YASKAWA MOTOMAN-MPL100 Instructions Manual

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MOTOMAN-MPL100

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INSTRUCTIONS

TYPE: YR-MPL0100-A00 (STANDARD SPECIFICATION) YR-MPL0100-A04 (WITH BUILT-IN TUBE FOR FIELDBUS CABLE)

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

MOTOMAN INSTRUCTIONS MOTOMAN-MPL100 INSTRUCTIONS

DX100 INSTRUCTIONS DX100 OPERA T OR’S MANUAL DX100 MAINTENACE MANUAL

The DX100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

Part Number: 157569-1CD Revision: 4

MANUAL NO.

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customers to assist in the operation of Motoman robots, related equipment and software This manual is copyrighted property of Yaskawa and may not be sold or redistributed in any way. You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files to another website, blog, cloud storage site or any other means of storing or distributing online content.

Printed in the United States of America

First Printing, 2011

Yaskawa America, Inc. Motoman Robotics Division 100 Automation Way Miamisburg, OH 45342 Phone: 937-847-6200

www.motoman.com

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MANDATORY

CAUTION

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• This instruction manual is intended to explain mainly on the mechanical part of the MOTOMAN-MPL100 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.

• 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.

• Y ASKAW A is not responsible for incident s arising from unauthorized modification of its products. Unauthorized modification voids your product's warranty.

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We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA R15.06-2012). You can obtain this document fro m the Robotic Industries Association (RIA) at the following address:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: (734) 994-6088

FAX: (734) 994-3338

www.roboticsonline.com

Ultimately, well-trained personnel are the best safeguard against accidents and damage that can result from improper operation of the equipment. The customer is responsible for providing adequately trained personnel to operate, program, and maintain the equipment. NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE EQUIPMENT!

We recommend approved Yaskawa training courses for all personnel involved with the operation, program ming , or re pair of the equip m en t.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

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WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

DANGER

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the MOTOMAN-MPL100.

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

DANGER

Indicates an imminent 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 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

To ensure safe and effi cient operation at all times, be sure to follow all instructions, even if not designated as “DANGER”, “WARNING” and “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 these safety precautions may result in death or serious injury from unexpected turning of the manipulator's arm.

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WARNING

TURN

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Notes for Safe Operation

• Before operating the manipulator, check that servo power is turned OFF pressing the emergency stop buttons. 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.

Figure 1: 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.

Figure 2: Release of Emergency Stop

• 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 b utton immediately if there is a problem.

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CAUTION

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Definition of Terms Used In this Manual

• 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 In this Manual

The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the

programming pendant, and supply cables. In this manual, the equipment is designated as follows:

Equipment Manual Designation

DX100 controller DX100 DX100 programming pendant Programming pendant Cable between the manipulator and the

controller

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • •” means that the cursor is moved to the object item and the SELECT key is pressed, or that the item is directly selected by touching the screen.

Registered Trademark

In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted.

Manipulator cable

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WARNING label A

WARNING label B

Nameplate

WARNING

Moving parts may cause injury

WARNING Label A:

WARNING Label B:

Nameplate

WARNING

Do not enter robot work area.

WARNING

Do not enter robot work area.

MADE IN JAPAN

YASKAWA ELECTRIC CORPORATION Kitakyushu 806-0004 Japan

2-1 Kurosakishiroishi, Yahatanishi-ku,

SERIAL NO.

PAYLOAD

TYPE

MASS DATE

ORDER NO.

MOTOMAN-

MODEL

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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.

Figure 3: Warning Label Locations

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Safeguarding Tips

All operators, programmers, maintenan c e personnel, supervisors, and anyone working near the system 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 equipment, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this equipment.

• Improper connections can damage the equipment. All connections must be made within the standard voltage and current ratings of the equipment.

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

• In accordance with ANSI/RIA R15.06-2012, 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).

Mechanical Safety Devices

The safe operation of this equipment is ultimately the users 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 R15.06-2012 safety standards, and other local codes that may pertain to the installation and use of this equipment.

Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or locatio n. The following safety equipment is provided as standard:

• Safety barriers

• Door interlocks

• Emergency stop palm buttons located on operator station

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety eq uip m en t imm e dia te ly.

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Programming, Operation, and Maintenance Safety

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

• Inspect the equipment 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.

• Check the E-St op button on the oper ator st a tion for pr oper o peration before programming. The equipment must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

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• 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.

• Any modifications to the controller unit can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to the controller unit. Making any changes without the written permission from Yaskawa will void the warranty.

• Some operations require standard passwords and some require special passwords.

• The equipment allows modifications of the software for maximum performance. Care must be taken when making th ese modifications. All modifications made to the software will change the way the equipment operates and can cause severe personal injury or death, as well as damage parts of the system. Double check all modifications under every mode of operation to ensure that the changes have not created hazards or dangerous situations.

• 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 equipment. All connections must be made within the standard voltage and current ratings of the equipment.

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Maintenance Safety

Turn the power OFF and disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

Perform only the maintenance described in this manual. Maintenance other than specified in this manual should be performed only by Yaskawatrained, qualified personnel.

Summary of Warning Information

This manual is provided to help users establish safe conditions for operating the equipment. S pecific consideration s and precautions are also described in the manual, but appear in the form of Dangers, Warnings, Cautions, and Notes.

It is important that users operate the equipment in accordance with this instruction manual and any additional information which may be provided by Yaskawa. Address any questions regarding the safe and proper operation of the equipment to Yaskawa Customer Support.

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NOTE

(937) 847-3200

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Customer Support Information

If you need assistance with any aspect of your MPL100 syste m, plea se contact YASKAWA Customer Support at the following 24-hour telephone number:

For routine te chnical inquiries, you can also cont act YASKAWA Customer Support at the following e-mail address:

When using e-mail to contact YASKAWA Customer Support, please provide a detailed description of your issue, along with complete contact information. Please allow approximately 24 to 36 hours for a response to your inquiry.

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techsupport@motoman.com

Please use e-mail for routine inquiries only. If you have an urgent or emergency need for service, replacem ent parts, or information, you must contact YASKAWA Customer Support at the telephone number shown above.

Please have the following information ready before you call Customer Support:

• System MPL100

• Robots ___________________________

• Primary Application ___________________________

• Controller DX100

• Software Version Access this information on the Programming Pendant’s LCD display screen by selecting {MAIN MENU} - {SYSTEM INFO} {VERSION}

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX100 controller data plate

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Table of Contents

1 Product Confirmation...................................................................................................................... 1-1

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

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

2 Transport.........................................................................................................................................2-1

2.1 Transport Method .............................................................................................................. 2-1

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

2.2 Shipping Bolts and Brackets.............................................................................................. 2-3

3 Installation.......................................................................................................................................3-1

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

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

3.2.1 Mounting Example................................................................................................3-3

3.3 Location.............................................................................................................................3-4

4 Wiring..............................................................................................................................................4-1

4.1 Grounding..........................................................................................................................4-1

4.2 Cable Connection..............................................................................................................4-2

4.2.1 Connection to the Manipulator..............................................................................4-2

4.2.2 Connection to the DX100 .....................................................................................4-2

5 Basic Specifications........................................................................................................................ 5-1

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 T-Point Maximum Envelope....................................................................5-3

5.5 Alterable Operating Range................................................................................................ 5-4

5.5.1 Components for Altering Operating Range ..........................................................5-5

5.5.2 Notes on the Mechanical Stopper Installation...................................................... 5-6

5.5.3 Adjustment of the Soft Limit of the S-Axis Pulse .................................................. 5-7

6 Allowable Load for Wrist Axis and Wrist Flange .............................................................................6-1

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

6.2 Wrist Flange.......................................................................................................................6-3

6.3 Levelness of the Wrist Flange ...........................................................................................6-4

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7 System Application..................................... .... ... ... ... ... .... ... ....................................... ... ....................7-1

7.1 Peripheral Equipment Mounts............................................................................................7-1

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

8 Electrical Equipment Specification............. .... ... ... .......................................... ... ... ...........................8-1

8.1 Position of Limit Switch......................................................................................................8-1

8.2 Internal Connections..........................................................................................................8-2

9 Maintenance and Inspection...........................................................................................................9-1

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

9.2 Notes on Maintenance Procedures....................................................................................9-7

