YASKAWA MOTOMAN MYS450L Manual

MYS450L
Operating and
Maintenance Instructions
MYS450L
Please read these instructions before operation and keep them for later
reference.
The operating instructions are only for internal use.
E1101000117GB01
Part Number: 160353-1CD
Revision: 0

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Reference list:
Documentnumber
List of modifications
Creation of
original
document
Modification in the original document
In section On page Date Author
E1101000117DE01 x 28.12.2010 REB
E1101000117GB01 translation 14.11.2011 REB

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E1101000117GB01 3
WARNING
This instruction manual is intended to explain mainly on the
mechanical part of the YASKAWA-MYS450L 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 safety precautions are described in section 1: Safety of the
NX100 Instructions. To ensure correct and safe operation, carefully
read the NX100 Instructions before reading this manual.
CAUTION
In order to illustrate details clearly, some drawings are shown with the
protective covers or shields removed. All protective covers and
shields must be mounted before the machine is operated.
The drawings and figures in this manual are representative
illustrations. Therefore, there may be differences between the
illustration and the delivered product.
YASKAWA Europe GmbH reserves the right to make technical
changes. These changes may include product improvements,
modifications or changes in specifications.
If a change is made, the manual number will also be revised.
If your copy of the operating instructions is damaged or lost, contact a
YASKAWA Europe GmbH representative to order a new copy. The
official representatives are listed on the last page. Please mention the
order number in your order. This is on the front of this manual.
YASKAWA Europe GmbH is not responsible for damage caused due
to unauthorized modification of the painting robot track. If any
impermissible modifications are made to the system and/or the robot,
all warranty claims, goodwill and liability claims will lapse!

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Notes for Safe Operation
Read this manual thoroughly before installation, operation, maintenance, or inspection of the
YASKAWA-MYS450L.
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 death or
serious injury to personnel. 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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WARNING
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 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 robot should not be used if the
emergency stop button does 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 robot.
Then switch on the control voltage.
Injury may result from unintentional or unexpected robot motion.
Figure 2: Release of emergency stop button
Take the following precautions when teaching jobs within the working area of the
robot:
If possible, always view the robot from the front.
Always follow the prescribed operating procedure.
Keep in mind the emergency response measures against the robot’s unexpected
motion toward you.
Ensure that you have a safe place to retreat to in case of emergency.
Wrong or unintended movement of the robot can lead to injuries.
Confirm that no person is present in the robot’s operating range and that you are in a
safe location before:
Turning ON the NX100 power.
Moving the robot with the programming pendant.
TURN

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Definition of Terms Used Often in This Manual
The YASKAWA robot is the YASKAWA industrial robot product.
The YASKAWA robot usually consists of the controller, the programming pendant, and supply
cables.
The components are designated as follows in this manual:
WARNING
Operating the system in the check mode.
Operating in automatic mode.
Injury may result if anyone enters the P-point maximum envelope of the robot
during operation. Always press an emergency stop button immediately if there
are problems.
The emergency stop button is located on the right of the programming pendant.
CAUTION
Perform the following inspection procedures prior to conducting manipulator
teaching. If you find any problems, correct them immediately and make sure
all other necessary measures have been taken.
Check for problems in robot movement.
Check for damage to insulation and sheathing of external wires.
Always return the programming pendant to the hook on the NX100 control
cabinet after use.
The programming pendant can be damaged if it is left in the robot'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 robot.
Unit Manual Designation
NX100 controller NX100
NX100 Programming Pendant Programming pendant
Supplying cable between robot and
control
Robot cable

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Table of Contents
1 Receiving................................................................................................................................ 8
1.1 Checking the Scope of Delivery...............................................................................................8
1.2 Location of the serial number .................................................................................................. 9
2 Transportation ..................................................................................................................... 10
2.1 Transporting Method.............................................................................................................. 10
3 Installation ............................................................................................................................ 12
3.1 Installation for Safeguarding .................................................................................................. 13
3.2 Mounting Procedures for robot Base ..................................................................................... 13
3.3 Location ................................................................................................................................. 17
4 Wiring.................................................................................................................................... 18
4.1 Grounding .............................................................................................................................. 18
4.2 Robot Cable Connection........................................................................................................ 19
5 Basic Specifications........................................................................................................... 22
5.1 Technical data ....................................................................................................................... 22
5.2 Part Names and Working Axes.............................................................................................. 24
5.3 Dimensions ............................................................................................................................ 26
5.4 Dimensions and P-point Maximum Envelope ........................................................................ 27
5.5 Motion Range Setting by Mechanical Stops .......................................................................... 28
6 Allowable Load .................................................................................................................... 34
6.1 Mounting an end effector ....................................................................................................... 34
7 System application .............................................................................................................. 36
7.1 Peripheral Equipment Mounts ............................................................................................... 36
7.2 Internal User I/O Wiring Harness & Air Lines......................................................................... 38
8 Electrical Equipment Specification .................................................................................... 40
8.1 Signal cable ........................................................................................................................... 40
8.2 Power cable ........................................................................................................................... 41
8.3 User cable.............................................................................................................................. 42
9 Maintenance and Inspection............................................................................................... 44
9.1 Inspection Schedule .............................................................................................................. 45
9.2 Maintenance procedures .......................................................................................................47
9.3 Greasing ................................................................................................................................ 54
9.4 Tightening the screws............................................................................................................ 55
9.5 Layout of Maintenance Parts ................................................................................................. 57
10 Spare Parts........................................................................................................................... 58
10.1 Recommended Spare Parts List ............................................................................................ 58

