•This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-MPL80 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 the Chapter 1: Safety of
the DX 100 instructions. To ensure correct and safe operation,
carefully read the DX 100 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-MPL80.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
157283-1CD
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
TURN
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•Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 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.
Figure 1: Emergency Stop Button
•Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
•Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– Be sure to lock out 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 DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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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 DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
•Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
Definition of Terms Used 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:
EquipmentManual Designation
DX100 controllerDX100
DX100 programming pendantProgramming 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 brand names for each company or
corporation. The indications of (R) and TM are omitted.
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MOTOMAN
TYPE
PAYLOAD
ORDER NO.
SERIAL NO.
MASS
DATE
YASKAWA ELECTRIC CORPORATION JAPAN
kg
kg
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
Nameplate:
WARNING Label B:
WARNING Label A:
Nameplate
WARNING label A
WARNING label B
WARNING label B
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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.
11 Parts List ..................................................................................................................................... 11-1
11.1 S-Axis Unit ..................................................................................................................... 11-1
11.2 L-Axis Unit ..................................................................................................................... 11-3
Check that the order number of the manipulator corresponds to the
DX100. The order number is located on a label as shown below.
Fig. 1-1: Location of Order Number Labels
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2Transport
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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.
2.1Transport Method
• Check that the eyebolts are securely fastened.
• The weight of the manipulator is approximately 580 kg
including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.
• Attached eyebolts 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, forklift, or other equipment.
Failure to observe this instruction may result in injury.
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Shipping bracket
Hexagon socket head cap screw M12
(8 screws)
Delivered with the manipulator
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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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Delivered with the manipulator
Shipping bracket
Forklift claw entry
Pallet
Bolt M20 (8 bolts)
NOTE
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2 Transport
2.2 Shipping Bolts and Brackets
2.1.2 Using a Forklift
When using a forklift, the manipulator should be fixed on a pallet with bolts
as shown in Fig. 2-2 “Using a Forklift”. Insert claws 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: Using a Forklift
2.2Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and a shipping brackets.
(See Fig. 2-1 “Transporting Position" on page 2-2.)
• The shipping bolts and bracket are painted yellow.
Before turning ON the power, make 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.
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CAUTION
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MPL80
3Installation
3 Installation
•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 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 the Safeguarding
3.1Installation of the Safeguarding
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 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.
3.2Mounting 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 referring to Table 3-1
"Maximum Repulsion Forces of the Manipulator at Emergency Stop" and
Table 3-2 "Endurance Torque in Operation".
A baseplate flatness must be kept at 0.5 mm or less: insufficient 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
Example” on page 3-3 or section 3.2.2 “When the Manipulator is Mounted
Directly on the Floor” on page 3-4.
Table 3-1:
Maximum torque in horizontal rotation
(S-axis moving direction)
Maximum torque in vertical rotation
(L-, U-axes moving direction)
Maximum Repulsion Forces of the Manipulator at Emergency Stop
24500 N•m
(2500 kgf•m)
45080 N•m
(4600 kgf•m)
Table 3-2: Endurance Torque in Operation
Endurance torque in horizontal operation
(S-axis moving direction)
Endurance torque in vertical operation
(L-, U-axes moving direction)
6125 N•m
(625 kgf•m)
11270 N•m
(1150 kgf•m)
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50
30
Flatness:
0.5mm or less
Hexagon head screw
M20 (8 screws)
Manipulator base
Spring washer
Washer
Baseplate
Anchor bolt M20 or more
Baseplate
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3 Installation
3.2 Mounting Procedures for Manipulator Base
3.2.1 Mounting Example
For the first process, anchor the baseplate firmly to the ground. The
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.
Next, fix the manipulator base to the baseplate. The manipulator base is
tapped for eight mounting holes; securely fix the manipulator base to the
baseplate with hexagon head screws M20 (70 mm long is recommended).
Tighten the hexagon head screws and anchor bolts firmly so that they will
not work loose during the operation.
Refer to Fig. 3-1 “Mounting the Manipulator Baseplate”.
Fig. 3-1: Mounting the Manipulator Baseplate
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600
900
800
720
385
320
300300
400
230
Bolt A
Tapped hole M20 (8 holes)
Bolt B
Tapped hole M24 (4holes) (Base B)
28dia. (4 holes) (Base A)
28dia. (4 holes) (Base B)
Base B
Base A
Bolt A: Bolt M20 X 70 mm (8 bolts),Spring Washer, Flat Washer
Tightening bolts or bases are prepared by the customer.
FL
Leveling is required
32
36250
350
200
100
100
200
JA Base bolt
M24 X315mm
Weld after adjusting
the installation
10
Manipulator base
Units: mm
Bolt B: Bolt M24 X 70 mm (4 bolts),Spring Washer, Flat Washer
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3 Installation
3.2 Mounting Procedures for Manipulator Base
3.2.2 When the Manipulator is Mounted Directly on the Floor
The floor should be strong enough to support the manipulator. Construct
a solid foundation with the appropriate thickness to withstand maximum
repulsion forces of the manipulator. As a rough standard, when there is a
concrete thickness (floor) is 200 mm or more, the manipulator base can
be fixed directly to the floor with M 20 anchor bolts. Before mounting the
manipulator, however, check that the floor is level and that all cracks, etc.
are repaired. Any thickness less than 200 mm is insufficient for mounting,
even if the floor is concrete.
Fig. 3-2: Direct Mounting on the Floor
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3 Installation
3.3 Protection Class
3.3Protection Class
The protection class at the main part conforms to IP54 and that of wrist
part is IP67.
