Yaskawa Motoman MCL130 Instructions

MOTOMAN-MCL130
INSTRUCTIONS
TYPE: YR-MCL0130-A00
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOVAN-MCL130 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.
Part Number: 158869-1CD
Revision: 0
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
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MANDATORY
•
This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-MCL130 for the application to
the actual operation and for proper maintenance and inspection. It
describes on safety and handling, details on specifications,
necessary items on maintenance and inspection, to explain
operating instructions and maintenance procedures. Be sure to
read and understand this instruction manual thoroughly before
installing and operating the manipulator.
•
General items related to safety are listed in 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. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
•
YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MCL130.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
WARNING
CAUTION
MANDATORY
PROHIBITED
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
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.
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 "CAUTION"
and "WARNING".
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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:
– 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 cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
•
Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
Definition of Terms Used Often in This Manual
The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator 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
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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.
Fig. : Warning Label Locations
WARNING Label B
WARNING Label A
Nameplate
WARNING Label B
WARNING Label A
Nameplate:
WARNING Label A:
WARNING
Moving parts
may cause
injury
WARNING Label B:
WARNING
Do not enter
robot
work area.
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Contents
1 Receiving ........................................................................................................................................ 1-1
1.1 Checking Package Contents ............................................................................................. 1-1
1.2 Checking the Order Number.............................................................................................. 1-2
2 Transporting.................................................................................................................................... 2-1
2.1 Transporting Method.......................................................................................................... 2-1
2.1.1 Using the Crane ................................................................................................... 2-1
2.2 Shipping Bolts and Brackets.............................................................................................. 2-3
2.3 After Removing the 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 When the Manipulator and Mounting Fixture are
Installed on a Common Base ............................................................................... 3-3
3.2.2 When the Manipulator is Mounted Directly on the Floor....................................... 3-3
3.3 Mounted Type.................................................................................................................... 3-5
3.4 Location ............................................................................................................................. 3-5
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-2
4.2 Cable Connection .............................................................................................................. 4-2
4.2.1 Connection to the Manipulator.............................................................................. 4-2
4.2.2 Connection to the DX100 ..................................................................................... 4-3
5 Basic Specifications ........................................................................................................................ 5-1
5.1 Basic Specifications........................................................................................................... 5-1
5.2 Manipulator Clean Specifications ...................................................................................... 5-2
5.3 Part Names and Working Axes.......................................................................................... 5-3
5.4 Manipulator Installation Base Dimensions......................................................................... 5-3
5.5 Dimensions and P-point Maximum Envelope .................................................................... 5-4
5.6 B-axis Working Range ....................................................................................................... 5-5
5.7 Alterable Working Range................................................................................................... 5-5
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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7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.2 Internal User I/O Wiring Harnesses and Air Line ............................................................... 7-2
8 HMOTOMAN Construction.............................................................................................................. 8-1
8.1 Position of S-axis Limit Switch ........................................................................................... 8-1
8.2 Internal Connections .......................................................................................................... 8-2
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-2
9.2 Notes on Maintenance Procedures.................................................................................... 9-6
9.2.1 Battery Pack Replacement ................................................................................... 9-6
9.2.2 Grease Replenishment/Replacement for S-axis Speed Reducer and Gear......... 9-8
9.2.2.1 Grease Replenishment (Refer to fig. 9-5 “S-axis Speed
Reducer and Gear Diagram” ) ................................................................. 9-8
9.2.2.2 Grease Replacement (Refer to fig. 9-5 “S-axis Speed
Reducer and Gear Diagram” at page 9-8)............................................... 9-9
9.2.3 Grease Replenishment/Replacement for L-axis Speed Reducer ....................... 9-10
9.2.3.1 Grease Replenishment (Refer to fig. 9-6 “L-axis Speed
Reducer Diagram” ) ............................................................................... 9-10
9.2.3.2 Grease Replacement (Refer to fig. 9-6 “L-axis Speed
Reducer Diagram” at page 9-10)........................................................... 9-11
9.2.4 Grease Replenishment/Replacement for U-axis Speed Reducer ...................... 9-12
9.2.4.1 Grease Replenishment (Refer to fig. 9-7 “U-axis Speed
Reducer Diagram” ) ............................................................................... 9-12
9.2.4.2 Grease Replacement (Refer to fig. 9-7 “U-axis Speed
Reducer Diagram” at page 9-12)........................................................... 9-13
9.2.5 Grease Replenishment/Replacement for R-axis Speed Reducer ...................... 9-14
9.2.5.1 Grease Replenishment (Refer to chapter Fig. 9-8: “R-axis Speed
Reducer Diagram”) ................................................................................ 9-14
9.2.5.2 Grease Replacement (Refer to fig. 9-8 “R-axis Speed
Reducer Diagram” at page 9-14)........................................................... 9-15
9.2.6 Grease Replenishment/Replacement for B-axis Speed Reducer and Gear....... 9-16
9.2.6.1 Grease Replenishment (Refer to fig. 9-9 “B-axis Speed
Reducer and Gear Diagram” ) ............................................................... 9-16
9.2.6.2 Grease Replacement (Refer to fig. 9-9 “B-axis Speed
Reducer and Gear Diagram” at page 9-16)........................................... 9-17
9.2.7 Grease Replenishment/Replacement for T-axis Speed Reducer and Gear....... 9-18
9.2.7.1 Grease Replenishment (Refer to fig. 9-10 “T-axis Speed
Reducer and Gear Diagram” ) ............................................................... 9-18
9.2.7.2 Grease Replacement (Refer to fig. 9-10 “T-axis Speed
Reducer and Gear Diagram” at page 9-18)........................................... 9-19
9.2.8 Grease Replenishment for Balancer Connection Part........................................ 9-20
9.2.9 Notes for Maintenance........................................................................................ 9-21
9.2.9.1 Battery Pack Connection for S-, L-, and U-axes Motors........................ 9-21
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Contents
9.2.9.2 Battery Pack Connection for R-, B-, and T-axes Motors ....................... 9-21
10 Recommended Spare Parts........................................................................................................ 10-1
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1.1
MCL130
1
Receiving
Checking Package Contents
Receiving
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
Checking Package Contents
When the package arrives, check the contents for the following standard
items (Any additional options ordered should be checked as well.):
• Manipulator
• DX100
• Programming pendant
• Manipulator cables (three cables)
• Accessories
Accessories
Quantity
Hexagon socket head cap bolt M20 × 90mm: Anti-corrosive
8
Flat washer M20: Anti-corrosive
8
Spring washer M20: Anti-corrosive
8
Flat washer M12: Anti-corrosive
4
Hexagon socket head cap bolt M12 × 35mm: Anti-corrosive
8
Hexagon socket head cap bolt M8 × 20mm: Anti-corrosive
2
Plate A: Anti-corrosive
2
Plate B: Anti-corrosive
1
Plate C: Anti-corrosive
1
Hexagon wrench × 17mm
1
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1.2
Receiving
Checking the Order Number
Checking the Order Number
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.
