YASKAWA Motoman-MPL300 II Instructions Manual

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MOTOMAN-MPL300 II

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INSTRUCTIONS

TYPE: YR-MPL0300-J00 (DX200 STANDARD SPECIFICATION)

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

MOTOMAN INSTRUCTIONS

MOTOMAN-MPL300 II INSTRUCTIONS DX200 INSTRUCTIONS DX200 OPERATOR’S MANUAL (for each purpose) DX200 MAINTENANCE MANUAL

The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

Part Number: 173124-1CD Revision: 2

MANUAL NO.

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All rights reserved. This manual is freely available as a service to Yaskawa 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, 2014

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-MPL300 II 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 DX200 Instructions. To ensure correct and safe operation, carefully read the DX200 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.

• YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product's warranty.

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DANGER

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the MOTOMAN-MPL300 II.

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

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

DANGER

• Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

• For disassembly or repair, contact your YASKAWA representative.

• Do not remove the motor, and do not release the brake.

Failure to observe these safety precautions may result in death or serious injury from unexpected turning of the manipulator's arm.

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TURN

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Notes for Safe Operation

WARNING

• 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.

Fig. : Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator. Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Fig. : Release of Emergency Stop

• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:

– Be sure to use a lockout device to the safeguarding when going

inside. Also, display the sign that the operation is being performed inside the safeguarding and make sure no one closes the safeguarding.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Keep in mind the emergency response measures against the

manipulator’s unexpected motion toward you.

– Ensure that you have a safe place to retreat in case of

emergency.

Improper or unintended manipulator operation may result in injury.

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

– Turning ON the power for the DX200.

– Moving the manipulator with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem.

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Definition of Terms Used Often 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 DX200 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 DX200 Instructions before operating the manipulator:

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.

In this manual, the equipment is designated as follows:

Equipment Manual Designation

DX200 controller DX200

DX200 programming pendant Programming pendant

Cable between the manipulator and the controller

Manipulator cable

Registered Trademark

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

are omitted.

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Explanation of Warning Labels

The following warning labels are attached to the manipulator.

Always follow the warnings on the labels.

Also, an identification label with important information is placed on the body of the manipulator. Prior to operating the manipulator, confirm the contents.

Note: Taking the maintenance-relevant trainings offered by YASKAWA is

indispensable for replacing the L-axis of the balancer-equipped manipulator.

Fig. : Warning Label Locations

Nameplate

MODEL MOTOMANTYPE

PAYLOAD

ORDER NO.

SERIAL NO.

YASKAWA ELECTRIC CORPORATION 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan MADE IN JAPAN

MASS

DATE

WARNING label A

WARNING Label A:

WARNING Label B:

WARNING Label C

WARNING

Moving parts may cause injury

WARNING

Do not enter robot work area.

WARNING Label B

WARNING Label C:

DANGER

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 arm.

Please contact your Yaskawa representive.

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Signal Output for Motor Protection

A cooling fan is equipped in order to protect the motor of S-axis of the

manipulator from overheating. If the cooling fan is aut of ordet, warning

message [COOLING FAN2 ERROR] will appear on the programming

pendant.

If operation is continued while this warning message remains displayed,

the component parts of the DX200 and robot components are liable to

become damaged, leading to a major breakdown.

During high speed continuous operation, the temperature may rise

abruptly depending upon the ambient temperature and the operation

pattern, so it is necessary to promptly detect a warning.

A warning message is output as a dedicated output signal, so it is

recommended that you monitor it on the system side as a warning signal

for the sake of safety.

Refer to “DX200 Concurrent I/O” for details on the signal output.

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Safeguarding Tips

All operators, programmers, maintenance 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:

Table: Dedicated output signal

80290

SOUT#0575

COOLING FAN2 ERROR

• 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).

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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 location. 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 equipment immediately.

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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 injury 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-Stop button on the operator station for proper operation 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 a standard passwords and some require special passwords.

• The equipment allows modifications of the software for maximum performance. Care must be taken when making these 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. Specific considerations 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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(937) 847-3200

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Customer Support Information

If you need assistance with any aspect of your MPL300 II system, please contact Customer Support at the following 24-hour telephone number:

For routine technical inquiries, you can also contact Customer Support at the following e-mail address:

When using e-mail to contact 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, replacement parts, or information, you must contact Customer Support at the telephone number shown above.

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

• System MPL300

• Primary Application ___________________________

• Controller DX200

• 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 DX200 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 Installation of Safeguarding ............................................................................................... 3-1

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

3.2.1 Mounting the Manipulator and Fixture on the Baseplate ...................................... 3-3

3.3 Protection Class................................................................................................................. 3-4

3.4 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 DX200 ..................................................................................... 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 Stopping Angle and Time at the Emergency Stop............................................................. 5-4

5.5.1 Stop Categiry 0: Emergency Stop ........................................................................ 5-4

5.5.1.1 Position 100% ......................................................................................... 5-4

5.5.1.2 Position 66% ........................................................................................... 5-5

5.5.1.3 Position 33% ........................................................................................... 5-5

5.5.2 Stop Category 1: Emergency Stop....................................................................... 5-6

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5.6 Alterable Operating Range ................................................................................................ 5-7

5.6.1 Components for Altering Operating Range........................................................... 5-8

5.6.2 Notes on the Mechanical Stopper Installation ...................................................... 5-9

5.6.3 Adjustment of the Soft Limit of the S-Axis Pulse ................................................ 5-10

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

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

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

6.3 Levelness of the Wrist Flange............................................................................................ 6-3

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

Table of Contents

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.................................................................................... 9-5

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

9.3 Grease Replenishment/Exchange ..................................................................................... 9-7

9.3.1 Notes on Grease Replenishment/Exchange Procedures .....................................9-7

9.3.2 Grease Replenishment/Exchange for S-Axis Speed Reducer and Gear ............. 9-8

9.3.2.1 Grease Replenishment............................................................................ 9-8

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

9.3.3 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-10

9.3.3.1 Grease Replenishment.......................................................................... 9-11

9.3.3.2 Grease Exchange.................................................................................. 9-12

9.3.4 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-13

9.3.4.1 Grease Replenishment.......................................................................... 9-13

9.3.4.2 Grease Exchange.................................................................................. 9-14

9.3.5 Grease Replenishment/Exchange for T-Axis Speed Reducer............................ 9-15

9.3.5.1 Grease Replenishment.......................................................................... 9-15

9.3.5.2 Grease Exchange.................................................................................. 9-16

9.3.6 Grease Replenishment for U-axis Cross Roller Bearing .................................... 9-17

9.3.7 Grease Replenishment for Links ........................................................................ 9-18

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

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

9.3.8 Notes for Maintenance ....................................................................................... 9-20

9.3.8.1 Battery Pack Connection....................................................................... 9-20

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

Table of Contents

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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 DX200 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):

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• Manipulator

• DX200

• Programming pendant

• Manipulator cables

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1 Product Confirmation

1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the DX200. The order number is located on a label as shown below.

Fig. 1-1: Location of Order Number Labels

Label (Enlarged View)

THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

Check that the manipulator and the DX200 have the same order number.

(a) DX200 (Front View)

(b) Manipulator (Side View)

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NOTE

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2 Transport

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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 1865kg including the shipping bolts and brackets. Use a wire rope strong enough to withstand the weight.

• Shipping bolts and brackets are designed to support the manipulator weight. Do not use them for anything other than transporting the manipulator.

• Mount the shipping bolts and brackets for transporting 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.

