YASKAWA MH180 Operating And Maintenance Manual

ROBOTICS
MH180
YR-MH180-A00
Operating and Maintenance Manual
Created on:
2018-11
Revision:
13
Document number:
E1101000180GB13
Author:
WOE
Modifications made:
Rev. 01: Revised version of the original HW1482326.0 in YEU-style (2014-04)
Rev. 02: Revision of the quantity of grease (2014-06).
Rev. 03: Revised version of the original HW1482326.2 (2014-08)
Rev. 04: Revised version of chapter "Notes on how to refill grease" (2014-09)
Rev. 05: Revision of table "Inspection intervals" and review of chapter "Grease replenishment/exchange" (2015-03)
Rev. 06: Revised version of the original HW1482326.3 (2015-03)
Rev. 07: Revised version of chapter "Notes on how to refill grease" (2015-08)
Rev. 08: Revised version of the original HW1482326.5 (Fig.: Internal connection diagram
(a)) (2015-08)
Rev. 09: Revised version of chapter "Internal cables and compressed air lines" and "Recommended spare parts" (DX200 Rev. 1.5 01.05.2015)
Rev. 10: Revised version of the original HW1482326.6 (2016-03)
Rev. 11: Addition of the chapter "Zeroing (optional)" (2016-08)
Rev. 12: Revised of chapter “Inspection schedule” (2016-09)
Rev. 13: Revision of chapter: 8 "Internal cables and compressed air lines")
© Copyright 2018
This documentation (or parts of it) must not be reproduced or made available to third parties without
the express approval of YASKAWA Europe "Robotics Division GmbH”.
We have checked the content of this publication for compatibility 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 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.8 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2
Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Transporting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Shipping brackets and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Damping material during transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Ambient conditions and installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.1 Connecting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.2 Connection of the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Parts and work axis label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Robot base dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Dimensions and defined working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.4 Adjustable working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.1 Components for Changing the Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.4.2 Adjusting the S-Axis Pulse Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.5 Stopping Angle and Time at the Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.5.1 Stop category 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5.2 Stop category 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7
Allowable load for wrist axis and wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 Wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3
Table of contents
8
Internal cables and compressed air lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9
Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.1 Inspection schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.2 Note on battery unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2.1 Battery pack replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2.2 Battery pack connector (including warning note) . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.3 Note on maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.4 Refill/Replace grease.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.4.1 Grease filling the main axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.4.2 Grease filling the wrist axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.4.3 Grease replenishment for balancer link part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.5 Gas maintenance procedure in the gas balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.5.1 Notes on gas maintenance procedure in the gas balancer . . . . . . . . . . . . . . . . . 66
9.5.2 Gas pressure inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.5.3 Gas discharging procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.5.4 Gas injecting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.6 Home position calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.6.1 Registering all axes at the time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.6.2 Registering individual axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.6.3 Changing the absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.6.4 Clearing absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.7 Setting the second home position (check point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.7.1 Purpose of position check operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.7.2 Procedure for the second home position setting . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.7.3 Procedure after alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.8 Zeroing Function (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.8.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.8.2 Overview and operation Reset to zero device YasXzero. . . . . . . . . . . . . . . . . . . 83
9.8.3 Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.8.4 Positions for the reset sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.8.5 Error and solutions during resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10
Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
11
Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.1 S-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.2 L-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.3 For R-, B- and T-axes drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
11.4 U arm unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
11.5 Wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4
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 GmbH. The robot is
normally supplied with the robot controller, programming pendant, and robot cable.
The terms are designated as follows in this manual:
Terms
Designation
Controller
Robot controller
Industrial robot
Robot
Programming pendant (teach box)
Programming pendant or PP
Cable between the robot and the robot con- Cable
troller
Robot, robot controller, and cable
Robot system
Yaskawa Electric Corporation
YEC
YASKAWA Europe “Robotics Division”
YEU-R
Movement, calibration, and setup of the robot
Teach
Sequence of movements of the robot
JOB
Technical Customer Service
TCS
Personal Computer
PC
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 control
•
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 more detailed information on the training
programs, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA
branch office.
1.4
Intended use
Typical applications:
1-6
•
Flange-mounting tools
•
Installation of spot welding guns
•
Installation of arc welding equipment
•
Installation of grippers
•
Machining and transporting workpieces or products
General
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.
1-7
General
1.6
About this manual
NOTICE
1-8
•
This manual describes the mechanics of the robot for the purpose of operation,
maintenance and inspection. It contains information on safety and handling, technical
data, the tools and materials required for maintenance and inspection and instructions
for operation and maintenance. Read this manual carefully and make sure you are
familiar with its contents before installing and operating the robot..
•
To ensure correct and safe operation, carefully read the operating instructions of the
robot controller ("Basic Information," "Setup," and "Connection 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 unauthorised
modification of the system. 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.
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 robot check the function of the emergency stop button. The
SERVO power has to immediately go off once the emergency stop button on the
programming pendant has been pressed (see).
 When the SERVO power is turned OFF, the SERVO ON LED on the programming
pendant goes off (see ).
SERVO ON
Fig. 1-2: LED SERVO ON
Fig. 1-3: Emergency Stop button
1-9
General
WARNING!
Death or injury because of danger of crushing
Before you release the emergency stop button (see ) 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 power by pressing the enable switch 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. The emergency stop button is
located on the programming pendant (see ).
Observe the following precautions when performing teaching operations within the robot’s
working range:
 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
measures have been performed.
1 - 10
•
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 control after use.
•
Make sure that the key for the key 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.
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 - 11
Supply
2
Supply
2.1
Checking the scope of delivery
The standard delivery includes the following items:
1
2
DX200
3
MOTOMAN
MANUAL
4
5
Fig. 2-1: Scope of delivery
1 Programming pendant
2 Robot controller
3 Robot
2 - 12
4 Assembly instruction
5 Cable
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 XXXXX
Part No.
Power Supply Peak
AC XXXXXXXX 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 - 13
Transportation
3
Transportation
CAUTION!
Personal injury or material damage
The system consists of precision components. Failure to observe this caution may
adversely affect performance.
 Crane and forklift trucks must be performed only by authorised personnel. The same
applies to the application of loops.
 Avoid excessive vibration or shock during transportation.
 No external forces may be exercised on the robot control, the robot or other
components.
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.
3 - 14
•
Check that the eyebolts are securely fastened.
•
The robot weights approximately 970 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.
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".
Using a crane
1 Position of the center of gravity
2 Wire rope (length: 2000 mm
or longer)
3 Shipping brackets and bolts1
4 8 screws M20 x 701, 8 spring
washers M20
1539
1610
1102
1. Must be mounted prior to transportation.
The robot is equipped with transport securing devices and shipping bolts to reduce external
forces to a minimum during transport
3 - 15
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. Make sure that the forklift and the transportation route have
sufficient bearing capacity.
Always take due care when transporting the robot.
Using a forklift
1 Shipping brackets
2 Pallet
3 - 16
3
8 screws M20
4
Openings for the fork prongs
Transportation
3.2
Shipping brackets and bolts
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.
•
The transportation brackets and the transportation pad in the figure are painted yellow.
1
2
3
1
Hook
2
Front view
3
Side view
3 - 17
Transportation
3.3
Damping material during transportation
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.
The robot is furnished with damping material for transportation (see section A and B in the ).
1
1
2
A
3
4
B
Fig. 3-1: Damping material during transportation
3 - 18
1
Housing
3
L-arm
2
U-arm
4
Mechsnical operation limit
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
Protection measures
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
material damage.
Implement the following protection measures
 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 - 19
Installation
4.2
Ambient conditions and installation location
When installing a robot, it is necessary to satisfy the undermentioned environmental
conditions:
4 - 20
•
Ambient temperature: From 0°C to +45°C.
•
Air humidity: 20% to 80% relative humidity (non-condensing).
•
Free of corrosive gases, liquids, or explosive gases. No water, oil or 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.
Installation
4.3
Installation example
1. At the first set out, anchor the base plate firmly onto the floor.
2. The robot base is tapped for 8 mounting holes. Fix the robot base with the screws M20
(strength class 12.9) Minimum length: 80 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 of
the robot on the base plate“).
1
2
3
40
4
6
5
7
230±0.1
185±0.1
420
420
8
500
230±0.1
9
295±0.1
10
185±0.1
10
320
500
11
745
Fig. 4-1: Mounting the robot on the base plate
1
Screws
7
Anchor bolt (M20 or greater)
2
Spring washer
8
2 holes Ø 20 H7
3
4
Washer
9
8 holes Ø 20
Robot base
10
Mating surfaces
5
6
Base plate
11
adhesive
at least 40 mm
NOTICE
 YASKAWA Europe recommends to use the robot only with a base plate.
 Please contact the manufacturer of the mounting material you use
4 - 21
Installation
Direction of movement
Emergency stop
Horizontal
Vertical
Force FH
Moment MH
Force FV
Torque MV
24000 N
37630 Nm
15680 N
49000 Nm
6370 N
9400 Nm
4900 N
22050 Nm
(Stop category 0)
Acceleration/Deceleration
(Stop category 1)
Tab. 4-1: Forces and torques
MV
FV
MH
FH
Fig. 4-2: Robot Force and Torque
4 - 22
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 the applicable electrical installation standards and wiring regulations for earthing.
The cable cross-section must be 6 mm² or more.
With regard to the direct connection of the earthing cable, see figure “Earthing connection”
NOTICE
Note on the earthing connection
Never use the earthing cable together with an earthing cable of, for example:
 A different electrical consumer
 A different motor-driven consumer
 Welding devices, etc.
If the earthing cable is laid in a metal duct, metal conduit or some other metal system, this
must be earthed in accordance with the applicable electrical installation standards.
5 - 23
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. 5-1: Connecting the robot system
Two cables are delivered with the robot (refer to ).
•
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. 5-2: Robot cable
5 - 24
1
Robot control side
3
Encoder cable (1BC)
2
Robot side
4
Power cable (2BC)
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).
3BC
3BC
1BC
2BC
1BC
2BC
Fig. 5-3: Connector plate of the robot
5 - 25
Wiring
5.2.2
Connection of the robot controller
Attach the robot cables in the following order.
1. Connect the encoder cable (1BC) X11 at 1BC connection to the robot controller.
2. Connect the power cable (2BC) X21 at 2BC connection 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. 5-4: Connection of the robot controller
5 - 26
Wiring
5.2.3
Connecting the programming pendant
Connect the programming pendant cable to the connection (X81) (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. 5-5: Connection programming pendant
1
Alignment marks
5 - 27
Technical data
6
Technical data
Type:
A00
Types of Mounting:
Floor mounting
Degree of freedom:
6
Payload:
180 kg
1
Repeatability:
±0.2 mm
Power consumption:
5.0 kVA
Weight:
970 kg
Working area of main axes:
S-axis (turning)
-180° ~ +180°
L-axis (lower arm)2
-60° ~ +76°
U-axis (upper arm)²
-147° ~ +90°
Working area wrist axes:
R-axis (wrist roll)²
-360° ~ +360°
B-axis (wrist yaw/pitch)
-130° ~ +130°
T-axis (wrist twist)
-360° ~ +360°
Protection class (IP):
Main axes
54
Wrist axes
67
Maximum speed:
S-axis
2.18 rad/s, 125°/s
L-axis
2.01 rad/s, 115°/s
U-axis
2.18 rad/s, 125°/s
R-axis
3.18 rad/s, 182°/s
B-axis
3.05 rad/s, 175°/s
T-axis
4.63 rad/s, 265°/s
Allowed moment (Nm):3
R-axis
1000 Nm
B-axis
1000 Nm
T-axis
618 Nm
Permissible moment of inertia (kgm²):
R-axis
90 kgm² kg
B-axis
90 kgm²
T-axis
46,3 kgm²
Sound pressure level (dB):4
76 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. Sound pressure level measured according to ISO 11201 (EN31201). 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 - 28
Technical data
6.1
Parts and work axis label
L-
U+
R+
B+ T+
U-
R-
B-
T-
L+
S+
S-
Fig. 6-1: Part names and working axes
6.2
Robot base dimension
Fig. 6-2: Robot base dimensions
1
2 holes Ø 20 H7
3
2
8 mounting holes Ø 22
All dimensions in mm
Mating surfaces
6 - 29
Technical data
6.3
Dimensions and defined working area
2
1
Fig. 6-3: Dimensions and defined work area
1
P point
All dimensions in mm
6 - 30
2
Working area, defined with point P
Technical data
6.4
Adjustable working area
The work area of the s-axis may be changed depending on the type of application.
If any modification is necessary, please contact the local YASKAWA branch office.
Item
S-axis working range
Specifications
± 180° (standard)
± 150°
± 120°
± 90°
± 60°
± 30°
The mechanical stop can only be adjusted in 60° steps
6 - 31
Technical data
6.4.1
Components for Changing the Working Area
To change the working area of S-axis, the following components are required (see the
following figure).
1
2
3
4
A
A
Fig. 6-4: Components of the S-axis limit
6 - 32
1
4 M16 x 35 screws (strength category
12.9) and 4 M16 washers
3
Section A-A
2
Limitation
4
Pin
Technical data
6.4.2
Adjusting the S-Axis Pulse Limit
If you want to change the movement range of S-axis, follow the instructions in the System
Setup Manual, section: "Changing the Parameter Setting".
–
Pulse limit [positive direction (+) of S-axis]: SICxG400.
–
Pulse limit [negative direction (+) of S-axis]: SICxG408.
Degree