9.2.1 Battery Pack Replacement...................................................................................9-7

9.3 Notes on Grease Replenishment/Exchange Procedures ..................................................9-9

Table of Contents

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer and Gear...........9-10

9.3.1.1 Grease Replenishment.............. ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ..9-10

9.3.1.2 Grease Exchange............ ... .... ... ... ... .... .......................................... ... ... ..9-11

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer.................... ... ... ..9-12

9.3.2.1 Grease Replenishment.............. ... ... .... ... ... .......................................... ..9-13

9.3.2.2 Grease Exchange............ ... .... ... ... ... .... .......................................... ... ... ..9-14

9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ...........................9-16

9.3.3.1 Grease Replenishment.............. ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ..9-16

9.3.3.2 Grease Exchange............ ... .... ... ... ... .... .......................................... ... ... ..9-17

9.3.4 Grease Replenishment/Exchange for T-Axis Speed Reducer............................9-18

9.3.4.1 Grease Replenishment.............. ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ..9-18

9.3.4.2 Grease Exchange............ ... .... ... ... ... .... .......................................... ... ... ..9-19

9.3.5 Grease Replenishment for U-axis Cross Roller Bearing ....................................9-20

9.3.6 Grease Replenishment for Links ......... ... ... ... .... ... ... ... .........................................9-21

9.3.7 Notes for Maintenance........................................................................................9-23

9.3.7.1 Battery Pack Connection.......................................................................9-23

10 Recommended Spare Parts........................................................................................................10-1

11 Parts List.....................................................................................................................................11-1

11.1 S-Axis Unit.....................................................................................................................11-1

11.2 L-Axis Unit......................................................................................................................11-4

11.3 U-Axis Unit.....................................................................................................................11-8

11.4 Wrist Unit .....................................................................................................................11-10

11.5 Balancer Unit ...............................................................................................................11-13

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CAUTION

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1 Product Confirmation

1.1 Contents Confirmation

1 Product Confirmation

• Confirm that the manipulator and the DX100 have the same order number . Special care must be taken when more than one manipulator is to be installed.

If the numbers do not match, manipulators may not perform as expected and cause injury or damage.

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives. Standard delivery includes the following four items (information for the

content of optional goods are given separately):

• Manipulator

• DX100

• Programming pendant

• Manipulator cables (between the DX100 and the Manipulator)

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PROPERLY.

CHECK ALL THE DOOR LOCKS

NJ3005-1

AVERAGE

PEAK

kVA kA

INTERRUPT CURRENT

ERDR-

POWER SUPPLY

TYPE

DX100

kVA

3PHASE

NJ2960-1

60Hz

SERIAL No. DATE

AC220V

MADE IN JAPAN

50/60HzAC200V

PROGRAMMING PENDANT

TRIPPED

RESET

OFF

THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

Check that the manipulator and the DX100 have the same order number.

Label (Enlarged View)

(a) DX100 (Front View) (b) Manipulator (Side View)

WARNING

Do not open the door

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1 Product Confirmation

1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the DX100. The order number is located on a label as shown below.

Fig. 1-1: Location of Order Number Labels

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CAUTION

NOTE

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2 Transport

2.1 Transport Method

• Sling applications 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 transport.

The system consists of precision components. Failure to observe this caution may adversely affect performance.

2.1 Transport Method

• The weight of the manipulator is approximately 1750kg including the shipping bolts and bracket s. Use a wire rope strong enough to withstand the weight.

• Mount the shipping bolts and brackets for transpor tin g the manipulator.

• Avoid putting external force on the arm or motor unit when transporting by a crane or other equipment. Failure to observe this instruction may result in injury.

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25°

45°

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2 Transport

2.1 Transport Method

2.1.1 Using a Crane

As a rule, the manipulator should be lifted by a crane with four wire ropes whe

n removing it from the package and moving it. Be sure that the manipulator is fixed with the shipping bolts and brackets before transport, and lift it in the posture as shown in Fig. 2-1 “Transporting Position”.

Fig. 2-1: Transporting Position

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NOTE

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2 Transport

2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at positions A, B, and C. (See Fig. 2-1 “Transporting Position”.)

• The shipping bolts and brackets are painted yellow.

Position Screw Type Pcs

A Hexagon socket head cap screw M20 8 B and C Hexagon socket head cap screw M10 4

Before turning ON the power, check to be sure that the shipping bolts and brackets are removed. The shipping bolts and brackets then must be stored for future use, in the event that the manipulator must be moved again.

Fig. 2-2: Shipping Bolts and Brackets

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CAUTION

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3 Installation

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3 Installation

WARNING

• Install the safeguarding. Failure to observe this warning may result in injury or damage.

• Install the manipulator in a location where the tool or the workpiece held by its fully extended arm will not reach the wall, safeguarding, or controller.

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.

• Do not install or operate the manipulator that is damaged or lacks parts.

Failure to observe this caution may cause injury or damage.

• Before turning ON the power, check to be sure that the shipping bolts and brackets explained in Fig. 2-2 “Shipping Bolts and Brackets” are removed.

Failure to observe this caution may result in damage to the driving parts.

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3 Installation

3.1 Safeguarding Installation

To insure safety, be sure to install safeguarding. It prevents unforeseen accidents with personnel and damage to equipment. Refer to the quoted clause for your information and guidance:

Responsibility for Safeguarding (ISO10218)

The user of a manipulator or robot system shall ensure that safeguards are 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 baseplate or foundation strong enough to support the manipulator and withstand repulsion forces during acceleration and deceleration.

Construct a solid foundation with the appropriate thickn ess to withstand maximum repulsion forces of the manipulator referring to Table 3-1

"Maximum Repulsion Forces of the Manipulator at Emergency Stop" and Table 3-2 "Endurance Torque in Operation".

A baseplate flatness must be kept at 0.5 mm or less: insufficient flatnes s of installation surface may deform the manipulator shape and affect its functional abilities. Mount the manipulator base as instructed in section

3.2.1 “Mounting Example”.

Table 3-1:

Maximum torque in horizontal rotation (S-axis moving direction)

Maximum torque in vertical rotation (L-, U-axes moving direction)

Maximum Repulsion Forces of the Manipulator at Emergency Stop

39200 N•m (4000 kgf•m)

62800 N•m (6400 kgf•m)

Table 3-2: Endurance Torque in Operation

Endurance torque in horizontal operation (S-axis moving direction)

Endurance torque in vertical operation (L-, U-axes moving direction)

11800 N•m (1200 kgf•m)

18800 N•m (1920 kgf•m)

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180

540

1000

180

540

180

1000

Hexagon socket head cap screw M20 (8 screws)

Spring washer

Manipulator base

Baseplate

Washer

50 mm or more

200 mm or more

Flatness: 0.5 mm or less

Manipulator base

Baseplate

28 dia. (12 holes)

Baseplate (reference)

Units: mm

Anchor bolt (M24 or larger)

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3 Installation

3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The b

aseplate should be rugged and durable to prevent shifting of the manipulator or the mounting fixture. It is recommended to prepare a baseplate of 50 mm or more thickness, and anchor bolts of M24 or larger size. The anchor bolts should be inserted at least 200 mm deep into the floor.

Next, fix the manipulator base to the baseplate. The manip ula to r ba se is tapped for eight mounting holes; securely fix the manipulator base to the baseplate with eight hexagon socket head cap screws M20 (80 mm long is recommended).

Tighten the hexagon socket head cap screws and anchor bolts firmly so that they will not work loose during the operation.

Refer to Fig. 3-1 “Mounting the Manipulator on Baseplate”.

Fig. 3-1: Mounting the Manipulator on Baseplate

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3 Installation

3.3 Location

When installing a manipulator, it is necessary to satisfy the following environmental conditions:

• Ambient temperature: 0 to + 45C

• Humidity: 20 to 80 %RH (non-condensing)

• Free from dust, soot, or water

• Free from corrosive gas or liquid, or explosive gas or liquid

• Free from excessive vibration  (Vibration acceleration: 4.9 m/s

• Free from large electrical noise (plasma)

• Flatness for installation: 0.5 mm or less

[0.5 G] or less)

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CAUTION

NOTE

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4 Wiring

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4 Wiring

4.1 Grounding

WARNING

• Ground resistance must be 100  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.

• 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 with heat insulating material, and avoid multiple cabling when laying manipulator cables from the manipulator to the DX100.

Failure to observe this caution may result in burn caused by cable heat emission failure.

4.1 Grounding

Follow electrical installation standards and wiring regulations for grounding. A ground wire of 5.5 mm

Refer to Fig. 4-1 “Grounding Method” to connect the ground line d irectly to the manipulator.

or more is recommended.

