YASKAWA MA1440 Operating And Maintenance Manual Download Page 5 | Manualshive

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General

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General

1.1

Notes for safe operation

DANGER!

Indicating immediate danger at high risk, hazard that can cause death or serious bodily
injuries if no precautions are taken.

WARNING!

Indicating possible medium risk hazard situation which can cause death or serious bodily
injuries if it is not avoided.

CAUTION!

Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries
result if it is not avoided. This signal word can also be used for property damage warnings.

NOTICE

Indicates important background information and application advice.

1.2

Frequently used terms

The YASKAWA robot is a product of YASKAWA Electric Corporation GmbH. The robot is
normally supplied with the robot controller, programming pendant, and robot cable.

The terms are designated as follows in this manual:

Terms

Designation

Controller

Robot controller

Industrial robot

Robot

Programming pendant (teach box)

Programming pendant or PP

Cable between the robot and the robot con-
troller

Cable

Robot, robot controller, and cable

Robot system

Yaskawa Electric Corporation

YEC

YASKAWA Europe “Robotics Division”

YEU-R

Movement, calibration, and setup of the ro-
bot

Teach

Sequence of movements of the robot

JOB

Technical Customer Service

TCS

Personal Computer

PC

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Summary of Contents for MA1440

Page 1: ...ROBOTICS MA1440 YR MA01440 A00 Operating and Maintenance Manual...

Page 2: ...ersion of the original HW1481883 0 in YEU R style 2013 11 Rev 02 Revised version of chapter Parts List 2013 12 Rev 03 Revised version of the original HW1481883 1 2014 01 Rev 04 Revision of the technic...

Page 3: ...nstallation location 20 4 3 Installation example 21 5 Wiring 25 5 1 Grounding 25 5 2 Cable connections 26 5 2 1 Connecting the robot 27 5 2 2 Connection of the robot controller 28 5 2 3 Connecting the...

Page 4: ...egistering all axes at the time 65 9 5 2 Registering individual axes 67 9 5 3 Changing the absolute data 68 9 5 4 Clearing absolute data 69 9 6 Setting the second home position check point 70 9 6 1 Pu...

Page 5: ...t background information and application advice 1 2 Frequently used terms The YASKAWA robot is a product of YASKAWA Electric Corporation GmbH The robot is normally supplied with the robot controller p...

Page 6: ...t system must receive training before they operate the robot For optimal use of our products we recommend our customers to take part in a training session at the YASKAWA Academy For more detailed info...

Page 7: ...holes or similar modifications can damage parts This will be regarded as improper use i e use that deviates from the intended use and will lead to loss of warranty and liability claims as well as los...

Page 8: ...covers or shields removed All protective covers and shields must be mounted before the robot is operated The drawings and figures in this manual are representative illustrations They may differ from t...

Page 9: ...in Menu JOB CONTENT 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 TEST01 TOOL CONTROL GROUP R1 S 0000 NOP SET B000 1 SET B001 0 MOVJ VJ 80 00 MOVJ VJ 80 00 DOUT OT 10 ON TIMER T 3 00 MOV...

Page 10: ...ge View the Robot from the front whenever possible Always follow the prescribed operating procedure see the instructions on robot control as well as the operating instructions on Handling or Universal...

Page 11: ...anufacturer Address YASKAWA ELECTRIC CORPORATION 2 1 KUROSAKISHIROISHI YAHATANISHI KU KITAKYUSHU JAPAN 1 9 Authorized representative Address YASKAWA Europe GmbH Robotics Division Yaskawastr 1 85391 Al...

Page 12: ...1 Checking the scope of delivery The standard delivery includes the following items Fig 2 1 Scope of delivery Programming pendant Assembly instruction Robot controller Cable Robot MOTOMAN MANUAL 1 2...

Page 13: ...te NOTICE Please contact the local YASKAWA branch office if the serial numbers do not match the information on the delivery note S N DX200 YASAKAW XXXXX Part No Power Supply Peak kVA AC XXXXXXXX Avera...

Page 14: ...rces may be exercised on the robot control the robot or other components 3 1 Transporting method CAUTION Damage to persons and damage to property due to external force influences External forces must...

Page 15: ...5 3 1 1 Using a crane Adequate load handling devices must be used to transport the robot Make sure that the robot is lifted as shown in the diagram Transport by crane Fig 3 1 Transport with crane 3 ey...

Page 16: ...uld be fixed on a pallet with transport securing devices and shipping bolts Make sure that the forklift and the transportation route have sufficient bearing capacity Always take due care when transpor...