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1 Receiving
1.1 Checking the Scope of Delivery
Check 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):
●Robot
●NX100
●Programming pendant
●Robot cable (between manipulator and NX100)
CAUTION
Check whether the robot and the NX100 have the same article
number. Special care must be taken when more than one robot is to
be installed.
If the numbers do not match, robots may not perform as expected
and cause injury or damage.

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1.2 Location of the serial number
Verify whether the serial number of the programming pendant, the control and the robot
matches the information on your delivery note. The serial number can be found on a type
plate as shown below.
Figure 1: Location of Order Number Labels
S/N. 
PROPERLY.
CHECKALL THE DOOR LOCKS
NJ3005-1
kVA
kVA
ERDR-
Average
Peak
NJ3053-1
Kammerfeldstr.1,D-85391 Allershausen
Motoman
2-1Kurosaki Shiroishi Yahatanishi-Ku Kitakyushu-City Fukuoka 806-0004 Japan
YASKAWAElectric corporation
RobotSerial No.
RobotOrder No.
RobotType
Type
Date/Signature
SerialNo.
AC400/415/440 V
PowerSupply
PartNo.
MotomanDX100
with power ON.
WARNING
Do not open the door
High Voltage
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
< Example >

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2Transportation
2.1 Transporting Method
CAUTION
Sling and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may cause injury or damage.
Avoid excessive vibration or shock during transportation.
The system consists of precision components. Failure to observe this
caution may adversely affect performan
Check that the eyebolts are securely fastened.
The weight of the manipulator is
approximately 20 kg including the shipping bolts and
brackets. Use a wire rope strong enough to withstand the
weight.
Attached eyebolts are designed to support the robot
weight. do not use them for anything other than
transporting the manipulator.
Before transport, be sure to mount the shipping bolts and
brackets to the robot. (See "Figure 2: Transporting
Position")
With any transportation equipment, make sure to avoid
external force on the arm or motor unit when transporting
the robot
NOTE

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2.1.1 Using a Crane
As a rule, the robot should be lifted by a crane with two wire ropes when removing it from the
package and moving it. Be sure that the Robot is fixed with the shipping bolts and brackets
before transport, and lift it in the posture as shown in "Figure 2: Transporting Position".
Figure 2: Transporting Position
1Bolt M4 x 15, Washer M6
2Cable tie
3Mounting screws arm, M12 x 20
42 eyebolts M12, delivered with the robot
1
2
3
4

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3 Installation
WARNING
Install the safeguarding.
Failure to observe this warning may result in injury or damage.
Install the robot in a location where the fully extended arm and tool
will not reach the wall, safeguarding, or controller.
Failure to observe this warning may result in injury or damage.
Do not start the Robot or even turn ON the power before it is firmly
anchored.
The Robot may overturn and cause injury or damage.
When mounting the robot on the wall, the base section must have
sufficient strength and rigidity to support the weight of the robot. Also,
it is necessary to consider countermeasures to prevent the robot from
falling.
Failure to observe these warning may result in injury or damage.
CAUTION
Do not install or operate the robot 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 are removed.
Failure to observe this caution may result in damage to the driving
parts.

