Motoman HP3JC Manipulator Manual

Motoman NXC100 Controller

HP3JC
Manipulator Manual

Part Number: 151562-1CD

Revision: 0

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: [phone]
FAX: [phone]
24-Hour Service Hotline: [phone]

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received with your Motoman robotic solution.

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The information contained within this document is the proprietary property of Motoman, Inc., and may not be

copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

©2007 by MOTOMAN

Because we are constantly improving our products, we reserve the right to change specifications without

notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

Inc.

All Rights Reserved

HP3JC*

151562-1

Chapter 1

Introduction

1.1 About This Document

This manual provides information for the HP3JC manipulator and contains the following sections:

CHAPTER 1 - INTRODUCTION

Provides general information about the structure of this manual, a list of reference documents, and
customer service information.

CHAPTER 2 - SAFETY

This section provides information regarding the safe use and operation of Motoman products.

CHAPTER 3 - HP3JC* INSTRUCTIONS

Provides detailed information for the HP3JC manipulator.

1.2 Reference to Other Documentation

For additional information refer to the following:

• NXC100 Controller Manual (P/N 150975-1)

• Concurrent I/O Manual (P/N 149230-1)

• Operator’s Manual for your application

• Vendor manuals for system components not manufactured by Motoman

1.3 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at [phone]. Please have
the following information ready before you call:

• Robot Type (HP3JC)

• Application Type (welding, handling, etc.)

• Robot Serial Number (located on back side of robot arm)

• Robot Sales Order Number (located on back of controller)

Final page 1

User’s Manual
Chapter 1 Introduction

Notes

page 2 Final

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151562-1

Chapter 2

Safety

2.1 Introduction

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

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries
Association by requesting ANSI/RIA R15.06-1999. The address is as follows:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: [phone]
FAX: [phone]

INTERNET: www.roboticsonline.com

Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel
who are adequately trained to operate, program, and maintain the robot cell. The robot must not be

operated by personnel who have not been trained!

We recommend that all personnel who intend to operate, program, repair, or use the robot system be
trained in an approved Motoman training course and become familiar with the proper operation of the
system.

Final page 3

User’s Manual
Chapter 2 Safety

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming, Operation, and Maintenance Safety (Section 2.6)

2.2 Standard Conventions

This manual includes the following alerts – in descending order of severity – that are essential to the
safety of personnel and equipment. As you read this manual, pay close attention to these alerts to
insure safety when installing, operating, programming, and maintaining this equipment.

DANGER!

Information appearing in a DANGER concerns the protection of personnel from the immediate
and imminent hazards that, if not avoided, will result in immediate, serious personal injury or
loss of life in addition to equipment damage.

WARNING!

Information appearing in a WARNING concerns the protection of personnel and equipment from
potential hazards that can result in personal injury or loss of life in addition to equipment
damage.

CAUTION!

Information appearing in a CAUTION concerns the protection of personnel and equipment,
software, and data from hazards that can result in minor personal injury or equipment damage.

Note: Information appearing in a Note provides additional information which is helpful in understanding the item being
explained.

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2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and
anyone working near the robot must become familiar with the operation of this equipment. All
personnel involved with the operation of the equipment must understand potential dangers of
operation. General safeguarding tips are as follows:

• Improper operation can result in personal injury and/or damage to the equipment. Only
trained personnel familiar with the operation of this robot, the operator's manuals, the system
equipment, and options and accessories should be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmers must have the
teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).

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

• In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of Energy, use
lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147
(29CFR, Part 1910), Occupational Safety and Health Standards for General Industry
(OSHA).

2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's
responsibility. The conditions under which the equipment will be operated safely should be reviewed
by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 safety
standards, and other local codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. The following safety equipment is provided as standard:

• Safety fences and barriers

• Light curtains and/or safety mats

• Door interlocks

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

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

Final page 5

User’s Manual
Chapter 2 Safety

2.5 Installation Safety

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

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

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

• Position all controllers outside the robot work envelope.

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

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

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

2.6 Programming, Operation, and Maintenance Safety

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

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

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

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

• Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.

• Back up all programs and jobs onto suitable media before program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.

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• Any modifications to PART 1, System Section, of the robot controller concurrent I/O
program can cause severe personal injury or death, as well as damage to the robot! Do not
make any modifications to PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use
these special passwords.

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

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

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

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

• Use proper replacement parts.

• Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).

Final page 7

User’s Manual
Chapter 2 Safety

Notes

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YASKAWA

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MOTOMAN-HP3J

INSTRUCTIONS

TYPE: YR-HP3J-J00

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

MOTOMAN INSTRUCTIONS

MOTOMAN-HP3J INSTRUCTIONS
NXC100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NXC100 MAINTENANCE MANUAL

The NX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.

YASKAWA

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MANDATORY

• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-HP3J.

• General items related to safety are listed in the Section 1: Safety of the
NXC100 Instructions. To ensure correct and safe operation, carefully
read the NXC100 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.

• Y ASKAWA 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
NXC100.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.

WARNING

CAUTION

MANDATORY

PROHIBITED

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

NOTE

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

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.

