (see

Fig. 3-8

) is a flexible tool fixture mounting system which improves tool repeatability and reduces loads on the headstock/tailstock bearing systems. MotoMount accommodates combined headstock/ tailstock/tooling misalignment up to two degrees.

MotoMount is required for use with all Motoman MHT-series (headstock/ tailstock) positioners. The MotoMount drive components are mounted onto the headstock faceplate, while the tailstock components replace earlier tailstock designs.

MotoMount is also available in a Heavy Duty (HD) configuration (see

Figure 3-9

). MotoMount HD is used on the1605/3105 drive assemblies.

MH95/MH185/MH505 drive assemblies use the standard MotoMount.

CAUTION

Do not use MotoMount with stand-alone (no tailstock) applications. Use in a stand-alone application will result in uncontrollable tooling fixture motion.

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3.4 * MotoMount™

Fig. 3-8: MotoMount Layout

FACEPLATE

DRIVE

BUSHING

WELD GROUND

CABLE

TAILSTOCK

TOOLING

ADAPTER

TAILSTOCK

COLUMN

Fig. 3-9: MotoMount HD Layout

FACEPLATE

PRIMARY

MOUNTING

HOLES

DRIVE

BUSHING

AUXILARY

MOUNTING

HOLES

WELD GROUND

CABLE

PRIMARY

MOUNTING

HOLES

TAILSTOCK

TOOLING

ADAPTER

LOCATING PIN

AUXILARY

MOUNTING

HOLES

BEARING

TAILSTOCK

COLUMN

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4 Installation

4.1 Materials Required

CAUTION

Installation of MotoMount and the MH-Series SIGMA-5 Positioner is not a task for the novice. These components are not fragile, but should still be handled with care. Rough handling can damage electronic components.

Installation of the MH-Series SIGMA-5 Positioner Manual positioner and

MotoMount should be performed by personnel who are familiar with this

Yaskawa Motoman product.

Follow established safety procedures at all times throughout the installation process. Failure to use safe work practices can result in damage to the equipment and injury to the workers.

4.1

Materials Required

This section identifies customer-supplied items and tools required to complete installation.

4.1.1

Customer-Supplied Items

• Servo motion control unit

• Incoming power supply

• Two earth ground cables with two earth ground stakes

4.1.2

List of Tools

Table 4-3: Tools

• Safety glasses

• Level

• Adjustable wrench set

• Hammer drill with appropriate concrete bits

• Forklift and/or overhead crane

• Open-end wrench set

• Wrench sets (standard and metric)

• Chalk String

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4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

4.2

Installing the MH-Series SIGMA-5 Positioner – Type I

4.2.1

Site Preparation

Mount each MH-Series SIGMA-5 Positioner system on a machine base or a reinforced concrete factory floor suitable to withstand the static and dynamic forces.

4.2.2

Unpacking

The headstock and optional tailstock are shipped on a shipping skid. To unpack the equipment, proceed as follows:

WARNING

See the specification tables for drive assembly weight. Make sure that the lifing device is capable of handling the weight or injury to personnel can result.

1. Carefully remove protective plastic wrapping from equipment.

2. Inspect equipment for shipping damage.

NOTE

Notify shipping contractor if there is any shipping damage.

3. Unbolt the equipment from the shipping skid (see

Fig. 4-10 ).

Fig. 4-10: Unbolting the Drive Assembly

SHIPPING BOLT

SHIPPING SKID

4. Attach a lifting device to the eye bolts on top of the housing and lift the equipment from the shipping skid.

5. Place the equipment in a position using the layout prints.

NOTE Make sure there is adequate room on all sides of the positioner for parts fixtures.

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4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

4.2.3

Headstock Assembly Mounting Hole Pattern –

MH95/185/505/1605

The headstock assembly may be mounted to the column assembly (see

Section 4.2.4)

or mounted to a customer-supplied machine base. For custom orientation auxiliary mounting holes are provided on top of the drive assembly housing, and may be used in addition to the base mounting holes.

Table 4-4 shows mounting specifications for positioners.

Table 4-4: Mounting Specifications for Positioners

Drive Assembly Bolt Size, Grade SHC Tightening Torque

(N•m/lbf-ft.)

MH95

MH185

MH505

MH1605

M10

M10

M10

M16

44/32

44/32

44/32

162/122

The following figures show the mounting hole patterns;

Fig. 4-11 shows the mounting hole pattern for the MH95/185.

• Fig. 4-12: shows the mounting hole pattern for the MH505.

Fig. 4-13 shows the mounting hole pattern for the MH1605.

Fig. 4-11: MH95/185 Mounting Hole Pattern

20 260.0

2X M10 X 1.5 THRU HOLES

FOR ADDITIONAL MOUNTING

SUPPORT AS REQUIRED FOR

SPECIFIC APPLICATIONS.

273

52.5

104.5

52.5

12.5

60.0

140.0

O 320.0

SWITCHES & BRACKETS NOT SHOWN

FOR CLARITY

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4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

Fig. 4-12: MH505 Mounting Hole Pattern

20 350.0

56.9

313

133.1

180.1

63.1

70.0

210.0

Ø400.0

SWITCHES & BRACKETS NOT SHOWN

FOR CLARITY

Fig. 4-13: MH1605 Mounting Hole Pattern

6X CLEARANCE FOR

M16 SCREWS 25

560

510

76.2

2X M10 x 1.5 THRU HOLES FOR

ADDITIONAL MOUNTING SUPPORT

AS REQUIRED FOR SPECIFIC

APPLICATIONS

75

150

150

300 350

207

100.0

G

4X M16 THRU HOLES FOR AUXILIARY

MOUNTING SUPPORT AS REQUIRED

FOR SPECIFIC APPLICATIONS.

160 240.0

72.1

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4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

4.2.4

Column Assembly Mounting – Type I Assembly

4.2.4.1

Hole Patterns

The column assembly for the MH-SERIES POSITIONER may be mounted to the floor or on a base. For accurate placement information, review the hole pattern in

Figure 4-14

and the specifications in

Table 4-5 .

Fig. 4-14: Column-Mounting Hole Pattern - Type I

A

C-LAG BOLT

CLEARENCE

B

Table 4-5: Mounting Hole Specifications

Drive Assembly Dynamic Rating per

Anchor

MHT95/185

MHT505

MHT1600

1360 kgf

1360 kgf

3400 kgf

A

300

300

700

B

250

250

420

C

M10

M10

M12

NOTE

Due to the variations in floor construction and preferences, this manual will not specify anchoring systems beyond

dynamic rating requirements as listed in Table 4-5

.

4.2.4.2

Installing the Type I Headstock Column Assembly

Refer to the system layout drawings to ensure set up location. To install

the headstock, refer to Figure 4-11 and proceed as follows:

1. Set the column assembly in desired position.

2. Use the leveling bolt holes as a guide and transfer the hole locations to the concrete.

3. Remove column assembly.

4. Install the anchors per the manufacture’s instructions.

5. Install a leveling shim at each anchor location and reset the column assembly.

6. Screw each leveling bolt down until it just contacts the leveling shim and hand tighten the anchor bolts or nuts.

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4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

4.2.4.3

Leveling the Type I Headstock

The headstock must be leveled in two directions (see

Figure 4-15 ):

• Parallel to the faceplate

• Perpendicular to the faceplate

Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts throughout each process. The fourth leveling bolt is used as an anchor only.

Before proceeding, make sure that the headstock is in the proper place.

Make sure leveling bolt, lock-nut, and leveling shim are installed in each column base hole.

 To level the headstock assembly axially, proceed as follows:

1. Place a level on top of the housing, perpendicular to the faceplate.

2. Use the two leveling bolts beneath the faceplate (A and B), and a third beneath the motor (C) to level axially. If the faceplate side needs adjustment, A and B must be turned equally.

 To level the headstock assembly cross-axially, proceed as follows:

1. Place a level on top of the housing, parallel to the faceplate.

2. Use the same three leveling bolts used above and adjust them until the level is balanced, adjusting B and C equally.

3. Repeat the axial and cross-axial leveling steps until level readings are achieved both ways.

4. Drive the fourth leveling bolt down to the leveling shim.

5. Check level axial and cross-axial again. When level, tighten the anchor system (customer supplied) to the specified torque.

6. Tighten the four lock-nuts to the column base.

Fig. 4-15: Leveling Hardware

HEADSTOCK

COLUMN

FACEPLATE

ANCHOR (CUSTOMER SUPPLIED)

LEVELING BOLT c

LEVELING SHIM

LOCK NUT

COLUMN BASE

B

A

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4.2 Installing the MH-Series SIGMA-5 Positioner – Type I

4.2.5

Connecting the Cables

Do not connect the encoder, power, and ground cables until after the drive assembly is securely in place.

NOTE

When installing stand-along drive assemblies, user will need to mount the junction boxes close to the drive assembly for motor cables.

4.2.5.1

Connection to Motoman Controller

When the MH-Series SIGMA-5 Positioner assembly is delivered with a

Motoman robot, connections between the two usually have been made at the factory, or if not, instructions for making connections can be found in the system manual. See separate documentation specific to your system.

4.2.5.2

Ground Cables – Type I

Two locations are provided for attaching weld ground cables see Figure

4-16 . Use one for each welding power supply. Remove paint as required

from the lug contact surface on the housing.

Fig. 4-16: Ground Cable Connections

LUG BOLT

WELD GROUND

4.2.6

Home Position

The MH-Series SIGMA-5 Positioner are set in HOME position at the factory. See Maintenance Section 6, Maintenance, if adjustment is necessary.

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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II

4.3

Installing the MH-Series SIGMA-5 Positioner – Type II

4.3.1

Site Preparation

Each MH-Series SIGMA-5 Positioner assembly should be firmly mounted on a machine base or foundation rigid enough to withstand static and dynamic forces.

4.3.2

Unpacking

The headstock and optional tailstock are shipped on a shipping skid. To unpack the equipment, proceed as follows:

WARNING

See the specification tables for drive assembly weight. Make sure that the lifing device is capable of handling the weight or injury to personnel can result.

1. Carefully remove protective plastic wrapping from equipment.

2. Inspect the equipment for shipping damage.

NOTE

Notify shipping contractor if there is any shipping damage.

3. Unbolt headstock from the shipping skid using a 3/4-inch socket.

4. Remove the top cover and attach eye bolts to the top of the housing and lift.

5. Place the equipment in a position using the layout prints.

NOTE Make sure there is room on all sides of the positioner for parts fixtures.

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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II

4.3.3

Unbolting the Drive Assembly

SHIPPING BOLT

SHIPPING SKID

Floor Mounting – Type II

Figure 4-17

provides dimensions for accurately floor mounting the

MH3105 headstocks.

Fig. 4-17: MH3105 Floor Mounting

1110.0 MM 45 MM

45 MM

710.0 MM

6 X CLEARANCE FOR

M12 ANCHOR

415.0 MM

695.0 MM

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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II

4.3.3.1

Installing the Type II Headstock

Before proceeding, refer to the system layout drawings to ensure precise set up location.