3.4Location
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, oil, or water
• Free from corrosive gas or liquid, or explosive gas or liquid.
• Free from excessive vibration (4.9 m/s
• Free from large electrical noise (plasma)
2
[0.5G] or less)
• The flatness for installation is 0.5 mm or less
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WARNING
CAUTION
NOTE
A
5.5mm or more
2
Delivered with the manipulator
Bolt M8 (for grounding)
View A
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4Wiring
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4 Wiring
4.1 Grounding
•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
4.1Grounding
Follow the local regulations and electrical installation standards for
grounding. A 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
2
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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4 Wiring
4.2 Cable Connection
4.2Cable 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" on page 4-3.)
Connect these cables to the manipulator base connectors and to the
DX100. Refer to Fig. 4-3(a) "Manipulator Cable Connectors (Manipulator
Side)" on page 4-4" and Fig. 4-3(b) "Manipulator Cable Connectors
(DX100 Side)" on page 4-4.
4.2.1 Connection to the Manipulator
Before connecting 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.
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MPL80
molexmolexmolexmolexmolexmolex
2BC
X11
1BC
1BC
X21
2BC
X11
1BC
X21
2BC
The DX100 side
The Manipulator side
Encoder cable
Power cable
The DX100 side
The Manipulator side
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4 Wiring
4.2 Cable Connection
4.2.2 Connection to the DX100
Before connecting cables to the DX100, verify the numbers on both
manipulator cables and the connectors on the DX100. When connecting,
insert the cables in the order of X21, then X11, and depress each lever low
until it clicks.
1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Conformed to ISO9283
3 The range of motion of type:MPL0080-A01 is limited with the limit switch before shipment.
4 The range of motion of the B-axis indicates the angle to the ground. With certain postures, however, motion may
be limited by the relative angle between the B-axis and the upper arm. Refer to section 5.5 “B-Axis Operating Range” on page 5-4.
5 Refer to section 6.1 “Allowable Wrist Load” on page 6-1 for details on the allowable inertia.
5)
B-Axis78.4 N•m (8 kgf•m)
T-Axis20.5N•m (2.1 kgf•m)
B-Axis16 kg•m
T-Axis6.1 kg•m
Humidity20 to 80% RH at constant temperature
Vibration AccelerationLess than 4.9 m/s
OthersFree from corrosive gas or liquid, or explosive gas or
liquid.
Free from water, oil, or dust.
Free from excessive electrical noise (plasma).
2
2
2
(0.5G)
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T-
B-
T+
B+
U-
U+
L-
L+
S-
S+
Wrist
Wrist flange
Lower arm
L-arm
Upper arm
U-arm
Rotary head
S-head
Manipulator base
30
A
153
455
608
455
±
0.1
195
385
320
±0.1
195
±0.1
195
±0.1
230
230±0.1
22 dia.(8 holes)
View A
+0.018
0
12 dia. (2 holes)
230
400
195
±0.1
Base dimensions
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5 Basic Specifications
5.2 Part Names and Working Axes
5.2Part Names and Working Axes
Fig. 5-1: Part Names and Working Axes
Fig. 5-2: Baseplate Dimensions
5.3Baseplate Dimensions
5-2
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3291
2170
1300
925
312
112 1
623
2192
543
471248
131
2061
57
175
1025
145
1807
187540870210
105105
6
A
P-point
276
343
253
234
234
R377
R543
R2061
View A
P-point
maximum
envelope
Units: mm
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5 Basic Specifications
5.4 Dimensions and P-Point Maximum Envelope
5.4Dimensions and P-Point Maximum Envelope
Fig. 5-3: Dimensions and P-Point Maximum Envelope
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15°
B-axis rotation center
Wrist flange
15°
15°
15°
15°
55°
(*1)
U-axis rotation center
15°
15°
15°
15°
S-axis rotation center
L-axis rotation center
55°
Upper arm
(U-arm)
(*1)
1515°15°
1515°15°
15°
15°
1515°15°
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5 Basic Specifications
5.5 B-Axis Operating Range
5.5B-Axis Operating Range
The operating range of the B-axis maintaining a constant angle to the
center of U-axis is shown in Fig. 5-4 “B-Axis Operating Range”.
By “B-axis adjustable motion function”, the B-axis maintains the same
posture to the ground regardless of the L- or U-axis angle.
The operating range is ±15° (0 degree is defined as the angle when the
wrist flange is horizontal and facing to the ground.) When the B-axis
position exceeds this limit, ”Special Soft Limit” occurs.
Note: In relation with interference with the upper arm, the range of motion
can be limited.
Fig. 5-4: B-Axis Operating Range
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5 Basic Specifications
5.6 Alterable Operating Range
5.6Alterable 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.
The allowable wrist load is 80 kg. If force is applied to the wrist instead of
the load, force on R-, B-, and T-axes should be within the value shown in
Table 6-1 "Allowable Wrist Load". Contact your Yaskawa representative
for further information or assistance.
Table 6-1: Allowable Wrist Load
AxisMoment N•m (kgf•m)
B-Axis78.4 (8)16
T-Axis20.5 (2.1)6
1 ( ): Gravitational unit
1)
GD
kg•m
2
/4 Total Moment of Inertia
2
When the volume load is small, refer to the moment arm rating shown in
Fig. 6-1 “Moment Arm Rating”.
The allowable total moment of inertia is calculated when the moment is at
the maximum. Contact your Yaskawa representative beforehand when
only the moment of inertia is created, or when the load moment is small
while the moment of inertia is large. Also, when the load mass is
combined with an outside force, contact your Yaskawa representative
beforehand.