ORDER NO.
AC200V
AC220V
50/60Hz
60Hz
kVA
kVA
kA
PEAK
AVERAGE
ER
GE N
Y
3PHASE
INTERRUPT CURRENT
C
ERDR-
POWER SUPPLY
EM
DX100
TYPE
Check that the manipulator
and the DX100 have the
same order number.
SERIAL No.
DATE
MADE IN JAPAN
S
NJ2960-1
T O P
RE
SE
T
OFF
TR
IP
PE
D
ON
WARNING
Do not open the door
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1529
PROGRAMMING PENDANT
X81
(a) DX100 (Front View)
(b) Manipulator (Side View)
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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 transporting.
The system consists of precision components, so failure to
observe this caution may adversely affect performance.
2.1
2.1.1
Transporting Method
Using the 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 transporting, and lift it in the
posture as shown in fig. 2-1 “Transporting Position” at page 2-2.
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2.1
Transporting
Transporting Method
Fig. 2-1: Transporting Position
A
B
C
• Check that the eyebolts are securely fastened.
• The mass of the manipulator is approximately 1400kg
including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.
• Attached eyebolts are designed to support the manipulator
NOTE
weight. Do not use them for anything other than transporting the manipulator.
• Mount the shipping bolts and brackets for transporting the
manipulator.
• Avoid external force on the arm or motor unit when transporting, use caution when using transporting equipment
other than a crane or forklift, as injury may occur.
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2.2
Transporting
Shipping Bolts and Brackets
Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets at points A,
B, and C (fig. 2-1 “Transporting Position” at page 2-2).
• The shipping bolts and brackets are painted yellow.
Installing
Location
Anti-corrosive Bolt
Quantity
A
Hexagon socket head cap bolt M8 × 20mm
(Tensile strength: 1200N/mm2 or more)
4
B
Hexagon socket head cap bolt M12 × 50mm
(Tensile strength: 1200N/mm2 or more)
Hexagon socket head cap bolt M12 × 35mm
(Tensile strength: 1200N/mm2 or more)
4
Hexagon socket head cap bolt M12 × 50mm
(Tensile strength: 1200N/mm2 or more)
4
C
NOTE
2
Before turning ON the power, check to be sure that the shipping bolts and brackets have been removed. The shipping
bolts and brackets then must be stored for future use, in the
event that the manipulator must be moved again.
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2.3
MCL130
2.3
Transporting
After Removing the Shipping Bolts and Brackets
After Removing the Shipping Bolts and Brackets
After removing the shipping bolts and brackets, install the parts described
in the following table on each installing location in fig. 2-2 “After Removing
the Shipping Bolts and Brackets” for preventing corrosion.
Fig. 2-2: After Removing the Shipping Bolts and Brackets
D
C
B
A (4 locations)
Installing
Location
Anti-corrosive Bolt
Quantity
A
(Four locations)
Flat washer M12
Hexagon socket head cap bolt
M12 × 35mm
1 (Four locations)
1 (Four locations)
B
(Two locations)
Plate A
Hexagon socket head cap bolt
M12 × 35mm
1 (Two locations)
2 (Two locations)
C
Plate B
Hexagon socket head cap bolt
M12 × 35mm
1
2
D
Plate C
Hexagon socket head cap bolt
M8 × 20mm
1
2
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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
fully extended arm and tool will not reach the wall,
safeguarding, or DX100.
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.
CAUTION
• Do not install or operate a manipulator that is damaged or lacking 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 have been
removed.
Failure to observe this caution may result in damage to the driving parts.
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3.1
MCL130
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.
(ISO10218)
Responsibility for Safeguarding
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.
Construct a solid foundation with the appropriate thickness to withstand
maximum repulsion forces of the manipulator as shown in table 3-1
“Maximum Repulsion Forces of the Manipulator”
During installation, if the flatness is not right, the manipulator shape may
change and its functional ability may be compromised. The flatness for
installation must be kept at 0.5mm or less. Mount the manipulator base in
either of the following ways: chapter 3.2.1 “When the Manipulator and
Mounting Fixture are Installed on a Common Base” at page 3-3 or
chapter 3.2.2 “When the Manipulator is Mounted Directly on the Floor” at
page 3-3
Table 3-1: Maximum Repulsion Forces of the Manipulator
Horizontal rotating maximum torque
( S-axis moving direction)
32000N • m
Vertical rotating maximum torque
(LU-axis moving direction)
78500N • m
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3
3.2
Installation
Mounting Procedures for Manipulator Base
When the Manipulator and Mounting Fixture are Installed on a Common Base
The common base should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. The thickness of the common base is
50mm or more and an M20 size or larger anchor bolt is recommended.
For the installation dimensions of the manipulator installation base, refer
to the dimensions ∗ in fig. 3-2 “Direct Mounting on the Floor” at page 3-4
Affix the manipulator securely with the hexagon head bolts M20 (90mm
long recommended). Tighten the bolts and anchor bolts securely so that
they will not work loose during operation. See "Fig. 3-1 Mounting on the
Common Base" for the method.
Fig. 3-1: Mounting on the Common Base
Spring washer
Hexagon socket head cap bolts M20 (8 bolts)
Manipulator installation base
50
Flat washer
Flatness: 0.5mm or less
3.2.2
When the Manipulator is Mounted Directly on the Floor
The floor should be strong enough to support the manipulator. Construct a
solid foundation with the appropriate thickness to withstand maximum
repulsion forces of the manipulator. As a rough standard, when there is a
concrete thickness (floor) is 200mm or more, the manipulator base can be
fixed directly to the floor with anchor bolts M20. Before mounting the
manipulator, however, check that the floor is level and that all cracks, etc.
are repaired. A non-concrete floor or a floor less than 200mm thick is
insufficient for installation, even if the floor is concrete.
