YASKAWA MOTOMAN-HP20 User manual

YASKAWA
YASKAWA
MANUAL NO. RE-MTO-A247 3
MOTOMAN-HP20
INSTRUCTIONS
TYPE: YR-HP20-A00 (STANDARD SPECIFICATIONS)
YR-HP20-A01 (WITH SLU-AXES LIMIT SWITCHES)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HP20 INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
149615-1CD
2

ii
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-HP20.
• General items related to safety are listed in the Section 1: Safety of the
NX100 Instructions. To ensure correct and safe operation, carefully
read the NX100 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 rep-
resentative 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 prod-
uct’s warranty.
MANDATORY
CAUTION

iii
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or inspection of the
NX100.
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.
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.
To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING.”
WARNING
CAUTION
MANDATORY
PROHIBITED
NOTE

iv
• Before operating the manipulator, check that servo power is turned OFF
when the emergency stop buttons on the front door of the NX100 and
programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the program-
ming 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.
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.
Release of Emergency Stop
• 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.
- 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 NX100 power.
- 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 prob-
lem.
The emergency stop buttons are located on the right of the front door of the NX100 and
the programming pendant.
WARNING
TURN

v
Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming pendant, and supply
cables.
In this manual, the equipment is designated as follows:
• Perform the following inspection procedures prior to conducting manip-
ulator 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 NX100 cabi-
net after use.
The programming pendant can be damaged if it is left in the P-point maximum envelope
of manipulator, on the floor, or near fixtures.
• Read and understand the Explanation of the Warning Labels in the
NX100 Instructions before operating the manipulator.
Equipment Manual Designation
NX100 Controller NX100
NX100 Programming Pendant Programming Pendant
Cable between the Manipulator and the Controller Manipulator Cable
CAUTION

vi
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 manipula-
tor. Prior to operating the manipulator, confirm the contents.
Warning label A Warning label B
Warning label B
Nameplate
WARNING
Do not enter
robot
work area.
WARNING
Moving parts
may cause
injury
Warning Label A:
Warning Label B:
Nameplate
WARNING
Donot enter
robot
workarea.
WARNING
Movingparts
maycause
injury
MADE IN JAPAN
YASKAWA ELECTRIC CORPORATION
Kitakyushu 806-0004 Japan
2-1 Kurosakishiroishi, Yahatanishi-ku,
SERIAL NO.
PAYLOAD
kg
TYPE
MASS
NJ3247
DATE
ORDER NO.
kg
MOTOMAN-
MODEL

vii
1Product Confirmation
1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . .1-2
2Transporting
2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.2 Using a Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2 Shipping Bolts and Brackets . . . . . . . . . . . . . . . . . . . . . . . .2-4
3Installation
3.1 Installation of Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . .3-2
3.2.1 Installation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.1 S-axis Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.2 Fixing the Manipulator Base . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.3 Precautions to Prevent the Manipulator from Falling. . . . . . . . .3-4
3.3.4 IP (International Protection) for Main Part of the Manipulator . .3-5
3.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
4Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2 Manipulator Cable Connection . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.2 Connection to the NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
5Basic Specifications
5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . .5-2
5.3 Manipulator Base Dimensions . . . . . . . . . . . . . . . . . . . . . .5-3
5.4 Dimensions and P-point Maximum Envelope . . . . . . . .5-4
5.5 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . .5-5

viii
6Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7System Application
7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 Installation Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Internal User I/O Wiring Harness and Air Line . . . . . . 7-2
8Electrical Equipment Specification
8.1 Position of Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9Maintenance and Inspection
9.1 Inspection Schedule
(Manipulator in the Home Position: Refer to “Fig.21.”) . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-5
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.2 Grease Replenishment/Exchange for S-axis Speed Reducer . 9-7
 Grease Replenishment (Refer to "Fig. 24 S-axis
Speed Reducer Diagram".). . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
 Grease Exchange
(Refer to "Fig. 24 S-axis Speed Reducer Diagram".) . . . . . 9-8
9.2.3 Grease Replenishment/Exchange for L-axis Speed Reducer . 9-9
 Grease Replenishment
(Refer to "Fig. 25 L-axis Speed Reducer Diagram".). . . . . . 9-9
 Grease Exchange
(Refer to "Fig. 25 L-axis Speed Reducer Diagram".). . . . . 9-10
9.2.4 Grease Replenishment/Exchange for U-axis Speed Reducer 9-11
 Grease Replenishment
(Refer to "Fig. 26 U-axis Speed Reducer Diagram".) . . . . 9-11
 Grease Exchange
(Refer to "Fig. 26 U-axis Speed Reducer Diagram".) . . . . 9-12
9.2.5 Grease Replenishment for R-axis Speed Reducer. . . . . . . . . 9-13
9.2.6 Grease Replenishment for B-, T-axes Speed
Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.2.7 Grease Replenishment for T-axis Gear . . . . . . . . . . . . . . . . . 9-15
9.2.8 Grease Replenishment for R-axis Cross Roller Bearing. . . . . 9-16
9.2.9 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

ix
 Wrist Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17
9.2.10 Encoder Connector (with CAUTION Label) . . . . . . . . . . . . .9-17
 Battery Pack Connection (for S-, L-, U-axes Motors) . . . . .9-17
 Battery Pack Connection (for R-, B-, T-axes Motors) . . . . .9-19
10 Recommended Spare Parts
11 Parts List
11.1 S-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
11.2 L-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.3 U-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5
11.4 R-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7
11.5 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9

