Yaskawa Motoman HP20RD Instructions

MOTOMAN-HP20RD
INSTRUCTIONS
TYPE:
YR-HP020RD-A00 (STANDARD SPECIFICATIONS)
YR-HP020RD-A01
(WITH SLU-AXES LIMIT SWITCHES SPECIFICATIONS)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HP20RD INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
YASKAWA ELECTRIC CORPORATION
157860-1CD
2
MANUAL NO.
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MANDATORY
•
This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMANHP20RD.
•
General items related to safety are listed in the Chapter 1: Safety of
the DX100 Instructions. To ensure correct and safe operation,
carefully read the DX100 Instructions before reading this manual.
CAUTION
•
Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
•
The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
•
YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
If such modification is made, the manual number will also be
revised.
•
If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. Be sure to tell the
representative the manual number listed on the front cover.
•
YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized modification
voids your product’s warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of your manipulator.
In this manual, the Notes for Safe Operation are classified as “DANGER,”
“WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
DANGER
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
CAUTION
MANDATORY
PROHIBITED
Always be sure to follow explicitly the
items listed under this heading.
Must never be performed.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “DANGER,” “CAUTION” and “WARNING.”
DANGER
•
Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
•
For disassembly or repair, contact your YASKAWA representative.
•
Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
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WARNING
•
Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button
•
Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN
•
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
•
Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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CAUTION
•
Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately,
and be sure that all other necessary processing has been
performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
•
Always return the programming pendant to the hook on the DX100
cabinet after use.
The programming pendant can be damaged if it is left in the P-point
maximum envelope of manipulator, on the floor, or near fixtures.
•
Read and understand the Explanation of the Warning Labels in the
DX100 Instructions before operating the manipulator.
Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming
pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
DX100 Controller
DX100
DX100 Programming Pendant
Programming Pendant
Cable between the Manipulator and the
Controller
Manipulator Cable
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
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Explanation of Warning Labels
The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Warning label B
Nameplate
Warning label A
Warning label B
Warning label A
Nameplate
Warning Label A:
WARNING
MODEL
MOTOMANTYPE
PAYLOAD
ORDER NO.
kg
MASS
DATE
Moving parts
may cause
injury
kg
SERIAL NO.
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku,
Kitakyushu 806-0004 Japan
MADE IN JAPAN
NJ3247
Warning Label B:
WARNING
Do not enter
robot
work area.
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Contents
1 Product Confirmation ...................................................................................................................... 1-1
1.1 Contents Confirmation ....................................................................................................... 1-1
1.2 Order Number Confirmation .............................................................................................. 1-2
2 Transporting.................................................................................................................................... 2-1
2.1 Transporting Method.......................................................................................................... 2-1
2.1.1 Using a Crane ...................................................................................................... 2-1
2.1.2 Using a Forklift...................................................................................................... 2-3
2.2 Shipping Bolts and Brackets.............................................................................................. 2-4
3 Installation....................................................................................................................................... 3-1
3.1 Installation of Safeguarding ............................................................................................... 3-2
3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2
3.2.1 Installation Example ............................................................................................. 3-3
3.3 Types of Mounting ............................................................................................................. 3-4
3.3.1 Fixing the Manipulator Base ................................................................................. 3-4
3.3.2 Precautions to Prevent the Manipulator from Falling............................................ 3-4
3.4 Location ............................................................................................................................. 3-5
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-2
4.2 Manipulator Cable Connection .......................................................................................... 4-3
4.2.1 Connection to the Manipulator.............................................................................. 4-3
4.2.2 Connection to the DX100 ..................................................................................... 4-3
5 Basic Specifications ........................................................................................................................ 5-1
5.1 Basic Specifications3......................................................................................................... 5-1
5.2 Part Names and Working Axes.......................................................................................... 5-2
5.3 Manipulator Base Dimensions ........................................................................................... 5-2
5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-3
5.5 Alterable Operating Range ................................................................................................ 5-4
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-2
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Contents
7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.1.1 Allowable Load ..................................................................................................... 7-1
7.1.2 Installation Position............................................................................................... 7-1
7.2 Internal User I/O Wiring Harness and Air Line................................................................... 7-2
8 Electrical Equipment Specification .................................................................................................. 8-1
8.1 Position of Limit Switch ...................................................................................................... 8-1
8.2 Internal Connections .......................................................................................................... 8-2
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-1
9.2 Notes on Maintenance Procedures.................................................................................... 9-6
9.2.1 Battery Pack Replacement ................................................................................... 9-6
9.3 Notes on Grease Replenishment/Exchange Procedures .................................................. 9-8
9.3.1 Grease Replenishment/Exchange for S-axis Speed Reducer.............................. 9-9
9.3.1.1 Grease Replenishment
(Refer to fig. 9-4 “S-axis speed Reducer Diagram” .) ............................. 9-9
9.3.1.2 Grease Exchange
(Refer to fig. 9-4 “S-axis speed Reducer Diagram” .) ........................... 9-10
9.3.2 Grease Replenishment/Exchange for L-axis Speed Reducer ............................ 9-11
9.3.2.1 Grease Exchange
(Refer to fig. 9-5 “T-axis speed Reducer Diagram” .) ........................... 9-11
9.3.2.2 Grease Exchange
(Refer to fig. 9-5 “T-axis speed Reducer Diagram” .) ........................... 9-12
9.3.3 Grease Replenishment/Exchange for U-axis Speed Reducer............................ 9-13
9.3.3.1 Grease Replenishment
(Refer to fig. 9-6 “U-axis Speed Reducer Diagram” .) .......................... 9-13
9.3.3.2 Grease Exchange
(Refer to fig. 9-6 “U-axis Speed Reducer Diagram” .) .......................... 9-14
9.3.4 Grease Replenishment for R-axis Speed Reducer............................................. 9-15
9.3.5 Grease Replenishment for B-, T-axes Speed Reducers .................................... 9-16
9.3.6 Grease Replenishment for T-axis Gear .............................................................. 9-18
9.3.7 Grease Replenishment for R-axis Cross Roller Bearing .................................... 9-19
9.3.8 Notes for Maintenance........................................................................................ 9-20
9.3.8.1 Wrist Axes ............................................................................................. 9-20
9.3.9 Encoder Connector (with CAUTION Label) ........................................................ 9-20
9.3.9.1 Battery Pack Connection (for S-, L-, U-axes Motors) ............................ 9-21
9.3.9.2 Battery Pack Connection (for R-, B-, T-axes Motors) ............................ 9-22
10 Recommended Spare Parts........................................................................................................ 10-1
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Contents
11 Parts List ..................................................................................................................................... 11-1
11.1 S-axis Unit ..................................................................................................................... 11-1
11.2 L-axis Unit...................................................................................................................... 11-3
11.3 U-axis Unit ..................................................................................................................... 11-5
11.4 R-axis Unit ..................................................................................................................... 11-7
11.5 Wrist Unit ..................................................................................................................... 11-10
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1
1.1
1
Product Confirmation
Contents Confirmation
Product Confirmation
CAUTION
•
Confirm that the manipulator and the DX100 have the same order
number. Special care must be taken when more than one
manipulator is to be installed.
If the numbers do not match, manipulators may not perform as
expected and cause injury or damage.
1.1
Contents Confirmation
Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following four items (information for the
content of optional goods is given separately):
• Manipulator
• DX100
• Programming pendant
• Manipulator cables (between Manipulator and DX100)
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1.2
Order Number Confirmation
Check that the order number of the manipulator corresponds to the
DX100. The order number is located on a label as shown below.
Fig. 1-1: Location of Order Number Labels
Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
DX100
3PHASE
AC200V
AC220V
50/60Hz
60Hz
INTERRUPT CURRENT
PEAK
AVERAGE
kVA
kVA
kA
ER
GE N
Y
POWER SUPPLY
C
ERDR-
TYPE
EM
ORDER NO.
Check that the manipulator
and the DX100 have the
same order number.
SERIAL No.
DATE
MADE IN JAPAN
NJ2960-1
S
T O P
ET
OFF
TR
IPP
ED
ON
RES
1.2
Product Confirmation
Order Number Confirmation
ORDER NO.
NJ1529
PROGRAMMING PENDANT
(a) DX100 (Front View)
(b) Manipulator (Top View)
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2.1
2
Transporting
Transporting Method
Transporting
CAUTION
•
Sling and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may result in injury or damage.
•
Avoid excessive vibration or shock during transportation.
The system consists of precision components, so failure to observe this
caution may adversely affect performance.
2.1
2.1.1
Transporting Method
Using a Crane
As a rule, when removing the manipulator from the package and moving
it, a crane should be used. The manipulator should be lifted using wire
rope threaded through attached eyebolts. Be sure the manipulator is fixed
with shipping bolts and brackets before transportation, and lift it in the
posture as shown in fig. 2-1 “Transporting Position” .
• Check that the eyebolts are securely fastened.
• The mass of the manipulator is approximately 310 kg
including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the mass.
NOTE
• Attached eyebolts are designed to support the manipulator
mass. Do not use them for anything other than transporting the manipulator.
• Be sure to mount the shipping bolts and brackets before
transporting the manipulator. (Refer to fig. 2-1 “Transporting Position” .)
• Avoid external force on the arm or motor unit when transporting the manipulator. Use caution when using transporting equipment other than a crane or forklift to avoid
injury.
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2.1
Transporting
Transporting Method
Fig. 2-1: Transporting Position
[B] Shipping Bolts and Brackets
(b)
Eyebolt M16 (4 eyebolts)
(Delivered with the manipulator)
Section [E]
(a)
[C] Shipping Bolts and Brackets
(b)
Shipping Bolts
and Brackets [A]
Section [D]
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2.1
2.1.2
Transporting
Transporting Method
Using a Forklift
When using a forklift, the manipulator should be fixed on a pallet with
shipping bolts and brackets as shown in fig. 2-2 “Using a Forklift” . Insert
claws under the pallet and lift it. The pallet must be strong enough to
support the manipulator. Transportation of the manipulator must be
performed slowly in order to avoid overturning or slippage.
Fig. 2-2: Using a Forklift
Pallet
Bolts M16 (4 bolts)
Forklift claw entry
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2.2
2.2
Transporting
Shipping Bolts and Brackets
Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets [A], [B] and
[C].
(fig. 2-1 “Transporting Position” )
Fig. 2-3: Shipping Bolts and Brackets
A
(b)
[B] Shipping Bolts and Brackets
Eyebolt M16 (4 eyebolts)
(Delivered with the manipulator)
(a)
Shipping Bolts and Brackets [A]
(b)
[C] Shipping Bolts and Brackets
View A
[E]
[D]
Enlarged View: Section D
Enlarged View: Section E
• The brackets [A], [B] and [C] are painted yellow.