Page 17: ...the power check to be sure that the shipping bolts and brackets are removed After removing the transport securing devices and the shipping bolts keep them at a safe place The transport securing device...

Page 18: ...Transportation 3 18 Fig 3 5 Damping material for transport A B...

Page 19: ...protective measures can lead to death of people serious bodily harm or material damage Implement the following protection measures Separating protection devices Non contact protection devices Enclosu...

Page 20: ...ons Ambient temperature From 0 C to 45 C Air humidity 20 to 80 relative humidity non condensing Free of corrosive gases liquids or explosive gases No water oil or dust and free from excessive electric...

Page 21: ...base to the base plate Tighten the hexagon head bolts and anchor bolts securely so that they will not work loose during operation see figure Mounting of the robot on the base plate Fig 4 1 Mounting t...

Page 22: ...22 Fig 4 2 Base plate NOTICE YASKAWA Europe recommends to use the robot only with a base plate Please contact the manufacturer of the mounting material you use 25 80 580 580 520 520 335 260 335 260 3...

Page 23: ...es and torques of the robot Direction of move ment Horizontal Vertical Force FH Moment MH Force FV Torque MV Emergency stop Stop category 0 10 000 N 4120 Nm 5100 N 4120 Nm Acceleration Decelera tion S...

Page 24: ...ing differs from assembly in a standing position in the following points S axis working range Fixing the robot base NOTICE For suspended mounting in any position please contact the local YASKAWA branc...

Page 25: ...ndards and wiring regulations for earthing The cable cross section must be 6 mm or more With regard to the direct connection of the earthing cable see figure Earthing connection NOTICE Note on the ear...

Page 26: ...ase and on the robot controller see the following chapter on robot connection and robot controller connection Fig 5 2 Robot cable Robot control side Encoder cable 1BC Robot side Power cable 2BC DX200...

Page 27: ...he power cable 2BC 2 Connect the encoder cable 1BC to the connector plate of the robot 3 Connect the power cable 2BC to the connector plate of the robot Make sure that you hear each locking clip snap...

Page 28: ...onnect the programming pendant cable to the connection X81 see diagram Connecting the programming pendant Fig 5 5 Connection programming pendant Alignment marks X 11 X 21 X 1 X 2 1 X81 X81 PROGRAMMING...

Page 29: ...in axes 54 Wrist axes 67 Maximum speed S axis 4 01 rad s 230 s L axis 3 49 rad s 200 s U axis 4 01 rad s 230 s R axis 7 50 rad s 430 s B axis 7 50 rad s 430 s T axis 11 00 rad s 630 s Allowed moment N...

Page 30: ...2 Robot base dimensions Upper arm U arm Rotating head of S axis Wrist flange Robot base Lower arm L arm 2 holes 16 H7 4 mounting holes 18 Hole 12 H7 All dimensions in mm T T B B R R U U L L S S 2 2 3...

Page 31: ...6 3 Part names and working axes P point Working area defined with point P All dimensions in mm 199 94 5 198 5 1734 299 361 450 614 200 100 155 640 100 84 705 777 2511 0 410 1440 206 848 1129 0 90 175...

Page 32: ...Technical data 6 32 6 4 Adjustable working area...

Page 33: ...HW0414041 2 Position of the limit stop 2 screws M12 x 30 strength category 12 9 tightening torque 170 Nm Mechanical limit Working range of S axis 18 mounting positions for the dogs section A A A A St...

Page 34: ...tegory 12 9 Tighten the screws with a tightening torque of 170 Nm With a working area of 170 the stop must be mounted as shown in the figure Components of the S axis limit The stop can be mounted at 1...

Page 35: ...ICxG408 NOTICE To change the movement range of the machine set both the pulse limit and the angle of the mechanical S axis limit Fig 6 5 Adjustable angle for the S axis limit Degree 15 30 45 60 75 90...

Page 36: ...The actual overrun distances and overrun times may differ due to internal and external influence on the braking torque According to the mode robot application and number of triggered safety stops wit...

Page 37: ...ion 33 deg deg s deg s sec 100 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0 5 10 15 20 25 30 35 deg deg s deg s sec 66 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4...

Page 38: ...deg s deg s sec 100 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0 5 10 15 20 25 30 35 deg deg s deg s sec 66 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0...

Page 39: ...deg s deg s sec 100 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0 5 10 15 20 25 30 35 deg deg s deg s sec 66 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0...

Page 40: ...2 1 Stop position S axis Fig 6 16 Stop position 100 Fig 6 17 Stop position 66 Fig 6 18 Stop position 33 deg deg s deg s sec 100 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0 10 5...

