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9-5

179394-1CD

HW1483905

Maintenance and Inspection

9.2 Notes on Maintenance Procedures

MFL15D-875/-1600

9.2

Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

Two battery packs are mounted on the position indicated 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

Plate mounting bolt M4
(10 bolts) (SUS Made)
Cross-recessed pan head machine screw
with captive washer

Plate

Battery pack: HW0470360-A

See step 5 below.

Connector

Battery pack before
replacement

See step 4 below.

New battery pack

57 of 74

Содержание MOTOMAN-MFL15D-875

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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