YASKAWA MOTOMAN-HP6 YR-HP6-A00 User manual

YASKAWA
YASKAWA MANUAL NO. HW0481893 2
MOTOMAN-HP6
INSTRUCTIONS
TYPE: YR-HP6-A00 (STANDARD SPECIFICATION)
YR-HP6-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-HP6 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.

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HW0481893
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-HP6.
• 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

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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 dam-
age 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

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• Before operating the manipulator, check that servo power is turned off
when the emergency stop buttons on the front door of the NX100 and
programing pendant are pressed.
When the servo power is turned off, the SERVO ON LED on the program-
ing 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 working 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 manipulator’s work envelope
and that you are in a safe location before:
- Turning on the NX100 power
- Moving the manipulator with the programing pendant
- Running check operations
- Performing automatic operations
Injury may result if anyone enters the working envelope of the manipulator during opera-
tion. Always press an emergency stop button immediately if there are problems.
The emergency stop button is located on the right of the front door of the NX100 and pro-
graming pendant.
WARNING
TURN

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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 programing pendant, and manipulator
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 programing pendant to the hook on the NX100 cabi-
net after use.
The programing 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 the Warning Labels in the
NX100 instructions before operating the manipulator.
Equipment Manual Designation
NX100 Controller NX100
NX100 Programing Pendant Programing Pendant
Cable between the manipulator and controller Manipulator Cable
CAUTION

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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 manipula-
tor. Prior to operating the manipulator, confirm the contents.
Nameplate
WARNINGlabelA
WARNINGlabelB
MOTOMAN
TYPE

ORDER NO.

PAYLOAD
 kg
MASS
 kg
SERIAL NO.

DATE

YASKAWA ELECTRIC CORPORATION
JAPAN
Nameplate:
WARNING
Moving parts
may cause
injury
WARNING
Do not enter
robot
work area.
WARNING label A:
WARNING label B:

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.1.2 Using a Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2 Shipping Bolts and Brackets . . . . . . . . . . . . . . . . . . . . . . . 2-3
3Installation
3.1 Installation of the Safeguarding . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . 3-2
3.2.1 Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3 Types of Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
3.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
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 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Dimensions and P-Point Maximum Envelope . . . . . . 5-3
5.5 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Dimensions and P-Point Maximum Envelope . . . . . . 1-3

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6Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
7System Application
7.1 Mounting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.2 Installation Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Internal User I/O Wiring Harness and Air Lines . . . . . 7-3
8Motoman Construction
8.1 Position of S-Axis Limit Switch . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9Maintenance and Inspection
9.1 Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-6
9.2.1 battery pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.2
Grease Replenishment/Exchange for S-Axis Speed Reducer . . . 9-7
Grease Replenishment
(Refer to " Fig. 28 S-Axis Speed Reducer Diagram ".) . . . . 9-8
Grease Exchange
(Refer to " Fig. 28 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. 29 L-Axis Speed Reducer Diagram ".) . . . . 9-9
Grease Exchange
(Refer to " Fig. 29 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. 30 U-Axis Speed Reducer Diagram ".) . . . 9-11
Grease Exchange
(Refer to " Fig. 30 U-Axis Speed Reducer Diagram ".) . . . 9-12
9.2.5 Grease Replenishment for R-Axis Speed Reducer . . . . . . . . 9-13
 For Application of Serial Numbers S3W120-5 to S3W120-6 . . . . 9-13
 For Application of Serial Numbers S3W120-7 to RH9520-3112 . . 9-14
 For Application of Serial Numbers RH9520-3121 and Over . . . . 9-15
9.2.6
Grease Replenishment for B- and T-Axes Speed Reducers . . . . 9-16
9.2.7 Grease Replenishment for T-Axis Gear . . . . . . . . . . . . . . . . . 9-17
9.2.8 Grease Replenishment for R-Axis Cross Roller Bearing . . . . 9-18