Fig. 6-1: Moment Arm Rating
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P.C.D.80
42
40
Unit: mm
6
6
10
axis
Tapped hole M8
8 dia
Alignment mark
6 dia.
+0.012
0
50 dia.
0
-0.025
(depth: 10mm)
(depth:14 mm) (pitch:1.25) (6 holes)
(depth: 14mm)
+0.015
0
100 dia.
0
-0.022
NOTE
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Fig. 6-2: Wrist Flange
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6 Allowable Load for Wrist Axis and Wrist Flange
6.2 Wrist Flange
6.2Wrist Flange
The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. In order
to see the alignment marks, it is recommended that the attachment be
mounted inside the fitting. Fitting depth of inside and outside fittings must
be 5 mm or less.
Wash off anti-corrosive paint (yellow) on the wrist flange
surface with thinner or light oil before mounting the tools.
The peripheral equipment mounts are provided on the U-axis (upper arm)
and S-axis (rotary head) as shown in Fig. 7-1 “Installing Peripheral Equipment” for easier installation of the users’ system applications. The
following conditions should be observed to attach or install peripheral
equipment.
Fig. 7-1: Installing Peripheral Equipment
Table 7-1: Conditions for Installation
SectionApplicationNote
ACable processing80 kg max. for attaching load mass including
wrist load.
BCable processing and
valve load
10 kg max.
N•m (5 kgf•m) max. for increased
49
moment amount of upper arm
COthers30 kg max.
7-1
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View A
Connector for Internal User I/O Wiring Harness
Pins used
Internal user I/O wiring harness :
0.5 mm
2
, 23 wires
AIR
1BC
2BC
8
4
9
6517
23
14
19
20
15
17
11 121813
21 22 23
10
16
P
P
P
P
P
P
P
P
P
P
P
1
6
5
3
4
2
7
8
9
10
15
14
13
12
11
20
19
17
18
16
22
23
21
Tapped hole PT3/8
with a pipe plug
Air inlet
Connector for internal user I/O wiring
harness: JL05-2A24-28PC (with a cap)
Prepare pin connector: JL05-6A24-28S
A
B
Connector for internal user I/O wiring
harness: JL05-2A24-28SC (with a cap)
Prepare pin connector: JL05-6A24-28S
View B
Air inlet
Tapped hole PT3/8
with a pipe plug
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7 System Application
7.2 Internal User I/O Wiring Harness and Air Line
7.2Internal User I/O Wiring Harness and Air Line
Internal user I/O wiring harness (0.5 mm2 x 23 wires), and an air line are
incorporated in the manipulator for the drive of peripheral device mounted
on the upper arm as shown in Fig. 7-2 “Connectors for Internal User I/O Wiring Harness and Air Line" on page 7-2.
The connector pins 1 to 23 are assigned as shown in Fig. 7-2. Wiring must
be performed by users.
The allowable current for internal user
I/O wiring harness
5.1A or less for each wire
(The total current value for pins 1 to 23
must be 34.5A or less.)
The maximum pressure for the air line 490 kPa (5 kgf/cm
(The air line inside diameter: 8.0 mm.)
Fig. 7-2: Connectors for Internal User I/O Wiring Harness and Air Line
2
) or less
The same numbered pins (1 to 23) of the two connectors are connected
with a single lead wire of 0.5 mm
2
.
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8 Electrical Equipment Specification
8.1 Location of Limit Switch
8Electrical Equipment Specification
8.1Location of Limit Switch
The limit switches are optional. See Fig. 8-1 “Location of Limit Switches”.
The overrun limit switches (the S- and L-axis overrun limit switches and
the LU-axes interference limit switch) are mounted only if the manipulator
type is : YR-MPL0080-A01.
Fig. 8-1: Location of Limit Switches
L-and U-axes interference limit switch
(YR-MPL0080-A01 with limit switch)
S-axis overrun limit switch
L-axis overrun limit switch
(YR-MPL0080-A01 with limit swich)
8-1
HW0485739
MPL80
1BC
2BC
Connector for internal
user I/O wiring harness
Connector for internal
user I/O wiring harness
L-and U-axes interference limit switch
(YR-MPL0080-A01 with limit switch)
S-axis overrun limit switch
L-axis overrun limit switch
(YR-MPL0080-A01
with limit switch)
34 of 69
8 Electrical Equipment Specification
8.2 Internal Connections
8.2Internal Connections
Highly reliable connectors are equipped on each connection part of the
manipulator to enable easy removal and installation for maintenance and
inspection. For the number and location of connectors, see Fig. 8-2
“Location and Numbers of Connectors” and Table 8-1 "List of Connector
Types".
Diagrams for internal connections of the manipulator are shown in Fig.
8-3(a) "Internal Connection Diagram" on page 8-3 and Fig. 8-3(b) "Internal
Connection Diagram" on page 8-4 .
Fig. 8-2: Location and Numbers of Connectors
157283-1CD
Table 8-1: List of Connector Types
NameType of Connector
Connector for the internal user I/O
wiring harness on the connector base
Connector for the internal user I/O
wiring harness on the U-arm
JL05-2A24-28PC
(JL05-6A24-28S: Optional)
JL05-2A24-28SC
(JL05-6A24-28P: Optional)
8-2
HW0485739
DX100
Board for encoder power
1.For the limit switch specification, the connection of the section A B are changed as follows:
<Notes>
S-axis overrun L.S.
Connected to
A1
L-axis overrun L.S.
A2
Connected to
L and U-axes interference L.S.
A3
Connected to
S-axis overrun L.S.
Connected to
B1
L-axis overrun L.S.
