YASKAWA MA2010 Operating And Maintenance Instructions Manual

YR-MA02010-A10
Operating and maintenance
instructions
MA2010
Created on:
12/2014
Revision:
4
Document number:
E1101000192GB04
Author:
WOE
Changes made in revision:
Rev. 1: Revised version of the original HW1482758.0 in YEU-R style (08/2014)
Rev. 2: Revised version of the table: Forces and moments of the robot (11/2014)
Rev. 3: Revised version of the original HW1482758.2 (Chapter "Internal user I/O wiring
harness and air lines" as well as chapter "Spare parts") (11/2014)
Rev. 4: Revision of the chapter "Technical data"
© Copyright 2014
This documentation – also in part – may be reproduced or made available to third parties only with the
express approval of YASKAWA Europe "Robotics Division GmbH".
We have checked the content of this publication for compliance with the hardware described.
Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.
However, the information given in this publication is checked regularly and any necessary corrections
will be made in subsequent editions.
Subject to technical modifications.
Table of contents
Table of contents
1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
3.2
Installing protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Connecting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Connecting the robot control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 22
. 23
. 24
. 25
. 26
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1
6.2
6.3
6.4
6.5
7
. 13
. 14
. 15
. 16
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1
5.2
6
Transporting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping brackets and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1
4.2
4.3
5
Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1
4
.. 5
.. 5
.. 6
.. 6
.. 6
.. 7
.. 8
. 10
. 10
Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1
2.2
3
Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts and work axis label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Robot base dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and defined working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping Angle and Time at the Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1 Stop category 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Stop category 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 28
. 28
. 29
. 30
. 30
. 32
. 35
Allowable load for wrist axis and wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1
7.2
7.3
7.4
7.5
Wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum load of the S-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optimal robot performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum capacity load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 37
. 37
. 37
. 38
. 38
3
Table of contents
8
Internal cables and compressed air lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9
Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.1
9.2
9.3
9.4
9.5
Inspection schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note on battery unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1 Changing battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.2 Battery pack connector (including warning note) . . . . . . . . . . . . . . . . . . . . . . .
9.2.3 Note on maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions on grease replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1 Grease replenishment/exchange for S-axis reduction gear unit. . . . . . . . . . . .
9.3.2 Grease replenishment/exchange for L-axis reduction gear unit . . . . . . . . . . . .
9.3.3 Grease replenishment/exchange for U-axis reduction gear unit. . . . . . . . . . . .
9.3.4 Grease replenishment/exchange for R-axis gear . . . . . . . . . . . . . . . . . . . . . . .
9.3.5 Grease replenishment/exchange for B- and T-axes gear . . . . . . . . . . . . . . . . .
9.3.6 Replenishment/Exchange for R-axis cross roller bearings . . . . . . . . . . . . . . . .
Home position calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.1 Register all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.2 Register individual axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.3 Changing absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.4 Clearing absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the second home position (check point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.1 Purpose of position check operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Procedure for the second home position setting . . . . . . . . . . . . . . . . . . . . . . .
9.5.3 Procedure after alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 46
. 53
. 53
. 56
. 58
. 58
. 59
. 60
. 61
. 62
. 63
. 65
. 65
. 67
. 69
. 70
. 70
. 71
. 71
. 73
. 75
10
Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11
Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.1
11.2
11.3
11.4
11.5
11.6
4
S-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U-axis drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 79
. 82
. 84
. 86
. 89
. 92
General
1
General
1.1
Notes for safe operation
DANGER!
Indicating immediate danger at high risk, hazard that can cause death or serious bodily
injuries if no precautions are taken.
WARNING!
Indicating possible medium risk hazard situation which can cause death or serious bodily
injuries if it is not avoided.
CAUTION!
Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries
result if it is not avoided. This signal word can also be used for property damage warnings.
NOTICE
Indicates important background information and application advice.
1.2
Frequently used terms
The YASKAWA robot is a product of YASKAWA Electric Corporation, and is provided by
default with the robot controller, the programming pendant and robot cable.
The terms are designated as follows in this manual:
Definitions
Used
Control
Robot controller
Industrial robot
Robot
Programming pendant / teach box
Programming pendant
Supplying cable between robot and robot
controller
Cable
Robot, robot controller and cable
Robot system
Yaskawa Electric Corporation
YEC
YASKAWA Robotics Division
YEU-R
Move, calibrate and setup of the robot
Teachen
Movement sequences of the robot
JOBs
Technical customer service
TCS
1-5
General
1.3
Target group
This manual is directed at users with the following knowledge:
•
Advanced knowledge of mechanical engineering
•
Advanced knowledge of electrical engineering
•
System knowledge of the robot controller
•
Specially trained staff
NOTICE
According to the international DIN EN ISO 10218-1 standard, operators of a robot system
must receive training before they operate the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For information on the training programme, please visit
www.yaskawa.eu.com or contact our branch offices directly.
1.4
Intended use
Typical applications:
•
Flange-mounting tools
•
Installation of spot welding guns
•
Installation of arc welding equipment
•
Installation of grippers
•
Machining and transporting workpieces or products
1.5
Improper use
Any use that deviates from the intended use shall be regarded as impermissible misuse.
This includes:
•
Transport of people and animals
•
Use as ascending aid.
•
Use outside the permissible operating limits.
•
Use in environments with risk of explosion (except for ATEX-approved robots).
•
Overload
•
Use without protective equipment.
NOTICE
Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.
This will be regarded as improper use (i.e. use that deviates from the intended use) and will
lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.
CAUTION!
The robot system is an incomplete machine.
The robot system may be put into operation only after it has been determined that the
incomplete or complete machine in which the robot system is being installed:
 Corresponds to the provisions of the Machinery Directive.
 Complies with all relevant (harmonized) standards.
 Corresponds to the state of the art.
1-6
General
1.6
About this manual
•
This instruction manual is intended to explain mainly on the mechanical part of the robot
for the application to the actual operation and for proper maintenance and inspection.
It describes on safety and handling, details on specifications, necessary items on
maintenance and inspection, to explain operating instructions and maintenance
procedures. Be sure to read and understand this instruction manual thoroughly before
installing and operating the robot.
•
To ensure correct and safe operation, read the robot control operating instructions
(basic information, installation and wiring and system setup).
•
In order to illustrate details clearly, some drawings are shown with the protective covers
or shields removed. All protective covers and shields must be mounted before the robot
is operated.
•
The drawings and figures in this manual are representative illustrations. They may differ
from the product delivered.
•
YEU-R reserves the right to make technical changes. These changes may include
product improvements, modifications or changes in specifications
•
If your copy of the operating and maintenance instructions is damaged or lost, please
contact the local YASKAWA branch office to order a new copy. The official branch
offices are listed on the last page. Please mention the manual number in your order.
•
YASKAWA Europe GmbH is not responsible for damage caused due to unauthorized
modification of the painting robot track. If any impermissible modifications are made to
the system and to the robot, all warranty and liability claims as well as the declaration
of incorporation will expire.
1-7
General
1.7
Safety
START
REMOTE
PLAY
1
HOLD
TEACH
JOB
EDIT
DISPLAY
JOB CONTENT
-TEST01
CONTROL GROUP:R1
0000 NOP
0001 SET B000 1
0002 SET B001 0
0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
UTILITY
S:0000
TOOL:
MOVJ VJ=0.78
Main Menu
Turn on servo power
Short Cut
TOOL SEL
LAYOUT
GO BACK
DIRECT
OPEN
COORD
PAGE
Multi
ENTRY
MAIN
MENU
X-
S-
S+
HIGH
SPEED
Y-
Y+
Z-
Z+
E-
E+
L-
CANCEL
ASSIST
SERVO ON
X+
AREA
SELECT
SERVO
ON
READY
SIMPLE
MENU
X-
X+
R-
R+
Y-
L+
Y+
B-
B+
FAST
U-
Z-
MANUAL SPEED
U+
Z+
T-
T+
8-
8+
SLOW
INTER
LOCK
7
8
9
ROBOT
INFORM
LIST
4
5
6
BWD
EX.AXIS
WELD
ON/OFF
1
2
3
DELETE
INSERT
AUX
MOTION
TYPE
0
.
-
MODIFY
ENTER
SHIFT
TEST
START
SHIFT
FWD
Fig. 1-1: Programming pendant
1 Emergency stop button
WARNING!
Death or injury because of danger of crushing
If the emergency stop button does not function properly, the robot cannot be stopped in the
event of an emergency.
 The robot should not be used if the emergency stop button does not function.
 Before operating the manipulator check the emergency stop button. The SERVO power
must be deactivated immediately when the emergency stop button is pressed (see Fig.
1-3: "Emergency stop button") on the programming pendant.
 When the SERVO power is turned OFF, the "SERVO ON" LED (see Fig. 1-2: "LED
SERVO ON") on the programming pendant.
SERVO ON
Fig. 1-2: LED SERVO ON
Fig. 1-3: Emergency stop button
1-8
General
WARNING!
Death or injury because of danger of crushing
Before you release the emergency stop button (see Fig. 1-4: "Release of emergency stop
button by turning") note the following:
 Make sure that there is no one within the maximum working range of the robot.
 Clear the cell of all items which could collide with the robot.
 Now you can switch ON the servo voltage by pressing the hold-to-run button on the
programming pendant.
Fig. 1-4: Release of emergency stop button by turning
WARNING!
Death or injury because of danger of crushing
if anyone enters the working area of the robot during operation or any problems occur,
always press the emergency stop button immediately. This is located on the programming
pendant (see Fig. 1-1: "Programming pendant").
Observe the following precautions when performing teaching operations within the
operating range of the robot:
 View the Robot from the front whenever possible.
 Always follow the prescribed operating procedure (see the instructions on robot control
as well as the operating instructions on "Handling" or "Universal Application").
 An area must be left clear so that the operator can retreat to it in case of emergency.
The following inspection procedures must be performed prior to teaching the robot. If