2-1

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Axis Angle

Pulse

Factory setting for angle and pulse of each axis

SLUT

-94720 -52622

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 when 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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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 4

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

3.1 Installation of Safeguarding

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.

3.1 Installation of Safeguarding

To insure safety, be sure to install the safeguarding. They prevent unforeseen accidents with personnel and damage to equipment. The following is quoted for the information and guidance.

Responsibility for Safeguarding (ISO 10218)

The user of a manipulator or robot system shall ensure that the safeguarding is provided and used in accordance with Chapter 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.

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3 Installation

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 thickness to withstand maximum repulsion forces of the manipulator as shown in Table 3-1 “Manipulator Repulsion Force and Torque”.

During installation, if the flatness is not right, the manipulator shape may be deformed and its functional ability may be compromised. The flatness for baseplate must be kept at 0.5 mm or less. Fix the manipulator base as described in section 3.2.1 “Mounting the Manipulator and Fixture on the

Baseplate”.

Table 3-1: Manipulator Repulsion Force and Torque

Horizontal rotation Vertical rotation

Repulsion force F

Emergency stop 20580 N

(2100 kgf)

Acceleration/deceleration 6370 N

(650 kgf)

Torque M

39200 N•m (4000 kgf•m)

11760 N•m (1200 kgf•m)

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Repulsion force FVTorque M

49980 N (5100 kgf)

21560 N (2200 kgf)

62720 N•m (6400 kgf•m)

15680 N•m (1600 kgf•m)

Fig. 3-1: Manipulator Repulsion Force and Torque

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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)

180

540

1000

180

540

180

1000

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3 Installation

3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting the Manipulator and Fixture on the Baseplate

For the first process, anchor the baseplate firmly on the floor. The baseplate should have enough rigidity, which is 50 mm or more in thickness. The size of the anchor bolt recommended for the baseplate fixation is M24 or more.

Next, fix the manipulator base to the baseplate. There are eight mounting holes on the manipulator base: securely fix the manipulator to the baseplate using eight hexagon head screws M20 (Tensile strength: 1200 N/mm

or more) (80 mm long is recommended). Tighten the bolts with a tightening torque of 402 N•m (41 kgf•m). Tighten the hexagon head screws and anchor bolts firmly so that they will not be loosened during the operation.

Fig. 3-2: Mounting the Manipulator on Baseplate

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3 Installation

3.3 Protection Class

For the standard type, environmental resistance for main part of the manipulator conforms to IP54; the wrist part conforms to IP67.

3.4 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

Bolt M8 (for grounding) Delivered with the manipulator

5.5 mm2 or more

Enlarged View A

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4Wiring

4 Wiring

4.1 Grounding

WARNING

• Ground resistance must be 100 Ω or less.

Failure to observe this warning may result in fire or electric shock.

• Before wiring, make sure to turn the primary power supply off, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in fire or electric shock.

• 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 DX200.

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 directly to the manipulator.

Fig. 4-1: Grounding Method

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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NOTE

Power Cable

DX200 side

Encoder Cable

Manipulator side

DX200 side Manipulator side

1BC

2BC

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4 Wiring

4.2 Cable Connection

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

Connect these cables to the manipulator base connectors and to the DX200. Refer to Fig. 4-3(a) “Manipulator Cable Connectors (Manipulator Side)” .

4.2.1 Connection to the Manipulator

Before connecting two cables to the manipulator, verify the numbers on both manipulator cables and the connectors on the connector base of the manipulator. When connecting, adjust the cable connector positions to the main key positions of the manipulator, and insert cables in the order of 2BC 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 DX200

Before connecting cables to the DX200, verify the numbers on both manipulator cables and the connectors on the DX200. When connecting, insert the cables in the order of X21 then X11, and depress each lever until it clicks.

Fig. 4-2: Manipulator Cables

4-2

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173124-1CD

Key positions

2BC

1BC

X21

X11

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4 Wiring

4.2 Cable Connection

Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)

Fig. 4-3(b): Manipulator Cable Connection (DX200 Side)

4-3

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MPL300 II

28 of 100

5 Basic Specifications

5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

173124-1CD

Table 5-1: Basic Specifications

Item Type MOTOMAN-MPL300II

Structure Vertically Articulated

Degree of Freedom 4

Payload 300 kg

Repeatability

Range of Motion S-Axis (turning) -180° − +180°

Maximum Speed S-Axis 1.57 rad/s, 90° /s

T-Axis Allowable Inertia (GD

Approx. Mass 1820 kg

Protective Structure Main part of the manipulator: IP54 or equivalent

Ambient Conditions Temperature 0 to 45°C

Power Requirements 8.0 kVA

Noise

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. 4 Conformed to ISO6926

1, Measurement is carried out when the maximum load is mounted to the manipulator and operated

2, Measurement is carried out:

- between 1.2m and 1.5m above the ground.

- 400mm away from the P-point maximum envelope.

in the maximum speed.

YR-MPL0300-J00

±0.5 mm

L-Axis (lower arm) -45° − +90°

U-Axis (upper arm) -120° − +15.5°

T-Axis (wrist twist) -360° − +360°

L-Axis 1.75 rad/s, 100° /s

U-Axis 1.92 rad/s, 110° /s

T-Axis 3.40 rad/s, 195° /s

/4)

Humidity 20 to 80% RH (non-condensing)

Vibration 4.9 m/s

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

140 kg•m

Wrist axis only: IP67 or equivalent

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

70dB

(0.5G) or less

5-1

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Page 29

173124-1CD

S+

S-

Lower arm (L-arm)

Base

Upper arm (U-arm)

Wrist

Wrist flange

Rotary head (S-head)

T-

T+

U-

U+

L- L+

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

Fig. 5-2: Manipulator Base Dimensions

5.3 Manipulator Base Dimensions

5-2

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MPL300 II

-point maximum envelope

Units: mm

-Point

P-point

625

616

16

2529

R1124

2776

614 2162

1300

1600

2363

2624

1241

45



R1037

R3159

2204

300

250

1400

820

31591037

R697

880 1250

270

120

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5 Basic Specifications

5.4 Dimensions and T-Point Maximum Envelope

Fig. 5-3:

Dimensions and T-Point Maximum Envelope

5-3

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173124-1CD

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5 Basic Specifications

5.5 Stopping Angle and Time at the Emergency Stop

Following data on stopping angle and time at the emergency stop are measured under the standard of ISO10218.

5.5.1 Stop Categiry 0: Emergency Stop

5.5.1.1 Position 100%

Fig. 5-4: Category 0, Position 100% : Stopping Angle and Time for each Axis at the Emergency Stop

(a)S-Axis

(b)L-Axis

(c)U-Axis

5-4

HW1482991

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173124-1CD

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5 Basic Specifications

5.5 Stopping Angle and Time at the Emergency Stop

5.5.1.2 Position 66%

Fig. 5-5: Category 0, Position 66% : Stopping Angle and Time for each Axis at the Emergency Stop

(a)S-Axis

Note: L- and U-axis takes one pose only for this structure.

5.5.1.3 Position 33%

Fig. 5-6: Category 0, Position 33% : Stopping Angle and Time for each Axis at the Emergency Stop

(a)S-Axis

Note: L-, U- axis takes one pose only for this structure.

5-5

HW1482991

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173124-1CD

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5 Basic Specifications

5.5 Stopping Angle and Time at the Emergency Stop

5.5.2 Stop Category 1: Emergency Stop

The stopping angle and time at the emergency stop in category 1 are not subjected to the manipulator position and the load.

Stop of category1 doesn't depend on the robot position and the load.