1.1 Contents Confirmation
1-1
1Product 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
• NX100
• Programming pendant
• Manipulator cable
• Confirm that the manipulator and the NX100 have the same order num-
ber. 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.
CAUTION

1.2 Order Number Confirmation
1-2
1.2 Order Number Confirmation
Check that the order number of the manipulator corresponds to the NX100. The order num-
ber is located on a label as shown below.
Fig. 1 Location of Order Number Labels
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
Check that the manipulator
and the NX100 have the
same order number.
Label (Enlarged View)
(a) NX100 (Front View)
(b) Manipulator (Top View)
NX100
200V 50Hz
kVA 3PHASE220V 50/60Hz
NJ2484-1 MADEIN JAPAN
DATE
SERIALNo.
ERCR-
TYPE
POWERSUPPLY
******
ORDER NO.
NJ1529
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
WARNING
Do not open the door
RESET
OFF
TRIPPED
ON

2.1 Transporting Method
2-1
2Transporting
2.1 Transporting Method
2.1.1 Using a Crane
As a rule, when removing the manipulator from the package and moving it, a crane should be
used. The manipulator should be lifted using wire rope threaded through attached eyebolts.
Be sure the manipulator is fixed with shipping bolts and brackets before transportation, and lift
it in the posture as shown in "Fig. 2 Transporting Position".
• 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 transportation.
The system consists of precision components, so failure to observe this caution may
adversely affect performance.
• Check that the eyebolts are securely fastened.
• The mass of the manipulator is approximately 280 kg including the shipping bolts and
brackets. Use a wire rope strong enough to withstand the mass.
• Attached eyebolts are designed to support the manipulator mass. Do not use them for
anything other than transporting the manipulator.
• Be sure to mount the shipping bolts and brackets before transporting the manipulator.
(Refer to "Fig. 2 Transporting Position.")
• Avoid external force on the arm or motor unit when transporting the manipulator. Use
caution when using transporting equipment other than a crane or forklift to avoid injury.
CAUTION
NOTE

2.1 Transporting Method
2-2
Fig. 2 Transporting Position
F
E
A
B
D
Eyebolt M12 (2 eyebolts)
(Delivered with the manipulator)
View E
View F
C
Eyebolt M12 (2 eyebolts)
(Delivered with the manipulator)

2.1 Transporting Method
2-3
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. 3 Using the Forklift." Insert claws under the pallet and lift it. The
pallet must be strong enough to support the manipulator. Transportation of the manipulator
must be performed slowly in order to avoid overturning or slippage.
Fig. 3 Using the Forklift
Forklift claw entry
Pallet
Bolts M16 (4 bolts)

2.2 Shipping Bolts and Brackets
2-4
2.2 Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets at sections A and B. ("Fig. 2
Transporting Position")
• The brackets in the sections A and B are painted yellow.
• The section A is fixed with a hexagon socket head cap screw M8, and the section B is
fixed with two hexagon socket head cap screws M6.
• A rubber cushion is respectively wedged at the sections C and D.
Before turning ON the power, check to be sure that the shipping bolts, brackets, and rubber
cushions have been removed. The shipping bolts, brackets, and rubber cushions then
must be stored for future use, in the event that the manipulator must be moved again.
Enlarged View: Section A Enlarged View: Section C Enlarged View: Sections B and D
Parts Drawing for Section A Parts Drawing for Section B
Eyebolts M12 (2 eyebolts)
(delivered with the manipulator)
D
B
C
A
NOTE

3-1
3Installation
• Install the safeguarding.
Failure to observe this warning may result in injury or damage.
• Install the manipulator in a location where the manipulator’s tool or the
workpiece held by the manipulator will not reach the wall, safeguarding,
or NX100 when the arm is fully extended.
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.
• When mounting the manipulator on the ceiling or wall, the base section
must have sufficient strength and rigidity to support the mass of the
manipulator. Also, it is necessary to consider countermeasures to pre-
vent the manipulator from falling.
Failure to observe these warning may result in injury or damage.
• Do not install or operate the manipulator that is damaged or lacks parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the shipping bolts
and brackets explained in " 2.2 Shipping Bolts and Brackets " are
removed.
Failure to observe this caution may result in damage to the driving parts.
WARNING
CAUTION

