YASKAWA ms80w User manual

MANUAL NO.
1
HW1480497
Part Number: 159328-1CD
Revision: 1
MOTOMAN-MS80W
INSTRUCTIONS
TYPE: YR-MS0080W-A00 (STANDARD SPECIFICATION)
TYPE: YR-MS0080W-A01
(WITH LIMIT SWITCHES FOR SLU-AXES SPECIFICATION)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MS80W INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 Operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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MANDATORY
• This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-MS80W for the application to
the actual operation and for proper maintenance and inspection. It
describes on safety and handling, details on specifications,
necessary items on maintenance and inspection, to explain
operating instructions and maintenance procedures. Be sure to
read and understand this instruction manual thoroughly before
installing and operating the manipulator.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 instructions before reading this manual.
CAUTION
• 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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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MS80W.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Even items described as “CAUTION” may result in a serious accident in
some situations. At any rate, be sure to follow these important items.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
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.
MANDATORY
Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED
Must never be performed.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as
“CAUTION” and “WARNING”.
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WARNING
• Before operating the manipulator, check that servo power is turned
off when the emergency stop buttons on the front door of the DX100
and programming pendant are pressed.
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 ON the servo power.
Injury may result from unintentional or unexpected manipulator motion.
TURN
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the P-point maximum
envelope of the manipulator and that you are in a safe location
before:
- Turning ON the DX100 power.
- Moving the manipulator with the programming pendant.
- Running check operations.
- Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop button is located on the right of front door of the
DX100 and the programming pendant.
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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:
CAUTION
• 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 DX100
cabinet after use.
The programming pendant can be damaged if it is left in the P-point
maximum envelope of the manipulator, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 instructions before operating the manipulator.
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
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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.
Figure 2: Warning Label Locations
Nameplate
Nameplate
WARNING Label B
WARNING Label A
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
Warning Label A
Warning Label B
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Table of Contents
1 Product Confirmation ...................................................................................................................... 1-1
1.1 Contents Confirmation ....................................................................................................... 1-1
1.2 Order Number Confirmation .............................................................................................. 1-2
2 Transport......................................................................................................................................... 2-1
2.1 Transport Method .............................................................................................................. 2-1
2.1.1 Using a Crane ...................................................................................................... 2-2
2.1.2 Using a Forklift...................................................................................................... 2-3
2.2 Shipping Bolts and Brackets.............................................................................................. 2-4
3 Installation....................................................................................................................................... 3-1
3.1 Installation of Safeguarding ............................................................................................... 3-2
3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2
3.2.1 Mounting the Manipulator on the Baseplate......................................................... 3-3
3.3 IP (International Protection)............................................................................................. 3-4
3.4 Location ............................................................................................................................. 3-4
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-1
4.2 Cable Connection .............................................................................................................. 4-2
4.2.1 Connection to the Manipulator.............................................................................. 4-2
4.2.2 Connection to the DX100 ..................................................................................... 4-2
5 Basic Specifications ........................................................................................................................ 5-1
5.1 Basic Specifications........................................................................................................... 5-1
5.2 Part Names and Working Axes.......................................................................................... 5-2
5.3 Manipulator Base Dimensions ........................................................................................... 5-2
5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-3
5.5 Alterable Operating Range ................................................................................................ 5-4
5.5.1 Necessary Parts ................................................................................................... 5-4
5.5.2 Notes on the S-Axis Mechanical Stopper Installation........................................... 5-5
5.5.3 Alteration of the S-Axis Pulse Soft Limit ............................................................... 5-6
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................ 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-2
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Table of Contents
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7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.2 Internal User I/O Wiring Harness and Air Lines for User’s System Applications ............... 7-2
8 Electrical Equipment Specification .................................................................................................. 8-1
8.1 Position of Limit Switch ...................................................................................................... 8-1
8.1.1 Specification of Limit Switch ................................................................................. 8-1
8.1.2 Location of Limit Switch ........................................................................................ 8-1
8.1.3 Setting of Operation Range .................................................................................. 8-2
8.1.3.1 S-Axis Operation Range.......................................................................... 8-2
8.1.3.2 L-Axis Operation Range .......................................................................... 8-2
8.2 Internal Connections .......................................................................................................... 8-3
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
9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer ............................. 9-8
9.3.1.1 Grease Replenishment ........................................................................... 9-8
9.3.1.2 Grease Exchange ................................................................................... 9-9
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-10
9.3.2.1 Grease Replenishment ......................................................................... 9-10
9.3.2.2 Grease Exchange ) ............................................................................... 9-11
9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-12
9.3.3.1 Grease Replenishment ......................................................................... 9-12
9.3.3.2 Grease Exchange ................................................................................. 9-13
9.3.4 Grease Replenishment/Exchange for R-Axis Speed Reducer ........................... 9-14
9.3.4.1 Grease Replenishment ......................................................................... 9-14
9.3.4.2 Grease Exchange ) ............................................................................... 9-15
9.3.5 Grease Replenishment/Exchange for B- and
T-Axis Speed Reducers and Gears .................................................................... 9-16
9.3.5.1 Grease Replenishment ......................................................................... 9-16
9.3.5.2 Grease Exchange ................................................................................. 9-17
9.3.6 Notes for Maintenance........................................................................................ 9-18
9.3.6.1 Battery Pack Connection ....................................................................... 9-18
10 Recommended Spare Parts........................................................................................................ 10-1
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Table of Contents
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 R-, B-, T-Axis Unit.......................................................................................................... 11-7
11.5 Wrist Unit ..................................................................................................................... 11-10
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1 Product Confirmation
1.1 Contents Confirmation
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1 Product Confirmation
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):
• Manipulator
• DX100
• Programming Pendant
• Manipulator cables (between the DX100 and the manipulator)
CAUTION
• 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.