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3.2
Installation
Mounting Procedures for Manipulator Base
Fig. 3-2: Direct Mounting on the Floor
∗640
880
1200
410
960
Tapped holes M20 (8 holes)
(Bolt A)
∗540
40
1100
Manipulator installation base
∗640
∗540
500
460
28 dia. through holes (4 holes)
(Base B)
160
320
160
320
440
28 dia. through holes (4 holes) (Base A)
Tapped holes M24 (4 holes) (Base B) (Bolt B)
10 Weld these portions after
installation and adjustment.
(Base A)
250
FL
350
32
50
(Base B)
The surface must be
level and even.
36
Dimensions in mm
200
JA type anchor bolts
200
100
M24 × 315mm
Bolt A: Bolts M20 (length: 90mm) (8 bolts), spring washers, flat washers
Bolt B: Bolts M24 (length: 70mm) (8 bolts), spring washers
Bolts, base A and B should be equipped by user.
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3.3
MCL130
3.3
Installation
Mounted Type
Mounted Type
The MOTOMAN-MCL130 is floor-mounted type.
3.4
Location
The MOTOMAN-MCL130 is used in the clean room.
When the manipulator is installed, it is necessary to satisfy the
undermentioned environmental conditions:
• 15° to +45°C (ambient temperature)
• 20 to 80%RH (no moisture, non-condensing)
• Free from water
• Free from corrosive gases or liquid, or explosive gases
• Free from excessive impact or vibration
(less than 4.9m/s2 (0.5G)
• Free from large electrical noise
• The flatness for installation is 0.5mm 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.
• Do not cover the cable or allow it to tangle. Keep
the cable as straight as possible.
Failure to observe this caution may result in preventing heat of
the cable from being discharged.
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4.1
MCL130
4.1
Wiring
Grounding
Grounding
Follow local regulations for grounding line size. A line of 5.5mm2 or more
is recommended. Refer to fig. 4-1 “Grounding Method” to connect the
ground line directly to the manipulator.
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
4.2
Cable Connection
There are three manipulator cables; an encoder cable for detection (1BC)
and power cables (2BC and 3BC). Connect these cables to the
manipulator base connectors and the DX100. Refer to fig. 4-3(a)
“Manipulator Cable Connection to the Manipulator” at page 4-4 and
fig. 4-3(b) “Manipulator Cable Connection to the DX100” at page 4-4.
4.2.1
Connection to the Manipulator
Before connecting three cables to the manipulator, verify the numbers:
1BC, 2BC, and 3BC on both manipulator cables and the manipulator base
connectors. When connecting, adjust the cable connector positions to the
main key positions of the manipulator, and insert cables in the order of
2BC, 3BC, 1BC, and then push down the lever until hearing a “click.”
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Wiring
Cable Connection
Connection to the DX100
Remove the cover on the DX100 side. Pass the encoder cable for
detection (1BC), the power cables (2BC and 3BC), through the opening
for the cables, and then fasten bolts on the opening.
Connect the 2BC and 3BC cables to the terminals inside of the DX100.
Be sure to verify the numbers on both the cable and board connectors
before connecting.
Connect the 1BC cable to the boards. Be sure to verify the numbers on
both the cable and board connectors before connecting, and to fasten the
bolts on connectors to prevent cables from loosening.
Fig. 4-2: Manipulator Cables
The DX100 Side
The Manipulator Side
1BC
X11
X11
1BC
1BC
Encoder Cable
The DX100 Side
The Manipulator Side
X21
2BC
2BC
X21
2BC
Power Cable
The DX100 Side
The Manipulator Side
X22
3BC
3BC
3BC
X22
4.2.2
4
4.2
Power Cable
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4.2
Wiring
Cable Connection
Fig. 4-3(a): Manipulator Cable Connection to the Manipulator
2BC
3BC
1BC
Key positions
Connector Details
(Manipulator Side)
Fig. 4-3(b): Manipulator Cable Connection to the DX100
;
;
;
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5.1
MCL130
5
Basic Specifications
Basic Specifications
Basic Specifications
5.1
Basic Specifications
Table 5-1: Basic Specifications1)
Item
Model
MOTOMAN-MCL130
Configuration
Vertically Articulated
Degree of Freedom
6
Payload
130 kg
Repeatability
2)
±0.2 mm
Range of Motion
Maximum Speed
Allowable Moment
Allowable Inertia
(GD2/4)
3)
S-axis (turning)
-150° - +150°
L-axis (lower arm)
-60° - +76°
U-axis (upper arm)
-130° - +240°
R-axis (wrist roll)
-360° - +360°
B-axis (wrist pitch/yaw)
-130° - +130°
T-axis (wrist twist)
-360° - +360°
S-axis
2.27 rad/s, 130°/s
L-axis
2.27 rad/s, 130°/s
U-axis
2.27 rad/s, 130°/s
R-axis
3.75 rad/s, 215°/s
B-axis
3.14 rad/s, 180°/s
T-axis
5.24 rad/s, 300°/s
R-axis
735N•m (75 kgf•m)
B-axis
735N•m (75 kgf•m)
T-axis
421 N•m (43 kgf•m)
R-axis
45 kg•m2
B-axis
45 kg•m2
T-axis
15 kg•m2
Mass
Ambient
Conditions
1300 kg
Temperature
15° C to 45° C
Humidity
20 to 80% RH (non-condensing)
Vibration
4.9 m/s2 or less (0.5 G)
Others
Free from corrosive gasses or liquids, or explosive
gases or liquids
Free from exposure to water, oil, or dust
Free from excessive electrical noise (plasma)
A baseplate flatness must be kept at 0.5 mm or
less.
Power Capacity
7.5 kVA
1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Conformed to ISO9283
3
Refer to chapter 6.1 “Allowable Wrist Load” at page 6-1 for details on the allowable inertia.
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5.2
MCL130
5.2
Basic Specifications
Manipulator Clean Specifications
Manipulator Clean Specifications
The MOTOMAN-MCL130 is ISO-14644 rated, cleanliness class 6*1
(equivalent to the FEDERAL STANDARD 209E, cleanliness class 1000).