• Never use this wire sharing 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 electrical installation standards.

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5.5 mm2 or more

Bolt M8 (for grounding) Delivered with the manipulator

Enlarged View A

NOTE

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Fig. 4-1: Grounding Method

4 Wiring

4.2 Cable Connection

Three manipulator cables are delivered with the manipulator: an encoder cable (1BC) and two power cables (2BC and 3BC). (Refer to Fig. 4-2 “Manipulator Cables”.)

Connect these cables to the manipulator base connectors and to the DX100. Refer to Fig. 4-3(a) “Manipulator Cable Connectors (Manipulator

Side, YR-MPL0100-A00)”, Fig. 4-3(b) “Manipulator Cable Connectors (Manipulator Side, YR-MPL0100-A04)” and Fig. 4- 3(c) “Manipulator Cable Connection (DX100 Side)”.

4.2.1 Connection to the Manipulator

Before connecting two cables to the manipulator, verify the numbers on

th manipulator cables and the connectors on the connector base of the

bo manipulator. When connecting, adjust the cable connector positions to the main key positions of the manipulator , and insert cable s in the order of 2BC, 3BC, then 1BC. After inserting the cables, depress the lever until it clicks.

DO NOT cover the cable with heat insulating material, and avoid multiple cabling.

4.2.2 Connection to the DX100

Before connecting cables to the DX100, verify the numbers on both

ipulator cables and the connectors on the DX100. When connecting,

man insert the cables in the order of X21, X22, then X11, and depress each lever until it clicks.

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MPL100

Power Cable

DX100 side

Encoder Cable

Manipulator side

DX100 side

Manipulator side

X11

1BC

X11

1BC

2BC

X21

2BC

3BC

X22

3BC

X22

2BC

X21

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Fig. 4-2: Manipulator Cables

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4 Wiring

4.2 Cable Connection

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Connector Details

(Manipulator Side)

Key positions

Connector Details

(Manipulator Side)

Key positions

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4 Wiring

4.2 Cable Connection

Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side, YR-MPL0100-A00)

Fig. 4-3(b): Manipulator Cable Connectors (Manipulator Side, YR-MPL0100-A04)

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MPL100

X22

X21

X11

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Fig. 4-3(c): Manipulator Cable Connection (DX100 Side)

4 Wiring

4.2 Cable Connection

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5 Basic Specifications

5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

Table 5-1: Basic Specifications

Item Type YR-MPL0100-A00, A04

Structure Vertically Articulated Degree of Freedom 4 Payload 100 kg Repeatability Range of Motion S-Axis (turning) ±180

Maximum Speed S-Axis 2.44 rad/s, 140/s

T-Axis Allowable Inertia (GD Approx. Mass 1700 kg Ambient Conditions Temperature 0 to 45C

Power Requirements 9.5 kVA

1 SI units are used in this table. However, gravitational unit is used in ( ). 2 Conformed to ISO9283 3 Refer to section 6.1 “Allowable Wrist Load” for details on the permissible moment of inertia.

±0.5 mm

L-Axis (lower arm) +90, -45 U-Axis (upper arm) +15.5, -120 T-Axis (wrist twist) ±360

L-Axis 2.44 rad/s, 140/s U-Axis 2.44 rad/s, 140/s T-Axis 5.3 2 rad/s, 305/s

/4)

Humidity 20 to 80% RH (non-condensing) Vibration Acceleration 4.9 m/s Others Free from corrosive gas or liquid, or explosive gas or

80 kg•m

liquid Free from exposure to dust, soot, or oil Free from excessive electrical noise (plasma)

(0.5G) or less

5-1

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MPL100

T-

T+

U-

U+

L- L+

S-

S+

Lower arm L-arm

Base

Upper arm (U-arm)

Wrist

Wrist flange

Rotary head S-head

540

710

350

879

519

640

Units: mm

View A

360±0.1

320±0.1

360±0.1

+0.021 0

20 dia. hole (2 places)

12 dia. hole

+0.018 0

22 dia. hole (8 places)

220±0.1

300±0.1320±0.1

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5 Basic Specifications

5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes

5.3 Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions

5-2

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625

616

15.5

2529

R1124

2776

614 2162

1300

1600

2363

2624

1241

45°

120°

R697

R1037

R3159

2204

300

250

1400

820

31591037

880 1250

270

-Point

-point maximum envelope

P-point

Units: mm

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5 Basic Specifications

5.4 Dimensions and T-Point Maximum Envelope

Fig. 5-3:

Dimensions and P-Point Maximum Envelope (YR-MPL0100-A00, A04)

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NOTE

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5 Basic Specifications

5.5 Alterable Operating Range

The operating range of the S-axis can be altered in accordance with the operating conditions as shown in Table 5-2 "S-Axis Operating Range".  If alteration is necessary, contact your YASKAWA representative in advance.

Table 5-2: S-Axis Operating Range

Item Specifications

S-Axis Operating Range

±180°(standard) *(±165°) ±150° ±135° ±120° ±105° ± 90° ± 75° ± 60° ± 45° ± 30° *(± 15°)

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* The interval between stoppers must be 60° or more.

When altering the operating range to ±15° or ±165°, please contact your YASKAWA representative.

5-4

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A’A

Stopper (HW0307574-1)

Pin (HW0407007-1)

Section A-A’

Hexagon head screw M20 (length: 70 mm, tensile strength: 1200 N/mm

or more, 3 screws)

Washer M20 (3 washers)

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5 Basic Specifications

5.5 Alterable Operating Range

5.5.1 Components for Altering Operating Range

When modifying the operating range of the S-axis, prepare the comp

onents shown in

the following list

Fig. 5-4 “Components of S-Axis Stopper” referring to

(1) Pin (drawing No. HW0407007-1, 1 pin) (2) Stopper (drawing No. HW0307574-1, 1 stopper) (3) Hexagon head screw M20

(length: 70 mm, tensile

strength: 1200 N/mm2 or more, 3 screws)

(4) Flat washer M20 (3 flat washers)

Fig. 5-4: Components of S-Axis Stopper

5-5

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Improper Installation Proper Installation

Hexagon head screws M20

NOTE

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5 Basic Specifications

5.5 Alterable Operating Range

5.5.2 Notes on the Mechanical Stopper Inst allation

• Apply the Locktite 242 to the thread p

• The S-axis mechanical stopper can be installed at a pitch of 15

• To ensure the stopper strength, make sure to fix both sides of the

• As in the figures: Fig. 5-6(a) “Properly-Mounted Mod els for S-Ax is

Fig. 5-5: Properly-Mounted Image

art of the pin HW0407007-1, and install the pin bottom up into the S-axis mechanical stopper HW0307574-1 as shown in Fig. 5-4 “Components of S- Axis Stopper”. Mount the stopper to the S-head with three hexagon head screws M20 (length: 70 mm) and tighten the screws to the tightening torque of  402 N•m (tensile strength: 1200 N/mm installed as shown in Fig. 5-4 when the operating range is ±180°.

degrees. However, to avoid the mechanical troubles caused by interference between stoppers (e.g. ±15°, ±165°), install the stopper referring to Table 5-3 "Settable Angle for S-Axis Stopper".

protrusion with screws. DO NOT fix only one side of the protrusion. (See Fig. 5-5 “Properly-Mounted Image”.)

Stopper” to Fig. 5-6( m) “Properly-Mounted Mo dels for S-Axis S topper”, the S-axis mechanical stopper is reversible that either side of the stopper can be used and installed except for the installation at the angles: ±30, ±60, ±120, ±150 degrees. If the stopper cannot be installed in the range shown in Table 5-3, flip the stopper and retry installing the stopper.

or more). The stopper is

1. Apply the specified components when mounting the  S-Axis mechanical stopper.

2. TURN OFF the electric power supply before mounting.

5-6

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NOTE

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5 Basic Specifications

5.5 Alterable Operating Range

5.5.3 Adjustment of the Soft Limit of the S-Axis Pulse

To limit the operating range of the S-axis, refer to "DX100 Concurrent I/O (m

anual No. RE-CKI-A453)" and change the following pa rameters with the

programming pendant. Pulse limit (positive (+) direction of the S-axis): SICxG400 Pulse limit (negative (-) direction of the S-axis): SICxG408

MPL100

Degree Number of Pulse

0 0

15  30 58179  45 87268  60 116357  75 145446  90 174536  105 203625  120 232714  135 261804  150 290893

165  180 349071

1 Refer to section 5.5 “Alterable Operating Range”.

 29089

 319982

Adjust both of the pulse limit and the angle of the S-axis mechanical stopper when modifying the range of motion of the manipulator.