Refer to

Figure 4-18

and proceed as follows:

1. Set the column assembly in desired position.

2. Use leveling bolt holes as a guide and transfer the hole locations to the concrete.

3. Remove column assembly.

4. Install the anchors per the manufacture’s instructions.

5. Install a leveling shim at each anchor location and reset the column assembly.

6. Screw each leveling bolt down until it just contacts the leveling shim and hand tighten the anchor bolts or nuts.

Fig. 4-18: Leveling Hardware

FACEPLATE

HEADSTOCK

RISER

ANCHOR (CUSTOMER

SUPPLIED)

LEVELING BOLT

LOCK-NUT

C

A

LEVELING SHIM

COLUMN BASE

B

4.3.3.2

Leveling the Type II Headstock

The headstock must be leveled in two directions;

• Parallel to the faceplate

• Perpendicular to the faceplate.

Since it only takes three points to define a plane, use only three of the six leveling bolts to level the positioner. It is important to consistently use the same three leveling bolts throughout each process. The other three leveling bolts will be used as anchors only.

Before proceeding, make sure that the headstock is in the proper place.

Make sure a leveling bolt, lock-nut, and leveling shim is installed in each column base hole.

 To level the headstock assembly axially, proceed as follows:

1. Place a level on top of the housing, perpendicular to the faceplate.

2. Use the two leveling bolts beneath the faceplate (A and B), and a third beneath the motor (C) to level axially. If the faceplate side needs adjustment, A and B must be turned equally.

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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II

 To level the headstock assembly cross-axially, proceed as follows:

1. Place a level on top of the housing, parallel to the faceplate.

2. Use the same three leveling bolts used above and adjust them until the level is balanced, adjusting B + C equally.

3. Repeat the axial and cross-axial leveling steps until level readings are achieved in both directions.

4. Drive the remaining leveling bolts down to their leveling shims.

5. Check level axially and cross-axially again. When level, tighten the anchor system (customer-supplied) to the specified torque.

6. Tighten the six lock-nuts to the column base.

4.3.4

Connecting the Cables

Do not connect the encoder, power, and ground cables until after the drive assembly is securely in place.

4.3.4.1

Connection to Motoman Controller

When the MH-Series SIGMA-5 Positioner assembly is delivered with a

Yaskawa Motoman robot, connections between the two usually have been made at the factory, or if not, instructions for making connections can be found in the system manual. See separate schematics and/or documentation specific to the system.

4.3.4.2

Ground Cables – Type II

A ground cable bar is provided for attaching weld ground cables. Route the ground cables from the power source, up through the bottom of the

Type II base, and attach to the ground cable bar.

Fig. 4-19: Ground Cable Connection MH3105

DRIVE ASSEMBLY

LUG BOLT

HEADSTOCK

WELD GROUND

4.3.5

Home Position

The MH-Series SIGMA-5 Positioner are set in the HOME position at the factory. See Section 6, if HOME position must be adjusted.

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4.4 Tailstock Column Installation

4.4

Tailstock Column Installation

4.4.1

Type I Installation

Before proceeding to install the tailstock, make sure the Type I headstock

is anchored to the floor. If it is not, refer to Section 4.2.

To install the tailstock onto a cell base or floor, proceed as follows:

1. Ensure the proper position of the headstock assembly per system layout. The headstock must be permanently anchored to the floor/ base.

2. Using a carpenter’s chalk string, strike a chalk line on the floor from the edge of the headstock base toward the location of the tailstock.

Fig. 4-20: Strike a Chalk Line

CHALKLINE

HEADSTOCK

COLUMN BASE

3. Set the tailstock in its approximate position on the floor using the chalk line.The headstock and tailstock are now facing each other.

4. Measure the distance (D) between the headstock and tailstock base.

To find the distance (D) between the headstock base and tailstock base, use the following tailstock mounting formula:

D = PD + X (PD = Tooling pin-to-pin distance; X = MotoMount Offset)

Fig. 4-21: Tailstock Placement without Tooling - Type I

HEADSTOCK

COLUMN BASE D

TAILSTOCK

COLUMN BASE

CHALKLINE

NOTE The placement position derived form this formula will position the tailstock in the nominal center position.

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4.4 Tailstock Column Installation

5. To find the X value in the tailstock mounting formula for the drive assembly, locate the drive assembly model name in

Table 4-6

Table 4-6: MotoMount Offset (X Value)

Type I System

MHT95 - mm

MHT180 - mm

MHT505 - mm

MHT1605 - mm

MHT3105 - mm

X - value

8

8

57

168

145

4.4.2

Type II Installation

To install the tailstock of a Type II assembly onto a cell base or floor, proceed as follows:

1. Ensure the proper position for the headstock assembly per system layout. The headstock must permanently anchored to the floor/base.

2. Using a carpenter’s chalk string, strike a chalk line on the floor from the edge of the headstock base towards location of the tailstock.

Fig. 4-22: Strike Chalk Line

CHALKLINE

HEADSTOCK

COLUMN BASE

3. Position the tailstock on the floor across from the headstock.

4. Use the chalk line and the center line of each component as guides for placement of the tailstock column on the floor.

NOTE

Keeping the center line of each component aligned is not critical. However, the closer the bearings of both components are aligned with one another, the greater the degree of misalignment allowed with other system components.

5. To position the tailstock accurately on the bearing center line, make two measurements from the tailstock base to the chalk line and adjust the base as necessary.

Fig. 4-23: Tailstock Placement - Type II

HEADSTOCK/TAILSTOCK

BEARING CENTERLINE

CHALK LINE

225 MM

(8.85 IN.)

4-13

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4.4 Tailstock Column Installation

4.4.3

Leveling the Tailstock

4.4.3.1

Type I Leveling Procedures

The tailstock must be leveled in two directions, axially and cross-axially.

Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts throughout each process. The fourth leveling bolt will be used as an anchor only.

Before proceeding, make sure that the tailstock is in the proper place.

Make sure a leveling bolt, lock-nut, and leveling shim is installed in each column base hole.

Fig. 4-24: Leveling the Tailstock - Type I

HEADSTOCK

RISER

AXIAL

ANCHOR

(CUSTOMER

SUPPLIED)

CROSS-AXIAL

LEVELING BOLT

LOCK-NUT

DRIVE ASSEMBLY

COLUMN BASE

LEVELING SHIM

C

A

B

 To level the tailstock assembly axially, proceed as follows:

1. Place a level on top of the tailstock column in the axial direction.

2. Use the leveling bolts A, B, and C to adjust the axial level. Adjust bolts

A and B equally.

 To level the tailstock assembly cross-axially, proceed as follows:

1. Place a level on top of the tailstock in the cross-axial direction.

2. Use the same three leveling bolts used above and adjust them until the level is balanced, adjusting B and C equally.

3. Repeat the axial and cross-axial leveling steps until level readings are achieved both ways

4. Drive the fourth leveling bolt down to the leveling shim.

5. Check level axially and cross-axially again. When level, tighten the anchoring system (customer-supplied) to the specified torque.

6. Tighten the four lock-nuts to the column base.

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4.4 Tailstock Column Installation

4.4.3.2

Type II Leveling Procedures

The Type II tailstock must be leveled in two directions, axially and crossaxially.Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts through out each process. The fourth leveling bolt will be used as an anchor only.

Before proceeding, make sure that the tailstock is in the proper place.

Make sure a leveling bolt, lock-nut, and leveling shim is installed in each column base hole.

Fig. 4-25: Leveling the Tailstock - Type II

AXIAL

HEADSTOCK

RISER

ANCHOR

(CUSTOMER

SUPPLIED)

CROSS-AXIAL

LEVELING

BOLT

LOCK-NUT

COLUMN BASE

C

LEVELING SHIM

A

B

 To level the tailstock assembly axially, proceed as follows:

1. Place a level on top of the tailstock column in the axial direction.

2. Use the leveling bolts A, B, and C to adjust the axial level. Adjust bolts

A and B equally.

 To level the tailstock assembly cross-axially, proceed as follows:

1. Place a level on top of the tailstock in the cross-axial direction.

2. Use the same three leveling bolts used above and adjust them until the level is balanced, adjusting B and C equally.

3. Repeat the axial and cross-axial leveling steps until level readings are achieved both directions.

4. Drive the fourth leveling bolt down to the leveling shim.

5. Check level axially and cross-axially again. When level, tighten the anchoring system (customer supplied) to the specified torque.

6. Tighten the four lock-nuts to the column base.

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4.4 Tailstock Column Installation

4.4.3.3

Allowable Misalignment

The flexibility of MotoMount HD allows for a misalignment between the tailstock and the tooling fixture without affecting performance. A misalignment of 0.5 degrees is allowed. If the tailstock is out of alignment more than 0.5 degrees, adjust the tailstock using the tailstock leveling bolts.

Fig. 4-26: Allowable Axial Leveling - Side View

LEVELING

DEVICE

0 – 0.5 DEGREE MAX.

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4.4 Tailstock Column Installation

4.4.4

Tooling Fixture Installation (initial)

The initial tooling installation is required prior to the headstock/tailstock alignment procedure.

1. Jog the headstock to the Home position. The tooling mounting holes and locating pin must be pointing up. If not, remove the MotoMount drive components and re-install in the proper orientation.

WARNING

Make certain servo power is OFF for the remainder of the installation, or serious operator injury and/or equipment damage may result.

2. Use a suitable lifting device to position the tooling above the headstock/tailstock assemblies.

3. Slowly lower tooling fixture while aligning with the headstock and tailstock locating pins.

Fig. 4-27: Tooling Fixture Installation - Headstock/Tailstock

CUSTOMER SUPPLIED BOLTS

M12 GRADE 8.8

HARDENED WASHERS

(MOTOMAN SUPPLIED)

CUSTOMER SUPPLIED

TOOLING FIXTURE

4. Continue lowering the tooling until the hoisting straps are loose.

5. Secure the tooling to the drive assembly with customer supplied M12, grade 8.8 (or better) bolts and hardened washers. Eight hardened washers are included with the MotoMount kit for this purpose.

6. Remove the hoisting straps.

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4.4 Tailstock Column Installation

4.4.5

Tooling Fixture Installation (regular)

1. Jog the headstock until MotoMount is horizontal. The tooling mounting holes and locating pin must be pointing up.

WARNING

Make certain servo power is OFF for the remainder of the installation, or serious operator injury and/or equipment damage may result.

2. Use a suitable lifting device to position the tooling above the headstock assembly.

3. Slowly lower one side of the tooling fixture onto the headstock using the locating pin.

4. Install the M12 tool mounting bolts and washers onto the headstock

(customer-supplied grade 8.8 bolts), and torque the bolts to 76 N•m

(56 lbf-ft).

4.4.6

Final Alignment Check

The MotoMount system helps reduce the load on bearings due to tooling fixture misalignment with the headstock and tailstock. However, optimum performance is achieved when the alignment is as close as possible.

