YASKAWA MH SIGMA-5 Series User manual

MANUAL NO.
0
162068-1CD
Part Number: 162068-1CD
Revision: 1
MH-SERIES
SIGMA-5 POSITIONER MANUAL
MH95, MH185, MH505, MH1605, and MH3105
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN INSTRUCTIONS
DX100 INSTRUCTIONS
DX100OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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MANDATORY
General items related to safety are listed in Section 2 of the DX100
Controller Manual. To ensure correct and safe operation, carefully read
the DX100 Controller Manual before reading this manual.
CAUTION
• 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 a 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 the
products warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MH-SERIES POSITIONER.
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.
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
personnelanddamageto equipment.
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 “CAUTION”
and “WARNING.”
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WARNING
• Before operating the MH-SERIES POSITIONER, check that servo
power is turned OFF by pressing the EMERGENCY STOP buttons
on the operator station or Programming Pendant (refer to Figure 1).
When 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 positioner during an emergency. The positioner should
not be used if the EMERGENCY STOP buttons do not function.
Figure 1: EMERGENCY STOP Button
• Release the EMERGENCY STOP button (refer to Figure 2). Once
this button is released, clear the cell of all items which could
interfere with the operation of the positioner then, turn servo power
ON.
Injury may result from unintentional or unexpected positioner motion.
Figure 2 : Release of EMERGENCY STOP Button
TURN
• Observe the following precautions when performing teaching
operations within the working envelope of the positioner:
– View the positioner from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that there is a safe place to retreat to in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the working envelope of the
positioner and that you are in a safe location before:
– Turning on the power for the DX100 controller.
– Moving the positioner with the Programming Pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the working envelope of the
positioner during operation. Always press an EMERGENCY STOP
button immediately if there is a problem. The EMERGENCY STOP
buttons are located on the operator station and on the Programming
Pendant.
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Definition of Terms Used Often in This Manual
The positioner usually consists of the controller, the Programming
Pendant, and supply cables.
In this manual, the equipment is designated as follows:
CAUTION
• Perform the following inspection procedures prior to conducting
positioner teaching. If problems are found, repair them immediately
and be sure that all other necessary processing has been
performed.
– Check for problems in positioner 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 controller after use.
• The Programming Pendant can be damaged if it is left in the work
area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Controller Manual before operating the MH-SERIES
POSITIONER.
Equipment Manual Designation
DX100 controller DX100
DX100 Programming Pendant Programming Pendant
Cable between the positioner and the
controller Power cables
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MH-SERIES
POSITIONER Table of Contents
1 Introduction.....................................................................................................................................1-1
1.1 About this Document .........................................................................................................1-1
1.2 System Overview...............................................................................................................1-2
1.3 System Layout...................................................................................................................1-2
1.3.1 System Layout......................................................................................................1-4
1.4 Customer Support Information...........................................................................................1-7
2 Safety..............................................................................................................................................2-1
2.1 Introduction........................................................................................................................2-1
2.2 General Safeguarding Tips................................................................................................2-1
2.3 Mechanical Safety Devices................................................................................................2-2
2.4 Installation Safety ..............................................................................................................2-2
2.5 Programming, Operation, and Maintenance Safety...........................................................2-3
3 Equipment Description....................................................................................................................3-1
3.1 General Information...........................................................................................................3-1
3.2 MH-Series SIGMA-5 Positioner Assembly – Type I ..........................................................3-1
3.2.1 MH-Series SIGMA-5 Positioner Type I – Specifications.......................................3-2
3.3 MH-Series SIGMA-5 Positioner Assembly – Type II .........................................................3-3
3.3.1 MH3105-Series SIGMA-5 Positioner, Type II – Specifications.............................3-4
3.4 MotoMount™.....................................................................................................................3-5
4 Installation.......................................................................................................................................4-1
4.1 Materials Required.............................................................................................................4-1
4.1.1 Customer-Supplied Items.....................................................................................4-1
4.1.2 List of Tools..........................................................................................................4-1
4.2 Installing the MH-Series SIGMA-5 Positioner – Type I......................................................4-2
4.2.1 Site Preparation....................................................................................................4-2
4.2.2 Unpacking ............................................................................................................4-2
4.2.3 Headstock Assembly Mounting Hole Pattern – MH95/185/505/1605...................4-3
4.2.4 Column Assembly Mounting – Type I Assembly..................................................4-5
4.2.5 Connecting the Cables.........................................................................................4-7
4.2.6 Home Position......................................................................................................4-7
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4.3 Installing the MH-Series SIGMA-5 Positioner – Type II.....................................................4-8
4.3.1 Site Preparation....................................................................................................4-8
4.3.2 Unpacking.............................................................................................................4-8
4.3.3 Unbolting the Drive Assembly Floor Mounting – Type II.......................................4-9
4.3.4 Connecting the Cables .......................................................................................4-11
