YASKAWA MOTOMAN-MS165 Instructions Manual

MOTOMAN-MS165

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INSTRUCTIONS

TYPE:
YR-MS165/MH180-A00 (

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

MOTOMAN INSTRUCTIONS

MOTOMAN-MS165 INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)

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

STANDARD SPECIFICATION)

Part Number: 167109-1CD
Revision: 5

MANUAL NO.

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Copyright © 2018, 2017, 2016, 2015 Yaskawa America, Inc.

Terms of Use and Copyright Notice

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, 2018

Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]

www.motoman.com

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• This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-MS165 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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We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: [phone]

FAX: [phone]

www.roboticsonline.com

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

We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.

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

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MS165.

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

DANGER

WARNING

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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WARNING

• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX200 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.

Fig. : Emergency Stop Button

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

Injury may result from unintentional or unexpected manipulator motion.

Fig. : Release of Emergency Stop

• 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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• 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

Description of the Operation Procedure

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

Registered Trademark

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

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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
(On the manipulator manufactured after June 2014)

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Nameplate
(On the manipulator
manufactured by May 2014)

Nameplate:

MODEL
MOTOMAN­TYPE

PAYLOAD

ORDERNO.

SERIALNO.

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

kg

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.

MASS

DATE

NJ3878

WARNING Label A

WARNING Label B

kg

WARNING Label C

WARNING Label B

WARNING Label C

WARNING Label A:

WARNING

Moving parts
may cause
injury

WARNING Label B:

WARNING

Do not enter
robot
work area.

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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:

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

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

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

• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).

Mechanical Safety Devices

The safe operation of this equipment is ultimately the users responsibility.
The conditions under which the equipment will be operated safely should
be reviewed by the user. The user must be aware of the various national
codes, ANSI/RIA R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this equipment.

Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or 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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Customer Support Information

If you need assistance with any aspect of your MS165 system, please
contact Yaskawa Customer Support at the following 24-hour telephone
number:

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

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

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[phone]

[e-mail]

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 Yaskawa Customer
Support at the telephone number shown above.

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

• System MS165

• 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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Contents

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 ..............................................................................................................2-2

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

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

2.3 Cushioning Material for Transport .....................................................................................2-3

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

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

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

3.2.1 Mounting Example................................................................................................ 3-4

3.3 Location ............................................................................................................................. 3-5

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 P-Point Maximum Envelope.................................................................... 5-3

5.5 Stopping Angles and Times for S-, L- and U-Axes ............................................................ 5-4

5.5.1 Stop Category 0: Stopping Angles and Times...................................................... 5-4

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

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

5.5.1.3 Position 33% ...........................................................................................5-6

5.5.2 Stop Category 1: Stopping Angles and Times...................................................... 5-7

5.5.2.1 Position100% ..........................................................................................5-7

5.5.2.2 Position 66% ...........................................................................................5-8

5.5.2.3 Position 33% ...........................................................................................5-9

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5.6 Alterable Operating Range ..............................................................................................5-10

5.6.1 Components for Altering Operating Range.........................................................5-11

5.6.2 Notes on the Mechanical Stopper Installation ....................................................5-12

5.6.3 Adjustment to the Pulse Limitation of S-Axis ...................................................... 5-12

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

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

6.2 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

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

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

8.1.1 Specification of Limit Switch .................................................................................8-1

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

8.1.3 Setting of Operation Range ..................................................................................8-2

8.1.3.1 S-Axis Operation Range.......................................................................... 8-2

8.1.3.2 L-Axis Operation Range ..........................................................................8-2

8.1.3.3 Setting Range of LU-Axes Interference Angle.........................................8-3

8.2 Internal Connections.......................................................................................................... 8-4

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

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

9.2 Battery Pack Replacement ................................................................................................9-5

9.3 Grease Exchange ..............................................................................................................9-7

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

9.3.2 List of Necessary Items ........................................................................................9-8

9.3.3 Grease Exchange................................................................................................. 9-9

9.3.3.1 Grease Exchange for S-, L-, U-, R-, B-, and T-Axes Speed Reducer .....9-9

9.3.4 Grease Replenishment for Gas Balancer Link Part............................................ 9-14

9.4 Gas Maintenance Procedure in the Gas Balancer...........................................................9-15

9.4.1 Notes on Gas Maintenance Procedure in the Gas Balancer .............................. 9-15

9.4.2 Gas Pressure Inspection ....................................................................................9-16

9.4.2.1 Adequate Gas Pressure ........................................................................9-16

9.4.2.2 Necessary Device..................................................................................9-17

9.4.2.3 Inspection Procedures........................................................................... 9-17

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9.4.3 Gas Discharging Procedure ..........................................................................9-19

9.4.3.1 Necessary Devices................................................................................ 9-19

9.4.3.2 Gas Discharging Procedures  

9.4.4 Gas Injecting Procedure ..................................................................................... 9-22

9.4.4.1 Necessary Devices................................................................................ 9-22

9.4.4.2 Gas Injecting Procedures ...................................................................... 9-22

9.5 Notes for Maintenance..................................................................................................... 9-24