5-7

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MPL100

180 165 150 135 120 105 90 75 60 45 30 15 0 -15 -30 -45 -60 -75 -90 -105 -120 -135 -150 -165 -180

-180

-165

-150

-135

-120

-105

-90

-75

-60

-45

-30

-15

1530456075

105

120

135

150

165

180

: Settable angle

: Disabled angle

This table can be used when installing two mechanical stoppers on the S-axis.

The vertical axis of the table shows the angles in the positive direction, and the horizontal axis of the table

shows the angles in the negative direction.

For example, if one stopper is to be installed at a 180 degree angle in the positive direction, the other one

can be installed within the range of +/-105 degree angles: since more than 60 degrees of interval is required

to mount two stoppers, the chart indicates that the other angles are inappropriate for the installation.

Exception: The top left cell indicates the mountability of one stopper.

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5 Basic Specifications

5.5 Alterable Operating Range

Table 5-3: Settable Angle for S-Axis Stopper

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+ Direction Angles

- Direction Angles

5-8

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165

Installation at + 180°

Installation at + 165°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

180

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5.5 Alterable Operating Range

Fig. 5-6(a): Properly-Mounted Models for S-Axis Stopper

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MPL100

135

150°

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is reversible. Either side of the stopper can be used.

Installation at + 150°

The stopper is irreversible. Only this side of the stopper can be used at this angle.

Installation at + 135°

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(b): Properly-Mounted Models for S-Axis Stopper

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105°

Installation at + 120°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at + 105°

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is irreversible. Only this side of the stopper can be used at this angle.

120°

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(c): Properly-Mounted Models for S-Axis Stopper

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MPL100

90°

Installation at + 90°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at + 75°

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is reversible. Either side of the stopper can be used.

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(d): Properly-Mounted Models for S-Axis Stopper

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45°

Installation at + 60°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is irreversible. Only this side of the stopper can be used at this angle.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at + 45°

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(e): Properly-Mounted Models for S-Axis Stopper

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MPL100

30°

Installation at + 30°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is irreversible. Only this side of the stopper can be used at this angle.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at + 15°

42 of 106

Fig. 5-6(f): Properly-Mounted Models for S-Axis Stopper

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5 Basic Specifications

5.5 Alterable Operating Range

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The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at + 0°

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(g): Properly-Mounted Models for S-Axis Stopper

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MPL100

165°

180°

Installation at - 180°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is reversible. Either side of the stopper can be used.

Installation at - 165°

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(h): Properly-Mounted Models for S-Axis Stopper

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150°

135

Installation at - 150°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is irreversible. Only this side of the stopper can be used at this angle.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at - 135°

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(i): Properly-Mounted Models for S-Axis Stopper

5-17

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MPL100

105

120°

Installation at - 120°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is irreversible. Only this side of the stopper can be used at this angle.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at - 105°

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(j): Properly-Mounted Models for S-Axis Stopper

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90°

Installation at - 90°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at - 75°

The stopper is reversible. Either side of the stopper can be used.

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5 Basic Specifications

5.5 Alterable Operating Range

Fig. 5-6(k): Properly-Mounted Models for S-Axis Stopper

5-19

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MPL100

60°

Installation at - 60°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is irreversible. Only this side of the stopper can be used at this angle.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at - 45°

48 of 106

Fig. 5-6(l): Properly-Mounted Models for S-Axis Stopper

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5 Basic Specifications

5.5 Alterable Operating Range

5-20

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15°

30°

Installation at - 15°

The stopper is reversible. Either side of the stopper can be used.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

The stopper is irreversible. Only this side of the stopper can be used at this angle.

Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20

Installation at - 30°

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Fig. 5-6(m): Properly-Mounted Models for S-Axis S topper

5 Basic Specifications

5.5 Alterable Operating Range

5-21

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J=Ji+WL

J Ji W L

: Total inertia (GD

/4) of the T-axis (kgm2)

: Inertia of the volume load on the flange (kgm

) : Payload (kg) : Eccentricity (mm)

Formula:

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

The allowable wrist load including the weight of the mount/gripper is  100 kg maximum.

1. The total moment of inertia (GD value shown in Table 6-1 "Allowable Total Inertia".

Ta ble 6-1: Allowable Total Inertia

T- Axis Total Moment of Inertia (GD2/4)

kg•m

80 kg•m

2. When the inertia of the volume load on the flange is small, the

eccentricity of load center measured from T-axis flange rotation center is in the range shown in Fig. 6-1 “Moment Arm Rating for MPL100”. When the inertia of the volume load on the flange (Ji) is large, use the

owing formula to calculate the eccentricity L

foll

/4) of T-axis should be within the

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Center of T-axis flange rotation

900 800 700 600500400 300 200100 100 200 300 400500 600 700 800900

100 200 300 400 500 600 700 800

900 1000

1100

LB (mm)

1000 1000

LT (mm)

W=100 kg W=80 kg

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

Fig. 6-1: Moment Arm Rating for MPL100

6-2

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MPL100

NOTE

Tappled hole M10 (10 places)(depth: 16)

10 dia. hole (2 places)(depth: 8)

+0.015 0

Units: mm

63 dia.

+0.030 0

160 dia.

-0.025

30°

PCD 125

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6 Allowable Load for Wrist Axis and Wrist Flange

6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. It is recommended that the attachment be mounted inside the fitting in orde r to identify the alignment marks. Fitting depth shall be 8 mm or less.

When the outside fitting is used, the depth of outside fitting must be 8 mm or less.

Fig. 6-2: Wrist Flange

Wash off anti-corrosive paint (yellow) on the wrist flange surface with thinner or light oil before mounting the tools.

6-3

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6.3 Levelness of the Wrist Flange

Fig. 6-3: Tilting of Wrist Flange

6 Allowable Load for Wrist Axis and Wrist Flange

6.3 Levelness of the Wrist Flange

The wrist flange is kept level to the mounting surface of the MOTOMANMPL100 in the full range of motion. However, minor tilting may occur due to the posture and load conditions.

When the manipulator will be used in applications in which the levelness of the wrist flange is important, first evaluate a nd check tilting with the actual posture and load conditions.

T-point maximum envelope

Tilting of wrist flange

T-point

Mounting surface

6-4

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Tapped hole M6 (6 places)(depth: 15)

View A

Units: mm

Section B-B’

Tapped hole M6 (2 places)(depth: 15)

122

53 dia.

177.5 122.5

B’

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7 System Application

7.1 Peripheral Equipment Mounts

7 System Application

7.1 Peripheral Equipment Mounts

The peripheral equipment mounts and tapped holes are provided on the wrist unit as shown in Fig. 7-1 “Installing Peripheral Equipment” for easier installation of the users’ system applications.

The following conditions shall be observed to attach or install peripheral equipment. (Refer to Table 7-1 "Conditions for Installation".)

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Fig. 7-1: Installing Peripheral

Equipment

Table 7-1: Conditions for Installation

Application Note

Cable Processing and Valve Load

Up to 100 kg including the peripheral equipment mass attached to the wrist unit

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

Internal user I/O wiring harness (0.5 mm2 x 23 wires), and air lines (6 lines for A00 and 5 lines for A04) are incorporated in the manipulator for the drive of peripheral devices mounted on the upper arm as shown in Fig.

7-2(a) “Connectors for Internal User I/O Wiring Harness and Air Line (YRMPL0100-A00)” and Fig. 7-2(b) “Connectors for Internal User I/O Wiring Harness and Air Line (YR-MPL0100-A04)”.

The connector pins 1 to 23 are assigned as shown in Fig. 7-2(d “Details of the Connector Pin Numbers”. Wiring must be performed by users.