Horizontal and vertical misalignment is possible. Both the horizontal and vertical alignment procedures require the measurement of the same gap on the MotoMount drive components. A tooling fixture must be installed to align the system.

4.4.6.1

Horizontal Alignment

Check the horizontal alignment by measuring the gap (see Figure 4-23) between the mounting fixture and mounting block. The measurement of this gap must not change more than 1 mm after the headstock is rotated

180 degrees. To check MotoMount’s horizontal alignment, proceed as follows:

1. Jog the positioner until MotoMount is horizontal.

NOTE

The alignment procedure may be easier if the weld ground cable is removed.

2. Using calipers, measure the alignment gap.

NOTE

It is important to measure the alignment gap at the same location. This will ensure proper alignment.

3. Rotate the positioner 180 degrees.

4. Measure the alignment gap at the second position. If the gaps differ by more than 1 mm, the horizontal alignment must be adjusted. Use the following procedure to adjust horizontal alignment:

• Calculate the average gap between the two positions, by adding both measurements together and dividing by two.

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4 Installation

4.4 Tailstock Column Installation

• Loosen the bearing mounting bolts and move the tailstock bearing housing towards the direction of the larger gap until the gap is at the average value.

• Ensure the bearing housing is perpendicular to the tailstock adapter within 1/2 degree (a visual check with a square is acceptable).

• Repeat this process until the gap at both positions is within 1 mm. If moving the bearing housing cannot provide the desired results, the columns are out of basic alignment and must be repositioned.

• Tighten the bearing mounting bolts to 76 N • m (56 lbf-ft).

Fig. 4-28: Measurement Point for Horizontal Alignment, Bottom View

HEADSTOCK FACEPLATE

ALIGNMENT GAP

FIXTURE BLOCK

MOUNTING BLOCK

DRIVE BUSHING

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4 Installation

4.4 Tailstock Column Installation

4.4.6.2

Vertical Alignment

MotoMount must be at a vertical position to check the vertical alignment.

Fig. 4-29: Vertical Position - Drive Bushing on Bottom

DRIVE BUSHING

The vertical alignment is checked by measuring the gap between the mounting fixture and mounting block. The measurement of this gap must not change more than 1 mm after the headstock is rotated 180 degrees.

To align MotoMount vertically, proceed as follows:

1. Jog the positioner to vertical position until the drive bushing is at the bottom.

2. Using calipers, measure the alignment gap.

NOTE

It is important to measure the alignment gap at the same location. This will ensure a proper alignment.

3. Rotate the positioner 180 degrees until the drive bushing is at the top.

4. Measure the alignment gap at the second position. If the gaps are different by more than 1 mm, the vertical alignment must be adjusted.

Use the following procedure:

• Calculate the average gap between the two positions by adding both measurements together and dividing by two.

• If the first measurement (with drive bushing at the bottom) is greater than the second measurement, the headstock must be raised until the gap is at the average gap value. Raise the headstock by making equal clockwise turns on the headstock leveling bolts.

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4 Installation

4.4 Tailstock Column Installation

• If the first measurement (with drive bushing at the bottom) is less than the second measurement, the tailstock must be raised until the gap is at the average gap value. Raise the tailstock by making equal clockwise turns on the tailstock leveling bolts.

Fig. 4-30: Vertical Position - Drive Busing on Top

DRIVE BUSHING

• Recheck the alignment gap and verify that both gaps are within one mm. If multiple attempts fail to reduce the gap difference below one mm, contact Yaskawa Motoman Customer Service.

• Recheck the horizontal alignment.

• Insure ground cable is installed and properly secured.

• When horizontal and vertical alignment is complete, ensure all bolts are tightened to the appropriate torque, including tailstock bearing mounting bolts.

4.4.7

Tooling Fixture Removal

1. Jog the headstock until the MotoMount is horizontal, with the tool mounting bolts and locating pin pointed up.

WARNING

Make certain servo power is OFF for the remainder of the removal, or serious operator injury and/or equipment damage may result.

2. Position a suitable lifting device and hoisting straps above the tooling.

Attach the hoisting straps to the tooling fixture.

3. Remove the tool fixture mounting bolts and tailstock bearing cap.

4. Slowly lift the tooling fixture off the headstock/tailstock assemblies.

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4 Installation

4.5 MotoMount Installation

4.5

MotoMount Installation

The MotoMount drive components are usually delivered assembled to the drive assembly (MH95, MH185, or MH505). However, if retrofitting

MotoMount on a system already installed in the plant, follow these instructions:

4.5.1

Preparation

Successful installation requires the MotoMount drive components be firmly mounted to the headstock faceplate. Before installation, ensure the faceplate is clean and is not warped or deformed.

4.5.2

Unpack and Assemble

The MotoMount system will be shipped in a box with the following components (unless it is part of a larger system):

• MotoMount drive components

• Dowel pins (2)

• Mounting hardware

• Weld ground cable

Carefully remove plastic wrapping from components and inspect them for shipping damage.

NOTE

Notify shipping contractor if there is any shipping damage.

4.5.2.1

Installing Fixture Dowel Pins

The dowel pins must be installed into the back of the mounting block before the assembly is mounted onto the faceplate. There are four holes in the back of the mounting block. See

Figure 4-31

to determine which holes to use for your application. If your headstock faceplate does not have the matching dowel holes, it must be modified per the following template.

Fig. 4-31: MotoMount Mounting Hole Pattern

250.00 MM +/- 0.015

125 MM

200 MM

100.0 MM

160.00 MM +/- 0.015

80 MM

CENTER OF

ROTATION

MH95/185 DOWEL

POSITION M12 X 1.75

DIA. 12.00 THRU

FOR DOWEL

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4 Installation

4.5 MotoMount Installation

To install the dowel pins, proceed as follows:

WARNING

Be sure to handle the MotoMount components carefully to avoid damage to the equipment or injury to personnel.

1. Use a small, 3-mm thick metal spacer (a 1/8-in. thick washer will work) to transfer the press force from the mounting block to the fixture block.

2. Place the spacer between the mounting block and the fixture block so that it is located behind the appropriate dowel hole.

3. Use an arbor press to force the dowel pins into the appropriate dowel pin hole in the mounting block. It is important that the dowel pin is pressed in as far as possible.

4. Relocate the spacer behind the other dowel hole and install the second dowel pin.

5. After the dowel pins are inserted properly, remove the spacer.

The MotoMount drive components are now ready to install onto the faceplate.

Fig. 4-32: Dowel Pin Installation

MOUNTING HOLES

MH95/185

ARBOR PRESS

DOWEL PIN

MOUNTING BLOCK

INSERT SPACER

MH500

MOUNTING

HOLES

ARBOR PRESS

BASE

FIXTURE BLOCK

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4 Installation

4.5 MotoMount Installation

4.5.3

Securing MotoMount Drive Components onto Faceplate

Use the previously inserted dowel pins to locate the exact position for the

MotoMount drive components to the faceplate. To mount the fixture block onto the faceplate, proceed as follows:

1. Jog the face plate to the Home position.

2. Align the previously installed dowel pins with the proper holes in the faceplate and push fixture block in as far as possible.

3. Insert both mounting bolts through the fixture block and tighten into the faceplate holes. Torque bolts to 76-N•m (56 lbf-ft.).

4. Install the ground cable with one lug secured to the fixture block. Use the fixture block hole nearest to the drive bushing. The other lug is secured to the appropriate hole in the headstock face plate.

Fig. 4-33: MotoMount Fixture Installation

HEADSTOCK

FACEPLATE

M16 LOCATING PIN

FIXTURE BLOCK

DRIVE

BUSHING

MOUNTING BOLT

GROUND

CABLE

MOUNTING BLOCK

4.5.4

Retrofitting Tailstock Assembly

Remove old tailstock and replace with new.

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4 Installation

4.6 MotoMount HD Adjustments

4.6

MotoMount HD Adjustments

MotoMount HD is used on the MH1605 (Type I), and MH3105 (Type II) drive assemblies.

The MotoMount components are delivered assembled to the headstock

and tailstock assemblies. See Section 4.4 for installation of the headstock

and tailstock assemblies.

Fig. 4-34: Nominal Center Position - Side View

TOOLING

FIXTURE

22 MM

ADAPTER

CLAMP

29 MM

ADAPTER

SHAFT

TAILSTOCK

COLUMN

TOP

TAILSTOCK

ADAPTER

TAILSTOCK

COLUMN

4.6.1

Allowable Misalignment

The flexibility of MotoMount allows for misalignment between the tailstock and the tooling fixture without affecting performance. A total misalignment

(combined tooling and headstock/tailstock) up to two degrees, from top view is permissible. If misalignment exceeds two degrees, check tooling and/or position of tailstock.

Fig. 4-35: Allowable Misalignment - Top View

2 DEGREES

TAILSTOCK

ADAPTER

TOOLING

FIXTURE

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4 Installation

4.6 MotoMount HD Adjustments

4.6.2

Tooling Fixture Installation – MotoMount HD

Both the headstock and tailstock must be permanently anchored to the floor and leveled prior to installation of the tooling fixture.

1. Jog the headstock until MotoMount HD is horizontal. The tooling mounting holes and locating pin must be pointing up.

WARNING

Make certain servo power is OFF for the remainder of the installation, or serious operator injury and/or equipment damage may result.

2. Use a suitable lifting device to position the tooling above the headstock assembly.

3. Slowly lower one side of the tooling fixture onto the headstock using the locating pin.

4. Install the M16 tool mounting bolts and washers onto the headstock

(customer-supplied grade 8.8 bolts), and torque the bolts to 190 N•m

(140 lbf-ft). Hardened washers are recommended.

5. Slowly lower tooling fixture onto the tailstock using the locating pin.

6. Install the M16 tool mounting bolts and washers onto the tailstock

(customer-supplied grade 8.8 bolts), and torque the bolts to 190 N•m

(140 lbf-ft). Hardened washers are recommended.

7. Remove the hoisting straps.

4.6.3

Tooling Fixture Removal

1. Jog the headstock until the MotoMount is horizontal, with the tool mounting bolts and locating pin pointed up.

WARNING

The servo motor must be off for the remainder of the removal, or serious operator injury and/or equipment damage may result.

2. Position a suitable lifting device and hoisting straps above the tooling.

Attach the hoisting straps to the tooling fixture.

3. Remove the tool fixture mounting bolts and tailstock bearing cap.

4. Slowly lift the tooling fixture off the headstock/tailstock assemblies.

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4 Installation

4.7 Conducting a Safety/Operation Check

4.6.4

Variable Tooling Size Accommodations

The MotoMount system can adapt to small variations in tooling fixture lengths without changing the tailstock’s performance or permanent location. Two steps can be taken to adjust the tooling fixture distance.

4.6.4.1

Changing Adapter Shaft Position

The preferred way change the adapter shaft position is to simply slide the tailstock adapter either way along the adapter shaft. If more adjustment is needed, loosen the four tailstock bolts and slide the adapter shaft and the tailstock adapter until a suitable position is acquired. These two processes do not effect MotoMount’s performance. It is important that a minimum distance is maintained between the tailstock adapter and the top of the tailstock column.