1. Under the condition that the manipulator is in the downflow of 0.4m/s
or more (vertically rectified state) and exhausted (exhausted amount of
400 liter/min) inside from the exhaust port A for the manipulator
internal air, and the balancer is exhausted (exhausted amount of 150
liter/min) inside from the exhaust port B for the manipulator internal air.
Refer to fig. 5-1 “Exhaust Ports for Manipulator Internal Air”
Fig. 5-1: Exhaust Ports for Manipulator Internal Air
Exhaust port B for manipulator internal air
(Tapped hole PT1/8:with pipe plug)
2BC
3BC
1BC
Exhaust port A for manipulator internal air
(Outer diameter: 34mm)
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5.3
MCL130
5.3
Basic Specifications
Part Names and Working Axes
Part Names and Working Axes
Fig. 5-2: Part Names and Working Axes
Upper arm
U-arm
U+
R+
B+
Wrist T+
U-
R-
B-
T-
Wrist flange
L+
L-
Lower arm
L-arm
S+
Rotary head
S-head
Manipulator installation base
S-
Manipulator Installation Base Dimensions
Fig. 5-3: Manipulator Base Dimensions
22 dia. holes (12 holes)
+0.018
12 0
0.1
365
0.1
dia. hole
640
725
540
320
365
0.1
0.1
320
50
5.4
540
640
A
855
Dimensions in mm
View A
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5.5
Dimensions and P-point Maximum Envelope
Fig. 5-4: Dimensions and P-point Maximum Envelope
150°
R7
29
25
R5
R265
0
150
4611
1961
2650
P-point maximum envelope
1250
230
60°
20.8°
76
?P-point
3130
69
.2°
189
285
2069
1150
°
90°
36
°
0°
13
50
242
222
5.5
Basic Specifications
Dimensions and P-point Maximum Envelope
730
MCL130
Dimensions in mm
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5.6
MCL130
5.6
Basic Specifications
B-axis Working Range
B-axis Working Range
The working range of the B-axis maintaining a constant angle to the
center of the U-arm is shown in fig. 5-5 “B-axis Working Range”
Fig. 5-5: B-axis Working Range
13
0°
Center of
U-axis
rotation
130°
Center of
B-axis
rotation
Center of
L-axis
rotation
Center of S-axis
rotation
5.7
Alterable Working Range
The working 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 Working
Range
-150° - + 150° (standard)
-120° - + 120°
-90° - + 90°
-60° - + 60°
-30° - + 30°
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6.1
MCL130
6
Allowable Load for Wrist Axis and Wrist Flange
Allowable Wrist Load
Allowable Load for Wrist Axis and Wrist Flange
6.1
Allowable Wrist Load
The allowable wrist load including the mass of the mount/gripper is:
• YR-MCL0130-A00 : 130kg maximum
If force is applied to the wrist instead of the load, force on R-, B-, and Taxes should be within the value shown in table 6-1 “Moment and Total
Inertia” Contact your Yaskawa representative for further information or
assistance.
Table 6-1: Moment and Total Inertia
Axis
Moment N•m (kgf•m)1)
Total Inertia kg•m2
R-axis
B-axis
T-axis
735 (75)
735 (75)
421 (43)
45
45
15
1 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in
"Fig. 6-1 Moment Arm Rating."
The allowable total inertia is calculated when the moment is at the
maximum. Contact your Yaskawa representative when only inertia
moment, or load moment is small and inertia moment is large. Also, when
the load is combined as a force but a mass, contact your Yaskawa
representative.
Fig. 6-1: Moment Arm Rating
L T(mm)
600
P-point
40Kg
Center
line of
T-and
R-axes
rotation
60Kg
400
130Kg
200
100Kg
80Kg
400
600
800 1000
L B(mm)
200
400
600
L T(mm)
Center line of B-axis rotation
YR-MCL0130-A00
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6.2
Wrist Flange
If the fitting is used to mount the attachment, the fitting depth inside the
fitting must be 8mm or less; outside 5mm or less.
Fig. 6-2: Wrist Flange
+0.015
10 0
+0.015
0
dia. holes (depth: 8mm) (2 holes)
dia. holes (depth: 8mm) (2 holes)
PC
D1
25
9
92
0
8
171 dia.
PCD
160-0.025 dia.
6.2
Allowable Load for Wrist Axis and Wrist Flange
Wrist Flange
63 +0.030
dia. hole
0
MCL130
Tapped holes M10 (depth: 12mm)
(6 holes)
5
Tapped holes M10 (depth: 12mm) (6 holes)
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7.1
MCL130
System Application
Peripheral Equipment Mounts
When peripheral equipment is attached to the U-axis, the following
conditions described in table 7-1 “Constraint for Attaching” at page 7-2
should be observed.
Fig. 7-1: Clamp and Trapped Holes
B Cap bolts M8 (length: 15mm) (pitch: 1.25mm) (4 bolts)
126 160
100
60
A1 Cap bolts M8 (length: 15mm) (pitch: 1.25mm) (4 bolts)
497.5
85
85
200
189
552.5
A2 Cap bolts M8 (length: 15mm) (pitch: 1.25mm) (4 bolts)
120
80
7.1
100
7
System Application
Peripheral Equipment Mounts
C Hexagon socket head cap bolts M12
(length: 25mm) (pitch: 1.75mm) (4 bolts)
With flat washer (WSSM35-12-10)
Dimensions in mm
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7.2
MCL130
System Application
Internal User I/O Wiring Harnesses and Air Line
Table 7-1: Constraint for Attaching
7.2
Application
Note
A1
A2
Cable Processing
Attaching load mass is
130kg max. for YR-MCL0130-A00
including wrist load.
B
Cable Processing
and Valve Load
30kg max.
49N‚m (5kgf.m) max. for moment
increase amount of upper arm
C
Others
200kg max.
Internal User I/O Wiring Harnesses and Air Line
Internal user I/O wiring harnesses (0.75mm2, 23 cables) and two air lines
are used in the manipulator for the drives of the peripheral devices
mounted on the upper arm and the connector pins (1 to 23) are assigned
as shown in fig. 7-2 “Internal User I/O Wiring Harnesses and Air Line” at
page 7-3. Wiring must be performed by user.