B2Connected to
L and U-axes interference L.S.
B3
Connected to
SLU-axes with Limit Switch Specification
S-axis with Limit Switch Specification
S-axis overrun L.S.
Connected to
B1
S-axis overrun L.S.
Connected to
A1
DC/DC
SP23
23
23
P
22
SP22
SP21
21
22
21
P
20
SP20
SP19
19
20
19
P
P
P
P
P
P
S1(24-28)
No.8CN(24-28)
3
2
1
SP1
SP2
SP3
SP6
7
8
9
SP7
SP8
6
5
SP5
SP4
4
13
14
15
16
12
11
SP12
SP13
SP14
SP15
SP11
SP10
18
SP18
SP17
17
SP16
10
SP9
P
P
P
1
2
6
8
7
4
5
3
12
13
15
14
10
11
18
17
16
9
LC1
LD1
LD1
+24V
LD1
LD2
LB1
LB2
LA1
LB1
P
0V
P
P
CN4-9
CN4-4
CN4-5
P
AWG23
AWG23
AWG23
CN4-4
CN4-5
CN2-10
CN2-9
CN2-5
CN2-4
CN3-4
CN3-5
AWG23
AWG23
AWG23
AWG23
AWG23
AWG23
CN3-10
AWG23
AWG23
CN3-9
CN2-10
CN3-4
CN3-5
CN2-4
CN2-5
CN2-9
+24V
LD1
CN3-9
CN3-10
CN4-9
CN4-10
AWG23
0V
CN4-10
S-AXIS
PG
PG
U-AXIS
PG
BAT
OBT
+5V
0V
DATA-5
-9
-6
-5
-4
-2
DATA+5
B-AXIS
DATA+6
BAT
DATA-6
OBT
-2
PG
+5V
FG6
0V
BAT
OBT
-10
-4
-9
-6
-5
T-AXIS
FG5-10
BAT
OBT
L-AXIS
PG
0BAT2
BAT1
0BAT1
18
19
17
0BAT3
BAT3
21
24
25
22
23
BAT2
20
0BAT5
0BAT6
BAT6
BAT5
27
29
30
28
31
PG0V3
PG0V2
PG5V2
PG5V1
PG0V1
5
2
3
4
1
32
26
1CN-1
No.1CN
-2
DATA-1
DATA+1
S
P
-4
-9
-10
-5
-6
0V
+5V
FG1
BAT
OBT
No.2CN
2CN-1
-6
-2
DATA-2
DATA+2
BAT
BAT
OBT
P
P
L
P
No.18CN
PG5V6
PG0V6
PG5V5
PG0V5
8
12
11
10
9
7
16
15
14
13
-3
-4
-2
-1
No.19CN
-1
PG5V1
PG0V1
0BAT1
BAT2
BAT1
PG5V3
6
0BAT12
BAT11
0BAT11
2
3
1
PK R BAT
0BT
0BT
0BAT21
50BT
BAT12
PK R BAT 4
0BAT22
BAT22
7
1
8PKR
0BT
BAT
7
4
5
6
3
2
BAT21
PK R BAT 6
X
3
1
-3
No.24CN
-1 +24V
0V
4
2
-2-4+24V
0V
1BC(10 4)
0V
+24V
CN1-5
CN1-4
P
AWG23
AWG23
SPG-1
SPG+1
0V
+24V
CN1-2
CN1-1
CN1-9
CN1-10
P
P
AWG23
AWG23
AWG23
AWG23
FG1
CN1-3
SPG-2
SPG+2
CN1-7
CN1-6
P AWG23
AWG23
CN1-5
0V
+24V
CN1-10
CN1-1
CN1-9
0V
SPG-1
SPG+1
+24V
CN1-4
CN1-3
FG1
CN1-6
CN1-7
SPG-2
SPG+2
CN1-2
8
-10
-4
-90V
BAT
OBT
FG2
+5V
-2
-5
-6
3CN-1
No.3CN
DATA-3
DATA+3
OBT
BAT
P
U
P
P
-9
-10
0V
OBT
BAT
FG3
P
-4+5V
-4
-3
No.20CN
-2
-1
-4
-3
PG5V3
PG0V3
0BAT3
PG0V2
PG5V2
BAT3
B
P
P
P
T
P
P
P
No.22CN
-4
-2
-3
-1
No.23CN
-2
-3
-4
-1
PG5V6
PG0V6
0BAT6
BAT6
PG0V5
0BAT5
PG5V5
BAT5
FG2
CN1-8
SPG-3
SPG+3
CN2-2
CN2-1
P
AWG23
AWG23
FG3
CN2-3
CN2-7
CN2-6
P
AWG23
AWG23
CN1-8
FG2
CN2-2
CN2-1
SPG-3
SPG+3
CN2-3
FG3
CN2-6
CN2-7
CN3-1
CN2-8
AWG23
FG5
SPG-5
CN3-3
CN3-2
P
AWG23
SPG+5
SPG+6
SPG-6
CN3-6
CN3-7
P
AWG23
AWG23
FG6
CN3-8
CN2-8
CN3-2
FG5
SPG-5
CN3-1
SPG+5
CN3-6
SPG-6
SPG+6
CN3-8
FG6
CN3-7
CN3-3
BC1
BC2
SS1
E
MANIPULATORCasingBase
E
LB1
+24V
CN4-6
P
AWG23
AWG23
CN4-1
SS2
BC2
SS2
CN4-3
CN4-7
CN4-2
P
AWG23
AWG23
AWG23
CN4-8
P
AWG23
CN4-6
CN4-1
LB1
+24V
CN4-7
CN4-2
BC2
SS2
CN4-8
CN4-3
E
-2
0BAT2P
-5OBT
6CN-1
No.6CN
5CN-1
No.5CN
LC3
LD3
LA3
LB3
LA1
LC1
LA3
LB3
LB2
LB1
LB1
LA1
LC3
LD3
LD2
LD1
LD1
LC1
LD1
LD1
LC1
LB1
LB1
LA1
LD1
LC2
LD2
LD2
LD1
LC1
LB1
LA2
LB2
LB2
LB1
LA1
LC2
LD2
LD2
LD1
LB1
LB2
LB2
LA2
FOR LAMP(OPTION)
B1
A1
B3
A3
B2
A2
35 of 69
157283-1CD
MPL80
8 Electrical Equipment Specification