Fig. 4-36: Adapter Shaft Position

TAILSTOCK

BOLT

TAILSTOCK

ADAPTOR

ADAPTER

SHAFT

12.7 MM MINIMUM

DISTANCE

TAILSTOCK

COLUMN

TOP

4.6.4.2

Reinstalling the Adapter Shaft

Once the new position for the adapter shaft is found, torque the tailstock bolts to 350 N•m (259 lbf-ft.).

4.7

Conducting a Safety/Operation Check

Before operating either MH-Series SIGMA-5 Positioner take a few minutes to perform a safety/operation check. To perform a safety/ operation check, proceed as follows:

1. Check that all cable connections are tight.

2. Verify the headstock and tailstock are level and parallel.

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5 Tooling Recommendations

5.1 Headstock Only – Tooling Recommendations

5 Tooling Recommendations

Installation of tooling and fixtures should be performed by personnel who are familiar with the operation of this system. Tooling and fixtures are supplied by the customer.

There are two system configurations possible with the MH-SERIES

POSITIONER headstock only and headstock/tailstock with MotoMount. To ensure optimal performance from the MH-SERIES POSITIONER tooling system, Yaskawa Motoman makes the following recommendations for each configuration.

5.1

Headstock Only – Tooling Recommendations

The stand-alone headstock assembly provides the only support for tooling and production parts. Proper tooling design directly effects the headstock performance and longevity. All tooling practices apply to the headstock assembly whether it is accompanied by a column or not.

Fig. 5-37: Headstock Assembly - Type I

AC SERVO

MOTOR

FACEPLATE

HOUSING

COLUMN

Fig. 5-38: Headstock Assembly - Type II

FACEPLATE

HOUSING

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5 Tooling Recommendations

5.1 Headstock Only – Tooling Recommendations

5.1.1

Customer-supplied Tooling Fixture

The customer-supplied tooling hangs from the faceplate as it supports production parts for welding. Customers control/change the design of tooling fixtures to match the design of the production parts.

5.1.1.1

Recommendations

To ensure optimum performance from the customer-supplied tooling fixture, please read the following recommendations:

• Use all bolt holes on the faceplate to mount the tooling fixture.

• Use the dowel pins.

5.1.1.2

Mounting Holes – Faceplate

The customer-supplied tooling must be designed to fit the MH-SERIES

POSITIONER faceplate mounting holes. See the following figure for the faceplate mounting hole pattern;

Figure 5-39

for MH95/185 faceplate

Figure 5-40

for MH505 faceplate

Figure 5-41

for MH1605 faceplate

Figure 5-42

for the 3105 faceplate

Fig. 5-39: Mounting Holes on Faceplate MH95/185

100.0 MM

80.0 MM

100.0 MM

80.0 MM

4 X 12 X 1.75

18 MM DEEP

100.0 MM

100.0 MM

2 X SLIP FIT FOR

M12 DOWEL

320.0 MM

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4 X M12 x 1.75

5 Tooling Recommendations

5.1 Headstock Only – Tooling Recommendations

Fig. 5-40: Mounting Holes on Faceplate MH505

100 MM 100 MM

100 MM

100 MM

2 X SLIP FIT

FOR M12

DOWEL

125 MM

250 MM

200 MM

5 MM DEEP

4 X M10 1.5 THRU

TYP.

30 MM

TYP.

12.5 MM

2 X M12 THRU

CAUTION

To proper secure fixture, rated loads required the use of all M16 mounting holes.

Fig. 5-41: Mounting Holes on Faceplate MH1605

112.5 MM 112.5 MM

0.0

194.9 MM 194.9 MM

225.0 MM

225.0 MM

225.0 MM

194.9 MM

112.5 MM

284.5 MM

TYP.

274.5 MM

264.5 MM

0.0

M16 X 2 THRU

112.5 MM

194.9 MM

225.0 MM

30 MM OD X 6 ID THRU

PILOT – 1/8-28 BSPT

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5 Tooling Recommendations

5.1 Headstock Only – Tooling Recommendations

Fig. 5-42: Mounting Holes on Faceplate MH3105

112.5 MM 112.5 MM

0.0

194.9 MM 194.9 MM

225.0 MM 225.0 MM

200 MM

5 MM DEEP

4 X M10 1.5 THRU

TYP.

30 MM

TYP.

12.5 MM

2 X M12 THRU

284.5 MM

TYP.

274.5 MM

264.5 MM

DIA. 120 THRU

225.0 MM

194.9 MM

112.5 MM

0.0

225.0 MM

M16 X 2 THRU

112.5 MM

194.9 MM

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5 Tooling Recommendations

5.2 Headstock/Tailstock with MotoMount

5.2

Headstock/Tailstock with MotoMount

5.2.1

Customer-supplied Tooling Fixtures

With MotoMount, the customer-supplied tooling fixture bridges the headstock and tailstock together as it supports production parts for welding. Customer design their tooling fixtures to fit their specific needs.

Modifications to existing tooling fixtures will be minimal as long it fits the current headstock/tailstock configuration (retrofit application)

5.2.2

Multiple Tooling Fixtures

Some applications require multiple tooling fixtures that are switched in and out of the positioner as production needs change. To prepare these extra fixtures to work with MotoMount, the following spare parts are needed:

• Bearing adapter

• Bearing

Contact Yaskawa Motoman Customer Service at (937) 847-3200, to purchase these parts.

5.2.3

Specifications

To ensure that the customer-supplied tooling fixture fits properly to

MotoMount, the following specifications must be met.

5.2.3.1

Parallelism

Inspect both mounting flanges for parallelism to one another. The combined angle of misalignment for both flanges should not exceed 1/2

degree ( Figure 5-43 ).

Fig. 5-43: Tooling Fixture Inspection

1/4-DEGREE

ANGLE OF

MISALIGNMENT

FLANGE

TOOLING FIXTURE

1/4-DEGREE

ANGLE OF

MISALIGNMENT

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5 Tooling Recommendations

5.2 Headstock/Tailstock with MotoMount

5.2.3.2

Hole Pattern on MotoMount

The tooling fixture flange that attaches to MotoMount must have the

following hole pattern ( Figure 5-44

).

Fig. 5-44: Tooling Template - MotoMount

177.8 MM

2 X DIAM. 13 MM

88.9 MM

SLIP FIT FOR

M16 LOCATING PIN

5.2.3.3

Hole Pattern on MotoMount HD

The tooling fixture flange that attaches to MotoMount HD must have the

following hole pattern ( Figure 5-45

).

Fig. 5-45: Tooling Template - MotoMount HD

400 MM

200 MM

200 MM

31.8 MM

100 MM

20 MM

SLIP FIT FOR

M16 LOCATING PIN

43.5 MM

4 X 17.5 MM

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5 Tooling Recommendations

5.2 Headstock/Tailstock with MotoMount

5.2.3.4

Headstock Flange Specifications

Figure 5-46 shows the specifications for the tooling fixture flange that is secured to MotoMount. 5.2.3.5

shows the specifications for the tooling

fixture flange that is secured to MotoMount and MotoMount HD.

Fig. 5-46: Drive Component Clearance - MotoMount

48.2

TOOLING FIXTURE

12.5

15.1

2X M12 X 1.75 ` 25.0

Ø30

88.9

CENTERLINE

88.9

Ø 16.0 LOCATING PIN

TOOLING

FIXTURE

FLANGE

Fig. 5-47: Drive Component Clearance - MotoMount HD

50 MM MINIMUM 90 MM DIAM X 20 MM DEEP

SHAFT CLEARANCE REQUIRED

FOR AUXILIARY MOUNTING

32 MM MAXIMUM

LOCATING PIN

CENTERLINE

63.5 MM

MOTOMOUNT

5.2.3.5

Tailstock Flange Specifications

Figure 5-48 shows the specifications for the tooling fixture flange that is secured to the MotoMount tailstock adapter. Figure 5-49 shows the

specifications for the tooling fixture flange that is secured to the

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5 Tooling Recommendations

5.2 Headstock/Tailstock with MotoMount

MotoMount HD tailstock adapter.

Fig. 5-48: Tailstock Adapter - MotoMount

36.5 +/- 7 MM MINIMUM

TOOLING

FIXTURE

FLANGE

Fig. 5-49: Tailstock Adapter - MotoMount HD

70 MM

MINIMUM

TOOLING

FIXTURE

FLANGE

TAILSTOCK

ADAPTER

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5 Tooling Recommendations

5.2 Headstock/Tailstock with MotoMount

5.2.3.6

Auxiliary Mounting Holes – MotoMount HD

To further secure the tooling fixture, there are two auxiliary mounting holes

Figure 5-50 on the face of the MotoMount HD tooling adapter.

These auxiliary mounting holes are for added security only. Do not use the auxiliary mounting holes for the primary tooling support.

Center shaft clearance required on the tooling fixture when using auxiliary mounting holes on the headstock are shown in

Figure 5-47

. Center shaft clearance required when using auxiliary mounting holes on the tailstock

are shown in Figure 5-50

.

Fig. 5-50: Auxiliary Mounting Holes

175.0 MM 175.0 MM

31.8 MM

TOOLING PIN

63.5 MM

TAILSTOCK

ADAPTER

90 MM DIAM X 40 MM DEEP

SHAFT CLEARANCE REQUIRED

FOR AUXILIARY MOUNTING

2 X M16 X 2.0 THRU

DIAM. 90 MM THRU

TAILSTOCK

ADAPTER

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6 Maintenance

6 Maintenance

6.1 Spare Parts

Maintenance of the MH-SERIES POSITIONER components should be performed only by authorized personnel who are familiar with the design and construction of this positioner. The following procedures should be performed only as needed. Read through the instructions completely before performing any maintenance procedure. Be sure to understand the procedure, have the proper tools, and observe all applicable safety precautions.

WARNING

Ensure that servo power is off before performing the following procedures. Observe standard lockout/tageout practices.

6.1

Spare Parts

When a part malfunctions, it is helpful to have replacement parts in stock

for quick replacement. Table 6-1: lists the recommended spare parts with

Yaskawa Motoman part numbers. Motoman recommends the following parts be kept on hand:

Table 6-1: Recommended Spare Parts

Component

Weld Ground Brush Post

Weld Ground Brush Holder

Switch

Brush

Grease

MH95/185/505/1605/3105 Recommended

Quantity

144370-1

144372-1

149473-1

1

1

3

144371-1

Moly white RE00

132412-1

1

1

NOTE

The motor and reducer are not recommended for field service. The unit should be returned to Yaskawa Motoman for repairs to these components.

6.2

Servomotor

The AC servomotor has no wear parts (i.e. brushes), so a simple daily inspection is sufficient. Do not disassemble the motor.

Contact the

Yaskawa Motoman Customer Service at (937) 847-3200 when an overhaul becomes necessary.