The allowable current for internal user I/O wiring harness

The maximum pressure for the air line 784 kPa (8 kgf/cm

2.0 A or less for each wire (The total current value for pins 1 to 23 must be 44 A or less.)

(The air line inside diameter: 7.5 mm)

) or less

7-2

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MPL100

Connector base

View B

View A

Connector for the internal user I/O wiring harness (base side):

JL05-2A24-28PC (with a cap) Prepare connector: JL05-6A24-28S

Connector for the internal user I/O wiring harness (wrist side):

JL05-2A24-28SC (with a cap) Prepare connector: JL05-6A24-28P

Exhaust port: A, B, C, D, E, F PT3/8 with a pipe plug (6 places)

Air inlet: A, B, C, D, E, F PT3/8 with a pipe plug (6 places)

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

Fig. 7-2(a): Connectors for Internal User I/O Wiring Harness an d Air Line (YR-MPL0100-A00)



7-3

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View B

Connector for the internal user I/O wiring harness (base side): JL05-2A24-28PC (with a cap) Prepare connector: JL05-6A24-28S

Connector for the internal user I/O wiring harness (wrist side): JL05-2A24-28SC (with a cap) Prepare connector: JL05-6A24-28P

Tube for field bus cable (inside dia.: 12)

Exhaust port: A, B, C, D, E PT3/8 with a pipe plug (5 places)

Air inlet: A, B, C, D, E PT3/8 with a pipe plug (5 places)

Cable B (See "Note 1" below.)

Details of Part Y

(inside the junction box of the wrist)

Part Y

Part X

Cable A (See "Note 1" below.)

Details of Part X

(inside the connector base)

View A

Connector base

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

Fig. 7-2(b): Connectors for Internal User I/O Wiring Harness and Air Line (YR-MPL0100-A04)



Note 1: YP-MPL0100-A04 has a built-in tube for a field bus cable. A cable with a

cross sectional area of 2 mm bus cable through the manipulator, remove the covers of the connector base and the junction box, fix the field bus cable with the cable , and pull the cable

on the wrist.

is provided in the tube in advance. To run a field

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MPL100

Tube for field bus cable (inside dia.: 12)

Wire harness

Union

S-head

Part Z

Cut

Tube for field bus cable (inside dia.: 12)

Union

Field bus cable C

Cable A

Step 1

Step 2

Step 3

Step 4

Step 5

Field bus cable C

ACA

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

Note 2: As shown in Fig. 7-2(c) “Field Bus Cable Connection”, the tube for a field

bus cable (inside dia.: 12 mm) is connected by a union in the Z part of the S-

ead. 

h Run the field bus cable by following the steps below.

Fig. 7-2(c): Field Bus Cable Connection

1. The tube for a field bus cable (inside dia.: 12 mm) is connected by a union, in which the cable

runs. (See the step 1 on the left.) 

 

2. Remove the union from the tube for a field bus cable. (See the step 2 on the left.) 

  

3. Pull the field bus cable fixed to the cable until it reaches the union. (See the step 3 on

the left.) 

 

4. Cut the cable from the field bus cable . (See the step 4 on the left.) 

  

5. Remove the union, fix the cable to the field

7-5

bus cable , and run it through the manipulator. (See the step 5 on the left.) 



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1 2

4312

5 7

211623

18 19

141311 12

10 12

15 17

20 21 22

578

Pins used

Internal user I/O wiring harness: 23 wires, size 0.5 mm

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

Fig. 7-2(d): Details of the Connector Pin Numbers

The same numbered pins (1 to 23) of the two connectors are connected

with

a single lead wire of 0.5 mm

7-6

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MPL100

Internal user I/O wiring harness, air line, etc.

Protective material

dia. 43 mm or less (inside diameter of the protective material)

dia. 53 mm (inside diameter of the hollow part)

user I/O wiring harness, air line, etc.

: Total cross section of the internal

: Cross section of protective material

Clearance between the protective material and the hollow part must be 10 mm or more.

must be 30 % or less of .

B A

Note

Note 3

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

The wrist part of MOTOMAN-MPL100 has a hollow structure for the internal user I/O wiring harness, air line, etc. To run the internal user I/O wiring harness, air line, etc. through the hollow part, follow the conditions below.

Table 7-2: Conditions to Run the Wiring Harness, Air Line, etc. through the Hollo w Par t

Item Notes

Inside diameter of the hollow part: 53 mm

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Inside diameter of the protective material for the

wiring harness: 43 mm or less

Ratio of the cross section of the wiring harness 

etc. to the protective material: 30 % or less

Fig. 7-3:

Conditions to Run the Wiring Harness, Air Line, etc. through the Hollow Part

Before running the wiring harness etc., prot ect it with  protective springs etc. Also, clearance of 10 mm or more is needed between the hollow part and the protective material.

Since sufficient clearance is also needed between the protective material and the wiring harness etc., make sure that the ratio of the total cross section of the wiring harness etc. to the cross section of the protective material is 30 % or less.

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L- and U-axes interference limit switch (optional)

L-axis overrun limit switch (optional)

S-axis overrun limit switch (optional)

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8 Electrical Equipment Specification

8.1 Position of Limit Switch

8 Electrical Equipment Specification

8.1 Position of Limit Switch

The limit switches are optional. For the S-, L-, and U-axes with limit switches specifications, the limit switches are located on the S-axis,  L-axis, and U-axis respectively. For the location, refer to Fig. 8-1

“Location of Limit Switches”.

Fig. 8-1: Location of Limit Switches

8-1

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MPL100

Connector for internal user I/O wiring harness

Enlarged View B

Connector for internal user I/O wiring harness

Enlarged View A

1BC

2BC

3BC

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8 Electrical Equipment Specification

8.2 Internal Connections

Highly reliable connectors are equipped on each connection part of the manipulator to enable easy removal and installation for maintenance and inspection. For the number and location of connectors, see Fig. 8-2(a)

“Locations and Numbers of Connectors (YR-MPL0100-A00)” and Fig. 8-2(b) “Locations and Numbers of Connectors (YR-MPL0100-A04)”.

Diagrams for internal connections of the manipulator are shown in Fig. 8-3(a) “Internal Connection Diagram” and Fig. 8-3(b) “Internal Co nnection Diagram”.

Fig. 8-2(a): Locations and Numbers of Connectors (YR-MPL0100-A00)

8-2

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Connector for internal user I/O wiring harness

Enlarged View B

Connector for internal user I/O wiring harness

Enlarged View A

1BC

2BC

3BC

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8 Electrical Equipment Specification

8.2 Internal Connections

Fig. 8-2(b): Locations and Numbers of Connectors (YR-MPL0100-A04)

Table 8-1: List of Connector Types

Name Type of Connector

Connector for the internal user I/O wiring harness on the connector base

Connector for the internal user I/O wiring harness on the wrist base

JL05-2A24-28PC (JL05-6A24-28S: Optional)

JL05-2A24-28SC (JL05-6A24-28P: Optional)

8-3

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LA1

LC1

LA3 LB3

LB2 LB1

LB1

LA1

LC3 LD3

LD2 LD1

LD1

LC1

LD1

LC1

LB1

LA1

LD1

LC2 LD2

LD2

LD1

LC1

LB1

LA2 LB2

LB2

LB1

LA1

+24V

LD1LC1

LD1

CN4-5

LD1

CN4-4

+24V

CN4-4

+24V

CN2-10

LD1

LD2

LB1

LB2

LD3

LC3

LB3

LA3

LB2

LB1

LD2

LD1

LB2

LA2

LD2

LC2

LB2

LA2

CN4-100V

CN4-10

SS2

AL1

CN4-7

AL1

CN4-8

CN4-3

CN4-1 CN4-6

CN4-2

AL2

BC2

+24V

LB1

SS2

CN4-3 CN4-8

CN4-2

CN4-6

CN4-1

AL2

BC2

+24V

SS2

LB1

FG6

SPG+6 SPG-6

CN3-6 CN3-7

CN3-8FG6

SPG+6 SPG-6

CN3-6 CN3-7

CN3-8

FG3

SPG+3 SPG-3

CN2-1 CN2-2

CN2-3FG3

SPG+3 SPG-3

CN2-1 CN2-2

CN2-3

SPG+2 SPG-2

CN1-6 CN1-7

FG2CN1-8

SPG+2 SPG-2

CN1-6 CN1-7

FG2

CN1-8

FG1CN1-3FG1

CN1-3

SPG+1 SPG-1CN1-2

CN1-1

SPG-1

CN1-2

SPG+1

CN1-1

BAT

OBT

BAT

+5V FG6

OBT

-6

-2

1CN-1

-10

-9

-4

-5

No.1CN

-1

-4

-3

-2

No,19CN

BAT6 PG5V6

PG0V6

OBAT6

DATA+6 DATA-6

BAT

-6

-2

8CN-1

No.8CN

FG3 OBT

+5V

BAT

-10

-9

-4

-5

OBT

-1

No,18CN

BAT3

-3

-4

PG5V3 PG0V3

OBAT3

-2

DATA-3

DATA+3

+5V

OBT

BAT

-2

-4

-5

-6

-9

7CN-1

No.7CN

-1

-4

-3

-2 PG0V2

BAT2

PG5V2

OBAT2

No,17CN

OBT BAT

-10

FG2

DATA+2 DATA-2

DATA+1 DATA-1

-2

FG1

+5V

OBT

OBT BAT

-4

-5

-9

-10

BAT

-6

P P P

No.6CN

6CN-1

OBAT1 PG5V1 PG0V1

BAT1

-2

-3

-4

-1

No,16CN

No.20CN

1BC(10PX4)

