YASKAWA MOTOMAN-MFL15D-875 Instructions Manual Download

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MANUAL NO.

HW1483905

Part Number:

179394-1CD

Revision:

MOTOMAN-MFL15D-875/-1600

INSTRUCTIONS

TYPE:

YR-MFL015D-A00 (875ST, MOTOMAN-MFL15D-875)

YR-MFL015D-A20 (1600ST, MOTOMAN-MFL15D-1600)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN-MFL15D-875/-1600 INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL

The DX200 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

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Summary of Contents for MOTOMAN-MFL15D-875

Page 1: ...Upon receipt of the product and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN MFL15D 875 1600 INSTRUCTIONS DX200 INSTRUCTIO...

Page 2: ...righted 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 t...

Page 3: ...manual CAUTION Some drawings in this manual are shown with the protective covers or shields removed for clarity Be sure all covers and shields are replaced before operating this product The drawings a...

Page 4: ...ponsible for providing adequately trained personnel to operate program and maintain the equipment NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE PROGRAM OR REPAIR THE EQUIPMENT We recommend approved YASKA...

Page 5: ...personnel CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury to personnel and damage to equipment It may also be used to alert against un...

Page 6: ...of the manipulator Be sure to use a lockout device to the safeguarding when going inside Also display the sign that the operation is being performed inside the safeguarding and make sure no one close...

Page 7: ...trademarks or brand names for each company or corporation The indications of R and TM are omitted CAUTION Perform the following inspection procedures prior to conducting manipulator teaching If proble...

Page 8: ...formation is placed on the body of the manipulator Prior to operating the manipulator confirm the contents WARNING Do not enter robot work area WARNING Moving parts may cause injury Nameplate Warning...

Page 9: ...er it is not in use In accordance with ANSI RIA R15 06 2012 section 4 2 5 Sources of Energy use lockout tagout procedures during equipment maintenance Refer also to Section 1910 147 29CFR Part 1910 Oc...

Page 10: ...a backup must always be made before any service procedures are done and before any changes are made to options accessories or equipment Any modifications to the controller unit can cause severe perso...

Page 11: ...ualified personnel Summary of Warning Information This manual is provided to help users establish safe conditions for operating the equipment Specific considerations and precautions are also described...

Page 12: ...ately 24 to 36 hours for a response to your inquiry Please have the following information ready before you call Customer Support techsupport motoman com NOTE Please use e mail for routine inquiries on...

Page 13: ...Manipulator and Mounting Fixture Are Installed on a Common Base 3 3 3 2 2 When the Manipulator Is Mounted Directly on the Floor 3 4 3 3 Installation Method 3 5 3 4 Location 3 5 3 5 Required Maintenan...

Page 14: ...Detection Sensors 8 1 8 2 Internal Connections 8 2 9 Maintenance and Inspection 9 1 9 1 Inspection Schedule 9 1 9 2 Notes on Maintenance Procedures 9 5 9 2 1 Battery Pack Replacement 9 5 9 3 Grease E...

Page 15: ...anipulator and Cap Mounting Positions and Fig 2 3 b MFL15D 1600 Thick Washer delivered with the manipulator and Cap Mounting Positions CAUTION Confirm that the manipulator and the DX200 have the same...

Page 16: ...CONTROLLER SHOULD HAVE SAME ORDER NUMBER ORDER No O T P S ER M E E G N Y C E T E S R F F O D E P P I R T N O DX200 MFL15DN NJ3005 1 CHECK ALL THE DOOR LOCKS PROPERLY PROGRAMMING PENDANT X 8 1 MADE IN...

Page 17: ...e manipulator is fixed with the shipping bolts and brackets before transporting and lift it in the posture as shown in Fig 2 1 a Transporting Position MFL15D 875 and Fig 2 1 b Transporting Position MF...

Page 18: ...ethod 2 2 179394 1CD HW1483905 MFL15D 875 1600 Fig 2 1 a Transporting Position MFL15D 875 Fig 2 1 b Transporting Position MFL15D 1600 Delivered with the manipulator Eyebolt M16 B Delivered with the ma...

Page 19: ...ng or slippage Fig 2 2 Using a Forklift NOTE Check that the eyebolts are securely fastened The mass of the manipulator is approximately 420 kg MFL15D 875 and 610 kg MFL15D 1600 with shipping bolts and...

Page 20: ...nd caps as shown in Fig 2 3 a MFL15D 875 Thick Washer delivered with the manipulator and Cap Mounting Positions and Fig 2 3 b MFL15D 1600 Thick Washer delivered with the manipulator and Cap Mounting P...