• Bolts that fix [A] and manipulator : Hexagon socket head cap screw
M10×2 (a)
• Bolts that fix [A] to [B] and [A] to [C] : Hexagon socket head cap
screw M8×2 (b) (2 places, 4 screws total)
• A rubber cushion is respectively wedged at the sections [D] and [E].
NOTE
Before turning ON the power, check to be sure that the shipping bolts, brackets, and rubber cushions have been
removed. The shipping bolts, brackets, and rubber cushions
then must be stored for future use, in the event that the
manipulator must be moved again.
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3
Installation
Installation
WARNING
•
Install the safeguarding.
Failure to observe this warning may result in injury or damage.
•
Install the manipulator in a location where the manipulator’s tool or
the workpiece held by the manipulator will not reach the wall,
safeguarding, or DX100 when the arm is fully extended.
Failure to observe this warning may result in injury or damage.
•
Do not start the manipulator or even turn ON the power before it is
firmly anchored.
The manipulator may overturn and cause injury or damage.
•
When mounting the manipulator on the ceiling or wall, the base
section must have sufficient strength and rigidity to support the
mass of the manipulator. Also, it is necessary to consider
countermeasures to prevent the manipulator from falling.
Failure to observe these warning may result in injury or damage.
CAUTION
•
Do not install or operate the manipulator that is damaged or lacks
parts.
Failure to observe this caution may cause injury or damage.
•
Before turning ON the power, check to be sure that the shipping
bolts and brackets explained in chapter 2.2 “Shipping Bolts and
Brackets” are removed.
Failure to observe this caution may result in damage to the driving
parts.
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3.1
3.1
Installation
Installation of Safeguarding
Installation of Safeguarding
To insure safety, be sure to install the safeguarding. It prevents
unforeseen accidents with personnel and damage to equipment. The
following is quoted for your information and guidance.
Responsibility for Safeguarding (ISO10218)
The user of a manipulator or robot system shall ensure that the
safeguarding is provided and used in accordance with Sections 6, 7, and
8 of this standard. The means and degree of safeguarding, including any
redundancies, shall correspond directly to the type and level of hazard
presented by the robot system consistent with the robot application.
Safeguarding may include but not be limited to safeguarding devices,
barriers, interlock barriers, perimeter guarding, awareness barriers, and
awareness signals.
3.2
Mounting Procedures for Manipulator Base
The manipulator should be firmly mounted on a base or foundation strong
enough to support the manipulator and withstand repulsion forces during
acceleration and deceleration.
Refer to table 3-1 “Maximum Repulsion Forces of the Manipulator at
Emergency Stop” and table 3-2 “Endurance Torque in Operation” to
construct a solid foundation with the appropriate thickness to withstand
maximum repulsion forces of the manipulator.
A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness
of installation surface may deform the manipulator shape and affect its
functional abilities. Mount the manipulator base as described in
chapter 3.2.1 “Installation Example” .
Table 3-1: Maximum Repulsion Forces of the Manipulator at Emergency
Stop
Horizontal rotating maximum torque
(S-axis moving direction)
8000 Nm
(815 kgfm)
Vertical rotating maximum torque
(LU-axes moving direction)
5000 Nm
(510 kgfm)
Table 3-2: Endurance Torque in Operation
Endurance torque in horizontal operation
(S-axis moving direction)
1700 Nm
(171 kgfm)
Endurance torque in vertical operation
(LU-axes moving direction)
3775 Nm
(385 kgfm)
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3.2
Installation Example
For the first process, anchor the baseplate firmly on the floor. The
baseplate should have enough rigidity, which is 32 mm or more in
thickness. The size of the anchor bolt recommended for the baseplate
fixation is M16 or larger.
Next, fix the manipulator base to the baseplate. There are 4 mounting
holes on the manipulator base: securely fix the manipulator to the
baseplate using 4 hexagon head screws M16 (60 mm long is
recommended). Tighten the hexagon head screws and anchor bolts
firmly so that they will not be loosened during the operation. See fig. 3-1
“Manipulator Installation Example” for the method.
Fig. 3-1: Manipulator Installation Example
Bolt M16 (4 bolts)
Spring washer
Washer
Manipulator base
25
Baseplate
32 mm
or more
Manipulator base
Anchor bolt
(M16 or larger)
Baseplate
375
335
+0.018
12 0
170±0.1
250
200±0.1
60
260±0.1
dia. holes (2 holes)
335
375
336
Baseplate
200±0.1
3.2.1
Installation
Mounting Procedures for Manipulator Base
18 dia. holes
(4 holes)
Manipulator Base
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3.3
3.3
Installation
Types of Mounting
Types of Mounting
The MOTOMAN-HP20RD is available in two types: floor-mounted type
(standard) and ceiling-mounted type. For ceiling-mounted type, the three
points listed below are different from the floor-mounted type.
• Fixing the Manipulator Base
• Precautions to Prevent the Manipulator from Falling
• IP (International Protection) for Main Part of the Manipulator
3.3.1
Fixing the Manipulator Base
For ceiling-mounted type, be sure to use four hexagon socket head cap
screws M16 (tensile strength: 1200 N/mm2 or more) when fixing the
manipulator base. Use a torque of 206 N•m when tightening the screws.
3.3.2
Precautions to Prevent the Manipulator from Falling
For the ceiling-mounted type, take appropriate measures to avoid the
falling of the manipulator in case of emergency. Refer to fig. 3-2
“Precaution Against Falling” for details.
Fig. 3-2: Precaution Against Falling
Support for fall prevention
Manipulator base
Hexagon socket head cap
screw M16 (4 places)
(Tensile strength: 1200 N/mm2 or more)
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3.4
3.4
Installation
Location
Location
When the manipulator is installed, it is necessary to satisfy the
undermentioned environmental conditions:
• Ambient temperature: 0° to + 45°C
• Humidity: 20 to 80%RH (no-condensing)
• Free from dust, soot, oil, or water
• Free from corrosive gas or liquid, or explosive gas or liquid.
• Free from excessive vibration (Vibration acceleration: 4.9 m/s2
[0.5 G] or less)
• Free from large electrical noise (plasma)
• Flatness for installation: 0.5 mm or less
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4
Wiring
Wiring
WARNING
•
Ground resistance must be 100 Ω or less.
Failure to observe this warning may result in fire or electric shock.
•
Before wiring, make sure to turn the primary power supply OFF, and
put up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
•
Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
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4.1
4.1
Wiring
Grounding
Grounding
Follow the local regulations and electrical installation standards for
grounding. The recommended grounding wire size is 5.5 mm2 at
minimum.
For grounding, connect the ground wire directly to the manipulator as
shown in fig. 4-1 “Grounding Method” .
NOTE
• Do not use this line in common with other ground lines or
grounding electrodes for other electric power, motor
power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks
are used for cable laying, ground in accordance with Electric Equipment Technical Standards.
Fig. 4-1: Grounding Method
Bolt M8 (for grounding)
(delivered with the
manipulator)
Section A-A
A
A
2
5.5 mm or more
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4.2
4.2
Wiring
Manipulator Cable Connection
Manipulator Cable Connection
There are two manipulator cables; an encoder cable for detection (1BC)
and power cable (2BC). (Refer to fig. 4-2 “Manipulator Cables” .)
Connect these cables respectively to the connectors at the manipulator
base and the DX100. Refer to fig. 4-3(a) “Manipulator Cable Connection
to the Manipulator” , and fig. 4-3(b) “Manipulator Cable Connection to the
DX100” .
4.2.1
Connection to the Manipulator
Before connecting the manipulator cables to the manipulator, verify the
numbers: 1BC and 2BC on both the cables and the connectors of the
manipulator. Connect 2BC first, and then connect 1BC. After inserting the
cables, lower each lever until it clicks.
Connection to the DX100
Before connecting two cables to the DX100, verify the numbers on both
manipulator cables and the connectors on the DX100. When connecting,
insert the cables in the order of X21, then X11, and depress each lever low
until it clicks.
Fig. 4-2: Manipulator Cables
DX100 side
Manipulator side
X11
1BC
X11
1BC
1BC
Encoder cable
DX100 side
Manipulator side
2BC
X21
4.2.2
2BC
X21
2BC
Power cable
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4.2
Wiring
Manipulator Cable Connection
Fig. 4-3(a): Manipulator Cable Connection to the Manipulator
Key position
2BC
1BC
Key position
3BC
Fig. 4-3(b): Manipulator Cable Connection to the DX100
X11
X21
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5
5.1
5
Basic Specifications
Basic Specifications3
Basic Specifications
5.1
Basic Specifications3
Table 5-1: Basic Specifications1)
Item
Model
MOTOMAN-HP20RD
Configuration
Vertically Articulated
Degree of Freedom
6
Payload
20 kg
Repeatability2)
±0.06 mm
Range of Motion
Maximum
Speed
Allowable
Moment3)
Allowable
Inertia
(GD2/4)
S-axis (turning)
-110° - +125°
L-axis (lower arm)
-130° - +105°
U-axis (upper arm)
-115° - +310°
R-axis (wrist roll)
-200° - +200°
B-axis (wrist pitch/yaw)
-140° - +140°
T-axis (wrist twist)
-360° - +360°
S-axis
3.14 rad/s, 180°/s
L-axis
3.05 rad/s, 175°/s
U-axis
3.58 rad/s, 205°/s
R-axis
6.98 rad/s, 400°/s
B-axis
6.98 rad/s, 400°/s
T-axis
10.47 rad/s, 600°/s
R-axis
39.2 Nm (4.0 kgfm)
B-axis
39.2 Nm (4.0 kgfm)
T-axis
19.6 Nm (2.0 kgfm)
R-axis
1.05 kgm2
B-axis
1.05 kgm2
T-axis
0.75 kgm2 4)
Mass
Ambient
Conditions5)
293 kg
Temperature
0 to 45°C
Humidity
20 to 80% RH (at constant temperature)
Vibration Acceleration
4.9 m/s2 (0.5G) or less
Others
Free from corrosive gasses or liquids, or explosive
gasses
Free from exposure to water, oil, or dust
Free from excessive electrical noise (plasma)
Power Requirements
2.0 kVA
1
2
3
4
SI units are used in this table. However, gravitational unit is used in ( ).
Conformed to ISO9283
Refer to chapter 6.1 “Allowable Wrist Load” for details on the allowable moment and inertia.
The allowable inertia of T-axis varies depending on the added value of the moment. Refer to chapter 6.1
“Allowable Wrist Load” for the details.
5 Conformed to IP54 for the main part of the manipulator (only floor-mounted type). Conformed to IP67 for the
wrist part (IP65 for the main part is optional.)