± 15°
± 30°
± 45°
± 60°
± 75°
± 90°
Number of
pulses
±0
±28672
±57344
±86016
±114688
±143360
±172032
Degree

± 120°
± 135°
± 150°
± 165°
± 180 (standard)
Number of
pulses
±20070
4
±22937
6
±258048
±286720
±315392
±344064
NOTICE
To change the movement range of the machine, set both the pulse limit and the angle of the
mechanical S-axis limit.
1
2
3
Fig. 6-5: Adjustable angle for the S-axis limit
1
2
The angle for S-axis limit in positive direction
3
Yellow: Adjustable angle
White: Non-adjustable angle
The angle for S-axis limit in negative
direction
1
1
2
1
Screw
2
The model shown at an angle of 180°
3
3
The model shown at an angle of 165°
6 - 33
Technical data
1
1
2
3
1
Screw
2
The model shown at an angle of 150°
3
The model shown at an angle of 135°
1
1
2
1
Screw
2
The model shown at an angle of 120°
3
3
1
1
2
6 - 34
1
Screw
2
The model shown at an angle of 90°
The model shown at an angle of 105°
3
3
The model shown at an angle of 75°
Technical data
1
1
2
1
Screw
2
The model shown at an angle of 60°
3
The model shown at an angle of 45°
3
1
1
2
1
Screw
2
The model shown at an angle of 30°
3
The model shown at an angle of 15°
3
1
2
1
Screw
2
The model shown at an angle of 0°
6 - 35
Technical data
6.5
Stopping Angle and Time at the Emergency Stop
The definition of the coastdown times is important for determining the safety distance for
protective devices. 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 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 following diagrams show only the values for the S, L, and U axes since these axes have
the largest deflection. For a safety stop with stop category 0, the mean values determined
through testing and simulation are specified.
The actual overrun distances and overrun times may differ due to internal and external
influence on the braking torque. According to the mode, robot application, and number of
triggered safety stops with stop category 0, a different brake wear may occur. We
recommend that the coastdown path be checked once a year.
100%
66%
33%
Fig. 6-6: Main axes at 100%, 66%, and 33% deflection
In the S, L, and U axes are shown at 33%, 66%, and 100% deflection according to DIN EN
ISO 10218-1.
In these three positions, the coastdown paths and coastdown times were determined during
a safety stop with stop category 0 and stop category 1. In the following diagrams, they are
specified at payloads of 33%, 66%, and 100%.
The pertinent legend can be found in the following table:
6 - 36
Definitions
Description
Load 100%
pink
Load 66%
green
Load 33%
gray
Load 100%
blue
Overrun distance degrees°
[deg]
Overrun time second
[sec]
Robot speed degrees°/second
[deg/s]
Technical data
6.5.1
Stop category 0
6.5.1.1
Stop position S-axis
•
100% deflection
㻠㻜
㻝㻘㻜
㻟㻡
㻜㻘㻥
㻜㻘㻤
㻜㻘㻣
㻞㻡
[sec]
[deg]
㻟㻜
㻞㻜
㻜㻘㻢
㻜㻘㻡
㻜㻘㻠
㻝㻡
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡
㻜㻘㻝
㻜
㻜㻘㻜
㻜
㻞㻜
㻠㻜
㻢㻜
㻤㻜
㻝㻜㻜
㻜
㻝㻞㻜
㻞㻜
㻠㻜
[deg/s]
•
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻤㻜
㻝㻜㻜
㻝㻞㻜
66% deflection
㻠㻜
㻝㻘㻜
㻟㻡
㻜㻘㻥
㻜㻘㻤
㻜㻘㻣
㻞㻡
[sec]
[deg]
㻟㻜
㻞㻜
㻜㻘㻢
㻜㻘㻡
㻜㻘㻠
㻝㻡
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡
㻜㻘㻝
㻜㻘㻜
㻜
㻜
㻞㻜
㻠㻜
㻢㻜
㻤㻜
㻝㻜㻜
㻜
㻝㻞㻜
㻞㻜
㻠㻜
[deg/s]
㻢㻜
[deg/s]
33% deflection
㻜㻘㻡
㻠㻜
㻟㻡
㻜㻘㻠
㻟㻜
㻞㻡
[sec]
[deg]
•
㻢㻜
[deg/s]
㻞㻜
㻜㻘㻟
㻜㻘㻞
㻝㻡
㻝㻜
㻜㻘㻝
㻡
㻜㻘㻜
㻜
㻜
㻞㻜
㻠㻜
㻢㻜
[deg/s]
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻜
㻞㻜
㻠㻜
㻢㻜
[deg/s]
6 - 37
Technical data
6.5.1.2
100% deflection
[sec]
[deg]
•
Stop position L-axis
[deg/s]
•
[deg/s]
66% deflection
㻠㻜
㻝㻘㻜
㻟㻡
㻜㻘㻥
㻜㻘㻤
㻜㻘㻣
㻞㻡
[sec]
[deg]
㻟㻜
㻞㻜
㻜㻘㻢
㻜㻘㻡
㻜㻘㻠
㻝㻡
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡
㻜㻘㻝
㻜㻘㻜
㻜
㻜
㻞㻜
㻠㻜
㻢㻜
㻤㻜
㻝㻜㻜
㻜
㻝㻞㻜
㻞㻜
㻠㻜
[deg/s]
•
㻢㻜
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻤㻜
㻝㻜㻜
㻝㻞㻜
[deg/s]
33% deflection
㻜㻘㻡
㻠㻜
㻟㻡
㻜㻘㻠
㻞㻡
[sec]
[deg]
㻟㻜
㻞㻜
㻜㻘㻟
㻜㻘㻞
㻝㻡
㻝㻜
㻜㻘㻝
㻡
㻜
㻜㻘㻜
㻜
㻞㻜
㻠㻜
㻢㻜
[deg/s]
6 - 38
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻜
㻞㻜
㻠㻜
㻢㻜
[deg/s]
Technical data
6.5.1.3
•
Stop position U-axis
100% deflection
㻠㻜
㻝㻘㻜
㻟㻡
㻜㻘㻥
㻜㻘㻤
㻟㻜
[sec]
[deg]
㻜㻘㻣
㻞㻡
㻞㻜
㻜㻘㻢
㻜㻘㻡
㻜㻘㻠
㻝㻡
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡
㻜㻘㻝
㻜
㻜
㻞㻜
㻠㻜
㻢㻜
㻤㻜
㻝㻜㻜
㻜㻘㻜
㻝㻞㻜
㻜
㻞㻜
㻠㻜
[deg/s]
•
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻤㻜
㻝㻜㻜
㻝㻞㻜
66% deflection
㻠㻜
㻝㻘㻜
㻟㻡
㻜㻘㻥
㻜㻘㻤
㻜㻘㻣
㻞㻡
[sec]
[deg]
㻟㻜
㻞㻜
㻜㻘㻢
㻜㻘㻡
㻜㻘㻠
㻝㻡
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡
㻜㻘㻝
㻜
㻜㻘㻜
㻜
㻞㻜
㻠㻜
㻢㻜
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻜
㻞㻜
㻠㻜
[deg/s]
㻢㻜
[deg/s]
33% deflection
㻜㻘㻡
㻠㻜
㻟㻡
㻜㻘㻠
㻟㻜
㻞㻡
[sec]
[deg]
•
㻢㻜
[deg/s]
㻞㻜
㻜㻘㻟
㻜㻘㻞
㻝㻡
㻝㻜
㻜㻘㻝
㻡
㻜
㻜㻘㻜
㻜
㻞㻜
㻠㻜
㻢㻜
[deg/s]
㻤㻜
㻝㻜㻜
㻝㻞㻜
㻜
㻞㻜
㻠㻜
㻢㻜
[deg/s]
6 - 39
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.
6.5.2.1
[sec]
100% deflection
[deg]
•
Stop position S-axis
[deg/s]
[sec]
66% deflection
[deg]
•
[deg/s]
[deg/s]
[sec]
33% deflection
[deg]
•
[deg/s]
6 - 40
[deg/s]
[deg/s]
Technical data
6.5.2.2
[sec]
100% deflection
[deg]
•
Stop position L-axis
[deg/s]
[sec]
66% deflection
[deg]
•
[deg/s]
[deg/s]
33% deflection
1.0
40
0.9
35
0.8
30
0.7
25
0.6
20
0.5
[sec]
[deg]
•
[deg/s]
15
10
0.4
0.3
0.2
0.1
5
0.0
0
20
40
60
[deg/s]
80
100
120
0
20
40
60
80
100
120
[deg/s]
6 - 41
Technical data
6.5.2.3
[sec]
100% deflection
[deg]
•
Stop position U-axis
[deg/s]
[sec]
66% deflection
[deg]
•
[deg/s]
[deg/s]
[sec]
33% deflection
[deg]
•
[deg/s]
6 - 42
[deg/s]
[deg/s]
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 home position marks can be seen at all times, the tool may only be flangemounted with the inner diameter. Fitting depth of inside fittings must be 8 mm.
NOTICE
Before mounting a tool, remove anticorrosive coating on the flange. Thinner or light fuel oil
are the most suitable for this purpose.
9
10
Fig. 7-1: Wrist flange
2 Holes Ø 9H7 x 8
5
Pitch circle Ø 92
2 Holes Ø 10H7 x 8
6
Ø 63H7
3 Pitch circle Ø 125
4 6 M10 x 14 threaded holes
All dimensions in mm
7
8
Ø 160h7
1
2
Alignment marks
7 - 43
Allowable load for wrist axis and wrist flange
7.2
Allowable Wrist Load
The allowable wrist loads amounts to a maximum of 180 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 help, please contact your YASKAWA branch office.
Axis
Allowable torque (Nm)
Allowable moment of inertia (kgm²)
R-axis
1000 Nm
90 kgm² kg
B-axis
1000 Nm
90 kgm²
T-axis
618 Nm
46,3 kgm²
Tab. 7-1: Allowable torque and allowable moment of inertia
Keep the centroidal distance of the load/mass within the specifications; refer to the following
figure, "Hand loads."
Fig. 7-2: Hand loads
1
P point
3
B-axis centre of rotation
2
R-axis/T-axis centre of rotation
All dimensions in mm
The peripheral devices are mounted on the upper arm of the U axis and the rotating head
of the S axis (see the following figure) to facilitate the installation of the system applications
of the user. The following conditions should be observed to attach or install peripheral
equipment.
7 - 44
Allowable load for wrist axis and wrist flange
1
A3
A1
A3
3
2
A3
1
A1
4
A1
B
5
A2
B
6
B
5
1
Fig. 7-3: Installing peripheral equipment mounts
1
4 threaded holes M8 x 14
4
4 threaded holes M12 x 24
2
2 threaded holes M5 x 9
5
4 threaded holes M20 x 39
3
2 threaded holes M6 x 11
6
4 threaded holes M6 x 11
A1, A2 and
A3
Wiring and valve
load
30 kg maximum.
B
Other
max. 250 kg
Not more than 49 Nm for increasing the torque of
the upper arm
7 - 45
Allowable load for wrist axis and wrist flange
The permissible moment of inertia is calculated when the permissible torque reaches the
maximum value. The permissible moment of inertia for the T-axis varies and depends on
the permissible torque.
Contact your YASKAWA branch office in a timely manner if you have questions regarding
the calculation of the load or centroidal distance.
Example:
In the case of the YASKAWA HP20D robot, for example, the permissible moment of inertial
for the T-axis amounts to 0.25 kgm² at a permissible torque of 19.6 Nm and to 0.75 kgm² at
a permissible torque of 0.1 Nm.
7 - 46
Internal cables and compressed air lines
8
Internal cables and compressed air lines
Internal cables (23 wires 11 x 0.75 mm² and 12 x 0.5 mm²) and cables for the external
axes(4 wires x 2.00 mm², 2 wires x 0.75 mm² and 5 wires x 0.20 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 23 (1 to 16) are assigned as shown in the following figure. Wiring must be
performed by the user.
The following requirements must be met:
•
The current-carrying capacity per single conductor (cross-section 2.00 mm², 0.75 mm²,
0.50 mm² and 0.20 mm²) must not exceed 16.1 A or less at 2.00 mm², 5.0 A at 0.75
mm², 3.5 A at 0.50 mm² and 2.3 A at 0.2 mm² .
•
The air pressure for the air hose must not exceed 600 kPA (the inner diameter of the air
hose is Ø 8 mm).
1 Exhaust port (air flow)
with locking cap (PT3/8)
2 Connector for the external axis (power cable ).
3 Connector for the external axis (encoder cable ).
4 Connector for the internal
wiring harness on casing
cover.
5 Connector for the internal
wiring harness on casing
cover.
6 Air inlet with locking cap
(PT3/8)
8 - 47
Internal cables and compressed air lines
2
5
4
6
2
3
7
4
8
9
4
6
1
10
Fig. 8-1: Detailed drawing of connector