problems are found, correct them immediately, and be sure that all other necessary
processing has been performed.
•
Check for problems in robot movement.
•
Check the connectors for tight fit and all cables for damage.
•
Hang the programming pendant back on the robot controller after use.
•
Make sure that the key for the operating mode selector switch (Teach/Automatic) of the
programming pendant is kept by a skilled person who has been specially trained.
•
The key may be inserted in the key switch of the programming pendant only during
teach operation; after the teach operation it must be immediately removed and kept in
a safe place.
1-9
General
1.8
Manufacturer
Address:
YASKAWA ELECTRIC CORPORATION
2-1 KUROSAKISHIROISHI
YAHATANISHI-KU
KITAKYUSHU
JAPAN
1.9
Authorized representative
Address:
YASKAWA Europe GmbH
Robotics Division
Yaskawastr. 1
85391 Allershausen
Germany
1 - 10
Supply
Supply
2.1
Checking the scope of delivery
The standard delivery includes the following items:
1
2
3
DX200
2
MOTOMAN
MANU
AL
4
5
Fig. 2-1: Scope of supply
1
Programming pendant
4
The present assembly instructions
2
Robot controller
5
Cable
3
Robot
2 - 11
Supply
2.2
Position type plate
Verify whether the serial number of the robot, the robot controller and the programming
pendant with the delivery. The serial number can be found on the type plate as shown
below.
S/N.
YASAKAW DX200
Part No.
Power Supply Peak
AC 400/415/440 Average
Serial No.
kVA
kVA
Date/Signature
Type
ERDR-
Robot Type
Robot Order No.
Robot Serial No.
YASKAWA ELECTRIC CORPORATION
2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN
DX200
YASKAWA Europe „Robotics Division“ GmbH
Yaskawastr. 1, D-85391 Allershausen
Fig. 2-2: Position type plate
NOTICE
Please contact the local YASKAWA branch office if the serial numbers do not match the
information on the delivery note.
2 - 12
Transportation
3
Transportation
CAUTION!
Personal injury or damage to property
The system consists of precision components. If this precaution is not taken, performance
may be impaired.
 A crane or forklift may only be operated by authorised personnel. The same applies to
the use of slings.
 Avoid strong vibrations or impacts during transportation.
 No external forces may be exerted on the robot controller.
3.1
Transporting method
CAUTION!
Damage to persons and damage to property due to external force influences
 External forces must not be exerted on the robot or the motors.
•
Check that the eyebolts are securely fastened.
•
The robot weights approximately 280 kg. Use load carrying devices strong enough to
withstand the weight.
•
The transport safety devices support the robot; therefore, use them exclusively for the
transport of the robot.
•
Before transport, be sure to mount the shipping bolts and brackets to the robot.
3 - 13
Transportation
3.1.1
Using a crane
Adequate load handling devices must be used to transport the robot. Make sure that the
robot is lifted as shown in the diagram "Transport by crane".
1
A
2
1
A
3
B
Fig. 3-1: Transport with crane
3 - 14
1
Shipping bracket and bolts
2
View A
3
2 screws M12 x 30
Transportation
3.1.2
Using a forklift
If the robot is transported using a forklift, it should be fixed on a pallet with transport securing
devices and shipping bolts as shown in the figure below "Transport using a forklift". Make
sure that the forklift and the transportation route have sufficient bearing capacity.
Always take due care when transporting the robot.
1
%&
%&
%&
2
3
Fig. 3-2: Using a forklift
1
4 screws M16
2
Palette
3
Forklift claw entries
3 - 15
Transportation
3.2
Shipping brackets and bolts
The robot is equipped with transport securing devices and shipping bolts to reduce external
forces to a minimum during transport.
•
The shipping brackets and bolts are painted yellow.
•
The shipping bracket will be fastened by 2 screws M12.
1
2
4
3
Fig. 3-3: Shipping brackets and bolts
1
Shipping brackets
3
2 screws M12 x 30
2
Side view
4
Front view
NOTICE
Before turning ON the power, check to be sure that the shipping bolts and brackets are
removed.
After removing the transport securing devices and the shipping bolts, keep them at a safe
place. The transport securing devices and shipping bolts will be required again if the system
is transported again.
NOTICE
Before turning ON the power, check to be sure that the rubber buffer are removed.
After removing the rubber pads, keep them at a safe place. The rubber pads will be required
again if the system is transported again.
For transportation purposes the robot is fitted in the range A and B with a rubber buffer
(see Fig. 3-4: "Damping material for transport").
B
A
Fig. 3-4: Damping material for transport
3 - 16
Installation
4
Installation
CAUTION!
Personal injury and damage to property
The following precautions must be taken.
 Check that the robot controller is complete and not damaged.
 Do not put into operation a robot controller that is damaged or incomplete.
 Check that all transport safety devices and transport screws have been removed.
4.1
Installing protective equipment
To ensure safe operation, the following procedures are to be taken into account.
DANGER!
Personal injury and material damage
The robot system must not be operated without protective devices. Starting up without
appropriate protective measures can lead to death of people, serious bodily harm or
damage to property.
Install following safeguardings:
 Separating protection devices
 Non-contact protection devices
 Enclosures
 Marked areas
 Signs
 Emergency stop button
 Display elements
NOTICE
Operator's responsibility
The operator of a robot or a robot system must ensure that all specifications and
requirements of the standards DIN EN ISO 10218-1 and DIN EN ISO 10218-2 are met.
In the first instance, the following must be observed:
 Preparing a risk assessment
 The installation of protective devices
 Regular training of the employees
 Regular inspection of all protective devices
 Checking for compliance with intended use
4 - 17
Installation
4.2
Location
When installing a robot, it is necessary to satisfy the undermentioned environmental
conditions:
•
Ambient temperature: from 0° C to + 45° C.
•
Air humidity: 20% to 80% relative humidity (non-condensing).
•
No corrosive gases, liquids or explosive gases. No water, oil, dust and free from
excessive electrical noise (plasma).
•
Free from excessive vibration (Vibration acceleration: 4.9 m/s² [0.5 G] or less).
•
Maximum unevenness of the support surface of the robot base: 0.5 mm.
4.3
Installation example
1. At the first setout, anchor the baseplate firmly onto the floor.
2. The robot base is tapped for 4 mounting holes. Fix the robot base with the screws M16
(Strength category 12.9) Minimum length: 50 mm.
3. Next, fix the Robot base to the base plate. Tighten the hexagon head bolts and anchor
bolts securely so that they will not work loose during operation (see figure „Mounting the
robot on the Baseplate“).
4 - 18
Installation
1
2
3
25
4
5
6
7
375
4
335
316
335
60
170±0.1
292
200±0.1
8
375
60
9
10
200±0.1
260±0.1
Fig. 4-1: Mounting the robot on the base plate
1
Screws
6
at least 25 mm
2
Spring washer
Anchor bolt (M16 or greater)
3
4
Washer
7
8
2 holes Ø 12 H7
Robot base
9
4 holes Ø 18
5
Base plate
10
adhesive
4 - 19
Installation
(4
x)
520
260
580
335
36
335
520
25
8x)
80
24 (
260
580
Fig. 4-2: Base plate
Horizontal direction
Vertical direction
Force FH
Moment MH
Force FV
Moment MV
Emergency stop
8820 N
6370 Nm
10290 N
13720 Nm
Acceleration
2940 N
1915 Nm
3430 N
5145 Nm
Deceleration
Tab. 4-1: Forces and moments of the robot
MV
FV
MH
FH
Fig. 4-3: Robot Force and Torque
4 - 20
Installation
Types of Mounting
The robot can be mounted in the following positions:
1
2
3
4
Fig. 4-4: Types of Mounting
1
0° = standing (standard)
3
180° = hanging from the ceiling
2
90°= hanging on the wall
4
10° - 90° = mounted on an angle
Suspended mounting
Suspended mounting differs from assembly in a standing position in the following points.
•
S-axis working range
•
Fixing the robot base
NOTICE
For suspended mounting in any position, please contact the local YASKAWA branch office.
S-axis working range
For the wall-mounted type, the S-axis movable range is ±30° (the range is adjusted prior to
the shipment).
B-Axis operating range
For ceiling-mounted type, the B-axis operating range is -90° to +135° (The range is
adjusted prior to the shipment).
Fastening the robot base
With suspended mounting, the robot must be fastened with 4 screws M16 (Strength
category 12.9). Use a torque of 400 Nm in tightening the screws.
Precaution against falling
In case of suspended mounting, take measures to prevent the robot from falling down.
NOTICE
If the setup is changed, please contact the local YASKAWA branch office.
4 - 21
Wiring
5
Wiring
DANGER!
Danger to life due to electric shock, risk of fire due to short circuit.
Wiring must be performed by authorized or certified personnel.
Follow the instructions given below before wiring.
 Make sure that the earthing resistance does not exceed 0.1 Ω.
 Turn OFF the main power supply.
 Put up the warning sign prescribed, e.g. "Do not turn the power on!".
 Install a switch-on guard as prescribed.
5.1
Grounding
Follow electrical installation standards and wiring regulations for grounding. The cable
cross-section must be 6 mm² or more.
With regard to the direct connection of the earthing cable, see Fig. 5-1: "Grounding
method".
NOTICE
Note on earthing connection!
Never use the earthing cable together with another earthing cable, e.g.
 Of a different electrical consumer
 Of a different motor-driven consumer
 Welding devices etc.
Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
grounding should be performed in accordance with applicable electrical installation
standards.
1
Fig. 5-1: Grounding method
1
5 - 22
M8 screw for earthing is supplied with the robot (at least 6 mm² protective earth conductor).
Wiring
5.2
Cable connections
YASAKAW DX200
Part No.
Power Supply Peak
AC 400/415/440 Average
Serial No.
kVA
kVA
Date/Signature
Type
ERDR-
Robot Type
Robot Order No.
Robot Serial No.
YASKAWA ELECTRIC CORPORATION
2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN
DX200
YASKAWA Europe „Robotics Division“ GmbH
Yaskawastr. 1, D-85391 Allershausen
Fig. 5-2: Connecting the robot system
Two cables are delivered with the robot (refer to Fig. 5-3: "Robot cable").
•
Encoder cable (1BC)
•
Power cable (2BC)
Before connecting the robot cable, check the marking on the robot cable and the
connections on the connector plate of the robot (see the following diagram "Robot cable").
Connect the cables to the connections on the robot base and on the robot controller (see
the following chapter on "robot connection" and "robot controller connection").
1
1BC
X11
2
1BC
X11
1BC
1BC
3
1
2BC
X21
2
2BC
2BC
X21
2BC
4
Fig. 5-3: Robot cable
1
Robot control side
3
Encoder cable (1BC)
2
Robot side
4
Power cable (2BC)
5 - 23
Wiring
5.2.1
Connecting the robot
1. Check the encoder cable (1BC) and the power cable (2BC).
2. Connect the encoder cable (1BC) to the connector plate of the robot.
3. Connect the power cable(2BC) to the connector plate of the robot.
Make sure that you hear each locking clip snap into place (clicking sound).
1BC 2BC 3BC
Fig. 5-4: Connector plate of the robot
5 - 24
Wiring
5.2.2
Connecting the robot control
Attach the robot cables in the following order.
1. Connect the encoder cable (1BC) X11 connection X-1 to the robot controller.
2. Connect the power cable (2BC) X21 connection X-2 to the robot controller.
Make sure that you hear the locking clips snap into place (clicking sound).
X 11
X -1
X 21
X -2
Fig. 5-5: Connection robot control
5 - 25
Wiring
5.2.3
Connecting the programming pendant
Connect the programming pendant cable to the connection (X81) on the door of the robot
controller (see diagram "Connecting the programming pendant").
X81
WARNING
Motoman DX100
Part No.
Power Supply
Peak
kVA
AC 400/415/440 V
Average
kVA
High Voltage
Do not open the door
with power ON.
Serial No.
Date/Signature
Type
ERDR-
Robot Type
Robot Order No.
Robot Serial No.
YASKAWA Electric corporation
2-1 Kurosaki Shiroishi Yahatanishi-Ku Kitakyushu-City Fukuoka 806-0004 Japan
Kammerfeldstr. 1, D-85391 Allershausen
NJ3053-1
CHECK ALL THE DOOR LOCKS