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9.2.9 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19
Wrist Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19
Battery Pack Connector (with CAUTION label). . . . . . . . . .9-19
10 Recommended Spare Parts
11 Parts List
11.1 S-axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 L-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.3 U-Axis Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.4 R-Axis Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

1.1 Contents Confirmation
1-1
HW0481893
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
• Programing Pendant
• Manipulator Cable (Between Manipulator and NX100)
• 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
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1.2 Order Number Confirmation
Check that the order number of the manipulator corresponds to the NX100. The order number
is located on a label as shown below.
Fig. 1 Location of Order Number Labels
(a) NX100 (Front View) (b) Manipulator (Top View)
Label(Enlarged view)
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER. No. 
Check that the manipulator
and the NX100 have the
same order number.
NX100
200V 50Hz
kVA 3PHASE220V 50/60Hz
NJ2484-1 MADEINJAPAN
DATE
SERIALNo.
ERCR-
TYPE
POWERSUPPLY
******
ORDERNO.
NJ1529
N
P
O
E
T
R
G
Y
C
M
S
E
E
SELECT
THEMANIPULATORANDTHECONTROLLER
SHOULDHAVESAMEORDERNUMBER.
PLAY
TEACH
REMOTE
WARNING
Donotopenthedoor
RESET
OFF
TRIPPED
ON
SERVO
POWER
S-
X+
S+
MAIN
MENU
R-
x
R+
x
ASSIST
COORD.
MULTI
DISPLAY
SWITCH
X-
yy
645
AUXILIARY
AUXILIARY
TIMER
1
WEAVING
COMPLETE
VOLTAGE CURRENT
2
WELD
COMPLETE
3
RETRUCT
DELETE
BACK
INSERT
NEXT
L+L-
R-
LOCK
INTER
WEAVING
START
7
+
R+
B+B-
z
T-
WELD
START
8
FEED
9
T ESTRUN
SHIFT
z
T+
EX-AXIS
SWITCH
ROBOT
SWITCH
-
SHIFT
Y+Y-
0
ENTER
CABCEK
INTER.
REF.
POINT
MODIFY
.
-
VOLTAGE CURRENT
SHORTCUT
MENU

2.1 Transporting Method
2-1
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2Transporting
2.1 Transporting 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 transporting.
Failure to observe this caution may adversely affect the performance as the system con-
sists of precision components.
• The weight of the manipulator is approximately 135kg including the shipping bolts and
brackets. Use a wire rope strong enough to withstand the weight.
• 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, fork-
lift, or other equipment. Failure to observe this instruction may result in injury.
CAUTION
NOTE

2.1 Transporting Method
2-2
HW0481893
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.
Be sure the manipulator is fixed with the shipping bolts and brackets before transporting, and
lift it in the posture as shown in " Fig. 2 Transporting Position ".
Fig. 2 Transporting Position
View A
Shipping bracket and
hexagon socket head cap screws
Hexagon socket head
cap screw M10
(2 screws)
Shipping bracket

2.2 Shipping Bolts and Brackets
2-3
HW0481893
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 a Forklift ". Insert claws under the pallet and lift it. The
pallet must be strong enough to support the manipulator. Transporting of the manipulator must
be performed slowly in order to avoid overturning or slippage.
Fig. 3 Using a Forklift
2.2 Shipping Bolts and Brackets
The manipulator is provided with a shipping bracket and 2 screws. (See Fig. 2 Transporting
Position").
Fig. 4 Shipping Bolts and Brackets
• The shipping bracket and screws are painted yellow.
• The shipping bracket is fixed with the hexagon socket head cap screw M10 (2 screws).
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.
Forklift claw entry
Pallet
Bolts M16 (4 bolts)
Front View Side View
Shipping bracket
Hexagon socket head
cap screw M10
(2 screws)
NOTE