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5.2
5.2
Basic Specifications
Part Names and Working Axes
Part Names and Working Axes
Fig. 5-1: Part Names and Working Axes
S+
L-arm
L-
S-head
S-
U+
U-
L+
U-arm
Manipulator base
R+
R-
B-
B+
Wrist
T-
T+
Wrist flange
Manipulator Base Dimensions
Fig. 5-2: Manipulator Dimensions
200±0.1
60
200±0.1
25
Fitting surface
Fitting surface
336
375
335
375
170±0.1
335
250
5.3
18 dia. holes (4 holes)
(for manipulator fixing)
12+0.018
dia. holes
0
(2 holes)
260±0.1
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5.4
5.4
Basic Specifications
Dimensions and P-Point Maximum Envelope
Dimensions and P-Point Maximum Envelope
Fig. 5-3: Dimensions and P-point Maximum Envelope
12
266
423
140
157
138.5
5°
0°
11
R20
2017
768
712
653
447
168
0
526
557
846
17
1872
450
760
140
80
81
1
42
0
°
795
°
05
220
P-point
5°
11
105
305
471
269
546
°
130
310 °
887
150
1262
P-point maximum working envelope
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5.5
5.5
Basic Specifications
Alterable Operating Range
Alterable Operating Range
The operating range of the S-axis can be altered according to the
operating conditions as shown in table 5-2 “S-axis Working Range” . If
alteration is necessary, contact your Yaskawa representative in advance.
Table 5-2: S-axis Working Range
Item
Specifications
S-axis
Operating
Range
+125°, -110° (standard)
±90°
±60°
±30°
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6
6.1
Allowable Load for Wrist Axis and Wrist Flange
6.1
Allowable Wrist Load
The allowable wrist load is 20 kg. If force is applied to the wrist instead of
the load, force on R-, B-, and T-axes should be within the value shown in
table 6-1 “Allowable Wrist Load” Contact your Yaskawa representative
for further information or assistance.
Table 6-1: Allowable Wrist Load
Axis
Moment N•m (kgf•m)1)
Inertia kg•m2
R-axis
B-axis
T-axis
39.2 (4)
39.2 (4)
19.6 (2)
1.05
1.05
0.75
1 ( ): Gravitational unit
The allowable moments of inertia for R-axis and B-axis are calculated
when the moment is at the maximum. The allowable moment of inertia for
T-axis varies depending on the moment, as shown in fig. 6-1 “T-axis
Allowable Moment of Inertia Diagram (Measured value from the Center of
the T-axis Flange Surface” ). Use the manipulator to meet those
conditions.
For example, the allowable moment of inertia for the T-axis is 0.25 kg•m2
when the moment is 19.6 N•m, and 0.75 kg•m2 when 0 N•m.
When the volume load is small, refer to the moment arm rating shown in
fig. 6-2 “Moment Arm Rating” .
Fig. 6-1: T-axis Allowable Moment of Inertia Diagram (Measured value
from the Center of the T-axis Flange Surface
20
Moment (Nžm)
6
Allowable Load for Wrist Axis and Wrist Flange
Allowable Wrist Load
19.6
15
10
5
0
0.25
0.3
0
0.75
0.6
0.9
Total Inertia GD2 /4 Kg m2
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6.2
Allowable Load for Wrist Axis and Wrist Flange
Wrist Flange
Fig. 6-2: Moment Arm Rating
Load gravity
position
LB
300
LT
LT (mm)
105
200
W=6Kg
W=10Kg
W=16Kg
100
T-axis, R-axis
rotation center line
W=20Kg
B-axis rotation center line
0
100
200
300
400
LB (mm)
Wrist Flange
The wrist flange dimensions are shown in fig. 6-3 “Wrist Flange” . In
order to see the alignment marks, it is recommended that the attachment
be mounted inside the fitting. Fitting depth of inside and outside fittings
must be 5 mm or less.
Fig. 6-3: Wrist Flange
Alignment mark
A
0.5
6
Tapped holes M6
(depth: 10)
(pitch: 1.0) (4 holes)
0
50 -0.039 dia.
6
+0.021
dia.
45°
25 0
6.2
P.C
.D4
0
+0.012
6 0 dia. hole
(depth: 6)
View A
Units: mm
6-2
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6.2
Allowable Load for Wrist Axis and Wrist Flange
Wrist Flange
NOTE
• Wash off anti-corrosive paint (yellow color) on the wrist
flange surface with thinner or light oil before mounting the
tools.
• Mount the attachment with the mounting bolts (length: 10
mm or less).
Failure to observe this instruction may affect the manipulator performance.
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7
7.1
7
System Application
Peripheral Equipment Mounts
System Application
7.1
Peripheral Equipment Mounts
The peripheral equipment mounts are fixed on the upper arm for easier
installation of the user’s system application as shown in fig. 7-1 “Installing
Peripheral Equipment” . When peripheral equipment is attached to the Uaxis, the following conditions should be observed.
7.1.1
Allowable Load
The allowable load on the U-axis is a maximum of 31 kg, including the
wrist load.
For instance, when the mass installed in the wrist point is 20 kg, the mass
which can be installed on the upper arm is 11 kg.
Installation Position
There is a limitation on the installation position.
fig. 7-2 “Allowable Load on U-axis” shows the distance between the
center of U-axis rotation and the load gravity.
Fig. 7-1: Installing Peripheral Equipment
Limited dimension
of Z-coordinate:
400 at a maximum
220
Center of U-axis rotation
W2
A
Z-coordinate
direction
X-coordinate
direction
W1
70
7.1.2
Units: mm
Tapped holes M6
(Depth:10mm)(pitch:1.0)(4 holes)
70
View A
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7.2
System Application
Internal User I/O Wiring Harness and Air Line
Fig. 7-2: Allowable Load on U-axis
(kg)
30
W1=6kg
W1=10kg
20
W1=16kg
Weight W2
W1=20kg*1
*1 In this case, unbalanced
moment is not permitted.
10
0
-200 -100
0
100 200 300 400 500 (mm)
Distance between Center of U-axis
Rotation and Load Gravity (X direction)
7.2
Internal User I/O Wiring Harness and Air Line
Internal user I/O wiring harness (14 wires: 0.2 mm2 x 8 wires and 1.25
mm2 x 6 wires), and an air line are used in the manipulator for the drives
of the peripheral devices mounted on the upper arm as shown in fig. 7-3
“Internal User I/O Wiring Harness and Air Line” . The connector pins (1 to
16) are assigned as shown in fig. 7-4 “Details of the Connector Pin
Numbers” . Wiring must be performed by users, following the conditions
below:
The allowable current for internal user
I/O wiring harness
3 A or less for each wire
(The total current value for pins 1 to 16
must be 40 A or less.)
The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0 mm .)
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7
7.2
System Application
Internal User I/O Wiring Harness and Air Line
Fig. 7-3: Internal User I/O Wiring Harness and Air Line
Connector for internal
user I/O wiring harness (for U-arm) :
JL05-2A20-29SC
(pin connector with a cap)
Prepare socket connector
JL05-6A20-29P.
Connector for internal
user I/O wiring harness:
JL05-2A20-29PC
(pin connector with a cap)
Prepare socket connector
JL05-6A20-29S.
2BC
1BC
3BC
Air inlet: Tapped hole
PT3/8 with pipe plug
View A
Exhaust port (air flow):
Tapped hole PT3/8 with
pipe plug
A
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7.2
System Application
Internal User I/O Wiring Harness and Air Line
Fig. 7-4: Details of the Connector Pin Numbers
Connector for Internal User I/O Wiring Harness
on the Connector Base
Pins used
1
2
3
4
5
6
7 (Open)
8 (Open)
9
10
2
11 (1.25 mm2)
12 (1.25 mm2)
13 (1.25 mm )
14 (1.25 mm2)
15 (1.25 mm2)
16 (1.25 mm2)
2
4
9
13
1
5
3
6
7
8
11
12
15
16
10
14
Internal user I/O wiring harness: 0.2 mm2, 8 wires
: 1.25 mm2, 6 wires
Connector for Internal User I/O Wiring Harness
on the U-arm
Pins used
NOTE
1
2
3
4
5
1
6
2
3
6
5
7 (+24V: for shock sensor)
4
8 (Shock sensor signal input)
7
8
10
9
9
10
12
11
2
13
14
11 (1.25 mm )
12 (1.25 mm2)
16
15
13 (1.25 mm22)
14 (1.25 mm2)
15 (1.25 mm2)
16 (1.25 mm )
Internal user I/O wiring harness: 0.2 mm2, 8 wires
: 1.25 mm2, 6 wires
• The 7th pin and 8th pin of 3BC connector on the U-arm are
respectively connected with the shock sensor power supply and shock sensor signal input port of the DX100 controller.
• The 7th pins and 8th pins of respective 3BC connectors
are not connected with each other.
• For the wiring, refer to fig. 8-3(a) “Internal Connection
Diagram” .
The same pin-number connectors (1 to 16) at both connector base part
and arm part are connected with the single wire lead of 0.2 mm2 or 1.25
mm2.
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8
8.1
8
Electrical Equipment Specification
Position of Limit Switch
Electrical Equipment Specification
8.1
Position of Limit Switch
Limit switches are optional. Refer to fig. 8-1 “Location of Limit Switch” for
location. A manipulator type with the S- or L-axis overrun limit switch or
the LU-axes interference limit switch is YR-HP020RD-A01.
Fig. 8-1: Location of Limit Switch
L-axis interference limit switch
(optional)
L-axis interference limit
switch (optional)
S-axis overrun limit switch
(optional)
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8.2
8.2
Electrical Equipment Specification
Internal Connections
Internal Connections
High reliability connectors which can be easily put on and removed are
used with each connector part. For the numbers, types, and locations of
connectors, refer to fig. 8-2 “Location and Numbers of Connectors” .
Diagrams for internal connections of the manipulator are shown in
fig. 8-3(a) “Internal Connection Diagram” and in fig. 8-3(b) “Internal
Connection Diagram” .