= used

= not used
1
Connector plug for the internal cable
feedthrough
6
shielded line
2
6 pins x 0.50 mm²
7
Connecting plug for the encoder cable
for the external axes
3
11 pins x 0.75 mm²
8
4 pins x 2.00 mm²
4
Pins used
9
2 pins x 0.75 mm²
5
6 pins x 0.20 mm²
10
Connecting plug for the mains cable
for the external axes
The pins used on the connectors (23 wires 11 x 0.75 mm² and 12 x 0.5 mm²) and cables for
the external axes(4 wires x 2.00 mm², 2 wires x 0.75 mm² and 5 wires x 0.20 mm²) are
connected to the stand and arm with individual wires.
The internal connections of the robot are shown in the following diagrams "Connection
diagram A" and "Connection diagram B".
8 - 48
DX200
SPG+3
SPG-3
FG3
SPG+4
SPG-4
FG4
SPG+5
SPG-5
FG5
SPG+6
SPG-6
FG6
CN2-1
CN2-2
CN2-3
CN2-6
CN2-7
CN2-8
CN3-1
CN3-2
CN3-3
CN3-6
CN3-7
CN3-8
CN4-4
CN4-5
CN4-9
P
P
SPG+3
SPG-3
FG3
SPG+4
SPG-4
FG4
SPG+5
SPG-5
FG5
SPG+6
SPG-6
FG6
SPG+GUN
SPG-GUN
FG-GUN
0V
5V
0V
5V
CN2-1
CN2-2
CN2-3
CN2-6
CN2-7
CN2-8
CN3-1
CN3-2
CN3-3
CN3-6
CN3-7
CN3-8
CN4-4
CN4-5
CN4-9
CN3-4
CN3-5
CN3-9
CN3-10
P
P
P
+24V
LD1
FG7
+24V
+24V
LB1
SS2
AL1
BC2
AL2
0V
CN2-4
CN2-5
CN2-9
CN2-10
CN4-1
CN4-6
CN4-2
CN4-7
CN4-3
CN4-8
CN4-10
P
P
P
P
P
P
CN4-10
E
0V
BC2
SS2
CN4-2
CN4-7
CN4-3
CN4-8
+24V
LB1
+24V
+24V
LD1
0V
5V
0V
5V
CN4-1
CN4-6
CN2-4
CN2-5
CN2-9
CN2-10
CN3-4
CN3-5
CN3-9
CN3-10
FG2
CN1-8
FG2
CN1-8
P
SPG+GUN
SPG-GUN
FG-GUN
SPG+2
SPG-2
CN1-6
CN1-7
SPG+2
SPG-2
CN1-6
CN1-7
CN1-3
FG1
CN1-3
P
FG1
CN1-1
CN1-2
SPG+1
SPG-1
CN1-1
CN1-2
P
SPG+1
SPG-1
CN1-10
CN1-9
+24V
0V
CN1-10
CN1-9
+24V
0V
+24V
0V
1BC(10×4)
CN1-5
CN1-4
P
+24V
0V
CN1-5
CN1-4
5
6
7
8
0BT
P BAT
0BT
P BAT
-2
-4
-3
+24V
0V
0V
No.24CN X
-1
+24V
1
2
3
4
5
6
7
8
1
2
3
4
0BT
P BAT
0BT
P BAT
0BAT21
BAT21
0BAT22
BAT22
0BAT11
BAT11
0BAT12
BAT12
2
4
1
3
SS2
SS1
Base
E
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
0BAT4
BAT4
0BAT5
BAT5
0BAT6
BAT6
0BAT7
BAT7
PG0V1
PG5V1
PG0V2
PG5V2
PG0V3
PG5V3
PG0V4
PG5V4
PG0V5
PG5V5
PG0V6
PG5V6
PG0V7
PG5V7
0BAT1
BAT1
0BAT2
BAT2
0BAT3
BAT3
Robot
B1
A1
LC1
LA1
LD1
LB1
LC1
LA1
LB1
No.24CN
7
-1
BAT7
-2
0BAT7
-3
PG5V7
-4
PG0V7
No.23CN
T
-1
BAT6
-2
0BAT6
-3
PG5V6
-4
PG0V6
No.22CN
B
-1
BAT5
-2
0BAT5
-3
PG5V5
-4
PG0V5
No.21CN
R
BAT4
-1
0BAT4
-2
PG5V4
-3
-4
PG0V4
No.20CN
U
BAT3
-1
0BAT3
-2
-3
PG5V3
PG0V3
-4
No.19CN
L
-1
BAT2
-2
0BAT2
PG5V2
-3
PG0V2
-4
LC3
LD3
B2
BC1
BC2
No.7CN
7CN-1
-2
-11
-12
-10
-9
-15
DATA+3
DATA-3
BAT
OBT
+5V
0V
FG3
OBT
BAT
DATA+2
DATA-2
BAT
OBT
+5V
0V
FG2
OBT
BAT
DATA+1
DATA-1
BAT
OBT
+5V
0V
FG1
OBT
BAT
PG
PG
PG
DATA+GUN
DATA-GUN
BAT
0BT
0V
+5V
FG-GUN
A3
PG
PG
PG
T-AXIS
B-AXIS
R-AXIS
For Lamp (o ptional)
B3
B2
B1
A3
A2
A1
B3
DATA+6
DATA-6
BAT
OBT
+5V
0V
FG6
OBT
BAT
DATA+5
DATA-5
BAT
OBT
+5V
0V
FG5
OBT
BAT
DATA+4
DATA-4
BAT
OBT
+5V
0V
FG4
OBT
BAT
U-AXIS
L-AXIS
S-AXIS
Gun
No.6CN
6CN-1
-2
-6
-5
-4
-9
-10
No.5CN
5CN-1
-2
-6
-5
-4
-9
-10
No.4CN
4CN-1
-2
-6
-5
-4
-9
-10
LC3
LD3
A2
No.3CN
3CN-1
-2
-6
-5
-4
-9
-10
No.2CN
2CN-1
-2
-6
-5
-4
-9
-10
No.1CN
1CN-1
-2
-6
-5
-4
-9
-10
LA3
LB3
Housing
LC2
LD2
LA2
LB2
Connected to
Connected to
L and U-axes interference L.S. Connected to
Overrun limit switch L axis
LB2
LB1
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
Connected to
Connected to
L and U-axes interference L.S. Connected to
Overrun limit switch L axis
Overrun limit switch S axis
LA3
LB3
Overrun limit switch S axis
LD2
LD1
LD1
LD2
LB1
LB2
LC2
LD2
LA2
LB2
SLU axes with limit switch specifications
LD2
LD1
LD1
LD2
LD1
LB2
LB1
LB1
LB2
No.18CN
S
-1
BAT1
-2
0BAT1
-3
PG5V1
-4
PG0V1
LC1
LD1
Overrun limit switch S axis Connected to B1
Overrun limit switch S axis Connected to A1
S-Axis limit switch specification
LC1
LD1
LC1
LD1
LA1
LB1
LA1
LB1
LA1
LB1
Note: The connecting terminal A and B for the indication of the end switch has been changed as follows:
Internal cables and compressed air lines
Fig. 8-2: Connection diagram for internal connections (a)
8 - 49
8 - 50
PE
MU2
MU2
MV2
MV2
MW2
MW2
ME2
ME2
BA2
MU3
MU3
MV3
MV3
MW3
MW3
ME3
ME3
BA3
MU4
MV4
MW4
ME4
BA4
BB4
MU5
MV5
MW5
ME5
BA5
F-8
F-7
F-2
F-1
F-6
F-5
F-4
F-3
B-4
D-8
D-7
D-4
D-3
D-6
D-5
D-2
D-1
B-3
A-6
A-3
A-1
A-5
B-2
B-9
C-11
C-9
C-7
C-8
B-12
C-6
C-4
C-2
C-5
B-11
A-11
A-9
A-2
A-4
B-8
B-7
MU2
MU2
MV2
MV2
MW2
MW2
ME2
ME2
BA2
MU3
MU3
MV3
MV3
MW3
MW3
ME3
ME3
BA3
MU4
MV4
MW4
ME4
BA4
BB4
MU5
MV5
MW5
ME5
BA5
MU6
MV6
MW6
ME6
BA6
MU7
MV7
MW7
ME7
BA7
BB7
F-8
F-7
F-2
F-1
F-6
F-5
F-4
F-3
B-4
D-8
D-7
D-4
D-3
D-6
D-5
D-2
D-1
B-3
A-6
A-3
A-1
A-5
B-2
B-9
C-11
C-9
C-7
C-8
B-12
C-6
C-4
C-2
C-5
B-11
A-11
A-9
A-2
A-4
B-8
B-7
Fig. 8-3: Connection diagram for internal connections (b)
MU7
MV7
MW7
ME7
BA7
BB7
MU6
MV6
MW6
ME6
BA6
MU1
MU1
MV1
MV1
MW1
MW1
ME1
ME1
BA1
BB1
E-8
E-7
E-2
E-1
E-6
E-5
E-4
E-3
B-5
B-10
E
2BC(8PX3+12PX3)
MU1
MU1
MV1
MV1
MW1
MW1
ME1
ME1
BA1
BB1
E
E-8
E-7
E-2
E-1
E-6
E-5
E-4
E-3
B-5
B-10
2BC
MU3
MV3
MW3
ME3
BA3
BB3
-1
-2
BA2
BB2
-1
-2
No.11CN
11CN-A
-B
-C
-D
MU2
MV2
MW2
ME2
BA1
BB1
MU1
MV1
MW1
ME1
No.10CN
10CN-A
-B
-C
-D
-1
-2
No.9CN
9CN-A
-B
-C
-D
YB
SM
YB
SM
YB
SM
U-axis
L-axis
S-axis
BA4
BB4
MU5
MV5
MW5
ME5
BA5
BB5
MU6
MV6
MW6
ME6
BA6
BB6
-1
-2
No.13CN
13CN-A
-B
-C
-D
-1
-2
No.14CN
14CN-A
-B
-C
-D
-1
-2
1
2
3
4
5
6
E
MU7
MV7
MW7
ME7
BA7
BB7
No15CN(18-1)
MU4
MV4
MW4
ME4
No.12CN
12CN-A
-B
-C
-D
Servo gun
YB
SM
YB
SM
YB
SM
T-axis
B-axis
R-axis
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 required warning sign, 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 unit.
9 - 51
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 ).
 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+
S-
L-
CANCEL
ASSIST
SERVO ON
S+
AREA
SELECT
SERVO
ON
READY
SIMPLE
MENU
X-
HIGH
SPEED
L+
X+
R-
R+
Y-
Y+
Z-
Z+
T-
T+
B-
B+
FAST
Z-
U-
Z+
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
MOTION
TYPE
0
.
-
MODIFY
ENTER
SHIFT
AUX
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
The numbers in the above figure are equal to the numbers in the table of "Inspection
intervals".
9 - 52
2 YASKAWA trained staff
3 YASKAWA personnel
Maintenance and inspection
1 Trained staff
9 - 53
Operation
36000
Method
24000
12000
6000
1000
Schedule (h)
Daily
Item number1
To be performed by:
1
2
3
1
Alignment marks