Fig. 5-7: Category 1: Stopping Angle and Time for each Axis at the Emergency Stop

(a)S-Axis

(b)L-Axis

(c)U-Axis

5-6

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MPL300 II

NOTE

34 of 100

5 Basic Specifications

5.6 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°)

173124-1CD

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

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

5-7

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5 Basic Specifications

5.6 Alterable Operating Range

5.6.1 Components for Altering Operating Range

When modifying the operating range of the S-axis, prepare the components shown in the following list

Fig. 5-8 “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 socket head cap screw M20

(length: 70 mm, tensile strength: 1200 N/mm

(4) Flat washer M20 (3 flat washers)

Fig. 5-8: Components of S-Axis Stopper

Hexagon socket head cap screw M20 (length: 70 mm, tensile strength: 1200 N/mm Washer M20 (3 washers)

Stopper (HW0307574-1)

Section A-A'

Pin (HW0407007-1)

or more, 3 screws)

5-8

A'A

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MPL300 II

Improper Installation Proper Installation

Hexagon head screws M20

NOTE

36 of 100

5 Basic Specifications

5.6 Alterable Operating Range

5.6.2 Notes on the Mechanical Stopper Installation

• Apply the Locktite 242 to the thread part of the pin HW0407007-1, and install the pin bottom up into the S-axis mechanical stopper HW0307574-1 as shown in Fig. 5-8 “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 as shown in Fig. 5-8 when the operating range is ±180°.

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

• To ensure the stopper strength, make sure to fix both sides of the protrusion with screws. DO NOT fix only one side of the protrusion. (See Fig. 5-9 “Properly-Mounted Image”.)

• As in the figures: Fig. 5-10(a) “Properly-Mounted Models for S-Axis

Stopper” to Fig. 5-10(m) “Properly-Mounted Models for S-Axis Stopper”, 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 installed

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Fig. 5-9: Properly-Mounted Image

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

2. TURN OFF the electric power supply before mounting.

5-9

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NOTE

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MPL300

5 Basic Specifications

5.6 Alterable Operating Range

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

Apply the Instruction for “DX200 Instructions chapter 8.17 Changing the Parameter Setting” as part of reference materials for adjusting the programming pendant when modifying the range of motion of S-Axis.

Pulse limit (positive (+) direction of the S-axis): S1CxG400

Pulse limit (negative (-) direction of the S-axis): S1CxG408

MPL300 II

Degree Number of Pulse

0° 0

±15°

± 30°± 68183

± 45°± 102275

± 60°± 136367

± 75°± 170458

± 90°± 204550

± 105°± 238642

± 120°± 272733

± 135°± 306825

± 150°± 340917

±165°

± 180°± 409100

1 Refer to section 5.6 “Alterable Operating Range”.

± 34092

± 375008

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

5-10

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MPL300 II

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

5.6 Alterable Operating Range

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

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+ Direction Angles

- Direction Angles

5-11

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5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(a): Properly-Mounted Models for S-Axis Stopper

180

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

Installation at + 180°

165

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°

5-12

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

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MPL300 II

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

5.6 Alterable Operating Range

Fig. 5-10(b): Properly-Mounted Models for S-Axis Stopper

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5-13

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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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MPL300

5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(c): Properly-Mounted Models for S-Axis Stopper

5-14

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MPL300 II

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

5.6 Alterable Operating Range

Fig. 5-10(d): Properly-Mounted Models for S-Axis Stopper

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5-15

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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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MPL300

5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(e): Properly-Mounted Models for S-Axis Stopper

5-16

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MPL300 II

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5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(f): Properly-Mounted Models for S-Axis Stopper

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

30°

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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 + 30°

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

5-17

Installation at + 15°

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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

5.6 Alterable Operating Range

Fig. 5-10(g): Properly-Mounted Models for S-Axis Stopper

5-18

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MPL300 II

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5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(h): Properly-Mounted Models for S-Axis Stopper

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

180°

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

Installation at - 180°

165°

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°

5-19

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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

5.6 Alterable Operating Range

Fig. 5-10(i): Properly-Mounted Models for S-Axis Stopper

5-20

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MPL300 II

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5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(j): Properly-Mounted Models for S-Axis Stopper

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120°

Installation at - 120°

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.

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

105

Installation at - 105°

5-21

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

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MPL300

5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(k): Properly-Mounted Models for S-Axis Stopper

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 - 90°

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

Installation at - 75°

5-22

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

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MPL300 II

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°

50 of 100

Fig. 5-10(l): Properly-Mounted Models for S-Axis Stopper

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5 Basic Specifications

5.6 Alterable Operating Range

5-23

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MPL300

5 Basic Specifications

5.6 Alterable Operating Range

Fig. 5-10(m): Properly-Mounted Models for S-Axis Stopper

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

30°

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

15°

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

Installation at - 30°

5-24

Installation at - 15°

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MPL300 II

J=Ji+WL

J Ji W L

: Total inertia (GD

/4) of the T-axis (kgžm2)

: Inertia of the volume load on the flange (kgžm

) : Payload (kg) : Eccentricity (mm)

Formula:

Center of T-axis flange rotation

W=300 kg

W=250 kg

W=200 kg

900 800 700 600 500 400 300 200 100 100 200 300 400 500 600 700 800 900

100

200

300

400

500

600

700

800

900

1000

1100

LB (mm)

LT (mm)

52 of 100

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 160 kg maximum.

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

Table 6-1: Allowable Total Inertia

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

kg•m

140 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 MPL300 II”. When the inertia of the volume load on the flange (Ji) is large, use the following formula to calculate the eccentricity L

/4) of T-axis should be within the

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Fig. 6-1: Moment Arm Rating for MPL300 II

6-1

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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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MPL300

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 order 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.

6-2

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MPL300 II

T-point maximum envelope

Mounting surface

Tilting of wrist flange

T-point

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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 MOTOMANMPL300 II 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 and check tilting with the actual posture and load conditions.

Fig. 6-3: Tilting of Wrist Flange

6-3

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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

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MPL300

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”.)

Fig. 7-1: Installing Peripheral Equipment

Table 7-1: Conditions for Installation

Application Note

Cable Processing and Valve Load

Up to 300 kg including the peripheral equipment mass attached to the wrist unit

7-1

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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 (5 lines ) 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”.

The connector pins 1 to 23 are assigned as shown in Fig. 7-2(c) “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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Connector for the internal user I/O wiring harness (base side): JL05-2A24-28PC (with a cap) Prepare connector: JL05-6A24-28S

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

View A

Connector base

2BC

1BC

View B

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)

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)

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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 and Air Line

Note 1: This manipulator 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.

Note 2: As shown in Fig. 7-2(b) “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 Shead.

7-3

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

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MPL300 II

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

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7 System Application

7.2 Internal User I/O Wiring Harness and Air Line

Run the field bus cable by following the steps below.

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

Wire harness

Union

S-head

Part Z

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

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

7-4

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1 2

4312

211623

18 19

141311 12

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(c): 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

7-5

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MPL300 II

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-MPL300 II 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 Hollow Part

Item Notes

Inside diameter of the hollow part: 53 mm

173124-1CD

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

Before running the wiring harness etc., protect 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.

Fig. 7-3: Conditions to Run the Wiring Harness, Air Line, etc. through the Hollow Part

7-6

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MPL300

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, Laxis, and U-axis respectively. For the location, refer to Fig. 8-1 “Location

of Limit Switches”.

