YASKAWA Smart Series User manual

Part Number: 188791-1
Revision: 0
YASKAWA SMART SERIES
HC10DT COLLABORATIVE ROBOT
QUICK START GUIDE
WITH SMART PENDANT AND YRC1000micro
Upon delivery of the product and prior to operation, read all included instructions thoroughly, and
retain for future reference.

ii
188791-1
188791-1
Copyright
Smart Series HC10DT
Collaborative Robot
Copyright
Copyright © 2019, 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 the 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, 2019
YASKAWA America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]
www.motoman.com
Notes for Safe Operation
Read all included manuals carefully before installing, operating,
maintaining, or inspecting the system.
In this instruction, Safe Operations are classified as “DANGER”,
“WARNING”, “CAUTION” or “NOTICE”.
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or bland names for each company or
corporation. The indications of ® and TM are omitted.
DANGER Indicates an imminently hazardous
situation which, if not avoided, WILL
result in death or serious injury.
WARNING Indicates a potentially hazardous
situation which, if not avoided, MAY
result in death or serious injury.
CAUTION Indicates a hazardous situation,
which if not avoided, MAY result in
minor to moderate injury.
CAUTION Indicate a situation which if not
avoided may result in equipment
damage.
NOTICE Indicates practices not related to
personal injury.

1-1
188791-1
188791-1
1 General Information
1.1 Introduction
Smart Series HC10DT
Collaborative Robot
1 General Information
1.1 Introduction
This is a YASKAWA Smart Series HC10DT Collaborative Robot Quick
Start Guide for Robots that have Smart Pendant Version 1.3.5 and newer.
This document is intended to guide the user through a basic installation
and setup of the Robot and the user to perform basic moves to confirm
setup was successful. A complete set of manuals is provided and are to
be reviewed by all working with or near the Robot.
1.2 Safety
Before installing and powering on the Robot, be sure to read and
understand all safety information. Refer to the safety sections of all
included manuals. All YASKAWA manuals are included on a USB.
1.3 Robot Assembly
Fig. 1-1: Robot Assembly Includes:
1.4 Training
YASKAWA recommends users complete the free online courses listed
below before proceeding to the next sections:
– HC10 w/wo DT YRC1000micro Controller w/ Smart Pendant
– Intro to Robotics
– Yaskawa Safety Principles
1.4.1 How to Access Free Online Training
1. Go to “YASKAWA Academy Catalog”
https://yaskawaacademy.myabsorb.com/#/catalog/
2. Press the {$0.00} located underneath each of the desired courses to
add them to the “Cart”
3. Review the items in the Cart and press {Proceed to Checkout}
4. Follow instructions to “Sign In” or “Sign Up”
• An activation link is sent to the email address on file, if signing up for
the first time
5. Enrolled courses can be found in “My Courses” on the dashboard, or
at https://yaskawaacademy.myabsorb.com/#/courses
6. Use {Start} to begin the course
Smart Pendant
Manipulator
YRC1000micro
USB
Ｒｏｂｏｔ Ｍａｎｕａｌ
READ ONLY MEMORY
Ｒ
ｂ
Ｍ
ｌ
Ｒｏｂｏｔ Ｍａｎｕａｌ
Ｒ
ｂ
ｔ
Ｍ
ｌ
Base I/O
Cable
25
13
14
1
1 2 3 4 5 6 7 8 9 10 11 12 13
XXXXXX
CN3
3
1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 2021 22 23 24
XXXXXX
2526
CN4
3
Terminal Blocks for Safety I/O (Left)
General Purpose I/O (Right)
CN3 Safety Cable
CN4 GPIO Cable
Switch/Lamp
Cable
Torque Sensor
Cable
Manipulator
Cable