PROPERLY.
NJ3005-1
PROGRAMMING PENDANT
X81
1
Fig. 5-6: Connection programming pendant
1
5 - 26
Alignment marks
Technical data
6
Technical data
Type:
A10
Types of Mounting:
Celling mounted
Degree of freedom:
6
Carrying capacity:
10 kg
Repeatability:1
± 0.08 mm
Power consumption:
2.0 kVA
Weight:
280 kg
Working area main axis:
S-axis (turning)
-180° ~ +180°
2
L-axis (lower arm)
-105° ~ +155°
U-axis (upper arm)²
-170° ~ +220°
Working area wrist axis:
R-axis (wrist roll)²
-150° ~ +150°
B-axis (wrist yaw/pitch)
-90° ~ +135°
T-axis (wrist twist)
-210° ~ +210°
Protection class (IP):
Main axes
54
Wrist axis
67
Maximum speed:
S-axis
3.44 rad/s, 197°/s
L-axis
3.32 rad/s, 190°/s
U-axis
3.67 rad/s, 210°/s
R-axis
7.16 rad/s, 410°/s
B-axis
7.16 rad/s, 410°/s
T-axis
Admissible moment (Nm):
10.06 rad/s, 610°/s
3
R-axis
22 Nm
B-axis
22 Nm
T-axis
9.8 Nm
Permissible moment of inertia (kgm²):
R-axis
0.65 kgm²
B-axis
0.65 kgm²
T-axis
0.17 kgm²
4
Sound pressure level (dB):
77 dB
1. Tested according to ISO 9283
2. The range of motion of L, U and R axes is limited depending on their position.
3. See the following diagram "Moment of arm rating in section 7" for further information on the permissible
moment of inertia.
4. It is measured at maximum load and speed of the robot. The measurement is performed at height of 1.2 m
and 1.5 m above the floor and at distance of 400 mm to the working area.
6 - 27
Technical data
6.1
Parts and work axis label
U+
R+
1
B+
T+
2
U-
L-
B-
R-
T-
L+
3
4
S+
S-
5
Fig. 6-1: Part names and working axes
1
Upper arm (U-arm)
4
Rotating head of S-axis
2
Wrist Flange
5
Robot base
3
Lower arm (L-arm)
6.2
Robot base dimension
375
335
316
60
375
60
292
335
1
2
Fig. 6-2: Robot base dimensions
1
4 mounting holes Ø 18
All dimensions in mm
6 - 28
2
Hole Ø 12 H7
Technical data
1710
1284
1287
792
0
561
559
Dimensions and defined working area
2010
6.3
1284
568
495
229 266
A
0
3649
505
199
850
760
157
139
1
100
1082
150
200
3
95
2365
R20
10
R5
61
2
Fig. 6-3: Part names and working axes
1
P point
3
The working area in which the robot can work with
its wrist units (B-axis) pointing downwards.
2
Working area, defined
with point P
All dimensions in mm
6 - 29
Technical data
6.4
Adjustable working area
Depending on the type of use, the S-axis working area can be changed.
If any modification is necessary, please contact the local YASKAWA branch office.
Item
Specifications
S-axis working range
± 180° (standard)
± 150°
± 120°
± 105°
± 90°
± 60°
± 30°
6.5
Stopping Angle and Time at the Emergency Stop
NOTICE
 The overrun distance is the angle that the robot travels from the point of time when the
stop signal is triggered until the robot comes to a complete stop.
 The overrun time is the time that elapses from the point of time when the stop signal is
triggered until the robot comes to a complete stop.
 The axis movement with the longest stopping point is the decisive axis movement for
calculating the safety distance .
 The values are shown for S, L and U axes.
 The values shown for stop category 0 are reference values determined through testing
and simulation. They are average values and fulfil the requirements according to DIN
EN ISO 10218-1. The actual overrun distances and overrun times may differ due to
internal and external influence on the braking torque. Therefore, if necessary, it is
recommended to determine the overrun distances and overrun times under real, local
conditions when the robot is used.
 The brake wear may vary depending on the operating mode, robot use and number of
times stop category 0 is triggered. Check the overrun distance at least once a year.
6 - 30
Technical data
100%
66%
33%
Fig. 6-4: Stop position of the robot axes
Definitions
Description
Category 0 Load 100%
pink
Category 0 Load 66%
green
Category 0 Load 33%
gray
Category 1
blue
Overrun distance degrees°
[deg]
Overrun time second
[sec]
Robot speed degrees°/second
[deg/s]
6 - 31
Technical data
6.5.1
Stop category 0
6.5.1.1
Stop position S-axis
100%
㻜㻚㻡
㻟㻡
㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
[sec]
[deg]
㻞㻜
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻜
㻞㻡㻜
㻜
㻡㻜
㻝㻜㻜
[deg/s]
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻞㻜㻜
㻞㻡㻜
㻞㻜㻜
㻞㻡㻜
[deg/s]
Fig. 6-5: Stop position 100%
66%
㻟㻡
㻜㻚㻡
㻟㻜
㻜㻚㻠
㻜㻚㻟
㻞㻜
[sec]
[deg]
㻞㻡
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
㻡㻜
㻝㻜㻜
[deg/s]
㻝㻡㻜
[deg/s]
Fig. 6-6: Stop position 66%
33%
㻟㻡
㻜㻚㻡
㻟㻜
㻜㻚㻠
㻜㻚㻟
㻞㻜
[sec]
[deg]
㻞㻡
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
[deg/s]
㻝㻜㻜
㻝㻡㻜
[deg/s]
Fig. 6-7: Stop position 33%
6 - 32
㻡㻜
Technical data
6.5.1.2
Stop position L-axis
100%
㻜㻚㻡
㻟㻡
㻟㻜
㻜㻚㻠
㻜㻚㻟
㻞㻜
[sec]
[deg]
㻞㻡
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
㻡㻜
㻝㻜㻜
[deg/s]
㻝㻡㻜
㻞㻜㻜
[deg/s]
Fig. 6-8: Stop position 100%
66%
㻟㻡
㻜㻚㻡
㻟㻜
㻜㻚㻠
㻜㻚㻟
㻞㻜
[sec]
[deg]
㻞㻡
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻜
㻞㻡㻜
㻡㻜
㻝㻜㻜
[deg/s]
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻞㻜㻜
㻞㻡㻜
[deg/s]
Fig. 6-9: Stop position 66%
33%
㻜㻚㻡
㻟㻡
㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
[sec]
[deg]
㻞㻜
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
[deg/s]
㻡㻜
㻝㻜㻜
㻝㻡㻜
[deg/s]
Fig. 6-10: Stop position 33%
6 - 33
Technical data
6.5.1.3
Stop position U-axis
100%
㻟㻡
㻜㻚㻡
㻟㻜
㻜㻚㻠
㻜㻚㻟
㻞㻜
[sec]
[deg]
㻞㻡
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
㻡㻜
㻝㻜㻜
[deg/s]
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
[deg/s]
Fig. 6-11: Stop position 100%
66%
㻜㻚㻡
㻟㻡
㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
[sec]
[deg]
㻞㻜
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
㻡㻜
㻝㻜㻜
[deg/s]
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻞㻜㻜
㻞㻡㻜
[deg/s]
Fig. 6-12: Stop position 66%
33%
㻜㻚㻡
㻟㻡
㻟㻜
㻜㻚㻠
㻞㻡
㻜㻚㻟
[sec]
[deg]
㻞㻜
㻝㻡
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻡
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
[deg/s]
㻝㻜㻜
㻝㻡㻜
[deg/s]
Fig. 6-13: Stop position 33%
6 - 34
㻡㻜
Technical data
6.5.2
Stop category 1
The stopping angle and time at the emergency stop in category 1 are not subjected to the
robot position and the load.
Stop of category1 doesn't depend on the robot position and the load.
6.5.2.4
Stop position S-axis
㻣㻜
㻜㻚㻤
㻢㻜
㻜㻚㻣
㻜㻚㻢
㻡㻜
㻜㻚㻡
[sec]
[deg]
㻠㻜
㻟㻜
㻞㻜
㻜㻚㻠
㻜㻚㻟
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻜
㻞㻡㻜
㻡㻜
㻝㻜㻜
[deg/s]
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻞㻜㻜
㻞㻡㻜
[deg/s]
Fig. 6-14: Stop position
6.5.2.5
Stop position L-axis
㻣㻜
㻜㻚㻤
㻢㻜
㻜㻚㻣
㻜㻚㻢
㻡㻜
㻜㻚㻡
[sec]
[deg]
㻠㻜
㻟㻜
㻞㻜
㻜㻚㻠
㻜㻚㻟
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
[deg/s]
㻡㻜
㻝㻜㻜
㻝㻡㻜
[deg/s]
Fig. 6-15: Stop position
6 - 35
Technical data
6.5.2.6
Stop position U-axis
㻣㻜
㻜㻚㻤
㻢㻜
㻜㻚㻣
㻜㻚㻢
㻡㻜
[sec]
[deg]
㻜㻚㻡
㻠㻜
㻟㻜
㻞㻜
㻜㻚㻠
㻜㻚㻟
㻜㻚㻞
㻝㻜
㻜㻚㻝
㻜
㻜
㻜
㻡㻜
㻝㻜㻜
㻝㻡㻜
㻞㻜㻜
㻞㻡㻜
㻜
[deg/s]
㻝㻜㻜
㻝㻡㻜
[deg/s]
Fig. 6-16: Stop position
6 - 36
㻡㻜
㻞㻜㻜
㻞㻡㻜
Allowable load for wrist axis and wrist flange
7
Allowable load for wrist axis and wrist flange
7.1
Wrist flange
The dimensions of the wrist flange are shown in the following figure "Wrist flange". To
ensure that the zero position marks can be seen at all times, the tool may only be flangemounted with the inner diameter. The internal depth of the threaded joint may not exceed
5 mm .
NOTICE
Before mounting a tool, remove anticorrosive coating on the flange. Thinner or light fuel oil
are the most suitable for this purpose.
2
1
3
6
5
4
8
7
4
5
4
Fig. 7-1: Wrist flange
8 tapped holes M4 x 8
5
Ø 62 h7
2
Hole Ø 4 H7x 6
6
Ø 50
3
4
P.C.D 56
7
Mount tools in this range.
Ø 100
8
Depth: 5
1
All dimensions in mm
7.2
Maximum load of the S-axis
For peripheral devices of specific applications, additional mounting options are provided on
the robot.
7.3
Optimal robot performance
To achieve optimal robot performance, the maximum load of the S-axis must never exceed
the permissible bearing capacity of the robot.
7 - 37
Allowable load for wrist axis and wrist flange
7.4
Allowable Wrist Load
The maximum allowable wrist load is 10 kg. Should however force instead of load be
exercised on the wrist axis, the power has to be at the axes within the moments (see the
following figure and table).
For further information or assistance, please contact your YASKAWA branch.
Allowed moment and maximum moment of inertia
Axis
Allowed moment (Nm)
Permissible moment of inertia (kgm²)
R-axis
22 Nm
0.65 kgm²
B-axis
22 Nm
0.65 kgm²
T-axis
9.8 Nm
0.17 kgm²
Keep the distance of the load/mass from the centre of gravity within the values specified,
see the following figure "Moment of arm rating".
LB
300
1
238
100
2
LT[mm]
LT
200
166
100
W=3kg
W=6kg
W=10kg
3
220
100
200
329
300
465
400
500
LB[mm]
Fig. 7-2: Moment of arm rating
1
P point
3
2
R-, T-axes rotation center line
All dimensions in mm
7.5
B-axis rotation center line
Maximum capacity load
The maximum permissible load for U-axis, including wrist, is 19 kg.
For example, if the load mounted on the joint is 10 kg, the load on the upper arm must not
exceed 9 kg.
The maximum load for S-axis is 20 kg. Install the peripheral devices on the S-axis in such
a way that the moment of inertia (GD2/4) of the rotation centre of the S-axis does not exceed
1.25 kgm² kg.
7 - 38
Allowable load for wrist axis and wrist flange
28.5
2
70
15 48 15
6
130
1
165
View B
50
3
300
60
A
B
4
165
917
5
70
100
13
30 229
26
130
168 70
2
8 45
92
6
15
45
7
Fig. 7-3: Installing peripheral equipment mounts
1
4 threaded holes M8 x 16
5
4 threaded holes M6 x 12
2
2 threaded holes M6 x 12
6
4 threaded holes M6 x 14
3
4
Mount the peripherals in this range.
7
2 threaded holes M10 x 12
Mount the accessories, so that the
centre of gravity of the accessories is
in the U arm within this range.
8
2 threaded holes M10 x 18
All dimensions in mm
7 - 39
Internal cables and compressed air lines
8
Internal cables and compressed air lines
Internal cables (3BC: 14 wires 8 x 0.20 mm², 2 x 0.75mm² and 4 x 1.25 mm²) and air hoses
are used in order to use peripheral devices (e.g. gripper). They are mounted on the upper
arm as shown in the following diagram "Connector for internal cables and compressed air
lines".
The pins 1 to 16 are assigned as shown in the following figure. Wiring must be performed
by the user.
The following requirements must be met:
8 - 40
•
The total current value for the internal wiring harness must be 40 A .
•
The current-carrying capacity per single conductor (cross-section 0.20 mm², 0.75 mm²
and 1.25 mm²) must not exceed 3 A or less .
•
The air pressure for the air hose must not exceed 600 kPA (the inner diameter of the air
hose is Ø 6.5 und Ø 8 mm).
Internal cables and compressed air lines
•
For the power cable when arc welding the nominal current may not exceed 500A. In
permanent operation the current may not exceed 80% of the nominal current
(permissible current at permanent operation = 80% x (500A/operating current)²).
2
1
3
4
A
5
6
2BC
1BC
3BC
7
9
8
Fig. 8-1: Connectors for internal user I/O wiring harness and air line
1
Air outlet with cap A
6
Air inlet with cap A
2
Air outlet with cap B
7
Power cable for arc welding (recommended connection: R100-10, cover
(TS200CHM) is included in the delivery).
3
Connector plug for the internal cable
feedthrough: JL05-2A20-29SC (socket connector with a cap) JL05-6A2029P.
8
View A
4
Power cable for arc welding
(TS200CHM)
9
Connector plug for the internal cable
feedthrough: JL05-2A20-29PC (socket connector with a cap) JL05-6A2029S.
5
Air inlet with cap B
List of connector types
Description
Type of connector
Connector for the internal user I/O wiring
harness on the base
JL05-2A20-29PC (optional: JL05-6A2029S)
Connector for the internal user I/O wiring
harness on the U-arm
JL05-2A20-29SC (optional: JL056A2029P)
Welding power cable
8 - 41
Internal cables and compressed air lines
The welding power cable is only integrated as standard in the robot MA2010-A00. Fig. 8-2:
"Robot type Welding power cable").
1
1
39
A
A
2
3
4
Fig. 8-2: Robot type Welding power cable
1
Internal wiring harness
2
Welding power cable
Section A-A MA2010-A00
3
4
Section -A MA2010 A10
1
2
1
2
3
4
5
6
7
8
9
10
11 (0.75mm22)
12 (0.75mm )
13 (1.25mm2)
14 (1.25mm2)
15 (1.25mm2)
16 (1.25mm2)
1
2
3
4
5
6
7
8
9
10
11 (0.75mm2)
12 (0.75mm2)
13 (1.25mm2)
14 (1.25mm2)
15 (1.25mm2)
16 (1.25mm2)
7
5
1
2
5
4
13
6
7
8
11
12
9
15
5
3
10
14
16
6
3
4
1
2
9
13
3
5
4
6
7
8
11
12
15
16
10
14
6
Fig. 8-3: Details of the plug