Visual inspection
Check alignment mark correspondence and
damage at the zero position.



2
External cables

Visual inspection
Check cables for damage.



3
Working area and robot

Visual inspection
If the working area is dirty, it must be cleaned.
Check the robot for damage and external cracks.



4
Motors for L and U-axes

Visual inspection
Check for grease discharge.2.



5
Fastening bolts of the base
plate

Using a corresponding tool,
tighten loose screws (replace if necessary).



6
Fixing screws of the cover

Using a corresponding tool,
tighten loose screws (replace if necessary).



7
S-, L-, and U-axes motor connection

Manually
Check for loose plug connections (tighten if necessary).



8
Power input module

Manually
Check for loose connections.



9
Balancer unit

Grease gun
The grease has to be refilled every 6000 hours
(see chapter 9.4.3 "Grease replenishment for
balancer link part" on page 65).



Special tools for
maintenance
Check the gas pressure every 6000 hours. If the
gas pressure is not correct, fill the Gas Balancer
(see chapter 9.5 "Gas maintenance procedure in
the gas balancer" on page 66).


Maintenance and inspection
9 - 54
Inspection intervals
10
Cable harness in robot
Visual inspection
with multimeter

Battery unit in robot
12
S, L, U, R, B and T-axes gear

Check the bushing between the connector on
the stand and the intermediate connectors by
manually moving the wires. Check the protective
coil.3).
2
3


Exchange4


To be performed by:
1

11
Operation
36000
Method
24000
12000
6000
1000
Schedule (h)
Daily
Item number1
Grease gun

If a battery alarm appears or after the robot has
been operated for 36000 hours, the battery must
be exchanged.


Check for malfunctions (replace if necessary).
The grease5 must be refilled every 6000 hours
and exchanged every 12000 hours (see Chapter
9.4.1 "Grease filling the main axes" and 9.4.2
"Grease filling the wrist axes").


Maintenance and inspection
Inspection intervals
9 - 55
13
Overhaul
Operation
36000
Method
24000
12000
6000
1000
Schedule (h)
Daily
Item number1
To be performed by:
1