Page 21: ...15D 1600 Thick Washer delivered with the manipulator and Cap Mounting Positions Flat washer M12 3 washers Tickness 5mm Nickel plated Flat washer M12 2 washers Tickness 5mm Nickel plated Flat washer M1...

Page 22: ...s fully extended Failure to observe this warning may result in injury or damage Do not start the manipulator or even turn ON the power before it is firmly anchored The manipulator may overturn and cau...

Page 23: ...gnals 3 2 Mounting Procedures for Manipulator Base The manipulator should be firmly mounted on a base or foundation strong enough to support the manipulator and withstand reaction forces during accele...

Page 24: ...is recommended for an anchor bolt There are four mounting holes on the manipulator base Fix the manipulator securely with the hexagon socket head cap screws M16 60 mm long recommended Tighten the scre...

Page 25: ...ion forces of the manipulator As a rough standard if a concrete thickness floor is 150 mm or more the manipulator base can be fixed directly on the floor with anchor bolts M16 Before mounting the mani...

Page 26: ...no moisture non condensing Free from water Free from corrosive gases or liquid or explosive gases Free from excessive impact or vibration vibration acceleration 4 9 m s2 0 5 G or less Free from large...

Page 27: ...3905 3 Installation 3 5 Required Maintenance Space MFL15D 875 1600 Fig 3 3 a Maintenance Space MFL15D 875 Fig 3 3 b Maintenance Space MFL15D 1600 1310 730 580 810 810 1620 R 1 7 0 460 700 810 1130 116...

Page 28: ...POWER ON Failure to observe this warning may result in fire or electric shock CAUTION Wiring must be performed by authorized or certified personnel Failure to observe this caution may result in fire o...

Page 29: ...ion method refer to Fig 4 3 a Manipulator Cable Connection Manipulator Side and Fig 4 3 b Manipulator Cable Connection DX200 Side 4 2 1 Connection to the Manipulator Verify the numbers on both the man...

Page 30: ...cables to the board in the order of 2BC and 1BC Be sure to verify the numbers on both the cables and board connectors before connection After the connection tighten attached screws on 1BC connector wi...

Page 31: ...R 2 L 1 L 2 R 1 1BC 2BC BCL X11 X21 O T P S ER M E E G N Y C E T E S R F F O D E P P I R T N O DX200 MFL15DN NJ3005 1 CHECK ALL THE DOOR LOCKS PROPERLY PROGRAMMING PENDANT X 8 1 MADE IN JAPAN AC220V D...

Page 32: ...ot use a cable duct lay down the encoder and power cables with keeping one cable away from the other cable The distance between the encoder cable and the power cable should be 50 mm or more as a rough...

Page 33: ...mum Speed U axis 700 mm s max 600 mm s max S axis 3 93 rad s 225 s L and R axes 1800 mm s max Allowable Moment L and R axes 30 0 N m 3 0 kgf m Allowable Inertia GD2 4 3 3 Refer to section 6 1 Allowabl...

Page 34: ...ecifications 5 3 Part Names and Working Axes Fig 5 1 Part Names and Working Axes The manipulator conforms to ISO cleanliness class 41 1 Under the condition that the manipulator is in the downflow of 0...

Page 35: ...r Base Dimensions MFL15D 1600 555 470 85 450 60 500 60 711 460 251 420 156 95 18 dia holes 4 holes for manipulator mounting Mounting holes Mounting holes Turning axis S axis center of rotation View A...

Page 36: ...pe 5 4 179394 1CD HW1483905 MFL15D 875 1600 5 5 Dimensions and Working Envelope Fig 5 3 a Dimensions and Working Envelope MFL15D 875 B 512 308 820 430 1324 165 165 210 820 820 Turning axis S axis cent...

Page 37: ...ications 5 5 Dimensions and Working Envelope MFL15D 875 1600 Fig 5 3 b Dimensions and Working Envelope MFL15D 1600 B 543 310 853 430 1324 165 165 210 820 820 Turning axis S axis center of rotation 195...

Page 38: ...e the pulse is positive the S and U axes cannot move faster than the specified speed limit The following alarm occurs if an attempt is made to use a move instruction to move the axes faster than the s...

Page 39: ...5 1600 R and L axes posture S and U axes movement No limitation Enabled at a speed lower than the speed limit Alarm occurs at a speed exceeding the speed limit In playback operation forward backward o...

Page 40: ...o move either the L or R axis move first the other axis backward from the limited position Then start moving the L or R axis from the position The following alarm occurs if an attempt is made to execu...

Page 41: ...Either the L or R axis can be moved without limitations when the other axis is in the backward position from the limited position The L axis cannot be moved when the R axis is in the direction from th...