= assigned

= unassigned
1
Connector plug for the internal cable
feedthrough on the connector base
5
Pins used
2
Connector plug for the internal cable
feedthrough on U-arm
6
Internal user I/O wiring harness: 8
wires 0.2 mm², 2 wires 0.75 mm², 4
wires 1.25 mm²
3
+24 V (1A) for shock sensor
7
7 and 8 are open
4
Shock sensor signal input
The pins used on the connectors (3BC: 14 wires 8 x 0.20 mm², 2 x 0.75mm² and 4 x 1.25
mm²) are connected to the stand and arm with individual wires.
In the standard specification, pins 7 and 8 are connected as follows:
•
•
To the 3BC connection for the collision sensor on the U arm.
To the 3BC connection for the collision sensor on the robot controller.
Pins 7 and 8 of the respective 3BC connections on the connector plate and U arm are
connected to each other.
8 - 42
1BC(10X4)
Controller
SPG+1
SPG-1
E
P
P
CN3-9
CN3-10
CN4-4
CN4-5
CN4-9
E
CN3-9 0V
CN3-10 +5V
+24V
CN4-4
LD1
CN4-5
CN4-9 FG8
CN4-10 0V
CN3-4
CN3-5 0V
+5V
P
CN3-4
CN3-5
CN4-3 BC2
CN4-8 AL2
P
CN4-10
CN4-3
CN4-8
CN2-9 FG7
CN3-6
SPG+6
CN3-7
SPG-6
CN3-8 FG6
P
P
CN3-8
CN3-6
CN3-7
CN2-9
CN2-4
CN2-5
CN3-3 FG5
CN2-4
CN2-5 SPG+7
SPG-7
SPG+5
SPG-5
CN3-1
CN3-2
CN3-1
CN3-2
P
A1
LA1
LB1
LB2
LB2
LB1
P
B1
LC1 LD1
LD2
LD2
LD1
P
P
P
P
P
P
CN2-10 +24V
CN3-3
PG0V1
PG5V1
PG0V2
PG5V2
PG0V3
PG5V3
PG0V4
PG5V4
PG0V5
PG5V5
PG0V6
PG5V6
0BAT4
BAT4
0BAT1
BAT1
0BAT2
BAT2
0BAT3
BAT3
SPG+4
SPG-4
CN2-10
CN2-6
CN2-7
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
P
CN2-8 FG4
P
CN2-6
CN2-7
2
4
1
3
0BAT21
BAT21
0BAT22
BAT22
0BAT11
BAT11
0BAT12
BAT12
Internal cable
FG3
CN2-8
CN2-3
SPG+3
SPG-3
P
CN2-3
CN2-1
CN2-2
P
CN2-1
CN2-2
P
CN1-8
CN4-1 +24V
CN4-6 LB1
CN4-2 SS2
CN4-7 AL1
CN1-8
CN4-1
CN4-6
CN4-2
CN4-7
FG2
SPG+2
SPG-2
CN1-6
CN1-7
P
CN1-1
CN1-2
+24V
0V
CN1-6
CN1-7
P
CN1-1
CN1-2
CN1-10
CN1-9
+24V
0V
CN1-3 FG1
P
CN1-10
CN1-9
CN1-5
CN1-4
1BC(10X4)
5
6
7
8
0BT
K R P BAT
0BT
K R P BAT
1
2
3
4
5
6
7
8
1
2
3
4
0BT
K R P BAT
0BT
K R P BAT
CN1-3
P
CN1-5
CN1-4
Mains cable
P
P
P
LD1
LB1
LA1
LB1
LB1
LC1
LD1
LD1
LA2
LB2
LC2
LD2
B2
OVERRUN LIMIT SWITCH L AXIS
connected to
B3
L AND U AXIS COLLISION LIMIT SWITCH L.S.
connected to
LA3
LB3
P
P
P
P
P
P
P
P
P
P
P
B2
A2
No. 16CN
16CN-1
-2
-6
-5
-4
-9
-10
DATA+6
DATA-6
+5V
0V
FG6
-4
-10
-5
-11
-6
LC3
LD3
LA3
LB3
P
P
P
P
P
DATA+3
DATA-3
BAT
OBT
+5V
0V
FG3
No. 23CN
23CN-1 DATA+2
-2
DATA-2
-6
BAT
-5
OBT
-4
+5V
-9
0V
FG2
-7
No. 22CN
22CN-1 DATA+1
-2
DATA-1
-6
BAT
OBT
-5
-4
+5V
-9
0V
-7
FG1
No. 13CN
-1
DATA+5
-7
DATA-5
-2
BAT
-8
OBT
-3
+5V
-9
0V
LC2
LD2
LA2
LB2
P
P
P
P
P
P
LA1
LB1
LB1
LB2
LB2
LB1
LA2
LB2
LC2
LD2
B3
A3
No. 9CN
9CN-1
-2
-3
-4
10CN-1
-2
-3
No. 10CN
U-AXIS
S-AXIS
PG
L-AXIS
PG
No. 3CN
3CN-1
-2
-3
-4
4CN-1
-2
-3
No. 4CN
No. 1CN
1CN-1
-2
-3
-4
2CN-1
-2
-3
No. 2CN
DATA+6
DATA-6
BAT
OBT
+5V
0V
FG6
OBT
BAT
DATA+5
DATA-5
BAT
OBT
+5V
0V
FG5
OBT
BAT
PG R-AXIS
FOR LAMP (OPTIONAL)
DATA+4
DATA-4
BAT
OBT
+5V
0V
FG4
OBT
BAT
PG
No. 19CN
19CN-1 DATA+2
DATA-2
-2
BAT
-6
OBT
-5
+5V
-4
0V
-9
FG2
-10
No. 18CN
18CN-1 DATA+1
DATA-1
-2
BAT
-6
OBT
-5
+5V
-4
0V
-9
FG1
-10
LA3
LB3
PG T-AXIS
PG B-AXIS
OVERRUN LIMIT SWITCH S AXIS
A1
connected to
LC3
LD3
B1
OVERRUN LIMIT SWITCH S AXIS
connected to
A3
L AND U AXIS COLLISION LIMIT SWITCH L.S.
connected to
S-Axis limit switch specification
LA1
LB1
LC1
LD1
LC1
LD1
LD1
LD2
LD2
LD1
A2
OVERRUN LIMIT SWITCH L AXIS
connected to
A1
OVERRUN LIMIT SWITCH S AXIS
connected to
LC3
LD3
B1
OVERRUN LIMIT SWITCH S AXIS
connected to
S, L, and U axes with overrun limit switch details
LA1
LB1 LB1
LC1
LD1 LD1
1. The connecting terminal A B for the indication of the end switch has been changed as follows:
2. The connection C applies only if the cable is for the main power supply of the automatic welding machine.
Notice
Internal cables and compressed air lines
For the wiring, see the following figure, "Connecting diagram for internal connections."
The internal connections of the robot are shown in the following diagrams "Connection
diagram A" and "Connection diagram B".
Fig. 8-4: Internal connection diagram (a)
8 - 43
8 - 44
2BC(6X6)
Fig. 8-5: Internal connection diagram (b)
MU5
MV5
MW5
MU6
MV6
MW6
ME3
ME4
ME5
ME6
BA1
BB1
BA2
BA3
BA4
BB4
BA5
BA6
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6
CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6
CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6
Note 2)
MU3
MV3
MW3
MU4
MV4
MW4
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
PE
MU2
MV2
MW2
MU2
MV2
MW2
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
E
ME1
ME2
ME2
MU1
MV1
MW1
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
2BC(6X6)
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
E
3BC(20-29)
E
1
3BC-1
-2 2
-3 3
-4 4
-5 5
-6
6
-7
7
-8 8
-9 9
-10 10
-11 11
-12 12
-13 13
-14 14
-15 15
-16 16
E
E
E
E
Stand
E
7
8
1
2
3
4
5
6
SS1
SS2
C
P
1
2 P
3
4 P
5
6 P
SS1
SS2P
No. 24CN
No. 21CN
4CN1-A MU2
MV2
-B
MW2
-C
ME2
-D
BA2
-1
BB2
-2
No. 20CN
MU1
3CN-3
MV1
-2
MW1
-1
-PE ME1
BA1
-4
BB1
-5
E
Housing
SS1
SS2
1
2
3
4
MU6
MV6
MW6
ME6
15CN-1BA5
-2
BB5
-3
BA6
-4
BB6
No. 15CN
-5
-6
-7
-8
No. 14CN
14CN-1MU5
MV5
-2
MW5
-3
ME5
-4
YB
SM
YB
SM
No. 17CN
17CN-3 MU3
MV3
-2
MW3
-1
-PE ME3
BA3
-4
BB3
-5
SS1
SS2
1
2
3
4
YB
SM
L-AXIS
S-AXIS
P
P
P
No. 8CN
No. 6CN
No. 12CN
MU5
MV5
MW5
ME5
BA5
BB5
No. 7CN
MU6
7CN-1
MV6
-2
MW6
-3
ME6
-4
BA6
-1
BB6
-2
5CN-1
-2
-3
-4
-1
-2
YB
SM
YB
SM
YB
SM
R-AXIS
T-AXIS
B-AXIS
For reserve cable
No. 5CN
No. 11CN
11CN-1 MU4
MV4
-2
MW4
-3
ME4
-4
BA4
-1
BB4
-2
U-AXIS
3BC(20-29)
E
1
3BC-1
2
-2
3
-3
4
-4
-5
5
-6
6
-7
7
-8
8
-9
9
10
-10
-11
11
12
-12
13
-13
14
-14
15
-15
16
-16
Internal cables and compressed air lines
Maintenance and inspection
9
Maintenance and inspection
DANGER!
Danger to life due to electric shock
Maintenance and inspections must be performed by specified personnel.
The instructions given below must be followed before taking maintenance and inspection
measures:
 Turn OFF the main power supply.
 Put up the warning sign prescribed, e.g. "Do not turn the power on!".
 Install a switch-on guard as prescribed.
If you have any questions regarding disassembly or repair, please contact the local
YASKAWA branch office.
NOTICE
Home position data is lost
Before removing the connector of the encoder cable to perform maintenance or inspection,
 Connect the spare battery pack.
9 - 45
Maintenance and inspection
9.1
Inspection schedule
Proper inspections are essential not only to assure that the mechanism will be able to
function for a long period. But also to prevent malfunctions and assure safe operation.
Inspection are classified into several time levels as shown by the following table "Inspection
intervals".
In the table of "Inspection intervals", the inspections are divided according to three levels of
requirement:
•
•
•
Works, carried out by trained staff.
Work carried out by staff trained by YASKAWA.
Works, carried out by YASKAWA staff.
Inspections are only carried out by trained staff.
NOTICE
 The inspection intervals depend on the SERVO power time (see point 1 in Fig. 9-1:
"SERVO power time").
 The table "Inspection intervals" applies to normal cases.
 Deviations are to be determined by the TCS service department of YEU-R.
START
REMOTE
PLAY
HOLD
TEACH
JOB
EDIT
DISPLAY
JOB CONTENT
-TEST01
CONTROL GROUP:R1
0000 NOP
0001 SET B000 1
0002 SET B001 0
0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
UTILITY
S:0000
TOOL:
MOVJ VJ=0.78
Main Menu
Turn on servo power
Short Cut
TOOL SEL
LAYOUT
GO BACK
DIRECT
OPEN
COORD
PAGE
Multi
ENTRY
MAIN
MENU
X-
X+
Y-
Y+
Z-
Z+
S-
L-
AREA
SELECT
SERVO
ON
READY
SIMPLE
MENU
CANCEL
ASSIST
SERVO ON
S+
X-
HIGH
SPEED
L+
X+
R-
R+
Y-
Y+
Z-
Z+
T-
T+
B-
B+
FAST
U-
MANUAL SPEED
U+
SLOW
E-
8-
E+
8+
INTER
LOCK
7
8
9
ROBOT
INFORM
LIST
4
5
6
BWD
EX.AXIS
WELD
ON/OFF
1
2
3
DELETE
INSERT
AUX
MOTION
TYPE
0
.
-
MODIFY
ENTER
SHIFT
TEST
START
SHIFT
FWD
DATA
EDIT
DISPLAY
UTILITY
SYS MONITORING TIME
1
CONTROL POWER TIME (1998/07/06 10:00 )
2385:42'02
SERVO POWER TIME
(1998/07/06 10:30 )
36000:00'00
PLAYBACK TIME
(1998/10/22 11:12 )
2210:00'20
MOVING TIME
(1998/10/22 15:30 )
1875:15'30
OPERATING TIME
(1998/10/22 16:12 )
0:0'0
Main Menu
ShortCut
Fig. 9-1: SERVO power time
9 - 46
Inspection intervals
Operation
Inspection
Charge:


