YASKAWA MOTOMAN-VS100 Operator's Manual

MOTOMAN-VS100

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INSTRUCTIONS

TYPE: YR-VS00100-A00

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

MOTOMAN INSTRUCTIONS

MOTOMAN-VS100 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: 175873-1CD Revision: 1

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, 2016

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-VS100 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: (734) 994-6088

FAX: (734) 994-3338

www.roboticsonline.com

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

We recommend approved Yaskawa training courses for all personnel involved with the operation, 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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MANDATORY

PROHIBITED

NOTE

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the DX200.

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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Notes for Safe Operation

WARNING

• Before operating the manipulator, check that servo power is turned off when 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 ON the servo power.

Injury may result from unintentional or unexpected manipulator motion.

• 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 persons are present in the P-point maximum envelope of the manipulator and that you are in a safe location before:

- Turning ON the DX200 power.

- Moving the manipulator with the programming pendant.

- Running check operations.

- 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 DX200 cabinet after use.

The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, 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

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Explanation of Warning Labels

The following warning labels are attached to the manipulator.

Always follow the warnings on the labels.

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

Fig. : Warning Label Locations

Nameplate

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WARNING Label B

WARNING Label A

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

NJ3878

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:

Safeguarding Tips

• 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 VS100 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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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 Yaskawa Customer Support at the telephone number shown above.

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

• System VS100

• 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

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

2.2 Shipping Bolts and Brackets.............................................................................................. 2-4

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

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

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

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

3.3 IP (International Protection) ............................................................................................... 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 P-Point Maximum Envelope.................................................................... 5-3

5.5 Stopping Distance and Time for S-, L-, and E-Axes .......................................................... 5-4

5.5.1 General Information.............................................................................................. 5-4

5.5.2 Definition of Use ................................................................................................... 5-4

5.5.3 Stopping Distance and Time for Stop Category 0: S-, L- and E-Axes.................. 5-4

5.5.4 Stopping Distance and Time for Stop Category 1: S-, L- and E-Axes.................. 5-5

5.5.4.1 Extension ................................................................................................ 5-5

5.5.4.2 Stopping Distance and Time for Stop Category 1: S-Axis....................... 5-7

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5.5.4.3 Stopping Distance and Time for Stop Category 1: L-Axis .......................5-8

5.5.4.4 Stopping Distance and Time for Stop Category 1: E-Axis....................... 5-9

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

5.6.1 Necessary Parts ................................................................................................. 5-10

5.6.2 Notes on the S-Axis Mechanical Stopper Installation ......................................... 5-11

5.6.3 Alteration of the S-Axis Pulse Soft Limit ............................................................. 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

Table of Contents

7.2 Internal User I/O Wiring Harness and Air Lines for User’s System Applications ...............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 L- and E-Axes Interference Angle................................ 8-3

8.1.3.4 Setting Range of E- and U-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 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 ............................. 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.......................................................................... 9-10

9.3.3.2 Grease Exchange.................................................................................. 9-11

9.3.4 Grease Replenishment/Exchange for E-Axis Speed Reducer ........................... 9-12

9.3.4.1 Grease Replenishment.......................................................................... 9-12

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9.3.4.2 Grease Exchange ................................................................................. 9-13

9.3.5 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-14

9.3.5.1 Grease Replenishment.......................................................................... 9-14

9.3.5.2 Grease Exchange ................................................................................. 9-15

9.3.6 Grease Replenishment/Exchange for R-, B-, T- Axes Gears in the Casing

9.3.7 Grease Replenishment/Exchange for B- and T-Axes Speed Reducers

9.4 Notes for Maintenance.....................................................................................................9-22

9.4.1 Battery Pack Connection .................................................................................... 9-22

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

and R-Axis Speed Reducer ................................................................................ 9-16

9.3.6.1 Grease Replenishment for R-, B-, T-Axes Gears in the Casing............ 9-16

9.3.6.2 Grease Replenishment for R-Axis Speed Reducer............................... 9-17

9.3.6.3 Grease Exchange for R-, B-, T-Axes Gears in the Casing.................... 9-18

9.3.6.4 Grease Exchange for R-Axis Speed Reducer....................................... 9-19

and Gears........................................................................................................... 9-20

9.3.7.1 Grease Replenishment.......................................................................... 9-20

9.3.7.2 Grease Exchange ................................................................................. 9-21

11.3 E-Axis Unit ..................................................................................................................... 11-5

11.4 U-Axis Unit..................................................................................................................... 11-7

11.5 R-,B-,T-Axes Unit........................................................................................................... 11-9

11.6 Wrist Unit ..................................................................................................................... 11-12

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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 is 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 indicated 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.

0 *76$ ࣡ࢩࣕ

&'

0; *76$ ࣡ࢩࣕ

(a) DX200 (Front View)

(b) Manipulator (Top View)

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2 Transport

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2 Transport

2.1 Transport Method

• Sling and crane or forklift operations must be performed by authorized personnel only.