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1.2 Order Number Confirmation
1.2 Order Number Confirmation
Check that the order number of the manipulator corresponds to the
DX100. The order number is indicated on a label as shown below.
Fig. 1-1: Location of Order Number Labels
X81
PROGRAMMINGPENDANT
Y
C
E
G
N
O
T
P
M
E
E
S
R
ON
TRIPPED
RESET
OFF
AVERAGE
PEAK
kVA
kA
INTERRUPTCURRENT
ERDR-
POWERSUPPLY
TYPE
DX100
kVA
3PHASE
NJ2960-1
60Hz
SERIALNo.
DATE
AC220V
MADEIN JAPAN
50/60HzAC200V
ORDERNO.
NJ1529
Motoman
No.
ORDER. No.
Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER. Check that the manipulator
and the DX100 have the
same order number.
(a) DX100 (Front View)
(b) Manipulator (Top View)
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2 Transport
2.1 Transport Method
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2 Transport
2.1 Transport Method
CAUTION
• Sling and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock during transport.
The system consists of precision components. Failure to observe this
caution may adversely affect performance.
NOTE
• Check that the eyebolts are securely fastened.
• The weight of the manipulator is approximately 610 kg
including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.
• The attached eyebolts are designed to support the
manipulator mass. Never use them for anything other
than transporting the manipulator.
• Mount the shipping bolts and brackets before transporting
the manipulator.
• Avoid putting external force on the arm of motor unit when
transporting by a crane, forklift, or other equipment.
Failure to observe this instruction may result in injury.
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2.1 Transport Method
2.1.1 Using a Crane
As a rule, the manipulator should be lifted by a crane with a four-leg bridle
sling using the shipping bolts and brackets when removing it from the
package 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 Transport Using a Crane.
Fig. 2-1: Transport Using a Crane
Shipping bolts and bracket
(Fixed to the manipulator
before shipment.)
Hexagon socket head cap
screw M12 (8 screws)
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2 Transport
2.1 Transport Method
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2.1.2 Using a Forklift
When using a forklift, the manipulator should be fixed on a pallet with
shipping bolts and brackets as shown in
Fig.2-2 Transport Using a Forklift.
Insert forks under the pallet and lift it. The pallet must be strong enough to
support the manipulator. Transport the manipulator slowly with due
caution in order to avoid overturning or slippage.
Fig. 2-2: Transport Using a Forklift
Shipping bolts and bracket
(Fixed to the manipulator
before shipment.)
Bolt M20 (8 bolts)
Pallet
Forklift fork entries
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2.2 Shipping Bolts and Brackets
2.2 Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets at positions
shown in Fig. 2-1 Transport Using a Crane on page 2-2.
• The shipping bolts and brackets are painted yellow.
• Refer to the following table for the shipping bolts and brackets fixing
screws.
Table 2-1: Shipping Bolts and Brackets Fixing Screws
Shipping Bolts and
Bracket Qty. Shipping Bolts and Bracket Fixing Screw Specification Fixing Screw Qty.
2 Hexagon Socket Head Cap Screw M12
(length: 25 mm)
(Tensile strength: 1200N/mm2)
4 screws x
2 places
NOTE
Before turning ON the power, check to be sure that the
shipping bolts and brackets are removed. The shipping
bolts and brackets then must be stored for future use, in the
event that the manipulator must be moved again.