8.1 Internal Connections
Fig. 8-3(a): Internal Connection Diagram
8-3
HW0485739
MPL80
YB
SM
B-AXIS
SM
YB
T-AXIS
13CN-3
No.13CN
MU5
-2
-1
-5
-4
-PE
MV5
MW5
BB5
BA5
ME5
-2
14CN-3
No.14CN
MU6
MV6
-1
-4
-5
-PE
MW6
BA6
BB6
ME6
EE
2BC
2BC(8X4+12X2)
PE
ME6
BB1
BA1
BA3
BA6
BA5
BB5
BA2
ME5
ME3
ME2
ME2
ME1
ME1
MW5
MV5
MU5
MU6
MW6
MV6
MV2
MV2
MW2
MU3
MV3
MW2
MU1
MV1
MV1
MW1
MU1
MU2
MU2
MW1
MW3
ME6
BB1
BA1
BA3
BA6
BA5
BB5
BA2
CN6-9
CN6-10
CN6-12
CN6-11
CN6-2
CN6-1
CN6-4
CN6-7
CN6-8
CN6-6
CN6-5
CN6-3
ME5
ME3
ME2
ME2
ME1
ME1
CN5-5
CN5-8
CN5-7
CN5-6
CN5-4
CN5-3
CN5-2
CN5-1
CN4-2
CN4-1
CN4-6
CN4-7
CN4-3
CN4-5
CN4-4
CN4-8
MW5
MV5
MU5
MU6
MW6
MV6
CN3-1
CN3-2
CN3-5
CN3-4
CN3-7
CN3-8
CN3-6
CN3-3
CN5-5
CN5-8
CN5-7
CN5-6
CN5-4
CN5-3
CN5-2
CN2-8
CN2-7
CN2-8
CN2-7
MV2
MV2
MW2
MU3
MV3
MW2
CN2-1
CN2-3
CN2-2
CN2-5
CN2-6
CN2-4
CN1-8
CN1-7
CN1-6
CN1-5
CN1-4
CN1-3
CN1-2
CN1-8
CN1-7
CN1-6
CN1-5
CN1-4
CN1-3
CN1-2
CN6-9
CN6-10
CN6-12
CN6-11
S-AXISSM
YB
L-AXIS
YB
SM
U-AXISSM
YB
-C
No.9CN
9CN-A
-B
MW1
MU1
MV1
-1
-D
-2
BA1
ME1
BB1
CN1-1
MU1
MV1
MV1
MW1
MU1
MU2
MU2
MW1
CN1-1
CN2-1
CN2-3
CN2-2
10CN-A
No.10CN
MU2
-2
-C
-1
-D
BB2
MW2
BA2
ME2
MV2-B
-C
-B
No.11CN
11CN-A
MW3
MV3
MU3
-2
-1BA3
BB3
ME3-D
MW3
CN2-5
CN2-6
CN2-4
CN3-1
CN3-2
CN3-5
CN3-4
CN4-2
CN3-7
CN4-1
CN3-8
CN3-6
CN3-3
CN4-6
CN4-7
CN4-3
CN4-5
CN4-4
CN4-8
CN5-1
CN6-2
CN6-1
CN6-4
CN6-7
CN6-8
CN6-6
CN6-5
CN6-3
36 of 69
157283-1CD
8 Electrical Equipment Specification
8.1 Internal Connections
Fig. 8-3(b): Internal Connection Diagram
8-4
HW0485739
157283-1CD
DANGER
WARNING
CAUTION
NOTE
37 of 69
MPL80
9 Maintenance and Inspection
9.1 Inspection Schedule
9Maintenance 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.
•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.
9.1Inspection 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 six
levels as shown in Table 9-1 "Inspection Items" on page 9-2.
In Table 9-1 "Inspection Items" on page 9-2, the inspection items are
classified into three types of operation: 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.000
• The inspection interval depends on the total servo
operation time.
• The inspection may be conducted at shorter intervals if the
manipulator is used very frequently for the application
such as handling; in this case, contact your Yaskawa
representative.
9-1
HW0485739
Table 9-1: Inspection Items (Sheet 1 of 2)
38 of 69
1)
Items
ScheduleMethodOperationInspection
MPL809.1 Inspection Schedule
Charge
1Alignment mark
2External lead
3Working area and
manipulator
4S, L, U, B, T-axes motor
9-2
5Baseplate mounting bolts
6Cover mounting screws
7S, L, U, B, T-axes motor
connector
8Connector base
9Wire harness in
manipulator
HW0485739
10Limit switches and dogs
(S,L,U-axes)
11Battery pack in
manipulator
12S-axis speed reducer
Daily
•
•
•
•
1000HCycle
•
•
•
•
6000HCycle
12000HCycle
•
•
••
24000HCycle
36000HCycle
VisualCheck alignment mark accordance at the home position.