The allowable current for internal user
I/O wiring harness
6.6 A or less / wire.
(The total current value for pins 1 to 23
must be 60A or less.)
The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0mm )
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7.2
System Application
Internal User I/O Wiring Harnesses and Air Line
Fig. 7-2: Internal User I/O Wiring Harnesses and Air Line
Cable connector provided on
U-axis is type JL05-2A24-28SC
(with cap).
Mating connector type is
JL05-6A24-28P.
Air A outlet:
tapped hole PT 3/8
with pipe plug
Air B outlet:
tapped hole PT 3/8
with pipe plug
Air B inlet:
tapped hole
PT 3/8 with
pipe plug
Air A inlet:
tapped hole PT 3/8
with pipe plug
A
View A
Cable connector provided on
U-axis is type JL05-2A24-28PC
(with cap).
Mating connector type is
JL05-6A24-28S.
Pins used
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15
16 17 18 19 20
21 22 23
Internal user I/O
wiring harness
(23 lead wires,
size:0.75mm2)
The same pin number (1-23) of two connectors is connected in the lead
wire of single 0.75mm2.
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8.1
MCL130
8
HMOTOMAN Construction
Position of S-axis Limit Switch
HMOTOMAN Construction
8.1
Position of S-axis Limit Switch
The limit switch is mounted on the S-axis as shown in fig. 8-1 “Location of
Limit Switch”
Fig. 8-1: Location of Limit Switch
S-axis overrun L.S.
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8.2
MCL130
8.2
HMOTOMAN Construction
Internal Connections
Internal Connections
High reliability connectors which can be easily removed are used with
each connector part. For the number and location of connectors, refer to
fig. 8-2 “Location and Numbers of Connectors”
Fig. 8-2: Location and Numbers of Connectors
Connector for internal
user I/O wiring harness
1BC
2BC
3BC
4BC (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 base
JL05-2A24-28PC
(JL05-6A24-28S: Optional)
Connector for internal user I/O wiring
harness on U-arm
JL05-2A24-28SC
(JL05-6A24-28P: Optional)
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8 Electrical Equipment Specification
8.2 Internal Connections
Fig. 8-3(a): Internal Connection Diagram
(HQFRGHU3RZHUVXSSO\ERDUG
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8 Electrical Equipment Specification
8.2 Internal Connections
Fig. 8-3(b): Internal Connection Diagram
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9
9
Maintenance and Inspection
Maintenance and Inspection
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
• 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.
• The battery pack must be connected before
removing detection connector when maintenance
and inspection.
Failure to observe this caution may result in the loss of home
position data.
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9.1
MCL130
9.1
Maintenance and Inspection
Inspection Schedule
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 displayed in six levels.
Conduct periodical inspections according to the inspection schedule in
table 9-1 “Inspection Items” at page 9-3
In table 9-1 “Inspection Items” at page 9-3 the inspection items are
classified into three types of operation: 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 service company personnel. Only specified personnel are to
do inspection work.
• The inspection interval must be based on the servo power
supply on time.
NOTE
• 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
Manipulator
L,U-axes motor
Base mounting bolts
Cover mounting screws
SLU-axes motor connectors
Base connectors
Balancer
RBT-axes timing belt
SLURBT-axes internal wires
2
3
4
5
6
7
8
9
10
11
Daily
1000H Cycle
12000H Cycle
Grease Gun
•
• •
•
Grease Gun
Manual
Visual
Multimeter
Visual
Spanner
Wrench
Screwdriver,
Wrench
Manual
Visual
Visual
Visual
14 L-axis speed reducer
•
•
18000H
Grease Gun
•
24000H
• •
•
•
•
•
6000H Cycle
Tighten loosen bolts.
Check for loose connectors.
Supply grease (6000H cycle). See chapter 9.2.8 at page 9-20
Check for belt tension and wear.
Check for conduction between the main connector of base and intermediate
connector with manually shaking the wire. Check for wear of protective
spring.4)
Replace.5)
Replace the battery pack when the battery alarm occurs or the manipulator
drove for 24000H.6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.2 at page 9-8 .6)
Replace grease (12000H cycle). See chapter 9.2.2 at page 9-8 6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.3 at page 9-10 6)
Replace grease (12000H cycle). See chapter 9.2.3 at page 9-10 6)
Tighten loose bolts. Replace if necessary.
Check alignment mark accordance and damage at the
home position.
Check for damage and deterioration of leads.
Clean the exterior.
Check for damage, exterior cracks, and grease leakage.2)
Check for grease leakage.3)
Tighten loose bolts. Replace if necessary.
Inspection
Charge
•
•
•
•
•
•
•
•
• •
•
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
9
9.1
13 S-axis speed reducer
and gear
•
•
•
•
Operation
MCL130
12 Battery pack in manipulator
Alignment mark
1
Method
Specified
Person
Schedule
Licensee
Items1)
Service
Company
Table 9-1: Inspection Items (Sheet 1 of 2)
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Inspection Schedule
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•
• •
• •
• •
Inspection No. correspond to the numbers in fig. 9-1 “Inspection Parts and Inspection Numbers” at page 9-5
If a grease leakage occurs, contact your Yaskawa representative as soon as possible.
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.
IWhen 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 to chapter 9.2.9 “Notes for Maintenance” at page 9-21)
5 Internal cables to be replaced at 18000H inspection.
6 For the grease, refer to fig. 9-2(a “Battery Pack Location (Rear View)” at page 9-6
•
Inspection
Charge
9
9.1
1
2
3
4
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.4 at page 9-12 6)
Replace grease (12000H cycle). See chapter 9.2.4 at page 9-12 6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.5 at page 9-14 6)
Replace grease (12000H cycle). See chapter 9.2.5 at page 9-14 6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.6 at page 9-16 and
chapter 9.2.7 at page 9-18 6)
Replace grease (12000H cycle). See chapter 9.2.6 at page 9-16 and
chapter 9.2.7 at page 9-18 6)
Operation
MCL130
18 Overhaul
Grease Gun
• •
17 BT-axes speed reducers
and gears
Daily
Grease Gun
1000H Cycle
• •
6000H Cycle
16 R-axis gear
12000H Cycle
Grease Gun
18000H
• •
24000H
15 U-axis speed reducer
Method
Specified
Person
Schedule
Licensee
Items1)
Service
Company
Table 9-1: Inspection Items (Sheet 2 of 2)
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Inspection Schedule
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9
9.1
Maintenance and Inspection
Inspection Schedule
Fig. 9-1: Inspection Parts and Inspection Numbers
B-axis
5
1
17
16
15
4
6
U-axis
11
7
1
1
1
R-axis
T-axis
6 10
2
L-axis
1
9
14
4
7
7
S-axis
6
2
1
2
13
12
8
Table 9-2: Inspection Parts and Grease Used
No.