2
External cable

Visual inspection
Check cable for damage.



3
Working area and robot

Visual inspection
Dirty working area has to be cleaned. Please
control the robot for damage and external
cracks.



4
Motor for S-, L-, U-axes

Visual inspection
Check for grease leakage.



5
Baseplate mounting bolts

Using corresponding tool
Tighten loose screws (replace if necessary).



6
Cover mounting screws

Using corresponding tool
Tighten loose screws (replace if necessary).



7
Power input module

Manual
Check for loose connectors



8
Toothed belt for B- and T-axes
Manual
Check for tension and wear



Every 36000 hours

Every 24000 hours
Check alignment mark accordance and damage
at the home position.
Every 12000 hours
Visual inspection
Every 6000 hours

Every 1000 hours
Alignment marks
Daily
1
9 - 47
Maintenance and inspection
YASKAWA staff
Checking method
YASKAWA trained staff
Schedule
trained staff
Item number1
Visual, multimeter
Check for conduction between the main connecter of base and intermediate connector with
manually shaking the wire. Check the protection
spring2.

11
Wiring harness in the robot
(wires of the B- and T-axis)
Protective tube
Visual, multimeter

Battery pack in robot


Check the wires between the terminals for wear.

Replacement

Visual inspection


12

Replacement3

10
Inspection
Charge:
trained staff
Every 36000 hours
Every 24000 hours
Every 12000 hours
Every 6000 hours
Operation
YASKAWA staff
Wiring harness in the robot
(wires of the S-, L-, U-, R-, Band T-axis)
Checking method
YASKAWA trained staff
9
Every 1000 hours
Schedule
Daily
Item number1



Inspect the protective tube for holes, cracks and
adhesion of welding spatters (replace if necessary).



Refer to manual "OPTIONS FOR PROTECTIVE
TUBING (VELCRO TYPE) REPLACING PROCEURES".





If a battery alarm appears or after the robot has
been operated for 36,000 hours, the battery
must be replaced.
Maintenance and inspection
9 - 48
Inspection intervals
Inspection intervals
Inspection
Charge:
Grease gun
Check for faults (replace if necessary). The
grease4 must be refilled every 6000 hours or replaced every 12000 hours (see chapter 9.3.1
"Grease replenishment/exchange for S-axis reduction gear unit" on page 59).


14
L- and U-axes gear


Grease gun
Check for faults (replace if necessary). The
grease must be refilled every 6000 hours or replaced every 12000 hours (see chapter 9.3.2
"Grease replenishment/exchange for L-axis reduction gear unit" on page 60).


15
R-axis gear

Grease gun
Check for faults, replace if necessary. The
grease has to be refilled every 6000 hours (see
chapter 9.3.4 "Grease replenishment/exchange
for R-axis gear" on page 62).


16
B-axis gear

Grease gun
Check for faults, replace if necessary. The
grease has to be refilled every 6000 hours (see
chapter 9.3.5 "Grease replenishment/exchange
for B- and T-axes gear" on page 63).


trained staff
Every 36000 hours

Every 24000 hours

Every 1000 hours
S-axis gear
Daily
13
9 - 49
Maintenance and inspection
YASKAWA staff
Operation
YASKAWA trained staff
Checking method
Every 12000 hours
Schedule
Every 6000 hours
Item number1
Grease gun
Check for faults, replace if necessary. The
grease has to be refilled every 6000 hours (see
chapter 9.3.5.10 "Refilling grease at T-axis gear"
on page 64).
Inspection
Charge:
trained staff
Every 36000 hours
Every 24000 hours
Every 12000 hours
Every 6000 hours

Operation
YASKAWA staff
T-axes gear
Checking method
YASKAWA trained staff
17
Every 1000 hours
Schedule
Daily
Item number1


Maintenance and inspection
9 - 50
Inspection intervals
Inspection intervals
18
Overhaul

YASKAWA staff
trained staff
Inspection
Charge:
YASKAWA trained staff
Operation
Every 36000 hours
Every 24000 hours
Checking method
Every 12000 hours
Every 6000 hours
Every 1000 hours
Schedule
Daily
Item number1