Page 41: ...deg deg s deg s sec 100 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0 10 50 20 40 30 60 deg deg s deg s sec 66 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0...

Page 42: ...deg deg s deg s sec 100 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0 10 50 20 40 30 60 deg deg s deg s sec 66 0 50 100 150 200 250 0 50 100 150 200 250 0 1 0 2 0 3 0 4 0 5 0 0 0...

Page 43: ...mounting a tool remove anticorrosive coating on the flange Thinner or light fuel oil are the most suitable for this purpose 7 2 Maximum load of the S axis For peripheral devices of specific applicati...

Page 44: ...for U axis including wrist is 15 kg For example if the load mounted on the joint is 6 kg the load on the upper arm must not exceed 9 kg The maximum allowable load on the S axis is 20 kg Install the pe...

Page 45: ...7 2 Installing peripheral equipment mounts 4 threaded holes M8 x 18 2 threaded holes M6 x 12 Mount the peripherals in this range Center of gravity of accessories mount on U arm in this range 4 thread...

Page 46: ...figure Wiring must be performed by the user The following requirements must be met The total current value for the internal wiring harness must be 40 A The current carrying capacity per single conduct...

Page 47: ...outlet B There is a connecting plug for internal cable ducting in the case Power cable for arc welding TS200CHM Air inlet B Air inlet A Optional a power cable for arc welding recommended connection R...

Page 48: ...figure Connecting diagram for internal connections The internal connections of the robot are shown in the following diagrams Connection diagram A and Connection diagram B assigned unassigned Connecto...

Page 49: ...13 16 8 1 3 4 2 5 PG0V3 7 P P P P CN1 5 1BC 10X4 CN1 4 P CN1 10 CN1 9 CN1 1 CN1 2 P P CN1 3 CN1 6 CN1 7 CN1 8 P DX100 SPG 2 SPG 2 FG2 FG1 SPG 1 SPG 1 24V 0V 24V 0V 0BT BAT 0BT BAT 0BT BAT BAT 0BT CN2...

Page 50: ...6 4 CN6 5 CN6 6 CN6 1 ME1 ME2 ME2 MU1 MV1 MW1 MV2 MU2 MW2 MW2 MU3 MV2 MU2 MW3 MV4 MU4 MV5 MU5 MW4 MU6 MW6 MV6 ME3 ME5 ME4 MW5 BA1 BA2 BB1 BA3 BA4 BB4 BA5 BA6 ME6 MV3 E PE 3 2 1 E 3 2 3BC 1 6 7 5 10 11...

Page 51: ...ing maintenance and inspection measures Turn OFF the main power supply Put up the required warning sign e g Do not turn the power on Install a switch on guard as prescribed If you have any questions r...

Page 52: ...Menu ShortCut CONTROL POWER TIME 1998 07 06 10 00 2385 42 02 SERVO POWER TIME 1998 07 06 10 30 36000 00 00 PLAYBACK TIME 1998 10 22 11 12 2210 00 20 MOVING TIME 1998 10 22 15 30 1875 15 30 OPERATING...

Page 53: ...Maintenance and inspection 9 53 1 Trained staff 2 YASKAWA trained staff 3 YASKAWA personnel...

Page 54: ...Fixing screws of the base plate Using a correspond ing tool tighten loose screws replace if necessary 6 Fixing screws of the cover Using a correspond ing tool tighten loose screws replace if necessary...

Page 55: ...ll Replace grease and 9 4 Refill Re place grease 14 Overhaul 1 The item numbers correspond with the following figure Inspection intervals 2 When checking for conduction with multimeter connect the bat...

Page 56: ...Maintenance and inspection 9 56 Fig 9 2 Inspection intervals The numbers in the above figure are equal to the numbers in the table of Inspection intervals...

Page 57: ...controller to the main power supply see Fig 9 4 Main power switch in switch off position 2 Remove the fixing screws from the cover plate 3 Carefully pull out the battery pack from the base NOTICE The...

Page 58: ...efore having installed new battery pack 7 Please remove old battery pack plug from circuit board NOTICE Make sure that no wires are pinched when you install the battery pack and the cover plate again...

Page 59: ...attery unit connector diagram for R B and T axes Motor Battery unit Motor power connector Plug for backup Encoder connector Encoder Warning label Motor cable Power connector Battery unit Wiring harnes...

Page 60: ...prevent fumes penetrating into wrist unit matched parts are sealed If you have removed the wrist cover the seal must be replaced with sealing compound Teroson Plast sealing compound material no 143813...