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6 Maintenance

6.3 Weld Ground Brush Replacement – Type I

6.3

Weld Ground Brush Replacement – Type I

6.3.1

MH95/185/505/1605

To replace the grounding brush(s) proceed as follows:

1. Shut down cell using main disconnect.

2. Use a flathead screwdriver to disconnect the brush cable(s) from the ground post (

Figure 6-1

).

Fig. 6-1: Brush Cable Removal

GROUND POST

GROUND BRUSH

CABLE

3. Release the spring tensioner on the back of the brush by squeezing both black spring levers and pulling away from the faceplate.

4. Reach in and steady the brush case with one hand.

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6 Maintenance

6.3 Weld Ground Brush Replacement – Type I

5. Use a 7/16-in. wrench to loosen and remove the two screws on top of the housing (

Figure 6-2

) that retains the case.

Fig. 6-2: Brush Assembly

BRUSH NUT

RETAINING

SCREW

FACE PLATE RETAINING

EDGE

BRUSH

VERIFY FULL

CONTACT WITH

FACEPLATE

BRUSH

HOLDER

HOUSING

SERVO

MOTOR

FACE PLATE

NOTE When pulling the brush holder out, identify and secure the nut plate that slides in the top side of the case.

6. Lower the case below the retaining edge, and slowly pull the brush

holder out of the housing ( Figure 6-3 ).

Fig. 6-3: Brush removal MH95/185/505/1605

1/4 IN. SCREW

BRUSH HOLDER

WITH BRUSH

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6 Maintenance

6.3 Weld Ground Brush Replacement – Type I

7. Slide the old brush out of the housing and replace it with the new one.

8. Put the brush holder back into housing compartment until the both holes on the nut plate are aligned with holes in the housing.

9. Insert both screws through housing and into nut plate. Thread the screws into nut plate loosely.

10. Push the brush holder up in front of the retaining edge and hold steady.

11. Squeeze the brush retaining spring and push the brush against the faceplate then release. The spring must hold the brush firmly against the face plate (

Figure 6-2

).

CAUTION

The weld ground brush must be affixed hold and evenly against the faceplate. Uneven contact can subject the gear reducer bearing to weld current.

12. Tighten the screws to 6.0 N•m (4.4 lbf-ft.).

13. Insert the ground cables onto the ground posts.

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6 Maintenance

6.4 Weld Ground Brush Replacement – Type II

6.4

Weld Ground Brush Replacement – Type II

6.4.1

MH3105

To replace the grounding brush(s) proceed as follows:

1. Shut down cell using main disconnect.

2. Remove the back panel of the drive assembly.

3. Use a flathead screwdriver to disconnect the brush cable(s) from the ground post (

Figure 6-4 ).

Fig. 6-4: Brush Cable Post

GROUND BRUSH

CABLE

DRIVE ASSEMBLY

HEADSTOCK

4. Release the spring tensioner on the back of the brush by squeezing both black spring levers and pulling away from the faceplate.

5. Reach in and steady the brush case with one hand.

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6 Maintenance

6.4 Weld Ground Brush Replacement – Type II

6. Use a 7/16-in wrench to loosen and remove the two screws on top of

the housing ( Figure 6-5 ) that retains the case.

Fig. 6-5: Brush Assembly

RETAINING

SCREW

BRUSH NUT

VERIFY FULL

CONTACT WITH

PLATE

BRUSH

BRUSH

HOLDER

HOUSING

NOTE When pulling the brush holder out, identify and secure the nut plate that slides in the top side of the case.

7. Lower the case below the retaining edge, and slowly pull the brush holder out of the housing (

Figure 6-6

).

Fig. 6-6: Brush Removal 3105

MOTOR

HOUSING

BRUSH

DRIVE ASSEMBLY

HEADSTOCK

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MH-SERIES

POSITIONER

6 Maintenance

6.5 Reset Headstock To Home Position

8. Slide the old brush out of the housing and replace it with the new one.

9. Put the brush holder back into housing compartment until the both holes on the nut plate are aligned with holes in the housing.

10. Insert both screws through housing and into nut plate. Thread the screws into nut plate loosely.

11. Push the brush holder up in front of the retaining edge and hold steady.

12. Squeeze the brush retaining spring and push the brush against the faceplate then release. The spring must hold the brush firmly against

the face plate ( Figure 6-2 ).

CAUTION

The weld ground brush must be hold firmly and evenly against the faceplate. Uneven contact can subject the gear reducer bearing to weld current.

13. Tighten the screws to 6.0 N•m (4.4 lbf-ft.).

14. Insert the ground cables onto the ground posts.

6.5

Reset Headstock To Home Position

The home position on the drive assembly is set in the controller by the operator. Any position of the headstock can be programmed as home. The factory setting of home position is found using the alignment hole, an alignment tool, and the programming pendant.

Resetting of the home position is typically done before new tooling and fixturing is installed, or when the motor has been serviced.

6.5.1

Homing

6.5.1.1

MH95/185/505/1605 – Type I

The factory home position for Type I positioners is located by aligning the homing pin against the housing, after installing the pin in the faceplate hole. Once Home position is found, some minor programming with the programming pendant is required. To reset a MH95/MH185/MH505/

MH1605 headstock, proceed as follows:

1. Make sure robot(s) is in home position.

6-7

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MH-SERIES

POSITIONER

162068-1CD

6 Maintenance

6.5 Reset Headstock To Home Position

2. Using the programming pendant in TEACH MODE, jog the faceplate slowly until the homing hole is near the home feature on the side of

the housing ( Figure 6-7 ).

Fig. 6-7: Home Position - Type I

HOME FEATURE

HOMING

HOLE

ROTATE

HOMING

PIN

3. Once the faceplate has been jogged close to the Home position, install the homing pin through the hole in the faceplate. The pin may need to be tapped in with a hammer.

4. Slowly jog the drive assembly until the plastic pin just touches the

home feature ( Figure 6-7

) on the housing. If you go too far the pin will bend, causing a gap at the other end of the pin. Slowly jog the faceplate in reverse rotation until the gap closes.

• Now that the faceplate has been set to home position, proceed with

Step 5 of resetting instructions:

6-8

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162068-1CD

MH-SERIES

POSITIONER

6 Maintenance

6.5 Reset Headstock To Home Position

5. Switch the programming pendant to MAINTENANCE MODE and proceed:

• Press TOP MENU key on programming pendant.

• Cursor to ROBOT and press SELECT.

• Cursor to HOME POSITION and press SELECT.

• Press the PAGE OVER key to the desired station (indicated in the top right corner).

• Make sure the headstock is in the position that you want to teach as home and press SELECT.

• Cursor to YES and press SELECT. The headstock is now reset to zero

6.5.1.2

MH3105 – Type II

The factory home position is located by aligning two homing pins after installing them into holes in the faceplate and housing. Once both pins are aligned, some minor programming with the programming pendant is required. To reset each a MH3105 headstock, proceed as follows:

1. Make sure robot(s) is in home position.

2. Locate the headstock homing hole. Using the programming pendant in

TEACH MODE, jog the faceplate slowly until the faceplate homing hole is just below to the headstock homing hole.

3. Install the faceplate homing pin through the faceplate homing hole in the faceplate. The pin may need to be tapped in with a hammer.

4. Install the headstock homing pin through the headstock homing hole in the headstock. The pin may need to be tapped in with a hammer.

5. Slowly jog the faceplate until faceplate homing pin just touches the

headstock homing pin ( Figure 6-8 ) on the housing. If you go too far

both pins will bend, causing an inaccuracy. Slowly jog the faceplate in reverse rotation until the both pins are straight and still touching each other.

Fig. 6-8: Home Position - Type II

HEADSTOCK

HOMING PIN FACEPLATE

HOMING PIN

HEADSTOCK

HOMING HOLE

HEADSTOCK

HOMING HOLE

FACEPLATE

6-9

162068-1CD 71/101

MH-SERIES

POSITIONER

162068-1CD

6 Maintenance

6.5 Reset Headstock To Home Position

6. Switch the programming pendant to MAINTENANCE MODE and proceed:

• Press TOP MENU key on programming pendant.

• Cursor to ROBOT and press SELECT.

• Cursor to HOME POSITION and press SELECT.

• Press the PAGE OVER key to the desired station (indicated in the top right corner).

• Make sure the headstock is in the position that you want to teach as home and press SELECT.

• Cursor to YES and press SELECT. The headstock is now reset to zero.

7. Remove both alignment pins from the faceplate headstock.

6-10

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162068-1CD

MH-SERIES

POSITIONER

6 Maintenance

6.6 Maintenance Schedule

6.6

Maintenance Schedule

6.6.1

MH-Series SIGMA-5 Positioner

See Table 6-2: for the periodic maintenance schedule.

Table 6-2: Maintenance Schedule

Inspection

Item

Physical damage

Excessive or unusual noise

Weld

Brushes

Frequency

Daily

Daily

First Week

Weekly

Inspection Operation

Check for physical damage; this indicates a load collision and is evidence of misuse.

Listen for grinding, excessive or irregular noise.

Contact Yaskawa Motoman Service Department at (937) 847-3200.

Check for dirt and ensure full contact with faceplate.

Check for dirt and ensure full contact with faceplate.

Cleaning As required Clean with dry cloth or compressed air.

Flush and relubricate using Moly white grease.

Lubrication Every

20,000 hours or 5 years

6.6.2

MotoMount

See Table 6-3: for periodic maintenance procedures.

Table 6-3: Periodic Maintenance

Frequency

Daily

Monthly

Procedure

Using compressed air or a suitable brush, remove any weld spatter and dirt from the drive components with particular attention to the drive bushing area.

Verify tooling bolts are tight.

Provide 2-3 pumps of grease (Motoman, Inc. 133174-2, Kluber

#039067, Lubriplate 3000, or equivalent) to the main bearing zerk fitting.

Verify the leveling and lag bolts are tight on the headstock/ tailstock columns

6-11

162068-1CD 73/101

MH-SERIES

POSITIONER

162068-1CD

6 Maintenance

6.7 Troubleshooting

6.7

Troubleshooting

6.7.1

MH-Series SIGMA-5 Positioner

Table 6-4: Troubleshooting

Symptom Probable Cause

Motor does not start Loose connection

Incorrect wiring

Unstable operation

Motor overheats

Unusual noise

Weld quality bad

Overload

Incorrect wiring

Excessive ambient temperature

Motor surface is dirty

Motor overloaded

Motor loosely mounted

Positioners misaligned

Noisy bearing

Brushes misaligned

Corrective Action

Check all wire connections.

Check that system has been wired correctly.

Reduce load or reduce unbalanced load.

Inspect and correct wiring across motor terminals L1,

L2, L3, and PE.

Reduce ambient temperature below 40° C

(104° F). Positioner has an operating range of 0 to 45°

C (32 to 113°F).

Clean motor surface.

Reduce load or unbalanced load.

Tighten mounting bolts.

Realign headstock/tailstock

(see Section 4.4.3,

"Leveling the Tailstock")

Check alignment, noise of bearing, lubrication. Call

Yaskawa Motoman

Customer Service.

Remove brush(s) and reinstall them properly.