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

• Avoid excessive vibration or shock during transport.

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

2.1 Transport Method

• Check that the eyebolts are securely fastened.

• The weight of the manipulator is approximately 810kg including the shipping bolts and brackets. Use a wire rope strong enough to withstand the weight.

• The attached eyebolts are designed to support the manipulator mass. Never use them for anything other than transporting the manipulator.

• Mount the shipping bolts and brackets before transporting the manipulator.

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

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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 a four-leg bridle sling using the shipping bolts and brackets when removing it from the package or 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 “Transport Using a Crane”.

Fig. 2-1: Transport Using a Crane

Shipping bolts and brackets

(Fixed to the manipulator before shipment.)

Hexagon socket head cap screw M12 (8 screws)

Factory setting for angle and pulse of each axis

Axis Angle Pulse

SLURBT

0㺽

-45㺽 -70㺽 90㺽 -90㺽 0㺽

-136192-107008

127377 0-124599

-45㺽

-102912

2-2

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2 Transport

2.1 Transport Method

2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet with shipping bolts and brackets as shown in Insert forks under the pallet and lift it. The pallet must be strong enough to support the manipulator. Transport the manipulator slowly with due caution in order to avoid overturning or slippage.

Fig. 2-2: Transport Using a Forklift

Shipping bolts and brackets (Fixed to the manipulator before shipment.)

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Fig. 2-2 “Transport Using a Forklift”.

Pallet

Forklift fork entries

Bolt M20 (8 bolts)

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2 Transport

2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at positions shown in Fig. 2-1 “Transport Using a Crane”.

• The shipping bolts and brackets are painted in yellow.

• Refer to the following table for the shipping bolts and brackets fixing screws.

Table 2-1: Shipping Bolts and Brackets Fixing Screws

Shipping Bolts and Brackets Qty.

2 Hexagon Socket Head Cap Screw M12

Shipping Bolts and Brackets Fixing Screw Specification

(length: 25 mm) (Tensile strength: 1200 N/mm

)

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

Fixing Screw Qty.

4 screws x 2 places

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3 Installation

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3 Installation

WARNING

• Install the safeguarding.

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

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

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

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

The manipulator may overturn and cause injury or damage.

• Do not install or operate a 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 Chapter 2 “Transport” are removed.

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

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3 Installation

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 your information and guidance.

Responsibility for Safeguarding (ISO 10218)

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

3.2 Mounting Procedures for Manipulator Base

The manipulator should be firmly mounted on a 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 section

3.2.1 “Mounting the Manipulator on the Baseplate”.

Table 3-1: Manipulator Reaction Force and Torque

Horizontal rotation Vertical rotation

Reaction force F

Emergency stop 23544 N

(2400 kgf)

Acceleration/deceleration 7358 N

(750 kgf)

Tor q u e M

23897 N•m (2436 kgf•m)

7171 N•m (731 kgf•m)

Fig. 3-1: Manipulator Reaction Force and Torque

Reaction force FVTor q u e M

35316 N (3600 kgf)

14715 N (1500 kgf)

49050 N•m (5000 kgf•m)

18394 N•m (1875 kgf•m)

3-2

)



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3 Installation

3.2 Mounting Procedures for Manipulator Base

3.2.1 Mounting the Manipulator on the Baseplate

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 thicker, 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 head screws M20 (70 mm long is recommended).

Next, fix the manipulator base to the baseplate. Tighten the hexagon head bolts and anchor bolts firmly so that they will not work loose during the operation.

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

Fig. 3-2: Mounting the Manipulator on the Baseplate

Spring washer

Washer

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Hexagon head screw M20 (8 screws)

Manipulator base

Flatness: 0.5mm or less

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Anchor bolt (M20 or more)

Baseplate

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Baseplate

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3 Installation

3.3 IP (International Protection)

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 exposure to 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/s [0.5 G] or less)

• Free from large electrical noise (plasma)

• Flatness for installation is 0.5 mm or less

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CAUTION

NOTE

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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 OFF the primary power supply, 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.

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.

5.5mm2 or more

4-1

Bolt M8 (for grounding)

(Delivered with the manipulator)

View A

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4 Wiring

4.2 Cable Connection

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

Connect these cables to the connectors on the manipulator connector base and the DX200 board connectors. Refer to Fig. 4-3(a) “Manipulator

Cable Connection (Manipulator Side)” and Fig. 4-3(b) “Manipulator Cable Connection (DX200 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.

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

The DX200 Side

X11

The DX200 Side

X21

The Manipulator Side

1BC

Encoder Cable

The Manipulator Side

2BC

4-2

2BC

Power Cable

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4.2 Cable Connection

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

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+ 63 hidden pages

YASKAWA MOTOMAN-VS100 Operator's 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

2.1.2 Using a Forklift

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 on the Baseplate

3.3 IP (International Protection)

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