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3.1 Installation for Safeguarding
To ensure safe, be sure to install safeguarding. It prevents unforeseen accidents with
personnel and damage to equipment. Refer to the quoted clause for your information and
guidance.
Responsibility for Safeguarding (ISO10218)
The user of a robot or robot system shall ensure that safeguards are 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 robot Base
The robot should be firmly mounted on a baseplate or foundation strong enough to support
the robot and withstand repulsion forces during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand maximum repulsion
forces of the robot referring to "Table 1: Maximum Repulsion Forces".
A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness of installation
surface may deform the Robot shape and affect its functional abilities. Mount the Robot base
as described in "3.2.1 Mounting Example" at Page 13.
●The treaded holes for the robot base are M12. Use mounting bolts with specifications
conforming to ISO898-1 property class: 10.9 or 12.9
●The plate for the robot mounting face shoud be 20 mm thick ore more and made of steel to
reduce vibration. The surface roughness of the steel plate shoud be 25 µm or less.
●The table must be secured on the floor or wall to prevent it from moving.
●The robot must be installed horizontally.
●Level the robot horizontal and vertical direction.
3.2.1 Mounting Example
For the first process, anchor the base plate firmly to the ground. The baseplate should be
rugged and durable to prevent shifting of the robot or the mounting fixture. It is recommend to
prepare a base plate of 20 mm or more thickness, and anchor bolts of M16 or larger size.
Table 1:
Maximum Repulsion Forces
Position Condition
Max. Reaction torque on the horizontal plate 500 Nm
Max. Horizontal reaction force 1,500 Nm
Max. Vertical reaction force 1,200 Nm

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The Robot base is tapped for four mounting holes. securely fix the Robot base to the base
plate with four hexagon head bolts M12 (40 mm long is recommended). Next, fix the Robot
base to the base plate.
Tighten the hexagon head bolts and anchor bolts securely so that they will not work loose
during operation
Refer to "Figure 3: Mounting the robot".
1
2
3
4
20
+0,02
0
6
75±0,05
+0,012
0
Ø6 H7( )
55±0,05
110
8

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Figure 3:Mounting the robot
1. Secure the base to the floor with four bolts
14 screws M12 x 40
2 Sprirng washer
3Flat washer
4Hole
CAUTION
Install the floor mounted Robot with four or more people. The Robot
weights are as follows. Be careful not to get hands, fingers, or feet
caught and / or have equipment damaged by a fall of the Robot.
MYS450L: approx. 20 kg
Use bolts with specifications conforming to
ISO898-1, property class: 10.9 or 12.9
NOTE
1
2
3
4
20

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Figure 4:
2. Using nippers, cut off the wire tie binding the shaft and arm retaining bracket on the bas.
Figure 5:
14 screws M12 x 40
2 Sprirng washer
3Flat washer
4Hole
1screw: M4 X 15
Plane washer: M6
2Cable tie
3Arm mounting bolt: M12 x 20
4Eyebolt (Attached at shipment)
1
2
3
4

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3.3 Location
When installing a manipulator, it is necessary to satisfy the following environmental
conditions:
●Ambient temperature: 0° to +45°C
●Air humidity: 20 to 80% relative humidity (no condensation water)
●Free from dust, soot, or water
●Free from corrosive gas or liquid, or explosive gas
●Free from excessive vibration
(vibration acceleration: 4.9 m/s2[0.5 G] or less).
●Free from large electrical noise (plasma)
●Flatness for installation: 0.5 mm

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4 Wiring
4.1 Grounding
Observe the local regulations for the wire cross-section.
A ground wire of 6.0 mm2 or more is recommended.
Refer to
"Figure 6: Grounding Method" at Page 19 to connect the ground wire directly to the robot.
WARNING
Ground resistance must be 0.1 Ωor less.
Failure to observe this warning may result in a fire or an electric
shock.
Before wiring, make sure to turn OFF the main power supply, and put
up a warning sign. (e.g. DO NOT TURN THE POWER ON).
Failure to observe this warning may result in a fire or an electric
shock.
CAUTION
Wiring must be performed by authorized or certified personnel.
Failure to observe this warning may result in a fire or an electric
shock.
Never use this line sharing with other ground lines or
grounding electrodes for other electric power, motor
power, welding devices, etc.
Where metal ducts, metallic conduits, or distributing
racks are used for cable laying, grounding should be
performed in accordance with electrical installation
standards.
NOTE

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Figure 6: Grounding Method
4.2 Robot Cable Connection
There are two robot cables; an encoder cable and a power cable. (See "Figure 7: Robot
Cable Connection" at Page 20)
4.2.1 Connection to the Robot
Before connecting the cables to the robot, verify the numbers: X1 and X100 on both the
cables and the robot base connectors. First connect the X100 cable then X1.
4.2.2 Connection to the NX100
Before connecting the manipulator cables to the NX100, verify the numbers: X11 and X21 on
both the cable connectors on NX100 side and connectors on the NX100. First connect the
X21 cable then X11.
1 at least 6.0 mm²
2 Bolt M8 (for grounding), delivered with robot
1
2

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Figure 7: Robot Cable Connection
1 Power supply cable
2 Encoder cable
3 NX100
4 Robot
X21 X100
X11
X21 X11 X81
PP
1
2
3
34
4
3