-4

-2

-3

-1 +24V 0V

+24V 0V

+24V

CN1-9

CN1-5 CN1-4

CN1-10

CN1-10 CN1-9

+24V

+24V 0V

CN1-4

CN1-5

PG0V6 PG5V6

9 11

PG0V2 PG0V3

PG5V2

3 5

7 8

PG5V36

5 7

6 8

0BAT2

BAT1

0BAT1

0BAT3 BAT3

BAT2

18 19

21 22

24 25

0BAT6 BAT6

PG5V1

PG0V1

28 29

30 31

2 3

BAT11 0BAT12 BAT12

0BAT21

0BAT11

BAT22

0BAT22

BAT21

BAT 0BT

0BT

BAT

0BT BAT

BAT

DX100

LD2

LC2

BC1 BC2

LB1LA1

No.12CN

2 4 6

SS1

12CN-1

SS1

LA1 BC2

LB1

BC1

FAN

AC2

AL2 AC1

AL1

Base

For lamp (option)

For S-axis fan (option)

S-AXIS OVERRUN L.S.

L AND U-AXIS INTERFERENCE L.S.

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

L AND U-AXIS INTERFERENCE L.S.

L-AXIS OVERRUN L.S.

S-AXIS OVERRUN L.S.

SLU-axes with Limit Switch Specification

S-axis with Limit Switch Specification

1. For the limit switch specification, the connection of the section

Notes

and parts are changed as follows:

Connected to

S-AXIS

U-AXIS

T-AXIS

L-AXIS

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8 Electrical Equipment Specification

8.2 Internal Connections

Fig. 8-3(a): Internal Connection Diagram

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Power Cable S-axis Internal Cable

LU-axis Internal Cable

Cable in the U-arm

For spare cable

S-axis

L-axis

U-axis

T-axis

4BC

(24-28)

-1

-2

9CN-A

No.9CN

-D

-C

-B

BA1 BB1

ME1

MU1

MW1

MV1

-2

10CN-A

No.10CN

-B

-1

-C

-D

BB2

MV2

BA2

MW2 ME2

MU2

MU6 MV6

ME6

BB6

BA6

MW6

11CN-A

No.11CN

-B

-D

-1

-2

-C

MV3

ME3

BA3 BB3

MW3

MU3

No.2CN 2CN-A

-2

-B

-1

-D

-C

CN2-6

CN2-5

CN2-4

CN2-3

CN1-6 CN1-8

CN1-7

CN2-1 CN2-2

CN1-4

CN1-3 CN1-5

CN1-2

CN1-1

2BC(8X5)

MW1 ME1

ME1

MW1

MV1

MW1

MV1 MV1

MW1

MU1 MU1

MV1

MU1

CN3-3

CN4-5

CN 6-2

CN 6-1

CN4-7 CN4-8

CN4-6

CN4-4

CN4-1 CN4-2

CN3-8

CN4-3

CN3-7

CN3-6

CN3-4 CN3-5

CN3-2

CN2-8

CN3-1

MU2

BA2

BA1

MW2 ME2

ME2

MW2

MV2

MW2

MU2 MV2

MV2 MV2

MU2

ME1

MU2

ME1CN2-7

CN3-2 CN3-4

CN3-3

CN 1-4

CN 2-6 CN3-1

CN 2-1 CN 2-2

CN 2-3 CN 2-4 CN 2-5

CN 1-5 CN 1-6

CN 6-6

CN 1-3

CN 1-2

CN 1-1

3BC(6X5)

CN 6-4 CN 6-5

ME3 ME3

ME3

BB6

ME3

MW3

MV3 MV3

MW3

MU3 MV3

MU3

BA6 BB1

AC1 AC2

CN5-3

CN5-4

4BC

CN 5-1 CN 5-2

CN 4-4 CN 4-5 CN 4-6

CN 4-1 CN 4-2 CN 4-3

(24-28)

MU6

ME6

MU6 MV6 MV6 MW6 MW6

BA3

CN 6-3

4BC-1

14 15

9 10

3 4

-10

-19

-20

-14

-15

-16

-17

-18

-12

-13

-11

-6

-9

-8

-7

-5

-4

-3

-2

-23

-21

-22

SP1

SP2

19 20

14 16

17 18

7 8 9

-10

-19

-20

-14

-15

-16

-17

-18

-12

-13

-11

4BC-1

-6

-7

-8

-9

-2

-3

-4

-5

-23

-21

-22

CN1-1

CN1-8

CN2-5

CN2-4

CN2-3

CN2-2

CN2-1

CN1-6 CN1-7

CN1-5

CN1-4

CN1-3

CN1-2

ME1 ME1

MW1

MV1

MW1

MW1 MW1

MV1

MU1

MV1

MU1 MV1

MU1

X21(8X5)

CN4-6 CN4-8

CN4-7

CN4-4 CN4-5

CN4-3

CN4-2

CN4-1

CN3-4

CN3-8

CN3-5 CN3-6 CN3-7

CN3-2 CN3-3

CN3-1

CN2-8

CN2-7

MU2

ME2

BA1 BA2

ME2 ME2

ME2

MW2

MW2 MW2

MV2

MV2 MV2

MU2

ME1

CN 6-1 CN 6-2

CN2-6

ME1

ME3 ME3 ME3

MU3

MW3 ME3

MW3 MW3 MW3

MV3 MV3

MV3

MU3 MU3

MU3

BB6

BB1

BA6

CN 6-5 CN 6-6

CN 3-2 CN 3-3 CN 3-4

CN 2-5

CN 2-3

CN 3-1

CN 2-6

CN 2-4

CN 1-4

CN 2-1 CN 2-2

CN 1-6

CN 1-5

CN 1-2 CN 1-3

CN 1-1

X22(6X5)

CN 6-4

CN 5-4

CN 5-3

AC2

AC1

ME6 ME6

MW6

MV6

MU6 MV6

MU6

CN 4-3

CN 5-1 CN 5-2

CN 4-6

CN 4-5

CN 4-4

CN 4-1 CN 4-2

CN 6-3

BA3

WRIST

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8 Electrical Equipment Specification

8.2 Internal Connections

Fig. 8-3(b): Internal Connection Diagram

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CAUTION

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9 Maintenance and Inspection

9.1 Inspection Schedule

9 Maintenance and Inspection

• 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.

• Maintenance and inspection must be performed by specified personnel.

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WARNING

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.

9.1 Inspection Schedule

Proper inspections are essential not only to assure that the mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. Inspection intervals are classified into several levels as shown in Table 9-1 "Inspection Items".

In Table 9-1 "Inspection Items", the inspection items are cate go rized by three types of operations: operations which can be performed by personnel authorized by the user, operations to be performed by trained personnel, and operations to be performed by service company personnel. Only specified personnel shall perform the inspection work.

9-1

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NOTE

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9 Maintenance and Inspection

9.1 Inspection Schedule

• The inspection interval depends on the total servo operation time.

• The following inspection schedule is based on the case that each axis is used under normal conditions. For axes which are used very frequently (in handling applications, etc.), it is recommended that inspections be conducted at intervals of 1/2 of the schedule indicated in Table 9-1 "Inspection Items".

• From the standpoint of the preventive maintenance, it is recommended that the following parts be replaced at the secondary inspection (18000 H).