Fig. 8-2: Location and Numbers of Connectors
3BC (For internal user
I/O wiring harness)
3BC (For internal user
I/O wiring harness)
Table 8-1: List of Connector Types
Name
Type of Connector
Connector for internal user I/O
wiring harness on connector base
JL05-2A20-29PC
(JL05-6A20-29S: Optional)
Connector for internal user I/O
wiring harness on U-arm
JL05-2A20-29SC
(JL05-6A20-29P: Optional)
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8 Electrical Equipment Specification
8.2 Internal Connections
Fig. 8-3(a): Internal Connection Diagram
POWER CABLE
INTERNAL CABLE IN S-AXIS
0BT
P BAT
0BT
P BAT
1
2
3
4
0BAT11
BAT11
0BAT12
BAT12
0BT
P BAT
0BT
P BAT
5
6
7
8
0BAT21
BAT21
0BAT22
BAT22
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
1
2
3
4
5
6
7
8
1BC(10X4)
DX100
CN1-5
CN1-4
CN1-10
CN1-9
CN1-1
CN1-2
P
CN1-5
CN1-4
+24V
0V
1
3
P
CN1-10
CN1-9
+24V
0V
2
4
P
CN1-1
CN1-2
SPG+1
SPG-1
CN1-3
FG1
INTERNAL CABLE IN L-AXIS
<NOTES>
0BAT1
BAT1
0BAT2
BAT2
0BAT3
BAT3
- For the limit switch specification, the connection of the section A is changed as follows:
- For the IP65 specification, the connection of the section A and B are changed as follows:
0BAT4
BAT4
PG0V1
PG5V1
PG0V2
PG5V2
PG0V3
PG5V3
PG0V4
PG5V4
PG0V5
PG5V5
PG0V6
PG5V6
P
SPG+2
SPG-2
CN1-8
FG2
P
No.20CN
20CN-1
-2
-6
-5
-4
-9
-10
P
DATA+1
DATA-1
BAT
OBT
+5V
0V
FG1
No.21CN
21CN-1
-2
-6
-5
-4
-9
-10
P
P
CN2-1
CN2-2
PG
SPG+3
SPG-3
P
P
CN2-3
S-AXIS
PG
CN2-6
CN2-7
P
FG3
CN2-6
CN2-7
SPG+4
SPG-4
DATA+3
DATA-3
BAT
OBT
+5V
0V
FG3
No.22CN
22CN-1
-2
-6
-5
-4
-9
-10
P
P
P
No.23CN
23CN-1
-2
-3
-4
24CN-1
-2
-3
P
P
CN2-8
FG4
CN3-1
CN3-2
SPG+5
SPG-5
LD1
LD1
LB1
LB1
LB1
LA1
LB1
LA1
P
LD1
LD1
LD1
LC1
LD1
LC1
P
A
LB3
L AND U-AXIS INTERFERENCE L.S
LC2
LD2
LC2
L-AXIS OVERRUN L.S
LC3
LD3
LD3
LB1
LA1
LA1
LA2
S-AXIS OVERRUN L.S
LD1
LC1
P
LC2
P
A
L-AXIS OVERRUN L.S
LA3
LC1
S-AXIS OVERRUN L.S
LA2
LB2
L AND U-AXIS INTERFERENCE L.S
LB3
LC2
LD2
L AND U-AXIS INTERFERENCE L.S
LB3
L-AXIS OVERRUN L.S
LC3
LD3
L AND U-AXIS INTERFERENCE L.S
LD3
- For the standard specification, the pins No.7 and No.8 of 3BC connector on the U-arm are
respectively connected with the shock sensor power supply and the shock sensor signal input
port of the DX100 controller.
DATA+3
DATA-3
BAT
OBT
+5V
0V
FG3
PG
DX100 Connection Port
Pin No.
Shock sensor power supply; +24V (1A)
7
Shock sensor signal input
8
U-AXIS
OBT
BAT
P
P
CN2-8
LB3
S-AXIS OVERRUN L.S
LC1
L-AXIS
No.6CN
1BC(10X4)
L-AXIS OVERRUN L.S
LA3
SLU-axes with Overrun Limit Switch Specification (IP65 specification)
DATA+2
DATA-2
BAT
OBT
+5V
0V
FG2
No.5CN
5CN-1
-2
-3
-4
6CN-1
-2
-3
P
CN2-3
LA2
LB2
LA2
SLU-axes with Overrun Limit Switch Specification
OBT
BAT
CN2-1
CN2-2
LB1
P
P
CN1-8
LB1
LC1
LD1
P
CN1-6
CN1-7
LA1
P
OBT
BAT
CN1-6
CN1-7
S-AXIS OVERRUN L.S
LA1
LB1
P
CN1-3
INTERNAL CABLE IN BT-AXIS
DATA+4
DATA-4
BAT
OBT
+5V
0V
FG4
PG
R-AXIS
OBT
BAT
CN3-1
CN3-2
P
P
No.7CN
7CN-1
-7
-2
-8
-3
-9
DATA+5
DATA-5
BAT
OBT
+5V
0V
P
-4
-10
DATA+6
DATA-6
-5
-11
-6
+5V
0V
FG6
P
P
CN3-3
CN3-3
P
P
P
FG5
No.14CN
14CN-1
-2
-3
-4
15CN-1
-2
-3
DATA+5
DATA-5
BAT
OBT
+5V
0V
FG5
No.16CN
16CN-1
-2
-3
-4
17CN-1
-2
-3
DATA+6
DATA-6
BAT
OBT
+5V
0V
FG6
PG
B-AXIS
PG
T-AXIS
OBT
BAT
CN3-6
CN3-7
P
CN3-6
CN3-7
SPG+6
SPG-6
P
P
CN3-8
CN3-8
P
FG6
P
OBT
BAT
CN4-1
CN4-6
P
CN4-1
CN4-6
+24V
LB1
CN4-2
CN4-7
CN4-2
CN4-7
SS2
P
CN4-3
CN4-8
P
CN4-10
CN4-3
CN4-8
AL2
CN4-10
0V
CN2-4
CN2-5
P
CN2-4
CN2-5
CN2-9
CN2-10
P
CN2-9
CN2-10
LA1
LB1
LC1
LD1
P
LB3
LA2
P
LD3
LC2
A
AL1
BC2
- When connecting the pin No.7 and No.8 of the connector base respectively with the pin No.7 and No.8
of 3BC connectors on the U-arm, the connection of crimped contact-pins (SS1, SS2) should be changed
as shown in the section C below.
(Contact your Yaskawa representative when modifying the wiring before use.)
FOR LAMP(OPTION)
P
INTERNAL CABLE
POWER CABLE
SPG+7
SPG-7
U-ARM
CONNECTOR BASE
CN3-4
CN3-5
P
CN3-9
CN3-10
CN4-4
CN4-5
CN4-9
P
P
CN3-4
CN3-5
CN3-9
CN3-10
CN4-4
CN4-5
CN4-9
E
+24V
LB1
LA1
LB1
LB1
LD1
LC1
LD1
LC1
LD1
LD1
P
0V
+5V
0V
+5V
FG7
E
E
P
LB3
LA2
P
LD3
LC2
CN4-1
CN4-2
1BC(10X4)
CN4-1
CN4-2
24V(1A)
SS2
Base
UNUSED
Casing
E
3BC(20-29)
E
E
7
8
1
2
3
4
5
6
SS1
SS2
E
1
2
3
4
1
2
P
3
4
P
5
6
P
SS1
SS2 P
SS1
SS2
P
C
2
3
4
SS1
SS2
P
P
P
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
E
3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Casing
SS1
SS2
E E
3BC(20-29)
3BC(20-29)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
P
DX100
Section A for IP65 Specification
E E
+24V
LD1
E
3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
LB1
LA1
Base
E
C
E
Crimped
Contact-Pin
E
3BC(20-29)
E
E
1
2
3
4
5
6
7
8
1
2
3
4
5
6
SS1
SS2
P
P
P
P
P
1
2
3
4
1
2
3
4
SS1
SS2
SS1
SS2
P
P
P
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
FOR SPARE CABLE
B
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8 Electrical Equipment Specification
8.2 Internal Connections
Fig. 8-3(b): Internal Connection Diagram
2BC(6X6)
E
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
ME1
ME2
ME2
MU1
MV1
MW1
MU2
MV2
MW2
MU2
MV2
MW2
FOR SPARE CABLE
Casing
E
No.3CN
3CN-3
-2
-1
-PE
-4
-5
No.4CN
4CN-1-A
-B
-C
-D
-1
-2
3BC(20-29)
E
No.8CN
MU1
MV1
MW1
ME1
BA1
BB1
8CN-1
2
3
4
5
6
7
8
9
10
9CN-1
2
3
4
5
6
S-AXIS
SM
YB
MU2
MV2
MW2
ME2
BA2
BB2
L-AXIS
SM
YB
E
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
P
1
2
3
4
P
SS1
SS2
P
1
2
3
4
P
P
P
SS1
SS2
P
P
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
SM
B-AXIS
No.9CN
Section B for IP65 Specification
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
2BC(6X6)
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
CN5-6
CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6
CN6-1
CN6-2
CN6-3
CN6-4
CN6-5
CN6-6
PE
No.26CN
MU3
MV3
MW3
MU4
MV4
MW4
26CN-3
-2
-1
-PE
-4
-5
No.25CN
MU5
MV5
MW5
MU6
MV6
MW6
ME3
ME4
ME5
ME6
BA1
BB1
BA2
BA3
BA4
BB4
BA5
BA6
25CN-1
-2
-3
-4
-1
-2
MU4
MV4
MW4
ME4
BA4
BB4
SM
U-AXIS
YB
SM
R-AXIS
YB
No.35CN
No.10CN
10CN-1
-2
-3
-4
MU3
MV3
MW3
ME3
BA3
BB3
No.18CN
MU5
MV5
MW5
ME5
18CN-1
-2
-3
-4
-1
-2
MU5
MV5
MW5
ME5
BA5
BB5
No.36CN
-5
-6
-7
-8
MU6
MV6
MW6
ME6
No.12CN
12CN-1
-2
-3
-4
No.19CN
BA5
BB5
BA6
BB6
19CN-1
-2
-3
-4
-1
-2
No.37CN
MU6
MV6
MW6
ME6
BA6
BB6
YB
SM
T-AXIS
YB
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9.1
9
Maintenance and Inspection
Inspection Schedule
Maintenance and Inspection
DANGER
•
Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
•
For disassembly or repair, contact your Yaskawa representative.
•
Do not remove the motor, and do not release the brake.
Failure to observe this caution may result in injury from unexpected
turning of the manipulator’s arm.
WARNING
•
Before maintenance or inspection, be sure to turn the main power
supply OFF, and put up a warning sign. (ex. DO NOT TURN THE
POWER ON.)
Failure to observe this warning may result in electric shock or injury.
CAUTION
•
The battery pack must be connected before removing detection
connector when maintenance and inspection.
Failure to this caution may result in the loss of home position data.
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 intervals are classified into six
levels. Conduct periodical inspections according to the inspection
schedule in table 9-1 “Inspection Items” .
In table 9-1, the inspection items are categorized by three types of
operations: operations which can be performed by personnel authorized
of the user, operations which can be performed by personnel being
trained, and operations which can be performed by your YASKAWA
representative. Only specified personnel are to do the inspection work.