Grease Used
Inspected Parts
13, 14, 15, 16,
17
VIGO Grease
RE No.0
All axes speed reducers and
R-, B-, and T-axes gears
9
Alvania EP Grease 2
L-axis balancer
The numbers in the above table correspond to the numbers in table 9-1
“Inspection Items” at page 9-3
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9.2
MCL130
9.2
9.2.1
Maintenance and Inspection
Notes on Maintenance Procedures
Notes on Maintenance Procedures
Battery Pack Replacement
If the battery alarm occurs in the DX100, replace the battery pack
according to the following procedure:
Fig. 9-2(a): Battery Pack Location (Rear View)
Manipulator
base
2BC
3BC
1BC
Battery pack mounting
screw M4
Connector base
Fig. 9-2(b): Battery Pack Location (Top View)
Axes battery pack
㸦HW0273162-A㸧
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9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Fig. 9-3: Battery Pack Connection
Battery pack
before replacement
See replacing step 5.
Connector
Board
See replacing step 4.
New battery pack
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.
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9.2.2
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replenishment/Replacement for S-axis Speed Reducer and Gear
Fig. 9-4: S-axis Speed Reducer and Gear Diagram
So: Grease exhaust port
㸦Hexagon socket head plug
PT1/8)
9.2.2.1
Si: Grease inlet
㸦Hexagon socket head plug
PT1/4㸧
S-axis speed reducer
Grease Replenishment (Refer to fig. 9-4 “S-axis Speed Reducer and Gear Diagram” )
Replenish the grease according to the following procedure:
1. Remove the So exhaust plug PT1/8.
NOTE
If grease is added without removing the exhaust plug, the
grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.
2. Remove the plug on the Si grease inlet and install the grease zerk APT1/4.
3. Inject the grease into the Si grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
530 cc
(1060 cc for 1st supply)
4. Move the S-axis for a few minutes to discharge the excess grease.
5. Wipe the So exhaust port with a cloth and reinstall the plug. (Confirm
that no oil adheres to the screw of the plug and spread Three Bond
1206C.)
6. Remove the grease zerk and reinstall the plug in the Si grease
inlet.(Confirm that no oil adheres to the screw of the plug and spread
Three Bond 1206C.)
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9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replacement (Refer to fig. 9-4 “S-axis Speed Reducer and Gear Diagram” at
page 9-8)
1. Remove the So exhaust plug PT1/8.
NOTE
If grease is added without removing the exhaust plug, the
grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.
2. Remove the plug on the Si grease inlet and install the grease zerk APT1/4.
3. Inject the grease into the Si grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
approx. 3650 cc
4. The grease replacement is complete when new grease appears in the
So 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 the excess grease.
6. Wipe the So exhaust port with a cloth and reinstall the plug.(Confirm
that no oil adheres to the screw of the plug and spread Three Bond
1206C.)
7. Remove the grease zerk and reinstall the plug in the Si grease
inlet.(Confirm that no oil adheres to the screw of the plug and spread
Three Bond 1206C.)
NOTE
If the plug is installed when the grease is still being replaced,
the grease will go inside the motor and may damage it.
Confirm that the old grease has been completely replaced
before reinstalling the plug.
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9.2.3
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replenishment/Replacement for L-axis Speed Reducer
Fig. 9-5: L-axis Speed Reducer Diagram
L-axis speed reducer
Lo: Grease exhaust port
Hexagon socket
head plug PT1/8)
Li: Grease inlet
Hexagon socket head
plug PT1/8
9.2.3.1
Grease Replenishment (Refer to fig. 9-5 “L-axis Speed Reducer Diagram” )
1. Make the L-arm vertical for ground.
2. Remove the Lo exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.
3. Remove the plug on the Li grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Li grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
400 cc
(800 cc for 1st supply)
5. Move the L-axis for a few minutes to discharge the excess grease.
6. Wipe the Lo exhaust port with a cloth and reinstall the plug. (Confirm
that no oil adheres to the screw of the plug and spread Three Bond
1206C.)
7. Remove the grease zerk and reinstall the plug in the Li grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.3.2
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replacement (Refer to fig. 9-5 “L-axis Speed Reducer Diagram” at page 9-10)
1. Make the L-arm vertical for ground.
2. Remove the Lo exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.
3. Remove the plug on the Li grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Li grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
approx 2000cc for Li
5. The grease replacement is complete when new grease appears in the
Lo exhaust port. The new grease can be distinguished from the old
grease by color.
6. Move the L-axis for a few minutes to discharge the excess grease.
7. Wipe the Lo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
8. Remove the grease zerk and reinstall the plug in the Li grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.4
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replenishment/Replacement for U-axis Speed Reducer
Fig. 9-6: U-axis Speed Reducer Diagram
Uo: Grease exhaust port
Hexagon socket head plug PT1/8
Ui: Grease inlet
Hexagon socket head plug PT1/8
U-axis speed reducer
Remove the cap.
9.2.4.1
Grease Replenishment (Refer to fig. 9-6 “U-axis Speed Reducer Diagram” )
1. Make the U-arm horizontal for ground.
2. Remove the Uo exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.
3. Remove the plug on the Ui grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Ui grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
250cc for Ui
(500cc for 1st supply)
5. Move the U-axis for a few minutes to discharge the excess grease.
6. Wipe the Uo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the plug in the Ui grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.4.2
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replacement (Refer to fig. 9-6 “U-axis Speed Reducer Diagram” at page 9-12)
1. Make the U-arm horizontal for ground.
2. Remove the Uo exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.
3. Remove the plug on the Ui grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Ui grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
approx. 1650cc for Ui
5. The grease replacement is complete when new grease appears in the
Uo 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 the excess grease.
