YASKAWA MOTOMAN MPL80 II User manual

MANUAL NO.
HW1483299
Part Number: 175875-1CD
Revision: 0
MOTOMAN-MPL80 II
SUPPLEMENTAL INSTRUCTIONS
TYPE
YR-MPL0080-JF0 (FOR FOOD GRADE GREASE (DX200))
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MPL80 II INSTRUCTIONS
MOTOMAN-MPL80 II SUPPLEMENTAL INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

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MPL 80 II Food Grade
Grease
Copyright © 2016, 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, 2016
Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com

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Introduction
Introduction
This supplementary instruction manual describes how YR-MPL0080-JF0
(Food grade grease specification) is different from the YR-MPL0080-J00
(Standard).
In case of using YR-MPL0080-JF0, read this supplementary instruction
manual thoroughly with: "MOTOMAN-MPL80 II INSTRUCTIONS"
(170904-1CD).
Point of Difference
YR-MPL0080-JF0 differ from the YR-MPL0080-J00 in the following point:
(1)Food grade grease specification
• 3.4 Location (Page 3-5)
• 5.1 Basic Specifications (Page 5-1)
• 9.1 Inspection Schedule (Page 9-2 to 9-3)
• 9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
• 10 Recommended Spare Parts (Page 10-1)
The differences are described based on "MOTOMAN-MPL80 II
INSTRUCTIONS" (170904-1CD). Read this manual thoroughly replacing
the subject matters for changes with this supplementary instruction
manual.

3.4 Location (Page 3-5)
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3.4 Location (Page 3-5)
When installing a manipulator, it is necessary to satisfy the following
environmental conditions:
• Ambient Temperature: +15°C to +45°C
• Humidity: 20 to 80%RH (non-condensing)
• Free from dust, soot, oil, or water
• Free from corrosive gas or liquid, or explosive gas or liquid.
• Free from excessive vibration (4.9 m/s2[0.5G] or less)
• Free from large electrical noise (plasma)
• The flatness for installation is 0.5 mm or less

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5.1 Basic Specifications (Page 5-1)
5 Basic Specifications
5.1 Basic Specifications (Page 5-1)
Table 5-1: Basic Specifications1)
Item Model MOTOMAN-MPL80 II
Structure Vertically Articulated
Degree of Freedom 5
Payload 80 kg
Repeatability2) ±0.07 mm
Range of Motion S-Axis (turning) -180° − +180°
L-Axis (lower arm) -90° − +135°
U-Axis (upper arm) -160° − +35°
B-Axis (wrist pitch/yaw) -15° − +15°3)
T-Axis (wrist twist) -360° − +360°
Maximum Speed S-Axis 2.97 rad/s, 170°/s
L-Axis 2.97 rad/s, 170°/s
U-Axis 2.97 rad/s, 170°/s
B-Axis 2.97 rad/s, 170°/s
T-Axis 6.11 rad/s, 350°/s
Allowable Moment4) B-Axis 78.4 N•m (8 kgf•m)
T-Axis 20.5 N•m (2.1 kgf•m)
Allowable Inertia
(GD2/4)
B-Axis 16 kg•m2
T-Axis 6.1 kg•m2
Approx. Mass 550 kg
Protective Structure Basic axis: IP54 or equivalent
Wrist axis only: IP67 or equivalent
Ambient Conditions Temperature +15°C to 45°C
Humidity 20 to 80% RH at constant temperature
Vibration Acceleration Less than 4.9 m/s2(0.5 G)
Others Free from corrosive gas or liquid, or explosive gas.
Free from water, oil, or dust.
Free from excessive electrical noise (plasma).
Power Capacity 4.0 kVA
Noise5) 70 dB

5.1 Basic Specifications (Page 5-1)
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1 SI units are used in this table. However, gravitational unit is used
in ( ).
2 Conformed to ISO9283
3 The range of motion of the B-axis indicates the angle to the
ground. With certain postures, however, motion may be limited
by the relative angle between the B-axis and the upper arm.
Refer to section 5.5 “B-Axis Operating Range” .
4 Refer to section 6.1 “Allowable Wrist Load” for details on the
permissible moment of inertia.
5 Conformed to ISO6926
1, Measurement is carried out when the maximum load is
mounted to the manipulator and operated in the maximum
speed.
2, Measurement is carried out:
- between 1.2 m and 1.5 m above the ground.
- 400 mm away from the P-point maximum envelope.