• The inspection interval must be based on the servo power
supply ON time.
NOTE
• These inspections were developed for applications where
the manipulator is used for arc welding work. For any different or special applications, the inspection process
should be developed on an case-by-case basis.
For axes which are used very frequently (in handling applications, etc.), it is recommended that inspections be conducted at shorter Intervals. Contact your Yaskawa
representative.
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External lead
Working area and whole exterior of
manipulator
SLU-axes motors
Manipulator base mounting bolts
Cover mounting screws
Connector base
BT-axes
timing belts
Wire harness in manipulator
(for SLU-axes) (for RBT-axes)
2
3
4
5
6
7
8
9
11
Battery pack in manipulator
Daily
•
•
•
•
1000H Cycle
•
24000 H
•
•
•
Visual,
multimeter
Visual,
multimeter
Manual
Manual
•
•
•
12000 H Cycle
•
•
36000 H
Phillips
screw
driver,
wrench
Wrench
Visual
Visual
Visual
Visual
Replace the battery pack when the battery alarm occurs or the
manipulator drove for 36000H.
Replace.4)
Check for connection between terminals.
Replace.4)
Check for conduction between the main connector of connector base
and intermediate connector with manually shaking the wire.
Check for wear of protective spring.3)
Check for belt tension and wear.
Check for loose connectors.
Tighten loose bolts. Replace if necessary.
Tighten loose bolts. Replace if necessary.
Check for grease leakage.2)
Clean the working area if dust or spatter is present.
Check for damage and exterior cracks.
Check for damage and deterioration of leads.
Check alignment mark accordance and damage at the
home position.
Operation
6000 H Cycle
Charge
Inspection
•
•
•
•
•
•
•
•
• •
•
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
9
9.1
10 Wire harness in manipulator
(for BT-axes)
Alignment mark
1
Method
Specified
Schedule
Person
Licensee
Items1)
Your YASKAWA
representative
Table 9-1: Inspection Items (Sheet 1 of 2)
HW1481348
Maintenance and Inspection
Inspection Schedule
9-2
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4
5
2
3
1
•
Check for malfunction. (Replace if necessary.)
Supply grease5) (12000H cycle). See chapter 9.3.7 .
Check for malfunction. (Replace if necessary.)
Supply grease5) (12000H cycle). See chapter 9.3.6 .
.
Inspection
Charge
• •
• •
•
• •
• •
• •
Inspection No. correspond to the numbers in fig. 9-1 “Inspection Items” .
The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your YASKAWA representative.
When checking for conduction with multimeter, connect the battery pack to “BAT” and “OBT” of connectors on the motor side for each axis, and then remove connectors on
detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer tochapter 9.3.8 “Notes for Maintenance” .)
Internal cables for S-, L-, U-, R- B- and T-axes to be replaced at 24000H inspection.
For the grease, refer to table 9-2 “Inspection Parts and Grease Used” .
17 Overhaul
Grease Gun
Grease Gun
•
•
15 T-axis gear
Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle).
See chapter 9.3.4 and chapter 9.3.5 .
Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle).
See chapter 9.3.2 and chapter 9.3.3 .
Exchange grease5) (12000H cycle).
See chapter 9.3.2 and chapter 9.3.3 .
Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle). See chapter 9.3.1 .
Exchange grease5) (12000H cycle). See chapter 9.3.1
Operation
9
9.1
16 R-axis cross roller bearing
Grease Gun
•
14 RBT-axes speed reducers
Daily
Grease Gun
1000H Cycle
• •
6000 H Cycle
13 LU-axes speed reducers
12000 H Cycle
Grease Gun
24000 H
• •
36000 H
12 S-axis speed reducer
Method
Specified
Schedule
Person
Licensee
Items1)
Your YASKAWA
representative
Table 9-1: Inspection Items (Sheet 2 of 2)
HW1481348
Maintenance and Inspection
Inspection Schedule
9-3
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9
9.1
Maintenance and Inspection
Inspection Schedule
Table 9-2: Inspection Parts and Grease Used
No.
Grease Used
Inspected Parts
12, 13
VIGO Grease RE No. 0
S-, L-, and U-axes speed
reducers
14, 15
Harmonic Grease SK-1A
R-, B- and T-axes speed
reducers,
T-axis gear
16
Alvania EP Grease 2
R-axis cross roller bearing
The numbers in the above table correspond to the numbers in table 9-1
“Inspection Items” .
9-4
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1
S-Axis
5
12
9
13 L-Axis
4 S-Axis
Fig. 9-1: Inspection Items
18
U-Axis
13
1
L-Axis
1
T-Axis
8
T-Axis
1
15
8
T-Axis
R-Axis
16
R-Axis
14
14
BT-Axis
L-Axis
4
7
11
2
9
9.1
10
1
U-Axis
U-Axis
4
HW1481348
Maintenance and Inspection
Inspection Schedule
9-5
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9.2
9.2
9.2.1
Maintenance and Inspection
Notes on Maintenance Procedures
Notes on Maintenance Procedures
Battery Pack Replacement
The battery packs (type: HW0470360-A)are attached in the two positions
indicated in fig. 9-2 “Battery Pack Location” . If the battery alarm occurs
in the DX100, replace the battery pack in accordance with the following
procedure:
Fig. 9-2: Battery Pack Location
Battery pack
Plate fastening
screw (M4)
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9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Fig. 9-3: Battery Pack Connection
Battery pack before replacement
See the step 5.
Connector
Circuit board
(Type: SGDR-EFBA02A)
See the step 4.
New battery pack
(HW0470360-A)
1. Turn OFF the DX100 main power supply.
2. Remove the plate fixing screws and the plate on the connector base,
then pull the battery pack out to replace it with the new one.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connector on the
board.
5. Remove the old battery pack from the board.
NOTE
Remove the old battery pack after connecting the new one
so that the encoder absolute data does not disappear.
6. Mount the new battery pack to the holder.
7. Reinstall the plate.
NOTE
Do not allow plate to pinch the cables when reinstalling the
plate.
9-7
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9.3
9.3
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Notes on Grease Replenishment/Exchange Procedures
Make sure to follow the instructions listed below at grease replenishment/
exchange. Failure to observe the following notes may result in damage to
motor and speed reducer.
• If grease is added without removing the plug/screw from
the grease exhaust port, the grease will leak inside a
motor or an oil seal of a speed reducer will come off, which
may result in damage to the motor. Make sure to remove
the plug/screw.
NOTE
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.
• Make sure to use a grease pump to inject grease. Set air
supply pressure to the grease pump at 0.3 MPa or less,
and the grease injection rate at 8 g/s or less.
• Make sure to fill the hose on the grease inlet with grease
beforehand to prevent air from leaking into the speed
reducer.
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9.3
9.3.1
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Replenishment/Exchange for S-axis Speed Reducer
Fig. 9-4: S-axis speed Reducer Diagram
Grease exhaust port
(Hexagon socket head plug PT1/8)
Grease inlet
(Hexagon socket head plug PT1/8)
NOTE
9.3.1.1
S-axis speed reducer
For the ceiling-mounted manipulator, the grease exhaust
port and the grease inlet are inverted.
Grease Replenishment (Refer to fig. 9-4 “S-axis speed Reducer Diagram” .)
Replenish the grease according to the following procedure:
1. Remove the hexagon socket head plugs PT1/8 from the grease inlet
and grease exhaust port.
NOTE
If grease is injected with the plug on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
2. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
3. Inject the grease through the grease inlet using a grease gun
– Grease type:
VIGO Grease RE No. 0
– Amount of grease:
360 cc (720 cc for 1st supply)
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate:
8 g/s or less
4. Move the S-axis for a few minutes to discharge excess grease.
5. Remove the grease zerk from the grease inlet, and reinstall the plug.
Before installing the plug, apply Three Bond 1206C on the thread part
of the plug, then tighten the plug with a tightening torque of 5 N•m
(0.51 kgf•m).
(Refer to table 10-1 “Spare Parts for the MOTOMAN-HP020RD-A00,
A01” .)
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9.3
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
6. Wipe the discharged grease with a cloth, and reinstall the plug. Before
installing the plug, apply Three Bond 1206C on the thread part of the
plug, then tighten the plug with a tightening torque of 5 N•m (0.51
kgf•m).
9.3.1.2
Grease Exchange (Refer to fig. 9-4 “S-axis speed Reducer Diagram” .)
1. Remove the hexagon socket head plugs PT1/8 from the grease inlet
and grease exhaust port.
NOTE
If grease is injected with the plug on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
2. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
3. Inject the grease through the grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No. 0
– Amount of grease:
approx. 1800 cc
– Air supply pressure of grease pump:
0.3 MPa or less
– Grease injection rate:
8 g/s or less
4. The grease exchange is completed when new grease appears in the
grease exhaust port. (The new grease can be distinguished from the
old grease by color.)
5. Move the S-axis for a few minutes to discharge excess grease.
6. Remove the grease zerk from the grease inlet, and reinstall the plug.
Before installing the plug, apply Three Bond 1206C on the thread part
of the plug, then tighten the plug with a tightening torque of 5 N•m
(0.51 kgf•m).
7. Wipe the discharged grease with a cloth, and reinstall the plug. Before
installing the plug, apply Three Bond 1206C on the thread part of the
plug, then tighten the plug with a tightening torque of 5 N•m (0.51
kgf•m).
9-10
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9.3
9.3.2
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Replenishment/Exchange for L-axis Speed Reducer
Fig. 9-5: T-axis speed Reducer Diagram
L-axis speed reducer
Grease exhaust port
(Hexagon socket head cap screw PT1/8)
L-arm
Grease inlet
(Hexagon socket head plug M6)
NOTE
9.3.2.1
For the ceiling-mounted manipulator, the grease exhaust
port and the grease inlet are inverted.
Grease Exchange (Refer to fig. 9-5 “T-axis speed Reducer Diagram” .)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT1/8 from the grease
exhaust port.
3. Remove the hexagon socket head cap screw M6 from the grease inlet.
NOTE
If grease is injected with the plug on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
4. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No. 0
– Amount of grease:
100 cc (200 cc for 1st supply)
– Air supply pressure of grease pump:0.3 MPa or less
– Grease injection rate:
8 g/s or less
6. Move the L-axis for a few minutes to discharge excess grease.
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9
9.3
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
7. Remove the grease zerk from the grease inlet, and reinstall the screw.
Before installing the screw, apply Three Bond 1206C on the thread
part of the screw, then tighten the screw with a tightening torque of 5
N•m (0.51 kgf•m).
