ROBOTICS
MH24
YR-MH00024-A00
Operating and Maintenance Manual
Page 1: ...ROBOTICS MH24 YR MH00024 A00 Operating and Maintenance Manual...
Page 2: ...the original HW1482751 1 in YEU style 2014 11 Rev 02 Revision of table Inspection intervals and review of chapter Grease replenish ment exchange 2015 03 Rev 03 Revised of chapter Wrist unit 2015 07 R...
Page 3: ...4 1 Protection measures 19 4 2 Ambient conditions and installation location 20 4 3 Installation example 21 5 Wiring 26 5 1 Grounding 26 5 2 Cable connections 27 5 2 1 Connecting the robot 28 5 2 2 Con...
Page 4: ...me 64 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 Purpose of position check opera...
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: ...ng 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 Shipping bracke...
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: ...ping bolts and brackets are removed After removing the transport securing devices and the shipping bolts keep them at a safe place The transport securing devices and shipping bolts will be required ag...
Page 18: ...ure that the rubber buffer are removed After removing the rubber pads keep them at a safe place The rubber pads will be required again if the system is transported again The robot is furnished with da...
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: ...ndermentioned environmental conditions 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 Free from excessiv...
Page 21: ...obot 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 Mounti...
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: ...and grease inlet opening see the figures below This is to prevent grease from emerging from the grease discharge aperture In a wall mounting you must assemble the robot with the plug plate facing up...
Page 24: ...e ceiling Grease outlet opening View Grease inlet opening Before the mounting to the ceiling Motor base plate View A Grease outlet opening Before the mounting to the wall Grease inlet opening Power in...
Page 25: ...e wall mounted type the S axis movable range is 30 the range is adjusted prior to the shipment Fastening the robot base With suspended mounting the robot must be fastened with 4 screws M16 strength cl...
Page 26: ...ounding Follow the applicable electrical installation standards and wiring regulations for earthing The cable cross section must be 6 mm or more With regard to the direct connection of the earthing ca...
Page 27: ...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 28: ...er 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 into p...
Page 29: ...order 1 Connect the encoder cable 1BC X11 at connection X11 to the robot controller 2 Connect the power cable 2BC X21 at connection X21 to the robot controller Make sure that you hear the locking clip...
Page 30: ...PROGRAMMING PENDANT PROPERLY CHECK ALL THE DOOR LOCKS NJ3005 1 kVA kVA ERDR Average Peak NJ3053 1 Kammerfeldstr 1 D 85391 Allershausen 2 1 Kurosaki Shiroishi Yahatanishi Ku Kitakyushu City Fukuoka 80...
Page 31: ...ss IP Main axes 54 Wrist axes 67 Maximum speed S axis 3 44 rad s 197 s L axis 3 32 rad s 190 s U axis 3 67 rad s 210 s R axis 7 16 rad s 410 s B axis 7 16 rad s 410 s T axis 10 82 rad s 620 s Allowed...
Page 32: ...base dimension Fig 6 2 Robot base dimensions Upper arm U arm Rotating head of S axis Wrist flange Robot base Lower arm L arm 4 mounting holes 18 2 holes 12 H7 All dimensions in mm T T B B R R U U L L...
Page 33: ...work area P point Working area defined with point P All dimensions in mm 180 180 180 630 70 168 130 100 15 45 26 13 R406 R1730 505 760 200 150 795 120 1003 1730 519 0 326 761 2085 0 1429 1024 807 694...
Page 34: ...he s axis may be changed depending on the type of application If any modification is necessary please contact the local YASKAWA branch office The mechanical stop can only be adjusted in 60 steps Item...
Page 35: ...S axis the following components are required see the following figure Components of the S axis limitation 180 150 120 90 60 30 Mechanical limit 2 M16 x 25 screws strength category 12 9 tightening torq...
Page 36: ...400 Pulse limit negative direction of S axis SICxG408 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 4 Adjustable angle...
Page 37: ...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 38: ...Technical data 6 38 6 5 1 Stop category 0 6 5 1 1 Stop position S axis 100 deflection 66 deflection 33 deflection deg deg s deg s sec deg deg s deg s sec deg deg s deg s sec...
Page 39: ...Technical data 6 39 6 5 1 2 Stop position L axis 100 deflection 66 deflection 33 deflection deg deg s deg s sec 100 deg deg s deg s sec deg deg s deg s sec...
Page 40: ...Technical data 6 40 6 5 1 3 Stop position U axis 100 deflection 66 deflection 33 deflection deg deg s deg s sec deg deg s deg s sec deg deg s deg s sec...
Page 41: ...not subjected to the robot position and the load Stop of category1 doesn t depend on the robot position and the load 6 5 2 1 Stop position S axis 100 deflection 6 5 2 2 Stop position L axis 100 defle...