Recheck as needed.

6.7.2

MotoMount

6.7.2.1

High Duty Cycles

High duty cycles under heavy loads and/or dirty operating conditions may cause the drive bushing to wear. This may be indicated by an increase in the tooling position repeatability. Call Yaskawa Motoman Customer

Service for details.

6-12

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162068-1CD

MH-SERIES

POSITIONER

A Performance Charts

A.1 MH-Series Positioner Assemblies

A Performance Charts

A.1

MH-Series Positioner Assemblies

A.1.1

MH95

Fig. A-1: MH95 Performance Charts

Holding Torque (N*m)=

Rated

195

Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf)

40

60

497

332

574

383

80

100

120

140

160

249

199

166

142

124

287

230

191

164

143

180

200

220

240

260

280

300

111

99

90

83

77

71

66

128

115

104

96

88

82

77

Peak

225

700

600

500

400

300

200

100

0

0 50

Holding Torque; Load CG Offcenter

100 150 200 250 300

Rated W (kgf)

Max W (kgf)

Maximum Bearing Moment (N*m) = 882

Load CG Overhang (from Tooling Plate)

D (mm) Rated W (kgf) Max W (kgf)

50 275 413

60 260 389

80

100

120

140

233

211

193

178

349

316

289

266

160

180

200

220

240

260

280

300

165

153

144

135

127

120

114

109

247

230

215

202

191

181

171

163

450

400

350

300

250

200

150

100

50

0

0

Rated Bearing Moment; Load CG Overhang

Rated W (kgf)

Max W (kgf)

50 100 150 200 250

CG Distance from Tooling Plate, D (mm)

300

HTS Applications assume 1/2 load on

Note: headstock @ 50 mm, using MotoMount.

2) Rated load based upon 50% maximum bearing moment.

3) Maximum load based upon 75% maximum bearing moment.

Reflected Ratio

Load Inertia Jl/Jm

20

22

24

26

2.5

2.75

3

3.25

34

36

38

40

28

30

32

3.5

3.75

4

4.25

4.5

4.75

5

Note: Maximum recommend inertia ratio is 5.

Allowable Load Inertia

5.5

5

4.5

4

3.5

3

2.5

2

15 16 17 18 19 20 21 22 23 24

Application Inertia, kg*m

2

25 26 27 28 29

Jl/Jm

A-1

162068-1CD 75/101

MH-SERIES

POSITIONER

A.1.2

MH185

162068-1CD

A Performance Charts

A.1 MH-Series Positioner Assemblies

Fig. A-2: MH185 Performance Charts

Holding Torque (N*m)=

Rated

299

Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf)

40 763 880

60

80

100

120

140

508

381

305

254

218

587

440

352

293

251

160

180

200

220

240

260

280

300

191

169

153

139

127

117

109

102

220

196

176

160

147

135

126

117

Peak

345

1000

900

800

700

600

500

400

300

200

100

0

0 50

Holding Torque; Load CG Offcenter

100 150 200 250 300

Rated W (kgf)

Max W (kgf)

Maximum Bearing Moment (N*m) = 882

350

375

400

425

450

225

250

275

300

325

475

500

Load CG Overhang (from Tooling Plate)

D (mm) Rated W (kgf) Max W (kgf)

50

75

275

239

413

358

100

125

150

175

200

211

189

171

156

144

316

283

256

234

215

133

124

116

109

103

97

92

88

84

80

76

73

146

138

131

125

120

199

186

174

163

154

115

110

HTS Applications assume 1/2 load on

Note: headstock @ 50 mm, using MotoMount.

2) Rated load based upon 50% maximum bearing moment.

3) Maximum load based upon 75% maximum bearing moment.

Reflected Ratio

Load Inertia Jl/Jm

47 2.5

51

56

61

66

70

2.75

3

3.25

3.5

3.75

75

80

84

89

94

4

4.25

4.5

4.75

5

450

400

350

300

250

200

150

100

50

0

0

5.5

5

4.5

4

3.5

3

2.5

2

58

Note: Maximum recommend inertia ratio is 5.

Rated Bearing Moment; Load CG Overhang

100 200 300 400

CG Distance from Tooling Plate, D (mm)

500

68

Allowable Load Inertia

78 88

Application Inertia, kg*m

2

98 108

Rated W (kgf)

Max W (kgf)

Jl/Jm

A-2

162068-1CD 76/101

162068-1CD

MH-SERIES

POSITIONER

A.1.3

MH505

A Performance Charts

A.1 MH-Series Positioner Assemblies

Fig. A-3: MH505 Performance Charts

Holding Torque (N*m)=

Rated

829

Load CG Offcenter from Tooling Plate r (mm)

80

Rated W (kgf) Max W (kgf)

1057 1219

100

120

140

160

845

705

604

528

976

813

697

610

180

200

220

240

260

280

300

470

423

384

352

325

302

282

542

488

443

406

375

348

325

Peak

957

1400

1200

1000

800

600

Holding Torque; Load CG Offcenter (from Tooling Plate)

Rated W (kgf)

Max W (kgf)

400

200

0

0 50 100 150 200

Load CG Offcenter, r (mm)

250 300

Maximum Bearing Moment (N*m) = 2156

Load CG Overhang (from Tooling Plate)

D (mm) Rated W (kgf) Max W (kgf)

50

75

537

478

805

717

100

125

150

175

431

393

361

333

647

589

541

500

200

225

250

275

300

325

350

310

289

271

256

242

229

218

465

434

407

384

362

344

327

375

400

425

450

475

500

207

198

190

182

174

168

311

297

284

273

262

252

Note: HTS Applications assume 1/2 load on headstock @ 50 mm, using MotoMount.

2) Rated load based upon 50% maximum bearing moment.

3) Maximum load based upon 75% maximum bearing moment.

Reflected Ratio

Load Inertia

105

Jl/Jm

2.5

115

126

136

147

157

2.75

3

3.25

3.5

3.75

168

178

189

200

210

4

4.25

4.5

4.75

5

5.5

5

4.5

4

3.5

3

2.5

2

110

Note: Maximum recommend inertia ratio is 5.

900

800

700

600

500

400

300

200

100

0

0

Rated Bearing Moment; Load CG Overhang

100 200 300 400

CG Distance from Tooling Plate, D (mm)

Allowable Load Inertia

500

130 150 170 190

Application Inertia, kg*m

2

210 230

Rated W (kgf)

Max W (kgf)

250

Jl/Jm

A-3

162068-1CD 77/101

MH-SERIES

POSITIONER

A.1.4

MH1605

162068-1CD

A Performance Charts

A.1 MH-Series Positioner Assemblies

Fig. A-4: MH1605 Performance Charts

Holding Torque (N*m)

Rated

2826

Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf)

40

60

7202

4801

8309

5540

80

100

120

140

3601

2881

2401

2058

4155

3324

2770

2374

160

180

200

220

240

260

280

300

1800

1600

1440

1309

1200

1108

1029

960

2077

1847

1662

1511

1385

1278

1187

1108

Peak

3261

9000

8000

7000

6000

5000

4000

3000

2000

1000

0

0 50

Holding Torque; Load CG Offcenter

100 150 200 250 300

CG Offcenter, r (mm)

Rated W (kgf)

Max W (kgf)

Maximum Bearing Moment (N*m) = 7056

Load CG Overhang (from Tooling Plate)

D (mm) Rated W (kgf) Max W (kgf)

50

60

1284

1240

1927

1860

80

100

120

140

1160

1090

1028

972

1740

1635

1541

1458

160

180

200

220

240

260

280

300

922

877

836

799

765

734

705

679

1383

1316

1255

1199

1148

1101

1058

1018

Note: HTS Applications assume 1/2 load on headstock @ 50 mm, using MotoMount.

2) Rated load based upon 50% maximum bearing moment.

3) Maximum load based upon 75% maximum bearing moment.

Load Inertia

672

Reflected Ratio

Jl/Jm

2.5

742

811

880

950

2.75

3

3.25

3.5

1019

1088

1158

1227

1296

1365

3.75

4

4.25

4.5

4.75

5

2500

2000

1500

1000

500

0

0

Rated Bearing Moment; Load CG Overhang

50 100 150 200 250

CG Distance from Tooling Plate, D (mm)

300

Allowable Load Inertia

5.5

5

4.5

4

3.5

3

2.5

678 778 878 978 1078 1178

Application Inertia, kg*m

2

1278 1378 1478

Rated W (kgf)

Max W (kgf)

Note: Maximum recommend inertia ratio is 5.

A-4

162068-1CD 78/101

162068-1CD

MH-SERIES

POSITIONER

A.1.5

MH3105

A Performance Charts

A.1 MH-Series Positioner Assemblies

Fig. A-5: MH3105 Performance Charts

Holding Torque; Load CG Offcenter

Holding Torque (N*m)=

Rated

5479

Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf)

50

60

11170

9308

12888

10740

80

100

120

140

6981

5585

4654

3989

8055

6444

5370

4603

160

180

200

220

240

260

280

300

3491

3103

2792

2539

2327

2148

1995

1862

4028

3580

3222

2929

2685

2479

2301

2148

Peak

6322 14000

12000

10000

8000

6000

4000

2000

0

0 50 100 150 200

Load CG Offcenter r(mm)

250 300

Maximum Bearing Moment (N*m) = 20580

Load CG Overhang (from Tooling Plate)

D (mm) Rated W (kgf) Max W (kgf)

50

100

3174

2757

4761

4135

150

200

2437

2183

3655

3274

250

300

350

400

450

500

550

600

650

1977

1807

1664

1541

1436

1344

1263

1191

1127

2966

2710

2495

2312

2154

2016

1895

1787

1691

700

750

800

850

900

950

1070

1018

971

928

889

852

1605

1527

1456

1392

1333

1279

Note: 1) HTS Applications assume 1/2 load on headstock @ 50 mm, using MotoMount.

2) Rated load based upon 50% maximum bearing moment.

3) Maximum load based upon 75% maximum bearing moment.

Load Inertia

Reflected Ratio

Jl/Jm

3058

3394

3730

4066

4402

4738

5073

5409

5745

6081

6417

2.5

2.75

3

3.25

3.5

3.75

4

4.25

4.5

4.75

5

Rated W (kgf)

Max W (kgf)

Rated Bearing Moment; Load CG Overhang

5000

4500

4000

3500

3000

2500

2000

1500

1000

500

0

0

Rated W (kgf)

Max W (kgf)

200 400 600 800

CG Distance from Tooling Plate, D (mm)

1000

Allowable Load Inertia

5.5

5

4.5

4

3.5

3

2.5

2

3000 3500 4000 4500 5000

Application Inertia, kg*m

2

5500 6000 6500

Jl/Jm

Note: Maximum recommend inertia ratio is 5.

A-5

162068-1CD 79/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

B Illustrated Parts list

B.1

Introduction

This Illustrated Parts List identifies, describes, and illustrates detail parts of the main assemblies for the MH-SERIES POSITIONER manufactured by Yaskawa Motoman.