4.3.5 Home Position ....................................................................................................4-11
4.4 Tailstock Column Installation...........................................................................................4-12
4.4.1 Type I Installation................................................................................................4-12
4.4.2 Type II Installation...............................................................................................4-13
4.4.3 Leveling the Tailstock.........................................................................................4-14
4.4.4 Tooling Fixture Installation (initial)......................................................................4-17
4.4.5 Tooling Fixture Installation (regular)...................................................................4-18
4.4.6 Final Alignment Check........................................................................................4-18
4.4.7 Tooling Fixture Removal.....................................................................................4-21
4.5 MotoMount Installation.....................................................................................................4-22
4.5.1 Preparation.........................................................................................................4-22
4.5.2 Unpack and Assemble........................................................................................4-22
4.5.3 Securing MotoMount Drive Components onto Faceplate...................................4-24
4.5.4 Retrofitting Tailstock Assembly...........................................................................4-24
4.6 MotoMount HD Adjustments............................................................................................4-25
4.6.1 Allowable Misalignment......................................................................................4-25
4.6.2 Tooling Fixture Installation – MotoMount HD......................................................4-26
4.6.3 Tooling Fixture Removal.....................................................................................4-26
4.6.4 Variable Tooling Size Accommodations.............................................................4-27
4.7 Conducting a Safety/Operation Check.............................................................................4-27
5 Tooling Recommendations .............................................................................................................5-1
5.1 Headstock Only – Tooling Recommendations...................................................................5-1
5.1.1 Customer-supplied Tooling Fixture.......................................................................5-2
5.2 Headstock/Tailstock with MotoMount ................................................................................5-5
5.2.1 Customer-supplied Tooling Fixtures.....................................................................5-5
5.2.2 Multiple Tooling Fixtures.......................................................................................5-5
5.2.3 Specifications........................................................................................................5-5
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6 Maintenance ...................................................................................................................................6-1
6.1 Spare Parts........................................................................................................................6-1
6.2 Servomotor........................................................................................................................6-1
6.3 Weld Ground Brush Replacement – Type I.......................................................................6-2
6.3.1 MH95/185/505/1605.............................................................................................6-2
6.4 Weld Ground Brush Replacement – Type II......................................................................6-5
6.4.1 MH3105................................................................................................................6-5
6.5 Reset Headstock To Home Position..................................................................................6-7
6.5.1 Homing.................................................................................................................6-7
6.6 Maintenance Schedule....................................................................................................6-11
6.6.1 MH-Series SIGMA-5 Positioner..........................................................................6-11
6.6.2 MotoMount .........................................................................................................6-11
6.7 Troubleshooting...............................................................................................................6-12
6.7.1 MH-Series SIGMA-5 Positioner..........................................................................6-12
6.7.2 MotoMount .........................................................................................................6-12
A Performance Charts .......................................................................................................................A-1
A.1 MH-Series Positioner Assemblies.....................................................................................A-1
A.1.1 MH95 ...................................................................................................................A-1
A.1.2 MH185 .................................................................................................................A-2
A.1.3 MH505 .................................................................................................................A-3
A.1.4 MH1605 ...............................................................................................................A-4
A.1.5 MH3105 ...............................................................................................................A-5
B Illustrated Parts list.........................................................................................................................B-1
B.1 Introduction .......................................................................................................................B-1
B.1.1 Contents...............................................................................................................B-1
B.1.2 Parts List..............................................................................................................B-1
B.1.3 Symbols and Abbreviations..................................................................................B-2
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1 Introduction
1.1 About this Document
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1 Introduction
1.1 About this Document
This manual provides the following information:
CHAPTER 1 – INTRODUCTION
Provides general information about the MH-SERIES POSITIONER
system and components and customer support contact information.
CHAPTER 2 – SAFETY
Provides general safety information regarding installation, maintenance,
and operation.
CHAPTER 3 – DESCRIPTION OF EQUIPMENT
Provides a description of the major components.
CHAPTER 4 – INSTALLATION
This chapter provides installation procedures.
CHAPTER 5 – TOOLING RECOMMENDATIONS
This chapter provides guidelines for customer-supplied tooling design.
CHAPTER 6 – MAINTENANCE
This chapter provides preventive maintenance requirements for certain
components MH-SERIES POSITIONER.
APPENDIX A – PERFORMANCE CHARTS
This appendix provides performance charts for each of the MH-SERIES
POSITIONER.
APPENDIX B – ILLUSTRATED PARTS LIST
This appendix contains the Illustrated Parts List (IPL). The IPL provides
detailed views (with part numbers).
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