Fig. 8-1: Location of Limit Switches

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

L-axis overrun limit switch (optional)

S-axis overrun limit switch (optional)

1BC

2BC

8-1

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MPL300 II

-22

-21

-23

22 23

-5

-4

-3

-2

-9

-8

-7

-6

-1

-11

-13

-12

-18

-17

-16

-15

-14

-20

-19

-10

3 4 5

12 13

-22

-21

-23

22 23

-2

-3

-4

-5

-7

-8

-9

-6

-11

-13

-12

-18

-17

-16

-15

-14

-20

-19

-10

1 2

5 6 7 8

-1

(24-28)

LA1 LB1

S1(24-28)

BC2

BC1

LC2 LD2

DX200

BATP

BAT

0BT

BATP

0BT

BATP

6BAT21

0BAT22 BAT22

2 3 4

7 8

0BAT11

0BAT21

BAT12

0BAT12

BAT11

32 1 2

PG0V1 PG5V1

BAT6

0BAT6

BAT2

BAT3

0BAT3

0BAT1 BAT1 0BAT2

6 7

PG5V3

4 5

PG5V2 PG0V3

PG0V2

2 4

12 13 14 15 16

10 11

PG5V6

PG0V6

CN1-5 CN1-4

+24V

+24V 0V

CN1-9

CN1-10

CN1-4

CN1-5

CN1-9

+24V

+24V-1

-3

-2

-4

1BC(10PX4)

No.20CN

No,5CN

-1

-4

-3

-2

BAT1

PG0V1

PG5V1

OBAT1

-1

No.1CN

-6

BAT

-10

-9

-5

-4

BAT

OBT

OBT +5V 0V FG1

-2

DATA-1

DATA+1

S-AXIS

DATA-2

DATA+2

FG2

-10

BAT

OBT

No,6CN

OBAT2 PG5V2

BAT2

PG0V2

-2

-3

-4

-1

No.2CN

-1

-9

-6

-5

-4

-2

BAT OBT +5V

L-AXIS

DATA+3 DATA-3

-2

OBAT3

PG0V3

PG5V3

-4

-3

BAT3

No,7CN

-1

OBT

-5

-4

-9

-10

BAT

+5V 0V

OBT

FG3

No.3CN

-1

-2

-6

BAT

U-AXIS

DATA-6

DATA+6

OBAT6

PG0V6

PG5V6

BAT6

No,8CN

-2

-3

-4

-1

No.4CN

-5

-4

-9

-10

-1

-2

-6 OBT

FG6

+5V

BAT

OBT

BAT

T-AXIS

CN1-1

SPG+1

CN1-2

SPG-1

CN1-1 CN1-2 SPG-1

SPG+1

CN1-3

FG1 CN1-3 FG1

CN1-8

FG2

CN1-7

CN1-6

SPG-2

SPG+2

CN1-8 FG2

CN1-7

CN1-6

SPG-2

SPG+2

CN2-3

CN2-2

CN2-1

SPG-3

SPG+3

FG3 CN2-3

CN2-2

CN2-1

SPG-3

SPG+3

FG3

CN3-8

CN3-7

CN3-6

SPG-6

SPG+6

FG6 CN3-8

CN3-7

CN3-6

SPG-6

SPG+6

FG6

LB1

+24V

BC2 AL2

CN4-1 CN4-6

CN4-8

CN4-3

LB1

+24V

BC2

AL2

CN4-6

CN4-1

CN4-3 CN4-8

AL1

CN4-7

AL1

CN4-10

0V CN4-10

LA2 LB2

LC2 LD2

LA2 LB2

LD1 LD2

LB1 LB2

LA3 LB3

LC3

LD3

LB2 LB1

LD2 LD1

CN2-10

+24V

CN2-4

+24V

CN2-4

LD1

CN2-5

LD1

LC1 LD1

+24V

S-AXIS OVERRUN L. S.

L-AXIS OVERRUN L. S.

L AND U-AXIS INTERFERENCE L.S.

LA1

LB1

LB2

LA2

LB1

Connected to

S-AXIS OVERRUN L.S.

L-AXIS OVERRUN L. S.

L AND U-AXIS INTERFERENCE L.S.

LC1

LD1

LD2

LC2

LD1

Connected to

S-AXIS OVERRUN L. S.

LA1

LB1

Connected to

S-AXIS OVERRUN L. S.

LC1

LD1

Connected to

LC1

LD1

LD2

LD3

LC3

LA1

LB1

LB2

LB3

LA3

LC1

LA1

AL1

AC1

AL2

AC2

FAN

For lamp (option)

For S-axis fan (option)

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:

Internal Wire

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8 Electrical Equipment Specification

8.2 Internal Connections

Fig. 8-2(a): Internal Connection Diagram

8-2

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8 Electrical Equipment Specification

8.2 Internal Connections

Fig. 8-2(b): Internal Connection Diagram

X21(8X5)

E-8 E-7

E-2 E-1

E-6 E-5

E-4 E-3

F-8 F-7

F-2 F-1

F-6 F-5

F-4 F-3

B-5 B-4 B-3 B-11 B-10 B-9

MU1 MU1

MV1 MV1

MW1 MW1

ME1 ME1

MU2 MU2

MV2 MV2

MW2 MW2

ME2 ME2

BA1 BA2 BA3 BA6 BB1 BB6

2BC(8X5)

E-8 E-7

E-2 E-1

E-6 E-5

E-4 E-3

F-8 F-7

F-2 F-1

F-6 F-5

F-4 F-3

B-5 B-4 B-3 B-11 B-10 B-9

MU1 MU1

MV1 MV1

MW1 MW1

ME1 ME1

MU2 MU2

MV2 MV2

MW2 MW2

ME2 ME2

BA1 BA2 BA3 BA6 BB1 BB6

BASE WRIST

No.9CN

No.10CN

No.11CN

No.12CN

MU1

-A

-B

MV1

-C

MW1

-D

ME1

-1

BA1

-2

BB1

MU2

-A MV2

-B

MW2

-C ME2

-D

-1

BA2

-2

BB2

S-AXIS

L-AXIS

MU3

D-8

MU3

D-7

MV3

D-4

MV3

D-3

MW3

D-6

MW3

D-5

D-2

ME3

D-1

ME3

MU6

C-6

MV6

C-4

MW6

C-2

ME6

C-5

AC1

A-6

AC2

A-3

D-8 D-7

D-4 D-3

D-6 D-5

D-2 D-1

C-6

C-4

C-2

C-5

A-6 A-3

MU3 MU3

MV3 MV3

MW3 MW3

ME3 ME3

MU6

MV6

MW6

ME6

AC1 AC2

No.13CN

No.14CN

No.15CN

No.16CN

MU3

-A MV3

-B

MW3

-C ME3

-D

-1

BA3

-2

BB3

-A

MU6

-B

MV6

-C

MW6

-D

ME6

-1

BA6

-2

BB6

U-AXIS

T-AXIS

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CAUTION

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9 Maintenance and Inspection

9.1 Inspection Schedule

9 Maintenance and Inspection

• 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.

• 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.

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WARNING

• 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, the inspection items are categorized 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.

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

• If the manipulator is used in a repetitive action pattern with a high frequency, inspection intervals or parts replacement intervals may become shorter. Perform preventive maintenance by referring to section 8.21 “Preventive Maintenance Function" of "DX200 INSTRUCTIONS."

9-1

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

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Items

1 Alignment mark

2 External lead

3 Working area and

manipulator

4 Motors for L- and U-axes

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5 Baseplate mounting bolts

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 Uaxes) (Wires for T-axis)

11 Links/Connections

12 Battery pack in manipulator

13 S-axis speed reducer

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.

Grease Gun, Visual

Multimeter, Visual

Visual, Manual

Screwdriver,

•

Wrench

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

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

Replace the battery pack when the battery alarm occurs or the manipulator drove for 36000H. See section 9.2.1.