This list provides parts identification and descriptive information for use in provisioning, requesting, purchasing, storing, and issuing spare parts.

B.1.1

Contents

The parts list contains a breakdown of the equipment into detail parts. All parts of the equipment are listed except the following:

1. Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are available commercially.

2. Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.

3. Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to other parts, or assemblies.

B.1.2

Parts List

This form is divided into four columns as follows:

1. “Figure - Item Number” Column

• This column lists the figure number of the illustration applicable to a particular parts list and also identifies each part in the list by an item number. These item numbers also appear on the illustration. Each item number on the illustration is connected to the part to which it pertains by a leader line and arrow. Thus, the figure and item numbering system ties the parts list to the illustrations and vice versa

2. “Motoman Part Number” Column

• All part numbers appearing in this column are Yaskawa Motoman part numbers.

3. “Description” Column

• The item nomenclature appears in this column.

4. “QTY” Column

• This column indicates the quantity of parts required for an assembly or subassembly in which the part appears. This column does not necessarily reflect the total used in the complete end item.

B-1

162068-1CD 80/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

B.1.3

Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list.

• amp – ampere

• AC – alternating current

• cyl – cylinder

• DC – direct current

• fig – figure

• hex – hexagon

• ID – inside diameter

• in – inch

• m – meter

• mm – millimeter

• No– number

• psi – pounds per square inch

• v – voltage

B-2

162068-1CD 81/101

Fig. B-1: MH95/M185 Head Stock

TORQUE TO 73.5 Nm

24

27

19

1

TORQUE TO 15.6 Nm

6

23

22

29

20

19

19

TORQUE TO 6.0 Nm

6

5

3

4

7

26

25 30

2

9

10

18

17

13 14 15 16

34 26

TORQUE TO 3.6 Nm

33

31

32 6

12

11

TORQUE TO 40.0 Nm

38

82/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

Table B-1: MH95/M185 Head Stock Parts List

Item P/N

4

5

2

3

B-1

1

158238-1

158241-2

156009-1

158242-1

144371-1

130235-3

Title

DRIVE ASSY, MH95, HEADSTOCK SERVO

PLATE, FACE, MH95/185 HEADSTOCK

MOTOR, AC SERVO, 450W, SIGMA V

HOUSING, MH95/185 HEADSTOCK

BRUSH, GROUND, METAL, GRAPHITE 1

SCREW,HHC,1/4-20X5/8,ZP,GR5 2

1

1

Qty

REF

1

10

11

12

13

14

8

9

6

7

470602-1

144372-1

144370-1

479154-1

WASHER, CONICAL, SPRING, M6

BRUSH HOLDER, 1" X 1.5" X 2"

TERMINAL, QUICK DISC, WELD GROUND LUG 2

CLAMP, CABLE SUPPORT 1

22

1

407249-3 SCREW,SHC,M6x12

407248-6 SCREW, SHC, M8 X 25, CLASS 12.9

470617-1 WASHER, CONICAL, SPRING, M8 4

1

1

4

1

19

20

21

22

15

16

17

18

479148-5 WASHER_LOCK_M8

479147-5 WASHER_FLAT_M8

158342-1 SCREW, PPH, M4x0.7 X 8, MACHINE

133963-3 BOLT,EYE,M10,DIN 580

146122-1

2

SEAL KIT, RV-20E, O-RING S120, S100, & S12.5 1

407249-7 SCREW,SHC,M6X30,CLASS 12.9

3

1

16

6

4

4

1

1

27

29

30

31

23

24

25

26

479296-14

471009-1

133937-1

145913-3

SCREW, SHC, M5 X 60, CLASS 12.9

WASHER, CONICAL, SPRING, M5

FITTING, ZERK 1/8 PT

REDUCER, RV, MH95 HEADSTOCK

158686-1

158244-1

GEAR, PINION, INPUT, RV REDUCER, 105:1

BRACKET, MTG, LIMIT SWITCH

407249-4 SCREW_SHC_M6X16 32

33

34

38

479296-6 SCREW,SHC,M5X16

Below Items Replace Above Items For A MH185

B-1

158238-2 DRIVE ASSY, MH185, HEADSTOCK SERVO

20

29

30

158941-10

145913-2

158686-2

LABEL, PRODUCT ID

REDUCER, RV, RV-20E-161

GEAR, PINION, INPUT, RV REDUCER, 161:1

Ref

1

1

1

4

2

1

2

4

1

1

1

1

5

B-4

162068-1CD 83/101

Fig. B-2: MSR205/MH505 Head Stock

34

28

33

36

5

MH505

ONLY

3

24

15

23

22

25

15

38 35

4

2

29

30 31 32

6

7

27 28

1

10

9

37

4 39

MSR205

ONLY

21 16 17

18

MH505

20

19 15

OR

16 17

18 20

MSR205

19 15

16 17

84/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

Table B-2: MSR205/MH505 Head Stock Parts List

30

31

32

33

26

27

28

29

21

22

23

24

25

17

18

19

20

9

10

15

16

6

7

8

4

5

2

3

Item P/N

B-2

1

158482-1

158484-2

156009-3

158483-1

Title

MH505 POSITIONER ASSEMBLY

PLATE, FACE, MH550/MSR205, HEADSTOCK

MOTOR, AC SERVO, SIGMA V, 1.3 kW

HOUSING, MH505/MSR205, HEADSTOCK

479281-105 FITTING, PLUG, 1/8BSPT, BLACK

158941-11 LABEL, PRODUCT ID MH505

(ONLY ON MH505)

479154-4 TIE MOUNT

158342-1

133963-3

479297-4

407248-5

SCREW, PPH, M4x0.7 X 8, MACHINE

BOLT,EYE,M10,DIN 580

SCREW, SHC, M10x1.5 X 25, CLASS 12.9

SCREW, SHC, M8 X 20, CLASS 12.9

470602-1

479296-6

471009-1

149473-1

WASHER, CONICAL, SPRING, M6

SCREW,SHC,M5X16

WASHER, CONICAL, SPRING, M5

LIMIT SWITCH

407249-4

158244-1

145896-1

144371-1

SCREW_SHC_M6X16

BRACKET, MTG, LIMIT SWITCH

PIN, HOMING

BRUSH, GROUND, METAL, GRAPHITE

130235-6

130443-15

144372-1

SCREW, HHC, 1/4-20 X 1", ZP, GR5

WASHER, FLAT, 1/4", SAE

BRUSH HOLDER, 1" X 1.5" X 2", WELD

GROUNDING

144370-1

407248-6

470617-1

133984-1

132616-3

479148-5

479147-5

407248-7

TERMINAL, QUICK DISC, WELD GROUND LUG

SCREW, SHC, M8 X 25, CLASS 12.9

WASHER, CONICAL, SPRING, M8

NAMEPLATE, GROUND

SCREW,HHC,M8 X 16

WASHER_LOCK_M8

WASHER_FLAT_M8

SCREW, SHC, M8 X 30, CLASS 12.9

4

4

20

1

1

1

1

16

2

1

1

1

Qty

Ref

1

4

4

1

2

2

4

2

4

2

9

4

6

12

4

4

2

17

18

20

39

34

35

36

37

146123-1

141575-2

151594-5

133937-1

SEAL KIT, RV80E 1

GEAR, PINION, INPUT, GEAR REDUCER, 153:1 1

REDUCER, RV, RV-80E

FITTING, ZERK 1/8 PT

1

1

1 38 407249-20 SCREW,SHC,M6X65

BELOW ITEMS REPLACE ABOVE ITEMS FOR A MSR205

B-2

16

158482-2

479296-6

DRIVE ASSEMBLY MSR 205

SCREW,SHC,M5X16

471009-1

149473-1

158486-1

153463-1

WASHER, CONICAL, SPRING, M5

LIMIT SWITCH

BRACKET, MTG, LIMIT SWITCH

SCREW, SHOULDER, M8 BODY, 55 LG

(ONLY ON MSR205)

8

4

REF

8

2

1

B-6

162068-1CD 85/101

Fig. B-3: MH1605 Head Stock

5

TORQUE TO 128 Nm

6

3

17

18

19

TORQUE TO 29.5 Nm

28

38

25

26

TORQUE TO 3.6 Nm

27

11

29

TORQUE TO 3.6 Nm

33

30

39

31

32

TORQUE TO 3.6 Nm

1

15

16

24

23

10

4

12

20

14

6

13

TORQUE TO 128 Nm

TORQUE TO 6 Nm

11

2

7

34 35

TORQUE TO 73.5 Nm

23

22

37

36

TORQUE TO 318 Nm

86/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

31

32

33

34

27

28

29

30

35

36

37

38

23

24

25

26

19

20

21

22

15

16

17

18

12

13

14

Table B-3: MH1605 Head Stock Components

Item P/N

8

9

10

11

6

7

4

5

2

3

B-3

1

161825-1

161829-1

161767-1

156009-6

133963-4

472303-7

471075-1

145896-1

144372-1

144371-1

144370-1

470602-1

Title

MH1605 Positioner Assembly

HOUSING, MACHINED

PLATE, FACE, MH-1605 DRIVE ASSY

MOTOR, AC SERVO, SIGMA V, 3.7 kW

BOLT, EYE, M16, DIN580

SCREW,SHC,M12X40,CLASS 12.9

WASHER, CONICAL SPRING, M12

PIN, HOMING

BRUSH HOLDER, 1" X 1.5" X 2"