9.5.1 Battery Pack Connection .................................................................................... 9-24

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

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

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

11.2 L-Axis Unit ..................................................................................................................... 11-3

11.3 URBT-Axes Unit ............................................................................................................11-6

11.4 U-Arm Unit ..................................................................................................................... 11-8

11.5 Wrist Unit ..................................................................................................................... 11-10

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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):

CAUTION

• Manipulator

• DX200

• Programming pendant

• Manipulator cables
(2 cables between the DX200 and the Manipulator)

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1 Product Confirmation

1.2 Order Number 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.

(a) DX200 (Front View)

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

25'(512

࢜㸫ࢲࡢྠ୍1R࡜᥋⥆ࡋᚚ౑⏝㢪࠸ࡲࡍࠋ
0RWRPDQᮏయ࡜ࢥࣥࢺ࣮ࣟࣛࡣࠊୗグ

View A (Enlarged View)

(b) Manipulator (Top View)

(On the manipulator manufatctured after Feb. 2016)

A

(b) Manipulator (Side View)

(On the manipulator manufactured by Jan. 2016)

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2 Transport

2 Transport

CAUTION

• 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 performances.

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2 Transport

2.1 Transport Method

2.1 Transport Method

• The weight of the manipulator is approximately 1070 kg
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

NOTE

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” .

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, forklift, or other equipment. Fail­ure to observe this instruction may result in injury.

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Fig. 2-1: Transporting Position

A

Shipping bolts and bracket (4 pieces)

(Fixed to the manipulator
before shipment.)

Hexagon head screw M20
(length: 70)(8 screws)
(Fixed to the manipulator before shipment.)

Factory setting for angle and pulse of each axis

Axis
Angle

Pulse

SLURBT
0
0

-183758 -217225

0

+116㺽-86㺽-60㺽

0

286142

B

0
0

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2 Transport

2.2 Shipping Bolts and Brackets

2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets.
(fig. 2-2 “Shipping Bolts and Brackets” ).

Fig. 2-2: Shipping Bolts and Brackets

176

4xR20

Hook

87

Front viewSide view

• The shipping brackets are painted in yellow.

If operating the manipulator with shipping bolts and brack-

NOTE

ets attached, the shipping bolts and brackets interfere with
the manipulator and that may cause a damage to the
manipulator. Make sure to remove the shipping bolts and
brackets before operation.

2.3 Cushioning Material for Transport

The manipulator is provided with the cushioning materials for transport at
section A and B. (See fig. 2-3 “Cushioning Materials for Transport” .)

Fig. 2-3: Cushioning Materials for Transport

Casing

U-arm

A

L-arm

L-arm

B

S-head mechanical stopper

• A rubber cushion is respectively wedged at the section A and B.

Before turning ON the power, check to be sure that the
cushioning materials for transport are removed.

NOTE

In the event that the manipulator must be moved again, to
avoid its main body from being damaged, the cushioning
materials such as rubber plate, etc. must be used.

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3 Installation

3 Installation

WARNING

• Install the safeguarding.

Failure to observe this warning may result in injury or damage.

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

Failure to observe this warning may result in injury or damage.

• Do not start the manipulator or even turn ON the power before it is
firmly anchored.

The manipulator may overturn and cause injury or damage.

CAUTION

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

Failure to observe this caution may cause injury or damage.

• Before turning ON the power, check to be sure that the shipping
bolts and brackets are removed.

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

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3 Installation

3.1 Safeguarding Installation

3.1 Safeguarding Installation

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

Responsibility for Safeguarding (ISO10218)

The user of a manipulator or robot system shall ensure that safeguards
are provided and used in accordance with Sections 6, 7, and 8 of this
standard. The means and degree of safeguarding, including any
redundancies, shall correspond directly to the type and level of hazard
presented by the robot system consistent with the robot application.
Safeguarding may include but not be limited to safeguarding devices,
barriers, interlock barriers, perimeter guarding, awareness barriers, and
awareness signals.

3.2 Mounting Procedures for Manipulator Base

The manipulator should be firmly mounted on a baseplate or foundation
strong enough to support the manipulator and withstand reaction forces
during acceleration and deceleration.

Construct a solid foundation with the appropriate thickness to withstand
maximum reaction forces of the manipulator referring to table 3-1
“Manipulator Reaction Force and Torque” .

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

chapter 3.2.1 “Mounting Example” .

Table 3-1: Manipulator Reaction Force and Torque

Horizontal rotation Vertical rotation

Reaction force F

Emergency stop 24000N

(2500kgf)

Acceleration/deceleration 6370N

(650kgf)

Torque M

H

37630 N•m
(3840 kgf•m)

9400 N•m
(960 kgf•m)

H

Reaction force FVTorque M

15680N
(1600kgf)

4900N
(500kgf)

49000 N•m
(5000 kgf•m)

22050 N•m
(2250kgf•m)

V

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3.2 Mounting Procedures for Manipulator Base

Fig. 3-1: Manipulator Reaction Force and Torque

M

V

F

V

HM

HF

3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The
baseplate should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. It is recommend to prepare a
baseplate of 50 mm or more thick, and anchor bolts of M20 or larger size.

