YASKAWA MOTOMAN-MPL100 User manual

MANUAL NO.
3
HW0485652
Part Number: 157569-1CD
Revision: 4
MOTOMAN-MPL100
INSTRUCTIONS
TYPE:
YR-MPL0100-A00 (STANDARD SPECIFICATION)
YR-MPL0100-A04 (WITH BUILT-IN TUBE FOR FIELDBUS CABLE)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MPL100 INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENACE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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Copyright © 2018, 2011 Yaskawa America, Inc.
Terms of Use and Copyright Notice
All rights reserved. This manual is freely available as a service to Yaskawa
customers to assist in the operation of Motoman robots, related equipment
and software This manual is copyrighted property of Yaskawa and may
not be sold or redistributed in any way. You are welcome to copy this
document to your computer or mobile device for easy access but you may
not copy the PDF files to another website, blog, cloud storage site or any
other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2011
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
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MANDATORY
• This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-MPL100 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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We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: [phone]
FAX: [phone]
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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MPL100 Notes for Safe Operation
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MPL100.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“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
DANGER
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
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
personnelanddamagetoequipment.
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 “DANGER”,
“WARNING” and “CAUTION”.
DANGER
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your YASKAWA representative.
• Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.
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Notes for Safe Operation
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WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons.
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
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 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.
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MPL100 Definition of Terms Used In this Manual
Definition of Terms Used 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:
Description of the Operation Procedure
In the explanation of the operation procedure, the expression “Select • • •”
means that the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
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.
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 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:
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
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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 3: Warning Label Locations
WARNING label A
WARNING label B
Nameplate
WARNING
Moving parts
may cause
injury
WARNING Label A:
WARNING Label B:
Nameplate
WARNING
Do not enter
robot
work area.
WARNING
Donot enter
robot
workarea.
MADE IN JAPAN
YASKAWA ELECTRIC CORPORATION
Kitakyushu 806-0004 Japan
2-1 Kurosakishiroishi, Yahatanishi-ku,
SERIAL NO.
PAYLOAD kg
TYPE
MASS
DATE
ORDER NO. kg
MOTOMAN-
MODEL
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MPL100 Safeguarding Tips
Safeguarding Tips
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General
safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
Mechanical Safety Devices
The safe operation of this equipment is ultimately the users responsibility.
The conditions under which the equipment will be operated safely should
be reviewed by the user. The user must be aware of the various national
codes, ANSI/RIA R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
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Programming, Operation, and Maintenance Safety
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Programming, Operation, and Maintenance Safety
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. Improper operation can result in personal injury and/or
damage to the equipment. Only trained personnel familiar with the
operation, manuals, electrical design, and equipment interconnections of
this equipment should be permitted to program, or maintain the system.
All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• Inspect the equipment to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Check the E-Stop button on the operator station for proper operation
before programming. The equipment must be placed in Emergency
Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot! Do not make any
modifications to the controller unit. Making any changes without the
written permission from Yaskawa will void the warranty.
• Some operations require standard passwords and some require
special passwords.
• The equipment allows modifications of the software for maximum
performance. Care must be taken when making these modifications.
All modifications made to the software will change the way the
equipment operates and can cause severe personal injury or death,
as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
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MPL100 Maintenance Safety
Maintenance Safety
Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by Yaskawa-
trained, qualified personnel.
Summary of Warning Information
This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notes.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by Yaskawa. Address any questions regarding the safe and proper
operation of the equipment to Yaskawa Customer Support.
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Customer Support Information
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Customer Support Information
If you need assistance with any aspect of your MPL100 system, please
contact YASKAWA Customer Support at the following 24-hour telephone
number:
For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:
When using e-mail to contact YASKAWA Customer Support, please
provide a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please have the following information ready before you call Customer
Support:
[email protected]
NOTE
Please use e-mail for routine inquiries only. If you have an
urgent or emergency need for service, replacement parts,
or information, you must contact YASKAWA Customer
Support at the telephone number shown above.