Page 42: ...wable wrist load is 15 kg arm If force is applied to the wrist instead of the load force on the R and L axes should be within the value shown in Table 6 1 Allowable Moment and Inertia Contact your YAS...

Page 43: ...e and outside of the attachment must be 8 mm or less Fig 6 1 Wrist Flange L side R side 10 10 10 10 3 0 PCD100 PCD150 30 3 0 PCD100 PCD150 30 8 fitting depth 8 fitting depth 8 fitting depth Details of...

Page 44: ...in the manipulator for the drives of the peripheral devices mounted on the upper arm as shown in Fig 7 1 Internal User I O Wiring Harness and Air Lines The connector pins 1 to 12 are assigned as shown...

Page 45: ...tails Air supply inlet 2 inlets Taped hole PT1 8 with pipe plug Left side Port L 1 Right side Port L 2 Section B B BCR for internal user I O wiring harness HR10A 10R 12S socket connector Prepare pin c...

Page 46: ...d with a single lead wire of 0 2 mm2 1 5 3 6 10 8 12 14 16 4 2 1 3 4 5 6 2 7 11 9 13 15 11 12 8 10 9 7 2 3 10 9 8 1 5 6 7 12 11 2 3 1 6 7 5 8 4 4 12 10 11 9 Key position Internal user I O wiring harne...

Page 47: ...1 Location of the Broken Belt Detection Sensor Fig 8 1 Location of the Broken Belt Detection Sensor NOTE If a message for a broken belt appears remove the cover on the U arm and check if the belt is b...

Page 48: ...5 d Internal Connection Diagram MFL15D 1600 for the internal connections between the inside of the manipulator and the DX200 Fig 8 2 Locations and Numbers of Connectors Connector for internal user I...

Page 49: ...BAT4 0BAT1 PG0V2 PG5V1 PG0V1 PG0V3 PG0V4 PG5V4 PG5V3 PG5V2 Encoder Power Board 0BAT12 0BAT21 0BAT22 0BAT11 8 2 4 1CN 1 3 24V 0V 0V BAT 6 BAT21 0BT BAT 2 5 4 3 7 6 8 7 1 BAT22 BAT 0BT BAT 0BT 0BT 4 BA...

Page 50: ...2 4 5 6 8CN 1 3 2 6CN 1 6 2 5 4 3 7CN 1 3 4 5 2 6 6 5 9CN 1 3 4 2 6 24CN 1 2 4 5 6 3 25CN 1 2 6 5 3 4 23CN 1 3 4 5 2 6 22CN 1 2 5 4 3 BCL BCR BCR 2 BCR 11 BCR 12 BCR 10 BCR 8 BCR 9 BCR 7 BCR 3 BCR 5...

Page 51: ...6 CN3 7 DATA 8 DATA 8 FG8 CN4 5 CN4 4 CN2 1 CN2 2 CN4 10 CN1 10 CN1 4 CN1 5 CN1 9 CN2 3 CN3 3 CN3 1 CN3 2 CN3 8 CN3 6 CN3 7 CN4 8 CN4 3 CN2 7 CN2 6 CN1 7 CN1 3 CN1 6 CN1 1 CN1 2 CN1 8 CN2 8 CN4 1 CN4...

Page 52: ...4 31CN 1 2 MW1 BA1 ME1 BB1 MV1 MU1 MW2 BB2 ME2 BA2 MV2 MU2 CN3 4 CN3 5 CN3 6 MW1 ME1 MV1 MU1 BB1 MV2 MU2 BA1 BB2 ME2 BA2 MW4 BB4 ME4 BA4 MV4 MU4 MW2 3 4 6 5 3 4 6 5 2 20CN 1 3 5 4 2 6 19CN 1 2 18CN 1...

Page 53: ...ection must be performed by specified personnel Failure to observe this caution may result in electric shock or injury For disassembly or repair contact your YASKAWA representative Do not remove the m...

Page 54: ...cks and grease leakage 2 Manipulator base mounting bolts Spanner wrench Tighten loose bolts Cover mounting screws Phillips screwdriver wrench Tighten loose screws Connector base Manual Check for loose...

Page 55: ...for U Axis Cross Roller Bearing Overhaul 1 Inspection No correspond to the numbers in Fig 9 1 Inspection Parts and Inspection Numbers 2 If a grease leakage occurs contact your YASKAWA representative a...

Page 56: ...ion Items 1 1 1 1 7 7 7 7 7 7 7 7 9 4 4 8 2 2 6 10 12 12 13 14 15 16 11 S axis R axis L axis U axis 14 15 16 Table 9 2 Inspection Parts and Grease Used No Grease Used Inspected Parts Molywhite RE No 0...