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9.1 Inspection Schedule (Page 9-2 to 9-3)
DX100 Controller Maintenance
9.1 Inspection Schedule (Page 9-2 to 9-3)
Table 9-1: Inspection Items (Sheet 1 of 2)
Items1) Schedule Method Operation Inspection
Charge
Daily 1000HCycle 3000HCycle 9000HCycle 18000HCycle Specified Personnel Licensee Service Company
1 Alignment mark •Visual Check alignment mark accordance at the home position.
Check for damage. •••
2 External lead •Visual Check for damage and deterioration of leads. •••
3 Working area and
manipulator •Visual Clean the work area if dust or spatter is present. Check for damage and outside cracks. •••
4 S, L, U, B, T-axes motor •Visual Check for grease leakage.2) •••
5 Baseplate mounting bolts •Spanner
Wrench
Tighten loose bolts. Replace if necessary. •••
6 Cover mounting screws •Screwdriver,
Wrench
Tighten loose bolts. Replace if necessary. •••
7 S, L, U, B, T-axes motor
connector •Manual Tighten loose bolts. •••
8 Connector base •Manual Check for loose connectors. •••
9 Wire harness in
manipulator •Visual Multimeter Check for conduction between the main connecter of base and intermediate connector with manually shaking the wire.
Check for wear of protective spring3)
••
•Replace it 18000H intervals. •
10 Battery pack in
manipulator •Replace the battery pack when the battery alarm occurs or the manipulator drove for 18000H. ••
11 S-axis speed reducer •• Grease Gun Check for malfunction. (Replace if necessary.) 4)
Replace grease. (3000H cycle)5). See section 9.3.2.••

9.1 Inspection Schedule (Page 9-2 to 9-3)
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The numbers in the above table correspond to the numbers in Table 9-1 "Inspection Items"
12 LU-axes speed reducers •• Grease Gun Check for malfunction. (Replace if necessary.) 4)
Replace grease (3000H cycle)5). See section 9.3.3, section 9.3.4.••
13 B,T-axes speed reducers
B,T-axes gears •• Grease Gun Check for malfunction. (Replace if necessary.) 4) Replace grease (3000H cycle)5). See section 9.3.5, section 9.3.6.••
14 Overhaul ••
1 Inspection No. correspond to the numbers in Fig. 9-1 “Inspection Items”.
2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa
representative.
3 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the motor side for each axis, and then remove connectors on
detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer to section 9.4 “Notes for Maintenance”.)
4 The grease might leak out from the air breather or the internal pressure might rise in case the manipulator is used very frequently for the application such as handling.
5 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used".
Table 9-2: Inspection Parts and Grease Used
No. Grease Used Inspected Parts
13,14,15,16 Cassida Grease
EPS 00
Speed reducers for all axes
B,T-axes gears
Table 9-1: Inspection Items (Sheet 2 of 2)
Items1) Schedule Method Operation Inspection
Charge
Daily 1000HCycle 3000HCycle 9000HCycle 18000HCycle Specified Personnel Licensee Service Company

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9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
9.3.2 Grease Replenishment/Exchange for S-axis Speed Reducer
Fig. 9-4: S-axis Speed Reducer Diagram
9.3.2.2 Grease Exchange
(Refer to Fig. 9-4 “S-axis Speed Reducer Diagram”.)
1. Remove the hexagon socket head plug PT1/4 from the grease inlet
and the hexagon socket head plug PT3/8 from the grease exhaust
port.
2. Install the grease zerk PT1/4 to the grease inlet.
(The grease zerk is delivered with the manipulator.)
3. Inject the grease through the grease inlet using a grease gun.
– Grease type: Cassida Grease EPS 00
– Amount of grease: approx. 2600 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
4. The grease exchange is complete when new grease appears from the
exhaust port. (The new grease can be distinguished from the old
grease by color.)
5. Move the S-axis for a few minutes to discharge the excess grease.
6. Remove the grease zerk from the grease inlet and reinstall the
hexagon socket head plug PT 1/4.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 12 N•m
(1.2 kgf•m).
$,5
%&
%&
Grease exhaust port
Hexagon socket
head plug PT3/8
S-axis speed reducer
Grease inlet
Hexagon socket
head plug PT1/4
NOTE
• If grease is injected with the plugs on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
• Do not install a joint, a hose, etc. to a grease exhaust port.
Failure to observe this instruction may result in damage to
the motor due to coming off of an oil seal.