1. The item numbers correspond to the following diagram "Inspection intervals"
2. When checking for conduction with multimeter, connect the battery to "BAT" and "OBT" of connectors on the motor side for each axis. Now remove the connectors of the encoders of the
respective motor. Failure to observe this sequence can lead to loss of home positions (see section 9.2.3.1 "Wrist unit" on page 58
3. The internal wiring harness in the robot (for the S, L, U, R, B and T axes) must be replaced at the 24,000 hours inspection.
4. The grease and/or lubricants used can be found in the following table "Inspection parts and grease used".
Tab. 9-1: Inspection intervals
Maintenance and inspection
9 - 51
4
13
14
12
9
11
11
5
4
15
8
8
14
17
4
Maintenance and inspection
Fig. 9-2: Inspection intervals
The numbers in the above figure are equal to the numbers in the table of "Inspection
intervals".
9 - 52
Maintenance and inspection
Inspection parts and grease used
No.
Grease Used
Material
no.
Inspected Parts
12, 13
Molywhite grease RE No. 0
100274
S-, L-, U axes gear
14, 15
Harmonic grease 4B No. 2
127612
R- and B-axes gear
16
Grease Shell Gadus S2 V220
2
146745
T-axes gear
Tab. 9-2: Grease used
Safety datasheets on grease types can be requested from YEU-R.
9.2
Note on battery unit
9.2.1
Changing battery unit
$%
$%
8#
OO0O
;$
$%
1
4
2
3
Fig. 9-3: Battery unit location
1
Battery holder
3
Connector plate
2
Battery pack
4
Mounting screws of cover plate
The battery units are installed as shown in picture "The location of the battery unit".
If battery alarm occuring in the robot controller, battery pack has to be changed in the
following form.
9 - 53
Maintenance and inspection
1. Turn the robot controller to the main power supply (see Fig. 9-4: "Main power switch in
"switch-off" position").
1
WARNING
High Voltage
Do not open the door
with power ON.
Fig. 9-4: Main power switch in "switch-off" position
1
Main power switch in "switch-off" position
2. Remove the fixing screws from the cover plate.
3. Carefully pull out the battery pack from the base.
NOTICE
The absolute encoder data will be lost
Removing the battery pack, make sure you not to remove the plug from circuit board.
4. Connect the new battery pack to the unoccupied connector on the board.
1
6
5
4
3
2
Fig. 9-5: Battery pack connections
1
Old battery pack before replacement
4
Plug
2
New battery pack
5
Circuit board
3
See exchange, step 6
6
See exchange, step 7
5. Remove the old battery pack from the battery holder.
6. Mount the new battery pack to the battery holder.
NOTICE
The absolute encoder data will be lost
Never remove old battery pack before having installed new battery pack.
9 - 54
Maintenance and inspection
7. Please remove old battery pack plug from circuit board.
NOTICE
Make sure that no wires are pinched when you install the battery pack and the cover plate
again.
8. Please apply Teroson Plast sealing compound (material no. 143813) to thread part of
screws.
Exchanging the battery unit iscompleted after reinstalling the cover plate on the plug plate.
9 - 55
Maintenance and inspection
9.2.2
Battery pack connector (including warning note)
1
3
2
OBT
b
a OBT*
BAT
a
b BAT
5
4
Fig. 9-6: Battery pack connector diagram for S-, L- and U-axes
1
Motor
4
Battery pack
2
Motor power connector
5
Plug for backup
3
Encoder connector
Before removing the encoder connector (with CAUTION label), connect the battery to the
motor as shown in the following figure.
9 - 56
Maintenance and inspection
1
9
2
8
7
b OBT4
a BAT4
OBT a
BAT b
CAUTION
Connect battery to encoder
to save the data before
removing connector.
5
3
6
4
OBT
a
BAT
b
b OBT4
a BAT4
Fig. 9-7: Battery pack connector diagram for R-, B- and T-axes
1
Encoder
6
Warning label
2
Motor cable
7
Power connector
3
Battery pack
Wiring harness of the robot
4
a: Plug - socket
b: Plug - pin
8
9
5
Encoder connector
Motor
9 - 57
Maintenance and inspection
9.2.3
Note on maintenance
9.2.3.1
Wrist unit
The motor and encoder units are provided with the wrist unit. To prevent fumes penetrating
into wrist unit, matched parts are sealed. If you have removed the wrist cover, the seal must
be replaced with Teroson Plast sealing compound (material no. 143813) (see section 10
"Recommended spare parts list" on page 77).
1
1
2
2
Fig. 9-8: Sealing wrist unit
1
Cover jointing face
9.3
2
Cover
Instructions on grease replenishment
Make sure to follow the instructions. If the following instructions are not followed, it might
cause damage to motor or gear.
NOTICE
 Make sure that the plug has been removed from the grease outlet. If the plug is not
removed, grease will enter the motor or the oil seal of the gear will be damaged. This
might cause damage to the motor or gear.
 Lubrication or grease replacement is only allowed at operating temperature.
 Do not install a joint, hose, etc. to the grease outlet. If this instruction is not followed, the
motor will be damaged.
 Avoid air getting into the gear.
 Insert grease with a grease gun.
 If an automatic lubricating pump is used, the grease supply pressure must be 0.3 kPa.
 Set the grease injection rate to a value not higher than 8 g/s.
 The limit values may not be exceeded also if a conventional grease gun is used.
 In ceiling-mounted robots the grease outlet and the grease inlet are located the other
way around (related to the figures in the operating and maintenance instructions).
9 - 58
Maintenance and inspection
9.3.1
Grease replenishment/exchange for S-axis reduction gear unit
1
3
2
Fig. 9-9: S-axis gear
1
Grease exhaust port (plug)
2
S-axis gear
9.3.1.2
3
Grease inlet port (plug)
Refill grease
See figure "S-axis gear diagram".
NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
400 cm³ / ca. 350 g
4. Move S-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9.3.1.3
Replace grease
See figure "S-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
1950 cm³ / ca. 1700 g
Grease exchange has completed if new grease appears from grease exhaust port.
New grease seperates from old grease by lighter color.
4. Move S-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9 - 59
Maintenance and inspection
9.3.2
Grease replenishment/exchange for L-axis reduction gear unit
2
1
3
Fig. 9-10: L-axis gear
1
Grease leakage detection hole
2
L-arm
9.3.2.4
3
Grease inlet port
Refill grease
See figure "L-axis gear diagram".
NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.
1. Remove plug from grease exhaust port and grease inlet port.
2. Install the lubricating nipple.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
170 cm³ / approx. 150 g
4. Move L-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9.3.2.5
Replace grease
See figure "L-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
860 cm³ / approx. 750 g
Grease exchange has completed if new grease appears from grease exhaust port.
New grease seperates from old grease by lighter color.
4. Move L-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9 - 60
Maintenance and inspection
9.3.3
Grease replenishment/exchange for U-axis reduction gear unit
3
2
1
4
Fig. 9-11: U-axis gear
1
U-arm
2
Grease leakage detection hole
9.3.3.6
3
4
U-axis gear
Grease inlet port
Refill grease
See figure "U-axis gear diagram".
NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.
1. Set U-arm horizontal to ground
2. Remove plug from grease exhaust port and grease inlet port.
3. Install lubricating nipple to grease inlet port.
4. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
90 cm³ / approx. 80 g
5. Move U-axis for a few minutes to discharge excess grease.
6. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9.3.3.7
Replace grease
See figure "U-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
460 cm³ / approx. 400 g
Grease exchange has completed if new grease appears from grease exhaust port.
New grease seperates from old grease by lighter color.
4. Move S-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before installing the plugs, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9 - 61
Maintenance and inspection
9.3.4
Grease replenishment/exchange for R-axis gear
1
3
2
Fig. 9-12: R-axis gear
1
R-axis gear
2
Grease inlet port (lubricating nipple)
9.3.4.8
3
Grease exhaust port (plug)
Refill grease
See figure "R-axis gear diagram".
NOTICE
Follow the instructions in the chapter 9.3 "Instructions on grease replenishment" on page
58.
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port
–
Amount of grease:
12 cm³ / approx. 10 g
4. Move R-axis for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9 - 62
Maintenance and inspection
9.3.5
Grease replenishment/exchange for B- and T-axes gear
9.3.5.9
Refilling grease at B-axis gear
3
1
4
2
Fig. 9-13: B-axis gear
1
Grease inlet port
3
Grease exhaust port
2
B-axis gear
4
Cover
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
6 cm³ / approx. 5 g
4. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9 - 63
Maintenance and inspection
9.3.5.10
Refilling grease at T-axis gear
3
2
1
Fig. 9-14: T-axis gear
1
Grease inlet 2
2
Grease exhaust port
3
Grease inlet 1
See figure "T-axis gear diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
11 cm³ / approx. 10 g
4. Move T-axis gear for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9 - 64
Maintenance and inspection
9.3.6
Replenishment/Exchange for R-axis cross roller bearings
2
1
3
Fig. 9-15: R-axes tapered roller bearing
1
Grease leakage detection hole
2
R-axis gear
3
Grease inlet port
See figure "R-axis cross roller bearing diagram".
1. Remove plug from grease exhaust port and grease inlet port.
2. Install lubricating nipple to grease inlet port.
3. Squeeze grease by grease gun in grease inlet port.
–
Amount of grease:
45 cm³ / 40 g
4. Move R-axis gear for a few minutes to discharge excess grease.
5. Wipe away excess grease with a cloth. Remove the grease zerk from the grease inlet
port, and reinstall the plug. Before mounting the plug, apply Teroson Plast sealing
compound (material no. 143813) to thread part.
9.4
Home position calibration
Follow the safety instructions described in section 1.7 "Safety" on page 8 .
9 - 65
Maintenance and inspection
NOTICE
 Teaching or playback are not possible before the completion of the home position
calibration.
 Teach and save a second testing position immediately after installing the robot system.
This second testing position can be determined, e.g., by using tips (screw-in tip on the
torch, fixed counterpart on the cell wall) and stored in the robot controller.
 After a collision or in the event of track deviations it is recommended not to re-teach
individual jobs, but to approach and reset the basic position and/or the second home