2
3

1. The item numbers correspond with the following figure, "Inspection intervals."
2. The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. The damage can be damaged as a result. In case of questions, please contact your YASKAWA
branch office.
3. When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of the plug connections of the respective motor. Then remove the connectors of the encoders of the
respective motor; if this is not observed, the zero positions are lost.
4. 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.
5. The lubricants used can be found in the following table, "Inspection points and lubricants used."
Tab. 9-1: Inspection intervals
Maintenance and inspection
9 - 56
Inspection intervals
Maintenance and inspection
Fig. 9-2: Inspection intervals
9 - 57
Maintenance and inspection
9.2
Note on battery unit
9.2.1
Battery pack replacement
3
1
4
2
Fig. 9-3: Battery unit location
3 Battery unit
2 Power input module
4 Circuit board
The battery units are installed as shown in picture "The location of the battery unit".
1
Fastening bolts of cover plate
If battery alarm occuring in the robot controller, battery pack has to be changed in the
following form.
1. Turn the robot controller to the main power supply (see ).
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.
9 - 58
Maintenance and inspection
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.
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 - 59
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 unit connector diagram for S-, L- and U-axes
1
2
Motor
4
Battery unit
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.
1
9
2
8
7
OBT
BAT
b OBT4
a BAT4
a
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 unit connector diagram for R-, B- and T-axes
9 - 60
1
2
Encoder
6
Warning label
Motor cable
7
Power connector
3
Battery unit
8
Wiring harness of the robot
4
a: Plug - socket
b: Plug - pin
9
Motor
5
Encoder connector
Maintenance and inspection
9.3
Note on maintenance
NOTICE
The absolute encoder data will be lost.
Removing the encoder connector without connecting the battery pack results in the
disappearance of the encoder absolute data.
 When performing maintenance such as replacement of a wire harness in the robot, the
encoder connector may be necessary to be removed. In this case, be sure to connect
the battery pack to the battery backup connector before removing the encoder
connector. The battery connectors are dealt with in the chapter 9.2.1 "Battery pack
replacement"on page 58.
9 - 61
Maintenance and inspection
9.4
Refill/Replace grease.
Make sure to follow the instructions. If the following instructions are not followed, it might
cause damage to motor or gear.
CAUTION!
Burns from heated grease
The grease may be under pressure and may spray out of the threaded hole when opening
the threaded hole.
 Wear safety goggles
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.
 Lack the labels "IN and" OUT "is generally lubricated from the bottom up.
 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 7 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).
 Install a receptacle at the grease outlet.
 Exchanged grease must be disposed of in an environmentally sound manner.
Lubricants used
Lubricant types
Material no.
Axis
Molywhite RE No. 00
176891
Gear for all axes and R-, B- and T-pinion.
Shell Gadus S2 V220 2
146745
Balancer unit
The safety data sheets for the lubricants can be requested from YEU-R.
9 - 62
Maintenance and inspection
Tightening torque of sealing plug
Designation
Tightening torque (Nm)
PT 3/8
23
PT 1/4
12
PT 1/8
5
PT 1/16
4
1. Remove plug from grease exhaust port (OUT) and grease inlet (IN) port.
Example:
2. Mount the lubricating nipple to the grease inlet opening.
3. Press the grease into the grease inlet opening using a grease gun.
4. To squeeze out the excess fat, all taxes must be brought to operating temperature.
•
In a operating JOB or a special moving JOBs (about 20 minutes at 100% speed).
5. Wipe away excess grease with a cloth.
6. Remove the lubricating nipple from the grease inlet opening and mount the plug again.
Before mounting the plug, apply to thread part.
Amount of grease
Axis types
Refill grease
Replace grease
S-axis
1000 cm³ / approx. 870 g
5000 cm³ / approx. 4350 g1
L-axis
500 cm³ / approx. 435 g
2500 cm³ / approx. 2175 g
U-axis
500 cm³ / approx. 435 g
2500 cm³ / approx. 2175 g
R-axis
330 cm³ / approx. 287 g
2200 cm³ / approx. 1914 g
R-, B- and T-pinion
400 cm³ / approx. 348 g
2600 cm³ / approx. 2262 g
B- and T-axes
B-axis 260 cm³ / approx. 226
g
B-axis 1300 cm³ / approx. 1130
g
Gas balancer type 1 /
type 2
8 cm³ / approx. 7 g
-
1. The grease exchange is complete when new grease appears from the exhaust port. (The new grease can be
distinguished from the old grease by color.)
9 - 63
Maintenance and inspection
9.4.1
Grease filling the main axes
Figures the main axes
S-axis gear
PT3/8
PT1/4
L-axis gear
PT3/8
PT1/8
U-axis gear
PT3/8
PT1/8
1
2
9 - 64
Grease outlet opening
Grease inlet opening
Maintenance and inspection
9.4.2
Grease filling the wrist axes
Figures the wrist axes
R-axis gear
PT1/8
PT1/8
B and T-axis gear
PT1/8
PT1/8
R-, B- and T-axes pinion
PT3/8
PT1/8
1
2
9.4.3
Grease outlet opening
Grease inlet opening
Grease replenishment for balancer link part
Figure the axes
1
Grease outlet type 1
9 - 65
Maintenance and inspection
Figure the axes
2
3
Grease inlet type 1
4
Grease inlet type 2
Grease outlet type 2
9.5
Gas maintenance procedure in the gas balancer
9.5.1
Notes on gas maintenance procedure in the gas balancer
Please read these precautions thoroughly before you perform the gas inspection, or
discharge of the gas, i.e. filling.
WARNING!
Risk of accident and injury when extending or shortening the compensating cylinder.
Risk of suffocation with insufficient ventilation
Before you carry out the gas inspection or discharge of the gas, i.e. filling, check that the
brake of the L-axis motor is working properly and that the L-axis is securely locked.
 The compensating cylinder is nitrogen filled.
 Feed no other gas than nitrogen into the balancer unit.
 When working with nitrogen, the possibility of suffocation exists. Therefore, adequate
ventilation is required during work.
 Before you carry out the gas pressure inspection of the balancer unit or discharge of
the gas, i.e. filling, check that the brake of the L-axis motor is working properly and that
the L-axis is securely locked so that it cannot move. Non-observance can lead to very
dangerous situations by loosening the brake of the L-axis motor. Because the L-axis
causes the rotating of the arm without retaining force.
 When dealing with nitrogen, sufficient caution, as well as compliance with the applicable
laws and regulations of local authorities are required.
 For gas filling devices, contact your YASKAWA service representative.
NOTICE
To maintain the sealing performance, small quantity of oil used may leak from the bottom
part of the gas balancer.
9 - 66
Maintenance and inspection
9.5.2
Gas pressure inspection
NOTICE
Personal injury or damage to property
The operation of the robot with an incorrect gas pressure in the compensating cylinder can
lead to failure or breakage.
 Run the gas pressure test every 6000 hours.
9 - 67
Maintenance and inspection
9.5.2.1
Necessary devices
Make sure you have following devices for checking gas pressure.
Description
Order no.
Digital pressure gauge: FRDSG-1
170839
Tapered roller bearing
168211
Rapid action coupling: T2-770-G1/8
Valve
168213
Valve tool
168214
Thermometer (to measure the surface/level of the compensating cylinder)
Nitrogen - pressure gas cylinders
Gas filling device: Have a suitable facility at hand for the compressed gas cylinders used in your region. For questions, please contact your Yaskawa representative.
9.5.2.2
Adequate gas pressure
Adequate nitrogen gas pressure in the compensating cylinder will vary depending to
temperature.
Refer to the following table.
Compensating cylinder
surface temperature
Adequate gas pressure
(MPa)
-10°
10.5
-5°
10.8
0°
11.1
5°
11.4
10°
11.6
15°
11.9
20°
12.2
25°
12.4
30°
12.7
35°
13.0
40°
13.2
45°
13.5
50°
13.8
55°
14.1
60°
14.4
Tab. 9-2: Adequate gas pressure according to the surface temperature of compensating cylinder
9 - 68
Maintenance and inspection
9.5.2.3
Inspection procedures
WARNING!
 Before you carry out the gas pressure inspection of the compensating cylinder or
discharge of the gas, i.e. filling, check if the brake of the L-axis motor is working properly
and if the L-axis is securely locked for that it cannot move.
 Non-observance can lead to very dangerous situations by loosening the brake of the Laxis motor. Without retaining force due to the extension or shortening, the L-axis causes
the compensating cylinder to rotate the L-arm.
1. Move the robot to home position and turn off the power of the robot control.
2. Remove the cover and insert the quick connector to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve, and gate valve of the gas filling device are firmly closed.
4. Check the compensating cylinder surface temperature.
5. Slowly open the needle valve of the gas filling device, and then check that the pressure
indicated on the digital pressure gauge is satisfying the value shown in table 9.5.2.2
"Adequate gas pressure" on page. 68
Depending on the value, procedures after this are subject to change.
Case 1:
If the value is exceeding the adequate value.
 Discharge the gas till the value satisfies the adequate value (refer to chapter 9.5.3
"Gas discharging procedure" on page 70).
Case 2:
If the value is lower than the adequate value by 0.5 MPa or more.
 Discharge the gas till the value satisfies the adequate value (refer to chapter 9.5.4
"Gas injecting procedure" on page 71).
Not according to case 1 and 2  Proceed to step 6.
6. Close the needle valve of the gas filling device and then remove the gas filling device
from the quick connector.
7. Disconnect the rapid-action coupling and mount the cover (tightening torque 5 Nm).
8. Turn on the power to the robot control.
Pressure testing of gas in the compensating cylinder
1 Gas inlet/outlet
2 2 screws M4 x 6
3 Cover
4 When you dismount/remove
the compensating cylinder
from the robot.
5 Screw M6
1
2
3
5
4
9 - 69
Maintenance and inspection
9.5.3
Gas discharging procedure
NOTICE
In the following cases, drain all gas from the compensating cylinder.
 When you dismount/remove the compensating cylinder from the robot.
 It is considered as dangerous goods, should you transport the robot by plane and the
compensating cylinder is filled with gas.
 When discharging the gas, the blowdown valve must not be fully opened. Take time and
discharge gas little by little. If the blowdown valve is fully opened with high internal
pressure, the non-return valve in the gas balancer can be damaged.
 If you drain all gas
1. Bring the robot to the home position and turn off the power of the robot controller.
2. Remove the cover and insert the rapid-action coupling to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve, and gate valve of the gas filling device are firmly closed.
4. Slowly open the needle valve.
5. Discharge gas a small amount at a time by slowly releasing the blowdown valve.
6. Close the needle valve and blowdown valve and then remove the gas filling device from
the quick connector.
7. Remove the quick connector and mount the cover, then tighten the screw with flange
by using a tightening torque shown in table 9.5.2.2 "Adequate gas pressure".
8. Turn on the power to the robot controller.
 When you let off gas to the pressure setting
1. Bring the robot to the home position and turn off the power of the robot controller.