8. Wipe the discharged grease with a cloth, and reinstall the plug. Before
installing the plug, apply Three Bond 1206C on the thread part of the
plug, then tighten the plug with a tightening torque of 5 N•m (0.51
kgf•m).
9.3.2.2
Grease Exchange (Refer to fig. 9-5 “T-axis speed Reducer Diagram” .)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT1/8 from the grease
exhaust port.
3. Remove the hexagon socket head cap screw M6 from the grease inlet.
NOTE
If grease is injected with the screw on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the screw before the grease injection.
4. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No. 0
– Amount of grease:
approx. 500 cc
– Air supply pressure of grease pump:
0.3 MPa or less
– Grease injection rate:
8 g/s or less
6. The grease exchange is completed when new grease appears in the
grease exhaust port. (The new grease can be distinguished from the
old grease by color.)
7. Move the L-axis for a few minutes to discharge excess grease.
8. Remove the grease zerk from the grease inlet, and reinstall the screw.
Before installing the screw, apply Three Bond 1206C on the thread
part of the screw, then tighten the screw with a tightening torque of 10
N•m (1.0 kgf•m).
9. Wipe the discharged grease with a cloth, and reinstall the plug. Before
installing the plug, apply Three Bond 1206C on the thread part of the
plug, then tighten the plug with a tightening torque of 4.9 N•m (0.5
kgf•m).
9-12
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9.3
9.3.3
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Replenishment/Exchange for U-axis Speed Reducer
Fig. 9-6: U-axis Speed Reducer Diagram
U-arm
U-axis
speed reducer
Grease exhaust port
Hexagon socket head cap
screw M6
Grease inlet
Hexagon socket head plug PT 1/8
NOTE
9.3.3.1
For the ceiling-mounted manipulator, the grease exhaust
port and the grease inlet are inverted.
Grease Replenishment (Refer to fig. 9-6 “U-axis Speed Reducer Diagram” .)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head cap screw M6 from grease exhaust
port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
NOTE
If grease is injected with the plug on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
4. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No. 0
– Amount of grease:
60 cc (120 cc for 1st supply)
– Air supply pressure of grease pump:
0.3 MPa or less
– Grease injection rate:
8 g/s or less
6. Move the U-axis for a few minutes to discharge excess grease.
7. Remove the grease zerk from the grease inlet, and reinstall the plug.
Before installing the plug, apply Three Bond 1206C on the thread part
of the plug, then tighten the plug with a tightening torque of 5 N•m
(0.51 kgf•m).
8. Wipe the discharged grease with a cloth, and reinstall the screw.
Before installing the screw, apply Three Bond 1206C on the thread
part of the screw, then tighten the screw with a tightening torque of 5
N•m (0.51 kgf•m).
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9.3
9.3.3.2
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Exchange (Refer to fig. 9-6 “U-axis Speed Reducer Diagram” .)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head cap screw M6 from the grease
exhaust port.
NOTE
• If grease is injected with the plug on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.
3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No. 0
– Amount of grease:
approx. 300 cc
– Air supply pressure of grease pump:
0.3 MPa or less
– Grease injection rate:
8 g/s or less
5. The grease exchange is complete when new grease appears in the
grease exhaust port. (The new grease can be distinguished from the
old grease by color.)
6. Move the U-axis for a few minutes to discharge excess grease.
7. Remove the grease zerk from the grease inlet, and reinstall the plug.
Before installing the plug, apply Three Bond 1206C on the thread part
of the plug, then tighten the plug with a tightening torque of 5 N•m
(0.51 kgf•m).
8. Wipe the discharged grease with a cloth, and reinstall the screw to the
grease exhaust port. Before installing the screw, apply Three Bond
1206C on the thread part of the screw, then tighten the screw with a
tightening torque of 5 N•m (0.51 kgf•m).
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9.3
9.3.4
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Replenishment for R-axis Speed Reducer
Fig. 9-7: R-axis Speed Reducer Diagram
Grease inlet
Grease zerk A-MT6X1
Exhaust port
Hexagon socket head cap screw M6
1. Remove the hexagon socket head cap screw M6 from the exhaust
port.
2. Inject grease through the grease inlet using a grease zerk A-MT6X1.
(Refer to fig. 9-7 “R-axis Speed Reducer Diagram” .)
– Grease type:
Harmonic grease SK-1A
– Amount of grease:
8 cc (16 cc for the first supply)
NOTE
The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject excessive grease through the grease inlet.
3. Reinstall the screw on the exhaust port. Before installing the screw,
apply Three Bond 1206C on the thread part of the screw, then tighten
the screw with a tightening torque of 5 N•m (0.51 kgf•m).
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9.3
9.3.5
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Replenishment for B-, T-axes Speed Reducers
Fig. 9-8: B-, T-axes Speed Reducers Diagram
Exhaust port (for B-axis)
(Plug LP-M5)
T-axis speed reducer
Exhaust port (for T-axis)
(Hexagon socket
set screw M6)
B-axis speed reducer
Gease inlet (for T-axis)
(Hexagon socket head
cap screw M6)
Gease inlet (for B-axis)
(Hexagon socket head cap screw M6)
1. Remove the plug LP-M5 and the hexagon socket head cap screw M6
from the exhaust ports.
NOTE
Remove the cover for the B-axis speed reducer.
2. Remove the hexagon socket head cap screws M6 from the grease
inlets.
3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
(Refer to fig. 9-8 “B-, T-axes Speed Reducers Diagram” .)
– Grease type:
Harmonic grease SK-1A
– Amount of grease:
For B-axis: 10 cc
(20 cc for the first supply)
For T-axis: 5 cc
(10 cc for the first supply)
NOTE
The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject excessive grease through the grease inlet.
5. Reinstall the plug/screw to the exhaust ports. Before installing the
plug/screw, apply Three Bond 1206C on the thread part of the plug/
screw, then tighten the plug/screw with a tightening torque of 5 N•m
(0.51 kgf•m).
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9.3
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
6. Remove the grease zerk from the grease inlets, and reinstall the
screws. Before installing the screws, apply Three Bond 1206C on the
thread part of the screws, then tighten the screws with a tightening
torque of 5 N•m (0.51 kgf•m).
NOTE
Mount the cover for the B-axis speed reducer.
(Refer to chapter 9.3.8 “Notes for Maintenance” .)
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9.3
9.3.6
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Replenishment for T-axis Gear
Fig. 9-9: T--axis Gear Diagram
Exhaust port
(Plug LP-M5)
Gear grease inlet
(Hexagon socket head cap screw M6)
1. Remove the plug LP-M5 from the exhaust port.
2. Remove the hexagon socket head cap screw M6 from the grease inlet.
3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
4. Inject grease through the gear grease inlet using a grease gun.
(Refer to fig. 9-9 “T--axis Gear Diagram” .)
– Grease type:
Harmonic grease SK-1A
– Amount of grease:
5 cc (10 cc for the first supply)
NOTE
The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject excessive grease through the grease inlet.
5. Reinstall the plug to the exhaust port. Before installing the plug, apply
Three Bond 1206C on the thread part of the plug, then tighten the
screw with a tightening torque of 5 N•m (0.51 kgf•m).
6. Remove the grease zerk from the gear grease inlet, and reinstall the
screw. Before installing the screw, apply Three Bond 1206C on the
thread part of the screw, then tighten the screw with a tightening
torque of 5 N•m (0.51 kgf•m).
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9.3
9.3.7
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Grease Replenishment for R-axis Cross Roller Bearing
Fig. 9-10: R-axis Cross Roller Bearing Diagram
Exhaust port
Plug LP-M5
R-axis cross roller bearing
Grease inlet
Hexagon socket head cap screw M6
(Length: 6mm)
1. Remove the plug LP-M5 from the exhaust port.
2. Remove the hexagon socket head cap screw M6 from the grease inlet.
3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
(Refer to fig. 9-10 “R-axis Cross Roller Bearing Diagram” .)
– Grease type:
Alvania EP grease 2
– Amount of grease:
8 cc (16 cc for the first supply)
NOTE
The exhaust port is used for air exhaust, and the grease is
not exhausted from the exhaust port. Do not inject excessive grease through the grease inlet.
5. Reinstall the plug to the exhaust port. Before installing the plug, apply
Three Bond 1206C on the thread part of the plug, then tighten the
screw with a tightening torque of 5 N•m (0.51 kgf•m).
6. Remove the grease zerk from the grease inlet, and reinstall the screw.
Before installing the screw, apply Three Bond 1206C on the thread
part of the screw, then tighten the screw with a tightening torque of 5
N•m (0.51 kgf•m).
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9.3
9.3.8
9.3.8.1
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Notes for Maintenance
Wrist Axes
The motor and encoder units are provided with the wrist unit. To prevent
fumes from penetrating into the wrist unit, the matched parts are sealed
with sealing bond. Therefore, if the wrist cover is disassembled, reseal
with sealing bond (Three Bond 1206C). Refer to table 10-1 “Spare Parts
for the MOTOMAN-HP020RD-A00, A01” .
Fig. 9-11: Sealing Part of Wrist Unit
Cover
Cover
9.3.9
Cover jointing face
Cover jointing face
Encoder Connector (with CAUTION Label)
NOTE
• When performing maintenance such as replacement of a
wire harness in the manipulator, the encoder connector
(with CAUTION label) 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. Removing the encoder connector without connecting the battery backup leads to disappearance of the
encoder absolute data.
For the battery pack connection, refer to fig. 9-12(a)
“Encoder Connector for S-, L- and U-axes” and
fig. 9-12(b) “Encoder Connector for R-, B- and T-axes” .
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9.3
9.3.9.1
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Battery Pack Connection (for S-, L-, U-axes Motors)
The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motors (marked as BAT and OBT). Connect the
battery pack according to the following procedure.
1. Remove the cap attached to the battery backup connector of the
motors.
2. Connect the battery packs (HW9470932-A) with the battery backup
connectors located at the end point of the cables for the encoder.
(Under this condition, remove the encoder connector and carry out the
maintenance checks).
3. After the maintenance check, verify that all the connectors are
connected and remove the battery pack. Install the caps attached to
the battery backup connector of the motor.
NOTE
Do not remove the battery pack in the connector base.
Fig. 9-12(a): Encoder Connector for S-, L- and U-axes
Encoder connector
Motor
CAUTION
Connect battery to encoder
to save the data before
removing conector.
Motor power connector
CAUTION label
0BT
b
a 0BT*
BAT
a
b BAT*
Battery pack (HW9470932-A)
Connector for the battery backup
CAUTION label (Enlarged view)
a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)
CAUTION
Connect battery to encoder
to save the data before
removing conector.