position.
 After each collision or emergency stop situation the robot must be moved to its basic
position in setup mode and its home position must be checked.
 In a system with two or more Robots, the home position of all the Robots must be
calibrated before starting teaching or playback.
 For more information, see also system setup in the manual or contact your YASKAWA
branch.
When setting the home position, the position of the absolute encoder must match it.
Although this operation is performed prior to shipment at the factory, the following cases
require this operation to be performed again.
•
Change in the combination of the robot and robot controller.
•
Replacement of the motor or absolute encoder.
•
Clearing stored memory (by replacement of the main CPU board, weak battery pack,
etc.).
•
Home position deviation caused by hitting the robot.
Home position calibration
To calibrate the home position mark on each axis, use the axis keys, so that the robot can
take their position as home position.
There are two operations for home position calibration:
•
All the axes can be moved at the same time.
– If the combination of robot and main board (CPU) has been changed, reset the
home position. The home position set by moving all axes simultaneously.
•
Axes can be moved individually.
– If you have replaced the motor or the absolute encoder, reset the home position for
the individual axes.
If the absolute data of its posture for the home position is already known, set them again
after completing home position registration.
NOTICE
The window for calibrating the home position is only displayed if safety mode is selected as
the management mode.
9 - 66
Maintenance and inspection
9.4.1
Register all axes
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {HOME POSITION}.
The <HOME POSITIONING> window appears.
9 - 67
Maintenance and inspection
3. Select {DISPLAY}
The pull-down menu appears.
The same operation as in step 3 can also be performed by selecting the {PAGE} button.
In this case a selection box appears.
4. Select the sub-assembly to calibrate (e.g. R1:ROBOT).
Select the control group for {HOME POSITIONING}.
The control group can also be selected by pressing page key
5. Select {EDIT} in the main menu.
The pull-down menu appears.
9 - 68
.
Maintenance and inspection
6. Select {SELECT ALL AXES}.
A confirmation dialog box is displayed.
7. Select {YES}.
Displayed position data of all axes are registered as home position.
When {NO} is selected, the registration will be canceled.
9.4.2
Register individual axes
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {HOME POSITION}.
3. Select the sub-assembly to calibrate (e.g. R1:ROBOT).
Carry out steps 3 and 4 as described in section 9.4.1 "Register all axes" on page 67 to
select the desired control group.
4. Move cursor to the axis that you want to register, and select it.
A confirmation dialog box appears.
5. Select {YES}.
The displayed position data of the selected axis is registered as home position.
When {NO} is selected, the registration will be canceled.
9 - 69
Maintenance and inspection
9.4.3
Changing absolute data
After you have set the home position, change the absolute data of the axis as follows:
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {HOME POSITION}.
3. select the sub-assembly/components to be calibrated.
Carry out steps 3 and 4 as described in section 9.4.1 "Register all axes" on page 67 to
select the desired control group.
4. Select the absolute data to be registered.
5. Enter the absolute data using the numeric keys.
6. Select {ENTER}.
The absolute encoder data is changed.
9.4.4
Clearing absolute data
Once you have set the home position, delete the absolute data of the axis as follows:
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {HOME POSITION}.
Carry out steps 3 and 4 as described in section 9.4.1 "Register all axes" on page 67 to
select the desired control group.
3. Select {DATA} from the main menu.
The pull-down menu appears.
9 - 70
Maintenance and inspection
4. Select {CLEAR ALL DATA}.
A confirmation dialog box appears.
5. Select {YES}.
All absolute data will be deleted.
When {NO} is selected, the registration will be canceled.
9.5
Setting the second home position (check point)
9.5.1
Purpose of position check operation
If the absolute number of rotations determined at power supply ON does not match the data
stored in the absolute encoder the last time the power supply was turned OFF, an error
message is issued.
There are two possible causes of this alarm:
•
Error in the pulse generator system
•
The robot was moved after the power supply was turned OFF
If the alarm "OUTSIDE THE RANGE (ABSOLUTE DATA)" appears, automatic mode is not
possible. The home position must be checked.
9 - 71
Maintenance and inspection
NOK
OK
9 - 72
1
If the "OUT OF RANGE (ABSO DATA)" alarm occurs:
6
Compare second home position
(check point)* pulses with current position pulses.
2
alarm reset
Alarm occurs again
3
SERVO-ON power ON
7
8
4
Procedure after alarm
9
* Position checking point
5
Position confirmation operation
10
Automatic mode possible
Correct the faulty axis, replace the
pulse generator system, set the home
position
Maintenance and inspection
Position check
After the "OUT OF RANGE (ABSO DATA)" alarm occurs, move to the second home position
using the axis keys and perform the position confirmation. Automatic mode, test runs and
FWD movement cannot be performed without checking the position with "CONFIRM
POSITION".
Pulse difference check
The pulse number at the second home position is compared with that at the current position.
If the deviation is within the allowable range, automatic operation can be performed.
If not, the alarm occurs again.
NOTICE
 The allowable range pulse is the number of pulses per rotation of the motor (PPR data).
 The initial value of the second home position is the home position (where all axes are
at pulse 0). The second home position can be changed. For further information, refer to
9.5.2 "Procedure for the second home position setting" on page73.
Alarm messages
If the alarm occurs again, there may be an error in the pulse generator system. Check the
pulse generator system. After adjusting the faulty axis, calibrate the home position of the
axis, then check the position again.
NOTICE
Home position calibration of all axes at the same time enables automatic mode without to
checking position.
However, as a rule, always perform "CONFIRM POSITION". Under the above special
conditions, the robot moves as follows:
 After the start, the robot moves at low speed (1/10 of the maximum speed) to the step
indicated by the cursor. If the robot stops and restarts during this motion, speed is
retained until wanted step at cursor is reached.
 Regardless of cycle setting, the robot stops after reaching cursor indicated step.
Starting the Robot again then moves it at the programmed speed and cycle of the job.
9.5.2
Procedure for the second home position setting
Apart from the “home position” of the robot, the second home position can be set up as a
check point for absolute data. Use the following steps to set the specified point.
NOTICE
If 2 or more Robots or stations are controlled by one controller, the second home position
must be set for each robot or station.
9 - 73
Maintenance and inspection
1. Select {ROBOT} from the main menu.
- The sub-menu choices appear.
2. Select {SECOND HOME POS}.
The {SECOND HOME POS} window appears. Message is spoken „Available to move
to and modify specified point“.
3. Press the „page key“
control group.
or select {PAGE} to display the selection window for the
Occuring 2 or more group axes, select those one to you intend to specify second home
position.
4. Press the axis keys.
- Move the Robot to the new second home position.
5. Press {MODIFY} then {ENTER}.
- The second home position is changed.
9 - 74
Maintenance and inspection
9.5.3
Procedure after alarm
Follow the safety instructions described in section 1.7 "Safety" on page 8 .
WARNING!
Death or injury because of danger of crushing
Irregularities in the PG system may lead to an alarm and the robot may perform unexpected
movements.
If the "OUT OF RANGE (ABSO DATA)" alarm occurs,
•
Reset the alarm.
•
the SERVO power ON.
Then confirm the second home position. After the confirmation, if the PG system is found
to be the cause of the alarm, perform the necessary operation, such as replacing the PG
system, etc.
The robot current position data when turning main power supply ON and OFF can be
confirmed in {POWER ON/OFF POS} window.
1. Select {ROBOT} from the main menu.
The sub-menu choices appear.
2. Select {SECOND HOME POS} from the main menu.
The SECOND HOME POS window appears.
3. Press the „page key“
control group.
or select {PAGE} to display the selection window for the
Occuring two or more group axes, select those one to you intend to specify second
home position.
9 - 75
Maintenance and inspection
4. Press {FWD}.
TCP moves to the second home position. The robot moving speed is set as selected
manual speed.
5. Select {DATA} in the menu.
6. Select {CONFIRM POSITION}.
A message "Home position checked" appears.
Pulse data of the second home position and current pulse data should be compared.
Automatic mode can be done if compared error is in allowed range.
If the error is beyond the allowed range, the alarm occurs again.
9 - 76
Recommended spare parts list
10 Recommended spare parts list
It is recommended to keep in stock parts and components in the following table as spare
parts. Product performance cannot be guaranteed when using spare parts from any
company other than YASKAWA.
The spare parts are ranked as follows:
•
Category A:
– Expendable and frequently replaced parts.
•
Category B:
– Parts for which replacement may be necessary as a result of frequent operation.
•
Category C:
– Motor
NOTICE
Please contact your YASKAWA branch office if you need spare or replacement parts.
Category
Description
Type
Material no.
Qty
Qty per unit
List of recommended spare parts for stocking
A
Grease
Molywhite RE No. 0
100274
16 kg
-
A
Grease
Harmonic grease SK1A
127610
2.5 kg
-
A
Grease
Grease Shell Gadus S2
V220 2
E146745
16 kg
-
A
Sealing compound
Teroson Plast
143813
200 ml
-
A
Battery pack
Robot
128708
1
1
A
Battery pack
Control
155543
1
1
A
Protective tube
MTK-50FR
1.5 m
1
B
Toothed belt B-axis
60S3.M642
164742
1
1
B
Toothed belt T-axis
80S3.M819
164744
1
1
B
S-axis gear
Y005C-MA02010A00S
E144081
1
1
HW0387753-B
B
Pinion S-axis
HW0312491-1
1
1
B
L-axis gear
Y005C-MA02010A00L
1
1
HW0387753-G
B
Pinion L-axis