2. Remove the cover and insert the quick connector to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve and gate valve of the gas filling device are firmly closed.
4. Check the temperature of the gas balancer surface.
5. Slowly open the needle valve.
6. Drain gas by opening the valve of the digital pressure gauge, until pressure will reach
the value according to the table 9.5.2.2 "Adequate gas pressure".
NOTICE
When you let off the gas or fill up, wait some minutes to allow for the stabilization of the gas
pressure and then measure the gas pressure.
7. Close the needle valve and blowdown valve and then remove the gas filling device from
the quick connector.
8. Remove the quick connector, then tighten the screw with flange by using the tightening
torque shown in the table 9.4 "Refill/Replace grease.".
9. Mount the cover and tighten the screws by using the tightening torque shown in the
table 9.4 .
10. Turn on the power to the robot controller.
9 - 70
Maintenance and inspection
9.5.4
Gas injecting procedure
 Gas injecting procedure
WARNING!
Danger of injury in case of unforeseeable robot motion
Releasing the brake of the L -axis motor will lead to loss of the retaining force. As a result
the compensating cylinder will extend or shorten and will lead to the rotation of the L-arm.
 Before you drain or fill the gas from the compensating cylinder, check the brake function
of the L -axis motor.
 The robot should be secured for the L- axis should not move unpredictably.
 Keep safe distance in the direction of movement of the robot axes.
 Keep the appropriate pressure value show in table Tab. 9-2: "Adequate gas pressure
according to the surface temperature of compensating cylinder".
1. Move the robot to the home position and turn off the power of the robot controller.
2. Remove the cover and insert the quick connector to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve and gate valve of the gas filling device are firmly closed.
4. Check the temperature of the gas balancer surface.
5. Connect the nitrogen gas cylinder to the gas filling device.
6. Release the valve of the nitrogen gas cylinder and then set the gas pressure slightly
higher than the adequate pressure shown in table Tab. 9-2: .
7. Slowly open the needle valve of the gas filling device.
8. Release the gate valve of the gas filling device to inject gas until the gas pressure
indicated by the digital pressure gauge is slightly higher than the adequate pressure
shown in table Tab. 9-2: .
9. Close the gate valve of the gas filling device, wait for the gas pressure in the gas
balancer to stabilize and then confirm that the gas pressure is the adequate pressure
shown in table Tab. 9-2: .
If the pressure is higher than the adequate pressure, discharge the gas gradually and
stabilize the gas pressure, then confirm that the gas pressure finally reached the
adequate value.
NOTICE
After draining/filling with gas, wait a few minutes to allow for the stabilization of the gas
pressure and then measure the gas pressure.
10. Close needle valve of the gas filling device and the valve of the nitrogen gas cylinder.
11. Disconnect the gas filling device from the quick connector.
12. Remove the quick connector and mount the cover, then tighten the screw M6 with
flange by using a tightening torque shown in table 9.4 "Refill/Replace grease.".
13. Mount the cover and tighten the screws by using the tightening torque shown in table
9.4 .
14. Release the blowdown valve of the gas filling device and regulator and then discharge
the gas in the hose.
15. Disconnect the gas filling device from the nitrogen gas cylinder.
16. Turn on the power to the robot controller.
9 - 71
Maintenance and inspection
9.6
Home position calibration
Follow the safety instructions described
see in chapter ExternalLink: Sicherheit.
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 SAFTEY mode is selected
as the MANAGEMENT mode.
9.6.1
Registering all axes at the time
1. Select {ROBOT} from the main menu.
9 - 72
Maintenance and inspection
2. Select {HOME POSITION}.
The <HOME POSITIONING> window appears.
3. Select {DISPLAY} under the menu, or select “PAGE” to display the selection window for
the control group, or press [PAGE].
The pull-down menu appears.
4. Select the desired control group.
5. Select {EDIT} in the main menu.
The pull-down menu appears.
9 - 73
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 - 74
Maintenance and inspection
9.6.2
Registering individual axes
1. Select {ROBOT} on the main menu.
The sub-menu choices appear.
2. Select {HOME POSITION}.
3. Select the module to be calibrated (e.g. R1:ROBOT).
Perform steps 3 and 4 which have been described in “Registering All Axes at One Time”
to select the desired control group.
4. Select the axis to be registered.
A confirmation dialog box appears.
5. Select {YES}.
Displayed position data of the axis are registered as home position.
When {NO} is selected, the registration will be canceled.
9 - 75
Maintenance and inspection
9.6.3
Changing the absolute data
To change the absolute data of the axis when home position calibration is completed,
perform the following:
1. Select {ROBOT} from the main menu.
2. Select {HOME POSITION}.
3. Select the desired control group.
Perform steps 3 and 4 which have been described in chapter “Registering All Axes at
One Time” to select the desired control group.
4. Select the absolute data to be registered.
The number can now be entered.
5. Enter the absolute data using the numeric keys.
6. Select {ENTER}.
Absolute data are modified.
9 - 76
Maintenance and inspection
9.6.4
Clearing absolute data
1. Select {ROBOT} from the main menu.
2. Select {HOME POSITION}.
Perform steps 2, 3, and 4 which have been described in “Registering All Axes at One
Time” to display the HOME POSITIONING window and select the desired control
group.
3. Select {DATA} under the menu.
The pull-down menu appears.
4. Select {CLEAR ALL DATA}.
The confirmation dialog box appears.
5. Select {YES}.
The all absolute data are cleared.
When {NO} is selected, the registration will be canceled.
9 - 77
Maintenance and inspection
9.7
Setting the second home position (check point)
9.7.1
Purpose of position check operation
If the absolute number of rotation detected at power supply ON does not match the data
stored in the absolute encoder the last time the power supply was turned off, alarm 4107
“OUT OF RANGE (ABSO DATA)” is issued when the controller power is turned ON.
There are two possible causes of this alarm:
•
An error was found in the encoder communication related components.
•
No error was found in the encoder communication related components, but the robot
was moved after the power supply was turned OFF.
If there is an error in the encoder communication related components, the robot may stall
when playback is started. If the absolute data allowable range error alarm has occurred,
playback and test runs will not function and the position must be checked.
1 If the "OUT OF RANGE (ABSO DATA)" alarm occurs:
1
2 Reset alarm
2
3 Turn ON SERVO power
4 Procedure after alarm occurs
3
5 Position confirmation operation
4
6 Compare second home position
(check point)* with current position
pulses.
5
7 Alarm occurs again
6
8 Correct defective axis
• Replace encoder communication related components
OK
• Home position calibration
9 * Position checking point
10 Playback possible
NOK
7
8
9
10
1. 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. For performing the
position confirmation, refer to chapter “Procedure after the Alarm”. Playback and test
runs will not function unless “CONFIRM POSITION” is performed.
2. Pulse difference check
The pulse number at the second home position is compared with that at the current
position. If the difference is within the allowable range, playback is enabled. If not, the
alarm occurs again.
•
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 details, refer to chapter
“Procedure for the Second Home Position Setting (Check Point)”.
3. Alarm Occurrence
9 - 78
Maintenance and inspection
If the alarm occurs again, there may be an error in the encoder communication related
components. Check the components. After adjusting the erroneous axis, calibrate the home
position of the axis and then check the position again.
NOTICE
Home position calibration of all the axes at the same time enables playback operations
without having to check the position.
Sometimes in a system with a robot that has no brake, it is possible to enable playback
without position checking after the alarm occurs. However, as a rule, always perform
“CONFIRM POSITION”.
Under the above special conditions, the robot moves as follows:
 After starting, the robot moves at low speed (1/10 of the maximum speed) to the step
indicated by the cursor.
 If it is stopped and restarted during this motion, the low speed setting is retained until
the step at cursor is reached. Regardless of cycle setting, the robot stops after the
cursor step is reached
 Starting the robot again then moves it at the programmed speed and cycle of the JOB.
9 - 79
Maintenance and inspection
9.7.2
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.
1. Select {ROBOT} under the main menu.
2. Select {SECOND HOME POS}.
The {SECOND HOME POS} window appears.
The Message „Available to move to and modify specified point“ shown.
3. Press the page key [PAGE] or select “PAGE” to display the selection window for the
control group.
The group axes by which the second home position is set is selected when there are
two or more group axes.
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.
9.7.3
Procedure after alarm
Follow the safety instructions described in chapter 1.7 "Safety".
WARNING!
Death or injury because of danger of crushing
When performing the position check operation, pay careful attention to ensure the safety of
the surrounding operation environment.
9 - 80
Maintenance and inspection
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.
NOTICE
For details on the “POWER ON/OFF POS“ window, refer to „Position Data When
Power is Turned ON/OFF“ in Maintenance manual.
9 - 81
Maintenance and inspection
9.8
Zeroing Function (Optional)
The zero setting function (optional function) enables the automatic recovery of the robot’s
initial data in case they get lost. This function is possible only on robots which are delivered
with this option.
The robot control memorizes the initial position of the robot on the basis of the pulse value
of each encoder axis. Since the initial position is factory-set and registered, the setting to
zero must not be carried out in normal operation.
However, the setting to zero must be carried out if the initial position must be restored. The
initial position data will get lost when you effect the following operations or if the following
events occur.
•
•
•
Replacement of motors
Replacement of Encoders
Discharging the battery of the robot
The home position data is stored by the backup battery. In the case of a discharged battery,
the data specific to the initial position will get lost if you switch off the power supply of the
robot control, even in the case of a reset. Make sure to change the battery on a regular
basis. You will find more information specific to changing the battery in the user manual of
the robot.
The initial position cannot be accurately set via the reset function if you modify the
combination robot and robot control.
9.8.1
Connection diagram
5
4
2
3
Zeroing Devices
8
6
1
7
9 - 82
1
Sensor
5
Data communication card (CF)
2
Amplifier YasXzero
6
Robot controller
3
Connection cable
7
Robot
4
Connection cable (RS232
8