• Speed reducers for the S-, L-, U-, and T-axes

• Cross roller bearing for the U-axis

• Oil seal for the L-, U-, and T-axis motor units

9-2

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Table 9-1: Inspection Items (Sheet 1 of 2)

68 of 106

Items

1 Alignment mark

2 External lead 3 Working area and

manipulator

9-3

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4 Motors for L- and U-axes 5 Baseplate mounting bolt s

6 Connector base 7 LU-axis connectors 8 Connectors in S-head 9 L-axis balancer

10 Wire harness in manipulator

(Wires for S-, L-, and U-axes) (Wires for T-axis)

1 1 Links/Connections

Schedule Method Operation Inspection

Charge

Daily

1000H Cycle

5000H Cycle

9000H Cycle

18000H

36000H

•

Visual Check alignment mark accordance and damage at the

home position. Visual Check for damage and deterioration of leads. Visual Clean the work area if dust or spatter is present. Check

for damage and outside cracks. Visual Check for grease leakage. Spanner

Wrench Manual Check for loose connectors and tighten if necessary. Manual Check for loose connectors and tighten if necessary. Manual Check for loose connectors. Grease

Gun, Visual

Multimeter, Visual

Visual, Manual

Tighten loose bolts. Replace if necessary.

Supply grease.

Check for loose screw nuts and shafts, and tighten if

necessary.

Check for conduction between the main connector of

base and intermediate connector with manually

shaking the wire.

Check for wear of protective spring

Replace

Move the L- and U-axes back and forth, up and down to

check any backlash.

Replenish grease

Replenishment for Links”.

See section 9.3.6 “Grease

Specified Person

Licensee

•••

••

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9 Maintenance and Inspection

Service Company

9.1 Inspection Schedule

•

Page 69

Table 9-1: Inspection Items (Sheet 2 of 2)

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Items

12 Battery pack in manipulator

13 S-axis speed reducer

9-4

14 Speed reducers for L- and

U-axes

15 T-axis speed reducer

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16 Bearing

17 Motor cooling fan 18 Overhaul

Schedule Method Operation Inspection

Charge

Daily

1000H Cycle

5000H Cycle

9000H Cycle

18000H

••

•

36000H

Screwdriver,

•

Wrench

Grease Gun Check for malfunction. (Replace if necessary.)

Grease Gun Replenish grease

Visual Check for damage and operation.

Replace the battery pack when the battery alarm

occurs or the manipulator drove for 36000H.

See section 9.2.1 “Battery Pack Replacement ” .

Replenish grease

See section 9.3.1 “Grease Replenishment/Exchange

for S-Axis Speed Reducer and Gear”.

Exchange grease

See section 9.3.1.

Replenish grease

See section 9.3.2 “Grease Replenishment/Exchange

for L-Axis Speed Reducer” and section 9.3.3 “Grease

Replenishment/Exchange for U-Axis Speed Reducer”.

Exchange grease

See section 9.3.2 and section 9.3.3.

Replenish grease

See section 9.3.4 “Grease Replenishment/Exchange

for T-Axis Speed Reducer”.

Exchange grease

See section 9.3.4.

Exchange grease

(5000H cycle).

(9000H cycle).

(5000H cycle).

(9000H cycle).

(5000H cycle).

(9000H cycle).

5) 6)

Specified Person

Licensee

••

MPL100

Service Company

9 Maintenance and Inspection

9.1 Inspection Schedule

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9-5

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1 Inspection item numbers correspond to the numbers in Fig. 9-1 “Inspection Items”. 2 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.

3 When checking for conduction with multimeter, connect the battery 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 section 9.3.6 “Grease Replenishment for Links”. 4 Wire harness in manipulator to be replaced at 18000H inspecti on. 5 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used". 6 Replenish grease to the U-axis cross-roller bearing at 5000 H or after a year, whichever comes first.

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MPL100

9 Maintenance and Inspection

9.1 Inspection Schedule

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Fig. 9-1: Inspection Items

View A

U-axis

L-axis

T-axis

S-axis

1611

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9 Maintenance and Inspection

9.1 Inspection Schedule

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Plate

Connector base

Base

Plate mounting screw M4

Plate

Connector base

Base

Plate mounting screw M4

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9 Maintenance and Inspection

9.2 Notes on Maintenance Procedures

Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts

13, 14, 15 Molywhite RE No.00 Speed reducers for S-, L-, U-

and T-axes

9, 16 Alvania EP Grease 2 L-axis balancer, bearings

The numbers in the above table correspond to the nu mbers in Table 9-1

"Inspection Items"

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

The battery packs are installed in the position shown in F

ig. 9-2(a) “Battery Location (Back View) (YR-MPL0100-A00)”, Fig. 9-2(b) “Battery Location (Back View) (YR-MPL0100-A04)” and Fig. 9-2(c) “Battery Location (Top View)”. If the battery alarm occurs in the DX100, replace the battery in

accordance with the following procedure:

Fig. 9-2(a): Battery Location (Back View) (YR-MPL0100-A00)

Fig. 9-2(b): Battery Location (Back View) (YR-MPL0100-A04)

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Battery pack

Board

New battery pack (HW0470360-A)

Battery pack before replacement

See the step 5.

See the step 4.

Connector

Board

NOTE

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9 Maintenance and Inspection

9.2 Notes on Maintenance Procedures

Fig. 9-2(c): Battery Location (Top View)

Fig. 9-3: Battery Connection

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 bo

ard.

5. Remove the old battery pack from the board.

Remove the old battery pack after connecting the new one so that the encoder absolute data does not disappear.

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

6. Mo u nt the ne w ba tte ry pack to the holder.

7. Reinstall the plate.

Do not allow the plate to pinch the cables when reinstalling the plate.

9.3 Notes on Grease Replenishment/Exchange Procedures

Make sure to follow the instructions listed below at grease replenishment/ exchange. Failure to observe the following notes may result in damage to a motor and a speed reducer.

• If grease is added without removing the plug/screw from the grease exhaust port, grease will leak inside a motor or an oil seal of a speed reducer will come off, which may result in damage to the motor. Make sure to remove the plug/screw.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

• Make sure to use a grease pump to inject grease. Set air supply pressure to the grease pump at 0.3 MP a or less, and the grease injection rate at 8 g/s or less.

• Make sure to fill hoses, which are joined to the grease inlet, with grease beforehand to prevent air from intruding into the speed reducer.

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Grease inlet Hexagon socket head plug

S-axis speed reducer

Grease exhaust port Hexagon socket head plug

1BC

4BC

2BC

3BC

DFE

BCA

NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer and Gear

Fig. 9-4: S-Axis Speed Reducer and Gear Diagram

9.3.1.1 Grease Replenishment (Refer to F

ig. 9-4 “S-Axis Speed Reducer and Gear Diagram”.)

1. Remove the hexagon socket head plugs from the grease inlet and

ease exhaust port.

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Install a grease zerk A-PT1/4 to the grease inlet.  (The grease zerk is delivered with the manipulator.)

3. Inject grease through the grease inlet using a grease gun – Grease type: Molywhite RE No.00 – Amount of grease: 2100 cc 

(4200 cc for 1st supply) – Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

4. Move the S-axis for a few minutes to discharge excess grease.

5. Wipe the discharged grease with a cloth, and reinstall the plug. Before inst

alling the plug, apply Three Bond 1206C on the thread part of the plug. Then tighten the plug with a tightening torque of 24.5 N•m  (2.5 kgf•m).

9-10

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

6. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply Three Bond 1206C on the thread part of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

9.3.1.2 Grease Exchange (Refer to Fig. 9-4 “S-Axis Speed Reducer and Gear Diagram”.)

1. Remove the hexagon socket head plugs from the grease inlet and

rease exhaust port.

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Install a grease zerk A-PT1/4 to the grease inlet.  (The grease zerk is delivered with the manipulator.)

157569-1CD

3. Inject grease through the grease inlet using a grease gun. – Grease type: Molywhite RE No.00 – Amount of grease: approx. 10400 cc – Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

4. The grease exchange is completed when new grease appears in the g

rease exhaust port. (The new grease can be distinguished from the

old grease by color.)

5. Move the S-axis for a few minutes to discharge excess grease.

6. Wipe the discharged grease with a cloth, a installing the plug, apply Three Bond 1206C on the thread part of the plug. Then tighten the plug with a tightening torque of 24.5 N•m  (2.5 kgf•m).

If the plug is installed while grease is being exhausted, grease will leak inside the motor and may cause a damage. Make sure to install the plug when the grease exhaust is completed.