Check for damage.
VisualCheck for damage and deterioration of leads.
VisualClean the work area if dust or spatter is present. Check for damage
and outside cracks.
VisualCheck for grease leakage.
Spanner
Wrench
Screwdriver,
Wrench
ManualTighten loose bolts.
ManualCheck for loose connectors.
Visual MultimeterCheck for conduction between the main connecter of base
•
Screwdriver,
Wrench,
Multimeter
•
Grease GunCheck for malfunction. (Replace if necessary.)
Tighten loose bolts. Replace if necessary.
Tighten loose bolts. Replace if necessary.
and intermediate connector with manually shaking the wire. Check
for wear of protective spring
Replace it 24000H intervals.
Tighten loose bolts. Replace if necessary.
Replace the battery pack when the battery alarm occurs or the
manipulator drove for 36000H.
Supply grease (6000H cycle)5)
Replace grease. (12000H cycle) 5)See section 9.3.1 on page 9-8.
2)
3)
4)
Specified
Personnel
Licensee
Service
Company
•••
•••
•••
•••
•••
•••
•••
•••
••
•
••
••
••
9 Maintenance and Inspection
157283-1CD
9-3
39 of 69
Table 9-1: Inspection Items (Sheet 2 of 2)
1)
Items
13LU-axes speed reducers
14B,T-axes speed reducers
B,T-axes gears
15Overhaul
1 Inspection No. correspond to the numbers in Fig. 9-1 “Inspection Items" on page 9-4.
2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa
representative.
3 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the motor side for each axis, and then remove
connectors on detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer to section 9.3.6 on page 9-19.)
4 The grease might leak out from the air breather or the internal pressure might rise in case the manipulator is used very frequently for the application such as
handling.
5 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used" on page 9-5.
ScheduleMethodOperationInspection
Charge
Daily
1000HCycle
6000HCycle
12000HCycle
24000HCycle
••
••
36000HCycle
Grease GunCheck for malfunction. (Replace if necessary.)
Supply grease (6000H cycle)5).
Replace grease (12000H cycle)5). See section 9.3.2 on page 9-11,
section 9.3.3 on page 9-13.
Grease GunCheck for malfunction. (Replace if necessary.)
Supply grease(6000H cycle)5).
Replace grease(12000H cycle)
5)
. See section 9.3.5 on page 9-17.
4)
4)
Specified
Personnel
Licensee
••
••
••
Service
157283-1CD
MPL809.1 Inspection Schedule
Company
9 Maintenance and Inspection
HW0485739
Fig. 9-1: Inspection Items
6
7
2
1
8
10
L-axis
15
1
B-axis
6
1
14
R-axis
1
U-axis
11
14
6
5
6
16
1
T-axis
6
6
4
13
6
1
9
12
S-axis
40 of 69
MPL809.1 Inspection Schedule
9 Maintenance and Inspection
9-4
HW0485739
157283-1CD
157283-1CD
41 of 69
MPL80
9 Maintenance and Inspection
9.1 Inspection Schedule
Table 9-2: Inspection Parts and Grease Used
No.Grease UsedInspected Parts
13,14,15,16Molywhite RE
No.00
The numbers in the above table correspond to the numbers in Table 9-1 "Inspection Items" on page 9-2.
Speed reducers for all axes
B,T-axes gears
9-5
HW0485739
MPL80
AIR
1BC
2BC
Top View
Backside View
Connector base
Battery pack (HW0470360-A)
Cross head APS bolt M6
(Length:12)(8 bolts)
Cross head APS bolt M4
(Length:8)(4 bolts)
42 of 69
157283-1CD
9 Maintenance and Inspection
9.2 Notes on Maintenance Procedures
9.2Notes on Maintenance Procedures
9.2.1 Battery Pack Replacement
The battery packs are installed in the position shown in Fig. 9-2 “Battery
Location”.
• Battery Type: HW0470360-A
Fig. 9-2: Battery Location
9-6
HW0485739
157283-1CD
See procedure 5
Connector
Battery pack before replacement
See procedure 4
New battery pack
Circuit Board
(Type: SGDR-EFBA02A)
NOTE
NOTE
43 of 69
MPL80
Fig. 9-3: Battery Connection
9 Maintenance and Inspection
9.2 Notes on Maintenance Procedures
1. Turn OFF the DX100 main power supply.
2. Remove the plate fixing screws and the plate on the connector base,
then
pull the battery pack out to replace it with the new one.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connectors on the
circuit boa
5. Remove the old battery pack from the circuit board.
6. Mount the new battery pack on the battery holder.
7. Reinstall the plate.
rd.
Remove the old battery pack after connecting the new one
so that the encoder absolute data does not disappear.
Do not allow plate to pinch the cables when reinstalling the
plate.
9-7
HW0485739
MPL80
NOTE
Grease exhaust port
Air breather
S-axis speed reducer
Grease inlet
Hexagon socket
head plug PT1/4
Air breather
44 of 69
157283-1CD
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
9.3Notes 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/air breather
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/air breather.
• 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.
9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer
Fig. 9-4: S-Axis Speed Reducer Diagram
9-8
HW0485739
157283-1CD
NOTE
45 of 69
MPL80
9.3.1.1 Grease Replenishment
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram" on page 9-8.)
1. Remove the hexagon socket head plug PT1/4 from the grease inlet
and the hexagon socket head air breather from the grease exhaust
port.
2. Install the grease zerk PT1/4 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
3. Inject the grease through the inlet using a grease gun.
– Grease type:Molywhite RE No. 00
• If grease is injected with the air breather on, grease will
leak inside the motor and may cause a damage. Make
sure to remove the air breather 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.