Page 61: ...e outlet If this instruction is not followed the motor will be damaged Avoid air getting into the gear Insert grease with a grease gun If an automatic lubricating pump is used the grease supply pressu...

Page 62: ...the grease inlet opening using a grease gun 4 To squeeze out the excess fat all taxes must be brought to operating temperature In a operating JOB or a special moving JOBs about 20 minutes at 100 spee...

Page 63: ...e 450 cm approx 396 g1 L axis gear Replenishment 65 cm approx 58 g Exchange 420 cm approx 378 g1 U axis gear Replenishment 40 cm approx 36 g Exchange 250 cm approx 225 g1 Grease outlet Grease inlet po...

Page 64: ...B and T axis gear Replenishment B axis 6 cm approx 5 g and T axis 2 cm approx 1 8 g Exchange 1 T axis pinion Replenishment Variable T Achsen Ritzel nachf l len not defined Exchange Variable T Achsen...

Page 65: ...ition of the absolute encoder must match it Although this operation is performed prior to shipment at the factory the following cases require this operation to be performed again Change in the combina...

Page 66: ...POSITIONING window appears 3 Select DISPLAY under the menu or select PAGE to display the selection window for the control group or press PAGE The pull down menu appears 4 Select the desired control g...

Page 67: ...xes 1 Select ROBOT on the main menu The sub menu choices appear 2 Select HOME POSITION 3 Select the module to be calibrated e g R1 ROBOT Perform steps 3 and 4 which have been described in Registering...

Page 68: ...t ROBOT from the main menu 2 Select HOME POSITION 3 Select the desired control group Perform steps 3 and 4 which have been described in chapter Registering All Axes at One Time to select the desired c...

Page 69: ...have been described in Registering All Axes at One Time to display the HOME POSITIONING window and select the desired control group 3 Select DATA under the menu The pull down menu appears 4 Select CLE...

Page 70: ...xis keys and perform the position confirmation For performing the position confirmation refer to chapter Procedure after the Alarm Playback and test runs will not function unless CONFIRM POSITION is p...

Page 71: ...ith a robot that has no brake it is possible to enable playback without position checking after the alarm occurs However as a rule always perform CONFIRM POSITION Under the above special conditions th...

Page 72: ...ears The Message Available to move to and modify specified point shown 3 Press the page key PAGE or select PAGE to display the selection window for the control group The group axes by which the second...

Page 73: ...ion if the PG system is found to be the cause of the alarm perform the necessary operation such as replacing the PG system etc The robot current position data when turning main power supply ON and OFF...

Page 74: ...g operations or if the following events occur Replacement of motors Replacement of Encoders Discharging the battery of the robot The home position data is stored by the backup battery In the case of a...

Page 75: ...hen the de vice is on LED CHG Charge Lights up when the power cable is inserted and when the battery is being charged LED BAT Battery Lights up when the battery must be charged The devices runtime wit...

Page 76: ...emely dirty conditions Strong movements or vibrations Strong magnetic fields For cleaning use a clean and dry cloth Never use liquids or aggressive cleaning agents The device must not be used in a pot...

Page 77: ...t to initial position as otherwise errors might occur if axes are coupled 3 Insert the CF data transmission card of the reset to zero device in the opening of the programming pendant Fig 9 9 Inserting...

Page 78: ...annex 1 Drive the axis in position so that the marking on the screw in point of the reset sensor coincides with the corresponding alignment marking The markings differ depending on the type of robot...

Page 79: ...ogramming pendant 12 Press Zeroing on the screen A window with a warning message opens If you have followed all the previously described steps then you fulfilled all the points stated on the list and...

Page 80: ...ing pendant 23 Press FWD to move the TCP in the second home position 24 Check if the second home position deviates from your required position 25 Press MAIN MENU CONFIRM POSITION DATA A message Home p...

Page 81: ...ensor for de formations Carry out a new reset Switch to TEACH mode Again execute zeroing The mode switch on the pro gramming pendant is in the Play Mode position when starting the reset Switch the mod...

Page 82: ...reset again Alarm Sensor amp battery The battery of the amplifier is empty Replace the battery Alarm Sensor amp write error EEPROM Amplifier EEPROM writing er ror Contact the local YASKAWA branch off...

Page 83: ...e to an er ror Confirm the error message and eliminate the error Repeat the reset from the begin ning Finished Error occur Operator stop The reset is ended with the Stop switch Repeat the reset from t...

Page 84: ...g compound Teroson Plast 143813 Battery pack Robot 128708 Battery pack Controller 155543 Wire harness welding HW1171418 B 164761 Wire harness handling HW1171418 A 164775 Protective tube MTK 50FR 17336...