2-1
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.1 Transportation
Smart Series HC10DT
Collaborative Robot
2 Setup HC10DT Smart Series Robot
2.1 Transportation
.
2.1.1 Manipulator
2.1.1.1 Using Crane
Remove the plastic cover between the R and U axis to install the included
hardware to lift and transport.
Refer to Chapter 2 Transporting in the MOTOMAN-HC10DT
INSTRUCTIONS, for transportation instructions.
Fig. 2-1: Lift Connections with Crane
2.1.2 Controller
The Controller can be moved manually with a forklift or a platform truck.
Refer to Chapter 3 Installation in the YRC1000micro INSTRUCTIONS, for
detailed instructions for transporting.
CAUTION
• Use at least two people to transport and unpack the Manipulator
and Controller to the installation location
• Do not transport the Manipulator and Controller at the same time.
Not following these CAUTIONs can result in injury and/or equipment
damage.
Factory setting for angle and pulse of each axis
Axis
Angle
Pulse
S
0°
0
L
0°
0
U
0°
0
R
0°
0
B
0°
0
T
0°
0
indicates the position of
the center of gravity.
Hexagon socket head cap screw M8
(length: 25 mm)(2 screws)
Conical spring washer M8 (2 washers)
Tightening torque: 24.5 N•m (2.5 kgf•m)
(130)
(454)
(34)
(541)
(301)
HW1307411-1 (shipping bolts and brackets)
(265)
Casing cover
Screw (provided with the cover)
Tightening torque:
1.2 N•m (0.12 kgf•m)
(1125)
CAUTION
• Hold the Controller firmly from the bottom if moving manually.
Not holding the Controller firmly from the bottom can damage the
Controller.

2-2
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.2 Manipulator Installation
Smart Series HC10DT
Collaborative Robot
2.2 Manipulator Installation
Attach the Manipulator base to the baseplate using four hexagon socket
head cap screws M12 (Tensile strength: 1200 N/mm2 or more,
recommended length: 45 mm) by tightening to 84 Nm. The hexagon
socket head cap screws and the anchor bolts must be tightened firmly so
they do not loosen over time.
Refer to section 3.2 Mounting Procedures for Manipulator Base in the
MOTOMAN-HC10DT INSTRUCTIONS.
Fig. 2-2: Installing Manipulator Base and Baseplate
Anchor bolt (M12 or larger)
Baseplate
67.5 ±0.1
195 ±0.1
67.5 ±0.1
97.5 ±0.197.5 ±0.1
195 ±0.1
(Reference hole)
Baseplate
8 dia. (2 holes)
+ 0.015
0
14 dia. hole for mounting (4 holes)
1632 or longer
Hexagon socket head cap
screw M12 (4 screws)
Conical spring washer
Washer
measurements in mm

2-3
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.3 Controller Installation
Smart Series HC10DT
Collaborative Robot
2.3 Controller Installation
The Controller can be installed in a 19 inch server rack with compatible
hardware (not included).
Refer to chapter 3 Installation in the YRC1000micro INSTRUCTIONS for
detailed instructions on Controller installation.
Fig. 2-3: Controller Dimensions
CUSTOMER
SUPPORT
(Back View) (Front View)
(Top View)
425W x 188H x 405D

2-4
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.4 Wiring Robot
Smart Series HC10DT
Collaborative Robot
2.4 Wiring Robot
2.4.1 Reference Material
Refer to the following manuals for detailed wiring instructions:
–READ FIRST!! YRC1000micro GPIO and Direct IN Connections
–Section 1.5.2 Connecting to the YRC1000micro of the YRC1000/
YRC1000micro INSTRUCTIONS FOR Smart Pendant
–Chapter 2 Connections of the YRC1000micro SUPPLEMENTARY
INSTRUCTIONS FOR HC10/HC10DT
–Chapter 4 Wiring of the MOTOMAN-HC10DT INSTRUCTIONS
2.4.2 Basic Wiring Overview
Fig. 2-4: Basic Wiring