3.1 Installation of Safeguarding
3-2
3.1 Installation of Safeguarding
To insure safety, be sure to install the safeguarding. It prevents unforeseen accidents with per-
sonnel and damage to equipment. The following is quoted for your information and guidance.
Responsibility for Safeguarding (ISO10218)
The user of a manipulator or robot system shall ensure that the safeguarding is provided and
used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safe-
guarding, 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 base or foundation strong enough to support
the manipulator and withstand repulsion forces during acceleration and deceleration.
Refer to "Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop" and
" Table. 2 Endurance Torque in Operation " to construct a solid foundation with the appropri-
ate thickness to withstand maximum repulsion forces of the manipulator.
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 described in " 3.2.1 Installation Example ".
Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop
Horizontal rotating maximum torque
(S-axis moving direction)
8000 Nm
(815 kgfm)
Vertical rotating maximum torque
(LU-axes moving direction)
5000 Nm
(510 kgfm)
Table. 2 Endurance Torque in Operation
Endurance torque in horizontal operation
(S-axis moving direction)
1700 Nm
(171 kgfm)
Endurance torque in vertical operation
(LU-axes moving direction)
3775 Nm
(385 kgfm)

3.2 Mounting Procedures for Manipulator Base
3-3
3.2.1 Installation Example
For the first process, anchor the baseplate firmly on the floor. The baseplate should have
enough rigidity, which is 32 mm or more in thickness. The size of the anchor bolt recom-
mended for the baseplate fixation is M16 or larger.
Next, fix the manipulator base to the baseplate. There are 4 mounting holes on the manipula-
tor base: securely fix the manipulator to the baseplate using 4 hexagon head screws M16 (60
mm long is recommended). Tighten the hexagon head screws and anchor bolts firmly so that
they will not be loosened during the operation. See "Fig. 4 Manipulator Installation Example"
for the method.
Fig. 4 Manipulator Installation Example
Baseplate
Spring washer
Bolt M16 (4 bolts)
Washer
Manipulator base
Baseplate
40 mm
or more
25
Manipulator base
Anchor bolt (M16 or larger)
Baseplate
18 dia. holes
(4 holes)
Manipulator Base
+0.018
0
12 dia. holes (2 holes)
375
60
335
± 0.1
200
313
375
335
±0.1
170±0.1
260
60
250
±0.1
200

3.3 Installation Method
3-4
3.3 Installation Method
The manipulator can be mounted in three different ways: floor-mounted (standard), wall-
mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the
three points listed below are different from the floor-mounted types.
• S-axis Operating Range
• Fixing the Manipulator Base
• Precautions to Prevent the Manipulator from Falling
• IP (International Protection) for Main Part of the Manipulator
3.3.1 S-axis Operating Range
For the wall-mounted type, the S-Axis operating range must be ±30 °. (Adjusted prior to the
shipment.)
3.3.2 Fixing the Manipulator Base
For the wall- or ceiling-mounted types, be sure to use 4 hexagon socket head cap screws M16
(tensile strength: 1200 N/mm
2
or more) to fix the manipulator base. Use a torque of 206 N  m
in tightening the screws.
3.3.3 Precautions to Prevent the Manipulator from Falling
For the wall- or ceiling-mounted types, take appropriate measures to avoid the falling of the
manipulator in case of emergency. Refer to "Fig. 5 When Using Ceiling and Wall-mounted
Types" for details.
Fig. 5 When Using Ceiling and Wall-mounted Types
(Tensile strength: 1200N/mm2)
Hexagon socket head cap screws M16 (4 screws)
Manipulator base
Preventive support from falling

3.4 Location
3-5
3.3.4 IP (International Protection) for Main Part of the
Manipulator
For wall-mounted or ceiling mounted types, environmental resistance for main part of the
manipulator does not conform to IP54; environmental resistance for IP65 is optionally avail-
able. However, the wrist part conforms to IP67.
3.4 Location
When the manipulator is installed, it is necessary to satisfy the undermentioned environmental
conditions:
• 0°to +45°C (ambient temperature)
• 20 to 80%RH (no moisture, at constant temperature)
• Free from dust, soot, or water
• Free from corrosive gases or liquid, or explosive gases
• Free from excessive impact or vibration (vibration acceleration: 4.9 m/s
2
[0.5 G] or less)
• Free from large electrical noise (plasma)
• The flatness for installation is 0.5 mm or less.
In case of using the wall-/ceiling-mounted type, inform Yaskawa of the matter when placing
an order. Be sure to contact Yaskawa representative (listed on the back cover of this
instruction manual) to execute a wall/ceiling installation on site.
NOTE