7. Wipe the Uo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
8. Remove the grease zerk and reinstall the plug in the Ui grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
NOTE
If the plug is installed when the grease is still being replaced,
the grease will go inside the motor and may damage it.
Confirm that the old grease has been completely replaced
before reinstalling the plug.
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9.2.5
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replenishment/Replacement for R-axis Speed Reducer
Fig. 9-7: R-axis Speed Reducer Diagram
Ro: Grease exhaust port
R-axis speed reducer
Hexagon socket head plug PT1/8
Ri: Grease inlet
Hexagon socket head plug PT1/8
9.2.5.1
Grease Replenishment (Refer to fig. 9-7 “R-axis Speed Reducer Diagram” )
1. Remove the Ro exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.
2. Remove the plug on the Ri grease inlet and install the grease zerk APT1/8.
3. Inject the grease into the Ri grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
28cc for Ri
(56cc for 1st supply)
4. Move the R-axis for a few minutes to discharge the excess grease.
5. Wipe the Ro exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
6. Remove the grease zerk and reinstall the plug in the Ri grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replacement (Refer to fig. 9-7 “R-axis Speed Reducer Diagram” at page 9-14)
1. Remove the Ro exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.
2. Remove the plug on the Ri grease inlet and install the grease zerk APT1/8.
3. Inject the grease into the Ri grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
approx. 140cc for Ri
4. The grease replacement is complete when new grease appears in the
Ro exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the R-axis for a few minutes to discharge the excess grease.
6. Wipe the Ro exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the plug in the Ri grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.6
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replenishment/Replacement for B-axis Speed Reducer and Gear
Fig. 9-8: B-axis Speed Reducer and Gear Diagram
Bo: Grease exhaust port
Hexagon socket head plug PT1/8
B-axis speed reducer
9.2.6.1
Bi: Grease inlet
Hexagon socket head cap bolt M6
Grease Replenishment (Refer to fig. 9-8 “B-axis Speed Reducer and Gear Diagram” )
1. Remove the Bo exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.
2. Remove the bolt on the Bi grease inlet and install the grease zerk AMT6.
3. Inject the grease into the Bi grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
200cc for Bi
(400 cc for 1st supply)
4. The grease replacement is complete when new grease appears in the
Bo exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the B-axis for a few minutes to discharge the excess grease.
6. Wipe the Bo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the bolt in the Bi grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.6.2
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replacement (Refer to fig. 9-8 “B-axis Speed Reducer and Gear Diagram” at
page 9-16)
1. Remove the Bo exhaust plug.
NOTE
If grease is added without removing the exhaust plug, the
grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.
2. Remove the bolt on the Bi grease inlet and install the grease zerk AMT6.
3. Inject the grease into the Bi grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
approx. 900cc for Bi
4. The grease replacement is complete when new grease appears in the
Bo exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the B-axis for a few minutes to discharge the excess grease.
6. Wipe the Bo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the bolt in the Bi grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.7
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replenishment/Replacement for T-axis Speed Reducer and Gear
Fig. 9-9: T-axis Speed Reducer and Gear Diagram
T-axis speed reducer
Ti: Grease inlet
Hexagon socket head cap bolt M6
(Seal washer M6)
To: Grease exhaust port
Hexagon socket head cap bolt M5
(Seal washer M5)
9.2.7.1
Grease Replenishment (Refer to fig. 9-9 “T-axis Speed Reducer and Gear Diagram” )
1. Remove the hexagon socket head cap bolt M5 in the To exhaust port.
NOTE
If grease is added without removing the bolt, the grease will
go outside the grease box and may damage it. It is absolutely necessary to remove the bolt.
2. Remove the bolt on the Ti grease inlet and install the grease zerk AMT6.
3.
Inject the grease into the Ti grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
200cc for Ti
(400cc cc for 1st supply)
4. Move the T-axis for a few minutes to discharge the excess grease.
5. Wipe the To exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
6. Remove the grease zerk and reinstall the bolt in the Ti grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.7.2
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replacement (Refer to fig. 9-9 “T-axis Speed Reducer and Gear Diagram” at
page 9-18)
1. Remove the hexagon socket head cap bolt M5 in the To exhaust port.
NOTE
If grease is added without removing the bolt, the grease will
go outside the grease box and may damage it. It is absolutely necessary to remove the bolt.
2. Remove the bolt on the Ti grease inlet and install the grease zerk AMT6.
3. Inject the grease into the Ti grease inlet using a grease gun.
– Grease type:
VIGO Grease RE No.0
– Amount of grease:
approx. 900 cc for Ti
4. The grease replacement is complete when new grease appears in the
To exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the T-axis for for a few minutes to discharge the excess grease.
6. Wipe the To exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the bolt in the Ti grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
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9.2.8
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Grease Replenishment for Balancer Connection Part
Fig. 9-10: Balancer Connection Part Diagram
Exhaust port
Exhaust port
(Hexagon socket head plug
PT1/8)
Vc: Grease inlet in connection
part
Tapered roller bearings (2 bearings)
in connection part
Needle bearing
in connection part
Vc: Grease inlets in connection part
(Hexagon socket head plugs PT1/8)
(2 plugs)
1. Remove two plugs for exhaust port in 1 and 2. (Refer to fig. 9-10
“Balancer Connection Part Diagram” )
2. Remove two plugs on the Vc grease inlets in 1 and 2and install the
grease zerk A-PT1/8.
3. Inject the grease into the Vc grease inlets in 1 and 2 using a grease
gun.
– Grease type:
Alvania EP grease 2
– Amount of grease:
5cc
(10 cc for 1st supply)
NOTE
The grease is not exhausted from the exhaust ports 1 and
2. Do not inject excessive grease into the Vc grease inlets.
4. Reinstall the plugs on the exhaust ports in 1 and 2.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
5. Remove the grease zerk and reinstall the bolts in the Vc grease inlets.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)]
6. Wipe off excess grease and abrasion power adhering to the rod with a
clean waste cloth, then lightly apply AFE grease.