2-5
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.4 Wiring Robot
Smart Series HC10DT
Collaborative Robot
2.4.2.1 Controller Detailed Connectors
– The Pendant connects to the bottom section of the Controller as shown
in Fig. 2-4.
– General Purpose I/O (GPIO) connects to the top section of the
Controller and the Safety I/O connects to the bottom section of the
Controller (see Fig. 2-4). Refer to the READ FIRST!! YRC1000micro
GPIO and Direct IN Connections for more details.
Fig. 2-5: Controller Connections
2.4.2.2 Manipulator Detailed Connectors
– Uses four cables:
• 1BC - encoder and axis (Manipulator) cable.
• SW - switch/lamp (collaborative button power & signal) cable.
• TQ - torque sensor (Torque sensor power & data) cable.
• S - Base I/O (using I/O through the arm) cable. For more information,
refer to Fig. 2-7.
Fig. 2-6: Manipulator Connections
SW
1BC TQ
S

2-6
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.4 Wiring Robot
Smart Series HC10DT
Collaborative Robot
Fig. 2-7: Base I/O Cable Assembly
WIRE SIDE SHOWN
2:1
18 19 20
1
2
14
11 12 13
3 4
10 17 16 15
56
9 8 7
XXXXXX
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 16
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
WHT22
RED22
ORN22
BLK22
BRN22
BLK22
YEL22
BLK22
BLU22
BLK22
GRN22
BLK22
WHT22
BLK22
RED22
BLK22

2-7
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.5 Power ON
Smart Series HC10DT
Collaborative Robot
2.5 Power ON
The main power supply is turned ON when the Controller’s [POWER]
switch is flipped to the “ON” position. After a few seconds, the startup
screen appears on the Pendant.
Fig. 2-8: Controller Power Switch
Fig. 2-9: Pendant Startup Screen
If the Pendant does not complete the startup sequence due to an error
(e.g. Controller Software incompatibility), an {Export Logs} button
appears. Use the {Export Logs} button to save internal logs to a USB
storage device that is inserted in the Smart Pendant to aid with
troubleshooting by Customer Support.
WARNING
• Perform a risk assessment of the Robot and application before
powering ON the Robot.
Not performing a risk assessment before Powering ON the Robot may
result in death or serious injury.

2-8
188791-1
188791-1
2 Setup HC10DT Smart Series Robot
2.6 Power OFF
Smart Series HC10DT
Collaborative Robot
Once the startup sequence completes, the Pendant displays the Home
screen.
Fig. 2-10: Pendant Home Screen
If contacting Customer Support, gather all software version information.
The software versions are available on the Pendant after starting the
Robot:
1. Select “MENU” → “System Settings” to view the systems “General
and Controller Settings”.
2. Notice the software versions for the Pendant and Controller appear.
Fig. 2-11: Controller and Pendant Software Version
2.6 Power OFF
To safely power the system down, turn servos OFF on the Pendant. Next,
flip the Controller’s [POWER] switch to the “OFF” position, shown in
Fig. 2-8.
• For more details concerning powering on/off and start up of the
Robot, refer to the chapter 5 Turning ON and OFF the Power Supply
of the YRC1000micro INSTRUCTIONS.
• More details on the Pendant are available in the YRC1000/
YRC1000micro INSTRUCTIONS FOR Smart Pendant.

3-1
188791-1
188791-1
3 Factory Settings
Smart Series HC10DT
Collaborative Robot
3 Factory Settings
Table 3-1: Robot Factory Settings
The factory force and speed settings are set very low to reduce the risk of
improper operation.
• Power and Force Monitoring Function (PFL) - Monitors the
external force acting on the Robot and performs a protective stop of
the Robot if the external force exceeds the user-defined setting. For
more information on PFL, see "PFL Function" on page 5-5.
• Speed Limit Function - Limits operating speed (TCP speed) of the
robot. This TCP Speed Limit will override higher speed(s)
programmed in a running Robot job. The TCP speed also defines
the maximum speed the Robot can be jogged.
An envelope with a personalized safety password (in the lower-right
corner of Collaborative Robot Password Agreement) is required to edit/
create Safety Setting(s). Review the Terms and Conditions included in the
agreement before modifying the factory settings.
WARNING
• Review the factory settings and modify them per the application and
risk assessment requirements prior to moving the Robot and
programming a job.
Not modifying the factory settings per the application and risk
assessment requirements may result in death or serious injury.
PFL Mode ON
TCP Speed Limit 50 mm/s
PFL Force Monitor in Relation to TCP 50N