Replenish grease Exchange grease

See section 9.3.7.

(5000H cycle). See section 9.3.2. (9000H cycle). See section 9.3.2.

Specified Person

Licensee

•••

••

MPL300

9 Maintenance and Inspection

Service Company

9.1 Inspection Schedule

•

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

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Items

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

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 9.3.7 “Grease Replenishment for Links”. 4 Wire harness in manipulator to be replaced at 18000H inspection. 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.

Schedule Method Operation Inspection

Charge

Daily

1000H Cycle

5000H Cycle

9000H Cycle

18000H

••

•

36000H

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

Replenish grease Exchange grease

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

Replenish grease (5000H cycle). See section 9.3.5. Exchange grease5) (9000H cycle). See section 9.3.5.

Grease Gun Replenish grease

Exchange grease

Visual Check for damage and operation.

(5000H cycle). See section 9.3.3 and section 9.3.4.

(9000H cycle). See section 9.3.3 and section 9.3.4.

5) 6)

Specified Person

••

Licensee

••

Service Company

9.1 Inspection Schedule

MPL300

9 Maintenance and Inspection

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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 numbers in Table 9-1 “Inspection Items”

Page 67

Fig. 9-1: Inspection Items

U-axis

L-axis

T-axis

S-axis

1611

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9.1 Inspection Schedule

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Plate

Connector base

Base

Plate mounting screw M4

2BC

1BC

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9 Maintenance and Inspection

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

The battery packs are installed in the position shown in Fig. 9-2(a) “Battery Location (Back View)” and Fig. 9-2(b) “Battery Location (Top View)”. If the battery alarm occurs in the DX200, replace the battery in

accordance with the following procedure:

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

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

Battery pack

Board

Fig. 9-3: Battery Connection

See the step 5.

Connector

Battery pack before replacement

Board Type: SGDR-EFBA02A

9-5

See the step 4.

New battery pack

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9.2 Notes on Maintenance Procedures

1. Turn OFF the DX200 main power supply.

2. Remove the plate fixing screws and the plate on the connector base, then pull the battery pack out to replace it with the new one.

3. Remove the battery pack from the battery holder.

4. Connect the new battery pack to the unoccupied connector on the board.

5. Remove the old battery pack from the board.

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

6. Mount the new battery pack to the holder.

7. Reinstall the plate.

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

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9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

9.3.1 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 MPa 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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9.3 Grease Replenishment/Exchange

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

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

Grease exhaust port Hexagon socket head plug

Grease inlet Hexagon socket head plug

1BC

2BC

S-axis speed reducer

9.3.2.1 Grease Replenishment

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

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

grease 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 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).

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).

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9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

9.3.2.2 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 grease 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: 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 grease exhaust port. (The new grease can be distinguished from the old grease by color.)

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

6. 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.

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

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Grease inlet Hexagon socket head plug

Section A-A'

L-axis speed reducer

Grease exhaust port Hexagon socket head plug

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9.3 Grease Replenishment/Exchange

9.3.3 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

Grease zerk A-PT1/8

225 mm

Joint PT1/8

Hose for grease replenishment

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NOTE

CAUTION

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9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

9.3.3.1 Grease Replenishment

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

1. Remove the hexagon socket head plugs from the grease inlet and grease 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-PT1/8 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

(720 cc for 1st supply)

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

4. If you cannot inject grease with your grease gun, prepare a grease hose as shown in Fig. 9-5(b) and inject grease.

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

• 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 the manipulator operation.

Plug for air exhaust

Link-C

9-11

170°

Link-C

90°

Link-C

80°

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9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

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

1. Remove the hexagon socket head plugs from the grease inlet and grease 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-PT1/8 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. 1800 cc

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

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

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

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.

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9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

9.3.4 Grease Replenishment/Exchange for U-Axis Speed Reducer

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

Grease exhaust port Hexagon socket head plug

9.3.4.1 Grease Replenishment

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

U-axis speed reducer

Grease inlet Hexagon socket head plug

173124-1CD

1. Remove the hexagon socket head plugs from the grease inlet and grease 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-PT1/8 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: 320 cc

(640 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 U-axis for a few minutes to discharge excess grease.

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.

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9.3.4.2 Grease Exchange

9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

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

1. Remove the hexagon socket head plugs from the grease inlet and grease 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-PT1/8 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 grease 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.

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.

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9.3 Grease Replenishment/Exchange

9.3.5 Grease Replenishment/Exchange for T-Axis Speed Reducer

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

Grease exhaust port Hexagon socket head plug

Grease inlet Hexagon socket head plug

9.3.5.1 Grease Replenishment

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

1. Remove the hexagon socket head plugs from the grease inlet and grease 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-PT1/8 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

T-axis speed reducer

– 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.

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9.3.5.2 Grease Exchange

9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

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.

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

1. Remove the hexagon socket head plugs from the grease inlet and grease 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-PT1/8 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 grease exhaust port. (The new grease can be distinguished from the old grease by color.)

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

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.

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Exhaust port Hexagon socket head plug

U-axis cross roller bearing

Grease inlet Hexagon socket head plug

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9.3 Grease Replenishment/Exchange

9.3.6 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 the exhaust port. (Refer to 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 the exhaust port. 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).

4. 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).

(The grease zerk is delivered with the manipulator.)

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

Do not inject excessive grease through the grease inlet.

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Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Section A-A'

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

1BC

4BC

2BC

3BC

BCA

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Exhaust port

Hexagon socket head plug PT1/8

Link

Grease inlet

Hexagon socket head plug PT1/8

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Fig. 9-9: Grease Replenishment for Links

9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

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9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

1. Remove the hexagon socket head plug PT1/8 from the exhaust port of each link. (Refer to Fig. 9-9 “Grease Replenishment for Links”)

2. Remove the hexagon socket head plug PT1/8 from the grease inlet of each link and install the grease zerk A-PT1/8. Inject grease through the grease inlet using a grease gun. with the manipulator.)

– Grease type: Alvania EP Grease 2

– Amount of grease for links 1, 2, 3, 6: 6 cc (12 cc for 1st supply)

– Amount of grease for links 4, 5, 9: 12 cc (24 cc for 1st supply)

– Amount of grease for links 7, 8: 3 cc (6 cc for 1st supply)

– Amount of grease for links 10, 11: 5 cc (10 cc for 1st supply)

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less

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

(The grease zerk is delivered

Do not inject excessive grease through the grease inlet.

3. Reinstall the plug into the exhaust port of each link. 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).

9-19

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NOTE

Motor

Motor power connector

Connector for motor encoder

Battery pack: HW9470932-A

Battery backup connector

a: Crimped contact-pin (pin) b: Crimped contact-pin (socket)

0BT

BAT

BAT*

0BT*

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9 Maintenance and Inspection

9.3 Grease Replenishment/Exchange

9.3.8 Notes for Maintenance

When performing maintenance such as replacement of a wire harness in the manipulator, the encoder connector may be necessary to be removed. In this case, be sure to connect the battery pack to the battery backup connector before removing the encoder connector.

Removing the encoder connector without connecting the battery pack leads to disappearance of the encoder absolute data.

For the battery pack connection, refer to Fig. 9-10 “Battery Pack Connection”.

9.3.8.1 Battery Pack Connection

The connectors (crimped contact-pin) for the battery backup are installed at the end point of the motors (BAT and OBT are marked). Connect the battery packs according to the following procedure.