9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
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7. Wipe the discharged grease with a cloth and reinstall the hexagon
socket head plug PT 3/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
NOTE
If grease is injected with the plug on, the grease will leak
inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection

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9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
9.3.3 Grease Replenishment/Exchange for L-Axis Speed Reducer
Fig. 9-5: L-Axis Speed Reducer Diagram
9.3.3.2 Grease Exchange
(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram”.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
4. Install the grease zerk PT1/8 to the grease inlet.
(The grease zerk is delivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type: Cassida Grease EPS 00
– Amount of grease: approx. 1650 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
6. The grease discharge is complete when new grease appears from the
exhaust port. The new grease can be distinguished from the old
grease by color.
7. Move the L-axis for a few minutes to discharge the excess grease.
8. Wipe the discharged grease with a cloth and reinstall the hexagon
socket head plug PT3/8 to the exhaust port.
Before installing the plugs, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
Grease exhaust port
Hexagon socket head
plug PT3/8
Grease inlet
Hexagon socket
head plug PT1/8
L-axis speed reducer
NOTE
• If grease is injected with the exhaust plug on, grease will
leak inside the motor and may cause a damage. Make
sure to remove the plug before the grease injection.
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in
damage to the motor due to coming off of an oil seal.
NOTE
If grease is injected with the plug on, grease will leak inside
the motor and may cause a damage. Make sure to remove
the plug before the grease injection.

9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
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9. Remove the grease zerk from the grease inlet and reinstall the
hexagon socket head plug PT1/8 to the grease inlet.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

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9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
9.3.4 Grease Replenishment/Exchange for U-Axis Speed Reducer
Fig. 9-6: U-Arm Posture
Fig. 9-7: U-Axis Speed Reducer Diagram
9.3.4.2 Grease Exchange
(Refer to Fig. 9-7 “U-Axis Speed Reducer Diagram”.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
4. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
5. Inject grease through the grease inlet using a grease gun.
– Grease type: Cassida Grease EPS 00
– Amount of grease: approx.700 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
U-arm
U-axis speed reducer
Grease inlet
Hexagon socket head
plug PT1/8
Grease exhaust port
Hexagon socket head
plug PT3/8
NOTE
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt before the grease injection.
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in
damage to the motor due to coming off of an oil seal.

9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
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6. The grease discharge is complete when new grease appears from the
exhaust port. The new grease can be distinguished from the old
grease by color.
7. Move the U-axis for a few minutes to discharge the excess grease.
8. Wipe the discharged grease with a cloth and reinstall the hexagon
socket head plug PT3/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
9. Remove the grease zerk from the grease inlet and reinstall the
hexagon socket head plug PT1/8.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
NOTE
If grease is injected with the plug on, grease will leak inside
the motor and may cause a damage. Make sure to remove
the plug before the grease injection.

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9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
9.3.5 Grease Replenishment for B- and T-Axis Gears
Fig. 9-8: B- and T-Axis Gears Diagram
9.3.5.2 Grease Exchange
(Refer to Fig. 9-8 “B- and T-Axis Gears Diagram”.)
1. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
2. Remove the hexagon socket head plug PT1/8 from the grease inlet.
3. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
– Grease type: Cassida Grease EPS 00
– Amount of grease: approx.3500 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
5. The grease discharge is complete when new grease appears from the
exhaust port. The new grease can be distinguished from the old
grease by color.
6. Move the B-axis for a few minutes to discharge the excess grease.
7. Wipe the discharged grease with a cloth and reinstall the hexagon
socket head plug PT3/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 23 N•m
(2.3 kgf•m).
U-arm
Grease inlet
Exhaust port
Hexagon socket head
plug PT3/8
Hexagon socket head
plug PT1/8
NOTE
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt before the grease injection.
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in
damage to the motor due to coming off of an oil seal.
NOTE
If grease is injected with the plug on, grease will leak inside
the motor and may cause a damage. Make sure to remove
the plug before the grease injection.

9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
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Maintenance
8. Remove the grease zerk from the grease inlet and reinstall the
hexagon socket head plug PT1/8.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).

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9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
9.3.6 Grease Replenishment for B- and T-Axis Speed Reducers and Gears
Fig. 9-9: B- and T-Axis Speed Reducers and Gears Diagram
9.3.6.2 Grease Exchange
(Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears Diagram”.)
1. Remove the hexagon socket head plug PT1/8 from the grease
exhaust port.
2. Remove the hexagon socket head plug PT1/8 from the grease inlet.
3. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
4. Inject grease through the grease inlet using a grease gun.
– Grease type: Cassida Grease EPS 00
– Amount of grease: approx.1500 cc
– Air supply pressure of grease pump: 0.3 MPa or less
– Grease injection rate: 8 g/s or less
5. The grease discharge is complete when new grease appears from the
exhaust port. The new grease can be distinguished from the old
grease by color.
6. Move the B-axes for a few minutes to discharge the excess grease.
7. Wipe the discharged grease with a cloth and reinstall the hexagon
socket head plug PT1/8 to the exhaust port.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
Grease inlet
Hexagon socket head
plug PT1/8
T-axis speed reducer, gear
Exhaust port
Hexagon socket head
plug PT1/8
B-axis speed reducer, gear
NOTE
• If grease is injected with the bolt on, grease will leak inside
the motor and may cause a damage. Make sure to
remove the bolt before the grease injection.
• Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in
damage to the motor due to coming off of an oil seal.