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9.3
9.3.9.2
Maintenance and Inspection
Notes on Grease Replenishment/Exchange Procedures
Battery Pack Connection (for R-, B-, T-axes Motors)
The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motors (marked as BAT and OBT). Connect the
battery pack according to the following procedure.
1. Connect the battery packs (HW9470984-A) with the battery backup
connectors located at the end point of the cables for the encoder.
(Under this condition, remove the encoder connector and carry out the
maintenance checks).
2. After the maintenance check, verify that all the connectors are
connected and remove the battery pack. Install the caps attached to
the battery backup connector of the motor.
NOTE
Do not remove the battery pack in the connector base.
Fig. 9-12(b): Encoder Connector for R-, B- and T-axes
Encoder
Motor
Motor cable, etc.
Wire harness
in manipulator
Power connector
Connection
0BT
b
BAT
a
CAUTION
Connect battery to encoder
to save the data before
removing conector.
Encoder connector
a
0BT
b
BAT
Battery pack
(HW9470932-A)
CAUTION label
0BT
b
a
0BT
BAT
a
b
BAT
CAUTION label (Enlarged view)
a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)
CAUTION
Connect battery to encoder
to save the data before
removing conector.
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Recommended Spare Parts
10 Recommended Spare Parts
It is recommended that the following parts and components be kept in
stock as spare parts for the MOTOMAN-HP20. The spare parts list for the
MOTOMAN-HP20 is shown below.
Check the serial number and contact your Yaskawa representative for
preparing lead wires for internal wiring, etc.
Product performance can not be guaranteed when using spare parts from
any company other than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts
• Rank B: Parts for which replacement may be necessary as a result of
frequent operation
• Rank C: Drive unit
NOTE
To replace parts in Rank B or Rank C, be sure to contact
your YASKAWA representative.
Table 10-1: Spare Parts for the MOTOMAN-HP020RD-A00, A01 (Sheet 1 of 2)
Rank
Parts
Name
Name
Type
Manufacturer
Qty
Qty
Remarks
per
Unit
A
1
Grease
Molywhite
RE No. 00
Yaskawa Electric
Corporation
16kg
-
A
2
Grease
Harmonic Grease
SK-1A
Harmonic Drive
System Co., Ltd.
2.5kg
-
A
3
Grease
Alvania EP Grease 2
Showa Oil Co.,
Ltd.
16kg
-
A
4
Liquid Gasket
Three Bond 1206C
Three Bond Co.,
Ltd.
-
-
A
5
Battery Pack
HW0470360-A
Yaskawa Electric
Corporation
1
1
A
6
Battery Pack
HW9470932-A
Yaskawa Electric
Corporation
1
1
B
7
B-axis Timing
Belt
80S4.5M653
Mitsuboshi
Belting Limited
1
1
B
8
T-axis Timing
Belt
80S4.5M518
Mitsuboshi
Belting Limited
1
1
B
9
S-axis
Speed Reducer
HW0387753-B
Yaskawa Electric
Corporation
1
1
B
10
S-axis
Input Gear
HW0313491-1
Yaskawa Electric
Corporation
1
1
B
11
L-axis
Speed Reducer
HW0387753-C
Yaskawa Electric
Corporation
1
1
B
12
L-axis
Input Gear
HW0313492-1
Yaskawa Electric
Corporation
1
1
For wire
harness
in manipulator
replacing
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Recommended Spare Parts
Table 10-1: Spare Parts for the MOTOMAN-HP020RD-A00, A01 (Sheet 2 of 2)
Rank
Parts
Name
Name
Type
Manufacturer
Qty
Qty
Remarks
per
Unit
B
13
U-axis
Speed Reducer
HW9280880-G
Yaskawa Electric
Corporation
1
1
B
14
R-axis
Speed Reducer
HW0381463-A
Yaskawa Electric
Corporation
1
1
B
15
B-axis
Speed Reducer
HW9381633-A
Yaskawa Electric
Corporation
1
1
B
16
T-axis
Speed Reducer
HW0382140-A
Yaskawa Electric
Corporation
1
1
B
17
Wire Harness in HW0175210-A
Manipulator
Yaskawa Electric
Corporation
1
1
B
18
Wire Harness in HW0270954-A
Manipulator for
B- and T-axes
Yaskawa Electric
Corporation
1
1
C
19
AC Servomotor
for S-axis
HW0388665-A
SGMRV-09ANA-YR1*
Yaskawa Electric
Corporation
1
1
C
20
AC Servomotor
for L-axis
HW0388666-A
SGMRV-13ANA-YR2*
Yaskawa Electric
Corporation
1
1
C
21
AC Servomotor
for U-axis
HW0388663-A
SGMRV-05ANA-YR1*
Yaskawa Electric
Corporation
1
1
C
22
AC Servomotor
for R-, B-, Taxes
HW0389298-A
SGMPH-02ANAYR1*
Yaskawa Electric
Corporation
1
3
C
23
Circuit Board
SGDR-EFBA02A
Yaskawa Electric
Corporation
1
1
10-2
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Parts List
11.1 S-axis Unit
11 Parts List
11.1
S-axis Unit
Fig. 11-1: S-axis Unit
1013
1014
1006
1053
1016
1005
1017
1031
1004
1003
1008
1002
1033
1027
1032
1028
1058
1056
1010
1009
1015
1007
1011
1011
1059
1011
1023
1039
1019
1018
1038
1020
1021
1025
1024
1001
1022
1026
1037
1034
1035
1036
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Parts List
11.1 S-axis Unit
Table 11-1: S-axis Unit
No.
DWG No.
Name
Pcs
1001
EZ5036A0
Cap
1
1002
CD-31
Saddle
1
1003
M6X10
Socket screw
2
1004
TA1-S10
Clamp
1
1005
M5X10
Pan screw with spring 1
washer
1006
PT1/8
Plug
1
1007
HW0305812-1
Holder
1
1008
M6X15
GT-SA bolt
2
1009
TA1-S10
Clamp
1
1010
M5X10
Pan screw with spring 1
washer
1011
M10
Eyebolt
3
1013
SGMRV-09ANA-YR1*
Motor
1
1014
M8X30
GT-SA bolt
3
1015
HW0305306-2
M base
1
1016
M5X10
APS Bolt
4
1017
HW0313055-1
Cover
1
1018
M16X20
Socket screw
2
1019
2H-16
Spring Washer
2
1020
MSB8-15
Stripper bolt
1
1021
HW0400645-1
Lever
1
1022
M5X10
APS bolt
6
1023
HW0102292-2
S head
1
1024
HW0387753-B
Speed reducer
1
1025
M10X40
GT-SA bolt
16
1026
HW0100544-2
Base
1
1027
M8X60
Socket Screw
3
1028
2H-8
Spring Washer
3
1031
HW0313491-1
Gear
1
1032
M6X60
Socket screw
1
1033
2H-6
Spring Washer
1
1034
TSH6-01M
Union
1
1035
HW9406775-1
Cover
1
1036
M6X8
APS Bolt
2
1037
NB-0640B
Tube
1
1038
HW0304221-1
Cover
1
1039
M6X15
GT-SA bolt
2
1053
UKM6-01
Union
1
1056
TSH6-01M
Union
1
1058
NB-0640B
Tube
1
1059
M12X35
GT-SA bolt
9
11-2
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Parts List
11.2 L-axis Unit
11.2
L-axis Unit
Fig. 11-2: L-axis Unit
2004
2007
2040
1023
2038
2001
2037
2029
2025
2024
2023
2028
2031
2036
2003
2006
2039
2010
2025
2024
2023
2029
2012
2011
2009
2008
2021
2037
2028
2033
2034
2044
2043
2020
2035
2017
2030
2019
2046
2014
2045
2041
2042
2013
2045
2016
2015
2041
2042
11-3
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Parts List
11.2 L-axis Unit
Table 11-2: L-Axis Unit
No.
DWG No.
Name
Pcs
2001
PT1/8
Plug
1
2003
M8X30
GT-SA bolt
4
2004
M8X25
GT-SA bolt
4
2006
HW0304229-1
M base
1
2007
SGMRV-13ANA-YR2*
Motor
1
2008
M6X90
Socket screw
1
2009
2H-6
Spring Washer
1
2010
HW0313492-1
Gear
1
2011
Y426012.5
Oil seal
1
2012
HW0401506-1
Plate
1
2013
HW0304226-1
Support
1
2014
M6X12
Socket screw
2
2015
HW0304227-1
Cover
1
2016
M6X8
APS Bolt
4
2017
M12X40
Socket screw
12
2019
HW0100546-2
L arm
1
2020
HW0387753-C
Speed reducer
1
2021
M10X40
GT-SA bolt
14
2023
M12X40
Socket screw
2
2024
2H-12
Spring Washer
2
2025
HW0404196-4
Washer
2
2028
TA1-S10
Clamp
2
2029
M5X10
Pan screw with spring 2
washer
2030
M6X10
Socket screw
1
2031
HW0412912-1
Support
1
2033
HW0313056-1
Cover
1
2034
M5X16
GT-SA bolt
4
2035
2H-12
Spring washer
12
2036
M5X16
GT-SA bolt
2
2037
T50L
Cable tie
2
2038
TAI-S10
Clamp
1
2039
M5X10
Pan screw with spring 1
washer
2040
T50L
Cable tie
1
2041
TAI-S10
Clamp
4
2042
M5X10
Pan screw with spring 4
washer
2043
M10X35
Socket screw
6
2044
2H-10
Spring washer
6
2045
T50R
Cable tie
4
2046
2H-6
Spring washer
2
1023
HW0102292-2
S head
1
11-4
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Parts List
11.3 U-axis Unit
11.3
U-axis Unit
Fig. 11-3: U-axis Unit
3003
3004
3002
3003
3004
3001
3020
3002
3019
3019
3012
3006
2019
3005
3013
3014
3008
3016
3018
3017
3009
3007
3016
3018
3017
3015
3011
3010
11-5
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Parts List
11.3 U-axis Unit
Table 11-3: U-Axis Unit
No.
DWG No.