1. Remove the cap attached to the battery backup connector of the motors.

2. Connect the battery packs (HW9470932-A) with the battery backup connectors (BAT and OBT are marked) located at the end point of the cables for the encoder. (Under this condition, remove the encoder connector and carry out the maintenance checks.)

3. Confirm all connectors connected after the maintenance check, and remove the battery packs. Install the caps attached to the battery backup connectors of the motors.

Do not remove the battery pack in the connector base.

Fig. 9-10: Battery Pack Connection

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NOTE

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10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table in stock as spare parts for the MOTOMAN-MPL300 II. Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA. The spare parts are ranked as follows:

• Rank A: Expendable and frequently replaced parts.

• Rank B: Parts for which replacement may be necessary as a result of frequent operation.

• Rank C: Drive unit.

For replacing parts in Rank B or Rank C, contact your YASKAWA representative.

Table 10-1: Spare Parts for the YR-MPL0300-J00 (Sheet 1 of 2)

173124-1CD

Rank Parts

No.

A 1 Grease Molywhite RE No.00 YASKAWA

A 2 Grease Alvania EP Grease 2 Showa Shell

A 3 Battery Pack HW0470360-A YASKAWA

A 4 Battery Pack HW9470932-A YASKAWA

A 5 Liquid Gasket Three Bond 1206C ThreeBond Co.,

B 6 Replacement Kit

B 7 Replacement Kit

B 8 Replacement Kit

B 9 Replacement Kit

B 10 U-axis Cross

C 11 AC Servomotor for

C 12 AC Servomotor for

Name Type Manufacturer Qty Qty

Electric Corporation

Sekiyu K.K.

Electric Corporation

Ltd.

Y005C-MPL0300J00S YASKAWA for S-Axis Speed Reducer

for L-Axis Speed Reducer

for U-Axis Speed Reducer

for T-Axis Speed Reducer

Roller Bearing

S-, L-, and U-axes

T-axis

Y005C-MPL0300J00L YASKAWA

Y005C-MPL0300J00U YASKAWA

Y005C-MPL0300J00T YASKAWA

HW9482144-A YASKAWA

SGMRV-44ANA-YR1*

HW0389698-A

SGMRV-13ANA-YR1*

HW0388666-A

Electric Corporation

YASKAWA Electric Corporation

Remarks per Unit

16kg - For speed

reducers

16kg - For links and

bearings

1 1 For replacement

of wire harness in

manipulator

10-1

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10 Recommended Spare Parts

Table 10-1: Spare Parts for the YR-MPL0300-J00 (Sheet 2 of 2)

Rank Parts

No.

C 13 Wire Harness in

C 14 Wire Harness in

C 15 Board SGDR-EFBA02A YASKAWA

Name Type Manufacturer Qty Qty

HW1172025-A YASKAWA

Manipulator

HW1372054-A YASKAWA

Manipulator

Electric Corporation

Remarks per Unit

10-2

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MPL300 II

1005

1006

1028

1029

1031

1032

1039

1001

1002

1078

1011

1012

1013

1079

1077

1021

1022

1023

1024

1025

1037

1038

1040

1017

1014

1015

1003

1004

1035

1030

1033

1026

1058

1059

1060

1061

1058

1062

1061

1059

1063

1048

1049

1050

1048

1051

1052

1053

1044

1045

1041

1042

1043

1066

1046

1047

1054

1055

1056

1057

1064

1065

1067

1036

1027

1019

1020

1034

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11 Parts List

Fig. 11-1: S-Axis Unit

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11 Parts List

11.1S-Axis Unit

11.1 S-Axis Unit

11-1

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11 Parts List

11.1 S-Axis Unit

Table 11-1: S-Axis Unit (Sheet 1 of 2)

No. DWG No. Name Pcs

1001 SGMRV-44ANA-YR1* Motor 1

1002 HW0281280-A Speed reducer 1

1003 M8X100 Socket screw 10

1004 2H-8 Spring washer 10

1005 M16X70 Socket screw 12

1006 2H-16 Spring washer 12

1011 HW0101143-1 S-head 1

1012 HW0101142-1 Base 1

1013 G415 O-ring 1

1014 M20X160 Socket screw 9

1015 2H-20 Spring washer 9

1017 M6X20 GT-SA Bolt 4

1019 M6X16 Socket screw 1

1020 2H-6 Spring washer 1

1021 G135 O-ring 1

1022 HW0414514-1 Shaft 1

1023 HW0307565-3 Shaft 1

1024 M8X115 Socket screw 1

1025 2H-8 Spring washer 1

1026 HW0407007-1 Pin 1

1027 HW0403903-1 Plate 1

1028 M20X70(12.9) Bolt 3

1029 M20 Washer 3

1030 HW0402102-1 Stopper 1

1031 M8X40 Socket screw 1

1032 2H-8 Spring washer 1

1033 HW9404486-1 Shaft 1

1034 M5X16 GT-SA Bolt 8

1035 S180 O-ring 1

1036 MSTM6-20 Pin 2

1037 M12X40 Socket screw 4

1038 2H-12 Spring washer 4

1039 HW0307574-1 Stopper 1

1040 HW0101152-1 Gear case 1

1041 AR175 Ring 1

1042 WR140 Ring 1

1043 6828ZZ Bearing 1

1044 HW0307564-1 Gear 1

1045 HW0307562-1 Gear 1

1046 M6X20 Socket screw 10

1047 2H-6 Spring washer 10

1048 HR33206J Bearing 2

1049 HW0307563-1 Gear 1

1050 HW9405047-1 Shaft 1

11-2

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11 Parts List

11.1S-Axis Unit

Table 11-1: S-Axis Unit (Sheet 2 of 2)

No. DWG No. Name Pcs

1051 HW9405304-* Shim *

1052 G85 O-ring 1

1053 HW9405048-1 Housing 1

1054 2H-8 Spring washer 8

1055 M8X25 Socket screw 8

1056 2H-5 Spring washer 7

1057 M5X16 Socket screw 7

1058 IRTW-72 Ring 2

1059 ISTW-35 Ring 2

1060 CIMR35-1 Shim 2

1061 6207ZZ Bearing 2

1062 HW9381477-A Gear 1

1063 HW9405051-1 Cover 1

1064 2H-5 Spring washer 7

1065 M5X16 Socket screw 7

1066 M12X20 Socket screw 1

1067 PT3/8 (STAINLESS) Plug 1

1077 HW0308464-1 Flange 1

1078 TC8511013 Oil seal 1

1079 HW0308465-1 Shaft 1

11-3

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2079

2051

2079

1011

2069

2081

2068

2052

2048

2072

2053

2048

2002

2054

2029

2030

2033

2035

2046

2070

2083

2047

2042

2036

2075

2082

2036

2029

2030

2045

2067

2076

2077

2078

2055

2057

2003

2008

2076

2077

2031

2035

2058

2043

2056

2041

2039

2040

2045

5004

2071

2073

2074

2045

2059

2085

2086

2025

2086

2025

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11.2 L-Axis Unit

Fig. 11-2(a): L-Axis Unit

11 Parts List

11.2 L-Axis Unit

11-4

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MPL300 II

2013

1011

2020

2008

2010

2019

2001

2011

2040

2032

2035

2037

2007

2012

2021

2014

2015

2016

2009

2028

2039

2040

2031

2080

2035

2026

2030

2022

2004

2023

2045

2002

2013

2018

2017

2087

2014

2015

2016

2021

2006

2022

2001

2005

2034

2035

2031

2035

2038

2040

2027

2030

2019

2087

2094

2045

2094

2045

2086

2045

2025

2045

2095

2045

2092

2093

2092

2093

90 of 100

Fig. 11-2(b): L-Axis Unit

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11 Parts List

11.2L-Axis Unit

11-5

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11 Parts List

11.2 L-Axis Unit

Table 11-2: L-Axis Unit (Sheet 1 of 2)