9.3 Grease Replenishment/Exchange (Page 9-8 to 9-17)
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Maintenance
8. Remove the grease zerk from the grease inlet and reinstall the
hexagon socket head plug PT1/8.
Before installing the plug, apply Three Bond 1206C on the thread part
of each plug, then tighten the plug with a tightening torque of 4.9 N•m
(0.5 kgf•m).
NOTE
If grease is injected with the plug on, grease will leak inside
the motor and may cause a damage. Make sure to remove
the plug before the grease injection.

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Maintenance
10 Recommended Spare Parts (Page 10-1)
It is recommended to keep the parts and components in the following table
in stock as spare parts for the MOTOMAN-MPL80 II . Product
performance cannot be guaranteed when using spare parts from any
company other than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts
• Rank B: Parts for which replacement may be necessary as a result of
frequent operation
• Rank C: Drive unit
NOTE
For replacing parts in Rank B or Rank C, contact your
Yaskawa representative.
Table 10-1: Spare Parts for YR-MPL0080-J00
Rank Parts
No.
Name Type Manufacturer Qty Qty
per
Unit
Remarks
A 1 Grease Cassida Grease
EPS 00
Yaskawa 16 kg - For speed reducers
in each axis
A 2 Liquid Gasket Three Bond 1206C Three Bond Co.,
Ltd.
--
A 3 Battery Pack HW9470932-A Yaskawa 1 1 For internal wire
harness
replacement
A 4 Battery Pack HW0470360-A Yaskawa 1 1
B5 S-axis
Speed Reducers Kit
Y005C-MPL0080JF0S Yaskawa 1 1
B6 L-axis
Speed Reducers Kit
Y005C-MPL0080JF0L Yaskawa 1 1
B7 U-axis
Speed Reducers Kit
Y005C-MPL0080JF0U Yaskawa 1 1
B8 B-axis
Speed Reducers Kit
Y005C-MPL0080JF0B Yaskawa 1 1
B9 T-axis
Speed Reducers Kit
Y005C-MPL0080JF0T Yaskawa 1 1
C 10 S-Axis
AC Servomotor
SGMRV-30ANA-YR11
HW0388669-A
Yaskawa 1 1
C 11 L-Axis
AC Servomotor
SGMRV-37ANA-YR11
HW0388670-A
Yaskawa 1 1
C 12 U-Axis
AC Servomotor
SGMRV-13ANA-YR11
HW0388666-A
Yaskawa 1 1
C13B-,T-Axes
AC Servomotor
SGMRV-09ANA-YR11
HW0388665-A
Yaskawa 1 2
C 14 Internal Wire
Harness
HW1171901-A Yaskawa 1 1
C 15 Connector Base HW0374528-C Yaskawa 1 1
C 16 Board SGDR-EFBA02A Yaskawa 1 1

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone [phone] Fax [phone]
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone [phone] Fax [phone]
YASKAWA America Inc. (Motoman Robotics Division)
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone [phone] Fax [phone]
YASKAWA Nordic AB
Yaskawastrasse 1, 85391 Allershausen, Germany
Phone [phone] Fax [phone]
YASKAWA Europe GmbHRobotics Divsion )
9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone [phone] Fax [phone]
YASKAWA Electric Korea Co., Ltd
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone [phone] Fax [phone]
YASKAWA Electric (Singapore) PTE Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone [phone] Fax [phone]
YASKAWA SHOUGANG ROBOT Co. Ltd.
#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Fax [phone]Phone [phone]
YASKAWA India Private Ltd. (Robotics Division)
YASKAWA Electric (China) Co., Ltd.
22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone [phone] Fax 㸩86-21-5385-3299
YASKAWA Electric (Thailand) Co., Ltd.
59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone
[phone] Fax [phone]
12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Fax [phone]Phone [phone]
YASKAWA Electric Taiwan Corporation
Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Fax [phone]Phone [phone]
PT. YASKAWA Electric Indonesia
Specifications are subject to change without notice
for ongoing product modifications and improvements.
MANUAL NO.
HW1483299
MOTOMAN-MPL80 II
SUPPLEMENTAL INSTRUCTIONS