The manipulator base is tapped for eight mounting holes; securely fix the
manipulator base to the baseplate with eight hexagon socket head cap
screws M20 (80 mm long is recommended). Next, fix the manipulator
base to the baseplate. Tighten the hexagon socket head cap screws and
anchor bolts firmly so that they will not work loose during the operation.

Refer to fig. 3-2 “Mounting the Manipulator on Baseplate” .

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3.2 Mounting Procedures for Manipulator Base

Fig. 3-2: Mounting the Manipulator on Baseplate

Hexagon socket head cap screw
M20 (8 screws)

Spring washer

Washer

Manipulator base

40

Baseplate

Flatness: 0.5mm or less

Units: mm

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3 Installation

3.3 Location

3.3 Location

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

• Ambient temperature: 0 to + 45C

• Humidity: 20 to 80%RH (no-condensing)

• Free from dust, soot, oil, or water

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

• Free from excessive vibration
(Vibration acceleration: 4.9 m/s2 [0.5 G] or less)

• Free from large electrical noise (plasma)

• Flatness for installation: 0.5 mm or less

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4 Wiring

4 Wiring

4.1 Grounding

WARNING

• Ground resistance must be 100  or less.

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

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

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

CAUTION

• Wiring must be performed by authorized or certified personnel.

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

• Do not cover the cable or allow it to tangle. Keep the cable as
straight as possible.

Failure to observe this caution may result in preventing heat of the
cable from being discharged.

4.1 Grounding

Follow electrical installation standards and wiring regulations for
grounding. A ground wire of 5.5 mm2 or more is recommended.

Refer to fig. 4-1 “Grounding Method” to connect the ground line directly
to the manipulator.

NOTE

• Never use this line 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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4.2 Cable Connection

Fig. 4-1: Grounding Method

A

5.5mm2 or more

4.2 Cable Connection

Two manipulator cables are delivered with the manipulator; an encoder
cable for detection (1BC) and 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)” and fig. 4-3(b) “Manipulator Cable Connection (DX200 Side)” .

4.2.1 Connection to the Manipulator

Before connecting three 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, then1 BC. After inserting the cables, depress the lever until it clicks.

4.2.2 Connection to the DX200

Bolt M8 (for grounding)

Delivered with manipulator

View A

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 low
until it clicks.

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4.2 Cable Connection

Fig. 4-2: Manipulator Cables

The Manipulator SideThe DX200 Side

1BC

X11

X11

1BC

1BC

Encoder Cable

The Manipulator SideThe DX200 Side

$%

:

X21

*9

2BC

2BC

Power Cable

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4.2 Cable Connection

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

Key positions

Key positions

Connector Details

(Manipulator Side)

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

X11

X21

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5 Basic Specifications

5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

Table 5-1: Basic Specifications

Item Model MOTOMAN-MS165

Flange for Cable Processing

Application Spot Welding

Structure Vertically Articulated

Degree of Freedom 6

Payload 180 kg 165 kg

Repeatability

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

Maximum Speed S-Axis 2.18 rad/s, 125°/s

Allowable Moment

Allowable Inertia

2

/4)

(GD

Approx. Mass 970 kg

Protective Structure Basic axis: IP54 or equivalent

Ambient Conditions Temperature 0° C to 45° C

Power Requirements 5.0 kVA

Noise

1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Specification changes when the manipulator is equipped with a flange for cable processing.

(Refer to fig. 5-3 “Dimensions and P-Point Maximum Envelope” .)
3 Conformed to ISO9283
4 Refer to table chapter 6.1 “Allowable Wrist Load” for details on the permissible moment of inertia.
5 Conformed to ISO6926
1, Measurement is carried out when the maximum load is mounted to the manipulator and

operated in the maximum speed.
2, Measurement is carried out:

-between 1.2m and 1.5m above the ground.

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

3)

L-Axis (lower arm) -60° - +76°

U-Axis (upper arm) -147° - +90°

R-Axis (wrist roll) -360° - +360° -210° - +210°

B-Axis (wrist pitch/yaw) -130° - +130° -125° - +125°

T-Axis (wrist twist) -360° - +360° -210° - +210°

L-Axis 2.01 rad/s, 115°/s

U-Axis 2.18 rad/s, 125°/s

R-Axis 3.18 rad/s, 182°/s

B-Axis 3.05 rad/s, 175°/s

T-Axis 4.63 rad/s, 265°/s

4)

R-Axis 1000 N•m (102 kgf•m) 951 N•m (97 kgf•m)

B-Axis 1000 N•m (102 kgf•m) 951 N•m (97 kgf•m)

T-Axis 618 N•m (63 kgf•m)

R-Axis 90 kg•m

B-Axis 90 kg•m

T-Axis 46.3 kg•m

Humidity 20 to 80% RH (non-condensing)

Vibration Acceleration 4.9 m/s

Others Free from corrosive gasses or liquids, or explosive gasses

5)

1)

2)

Not Equipped Equipped

±0.2 mm

2

2

Wrist axis only: IP67 or equivalent

2

or less (0.5 G)

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

76 dB

88 kg•m

88 kg•m

2

2

2

5-1

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