BRUSH, GROUND, METAL, GRAPHITE

TERMINAL, QUICK DISC, WELD GROUND LUG 4

WASHER, CONICAL, SPRING, M6 8

2

2

20

1

2

4

1

1

Qty

Ref

1

130235-8

472303-9

151592-7

152538-1

151593-7

145428-2

470617-1

SCREW, HHC, 1/4 X 1 1/2

SCREW, SHC, M12 X 50, CLASS 12.9

REDUCER, RV, RV-320E, 185

ADAPTER, FLYWHEEL, MRM2-250/750-M3X

GEAR, INPUT, PINION, 185

WASHER, FLAT, M8 X 16 OD X 3 THK

WASHER, CONICAL, SPRING, M8

407248-21

146924-1

133419-1

133937-1

SCREW, SHC, M8 X 100

SEAL, O-RING, INPUT

ADHESIVE, LOCTITE, #242, 0.5CC

FITTING, ZERK 1/8 PT

479281-105 FITTING, PLUG, 1/8BSPT, BLACK

147078-1 LABEL,WARNING

479154-4

158342-1

CLAMP, CABLE SUPPORT

SCREW,PPH,M4 X 07 X 8

158244-1

158941-21

407249-4

149473-1

BRACKET, MTG, LIMIT SWITCH

LABEL, PRODUCT ID,MH1605 TR

SCREW_SHC_M6X16

LIMIT SWITCH

471009-1

479296-6

WASHER, CONICAL, SPRING, M5

SCREW,SHC,M5X16

4

4

162068-1CD MANUAL, MH1605 DRIVE ASSEMBLY SIGMA 5 1

470541-1 WASHER, CONICAL SPRING, M10 18

4

2

2

1

479297-7

130532-2

132049-1

133984-1 screw_shc_m10x40

SCREW, SHC, M16 X 35

WASHER, CONICAL SPRING, GTS16

NAMEPLATE, GROUND

6

1

18

6

4

4

2

1

1

1

1

1

1

1

1

1

4

16

1

B-8

162068-1CD 87/101

Fig. B-4: Type II Drive Assembly Components

17

16

15

18

19

20

21

1

2

3

4

5

6

7

13

11

22

8

9

88/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

28

29

30

31

24

25

26

27

20

21

22

23

15

16

17

18

19

36

37

38

39

32

33

34

35

40

41

Table B-4: Type II Drive Assembly Components

Item P/N

8

9

10

11

12

6

7

4

5

2

3

B-4

1

13

14

162579-3

146198-1

146199-1

130532-3

132049-1

146010-1

162584-1

131272-7

471075-1

162580-1

149473-1

479296-9

471009-1

144370-1

146015-2

Title

DRIVE ASSY,TYPE II,SIGMA 5

PLATE, DRIVE ASSY

PLATE, FACE, 2000kg HEADSTOCK

SCREW, SHC, M16 X 40

WASHER, CONICAL SPRING, GTS16

HOUSING, CAST, POSITIONER

PLATE, MTG, DRIVE ASSY, TYPE II

SCREW,HHC,M12X40,GRADE 8.8

WASHER, CONICAL SPRING, M12

MOTOR ASSY,AC SERVO,4.4KW,SIGMA

5,TYPE II

LIMIT SWITCH

SCREW, SHC, M5 X 30

WASHER, CONICAL, SPRING, M5

TERMINAL, QUICK DISC, WELD GROUND LUG 6

BRACKET, MTG, BRUSH HOLDER 3

2

4

4

1

10

32

1

1

15

32

1

Qty

Ref

1

407249-8

470602-1

130060-12

130444-5

130443-15

144371-1

144372-1

140837-6

472303-6

131272-3

133937-1

145785-1

130532-21

146742-2

146970-1

407249-5

146743-1

SCREW, SHC, M6 X 35

WASHER, CONICAL, SPRING, M6

SCREW, SHC, 1/4”20 X 2 1/2”, GR8

WASHER, LOCK, 1/4

WASHER, FLAT, 1/4”, SAE

BRUSH, GROUND, METAL, GRAPHITE

BRUSH HOLDER, 1" X 1.5" X 2"

PIN,DOWEL,M10X35

SCREW,SHC,M12X35,CLASS 12.9

SCREW,HHC,M12X35,GRADE 8.8

FITTING, ZERK 1/8 PT

FITTING, PLUG

SCREW,SHC,M16X25

GEAR ASSY, COMPOUND

GEAR ASSY, IDLER

SCREW, SHC, M6 X 20

GEAR ASSY, DRIVE

140568-4

162589-1

407249-6

146009-1

146071-2

146022-1

472303-15

146071-3

SEAL OIL, 130 X 160 X 14, VITON

PLATE, GROUNDING BRUSH, DUAL CHANNEL

SCREW_SHC_M6X25

REDUCER, RV, POSITIONER

SEAL, O”RING, 129.6 X 5.7

POST, MTG, DRIVE GEAR, RV

SCREW,SHC,M12X80,CLASS 12.9

SEAL, O”RING, 380.59 X 3.53

479281-105 FITTING, PLUG, 1/8BSPT, BLACK

132613-4 SCREW, SET, M12 X 16

1

1

1

2

8

1

1

1

16

1

4

1

1

1

2

1

2

17

2

4

3

3

6

6

6

18

6

B-10

162068-1CD 89/101

Fig. B-5: MotoMount

TM

Tailstock Components – 95/185/505

3

7

2

12

13

14

15

90/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

13

14

15

9

10

11

12

7

8

5

6

3

4

1

2

Table B-5: MotoMount

TM

Tailstock Components – 95/185/505

Item P/N Title

B-5

155871-1

148757-1

148136-2

148135-1

148124-1

155870-1

156164-1

146953-3

407249-3

470602-1

156211-1

407249-1

155941-1

145260-1

130429-11

146456-1

ADAPTER ASSY, TAILSTOCK, GEN2,

MOTOMOUNT

SHAFT, FLANGED, MTG, MOTOMOUNT, TS

BEARING, SPHERICAL ROLLER

SCREW, SET, CONE PT M8X6

PIN, LOCATOR, 16MM

ADAPTER, BLOCK, TAILSTOCK, GEN2

RETAINER, TAILSTOCK BEARING

RING, RETAINING, EXTERNAL, 55

SCREW, SHC,M6X12

WASHER,CONICAL SPRING, M6

SEAL, FACE, SPHERICAL BEARING

SCREW, SHC, M6x1 X 8

COLUMN,TAILSTOCK,MHT-500,GEN 2

BOLT,LEVELING,M20X50

NUT,HEX JAM,M20,ZP

WASHER,SQUARE,3/8IDX1/4X2X2

4

4

4

2

1

8

2

1

6

1

2

1

1

1

1

Qty

Ref

B-12

162068-1CD 91/101

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

Fig. B-6: MotoMount

TM

Tailstock Components – 1605/3105

2

162068-1CD

11

12

13

10

3

5

15

7

4

8

14

6

9

B-13

162068-1CD 92/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

Table B-6: MotoMount

TM

Tailstock Components – 1605/3105

Item P/N Title

B-6

146964-3

10

11

12

13

14

15

8

9

6

7

4

5

2

3

131275-1

146951-1

148124-1

146950-4

148136-1

146940-4

146965-3

146953-3

146949-1

140784-1

130440-12

146456-2

148135-1

147632-2

ADAPTER, ASSY, TAILSTOCK, MOTOMOUNT

HD

SCREW, HHC, M20 X 120

CLAMP, SHAFT

PIN, LOCATING, DIA16

SHAFT, SQUARE

BEARING, SPHERICAL, ROLLER

RING, RETAINING, INTERNAL

ADAPTER, TAILSTOCK

RING, RETAINING, EXTERNAL

COLUMN, TAILSTOCK

BOLT, LEVELING

NUT, HEX JAM, M20

WASHER, SQUARE, 1/2 ID

SCREW, SET, M8 X 6, POINTED

BUMPER,ROTATION LIMITER

4

4

1

1

4

1

1

1

1

1

1

1

4

1

Qty

Ref

B-14

162068-1CD 93/101

Fig. B-7: MotoMount Components

8 7

30

29

9 10

11

31

28

8

7

6

26

16

17

19 4

3

1 2

15 14 13 12

22 21 23 27 20 25 24 18

5

94/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

28

29

30

31

24

25

26

27

20

21

22

23

17

18

19

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

145848-2

133937-1

145849-1

130398-4

132049-1

131274-5

145724-1

145753-1

148135-1

148124-1

132613-3

145710-1

146496-1

146993-1

145725-1

145708-1

151233-1

472303-9

471075-1

155872-1

146497-1

139965-1

470602-1

132614-1

470541-1

146503-1

130887-11

131272-1

479148-7

147462-1

145848-1

Table B-7: MotoMount Components

Item P/N Title

B-7

155873 FIXTURE ASSY, HEADSTOCK, GEN2,

MOTOMOUNT

BLOCK,MTG,MOTO-MOUNT

PIN,DOWEL,M12X40,MODIFIED

SCREW,SHC,M12X50,CLASS 12.9

WASHER,CONICAL SPRING,GTS12

BLOCK,MOUNTING,FIXTURE,GEN2

COVER,DUST,CAM BLOCK

SCREW,HHC,M6X10,CLASS 8.8

WASHER,CONICAL SPRING,GTS6

SCREW,HHC,M10X40,CLASS 8.8

WASHER,CONICAL SPRING,GTS10

PLATE,SIDE,BLOCK

CABLE,WELD,4/0,1FT

SCREW,HHC,M12X25,ZP,CLASS 8.8

WASHER,LOCK,M12

WASHER,M12,HIGH STRENGH

SEAL,O-RING,34.29MM ID X 5.33

SEAL,O-RING,43.82MM ID X 5.33

FITTING,ZERK,GREASE,1/8(R)PT

SPACER,CUSTOM,25.0ID X 8.0LG

RING,RETAINING,INTERNAL,42MM

WASHER,CONICAL SPRING,GTS16

SCREW,HHC,M16X65,ZP,CL 8.8

BUSHING,BEARING,MAIN

BEARING,SPHERICAL,25ID

SCREW,SET,M8X6,POINTED

PIN,LOCATOR,16mm

SCREW,SET,M8X10

BLOCK,GUIDE

PLATE,CAM BLOCK

PIN,DOWEL,WHISTLE STOP

BUSHING,BLOCK,MOTOMOUNT

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

5

1

3

3

1

2

2

2

4

4

1

1

2

2

1

2

Qty

REF

B-16

162068-1CD 95/101

Fig. B-8: MotoMount HD Drive Components

2

3

4

5

6

11

7

8

9

10

96/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

Table B-8: MotoMount HD Drive Components

Item P/N

B-8

4

5

2

3

6

7

146200-2

149227-1

146195-3

149768-1

148124-1

146196-3

146927-1

Title

ADAPTER, ASSY, MOTOMOUNT HD

HUB, MOUNTING

BLOCK, GUIDE

BEARING, CAM FOLLOWER

PIN, LOCATING, DIA. 16 MM HEAD

BLOCK, MOUNTING, FIXTURE 1

BEARING, SPHERICAL, PRECISION, 50 MM ID 1

1

1

1

1

Qty

Ref

8

9

10

146940-1

130330-7

130887-11

RING, RETAINING, INTERNAL, 80 MM

NUT, BEARING

CABLE, WELD, 4/0, 1 FT

1

1

1

B-18

162068-1CD 97/101

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

Fig. B-9: Slip Ring Components

2

3

162068-1CD

4

5

6

7

8

B-19

162068-1CD 98/101

162068-1CD

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

Table B-9: Slip Ring Kit Components

Item P/N Title

7

8

5

6

3

4

B-9

2

148634-1

148636-1

148635-1

148848-1

146913-2

148847-1

148637-1

148849-1

ACCESSORY, SLIP RING, MOTOMOUNT HD

SUPPORT, GUARD, SLIP RING

GUARD, SLIP RING

SLIP RING ASSY, MOTOMOUNT HD

FITTING, NIPPLE, PIPE, BRASS, 3/8-INCH

RING, RETAINING, EXT, 42 MM SHAFT

GUIDE, OUTLET, PIPE

PLATE, CLAMP, DRIVE, DOG

1

1

1

1

1

1

Qty

Ref

1

B-20

162068-1CD 99/101

MH-SERIES

POSITIONER

B Illustrated Parts list

B.1 Introduction

162068-1CD

B-21

162068-1CD 100/101

MH-SERIES

SIGMA-5 POSITIONER MANUAL

Specifications are subject to change without notice for ongoing product modifications and improvements.

MANUAL NO.

162068-1CD

0

101/101

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