Page 42: ...re that the home position marks can be seen at all times the tool may only be flange mounted with the inner diameter Fitting depth of inside fittings must be 5 mm NOTICE Before mounting a tool remove...
Page 43: ...e Tab 7 1 Allowable torque and allowable moment of inertia Keep the centroidal distance of the load mass within the specifications refer to the following figure Hand loads Fig 7 1 Moment of arm rating...
Page 44: ...s 4 M6 x 14 threaded holes Mount the peripherals in this range 2 M10 x 12 threaded holes Mount the accessories so that the centre of gravity of the accessories is in the U arm within this range 2 M10...
Page 45: ...le In the case of the YASKAWA HP20D robot for example the permissible moment of inertial for the T axis amounts to 0 25 kgm at a permissible torque of 19 6 Nm and to 0 75 kgm at a permissible torque o...
Page 46: ...he total current value for the internal wiring harness must be 40 A The current carrying capacity per single conductor cross section 1 25 mm 0 75 mm and 0 20 mm must not exceed 3 A or less The air pre...
Page 47: ...wing diagrams Connection diagram A and Connection diagram B assigned unassigned Detailed drawing base Detailed drawing casing Pins used 24 V 1A for shock sensor 7 and 8 are open Shock sensor signal in...
Page 48: ...3 1 CN2 8 CN3 3 CN3 7 CN3 6 CN4 1 CN4 7 CN4 3 CN4 2 CN4 6 CN3 8 CN4 8 1BC 10X4 DATA 1 DATA 1 BAT 0V 5V FG1 PG DATA 2 DATA 2 5V OBT BAT 0V L AXIS PG S AXIS OBT PG U AXIS PG R AXIS No 16CN 16CN 1 6 2 4...
Page 49: ...4 CN5 5 CN5 6 CN6 1 CN6 2 CN6 3 CN6 4 CN6 5 CN6 6 2BC 6X6 Note 2 E E E 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 B...
Page 50: ...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 51: ...MONITORING TIME DATA EDIT DISPLAY UTILITY Main 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 MOV...
Page 52: ...Maintenance and inspection 9 52 1 Trained staff 2 YASKAWA trained staff 3 YASKAWA personnel...
Page 53: ...astening bolts 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 necessar...
Page 54: ...s see Chapter 9 4 1 Grease filling the main axes and 9 4 2 Grease filling the wrist axes 14 Overhaul 1 The item numbers correspond with the following figure Inspection intervals 2 When checking for co...
Page 55: ...Maintenance and inspection 9 55 Fig 9 2 Inspection intervals...
Page 56: ...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 57: ...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 58: ...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 59: ...ect the battery pack to the battery backup connector before removing the encoder connector The battery connectors are dealt with in the chapter 9 2 1 Battery pack replacement on page 56 9 3 1 Wrist un...
Page 60: ...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 pressure...
Page 61: ...eeze 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 speed 5 Wipe away excess grease with a cloth 6 Remove the...
Page 62: ...g Exchange 1950 cm ca 1700 g1 1 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 L axis gear Replenishment...
Page 63: ...ge 1 1 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 B and T axis gear Replenishment B axis 6 cm approx...
Page 64: ...n 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 combination...
Page 65: ...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 66: ...inspection 9 66 6 Select SELECT ALL AXES A confirmation dialog box is displayed 7 Select YES Displayed position data of all axes are registered as home position When NO is selected the registration w...
Page 67: ...module to be calibrated e g R1 ROBOT Perform steps 3 and 4 which have been described in Registering All Axes at One Time to select the desired control group 4 Select the axis to be registered A confi...
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: ...on related components but the robot was moved after the power supply was turned OFF If there is an error in the encoder communication related components the robot may stall when playback is started If...
Page 71: ...tion Setting Check Point 3 Alarm Occurrence If the alarm occurs again there may be an error in the encoder communication related components Check the components After adjusting the erroneous axis cali...
Page 72: ...elect ROBOT under the main menu 2 Select SECOND HOME POS The SECOND HOME POS window appears The Message Available to move to and modify specified point shown 3 Press the page key PAGE or select PAGE t...
Page 73: ...necessary operation such as replacing the PG system etc The robot current position data when turning main power supply ON and OFF can be confirmed in POWER ON OFF POS window NOTICE For details on the...
Page 74: ...cted manual speed 5 Select DATA on the menu 6 Select CONFIRM POSITION A message Home position checked appears Pulse data of the second home position and current pulse data should be compared Automatic...
Page 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...ng compound Teroson Plast 143813 Battery pack Robot 128708 Battery pack Controller 155543 Protective tube MTK 50FR 173362 Wire harness HW1171741 A 173375 Wire harness B and T axis HW1271106 A 173559 W...
Page 86: ...afety I O logic board JANCD YSF22 E 169501 General I O board PNP Type JANCD YIO22 E 164762 Power ON unit Cat 4 JZRCR YPU52 1 164764 Axis board SRDA EAXA21A 170560 Converter module SRDA COA30A21B E 164...