3-2
188791-1
188791-1
3 Factory Settings
3.1 Modifying Factory Settings
Smart Series HC10DT
Collaborative Robot
3.1 Modifying Factory Settings
1. Select “MENU” → “Security: Edit” to open the Security Access
pop-up.
2. Select the {SAFETY} access level
3. Enter the personalized safety password, found in the included
envelope.
4. Press {ENTER} or {SAVE}
NOTICE
“Safety” Access Level is required to edit Safety Settings.
NOTICE
Passwords can be changed on the Pendant from
“Menu” → “System Settings” → “General”.
Follow the notifications and instructions for each access level.

3-3
188791-1
188791-1
3 Factory Settings
3.1 Modifying Factory Settings
Smart Series HC10DT
Collaborative Robot
3.1.1 Changing TCP Speed
Complete section 3.1 before to changing the TCP Speed.
1. Select “MENU” → “Safety Settings” → “Safety Functions”.
2. Highlight the Speed Limit file for collaborative operation.
3. Enter the TCP speed on the numeric keypad that satisfies the risk
assessment and press the green {READBACK}.
4. Press {WRITE} to save the new data.

3-4
188791-1
188791-1
3 Factory Settings
3.1 Modifying Factory Settings
Smart Series HC10DT
Collaborative Robot
3.1.2 Changing PFL Settings
Complete section 3.1 before changing the PFL External Force Monitor
Settings.
1. Select “MENU” → “Safety Settings” → “Safety Function”
2. Highlight the External Force Monitor file.
3. Enter new value(s) for Resultant and XYZ “Forces” that satisfy the risk
assessment.
4. Disable the factory External Force Monitor setting by selecting “Always
OFF” in the “Enable Condition” drop down.
5. Press {READBACK}, {WRITE} and {CONFIRM} to save changes.
NOTICE
Disabling the External Force Monitor enables the ability to complete
Torque Sensor Calibration with fewer alarms.
NOTICE
• Refer to section 1.17 Security Level Setting of the YRC1000/
YRC1000micro INSTRUCTIONS FOR Smart Pendant, for more
details about safety and security settings.
• Refer to section 3.2 for PFL (Power Force Limitation and FSU
(Functional Safety Function) of the YRC1000/YRC1000micro
Collaborative Operation Instructions, Speed Limit settings.

3-5
188791-1
188791-1
3 Factory Settings
3.2 Torque Sensor Calibration
Smart Series HC10DT
Collaborative Robot
3.2 Torque Sensor Calibration
For the Collaborative Robot system to function properly, Torque Sensor
Calibration must be performed prior to programming the first job and/or
mounting any EOAT (End of Arm Tooling)
To calibrate the Robot’s torque sensors:
1. Complete section 3.1.2
2. Select MENU → “Safety Settings” → “Torque Sensor Calibration”
3. Move the Robot to a position where the gravitational torque (e.g. by a
tool or other external loads) is near zero for all axes.
Fig. 3-1: Torque Calibration
NOTICE
If the Robot is not at a recommended position, the {GO TO “MOVE
ROBOT” SCREEN} button displays in blue. Press this button to move
the Robot to the recommended position.