7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before ins of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

talling the plug, apply Three Bond 1206C on the thread part

nd reinstall the plug. Before

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Grease inlet Hexagon socket head plug

Section A-A’

L-axis speed reducer

Grease exhaust port Hexagon socket head plug

225 mm

Grease zerk A-PT1/8

Joint PT1/8

Hose for grease replenishment

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9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

Fig. 9-5(a): L-Axis Speed Reducer Diagram

Fig. 9-5(b): L-Axis Grease Replenishment

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.2.1 Grease Replenishment (Refer to Fig

Axis Grease Replenishment”.)

1. Remove the hexagon socket head plugs from the grease inlet and

rease exhaust port.

2. Install a grease zerk A-PT1/8 to the grease inlet. 

(The grease zerk is delivered with the manipulator.)

3. Inject grease through the grease inlet using a grease gun

– Grease type: Molywhite RE No.00 – Amount of grease: 360 cc 

– Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

4. If you cannot inject grease with your grease gun, prepare a grease

ose as shown in Fig. 9-5(b) “L-Axis Grease Replenishment” and

inject grease.

. 9-5(a) “L-Axis Speed Reducer Diagram” and Fig. 9-5(b) “L-

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

(720 cc for 1st supply)

5. Move the L-axis for a few minutes t

7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before ins of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

talling the plug, apply Three Bond 1206C on the thread part

o discharge excess grease.

nd reinstall the plug. Before

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CAUTION

80°

90°

170°

Plug for air exhaust

Link-C

Plug for air exhaust

Link-C

NOTE

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9.3 Notes on Grease Replenishment/Exchange Procedures

• If the L-arm is tilted at 80 degrees or more, the link- C interferes with the plug for air exhaust.

Do not tilt the L-arm over 80 degrees when verifying th e ma n i pu lat or operation.

9.3.2.2 Grease Exchange (Refer to Fig. 9-5(a) “L-Axis Speed Reducer Diagram”.)

1. Remove the hexagon socket head plugs from the grease inlet and

2. Install a grease zerk A-PT1/8 to the grease inlet. 

3. Inject grease through the grease inlet using a grease gun.

ease exhaust port.

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

(The grease zerk is delivered with the manipulator.)

– Grease type: Molywhite RE No.00 – Amount of grease: approx. 1800 cc – Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

4. The grease exchange is completed when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color.)

5. Move the L-axis for a few minutes t

If the plug is installed while grease is being exhausted, grease will leak inside the motor and may cause a damage. Make sure to install the plug when the grease exhaust is completed.

7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before ins of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

talling the plug, apply Three Bond 1206C on the thread part

o discharge excess grease.

nd reinstall the plug. Before

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Grease inlet Hexagon socket head plug

Grease exhaust port Hexagon socket head plug

U-axis speed reducer

NOTE

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9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

Fig. 9-6: U-Axis Speed Reducer Diagram

9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.3.1 Grease Replenishment (Refer to Fig

1. Remove the hexagon socket head plugs from the grease inlet and

2. Install a grease zerk A-PT1/8 to the grease inlet. 

3. Inject grease through the grease inlet using a grease gun

ease exhaust port.

(The grease zerk is delivered with the manipulator.)

– Grease type: Molywhite RE No.00 – Amount of grease: 320 cc 

– Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

. 9-6 “U-Axis Speed Reducer Diagram”.)

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

(640 cc for 1st supply)

4. Move the U-axis for a few minutes to discharge excess grease.

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NOTE

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9.3 Notes on Grease Replenishment/Exchange Procedures

5. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply Three Bond 1206C on the thread part of the plug. Then tighten the plug with a tightening torque of 24.5 N•m  (2.5 kgf•m).

If the plug is installed while grease is being exhausted, grease will leak inside the motor and may cause a damage. Make sure to install the plug when the grease exhaust is completed.

6. Remove the grease zerk from the grease inlet, and reinstall the plug. Before ins of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

9.3.3.2 Grease Exchange (Refer to Fig. 9-6 “U-Axis Speed Reducer Diagram”.)

1. Remove the hexagon socket head plugs from the grease inlet and

rease exhaust port.

talling the plug, apply Three Bond 1206C on the thread part

157569-1CD

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Install a grease zerk A-PT1/8 to the grease inlet.  (The grease zerk is delivered with the manipulator.)

3. Inject grease through the grease inlet using a grease gun. – Grease type: Molywhite RE No.00 – Amount of grease: approx. 1600 cc – Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

4. The grease exchange is completed when new grease appears in the g

rease exhaust port. (The new grease can be distinguished from the

old grease by color.)

5. Move the U-axis for a few minutes to discharge excess grease.

nd reinstall the plug. Before

If the plug is installed while grease is being exhausted, grease will leak inside the motor and may cause a damage. Make sure to install the plug when the grease exhaust is completed.

7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before ins of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

talling the plug, apply Three Bond 1206C on the thread part

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Grease inlet Hexagon socket head plug

T-axis speed reducer

Grease exhaust port Hexagon socket head plug

NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.4 Grease Replenishment/Exchange for T-Axis Speed Reducer

Fig. 9-7: T-Axis Speed Reducer Diagram

9.3.4.1 Grease Replenishment (Refer to Fig

1. Remove the hexagon socket head plugs from the grease inlet and

ease exhaust port.

2. Install a grease zerk A-PT1/8 to the grease inlet. 

(The grease zerk is delivered with the manipulator.)

3. Inject grease through the grease inlet using a grease gun

– Grease type: Molywhite RE No.00 – Amount of grease: 180 cc 

(360 cc for 1st supply) – Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

4. Move the T-axis for a few minutes to discharge excess grease.

. 9-7 “T-Axis Speed Reducer Diagram”.)

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

5. Wipe the discharged grease with a cloth, and reinstall the plug. Before inst

alling the plug, apply Three Bond 1206C on the thread part of the plug. Then tighten the plug with a tightening torque of 4.9 N•m  (0.5 kgf•m).

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NOTE

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

If the plug is installed while grease is being exhausted, grease will leak inside the motor and may cause a damage. Make sure to install the plug when the grease exhaust is completed.

9.3.4.2 Grease Exchange (Refer to Fig. 9-7 “T-Axis Speed Reducer Diagram”.)

1. Remove the hexagon socket head plugs from the grease inlet and

rease exhaust port.

• If grease is injected with the plug on, grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

157569-1CD

• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

2. Install a grease zerk A-PT1/8 to the grease inlet.  (The grease zerk is delivered with the manipulator.)

3. Inject grease through the grease inlet using a grease gun. – Grease type: Molywhite RE No.00 – Amount of grease: approx. 900 cc – Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

4. The grease exchange is completed when new grease appears in the g

rease exhaust port. (The new grease can be distinguished from the

old grease by color.)

5. Move the T-axis for a few minutes t

6. Wipe the discharged grease with a cloth, a installing the plug, apply Three Bond 1206C on the thread part of the plug. Then tighten the plug with a tightening torque of 4.9 N•m  (0.5 kgf•m).

If the plug is installed while grease is being exhausted, grease will leak inside the motor and may cause a damage. Make sure to install the plug when the grease exhaust is completed.

o discharge excess grease.

nd reinstall the plug. Before

7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before ins of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

talling the plug, apply Three Bond 1206C on the thread part

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NOTE

Exhaust port Hexagon socket head plug

U-axis cross roller bearing

Grease inlet Hexagon socket head plug

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9 Maintenance and Inspection

9.3 Notes on Grease Replenishment/Exchange Procedures

9.3.5 Grease Replenishment for U-axis Cross Roller Bearing

Fig. 9-8: U-Axis Cross Roller Bearing Diagram

1. Remove the hexagon socket head plug of Fig. 9-8 “U-Axis Cross Roller Bearing Diagram”.)

2. Remove the hexagon socket head plug of the grease inlet and install the

grease zerk A-PT1/8. Inject grease through the grease inlet using

a grease gun. – Grease type: Alvania EP Grease 2 – Amount of grease: approx. 60 cc – Air supply pressure of grease pump: 0.3 MPa or less – Grease injection rate: 8 g/s or less

3. Reinstall the plug into apply Three Bond 1206C on the thread part of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

4. Remove the grease zerk from the grease inlet, and reinstall the plug. Before inst of the plug. Then tighten the plug with a tightening torque of 4.9 N•m (0.5 kgf•m).

the exhaust port. (Refer to

(The grease zerk is delivered with the manipulator.)

the exhaust port. Before installing the plug,

The exhaust port is for AIR flow: Grease is not exhausted from the exhaust port.

Do not inject excessive grease through the grease inlet.

alling the plug, apply Three Bond 1206C on the thread part

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