Zeroing device YasXzero
Maintenance and inspection
9.8.2
Overview and operation Reset to zero device YasXzero
Data exchange in case of resetting to zero occurs between sensor and programming
pendant via the amplifier.
Scope of supply
The following elements are included in the box:
•
•
•
•
•
Amplifier YasXzero
Mains unit for power supply and for charging the battery.
Sensor with connection cable to the amplifier.
Extension cable RS232
Connection cable RS232 with CF data transmission card for programming pendant.
Display and operating elements front panel
R
PW
CH
G
T
BA
M
CO
OK
SENSOR
F
IN
RN
G
POWER
Socket sensor:
Plug in the sensor cable.
LED PWR (Power):
Lights up when the power cable is inserted or when the device is on.
LED CHG (Charge):
Lights up when the power cable is inserted and when the
battery is being charged.
LED BAT (Battery):
Lights up when the battery must be charged. The devices’
runtime with battery is approximately 2 – 3 hours.
LED COM (Communication): Flickers when data between YasXzero and the programming pendant are being transmitted.
LED OK:
Flashes at one-second intervals when the reset process is
taking place properly.
Lights up continuously in case of a hardware failure. Try to
restart the device. In case of further error signals please
contact your local YASKAWA branch office.
LED INF (Information):
Without function
LED RNG (Range):
Lights up continuously when the sensor is in a ± 0,2 mm
range.
Flashes if the ± 5mm measuring range is exceeded.
POWER Key:
To switch-on the device.
9 - 83
Maintenance and inspection
Operating elements Rear side
RoHS
RS232
6V DC
CONFIG
Material No. 157471
Socket 6VDC:
Plug in the power supply.
CONFIG Key:
Without function (only for manufacturer’s device configuration).
Socket RS232:
Plug in the cable specific to the programming pendant.
Description sensor
The sensor comprises the following parts
•
•
•
Screw-fitted sensor tips
Adapter for screwing to the robot
LVDT sensor module
Application instruction
Avoid the following when using and storing the device:
•
•
•
•
•
•
Direct sunlight.
High humidity. Humidity must not condense.
Extreme ambient temperatures.
Large amounts of dust or other extremely dirty conditions.
Strong movements or vibrations.
Strong magnetic fields.
For cleaning use a clean and dry cloth. Never use liquids or aggressive cleaning agents.
The device must not be used in a potentially explosive environment.
The device can cause interferences to the reception of radio receivers, televisions or similar
devices. Ensure a sufficient distance to the devices.
9 - 84
Maintenance and inspection
9.8.3
Resetting
The zero setting function can be effected only if the safety mode is set as extended mode.
To this effect, refer to the operating manual of the robot control system.
9.8.3.1
Preparatory measures
1. Remove the tools fastened to the robot.
If the zero setting is effected on a robot with tools, the weight of the tool can affect the
positioning accuracy.
2. Drive all the axes of the robot to home position, as otherwise errors might occur if axes
are coupled.
3. Insert the CF data transmission card of the reset to zero device in the opening of the
programming pendant.
Fig. 9-8: Inserting the data transmission card
4. Connect the CF data transmission card and the amplifier to the RS232 connecting cable
(extension cable and connecting cable to the CF card).
5. Connect the connecting wire to the YasXzero amplifier (socket “Sensor”). Do not
connect the sensor yet.
NOTICE
To install the reset to zero device and the reset sensor, please refer to chapter “Overview
of the YasXzero reset to zero device” included in this manual.
9 - 85
Maintenance and inspection
9.8.3.2
Resetting an axis
WARNING!
Danger caused by unintentional start of the robot.
An unexpected start of the robot while people are standing in its movement area can cause
life threatening injuries.
 Ensure before entering the danger zone that the programming pendant is active and
that the robot cannot be controlled from other positions (e.g. central control desk).
 All the following robot movements must be effected exclusively by trained specialized
personnel and with the programming pendant.
NOTICE
Resetting will be described in the following using an S axis as example. This procedure
applies to all other axes.
The illustrations serve as example as the installation situation varies depending on robot
and robot axis. To this effect refer to the drawings in the annex.
1. Drive the axis in position so that the marking on the screw-in point of the reset sensor
coincides with the corresponding alignment marking.
The markings differ depending on the type of robot and the axis. Also refer to the
enclosed drawing that illustrates the resetting points.
2. Remove the locking device and the cover on the screw-in point for the sensor.
3. Ensure that the fastening bore is free from dirt, rust or any other impurities.
When the reset sensor becomes visible through the fastening bore, you should be able
to see a counter bore for resetting. If not, then probably the axis is not accurately
positioned between the alignment markings. Re-position the axis.
4. Screw-in the reset sensor manually.
Do not use a screwing tool to avoid damaging the sensor. Clean the sensor before
screwing with a soft cloth.
5. Connect the connecting cable to the sensor.
6. Switch on the YasXzero amplifier.
7. Switch the mode switch on the programming pendant to TEACH.
8. Select <MAIN MENU> → <ROBOT> → <ZEROING>..
9 - 86
Maintenance and inspection
9. Select the axis on the screen (e.g. S-axis).
10. Leave the movement area of the robot and ensure that nobody is standing in this area.
11. Switch on the SERVO power. Press <SERVO ON READY> and the on-off switch on
the programming pendant.
12. Press <Zeroing> on the screen.
A window with a warning message opens:
If you have followed all the previously described steps, then you fulfilled all the points
stated on the list and you can proceed with the following step.
13. Press <OK>.
The robot starts automatically and carries out the reset movements. The movements
are very slow and very small, therefore they are hard to recognize. Observe the screen
of the programming pendant.
9 - 87
Maintenance and inspection
14. The message confirming the resetting of the axis (S-axis in the example) appears on
the screen of the programming pendant. The calculated absolute data are then
displayed.
XXXXXXXX
15. Switch off the SERVO power.
16. Switch off the YasXzero amplifier.
17. Disconnect the connecting cable from the sensor.
18. Remove the sensor from the robot.
19. Mount the locking device of the sensor opening and the cover on the robot.
20. Check the position of the robot. Press <MAIN MENU> → <SECOND HOME
POSITION> → <ROBOT>.
The window SECOND HOME POSITION opens.
21. Leave the movement area of the robot and ensure that nobody is standing in this area.
22. Switch on the SERVO power. To this effect, press <SERVO ON READY> and the onoff switch on the programming pendant.
23. Press <FWD> to move the TCP in the second home position.
24. Check if the second home position deviates from your required position.
25. Press <MAIN MENU> → <CONFIRM POSITION> → <DATA>.
A message "Home position checked" appears.
26. Check the home position with a Teach operation before starting automatic operation in
playback. To this effect, check the following points:
-Are there deviations from the second home position of the robot?
-Are there position deviations at one or several points?
-Are there irregularities during the test drive?
NOTICE
The home position must be checked before starting automatic operation.
If during the reset a wrong home position is entered, this can cause the robot to malfunction
during operation.
9.8.4
Positions for the reset sensor
In the following drawings, the positions at which the reset sensors are mounted will be
illustrated on the corresponding robots. The letters correspond to designations of the axis.
9 - 88
Maintenance and inspection
T (b)
R (b)
T (a)
R (a)
B
U
L
S
Fig. 9-9: Installation positions
9.8.5
Error and solutions during resetting
If an error occurs during resetting, please refer to the following table that illustrates the most
common errors and their possible solutions.
Error message
Possible error
Possible solution
The bore is not deep enough of
too big.
Sensor captures wrong bore
depth.
• Check if dust or spilled liquids
penetrated in the bore.
Inspect the hole. Error
code:55550004
• Check the exterior of the sensor
for damages or cracks as well
as the end of the sensor for deformations.
• Carry out a new reset.
Switch to TEACH mode.
Switch the mode switch onto
TEACH and carry out the reset.
Again, execute zeroing.
The mode switch on the programming pendant is in the
“Play Mode” position when
starting the reset.
"Keep servo on state in teach
mode between under zeroing
execution."
The SERVO power is not
Turn ON the SERVO power by
turned ON at the start of the ze- pressing the enable switch of the
roing operation.
programming pendant.
Again, execute zeroing.
Loop error
[The maximum measurement
point were exceeded.]
Error code:55550005
Error in the zeroing processing. Possible cause: False parameter
settings for zeroing speed, distance, radius, false starting point
of the zeroing operation. Contact
the local YASKAWA branch office.
9 - 89
Maintenance and inspection
Error message
Possible error
Possible solution
Loop error
Communication errors
Possible cause: Incorrect software version. Please contact
your local YASKAWA branch office.
Communication errors
Contact the local YASKAWA
branch office.
Communication errors
• Check if the alarm lamp is lit and
if the cable etc. is correctly connected.
[Error by pulse capturing.]
Error code:55550006
Loop error
[Error in the process that starts
robot movements.]
Error code:55550008
Loop error
[Error in the process that stops
robot movements.]
Error code:55550009
Loop error
[Error when capturing sensor
values.]
Error code:55550010
error
[Sensor Amp (Read():D1)]
Error code:55550044
Information* Check the SERVO
power of the sensor.* Check the
connection of the cable RS232C.* Check the battery.
• Switch off the amplifier then
switch it on again.
• Carry out the reset again.
Alarm: Sensor amp (battery)
The battery of the amplifier is
empty.
Replace the battery.
Alarm: Sensor amp (write error
EEPROM)
Amplifier EEPROM writing error
Contact the local YASKAWA
branch office.
Alarm: Sensor amp (AD over)
AD over alarm of the amplifier
Contact the local YASKAWA
branch office.
Error
Error when resetting the amplifier
Contact the local YASKAWA
branch office.
The reset was carried out with a
controller without robot control
group.
Carry out the reset with a controller with robot control group.
The reset was carried out with
the robot control group without
movement axis.
Enter the robot control group with
movement axis.
The CF card for the RS-232C is
located in the storage opening
of the programming pendant.
Slide the CF card for the RS232C in the storage opening.
[Sensor amp (auto zero:OK)]
Error code:55550046
Error [No CtrlGroup]
Error code:55550052
Error [no axis]
Error code:55550056
Not found:
CF card RS-232C
Error code:55550001
9 - 90
Maintenance and inspection
Error message
Possible error
Possible solution
error
Error during the amplifier communication
Contact the local YASKAWA
branch office.
[RS-232C communication]
Error code:55550017
error
[RS-232C communication]
Error code:55550018
error
[RS-232C communication]
Error code:55550019
error
[RS-232C communication]
Error code:55550020
Error occur
Finished! (Error occur)
The reset will end due to an er- • Confirm the error message and