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WARNING

• Before operating the manipulator , c hec k tha t servo power is turned OFF
when the emergency stop buttons on the front face of the NXC100 and
on the right side of the programming pendant are pressed.
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.

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.

TURN

Release of Emergency Stop

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WARNING

• Observe the following precautions when performing teaching opera­tions:

-Always follow the predetermined operating procedure.

-Ensure that you have a safe place to retreat in case of emergency.

Improper operation or unintended manipulator motion may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of
the manipulator and that you are in a safe location before:

-Turing ON the robot system power.

-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 button is located on the right side of the programming pendant and
on the front face of the NXC100.

Mode selector switch

REMOTE

TEACH

PLAY

Programming pendant

Start button

Hold button

HOLDSTART

Emergency
stop button

DATE

SER NO.

44A220-011

TYPE

ERCR-NS00-A200
YASKAWA ELECTRIC CORPORATION

JAPAN

POWER SUPPLY
AC200/220V 50/60Hz 1 1 KVA

Approx mass.

16 Kg

NJ2520-2

ON (I)

F1

FU1

ON

SOURCE

FU2

OFF

OFF (O)

F2

Emergency stop button

3-2005

NJ2518-2

NJ2519-2

X52

SOURCE

X51

X31

BATTERY
FUSE

AC FUSE : F1,F2

15A / 250V
SLOW BLOW

I/O FUSE : F1,F2,F3,F4

3.15A / 250V
FAST BLOW

X81

NXC100

BAT

NXC100

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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 movement of the manipulator and servo track.

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

• Read and understand the Explanation of Warning Labels before operat­ing the robot system.

• For safety, operate under the proper lighting.

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

NXC100 Controller NXC100

NXC100 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.

Nameplate

Nameplate

MOTOMAN

TYPE
PAYLOAD

ORDER NO.

SERIAL NO.

YASKAWA ELECTRIC CORPORAION JAPAN

Warning label B

Warning label A

Warning label B

Warning Label A:

WARNING

kg

MASS
DATE

kg

Moving parts
may cause
injury

Warning Label B:

WARNING

Do not enter
robot
work area.

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1 Product Confirmation

1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . .1-2

2 Transporting

2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.1.1 Using a Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.1.2 Using a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

3 Installation

3.1 Installation of Safeguarding . . . . . . . . . . . . . . . . . . . . . . . .3-2

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3.2 Mounting Procedures for Manipulator Base. . . . . . . . .3-2

3.2.1 When the Manipulator and Mounting Fixture are Installed on a

Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.2 When the Manipulator is Mounted Directly on the Floor

without the Mounting Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.4 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

4 Wiring

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 NXC100. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5 Basic Specifications

5.1 Basic Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Special Interference Area . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.6 B-Axis Operating Range. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5.7 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Wrist Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

7 System Application

7.1 Peripheral Equipment Mount. . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Internal User I/O Wiring Harness and Air Lines . . . . 7-2

8 Electrical Equipment Specification

8.1 Internal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 Maintenance and Inspection

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . 9-5

9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

9.2.2 Grease Replenishment for S-axis Speed Reducer . . . . . . . . . .9-7

 Grease Replenishment (Refer to " Fig. 22 S-axis

Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . .9-7

9.2.3 Grease Replenishment for L-axis Speed Reducer . . . . . . . . . .9-8

 Grease Replenishment (Refer to " Fig. 23 L-axis

Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . .9-8

9.2.4 Grease Replenishment for Speed Reducers of U- and R-axes.9-9

 Grease Replenishment (Refer to " Fig. 24 UR-Axis Speed

Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9

9.2.5 Grease Replenishment for Speed Reducers of

B- and T-axes, and T-axis Gear . . . . . . . . . . . . . . . . . . . . . . .9-10

 Grease Replenishment (Refer to " Fig. 25 BT-Axis

Speed Reducer and T-axis Gear Diagram ".) . . . . . . . . . . .9-10

9.2.6 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

 Battery Pack Connection. . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

10 Recommended Spare Parts

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1.1 Contents Confirmation

1 Product Confirmation

CAUTION

• Confirm that the manipulator and the NXC100 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

• NXC100

• Programming pendant

• Manipulator cable (2 cables, between the manipulator and NXC100)

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1.2 Order Number Confirmation

1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the NXC100. The order
number is located on a label as shown below.

Label (Enlarged View)

THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

WARNING

HEAVY OBJECT

Can cause muscle strain or
back injury. Use lifting aids

proper lifting technjques

when removing or replacing

WARNING

HAZAARDOUS VOLTAGE

208/110 VAC PRESENT

Contact may cause
electric shock or burn
Turn off and lock out
system power before servicing

(a) NXC100 (Top View)

Fig. 1 Location of Order Number Labels

Check that the manipulator
and the NXC100 have the
same order number.

(b) Manipulator (Top View)

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2 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.

NOTE

• Be sure to mount two eyebolts and check that the eyebolts are securely fastened before
transporting the manipulator.

• The mass of the manipulator is approximately 27 kg. Use a wire rope strong enough to
withstand the mass.

• Attached eyebolts are designed to support the manipulator mass. Do not use them for
anything other than transporting the manipulator.

• Avoid exerting 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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