No. DWG No. Name Pcs

2001 SGMRV-44ANA-YR1* Motor 2

2002 HW0101144-1 L-arm 1

2003 HW0101146-1 Link A 1

2004 HW9482144-A Cross roller bearing 1

2005 HW9301736-1 B-cover 1

2006 HW9200827-1 M-base 1

2007 HW0200685-1 M-base 1

2008 HW0101145-1 Link-B 1

2009 HW9481363-B Bolt 1

2010 HW0307569-1 Shaft 1

2011 HW0308096-1 Spacer 1

2012 HW0414515-1 Shaft 1

2013 HW0388209-A Speed reducer 2

2014 HW9482126-A Gear 2

2015 HW9481343-A Shaft 2

2016 HW9482306-F Shaft 2

2017 HW9481363-A Bolt 1

2018 ISTW-12 Stopper 2

2019 G270 O-ring 2

2020 GS310 O-ring 1

2021 Y507212.5 Oil seal 2

2022 VB 265 280 7 Oil seal 2

2023 M8X25 Socket screw 12

2025 2H-8 Spring washer 20

2026 M10X60 Socket screw 18

2027 M10X50 Socket screw 18

2028 M10X45 Socket screw 1

2029 M10X25 Socket screw 2

2030 2H-10 Spring washer 38

2031 M12X75 Socket screw 33

2032 M12X55 Socket screw 4

2033 M12X50 Socket screw 12

2034 M12X40 Socket screw 4

2035 2H-12 Spring washer 53

2036 M8X25 Socket screw 8

2037 M16X65 Socket screw 6

2038 M16X60 Socket screw 6

2039 M16X50 Socket screw 18

2040 2H-16 Spring washer 30

2041 M6X15 GT-SA bolt 8

2042 M6X20 GT-SA bolt 3

2043 M6X6 Socket screw 1

2045 PT1/8 (STAINLESS) Plug 14

11-6

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11 Parts List

11.2L-Axis Unit

Table 11-2: L-Axis Unit (Sheet 2 of 2)

No. DWG No. Name Pcs

2046 HW0307641-1 Shaft 1

2047 HW0406922-1 B-cover 1

2048 HW0406923-1 Pup washer 2

2051 HW9405055-1 Shaft 2

2052 HW9405699-1 B-cover 2

2053 HW9302054-1 Shaft 1

2054 HW0308094-1 Link-C 1

2055 HW0400016-1 Shaft 1

2056 HW0400008-1 B-cover 1

2057 HW0406931-1 B-cover 1

2058 HW0400015-1 Shaft 1

2059 HW0400012-* Shim *

2067 HW0200688-1 Counter wait 1

2068 S105 O-ring 2

2069 HR32916J Bearing 2

2070 AG3217A4 Oil seal 1

2071 VB60787 Oil seal 1

2072 WR60 Clip 1

2073 VB75956 Oil seal 1

2074 AR-85 Clip 1

2075 NA6912 Needle bearing 1

2076 AG3512E1 Oil seal 2

2077 HR32011XJ Bearing 2

2078 G85 O-ring 1

2079 KE901107 Oil seal 2

2080 M10X45 Socket screw 9

2081 M10X50 Socket screw 18

2082 G75 O-ring 1

2083 HW0484003-A Bearing 1

2085 2H-6 Spring washer 1

2086 2H-10 Spring washer 27

2087 HW0408806-2 Washer 2

2092 TSH6-01M Union 2

2093 UB-0640-0.1C House 2

2094 PT3/8 (STAINLESS) Plug 2

2095 EZ0094-A0 Air breather 2

5004 HW0100477-1 Case 1

1011 HW0101143-1 S-head 1

11-7

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3034

3030

3032

3022

3009

3023

3005

3001

3006

3007

3008

3010

3011

3012

3013

3014

3015

3020

3021

3028

3031

3041

3034

3036

3038

3039

3016

3017

3018

3002

3003

3004

3005

3001

3004

3017

3018

3023

3030

3032

3030

3032

3024

3033

3027

3024

3033

3022

3023

3030

3032

3035

3019

3021

3009

2002

2054

3009

3030

3032

3029

3028

3032

3031

3034

3005

3037

3005

2003

3027

3005

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MPL300

Fig. 11-3: U-Axis Unit

11 Parts List

11.3 U-Axis Unit

11-8

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11 Parts List

11.3U-Axis Unit

Table 11-3: U-Axis Unit

No. DWG No. Name Pcs

3001 HW9403571-2 Shaft 2

3002 HW9301405-1 B-cover 1

3003 HW9403656-* Shim *

3004 AG4059E0 Oil seal 2

3005 PT1/8 (STAINLESS) Plug 13

3006 HR32016XJ Bearing 2

3007 M6X6 Socket screw 1

3008 2H-6 Spring washer 1

3009 M6X20 GT-SA Bolt 9

3010 M6X15 GT-SA Bolt 8

3011 HW0400016-1 Shaft 1

3012 HW0400008-1 B-cover 1

3013 HW0406931-1 B-cover 1

3014 G85 O-ring 1

3015 HW0400015-1 Shaft 1

3016 HW0400012-* Shim *

3017 AG3512E1 Oil seal 2

3018 HR32011XJ Bearing 2

3019 M12X45 Socket screw 10

3020 M12X75 Socket screw 1

3021 2H-12 Spring washer 11

3022 HW0406922-1 B-cover 3

3023 HW0406923-1 Pup washer 5

3024 HW0307641-1 Shaft 2

3027 HW0484003-A Bearing 3

3028 M10X30 Socket screw 8

3029 2H-10 Spring washer 8

3030 M10X25 Socket screw 5

3031 M10X50 Socket screw 8

3032 2H-10 Spring washer 13

3033 AG3217A4 Oil seal 3

3034 G75 O-ring 3

3035 MSTH6-10 Pin 2

3036 HW0200686-1 Link-D 1

3037 HW0308095-1 Link-E 1

3038 HW0101147-1 Casing 1

3039 HW0101148-1 U-arm 1

3041 HW0307566-1 Shaft 1

2002 HW0101144-1 L-arm 1

2003 HW0101146-1 Link A 1

2054 HW0308094-1 Link-C 1

11-9

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173124-1CD

3039

4025

4021

4016

4015

4010

4014

4013

4017

4018

4017

4011

4012

4019

4020

4019

4005

4020

4004

4008

4009

4003

4007

4024

4006

4023

4022

4024

4018

3037

4002

4026

4040

4030

4031

4055

4054

4051

4050

4043

4042

4041

4035

4049

4027

4039

4053

4036

4028

4034

4052

4001

4045

4029

4037

4032

4045

4044

4046

4038

4033

4038

4024

4049

4056

4048

4047

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MPL300

Fig. 11-4: Wrist Unit

11 Parts List

11.4Wrist Unit

11.4 Wrist Unit

11-10

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11 Parts List

11.4Wrist Unit

Table 11-4: Wrist Unit (Sheet 1 of 2)