–
Amount of grease: 520 cc
(1040 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 the excess grease.
5. Wipe the discharged grease with a cloth and reinstall the air breather
up
ward.
Before installing the air breather, apply
thread part of each plug.
6. Remove the grease zerk from the grease inlet and reinstall the
he
xagon socket head plug PT1/4.
Before installing the plug, apply Three Bond
of each plug, then tighten the plug with a tightening torque of 12 N•m
(1.2 kgf•m).
Three Bond 1206C on the
1206C on the thread part
9-9
HW0485739
MPL80
NOTE
NOTE
46 of 69
9.3.1.2 Grease Exchange
157283-1CD
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram" on page 9-8.)
1. Remove the hexagon socket head plug PT1/4 from the grease inlet
and the hexagon socket head air breather from the grease exhaust
port
.
• If grease is injected with the air breather, the grease will
leak inside the motor and may cause a damage. Make
sure to remove the air breather before the grease
injection.
• Do not install a joint, a hose, etc. to a 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 the grease zerk PT1/4 to the grease inlet.
(The grease zerk is delivered with the manipulator.)
3. Inject the grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No. 00
–
Amount of grease: approx. 2600 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 complete when new grease appears from the
e
xhaust port. (The new grease can be distinguished from the old
grease by color.)
5. Move the S-axis for a few minutes to discharge the excess grease.
6. Wipe the discharged grease with a clo
upward.
Before installing the air breather
thread part of each plug.
If grease is injected with the air breather on, grease will leak
inside the motor and may cause a damage. Make sure to
remove the air breather before the grease injection.
7. Remove the grease zerk from the grease inlet and reinstall the
exagon socket head plug PT1/4.
h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 12 N•m
(1.2 kgf•m).
th and reinstall the air breather
, apply Three Bond 1206C on the
on the thread part
9-10
HW0485739
157283-1CD
Grease exhaust port
Hexagon socket head
plug PT3/8
Grease inlet
Hexagon socket
head plug PT1/8
L-axis speed reducer
NOTE
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MPL80
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer
Fig. 9-5: L-Axis Speed Reducer Diagram
9.3.2.1 Grease Replenishment
(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram”.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
• If grease is injected with the exhaust 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.
4. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is
d
elivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type:Molywhite RE No. 00
–
Amount of grease: 250 cc
(500 cc for 1st supply)
– Air supply pressure of grease pump:0.3 MPa or less
– Grease injection rate: 8 g/s or less
6. Move the L-axis for a few minutes to discharge the excess grease.
7. Wipe the discharged grease with a cloth and reinstall the hexagon
so
cket head plug PT3/8 to the exhaust port.
Before installing the plugs, apply Three
Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
8. Remove the grease zerk from the grease inlet and reinstall the
xagon socket head plug PT1/8 to the grease inlet.
he
Before installing the plug, apply Three Bond
1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
9-11
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NOTE
NOTE
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9.3.2.2 Grease Exchange
157283-1CD
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram" on page 9-11.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
• If grease is injected with the exhaust 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.
4. Install the grease zerk PT1/8 to the gr
(The grease zerk is delivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No. 00
–
Amount of grease: approx. 1650 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
6. The grease discharge is complete when new grease appears from the
e
xhaust port. The new grease can be distinguished from the old
grease by color.
7. Move the L-axis for a few minutes to discharge the excess grease.
8. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Before installing the plugs, apply Three Bond 1206C on the thread part
f each plug, then tighten the plug with a tightening torque of 23 N•m
o
(2.3 kgf•m).
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.
ease inlet.
th and reinstall the hexagon
9. Remove the grease zerk from the grease inlet and reinstall the
exagon socket head plug PT1/8 to the grease inlet.
h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
on the thread part
9-12
HW0485739
157283-1CD
U-arm
NOTE
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MPL80
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer
Fig. 9-6: U-Arm Posture
Fig. 9-7: U-Axis Speed Reducer Diagram
Grease inlet
Hexagon socket head
plug PT1/8
9.3.3.1 Grease Replenishment
(Refer to Fig. 9-7 “U-Axis Speed Reducer Diagram”.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
4. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is
d
U-axis speed reducer
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt 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.
elivered with the manipulator.)
Grease exhaust port
Hexagon socket head
plug PT3/8
5. Inject grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No. 00
– Amount of grease: 140 cc
(280 cc for 1st supply)
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
9-13
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MPL80
NOTE
NOTE
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157283-1CD
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
6. Move the U-axis for a few minutes to discharge the excess grease.
9.3.3.2 Grease Exchange
7. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Three Bond 1206C on the thread part of each plug, then tighten the
lug with a tightening torque of 23 N•m (2.3 kgf•m)
p
8. Remove the grease zerk from the grease inlet and reinstall the
h
exagon socket head plug PT1/8.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m)
Refer to Fig. 9-7 “U-Axis Speed Reducer Diagram" on page 9-13.)
(
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease
ex
haust port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt 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.
th and reinstall the hexagon
on the thread part
4. Install the grease zerk PT1/8 to the gr
delivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No. 00
–
Amount of grease: approx.700 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
6. The grease discharge is complete when new grease appears from the
ex
haust port. The new grease can be distinguished from the old
grease by color.