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3 Installation
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3 Installation
WARNING
• Install the safeguarding.
Failure to observe this warning may result in injury or damage.
• Install the manipulator in a location where the tool or the workpiece
held by its fully extended arm will not reach the wall, safeguarding,
or controller.
Failure to observe this warning may result in injury or damage.
• Do not start the manipulator or even turn ON the power before it is
firmly anchored.
The manipulator may overturn and cause injury or damage.
CAUTION
• Do not install or operate a manipulator that is damaged or lacks
parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the shipping
bolts and brackets explained in Chapter 2.2 Shipping Bolts and
Brackets on page 2-4 are removed.
Failure to observe this caution may result in damage to the driving
parts.
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3.1 Installation of Safeguarding
3.1 Installation of Safeguarding
To insure safety, be sure to install the safeguarding. They prevent
unforeseen accidents with personnel and damage to equipment. The
following is quoted for your information and guidance.
Responsibility for Safeguarding (ISO 10218)
The user of a manipulator or robot system shall ensure that safeguarding
is provided and used in accordance with Sections 6, 7, and 8 of this
standard. The means and degree of safeguarding, including any
redundancies, shall correspond directly to the type and level of hazard
presented by the robot system consistent with the robot application.
Safeguarding may include but not be limited to safeguarding devices,
barriers, interlock barriers, perimeter guarding, awareness barriers, and
awareness signals.
3.2 Mounting Procedures for Manipulator Base
The manipulator should be firmly mounted on a baseplate or foundation
strong enough to support the manipulator and withstand 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 Force 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 bases as instructed in Section
3.2.1 “Mounting the Manipulator on the Baseplate” on page 3-3.
Table 3-2: Endurance Torque in Operation
Table 3-1: Maximum Repulsion Force of the Manipulator at Emergency
Stop
Maximum torque in horizontal rotation
(S-axis moving direction)
24500 N•m
(2500 kgf•m)
Maximum torque in vertical rotation
(L-,U-axes moving direction)
45080 N•m
(4600 kgf•m)
Endurance torque in horizontal operation
(S-axis moving direction)
6125N•m
(625 kgf•m)
Endurance torque in vertical operation
(L-,U-axes moving direction)
11270 N•m
(1150 kgf•m)
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3 Installation
3.2 Mounting Procedures for Manipulator Base
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3.2.1 Mounting the Manipulator on the Baseplate
For the first process, anchor the baseplate firmly to the ground. The
baseplate should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. It is recommend to prepare a
baseplate of 50 mm or more thick, and anchor bolts of M20 or larger size.
The manipulator base is tapped for eight mounting holes; securely fix the
manipulator base to the baseplate with eight hexagon head screws M20
(70 mm long is recommended).
Next, fix the manipulator base to the baseplate. Tighten the hexagon
head bolts and anchor bolts firmly so that they will not work loose during
the operation.
Refer to Fig.3-1 Mounting the Manipulator on the Baseplate.
Fig. 3-1: Mounting the Manipulator on the Baseplate
3050
Hexagon head cap screw
M20 (8 screws)
Spring washer
Washer
Manipulator base
Baseplate
Baseplate
Anchor bolt (M20 or more)
Flatness: 0.5mm or less
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3.3 IP (International Protection)
3.3 IP (International Protection)
For the standard type, environmental resistance for main part of the
manipulator conforms to IP54; the wrist part conforms to IP67.
3.4 Location
When installing a manipulator, it is necessary to satisfy the following
environmental conditions.
• Ambient temperature: 0to 45C
• Humidity: 20 to 80%RH (no-condensing)
• Free from exposure to dust, soot, oil, or water.
• Free from corrosive gas or liquid, or explosive gas or liquid
• Free from excessive vibration (Vibration acceleration: 4.9 m/s2
[0.5 G] or less)
• Free from large electrical noise (plasma)
• Flatness for installation is 0.5 mm or less
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4 Wiring
4.1 Grounding
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4 Wiring
4.1 Grounding
Follow electrical installation standards and wiring regulations for
grounding. A ground wire of 5.5 mm2or more is recommended.
Refer to Fig. 4-1 Grounding Method on page 4-1 to connect the ground
line directly to the manipulator.
Fig. 4-1: Grounding Method
WARNING
• Ground resistance must be 100 or less.
Failure to observe this warning may result in fire or electric shock.
• Before wiring, make sure to turn OFF the primary power supply, and
put up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
• Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
NOTE
• 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.
View A
Bolt M8 (for grounding)
(Delivered with the manipulator)
5.5mm2or more
A
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