Page 57: ...in Fig 9 2 Battery Pack Location If a battery alarm occurs in the DX200 replace the battery pack according to the following procedure Fig 9 2 Battery Pack Location Fig 9 3 Battery Pack Connection Pla...

Page 58: ...ace it with the new one 3 Remove the battery pack from the battery holder 4 Connect the new battery pack to the unoccupied connector on the board 5 Remove the old battery pack from the board 6 Mount t...

Page 59: ...damage to the motor and speed reducer Make sure to remove the plug before the grease injection When attaching a joint and a hose to the grease exhaust port make sure to use the hose whose inside diame...

Page 60: ...nt Exchange for U Axis Speed Reducer Fig 9 4 U Axis Speed Reducer Cover Ui Grease inlet Hexagon socket head plug PT1 8 U axis speed reducer U axis speed reducer Uo Grease exhaust port Hexagon socket h...

Page 61: ...off and the new grease appears in the Uo grease exhaust ports The new grease can be distinguished from the old grease by color 4 Move the U axis for a few minutes to discharge excess grease 5 Wipe off...

Page 62: ...1 Posture the R and L axes as shown in Fig 9 5 2 Remove the hexagon socket head plugs PT1 8 on the So grease exhaust port and the Si grease inlet So Grease exhaust port Hexagon socket head plug PT1 8...

Page 63: ...plete when the old grease is drained off and the new grease appears in the So grease exhaust port The new grease can be distinguished from the old grease by color 5 Move the S axis for a few minutes t...

Page 64: ...gon socket head plug PT 1 8 Ro Exhaust port Hexagon socket head plug PT1 8 Ro Exhaust port Hexagon socket head plug PT1 8 Ri Grease inlet Hexagon socket head plug PT1 8 Ri Grease inlet Hexagon socket...

Page 65: ...3 Install grease zerks A PT1 8 on the respective Ri and Li grease inlets then inject grease into the respective Ri and Li grease inlets 4 Move the R and L axis for a few minutes to discharge excess g...

Page 66: ...omplete when the old grease is drained off and the new grease appears in the Ro and Lo grease exhaust ports The new grease can be distinguished from the old grease by color 5 Move the R and L axis for...

Page 67: ...ig 9 7 U Axis Cross Roller Bearing 3 Reinstall the hexagon socket head plug PT1 8 on the Uco exhaust port Apply ThreeBond 1206C to the thread parts 4 Reinstall the hexagon socket head plug PT1 8 on th...

Page 68: ...enance Inspecting Broken Belt Detection Sensor Remove the cover and check if any foreign matter adheres to the projector or the photo detector of the broken belt detection sensor If any dirt or dust i...

Page 69: ...nector Diagram for S L and R Axes b a a b 0BT BAT BAT 0BT Motor Motor power connector Encoder connector Battery pack HW9470917 A Connector for battery back up OBT BAT OBT4 BAT4 OBT BAT b b OBT4 BAT4 b...

Page 70: ...your YASKAWA representative Table 10 1 Spare Parts for the MOTOMAN MFL15D 875 YR MFL015D A00 Rank Parts No Name Type Manufacturer Qty Qty per Unit Remarks A 1 Grease Molywhite RE No 00 YASKAWA 16 kg A...

Page 71: ...e casing B 17 Internal cable HW1372398 A HW0373537 A HW0373537 B HW0373536 C HW0373536 D YASKAWA 1 each 1 each B 18 Internal cable HW1271492 Z YASKAWA 1 1 Between the box and U axis motor B 19 Broken...

Page 72: ...imited 1 each 2 each B 10 Replacement kit for U axis lower part speed reducer Y005C MFL015DA20U1 YASKAWA 1 1 B 11 Replacement kit for U axis upper part speed reducer Y005C MFL015DA20U2 YASKAWA 1 1 B 1...

Page 73: ...or for U axis HW0382198 A SGMRS 30A2A YR1 YASKAWA 1 1 C 22 AC servomotor for S axis HW0383251 A SGMPH 04A2A YR2 YASKAWA 1 1 C 23 AC servomotor for R L axes HW0382152 A SGMPH 02A2A YR1 YASKAWA 1 2 Tabl...

Page 74: ...aon Haryana India Fax 91 124 475 8542 Phone 91 124 475 8500 YASKAWA India Private Ltd Robotics Division YASKAWA Electric China Co Ltd 22F One Corporate Avenue No 222 Hubin Road Huangpu District Shangh...

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