HW1304336-1
1
1
B
U-axis gear
Y005C-MA02010A00U
1
1
1
1
HW0386621-C
B
Pinion U-axis
HW1304321-1
10 - 77
Recommended spare parts list
Category
Description
Type
Material no.
Qty
Qty per unit
List of recommended spare parts for stocking
B
R-axis gear
Y005C-MA02010A00R
164748
1
1
HW1382521-A
B
B-axis gear
Y005C-MA02010A00B
1
1
B
Pinion T-axis
Y005C-MA02010A00T
1
1
B
Pinion R-axis
Y005C-MA02010A00RU
1
1
B
Wrist unit
Y005C-MA02010A00BT
1
1
B
Wiring harness in the robot
HW1171441-A
1
1
B
Internal wiring harness for
B- and T-axes
HW1271107-A
1
1
C
S-axis motor
HW0388665-A
1
1
1
1
1
2
1
1
1
2
1
1
E144076
SGMRV-09ANA-YR1*
C
L-axis motor
HW0388666-A
SGMRV-13ANA-YR1*
C
U-axis motor
HW0388663-A
SGMRV-05ANA-YR1*
C
R-axis motor
HW0389295-A
SGMAV-02ANA-YR1*
C
B- and T-axes motor
HW0389294-A
E144070
SGMAV-01ANA-YR1*
C
10 - 78
Circuit board
SGDR-EFBA02A
Parts lists
11 Parts lists
11.1
S-axis unit
1026
1027
1002
1014
1003
1004
1027
1044
1008
1030
1012
1011
1005
1006
1038
1039
1035
1037
1032
1007
1043
1033
1036
1034
1036
1041
1042
1037
1039
1040
1038
1001
1015
1021
1046
1045
1016
1024
1046
1022
1045
1029
1046
1010
1031
1019
1009
1020
1023
1028
1013
1025
1017
1018
Fig. 11-1: S-axis drive
11 - 79
Parts lists
11 - 80
No.
DWG no.
Designation
Pcs
1001
HW1100684-1
Stand
1
1002
M8 x 30
Screw
3
1003
M4 X 8
Screw
4
1004
2H-4
Washer
4
1005
M8 x 50
Screw
3
1006
2H-8
Washer
3
1007
HW1304342-1
Housing
1
1008
HW0313491-1
Pinion
1
1009
HW0387753-B
Gear box
1
1010
M10 x 40
Screw
16
1011
M6 x 60
Screw
1
1012
2H-6
Washer
1
1013
HW1100683-1
Housing
1
1014
SGMRV-09ANA-YR1*
Motor
1
1015
M12 x 45
Screw
8
1016
2H-12
Washer
8
1017
TSH8-03
Link
1
1018
NB-0860
Hose
1
1019
MSB8-15
Screw
1
1020
HW0400645-3
Plug
1
1021
TSH8-03
Support
1
1022
HW1304380-1
Cover
1
1023
M6 x 15
Screw
7
1024
M6 x 15
Screw
2
1025
M5 x 10
Screw
6
1026
HW1304381-A
Cover
1
1027
M6 x 15
Screw
11
1028
EZ5036A0
Sealing plug
1
1029
HW1304382-1
Cover
1
1030
HW1304379-1
Cover
1
1031
PMF8-03
Link
1
1032
HW1405431-1
Support
1
1033
TA1-S10
Terminal
1
1034
M5 x 8
Screw
1
1035
T50R
Cable tie
1
1036
M5 x 12
Screw
4
1037
CD-31
Clamp
2
1038
M5 x 8
Screw
4
Parts lists
No.
DWG no.
Designation
Pcs
1039
2H-5
Washer
4
1040
HW1405589-1
Support
1
1041
TA1-S10
Terminal
1
1042
M5 x 8
Screw
1
1043
T50R
Cable tie
1
1044
C-30-SG-30A
Cover
1
1045
KQ2L08-00
Link
2
1046
NB-0860
Hose
3
Tab. 11-1: S-axis drive
11 - 81
Parts lists
11.2
L-axis unit
2016
2024
2022
2025
2018
2023
2017
2013
2020
2019
2002
2015
2004
2003
2014
2012
2001
2011
2008
2007
2021 2006
2010
2009
1001
Fig. 11-2: L-axis drive
11 - 82
No.
DWG no.
Designation
Pcs
2001
HW1100696-1
L-arm
1
2002
HW1304336-1
Pinion
1
2003
M6 x 90
Screw
1
2004
2H-6
Washer
1
2005
M12 x 40
Screw
12
2006
2H-12
Washer
12
2007
M10 x 35
Screw
6
2008
2H-10
Washer
6
2009
M12 x 35
Screw
2
2010
HW1405429-1
Washer
2
2011
HW0387753-G
Gear box
1
2012
M10 x 40
Screw
16
2013
HW0401506-1
Washer
1
2005
Parts lists
No.
DWG no.
Designation
Pcs
2014
HW1304555-1
Housing
1
2015
M8 x 30
Screw
4
2016
SGMRV-13ANA-YR1*
Motor
1
2017
Y426012.5
Oil seal
1
2018
M8 x 25
Screw
4
2019
PT1/8
Set screw
2
2020
PT3/8
Set screw
1
2021
NPTF3/8
Set screw
1
2022
HW1405456-1
Cover
1
2023
M6 x 15
Screw
4
2024
HW1405226-1
Support
1
2025
M5 x 10
Screw
2
1001
HW1100684-1
Housing
1
Tab. 11-2: L-axis drive
11 - 83
Parts lists
11.3
U-axis drive
3021
3023
3022
3025
3024
3018
3019
3026
3027 3028
3020
3001
3029
3004
3011
3007
3017
3015
3014
3006 3002
3012
3013
3003
3002
2001
3016
3009
3005
3008
Fig. 11-3: U-axis drive
11 - 84
Parts lists
No.
DWG no.
Designation
Pcs
3001
HW1100686-1
Housing
1
3002
M12 x 25
Screw
2
3003
2H-12
Washer
2
3004
HW1304321-1
Pinion
1
3005
NPTF3/8
Set screw
1
3006
M5 x 90
Screw
1
3007
2H-5
Washer
1
3008
HW0386621-C
Gear box
1
3009
M6 x 35
Screw
16
3011
M5 x 16
Screw
3
3012
M8 x 40
Screw
18
3013
2H-8
Washer
18
3014
SGMRV-05ANA-YR1*
Motor
1
3015
M8 x 30
Screw
4
3016
PT3/8
Set screw
1
3017
M4 X 12
Screw
3
3018
HW1405434-1
Cover
1
3019
CP-30-OB-8
Plug
1
3020
HW1405433-1
Cover
1
3021
M4 X 12
Screw
3
3022
KQE12-03
Union
1
3023
PT3/8
Set screw
1
3024
KQE10-03
Union
1
3025
PT3/8
Set screw
1
3026
M3 x 16
Screw
2
3027
M3
Nut
2
3028
HW1405648-1
Housing
1
3029
M4 X 12
Screw
5
2001
HW1100696-1
L-arm
1
Tab. 11-3: U-axis drive
11 - 85
Parts lists
11.4
R-axis unit
5063
4056
4057
4054
4055
4058
4061
4062
4063
4059
4060
4011
4012
4008
4010
4013
4031
4029
4032
4030
4028
4009
3001
4034
4042
4040
4035
4036 4033
4035
4037
4038
4038
4039
4006
4002
4052
4016
4007
4023
4041
4048
4024
4026
4005
4004
4025
4001
4003
4019
4018
4015 4017
4020
4027
4051
4043
4046
4014
4053 4045
4050
4021
4022
Fig. 11-4: R-axis drive
11 - 86
4044
4049
4047
Parts lists
No.
DWG no.
Designation
Pcs
4001
HW1200340-1
Housing
1
4002
M5 x 45
Screw
8
4003
HW1304319-1
Pinion
1
4004
HW1303257-2
Shaft
1
4005
M3 x 12
Screw
5
4006
HW1382521-A
Gear box
1
4007
TC52647
Oil seal
1
4008
M6 x 40
Screw
7
4009
HW1304069-1
Shaft
1
4010
TC1151306
Oil seal
1
4011
M6 x 20
Screw
6
4012
M6 x 20
Screw
7
4013
HW1304196-1
Shaft
1
4014
SGMAV-02ANA-YR1*
Motor
1
4015
TC20305 (FKM)
Oil seal
1
4016
M3 x 12
Screw
6
4017
HW1405390-1
Housing
1
4018
HW1304320-1
Pinion
1
4019
M4 X 14
Screw
1
4020
2H-4
Washer
1
4021
M3 x 12
Screw
4
4022
M4 X 12
Screw
4
4023
M4 X 12
Screw
4
4024
PT1/8
Set screw
3
4025
PT1/8
Set screw
1
4026
HW1404157-*
Sim
1
4027
HW1405571-*
Sim
1
4028
TA1-S8
Terminal
1
4029
M4 X 6
Screw
1
4030
M4
Washer
1
4031
T30R
Cable tie
1
4032
HW1405181-1
Support
1
4033
PZ1212
Clamp
1
4034
PZ1208
Clamp
1
4035
M4 x6
Screw
4
4036
M4 X 12
Screw
2
4037
HW1405459-1
Cover
1
4038
M4 X 6
Screw
4
4039
PZ1208
Clamp
1
4040
HW1405430-1
Support
1
4041
M4 X 12
Screw
2
11 - 87
Parts lists
No.
DWG no.
Designation
Pcs
4042
PZ1212
Clamp
1
4043
TA1-S8
Terminal
1
4044
M4X6 (STAINLESS)
Screw
1
4045
T50R
Cable tie
1
4046
HW1404041-1
Production support
1
4047
M4 X 12
Screw
2
4048
HW1404786-1
Gasket
1
4049
HW1303904-1
Cover
1
4050
M4 X 12
Screw
7
4051
HW9481319-D
Cable feedthrough
1
4052
M4 X 12
Screw
1
4053
M4 X 12
Screw
2
4054
HW1200341-1
Spacer
1
4055
HW1405367-1
Cover
1
4056
M4 X 10
Screw
10
4057
MSTH6-20
Pin
1
4058
HW1304345-1
Shaft
1
4059
M6X25
Screw
6
4060
HW1405461-1
Support
2
4061
M4X12
Screw
4
4062
M6X25
Screw
6
4063
HW1405368-1
Cover
1
3001
HW1100686-1
Housing
1
5063
HW1100618-1
U-arm
1
Tab. 11-4: R-axis drive
11 - 88
Parts lists
11.5
Wrist unit
5043
5045
5008
5007
5001
5006
5047
5035
5041
5040
5005
5046
5042
5009
5028
5001
5002
5026
5021
5003
5005
5005
5025
5019
5022
5044
5055
5039
5038
5036
5037
5018
5020
5005
5027
5009
5029 5031
5030
5024
5016
5005
5033
5017
5066
5028
5032
5015
5011
5013
5014
5012
5034
5023
5062
5065
5063
5054
5051
5050
5010
5058
5058
5059
5064
5060
5010
5048
5005
5052
5049
5005
5061
5053
5065
5066 5015
5014
5056
4054
5057
5009
Fig. 11-5: Wrist unit
11 - 89
Parts lists
11 - 90
No.
DWG no.
Designation
Pcs
5001
M6 x 6
Screw
5
5002
HW0404371-1
Screw
1
5003
HW1404058-1
Cover
1
5005
M3 x 10
Screw
39
5006
HW1404060-1
Packing
1
5007
HW1404069-1
Cover
1
5008
M4X10 (STAINLESS)
Screw
2
5009
M4 X 12
Screw
23
5010
M4 X 10
Screw
4
5011
HW1404053-1
Flywheel
1
5012
HW1404038-A
Pulley
1
5013
M4 X 16
Screw
1
5014
2H-4
Washer
2
5015
M4 X 16
Screw
4
5016
HW1303244-1
Cover
1
5017
80S3M819
Toothed belt
1
5018
WR20
Terminal
1
5019
HW1303260-1
Shaft
1
5020
HW1404049-1
Cover
1
5021
M8 x 40
Screw
1
5022
2H-8
Washer
1
5023
HW1481728-A
Bearing
1
5024
6809DDU
Bearing
1
5025
HW1404059-6
Spring
1
5026
HW1303248-1
Pinion
1
5027
6804
Bearing
1
5028
M3 x 28
Screw
18
5029
M8 x 20
Screw
1
5030
2H-8
Washer
1
5031
HW1404039-A
Pulley
1
5032
HW1303249-1
Pinion
1
5033
HW1404048-1
Cover
1
5034
HW1404054-1
Shaft
1
5035
TC50606
Oil seal
1
5036
AR28
Terminal
1
5037
WR15
Terminal
1
5038
NA4902
Bearing
1
5039
HW1303250-1
Pinion
1
5040
HW1371294-A
Assembly gear
1
5041
RA9008C0
Bearing
1
5042
TC1001105
Oil seal
1
Parts lists
No.
DWG no.
Designation
Pcs
5043
TC64746
Oil seal
1
5044
HW1303261-1
Flange
1
5045
HW1404055-1
Holder
1
5046
HW1303262-1
Flange
1
5047
HW1100619-1
Housing
1
5048
HW1303259-1
Shaft
1
5049
M3 x 20
Screw
12
5050
IRTW26
Circlip
1
5051
6803LLU
Bearing
1
5052
HW1404037-A
Pulley
1
5053
M3 x 16
Screw
4
5054
HW1404047-1
Housing
1
5055
HW1382522-A
Gear box
1
5056
60S3M642
Toothed belt
1
5057
HW1303243-1
Cover
1
5058
SGMAV-01ANA-YR1*
Motor
2
5059
HW1404046-1
Housing
1
5060
HW1404036-A
Pulley
1
5061
M4 X 12
Screw
1
5062
HW1404052-1
Housing
1
5063
HW1100618-1
U-arm
1
5064
6902
Bearing
1
5065
HW1404516-1
Cover
2
5066
M4 X 8
Screw
4
4054
HW1200341-1
Spacer
1
Tab. 11-5: Wrist unit
11 - 91
Parts lists
11.6
Gear unit
6004
6001
6007
6002
6005
6003
6006
Fig. 11-6: Gear unit
No.
DWG no.
Designation
Pcs
6001
HW1303251-1
Gear box
1
6002
HW1303252-1
Gear box
1
6003
HW1404051-1
Sleeve
2
6004
HW1404050-1
Pin
6
6005
WB5-30
Clamping sleeve
3
6006
M3 x 12
Screw
2
6007
M3 x 10
Screw
2
Tab. 11-6: Parts list gear unit
11 - 92
Parts lists
11 - 93
YASKAWA contacts
YASKAWA
Headquarters
YASKAWA Europe GmbH
Robotics Division
Yaskawastraße 1
D-85391 Allershausen
Tel. +49 (0) 8166/90-0
Fax +49 (0) 8166/90-103
YASKAWA academy and
sales office Frankfurt
YASKAWA Europe GmbH
Robotics Division
Hauptstraße 185
D-65760 Eschborn
Tel. +49 (0) 6196/77725-0
Fax +49 (0) 6196/77725-39
YASKAWA Group
Distributors
A
YASKAWA Austria
Schwechat/Wien +43(0)1-707-9324-15
BG
Kammarton Bulgaria Ltd.
Sofia +359-02-926-6060
CZ
YASKAWA Czech s.r.o.
Rudná u Prahy +420-257-941-718
CH
Messer Eutectic Castolin Switzerland S.A.
Dällikon +41-44-847-17-17
E
YASKAWA Ibérica, S.L.
Gavà/Barcelona +34-93-6303478
DK
Robotcenter Danmark
Løsning +45 7022 2477
F
YASKAWA France SARL
Saint-Aignan-de-Grand-Lieu
+33-2-40131919
EE
RKR Seadmed OÜ
Tallinn/Estonia +372-68-35-235
GR
FIN
YASKAWA Finland Oy
Turku +358-(0)-403000600
Gizelis Robotics
Nea Kifissia +30-2106251455
H
GB
YASKAWA UK Ltd.
Banbury +44-1295-272755
Flexman Robotics Kft
Budapest +36-30-9510065
LT
I
YASKAWA Italia s.r.l.
Torino +39-011-9005833
Profibus UAB
Panevezys +370-45-518575
N
IL
YASKAWA Europe Technology Ltd.
Rosh Ha’ayin +972-3-9004114
Skala Robotech AS
Lierstranda +47-32240600
PL
NL
YASKAWA Benelux B.V.
EB Son +31-40-2895500
Integrator RHC Sp. z o.o.
Torun +48-56-6519710
PT
RUS YASKAWA Nordic AB
Moskva +46-480-417-800
ROBOPLAN Lda
Aveiro +351-234 943 900
RO
Sam Robotics srl
Timisoara +40-720-279-866
RO
MPL Automation S.R.L.
Satu Mare +40 (0) 261 750 741
SE
YASKAWA Nordic AB
Torsås +46-480-417-800
SI
YASKAWA Slovenia
Ribnica +386-1-8372-410
TR
YASKAWA Turkey Elektrik Ticaret Ltd. Sti.
İstanbul +90-216-5273450
ZA
YASKAWA Southern Africa (PTY) Ltd
Johannesburg +27-11-6083182
www.yaskawa.eu.com
[email protected]
Technical data may be subject to change without previous notice.
">