Page 85: ...t I F board JANCD YIF01 2E 145855 Machine safety CPU board JANCD YSF21 E 164757 Machine safety I O logic board JANCD YSF22B E 169501 General I O board PNP Type JANCD YIO22 E 164762 Power ON unit Cat 4...

Page 86: ...t Fig 11 1 S axis drive 1003 1005 1004 1009 1006 1014 1012 1010 1010 1011 1028 1025 1029 1018 1016 1017 1024 1025 1001 1033 1006 1007 1026 1022 1023 1032 1031 1030 1019 1025 1002 1008 1025 1019 1021 1...

Page 87: ...HW1100499 1 Housing 1 1012 PT3 8 Grub screw 1 1014 NB 0860 0 2 Hose 1 1015 SGMRV 05ANA YR2 Motor 1 1016 M5 x 16 Screw 2 1017 2L 5 Washer 2 1018 TS200CHM Block 1 1019 CD31 Clamp 2 1020 M5 x 8 Screw 4 1...

Page 88: ...Screw 1 2004 2L 6 Washer 1 2005 HW0312735 2 L axis gear 1 2006 M6 x 15 Screw 4 2007 SGMRV 09ANA YR1 Motor 1 2008 M8 x 25 Screw 22 2009 PT3 8 Grub screw 1 2010 HW0387809 A Gear 1 2011 HW1100500 1 L ar...

Page 89: ...ion Piece 3001 HW1100501 1 Housing 1 3002 M12 x 20 Screw 2 3003 M4 x 12 Screw 5 3004 M5 x 75 Screw 1 3002 3007 2011 3005 3004 3006 3001 3008 3009 3024 3025 3013 3010 3003 3003 3014 3015 3016 3021 3028...

Page 90: ...3014 HW1404044 1 Bearing plate 1 3015 PT3 8 Grub screw 1 3016 HW1404041 1 Support 1 3017 HW0404554 2 Housing 1 3018 M3 x 16 Screw 2 3019 M3 Nut 1 3020 M4 x 12 Screw 4 3021 KQE10 03 Connection 1 3022 K...

Page 91: ...010 4011 4004 4015 4016 4007 4020 4017 4001 4034 4035 4036 4037 4019 4006 4013 4021 4001 4023 4001 4001 4008 3001 4018 4014 4002 4030 4029 4026 4028 4026 4024 4028 4027 4027 4032 5063 4038 4046 4001 4...

Page 92: ...4045 1 Housing 1 4017 M3 x 16 Screw 3 4018 M4 x 16 Screw 1 4019 2L 4 Washer 1 4020 HW0404304 2 Gasket 1 4021 HW1406288 1 Cover 1 4022 SGMAV 01ANA YR13 Motor 1 4023 M4 x 12 Screw 11 4024 HW1405970 1 Se...

Page 93: ...list R axis drive 4043 M4 Washer 1 4044 M4 x 6 Screw 1 4045 T30R Cable tie 1 4046 TG107 Gasket 1 3001 HW1100501 Housing 1 5063 HW1100502 1 U arm 1 1 Delivered after August 2014 2 Delivered before July...

Page 94: ...5048 5005 5024 5047 5057 5026 5027 5042 5045 5044 5043 5041 5046 5038 5039 5036 5037 5001 5025 5020 5019 5021 5022 5005 5005 5018 5040 5005 5009 5008 5016 5056 5068 5023 5055 5064 5029 5031 5033 5032...

Page 95: ...belt 1 5018 WR20 Terminal 1 5019 HW1303260 1 Shaft 1 5020 HW1404049 Cover 1 5021 M8 x 40 Screw 1 5022 2L 8 Washer 1 5023 HW1481728 A Bearing 1 5024 6809DDU Bearing 1 5025 HW1404059 6 Spring 1 5026 HW1...

Page 96: ...1 5057 HW1303243 1 1 Cover 1 HW1304179 1 2 Cover 1 5058 SGMAV 01ANA YR1 Motor 2 5059 HW1404046 1 3 Fastening 1 HW1406071 1 4 Fastening 1 5060 HW1404036 A Pulley 1 5061 M4 12 Screw 1 5062 HW1404052 1...

Page 97: ...Parts lists 11 97...

Page 98: ...yin 972 3 9004114 NL YASKAWA Benelux B V Son 31 40 2895500 PL YASKAWA Polska Sp z o o Wroc aw 48 71 7928670 RUS YASKAWA Nordic AB Moskva 46 480 417 800 SE YASKAWA Nordic AB Tors s 46 480 417 800 SI YA...

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