7. Move the U-axis for a few minutes to discharge the excess grease.
8. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
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.
ease inlet. (The grease zerk is
th and reinstall the hexagon
on the thread part
9. Remove the grease zerk from the grease inlet and reinstall the
exagon socket head plug PT1/8.
h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
on the thread part
9-14
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157283-1CD
NOTE
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MPL80
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.4 Grease Replenishment for B- and T-Axis Gears
Fig. 9-8: B- and T-Axis Gears Diagram
9.3.4.1 Grease Replenishment
(Refer to Fig. 9-8 “B- and T-Axis Gears Diagram”.)
Exhaust port
Hexagon socket head
plug PT3/8
U-arm
Grease inlet
Hexagon socket head
plug PT1/8
1. Remove the hexagon socket head plug PT3/8 from the exhaust port.
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt 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. Remove the hexagon socket head plug PT1/8.
3. Inject grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No. 00
–
Amount of grease: approx.700 cc
(1400 cc for 1st supply)
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
4. The grease discharge is complete when new grease appears from the
exha
ust port. The new grease can be distinguished from the old
grease by color.
5. Move the B-axis for a few minutes to discharge the excess grease.
6. Wipe the discharged grease with a cloth and reinstall the hexagon
so
cket head plug PT3/8 to the exhaust port.
Before installing the plug, apply Three Bond
1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
7. Remove the grease zerk from the grease inlet and reinstall the
xagon socket head plug PT1/8.
he
Before installing the plug, apply Three Bond
1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
9-15
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MPL80
NOTE
NOTE
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9.3.4.2 Grease Exchange
157283-1CD
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
(Refer to Fig. 9-8 “B- and T-Axis Gears Diagram" on page 9-15.)
1. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
2. Remove the hexagon socket head plug PT1/8 from the grease inlet.
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt 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.
3. Install the grease zerk PT1/8 to the gr
delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No. 00
–
Amount of grease: approx.3500 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
5. The grease discharge is complete when new grease appears from the
ex
haust port. The new grease can be distinguished from the old
grease by color.
6. Move the B-axis for a few minutes to discharge the excess grease.
7. Wipe the discharged grease with a clo
socket head plug PT3/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
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.
ease inlet. (The grease zerk is
th and reinstall the hexagon
on the thread part
8. Remove the grease zerk from the grease inlet and reinstall the
exagon socket head plug PT1/8.
h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
on the thread part
9-16
HW0485739
157283-1CD
Grease inlet
Hexagon socket head
plug PT1/8
T-axis speed reducer, gear
Exhaust port
Hexagon socket head
plug PT1/8
B-axis speed reducer, gear
NOTE
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MPL80
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.5 Grease Replenishment for B- and T-Axis Speed Reducers and Gears
Fig. 9-9: B- and T-Axis Speed Reducers and Gears Diagram
9.3.5.1 Grease Replenishment
(Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears Diagram”.)
1. Remove the hexagon socket head plug PT1/8 from the exhaust port.
2. Remove the hexagon socket head plug PT1/8.
3. Inject grease through the grease inlet using a grease gun.
4. The grease discharge is complete when new grease appears from the
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt 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.
– Grease type: Molywhite RE No. 00
–
Amount of grease: approx.300 cc
(600 cc for 1st supply)
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
exha
ust port. The new grease can be distinguished from the old
grease by color.
5. Move the B-axes for a few minutes to dischar
6. Wipe the discharged grease with a cloth and reinstall the hexagon
so
cket head plug PT1/8 to the exhaust port.
Before installing the plug, apply Three Bond
ge the excess grease.
1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
7. Remove the grease zerk from the grease inlet and reinstall the
xagon socket head plug PT1/8.
he
Before installing the plug, apply Three Bond
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
1206C on the thread part
9-17
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NOTE
NOTE
54 of 69
9.3.5.2 Grease Exchange
157283-1CD
9 Maintenance and Inspection
9.3 Notes on Grease Replenishment/Exchange Procedures
(Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears Diagram" on page 9-17.)
1. Remove the hexagon socket head plug PT1/8 from the grease
exhaust port.
2. Remove the hexagon socket head plug PT1/8 from the grease inlet.
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt 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.
3. Install the grease zerk PT1/8 to the gr
delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
– Grease type: Molywhite RE No. 00
–
Amount of grease: approx.1500 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
5. The grease discharge is complete when new grease appears from the
ex
haust port. The new grease can be distinguished from the old
grease by color.
6. Move the B-axes for a few minutes to discharge the excess grease.
7. Wipe the discharged grease with a clo
socket head plug PT1/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
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.
ease inlet. (The grease zerk is
th and reinstall the hexagon
on the thread part
8. Remove the grease zerk from the grease inlet and reinstall the
exagon socket head plug PT1/8.
h
Before installing the plug, apply Three Bond 1206C
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
9.3 Notes on Grease Replenishment/Exchange Procedures
9.3.6 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”.
9.3.6.1 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
2. Connect the battery packs (HW9470932-A) with the battery backup
motors.
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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10 Recommended Spare Parts
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-MPL80. 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 YR-MPL0080-A00, -A01 (Sheet 1 of 2)
YASKAWA Nordic AB
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.
22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㧗86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone
+86-10-6788-2858
Fax
+86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)
#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
YASKAWA Electric Korea Co., Ltd
9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.
252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek Road㧘Huaykwang, Bangkok 10320, Thailand
Phone
+66-2693-2200
PT. YASKAWA Electric Indonesia
Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Fax +91-124-475-8542Phone +91-124-475-8500
Fax +886-2-8913-1513Phone +886-2-8913-1333
Fax
+66-2693-4200
Fax +62-21-2982-6741Phone +62-21-2982-6470
Specifications are subject to change without notice
for ongoing product modifications and improvements.
MANUAL NO.
HW0485739
4
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