• System MPL100
• Robots ___________________________
• Primary Application ___________________________
• Controller DX100
• Software Version Access this information on the
Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX100 controller
data plate
[phone]
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MPL100 Table of Contents
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
2.2 Shipping Bolts and Brackets..............................................................................................2-3
3 Installation.......................................................................................................................................3-1
3.1 Safeguarding Installation...................................................................................................3-2
3.2 Mounting Procedures for Manipulator Base ......................................................................3-2
3.2.1 Mounting Example................................................................................................3-3
3.3 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 T-Point Maximum Envelope....................................................................5-3
5.5 Alterable Operating Range................................................................................................5-4
5.5.1 Components for Altering Operating Range .......................................................... 5-5
5.5.2 Notes on the Mechanical Stopper Installation......................................................5-6
5.5.3 Adjustment of the Soft Limit of the S-Axis Pulse..................................................5-7
6 Allowable Load for Wrist Axis and Wrist Flange.............................................................................6-1
6.1 Allowable Wrist Load.........................................................................................................6-1
6.2 Wrist Flange.......................................................................................................................6-3
6.3 Levelness of the Wrist Flange ...........................................................................................6-4
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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 Line...................................................................7-2
8 Electrical Equipment Specification..................................................................................................8-1
8.1 Position 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....................................................................................9-7
9.2.1 Battery Pack Replacement...................................................................................9-7
9.3 Notes on Grease Replenishment/Exchange Procedures ..................................................9-9
9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer and Gear ...........9-10
9.3.1.1 Grease Replenishment..........................................................................9-10
9.3.1.2 Grease Exchange..................................................................................9-11
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................9-12
9.3.2.1 Grease Replenishment..........................................................................9-13
9.3.2.2 Grease Exchange..................................................................................9-14
9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer...........................9-16
9.3.3.1 Grease Replenishment..........................................................................9-16
9.3.3.2 Grease Exchange..................................................................................9-17
9.3.4 Grease Replenishment/Exchange for T-Axis Speed Reducer............................9-18
9.3.4.1 Grease Replenishment..........................................................................9-18
9.3.4.2 Grease Exchange..................................................................................9-19
9.3.5 Grease Replenishment for U-axis Cross Roller Bearing ....................................9-20
9.3.6 Grease Replenishment for Links ........................................................................9-21
9.3.7 Notes for Maintenance........................................................................................9-23
9.3.7.1 Battery Pack Connection.......................................................................9-23
10 Recommended Spare Parts........................................................................................................10-1
11 Parts List.....................................................................................................................................11-1
11.1 S-Axis Unit.....................................................................................................................11-1
11.2 L-Axis Unit......................................................................................................................11-4
11.3 U-Axis Unit.....................................................................................................................11-8
11.4 Wrist Unit .....................................................................................................................11-10
11.5 Balancer Unit ...............................................................................................................11-13
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MPL100 1 Product Confirmation
1.1 Contents Confirmation
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 are 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 Product Confirmation
1.2 Order Number Confirmation
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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
PROPERLY.
CHECKALL THE DOOR LOCKS
NJ3005-1
AVERAGE
PEAK
kVA
kA
INTERRUPTCURRENT
ERDR-
POWERSUPPLY
TYPE
DX100
kVA
3PHASE
NJ2960-1
60Hz
SERIALNo.
DATE
AC220V
MADEINJAPAN
50/60HzAC200V
PROGRAMMINGPENDANT
Y
C
E
G
N
O
T
P
M
E
E
S
R
ON
TRIPPED
RESET
OFF
THE MANIPULATORAND 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) DX100 (Front View) (b) Manipulator (Side View)
WARNING
Do not open the door
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MPL100 2 Transport
2.1 Transport Method
2 Transport
2.1 Transport Method
CAUTION
• 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.
NOTE
• The weight of the manipulator is approximately 1750kg
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 or other equipment. Failure to
observe this instruction may result in injury.
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2 Transport
2.1 Transport Method
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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
25°
45°
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MPL100 2 Transport
2.2 Shipping Bolts and Brackets
2.2 Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets at positions
A, B, and C. (See Fig. 2-1 “Transporting Position”.)
• The shipping bolts and brackets are painted yellow.
Fig. 2-2: Shipping Bolts and Brackets
Position Screw Type Pcs
A Hexagon socket head cap screw M20 8
B and C Hexagon socket head cap screw M10 4
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.
C
A
B
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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 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 Fig. 2-2 “Shipping Bolts and
Brackets” are removed.
Failure to observe this caution may result in damage to the driving
parts.
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