No. DWG No. Name Pcs

4001 SGMRV-13ANA-YR1* Motor 1

4002 HW0381150-D Speed reducer 1

4003 HW0102580-1 Wrist base 1

4004 HW0406923-1 Pup washer 2

4005 G75 O-ring 1

4006 HW0406922-1 B-cover 1

4007 HW0484003-A Bearing 1

4008 HW0307641-1 Shaft 1

4009 AG3217A4 Oil seal 1

4010 S90 O-ring 1

4011 HW9404246-* Shim *

4012 HW0405915-1 B-cover 1

4013 AG3584A0 Oil seal 2

4014 HW9404245-1 Shaft 2

4015 HR32012XJ Bearing 2

4016 HW9404383-1 B-cover 1

4017 M8X65 Socket screw 8

4018 2H-8 Spring washer 8

4019 M10X25 Socket screw 2

4020 2H-10 Spring washer 2

4021 M8X25 GT-SA Bolt 3

4022 M8X30 GT-SA Bolt 3

4023 M6X20 GT-SA Bolt 3

4024 PT1/8 (STAINLESS) Plug 7

4025 LP-M5 Plug 1

4026 HW0314598-1 Guide 1

4027 HW0314599-2 Gear 1

4028 HW0314600-1 Gear 1

4029 HW0314601-1 M base 1

4030 HW0314602-1 Flange A 1

4031 HW0314603-1 Flange B 1

4032 HW0414320-1 B-nut 1

4033 HW0414321-1 Housing 1

4034 HW0412116-1 Shaft 1

4035 HW0403139-1 B-cover 1

4036 R10-27 Washer 1

4037 S105 O-ring 1

4038 HR32909J Bearing 2

4039 ARP568-169 O-ring 1

4040 G60 O-ring 1

4041 6813 Bearing 1

4042 WR65 Circlip 1

4043 TC57676 Oil seal 1

4044 M6X8 H set screw 2

11-11

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11 Parts List

11.4Wrist Unit

Table 11-4: Wrist Unit (Sheet 2 of 2)

No. DWG No. Name Pcs

4045 M8X25 GT-SA Bolt 8

4046 M6X20 GT-SA Bolt 4

4047 M10X20 Socket screw 8

4048 2H-10 Spring washer 8

4049 M4X10 GT-SA Bolt 8

4050 M8X80 Socket screw 30

4051 2H-8 Spring washer 30

4052 M6X20 Socket screw 1

4053 2H-6 Spring washer 1

4054 M10X20 Socket screw 9

4055 2H-10 Spring washer 9

4056 MSTH8-20 Pin 1

3037 HW0308095-1 Link-E 1

3039 HW0101148-1 U-arm 1

11-12

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11.5 Balancer Unit

Fig. 11-5: Balancer Unit

11 Parts List

11.5Balancer Unit

5018

5019

173124-1CD

5006

5011

5001

5016

5015

5012

5003

5004

5020

5007

5005

5002

5017

5008

5013

5003

5012

5014

5010

5009

11-13

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11 Parts List

11.5 Balancer Unit

Table 11-5: Balancer Unit

No. DWG No. Name Pcs

5001 HW0481740-A Coil spring 1

5002 HW0481741-A Coil spring 1

5003 SOB607440 OILES bearing 2

5004 HW0100477-1 Case 1

5005 HW0306033-1 Flange 1

5006 HW0200420-1 Flange 1

5007 HW0401112-1 Flange 1

5008 HW0303581-1 Rod 1

5009 HW9405057-1 Clevis 1

5010 FD3187A0 Dust seal 1

5011 EZ2228B0 Cap 1

5012 IRTW-75 Stopper 2

5013 M6X8 Magic screw

(set screw)

5014 PT1/8 (STAINLESS) Plug 3

5015 M10X40 Socket screw 8

5016 2H-10 Spring washer 8

5017 HW0481742-A Coil spring 1

5018 M8X16 Socket screw 3

5019 2H-8 Spring washer 3

5020 M5X10 Socket screw 2

11-14

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MOTOMAN-MPL300 II

HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802

100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA America Inc. (Motoman Robotics Division)

Yaskawastrasse 1, 85391 Allershausen, Germany Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Europe GmbHRobotics Divsion )

Phone +82-2-784-7844 Fax +82-2-784-8495

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741 Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Singapore) PTE Ltd.

No7 Yongchang North Road, Beijing E&T Development AreaChina 100176 Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA SHOUGANG ROBOT Co. Ltd.

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India

Fax +91-124-475-8542Phone +91-124-475-8500

YASKAWA India Private Ltd. (Robotics Division)

YASKAWA Electric (China) Co., Ltd. 22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299

YASKAWA Electric (Thailand) Co., Ltd. 59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road, Huaykwang, Bangkok 10310, THAILAND Phone +66-2-017-0099 Fax +66-2-017-0199

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan

Fax +886-2-8913-1513Phone +886-2-8913-1333

YASKAWA Electric Taiwan Corporation

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma, Jakarta 13610, Indonesia

Fax +62-21-2982-6741Phone +62-21-2982-6470

PT. YASKAWA Electric Indonesia

Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Nordic AB Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326

YASKAWA Electric Korea Corporation

100 of 100

INSTRUCTIONS

Specifications are subject to change without notice for ongoing product modifications and improvements.

Printed in Japan May 2018 15-04

MANUAL NO.

HW1482991

YASKAWA Motoman-MPL300 II Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Product Confirmation

1.1 Contents Confirmation

1.2 Order Number Confirmation

2 Transport

2.1 Transport Method

2.1.1 Using a Crane

2.2 Shipping Bolts and Brackets

3 Installation

3.1 Installation of Safeguarding

3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting the Manipulator and Fixture on the Baseplate

3.3 Protection Class

3.4 Location

4 Wiring

4.1 Grounding

4.2 Cable Connection

4.2.1 Connection to the Manipulator

4.2.2 Connection to the DX200

5 Basic Specifications

5.1 Basic Specifications

5.2 Part Names and Working Axes

5.3 Manipulator Base Dimensions

5.4 Dimensions and T-Point Maximum Envelope

5.5 Stopping Angle and Time at the Emergency Stop

5.5.1 Stop Categiry 0: Emergency Stop

5.5.1.1 Position 100%

5.5.1.2 Position 66%

5.5.1.3 Position 33%

5.5.2 Stop Category 1: Emergency Stop

5.6 Alterable Operating Range

5.6.1 Components for Altering Operating Range

5.6.2 Notes on the Mechanical Stopper Installation

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

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

6.2 Wrist Flange

6.3 Levelness of the Wrist Flange

7 System Application

7.1 Peripheral Equipment Mounts

7.2 Internal User I/O Wiring Harness and Air Line

8 Electrical Equipment Specification

8.1 Position of Limit Switch

9 Maintenance and Inspection

9.1 Inspection Schedule

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

9.3 Grease Replenishment/Exchange

9.3.1 Notes on Grease Replenishment/Exchange Procedures

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

9.3.2.1 Grease Replenishment

9.3.2.2 Grease Exchange

9.3.3 Grease Replenishment/Exchange for L-Axis Speed Reducer

9.3.3.1 Grease Replenishment

9.3.3.2 Grease Exchange

9.3.4 Grease Replenishment/Exchange for U-Axis Speed Reducer

9.3.4.1 Grease Replenishment

9.3.4.2 Grease Exchange

9.3.5 Grease Replenishment/Exchange for T-Axis Speed Reducer

9.3.5.1 Grease Replenishment

9.3.5.2 Grease Exchange

9.3.6 Grease Replenishment for U-axis Cross Roller Bearing

9.3.7 Grease Replenishment for Links

9.3.8 Notes for Maintenance

9.3.8.1 Battery Pack Connection

10 Recommended Spare Parts

11 Parts List

11.1S-Axis Unit

11.2 L-Axis Unit

11.3 U-Axis Unit

11.4Wrist Unit

11.5Balancer Unit