Page 87: ...tion Piece 1001 HW1100684 1 Housing 1 1002 M8 x 30 Screw 3 1007 1006 1005 1010 1022 1001 1023 1009 1013 1002 1003 1004 1015 1024 1027 1027 1016 1019 1020 1008 1012 1014 1011 1026 1044 1030 1017 1018 1...
Page 88: ...B 0860 Pipe 1 1019 MSB8 15 Screw 1 1020 HW0400645 3 Stop 1 1021 ATSH8 03 Connection 1 1022 HW1304380 1 Cover 1 1023 M6 x 15 Screw 7 1024 M6 x 15 Screw 2 1025 M5 x 10 Screw 6 1026 HW1304381 A Cover 1 1...
Page 89: ...2004 2L 6 Washer 1 2005 M12 x 40 Screw 12 2006 2H 12 Washer 12 2007 M10 x 35 Screw 6 2008 2L 10 Washer 6 2009 M12 x 35 Screw 2 2010 HW1405429 1 Washer 2 2011 HW0387753 G Gear 1 2012 M10 x 40 Screw 16...
Page 90: ...2016 SGMRV 13ANA YR1 Motor 1 2017 Y426012 5 Oil seal 1 2018 M8 x 25 Screw 4 2019 PT1 8 Grub screw 2 2020 PT3 8 Grub screw 1 2021 NPTF3 8 Grub screw 1 2022 HW1405456 1 Cover 1 2023 M6 x 15 Screw 4 2024...
Page 91: ...86 1 Housing 1 3002 M12 x 25 Screw 2 3003 2H 12 Washer 2 3004 HW1304321 1 Pinion 1 3005 NPTF3 8 Grub screw 1 3006 M5 x 90 Screw 1 3007 2L 5 Washer 1 3001 2001 3014 3006 3007 3002 3002 3005 3008 3003 3...
Page 92: ...M8 x 30 Screw 4 3016 PT3 8 Grub screw 1 3017 M4 x 12 Screw 3 3018 HW1405434 1 Cover 1 3019 CP 30 OB 8 Socket 1 3020 HW1405433 1 Cover 1 3021 M4 x 12 Screw 3 3022 KQE12 03 Connection 1 3023 PT3 8 Grub...
Page 93: ...ft 1 4005 M3 x 12 Screw 5 4006 HW1382521 A Gear 1 4007 TC52647 Oil seal 1 4008 M6 x 40 Screw 7 4002 4001 4003 4051 4004 4005 4016 4006 4026 4009 4010 4013 4007 4017 4032 4048 4037 4046 4049 4040 4018...
Page 94: ...T1 8 Grub screw 1 4026 HW1404157 Adjusting washer 1 4027 HW1405571 Adjusting washer 1 4028 TA1 S8 Terminal 1 4029 M4 x 6 Screw 1 4030 M4 Washer 1 4031 T30R Cable tie 1 4032 HW1405181 1 Support 1 4033...
Page 95: ...95 Tab 11 4 Parts list R axis drive 4050 M4 x 12 Screw 7 4051 HW9481319 D Cable feedthrough 1 4052 M4 x 12 Screw 1 4053 M4 x 12 Screw 2 3001 HW1100686 1 Housing 1 5001 HW1100687 1 U arm 1 No DWG no De...
Page 96: ...1 5008 HW1405425 1 Cover 2 5009 M4 x 16 Screw 2 5055 5047 5052 5053 5044 5045 5062 5063 5049 5006 5075 5004 5002 5074 5005 5002 5001 5013 5003 5012 5011 5010 5008 5056 5027 5050 5016 5015 5022 5019 5...
Page 97: ...ion 1 5027 M3 x 10 Screw 4 5028 AR28 Circlip 1 5029 HW1405355 1 Cover 1 5030 HW1405356 1 Shaft 1 5031 TCY53625 NBR Oil seal 1 5032 RNA4902 Bearing 1 5033 HW1304340 1 Pinion 1 5034 HW1371294 A Assembly...
Page 98: ...5061 M4 x 12 Screw 4 5062 HW1405650 1 Cover 1 5063 HW1405651 1 Sealing 1 5064 M4 x 10 Screw 2 5065 M4 x 12 Screw 4 5066 M3 x 10 Screw 4 5067 M3 x 10 Screw 2 5068 M4 x 12 Screw 4 5069 M4 x 12 Screw 14...
Page 99: ...Parts list gear unit No DWG no Description Pcs 6001 HW1303251 1 Pinion outer part 1 6002 HW1303252 1 Pinion outer part 1 6003 HW1404051 1 Sleeve 2 6004 HW1404050 1 Pin 6 6005 HW1405463 2 Clamping slee...
Page 100: ...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...
