Yaskawa MPL80 User Manual

MOTOMAN-MPL80

1 of 69

INSTRUCTIONS

TYPE: YR-MPL0080-A00 (STANDARD SPECIFICATION) YR-MPL0080-A01 (WITH LIMIT SWITCHES FOR S-, L-, U-AXES)

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

MOTOMAN INSTRUCTIONS

MOTOMAN-MPL80 INSTRUCTIONS DX 100 INSTRUCTIONS DX 100 OPERATOR’S MANUAL DX100 MAINTENANCE MANUAL

The DX 100 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

Part Number: 157283-1CD Revision: 4

MANUAL NO.

HW0485739

MPL80

2 of 69

157283-1CD

HW0485739

157283-1CD

MANDATORY

CAUTION

3 of 69

MPL80

• 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.

iii

HW0485739

MPL80

DANGER

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

4 of 69

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.

HW0485739

157283-1CD

WARNING

TURN

5 of 69

MPL80

• 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.

HW0485739

MPL80

CAUTION

6 of 69

157283-1CD

• 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:

Equipment Manual Designation

DX100 controller DX100

DX100 programming pendant Programming pendant

Cable between the manipulator and the controller

Manipulator cable

Registered Trademark

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

HW0485739

157283-1CD

MOTOMAN

TYPE

PAYLOAD

ORDER NO.

SERIAL NO.

MASS

DATE

YASKAWA ELECTRIC CORPORATION JAPAN

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

7 of 69

MPL80

Explanation of Warning Labels

The following warning labels are attached to the manipulator.

Always follow the warnings on the labels.

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

Figure 3: Warning Label Locations

vii

HW0485739

157283-1CD

8 of 69

MPL80

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 .............................................................................................. 2-3

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

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

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

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

3.2.2 When the Manipulator is Mounted Directly on the Floor....................................... 3-4

3.3 Protection Class................................................................................................................. 3-5

3.4 Location ............................................................................................................................. 3-5

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

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

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

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

4.2.2 Connection to the DX100...................................................................................... 4-3

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

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

5.2 Part Names and Working Axes.......................................................................................... 5-2

5.3 Baseplate Dimensions ....................................................................................................... 5-2

5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-3

5.5 B-Axis Operating Range ....................................................................................................5-4

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

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

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

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

viii

HW0485739

157283-1CD

9 of 69

MPL80

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

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

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

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

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

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

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

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

9.2 Notes on Maintenance Procedures ................................................................................... 9-6

9.2.1 Battery Pack Replacement ................................................................................... 9-6

9.3 Notes on Grease Replenishment/Exchange Procedures .................................................. 9-8

Table of Contents

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer ............................. 9-8

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

9.3.1.2 Grease Exchange ................................................................................. 9-10

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-11

9.3.2.1 Grease Replenishment.......................................................................... 9-11

9.3.2.2 Grease Exchange ................................................................................. 9-12

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

9.3.3.1 Grease Replenishment.......................................................................... 9-13

9.3.3.2 Grease Exchange ................................................................................. 9-14

9.3.4 Grease Replenishment for B- and T-Axis Gears ................................................ 9-15

9.3.4.1 Grease Replenishment.......................................................................... 9-15

9.3.4.2 Grease Exchange ................................................................................. 9-16

9.3.5 Grease Replenishment for B- and T-Axis Speed Reducers and Gears ............. 9-17

9.3.5.1 Grease Replenishment.......................................................................... 9-17

9.3.5.2 Grease Exchange ................................................................................. 9-18

9.3.6 Notes for Maintenance ....................................................................................... 9-19

9.3.6.1 Battery Pack Connection....................................................................... 9-19

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

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

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

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

11.3 U-Axis Unit..................................................................................................................... 11-5

11.4 B-,T-Axes Unit ............................................................................................................... 11-7

11.5 Wrist Unit ....................................................................................................................... 11-9

HW0485739

MPL80

CAUTION

10 of 69

1 Product Confirmation

1.1 Contents Confirmation

1 Product Confirmation

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

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

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (Information for the content of optional goods is given separately):

157283-1CD

• Manipulator

• DX100

• Programing Pendant

• Manipulator Cable (between the DX100 and the Manipulator)

1-1

HW0485739

157283-1CD

THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

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

Label (Enlarged View)

(a) DX 100 (Front View) (b) Manipulator (Side View)

TRIPPED

RESET

OFF

X81

PROGRAMMING PENDANT

PROPERLY.

CHECK ALL THE DOOR LOCKS

NJ3005-1

AVERAGE

PEAK

kVA

INTERRUPT CURRENT

ERDR-

POWER SUPPLY

TYPE

DX100

kVA

3PHASE

NJ2960-1

60Hz

SERIAL No.

DATE

AC220V

MADE IN JAPAN

50/60HzAC200V

11 of 69

MPL80

1 Product Confirmation

1.2 Order Number Confirmation

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

Fig. 1-1: Location of Order Number Labels

1-2

HW0485739

MPL80

CAUTION

NOTE

12 of 69

2 Transport

157283-1CD

2 Transport

2.1 Transport Method

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

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

• Avoid excessive vibration or shock during transport.

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

2.1 Transport Method

• 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.

2-1

HW0485739

157283-1CD

Shipping bracket

Hexagon socket head cap screw M12 (8 screws)

Delivered with the manipulator

13 of 69

MPL80

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

2-2

HW0485739

MPL80

Delivered with the manipulator

Shipping bracket

Forklift claw entry

Pallet

Bolt M20 (8 bolts)

NOTE

14 of 69

157283-1CD

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

2.2 Shipping 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.

2-3

HW0485739

157283-1CD

WARNING

CAUTION

15 of 69

MPL80

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.

3-1

HW0485739

MPL80

16 of 69

157283-1CD

3 Installation

3.1 Installation 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.

3.2 Mounting Procedures for Manipulator Base

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

Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the manipulator 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)

3-2

HW0485739

157283-1CD

Flatness:

0.5mm or less

Hexagon head screw M20 (8 screws)

Manipulator base

Spring washer

Washer

Baseplate

Anchor bolt M20 or more

Baseplate

17 of 69

MPL80

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

3-3

HW0485739

MPL80

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.

Leveling is required

36250

350

200

100

200

JA Base bolt M24 X315mm

Weld after adjusting the installation

Manipulator base

Units: mm

Bolt B: Bolt M24 X 70 mm (4 bolts),Spring Washer, Flat Washer

18 of 69

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

157283-1CD

3-4

HW0485739

157283-1CD

19 of 69

MPL80

3 Installation

3.3 Protection Class

The protection class at the main part conforms to IP54 and that of wrist part is IP67.

3.4 Location

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

• Ambient Temperature: 0° to +45°C

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

• Free from dust, soot, 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)

[0.5G] or less)

• The flatness for installation is 0.5 mm or less

3-5

HW0485739

MPL80

WARNING

CAUTION

NOTE

5.5mm or more

Delivered with the manipulator

Bolt M8 (for grounding)

View A

20 of 69

4 Wiring

157283-1CD

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

4.1 Grounding

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

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.

4-1

HW0485739

157283-1CD

21 of 69

MPL80

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" 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.

4-2

HW0485739

+ 48 hidden pages