3-1
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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 weight of the
manipulator. Also, it is necessary to consider countermeasures to pre-
vent the manipulator from falling.
Failure to observe these warnings may result in injury or damage.
• Do not install or operate a manipulator that is damaged or lacking 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 "Fig. 4 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 the Safeguarding
3-2
HW0481893
3.1 Installation of the Safeguarding
To insure safety, be sure to install safeguarding. They prevent unforeseen accidents with
personnel 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 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 as shown in "Table. 1 Maximum Repulsion Forces of the Manipulator
at Emergency Stop" and "Table. 2 Maximum Torque of Acceleration and Deceleration". If the
mounting face is out of plane, the manipulator shape may change and its functional ability
may be compromised. Out of the plane for installation must be kept at 0.5mm or less. Mount
the manipulator base as in the following way: " 3.2.1 Mounting Example ".
Table. 2 Maximum Torque of Acceleration and Deceleration
Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop
Horizontal rotating maximum torque
( S-axis moving direction)
2000N • m
(204kgf• m)
Vertical rotating maximum torque
(LU-axis moving direction)
3500N • m
(357kgf• m)
Horizontal maximum torque of
acceleration and deceleration
( S-axis moving direction)
450N • m
(46kgf • m)
Vertical maximum torque of acceler-
ation and deceleration
(LU-axis moving direction)
1300N • m
(132kgf • m)

3.2 Mounting Procedures for Manipulator Base
3-3
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3.2.1 Mounting Example
Fix the baseplate onto the floor. The baseplate should be rugged and durable to prevent
shifting of the manipulator or the mounting fixture. The thickness of the baseplate is 40mm or
more, and an M16 size or larger anchor bolt is recommended.
Fix the manipulator base onto the baseplate with the hexagon socket head cap screws M16
(mm). The plate is tapped for M16 (length: 50mm) screws. Tighten the screws and anchor
bolts securely so that they will not work loose during operation. See “Fig. 4 Mounting the
Manipulator Baseplate” for the method.
Fig. 5 Mounting the Manipulator Baseplate
40
or more
20
Manipulator base
Manipulator base
Anchor bolt M16 or more
Baseplate
Manipulator Base
Washer
Spring washer
Hexagon socket head cap screw
M16 (4 screws)
Baseplate
Units: mm
300
Baseplate
132 0.1
102 0.1
153 0.1
260
240
60
216 300 260
132 0.1
102 0.1
153 0.1
130 0.1
100 0.1
60
Tapped hole 18 dia.
(4 holes)
+0.018
0
12 dia.
16 dia.
(2 holes)
+0.018
0

3.3 Types of Mounting
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HW0481893
3.3 Types of Mounting
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
following points are different from the floor-mounted types.
• S-Axis Operating Range
• Fixing the Manipulator Base
• Precautions to Prevent the Manipulator from Falling
3.3.1 S-Axis Operating Range
For the wall-mounted type, the S-Axis movable range must be ±30°.
3.3.2 Fixing the Manipulator Base
For the wall- or ceiling-mounted types, be sure to use four hexagon socket head cap screws
M16 when fixing the manipulator base. Use a torque of 206N• m when tightening the bolts.
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. 6 When Using Ceiling- and Wall-Mounted Types
When using wall-mounted or ceiling-mounted types, contact your Yaskawa representative.
Manipulatorbase
Support
HexagonsocketheadcapscrewM16
(4screws)
(Tensilestrength:1200N/mm2orabove)
NOTE

3.4 Location
3-5
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3.4 Location
When installing the manipulator, it is necessary to satisfy the undermentioned environmental
conditions:
• Ambient Temperature: 0°to +45°C
• Humidity: 20 to 80%RH (non-condensing)
• Free from dust, soot, or water
• Free from corrosive gas or liquid, or explosive gas
• Free from excessive vibration (less than 4.9m/s2[0.5G])
• Free from large electrical noise (plasma)
• The flatness for installation is 0.5mm or less

4-1
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4Wiring
• Ground resistance must be 100 Ωor 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.
WARNING
CAUTION