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9.2.9
9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Notes for Maintenance
Remove the old battery pack after connecting the new one so that the
encoder absolute data does not disappear. For the battery pack
connection for the S-, L-, and U-axes motors and R-, B-, and T-axes
motors, refer to fig. 9-11 “Battery Pack Connection for Motor” at
page 9-22
9.2.9.1
Battery Pack Connection for S-, L-, and U-axes Motors
The connector (crimped contact-pin) for the battery backup is installed in
the end point of the cable for the encoder of the S-, L-, and U-axes motors
(BAT and OBT are marked). Connect the battery pack according to the
following procedure.
1. Connect battery pack (HW9470917-A) with the battery backup
connector (BAT and OBT are marked) located in the end point of the
cable for the encoder. (Under such a condition, remove the encoder
connector and do the maintenance check work.)
2. Confirm all connectors connection after the maintenance check ends,
and remove the battery pack.
NOTE
9.2.9.2
Do not remove the battery pack in the base connector.
Battery Pack Connection for R-, B-, and T-axes Motors
The connector (crimped contact-pin) for the battery backup is installed in
the end point of the cable for the encoder of the R-, B-, and T-axes motors
(BAT and OBT are marked). Connect the battery pack according to the
following procedure.
1. Connect battery pack (HW9470917-B) with the battery backup
connector (BAT and OBT are marked) located in the end point of the
cable for the encoder. (Under such a condition, remove the encoder
connector and do the maintenance check work.)
2. Confirm all connectors connection after the maintenance check ends,
and remove the battery pack.
NOTE
Do not remove the battery pack in the base connector.
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9
9.2
Maintenance and Inspection
Notes on Maintenance Procedures
Fig. 9-11: Battery Pack Connection for Motor
Motor
Motor power connector
Connector for the encoder
0BT
b
a 0BT*
BAT
a
b BAT*
Battery Pack: HW9470917-A
Connector for the battery backup
a:Insertion-type pin terminal (Pin)
b:Insertion-type pin terminal (Socket)
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10
MCL130
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-MCL130. The spare parts list for
the MOTOMAN-MCL130 is shown below. 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, contact your Yaskawa
representative.
Fig. 10-1: Spare Parts for the MOTOMAN-MCL130 (Sheet 1 of 2)
Rank
Parts
No.
Name
Type
Manufacturer
Qty
Qtyp
er
Unit
Remarks
A
1
Grease
VIGO Grease
RE NO.0
Yaskawa
Electric
Corporation
16kg
-
For all axes speed
reducers and wrist
units
A
2
Grease
Alvania EP
Grease 2
Showa Oil
Co., Ltd.
16kg
-
For balancer joint
parts
A
3
Liquid Gasket
Three Bond 1206C THREE BOND
CO., LTD.
1
1
A
4
Battery Pack
HW9470917-A
Yaskawa
Electric
Corporation
1
1
For SLU-axes
A
5
Battery Pack
HW9470917-B
Yaskawa
Electric
Corporation
1
1
For RBT-axes
B
6
R-axis Timing Belt
200S8M976
Mitsuboshi
Belting Limited
1
1
B
7
B-axis Timing Belt
200S8M800
Mitsuboshi
Belting Limited
1
1
B
8
T-axis Timing Belt
200S8M656
Mitsuboshi
Belting Limited
1
1
B
9
S-axis
Speed Reducer
HW9381388-F
Yaskawa
Electric
Corporation
1
1
Drawing number
for painting
HW0300979-1
B
10
L-axis
Speed Reducer
HW9381442-F
Yaskawa
Electric
Corporation
1
1
Drawing number
for painting
HW0300983-1
B
11
U-axis
Speed Reducer
HW9381465-F
Yaskawa
Electric
Corporation
1
1
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MCL130
Recommended Spare Parts
Fig. 10-1: Spare Parts for the MOTOMAN-MCL130 (Continued) (Sheet 2 of 2)
Rank
Parts
No.
Name
Type
Manufacturer
Qty
Qtyp
er
Unit
Remarks
B
12
R-axis
Speed Reducer
HW0380815-F
Yaskawa
Electric
Corporation
1
1
Drawing number
for painting
HW0300989-1
B
13
B-axis
Speed Reducer
HW9380961-F
Yaskawa
Electric
Corporation
1
1
Drawing number
for painting
HW0301816-1
B
14
T-axis
Speed Reducer
HW1380173-A
Yaskawa
Electric
Corporation
1
1
Drawing number
for painting
HW0300994-1
B
15
Wrist Unit
HW0175514-A
Yaskawa
Electric
Corporation
1
1
C
16
AC Servomotor for
S-axis
HW0389698-A
Yaskawa
Electric
Corporation
1
1
C
17
AC Servomotors for HW0388670-A
L-and U-axes
Yaskawa
Electric
Corporation
1
2
C
18
AC Servomotor for
R-axis
HW0388933-A
Yaskawa
Electric
Corporation
1
1
C
19
AC Servomotors for HW0388934-A
B-and T-axes
Yaskawa
Electric
Corporation
1
2
C
20
Internal Wiring
Yaskawa
Electric
Corporation
1
1
HW0175541-A
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MOTOMAN-MCL130
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan
Phone +81-93-645-7745
Fax +81-93-645-7746
YASKAWA America Inc. MOTOMAN Robotics Division
805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200
Fax +1-937-847-6277
YASKAWA Nordic AB
Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden
Phone +46-480-417800
Fax +46-480-417999
YASKAWA Europe GmbH Robotics Division
Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100
Fax +49-8166-90-103
YASKAWA Electric Korea Co., Ltd.
7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA
Phone +82-2-784-7844
Fax +82-2-784-8495
YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003
Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.
252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek Road, Huaykwang Bangkok, 10320 Thailand
Phone +66-2-693-2200
Fax +66-2-693-4200
Shougang MOTOMAN Robot Co. Ltd.
No.7, Yongchang-North Road, Beijing E&T Development Area, China 100176
Phone +86-10-6788-2858
Fax +86-10-6788-2878
MOTOMAN Motherson Robotics Ltd.
Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana
Phone +91-124-475-8500
Fax +91-124-414-8016
Specifications are subject to change without notice
for ongoing product modifications and improvements.
C Printed in Japan Junuary 2011 11-01
YASKAWA ELECTRIC CORPORATION
MANUAL NO.
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