3-6
188791-1
188791-1
3 Factory Settings
3.2 Torque Sensor Calibration
Smart Series HC10DT
Collaborative Robot
4. Verify the “Hand” icon appears in the top corner of the Pendant
indicating Manual (Teach) mode.
Fig. 3-2: Manual (Teach) Mode
5. Select the Torque Sensor Calibration Position that best suits the
installed tool.
• Move the Robot to this position by pressing {Move To Position}.
Fig. 3-3: Move to Position for Torque Sensor Calibration
NOTICE
Remove any End of Arm Tooling (EOAT) that is non-symmetric in X or
Y prior to Torque Sensor Calibration for accurate results.

3-7
188791-1
188791-1
3 Factory Settings
3.2 Torque Sensor Calibration
Smart Series HC10DT
Collaborative Robot
6. Once the Robot reaches the recommended position, go back to the
Torque Sensor Calibration screen and notice the “ROBOT AT
RECOMMENDED POSITION” is visible in green.
Fig. 3-4: Robot at Recommended Position
7. Press {CALIBRATE ALL TORQUE SENSOR AT CURRENT
POSITION}.
8. Press {READBACK}, {WRITE}, {YES} to save the calibration data.
9. Refer to section 3.1.2 and change PFL Enable Condition from
ALWAYS OFF to ALWAYS ON.
NOTICE
• For more details on Torque Sensor Calibration refer to section
11.5.8.4 Daily Inspection, Periodic Inspection of Torque Sensors of
the YRC1000/YRC1000micro INSTRUCTIONS FOR Smart
Pendant
• Inspect the Torque Sensor values daily to determine if torque
sensor calibration is required.

4-1
188791-1
188791-1
4 Start Using the Robot
4.1 Jogging
Smart Series HC10DT
Collaborative Robot
4 Start Using the Robot
4.1 Jogging
Jogging is the most commonly used operation for the Robot. To satisfy the
needs under different situations, YASKAWA provides features to help the
user to complete the work safely and efficiently.
Most jogging features are found on the Robot Jog Panel. The Jog Panel is
available from the Job Editing screen by pressing {JOGGING} on the
bottom navigation bar and can only be done in Manual (Teach) mode.
4.1.1 Common Features of the Robot Job Panel
 Jogging Mode
Control for selecting the jogging mode (Manual (Teach) mode). The
Pendant supports six types of Coordinate Frames:
• Smart Frame: Moves the Robot in Cartesian directions relative to
where the Pendant is with respect to the Robot
• Joint: Moves each joint axis independently
• XYZ-World: Moves the Robot in Cartesian directions relative to the
Robot base
• XYZ-Tool: Moves the Robot in Cartesian directions relative to the
tool
• XYZ-User: Moves the Robot in Cartesian directions relative to a user
frame
• Hand Guiding: Moves the Robot by applying a force to the Robot
arm using hands instead of the Pendant controls.
The Coordinate Frame can be selected by three different ways:
• Icon on Status Bar
• Robot Jog Panel
• Membrane Key
 Jogging Mode  Active Tool  Current Axis Status Panel
 Jog Speed  Toggle Tool  Go To Point Button

4-2
188791-1
188791-1
4 Start Using the Robot
4.1 Jogging
Smart Series HC10DT
Collaborative Robot
 Jog Speed
The Pendant provides four levels of speed. For safety reasons, the default
speed is set to “Low”. Select the desired speed prior to jogging:
There are three ways to select the jogging speed of operation:
• Status Bar
• Robot Jog Panel
• [SLOW] and [FAST] membrane keys
Review chapters 2 through 5 of the YRC1000/YRC1000micro
INSTRUCTIONS FOR Smart Pendant for detailed descriptions for
programming and operating the Robot.
NOTICE
• A Speed Limit Setting labeled “Manual (Teach) Mode” defines the
upper limit for jogging speed.
• If the Robot moves too slow when set to Top or High speeds for
jogging the Robot, review the Speed Limit Safety file settings and
adjust per safety requirements. See section 3.1.1 “Changing TCP
Speed” on page 3-3.