ror.
eliminate the error.
• Repeat the reset from the beginning.
Operator stop
Finished! (Operator stop)
The reset is ended with the
Stop switch.
Repeat the reset from the beginning.
The operator has pressed the
Stop key.
Error [Any axis don't set ABSO.] Error in the zeroing processing
Error code:55550088
Loop error
[Exceeding the maximal movement pulse.]
Error in the zeroing processing
Contact the local YASKAWA
branch office.
Contact the local YASKAWA
branch office.
Error code:55550097
Tab. 9-3: Error and solutions during resetting
9 - 91
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.
NOTICE
Please contact your YASKAWA branch office if you need spare or replacement parts.
Part List robot
Description
Part-No.
Material no.
Grease
Molywhite RE No. 0
176891
Grease
Grease Shell Gadus S2
V220 2
146745
Sealing compound
Teroson Plast
143813
Battery pack
Robot
128708
Battery pack
Controller
155543
Wire harness
HW1171456-A
164778
Power input module
HW1371448-A
164779
Wrist unit
HW1171565-A
164791
Balancer unit
HW1382567-A
164777
Battery board
SGDR-EFBA02A
154241
Gear
HW0388208-B
159169
Pinion
HW1303369-1
164766
Motor
SGMRV-37ANA-YR1*
144071
Limit switches
HW1470807-A
164780
Gear
HW1382455-C
164785
Pinion
HW1303887-1
164786
Motor
SGMRV-37ANA-YR1*
144071
Limit switches
HW1470430-B
164783
Gear
HW0388209-F
164788
Pinion
HW1303890-1
164789
Motor
SGMRV-37ANA-YR1*
144071
Limit switches
HW1470430-C
164784
Gear
HW0386260-A
139436
Motor
SGMRV-13ANA-YR1*
144074
Gear
HW9380961-G
145908
Motor
SGMRV-13ANA-YR1*
144074
S-axis:
L-axis:
U-axis:
R-axis:
B-axis:
T-axis:
10 - 92
Recommended spare parts list
Part List robot
Description
Part-No.
Material no.
Gear
HW0389174-C
164790
Motor
SGMRV-13ANA-YR1*
144074
Part List robot controller
Description
Part-No.
Material no.
Power supply
JZNC-YPS21-E
164754
Additional power supply
JZNC-YPS02-E
147571
CPU Rack
JZNC-YRK21-1E
164756
CPU Circuit Board
JANCD-YCP21-E
168996
Robot I/F board
JANCD-YIF01-2E
145855
Machine safety CPU board
JANCD-YSF21-E
164757
Machine safety I/O logic board
JANCD-YSF22B-E
169501
General I/O board (PNP Type)
JANCD-YIO22-E
164762
Power ON unit (Cat.4)
JZRCR-YPU52-1
164764
Axis board
SRDA-EAXA21A
170650
Converter module
SRDA-COA30A21B-E
164767
Capacitor module (12A Type)
SRDA-CUA662AA
164781
SERVO Amplifier S
SRDA-SDA71A01A-E
144169
SERVO Amplifier L
SRDA-SDA71A01A-E
144169
SERVO Amplifier U
SRDA-SDA71A01A-E
144169
SERVO Amplifier R
SRDA-SDA35A01A-E
155478
SERVO Amplifier B
SRDA-SDA35A01A-E
155478
SERVO Amplifier T
SRDA-SDA35A01A-E
155478
Resistor
SMVK500W6R0J
164775
Memory device (Compact Flash)
SFCF0256H1BK1MT-I-MS553-SMA
172731
10 - 93
Parts lists
11 Parts lists
11.1
S-axis unit
1031
1032
1012
1002
1003
1018
1019
1027
1028
1001
1046
1004
1005
1013
1006
1016
1015
1029
1025
1009
1020
1034
1024
1045
1022
1023
1033
1030
1021
1011
1008
1017
1010
1045
1047
1041
1026
1043
1042
1044
1007
1038
1039
1014
1035
1036
1037
1040
Fig. 11-1: S-axis drive
11 - 94
Parts lists
No.
DWG no.
Designation
Piece
1001
HW0388208-B
Gear
1
1002
SGMRV-37ANA-YR1*
Motor
1
1003
TC12015014
Oil seal
1
1004
STW-50
Circlip
1
1005
6310
Bearing
1
1006
HW1303369-1
Gear
1
1007
HW1100520-1
Housing
1
1008
HW1100521-1
Housing
1
1009
HW1303370-1
Pipe
1
1010
HW9404863-1
Stop
1
1011
HW9404486-1
Shaft
1
1012
MSTH12-30
Pin
1
1013
MSTH12-30
Pin
2
1014
KQ2L10-01S
Support
1
1015
PT3/8
Sealing plug
1
1016
G415
O-ring
1
1017
G130
O-ring
1
1018
M12 x 50
Screw
16
1019
SW2H-12
Washer
16
1020
M8 x 45
Screw
1
1021
2L-8
Washer
1
1022
M6 x 16
Screw
6
1023
2L-6
Washer
6
1024
M16 x 55
Screw
12
1025
GT-SH-16
Washer
12
1026
EZ5002A0
Sealing plug
1
1027
HW1303371-1
Spacer
1
1028
HW1404226-1
Flywheel
1
1029
M8 x 70
Screw
1
1030
2L-8
Washer
1
1031
M12 x 60
Screw
4
1032
2H-12
Washer
4
1033
M6 x 12
Washer
5
1034
HW1404239-1
Cover
1
1035
HW1404229-1
Cover
1
1036
M6 x 16
Screw
2
1037
2L-6
Washer
2
1038
HW1404228-1
Cover
1
1039
M6 x 12
Screw
6
1040
M6
Washer
2
1041
HW1401636-1
Stop
1
11 - 95
Parts lists
No.
DWG no.
Designation
Piece
1042
M16 x 35
Screw
4
1043
2H-16
Washer
4
1044
HW0402104-1
Pin
1
1045
HW1404681-1
Shaft
2
1046
M6 x 30
Screw
2
1047
HW1405024-1
Gasket
1
Tab. 11-1: Parts list S-axis drive
11 - 96
Parts lists
11.2
L-axis unit
2057
2073
2056
2053 2022
2016
2007
2004
2028
2045
2015
2011
2010
2008
2028
2028
2046
2047
2074
2009
2026
2025
2054
2026
2026
2025
2026
2025
2026
2025
2073
2001
2017
2060
2006
2073
2042
2063
2062
2064
2061
2044
2072
2071
2043
2059
2058 2034
2033
2028
2005
2023
2035
2002
2027
2036
1008
2003
2031
2032
2038
2029
2030
2067
2025
2026
2074
2070
2066
2021
2065
2026
2025
2028
2028
2011
2010
2022
2007
2053
2028
2016
2009
2069
2068
2073
2018
2057
2056
2026
2008
2025
Fig. 11-2: L-axis drive
No.
DWG no.
Designation
Piece
2001
HW1382455-C
Gear
1
2002
SGMRV-37ANA-YR1*
Motor
1
2003
HW9482447-A
Oil seal
1
2004
HW1100591-1
L-arm
1
11 - 97
Parts lists
11 - 98
No.
DWG no.
Designation
Piece
2005
HW1304057-1
Pinion
1
2006
AS568-275
O-ring
1
2007
VB75956
Oil seal
2
2008
VB60787
Oil seal
1
2009
22212EAE4
Bearing
2
2010
G105
O-ring
2
2011
STW-60
Circlip
2
2014
HW1404638-1
Holder
2
2015
HW1305071-1
Shaft
1
2016
HW1303707-1
Fork head
2
2017
HW1304162-1
Spacer
1
2018
HW1305071-2
Shaft
1
2021
HW1405133-1
Spacer
1
2022
HW1482236-A
Bearing
2
2023
M12 x 35
Screw
4
2025
M8 x 20
Screw
36
2026
2L-8
Washer
36
2027
PT3/8
Sealing plug
1
2028
PT1/8
Sealing plug
7
2029
M12 x 30
Screw
23
2030
2H-12
Washer
23
2031
M16 x 35
Screw
6
2032
2H-16
Washer
6
2033
M12 x 75
Screw
25
2034
2H-12
Washer
25
2038
HW1304368-1
Cover
1
2042
HW1303711-A
Support
1
2043
HW1382567-A
Balancer unit
1
2044
HW1404713-1
Cover
1
2045
HW1404712-1
Cover
1
2046
M6 x 12
Screw
4
2047
2L-6
Washer
4
2053
M6 x 10
Screw
4
2054
HW1304161-1
Spacer
1
2056
HW1303630-1
Shaft
1
2057
HW0408806-2
Washer
1
2058
HW0483320-C
Screw
1
2059
HW1404554-1
Shaft
1
2060
ISTW10
Circlip
1
2061
M12 x 40
Screw
12
2062
2H-12
Washer
12
Parts lists
No.
DWG no.
Designation
Piece
2063
SLH-M6X12
Screw
4
2064
2L-6
Washer
4
2066
HW1405134-1
Cover
1
2067
M4 x 6
Screw
2
2068
2L-4
Washer
2
2069
HW1304369-A
Cover
1
2070
M6 x 16
Screw
3
2071
2H-6
Washer
3
2072
M6
Washer
3
2073
M5 x 10
Screw
2
2074
2L-5
Washer
2
2075
HW1406698-1
Cover
1
2076
M6 x 16
Screw
2
2077
2L-6
Washer
2
2078
MSTH6-20
Pin
4
2079
HW1406482-1
Holder
2
1008
HW1100521-1
Housing
1
Tab. 11-2: Parts list L-axis drive
11 - 99
Parts lists
11.3
For R-, B- and T-axes drive
T-axis
R-axis
3010
3010
3027
3027
3003
3011
3030
3001
3028
3005
3008
3004
3002
3010
3031
3009
3029
3009
3029
B-axis
3007
3011
3008
3013
3014
3027
3012
3006
3011
3029
3015
3009
4016
3014
3008
4001
3026
3009
3014
3034
3033
3032
3035
3036
3037
3023
3025
3016
3024
3020
3019
2004
3022
3021
3018
3017
3032
Fig. 11-3: URBT-axis unit
11 - 100
No.
DWG no.
Designation
Piece
3001
HW0402391-1
Sleeve
1
3002
HW0402406-1
Sleeve
1
Parts lists
No.
DWG no.
Designation
Piece
3003
HW1303889-1
Gear
1
3004
ISTW-36
Circlip
1
3005
HW0402390-1
Sleeve
1
3006
HW1303377-1
Gear
1
3007
HW1303378-1
Gear
1
3008
M6 x 25
Screw
3
3009
2L-6
Washer
5
3010
SGMRV-13ANA-YR1*
Motor
3
3011
M8 x 25
Screw
9
3012
HW1100592-1
Housing
1
3013
HW9482447-A
Oil seal
1
3014
PT3/8
Sealing plug
3
3015
SGMRV-37ANA-YR1*
Motor
1
3016
HW0388209-F
Gear
1
3017
M12 x 55
Screw
16
3018
2H-12
Washer
16
3019
M10 x 25
Screw
18
3020
2L-10
Washer
18
3021
M16 x 35
Screw
6
3022
2H-16
Washer
6
3023
HW0481083-A
Screw
1
3024
ISTW-12
Circlip
1
3025
HW1303890-1
Gear
1
3026
G270
O-ring
1
3027
Y507212.5
Oil seal
3
3028
TAFI405520
Bearing
1
3029
HW0401506-1
Washer
3
3030
IRTW-55
Circlip
1
3031
M12 x 35
Screw
4
3032
PT1/8
Sealing plug
2
3033
HW1404759-1
Cover
1
3034
M6 x 12
Screw
2
3035
HW9482306-E
Shaft
1
3036
HW9481343-A
Shaft
1
3037
HW0408806-1
Washer
1
2004
HW1100591-1
L-arm
1
4001
HW1100593-1
U-arm
1
4016
HW0100173-2
Housing
1
Tab. 11-3: Parts list URBT-axis unit
11 - 101
Parts lists
11.4
U arm unit
3012
4024
4025
4021
4022
4002
4019 4023
4027
4035
4027
4016
4012
4008 4030
4018
4017
4010
4006
4007
4030
4014
4020
4011
4033
4013
4032
4031
4005
4001
4003
4004
4034
4009
4029
4028
4036
4026
Fig. 11-4: U-arm unit
11 - 102
No.
DWG no.
Designation
Piece
4001
HW1100593-1
U-arm
1
4002
HW0401508-1
Washer
1
4003
6810DDU
Bearing
1
4004
WR50
Circlip
1
4005
AC2847F3*NOK*
Oil seal
1
4006
NK25/20R
Bearing
1
4007
WR20
Terminal
1
4008
LRT202526
Bearing
1
4009
HW0386260-A
Gear
1
4010
HR32017XJ
Bearing
1
4011
AC3842-F1-(FKM)
Oil seal
1
Parts lists
No.
DWG no.
Designation
Piece
4012
HW1303780-1
Shaft
1
4013
HW0302261-A
Shaft
1
4014
HW0302262-B
Shaft
1
4016
HW0100173-2
Housing
1
4017
HR32013XJ
Bearing
1
4018
HW1303381-1
Gear
1
4019
HW0401505-1
Nut
1
4020
HW0303951-1
Gear
1
4021
M8 x 20
Screw
1
4022
2L-8
Washer
1
4023
M4 x 6
Screw
1
4024
M8 x 20
Screw
6
4025
2L-8
Washer
6
4026
PT1/8
Sealing plug
1
4027
HR32006XJ
Bearing
2
4028
M8 x 95
Screw
16
4029
2L-8
Washer
16
4030
M5 x 12
Screw
6
4031
M12 x 35
Screw
18
4032
2H-12
Washer
18
4033
GS210
O-ring
1
4034
MSTM8-20
Pin
1
4035
HW0303948-1
Gear
1
4036
MSTH6-15
Pin
1
3012
HW1100592-1
Housing
1
Tab. 11-4: Parts list U-arm unit
11 - 103
Parts lists
11.5
Wrist unit
4013
4012
5014
5013
5013
5009
5068
5012
5018
5015
5010
5001
5011
5025
5073
5026
5024
5037
5088
5008
5003
5002
5061
5027
5023
5021
5080
5076
5075
5019
5074
5022
5078
5079
5077
5034
5035
5036
5038
5023
5089
5043
5050
5095
5004
5094
5016
5042
5047
5042
5044
5046
5045
5039
5093
5092
5033
5038
5032
5033
5031
5023
5057
5090
5091
5065
5029
5020
5085
5086
5084
5087 5086
5017
5005 5018
5007
5006
5041
5040
5042
Fig. 11-5: Wrist unit
11 - 104
5042
5030
5032
5023
5028
No.
DWG no.
Designation
Piece
5001
HW1100595-1
Wrist unit
1
5002
M12 x 35
Screw
8
5003
2H-12
Washer
8
5004
HW1100594-1
Manual
1
5005
HW9380961-G
Gear
1
5006
M8 x 15
Screw
14
5007
2L-8
Washer
14
5008
G110
O-ring
1
5009
6908DB
Bearing
1
5010
HW0401511-1
Holder
1
Parts lists
No.
DWG no.
Designation
Piece
5011
HW0401509-1
Housing
1
5012
HW0401510-1
Nut
1
5013
M4 x 12
Screw
8
5014
M4 x 6
Screw
1
5015
6909
Bearing
1
5016
ARP568-263
O-ring
1
5017
6009
Bearing
1
5018
STW-45
Circlip
2
5019
HW1303384-1
Gear
1
5020
HW0301223-1
Gear
1
5021
HW9481236-A
Bearing
1
5022
HW1404234-1
Cover
1
5023
HR32004XJ
Bearing
4
5024
6911
Bearing
1
5025
AE3290E3
Oil seal
1
5026
AR80
Circlip
1
5027
S60
O-ring
1
5028
HW9403618-1
Housing
1
5029
M6 x 15
Screw
5
5030
HW0301224-1
Gear
1
5031
HW0301225-1
Gear
1
5032
HW0401514-1
Nut
2
5033
M5 x 7
Screw
4
5034
M8 x 20
Screw
3
5035
2L-8
Washer
3
5036
HW9403617-1
Housing
1
5037
HW0200615-1
Cover
1
5038
M6 x 15
Screw
10
5039
HW0300889-1
Cover
1
5040
M6 x 25
Screw
4
5041
2L-6
Washer
4
5042
PT1/8
Sealing plug
4
5043
HW0301227-1
Gear
1
5044
HW0389174-C
Gear
1
5045
M14 x 40
Screw
4
5046
GT-SH-M14
Washer
4
5047
HW1303903-1
Flange
1
5050
HW0406766-*
Adjusting washer
1
5057
HW9403621-*
Adjusting washer
1
5061
HW9403622-*
Adjusting washer
1
5065
HW0401517
Adjusting washer
1
11 - 105
Parts lists
No.
DWG no.
Designation
Piece
5068
HW0401516-*
Adjusting washer
1
5073
PT3/8
Sealing plug
2
5074
HW9405444-1
Nut
1
5075
HW9403610-1
Cover
1
5076
*HW1404864-1*G
Housing
1
5077
M4 x 6
Screw
1
5078
M8 x 20
Screw
16
5079
2HL-8
Washer
16
5080
HW9403623-*
Adjusting washer
1
5084
M4 x 16
Screw
4
5085
M4 x 8
Screw
8
5086
2L-4
Washer
12
5087
HW0301231-1
Gear
1
5088
HW0301230-1
Gear
1
5089
HW0301226-1
Gear
1
5090
M8 x 40
Screw
14
5091
2L-8
Washer
14
5092
M8 x 85
Screw
6
5093
2L-8
Washer
6
5094
HW9482951-A
Gasket
1
5095
HW1405841-1
Sleeve
1
4012
HW1303780-1
Shaft
1
4013
HW0302261-A
Shaft
1
Tab. 11-5: Parts list wrist unit
11 - 106
Parts lists
11 - 107
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
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Fax +49 (0) 6196 / 77725 - 39
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