Name
Pcs
3001
SGMRV-05ANA-YR1*
Motor
1
3002
HW0313489-1
Cover
1
3003
M4X10
APS bolt
7
3004
M4
Washer
7
3005
HW0102379-1
Casing
1
3006
HW9280880-G
Speed reducer
1
3007
M8X45
GT-SA bolt
16
3008
M5X65
Socket screw
1
3009
2H-5
Spring washer
1
3010
M14X35
Socket screw
6
3011
GT-SH-14
GT-SH washer
6
3012
M8X30
GT-SA bolt
4
3013
M10X20
Socket screw
1
3014
2H-10
Spring washer
1
3015
M6X10
Socket screw
1
3016
HW0404196-2
Washer
2
3017
M10X35
Socket screw
2
3018
2H-10
Spring washer
2
3019
PT1/8
Plug
2
3020
EZ2940A0
Cap
1
2019
HW0100546-2
L arm
1
11-6
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Parts List
11.4 R-axis Unit
11.4
R-axis Unit
Fig. 11-4: R-axis Unit
4058
4005
4056
4003
4033
4074
4031
4032
4012
4029
4008
4071
4006
4007
4010
4029
4009
4030
4029
4036
4042
4081 4072
4066
4035
3005
4057
4043
4079
4037
4076
4075
4073 4060
4011
4044
4004
4017
4051
4034
4018
4055
4062
4023 4022
4070
4078
4020
4080
4039
4040
4078
4077
4025
4046
4045
4002
4001
4069
4068
4021
4024
4013
4027
4065
4026
5045
4019
4067
4015
4014
4016
11-7
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Parts List
11.4 R-axis Unit
Table 11-4: R-Axis Unit (Sheet 1 of 2)
No.
DWG No.
Name
Pcs
4001
M6X65
Socket screw
8
4002
2H-6
Spring Washer
8
4003
M5X20
GT-SA bolt
4
4004
M4X12
GT-SA bolt
4
4005
HW0305305-1
M cover
1
4006
M4X20
Socket screw
12
4007
2H-4
Spring Washer
12
4008
HW0404196-5
Washer
1
4009
M6X20
GT-SA bolt
8
4010
M4X45
Socket screw
1
4011
M6X6
Socket screw
1
4012
A-MT6X1
G Nipple
1
4013
HW0381872-A
Cross roller bearing
1
4014
M6X35
GT-SA bolt
8
4015
HW0403879-1
Saddle
1
4016
TC941045*A727*
Oil seal
1
4017
HW0403857-1
Shaft
1
4018
HW0405201-2
Block
1
4019
HW0304318-1
Housing
1
4020
HW0304085-1
Shaft
1
4021
HW0304914-1
Support
1
4022
HW0403879-1
Saddle
1
4023
M4X20
Socket screw
2
4024
M4X12
GT-SA bolt
2
4025
HW0200530-1
S cover
1
4026
HW0404919-1
Support
1
4027
M5X16
GT-SA bolt
2
4029
HW0381463-A
Speed reducer
1
4030
HW0404403-1
Shaft
1
4031
AE1314A0
Oil seal
1
4032
HW0304932-1
M base
1
4033
HW0404402-1
Shaft
1
4034
2H-4
Spring Washer
2
4035
HW0404900-1
N base
1
4036
M4X10
APS bolt
4
4037
M5X16
GT-SA bolt
4
4039
TA1-S8
Clamp
4
4040
M4X8
Screw with spring
washer
4
4042
M5X8
APS bolt
1
4043
M6X6
Socket screw
1
4044
LP-M5
Plug
1
4045
M5X35
Socket screw
2
4046
2H-5
Spring Washer
2
11-8
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Parts List
11.4 R-axis Unit
Table 11-4: R-Axis Unit (Sheet 2 of 2)
No.
DWG No.
Name
Pcs
4051
M4X12
GT-SA bolt
2
4055
HW0404918-1
Support
1
4056
SGMPH-02ANA-YR1*
Motor
1
4057
EZ5036A0
Cap
1
4058
M6X20
GT-SA bolt
6
4060
HW0304930-1
Support
1
4062
6811LLU
Bearing
1
4065
M4X20
Socket screw
2
4066
KQE12-03
Union
1
4067
2H-4
Spring Washer
2
4068
M4X20
Socket screw
2
4069
2H-4
Spring Washer
2
4070
MS4-10
Pin
2
4071
2H-4
Spring Washer
1
4072
PT 3/8
Plug
1
4073
M4X12
GT-SA bolt
2
4074
M6X30
GT-SA bolt
3
4075
TA1-S8
Clamp
3
4076
M4X8
Screw with spring
washer
3
4077
M4X16
GT-SA bolt
4
4078
HW0404179-1
Support
2
4079
T50R
Cable tie
3
4080
T50R
Cable tie
1
4081
M3X16
Screw with Spring
washer
4
3005
HW0102379-1
Casing
1
5046
HW0100623-1
U arm
1
11-9
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Parts List
11.5 Wrist Unit
11.5
Wrist Unit
Fig. 11-5: Wrist Unit
5073
5074
5002
5075
5001
3005
5005
5045
5046
5003
5006
5008
5005
5045
5044
5007
5067
5008
5067
5007
5011
5014
5063 5019
5006
5035
5071
5034
5013
5003
5018
5053
5012
5026
5064
5043
5062
5042
5037
5048
5040
5050
5072
5038
5049 5041
5039
5040
5017
5023
5071
5033
5020
5021
5022
5032
5072
5047
5031
5036
5016
5068
5031
5047
5024
5029
5031
5028
5027
5025
5026
5030
5052
5066
5065
5060
11-10
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Parts List
11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)
No.
DWG No.
Name
Pcs
5001
5002
HW9406556-1
Support
1
M4X12
GT-SA bolt
2
5003
M5X20
GT-SA bolt
4
5005
HW9200798-1
Cover
2
5006
SGMPH-02ANA-YR1*
Motor
2
5007
M4X16
Socket screw
2
5008
HW9482727-A
Pulley
2
5011
80S4.5M518
Belt
1
5012
HW9381658-A
Gear
1
5013
M4X12
GT-SA bolt
4
5014
HW9405452-1
B cover
1
5016
HW9482725-A
Pulley
1
5017
M5X16
Socket screw
1
5018
M4X16
GT-SA bolt
4
5019
HW9482218-A
Bearing
1
5020
HW9405199-1
B nut
1
5021
SP-0120**
Shim
1
5022
HW9481180-A
Bearing
1
5023
M5X16
Socket screw
1
5024
M5X12
GT-SA bolt
8
5025
HW0304232-1
Shaft
1
5026
TC60747
Oil seal
2
5027
HW9481187-A
Bearing
1
5028
HW0304233-1
Shaft
1
5029
S75
O ring
1
5030
HW0304087-1
Housing
1
5031
HW0382140-A
Speed reducer
1
5032
HW0304086-1
Housing
1
5033
HW9381659-A
Gear
1
5034
HW9482726-A
Pulley
1
5035
M5X16
Socket screw
1
5036
6002ZZ
Bearing
1
5037
6901ZZ
Bearing
1
5038
6814ZZ
Bearing
1
5039
HW9482668-A
Oil seal
1
5040
HW9381633-A
Speed reducer
1
5041
HW9405792-1
Housing
1
5042
HW0200451-1
Wrist base
1
5043
M5X16
GT-SA bolt
11
5044
80S4.5M653
Belt
1
5045
M5X12
GT-SA bolt
24
5046
HW0100623-1
U arm
1
5047
M6X6
Socket screw
2
5048
M4X16
GT-SA bolt
12
11-11
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Parts List
11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)
No.
DWG No.
Name
Pcs
5049
5050
M4X12
GT-SA bolt
4
M6X6
Socket screw
1
5052
M5X16
GT-SA bolt
5
5053
M6X6
Socket screw
1
5060
N5X16
GT-SA bolt
4
5062
LP-M5
Plug
1
5063
HW9405791-3
Housing
1
5064
6811LLU
Bearing
1
5065
HW0404606-1
Cover
1
5066
HW0404605-1
Plug
1
5067
2H-4
Spring washer
2
5068
2H-5
Spring washer
1
5071
2H-5
Spring washer
2
5072
M6
Washer
2
5073
TA1-S8
Clamp
1
5074
M4X8
Screw with Spring
washer
1
5075
T50R
Cable tie
1
3005
HW0102379-1
Casing
1
11-12
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MOTOMAN-HP20RD
INSTRUCTIONS
For inquiries or after-sales service on this product, contact
your local YASKAWA representative as shown below.
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu, 806-0004, Japan
Phone: +81-93-645-7703 Fax: +81-93-645-7802
www.yaskawa.co.jp
YASKAWA AMERICA, INC. (MOTOMAN ROBOTICS DIVISION)
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone: +1-937-847-6200 Fax: +1-937-847-6277
www.motoman.com
YASKAWA EUROPE GmbH (ROBOTICS DIVISION)
Yaskawastrasse 1, 85391, Allershausen, Germany
Phone: +49-8166-90-100 Fax: +49-8166-90-103
www.yaskawa.eu.com
YASKAWA NORDIC AB
Verkstadsgatan 2, Box 504, SE-385 25 Torsas, Sweden
Phone: +46-480-417-800 Fax: +46-486-414-10
www.yaskawa.se
YASKAWA ELECTRIC (CHINA) CO., LTD.
22F, One Corporate Avenue, No.222 Hubin Road, Huangpu District, Shanghai 200021, China
Phone: +86-21-5385-2200 Fax: +86-21-5385-3299
www.yaskawa.com.cn
YASKAWA SHOUGANG ROBOT CO., LTD.
No.7 Yongchang North Road, Beijing E&T Development Area, Beijing 100076, China
Phone: +86-10-6788-2858 Fax: +86-10-6788-2878
www.ysr-motoman.cn
YASKAWA ELECTRIC KOREA CORPORATION
35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, 07326, Korea
Phone: +82-2-784-7844 Fax: +82-2-784-8495
www.yaskawa.co.kr
YASKAWA ELECTRIC TAIWAN CORPORATION
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone: +886-2-8913-1333 Fax: +886-2-8913-1513
www.yaskawa.com.tw
YASKAWA ASIA PACIFIC PTE. LTD.
30A Kallang Place, #06-01, 339213, Singapore
Phone: +65-6282-3003 Fax: +65-6289-3003
www.yaskawa.com.sg
YASKAWA ELECTRIC (THAILAND) CO., LTD.
59, 1st-5th Floor, Flourish Building, Soi Ratchadapisek 18, Ratchadapisek Road, Huaykwang,
Bangkok 10310, Thailand
Phone: +66-2-017-0099 Fax: +66-2-017-0199
www.yaskawa.co.th
PT. YASKAWA ELECTRIC INDONESIA
Secure Building-Gedung B Lantai Dasar & Lantai 1 Jl. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone: +62-21-2982-6470 Fax: +62-21-2982-6471
www.yaskawa.co.id
YASKAWA INDIA PRIVATE LIMITED (ROBOTICS DIVISION)
#426, Udyog Vihar Phase-IV, Gurugram, Haryana 122016, India
Phone: +91-124-475-8500 Fax: +91-124-475-8542
www.yaskawaindia.in
Specifications are subject to change without notice
for ongoing product modifications and improvements.
C Printed in Japan May 2021 10-02
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
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