Operating and Mantenance HP20D

H50 06.560GB

HP20D-C09

Operating and Maintenance Instructions

HP20D-C09TYP: YR-HP20D-C09 (STANDARD-SPECIFICATION)

(IP65 AND SPECIAL WIRE HARNESS IN MANIPULATOR SPECIFICATION)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference
The operating instructions are only for internal use.

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Reference list:

Documentnumber

List of modifications

Creation of original

document

Modification in the original document

In section On page Date Author

E1101000130GB01 x 29.10.2010 DD

E1101000130GB02 rework 09.11.2010 REB

E1101000130GB03 rework chapter 3 10.11.2010 REB

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WARNINGThis instruction manual is intended to explain mainly on the mechanical part of the YASKAWA-HP20D-C09 for the application to the actual operation and for proper maintenance and inspection. It describes on safety and handling, details on specifications, necessary items on maintenance and inspection, to explain operating instructions and maintenance procedures. Be sure to read and understand this instruction manual thoroughly before installing and operating the robot.

General items related to safety are listed in Section 1: Safety of the DX100 Instructions. To ensure correct and safe operation, carefully read the DX100 Instructions before reading this manual.

CAUTIONSome 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 and photos in this manual are representative examples and differences may exist between them and the delivered product.

YASKAWA europe GmbH may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications.

If such modification is made, the manual number will also be revised.

If your copy of the manual is damaged or lost, contact a YASKAWA europe GmbH 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 europe GmbH is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product's warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the YASKAWA-HP20D.

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

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

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 unsafe practices.

Always be sure to follow explicitly the items listed under this heading.

Must never be performed.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as "CAU-TION" and "WARNING".

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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WARNINGBefore operating the robot, check that servo power is turned OFF pressing the emergency stop buttons on the front door of the DX100 and the programming pendant.When the 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 robot during an emergency. The robot should not be used if the emergency stop buttons do not function.

Fig 1: Emergency Stop Button

Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the robot. Then turn the servo power ON.

Injury may result from unintentional or unexpected robot motion.

Fig 2: Release of Emergency Stop

Observe the following precautions when performing teaching operations within the P-point maximum envelope of the robot:

– View the robot from the front whenever possible.

– Always follow the predetermined operating procedure.

– Ensure that you have a safe place to retreat in case of emergency.

– Improper or unintended robot operation may result in injury.

Confirm that no person is present in the P-point maximum envelope of the robot and that you are in a safe location before:

– Turning on the power for the DX100.

– Moving the robot with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the robot during operation. Always press an emergency stop button immediately if there is a problem.

The emergency stop buttons are located on the right of front door of the DX100 and the programming pendant.

TURN

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Definition of Terms Used Often in This Manual

The YASKAWA robot is the YASKAWA industrial robot product.

The YASKAWA usually consists of the controller, the programming pendant, and supply cables.

In this manual, the equipment is designated as follows:

CAUTIONPerform the following inspection procedures prior to conducting robot teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.

- Check for problems in robot 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 after use.

The programming pendant can be damaged if it is left in the robot's work area, on the floor, or near fixtures.

Read and understand the Explanation of Warning Labels in the DX100 Instructions before operating the robot:

Equipment Manual Designation

DX100 controller DX100

DX100 programming pendant Programming pendant

Cable between the robot and the controller Robot cable

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Table of Contents

1 Product Confirmation............................................................................................................ 81.1 Contents Confirmation ............................................................................................................. 81.2 Order Number Confirmation .................................................................................................... 9

2 Transport .............................................................................................................................. 102.1 Transport Method .................................................................................................................. 102.2 Shipping Bolts and Brackets.................................................................................................. 12

3 Installation............................................................................................................................ 143.1 Safeguarding Installation ....................................................................................................... 153.2 Mounting Procedures for Robot Base.................................................................................... 153.3 Types of Mounting ................................................................................................................. 173.4 Location ................................................................................................................................. 18

4 Wiring.................................................................................................................................... 194.1 Grounding .............................................................................................................................. 194.2 Cable Connection .................................................................................................................. 20

5 Basic Specifications............................................................................................................ 235.1 Basic Specifications............................................................................................................... 235.2 Part Names and Working Axes.............................................................................................. 255.3 Robot Base Dimensions ........................................................................................................ 265.4 Dimensions and P-Point Maximum Envelope........................................................................ 275.5 Alterable Operating Range .................................................................................................... 28

6 Allowable Load for Wrist Axis and Wrist Flange .............................................................. 296.1 Allowable Wrist Load ............................................................................................................. 296.2 Wrist Flange........................................................................................................................... 31

7 System Application ............................................................................................................. 327.1 Peripheral Equipment Mounts ............................................................................................... 327.2 Internal User I/O Wiring Harness and Air Line....................................................................... 33

8 Electrical Equipment Specification.................................................................................... 368.1 Position of Limit Switch.......................................................................................................... 368.2 Internal Connections.............................................................................................................. 36

9 Maintenance and Inspection............................................................................................... 409.1 Inspection Schedule .............................................................................................................. 419.2 Notes on Maintenance Procedures ....................................................................................... 469.3 Notes on Grease Replenishment/Exchange Procedures ...................................................... 489.4 Setting the Second Home Position (Check Point) ................................................................. 69

10 Recommended Spare Parts ................................................................................................ 82

11 Parts List .............................................................................................................................. 8411.1 S-Axis Unit ............................................................................................................................. 8411.2 L-Axis Unit ............................................................................................................................. 8611.3 U-Axis Unit ............................................................................................................................. 8811.4 R-Axis Unit ............................................................................................................................. 9011.5 Wrist Unit ............................................................................................................................... 93

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1 Product Confirmation

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (information for the content of optional goods are given separately):

● Robot

● DX100

● Programming pendant

● Robot cables (Between Robot and DX100)

CAUTIONConfirm that the robot and the DX100 have the same order number. Special care must be taken when more than one robot is to be installed.

If the numbers do not match, robots may not perform as expected and cause injury or damage.

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1.2 Order Number Confirmation

Check that the order number of the robot corresponds to the DX100. The order number is located on a label as shown below.

Fig. 3: Location of Order Number Labels

S/N. � � � � � � � �

PROPERLY.

CHECK ALL THE DOOR LOCKS

NJ3005-1

kVAkVA

ERDR-

Average

Peak

NJ3053-1

Kammerfeldstr. 1, D-85391 Allershausen

Motoman2-1 Kurosaki Shiroishi Yahatanishi-Ku Kitakyushu-City Fukuoka 806-0004 Japan

YASKAWA Electric corporation

Robot Serial No.

Robot Order No.

Robot Type

TypeDate/Signature

Serial No.

AC 400/415/440 V

Power Supply

Part No.

Motoman DX100

with power ON.

WARNINGDo not open the door

High Voltage

THE MANIPULATOR AND THE CONTROLLERSHOULD HAVE SAME ORDER NUMBER.

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2 Transport

2.1 Transport Method

CAUTIONSling applications and crane or forklift operations must be performed by authorized personnel only.

Failure to observe this caution may result in injury or damage.

Avoid excessive vibration or shock during transport.

The system consists of precision components; failure to observe this caution may adversely affect performance.

Check that the eyebolts are securely fastened.

The weight of the robot is approximately 280 kg including the shipping bolts and brackets. Use a wire rope strong enough to withstand the weight.

Attached eyebolts are designed to support the robot mass. Do not use them for anything other than transporting the robot.

Make sure to mount the shipping bolts and brackets when transporting the robot. (Refer to Fig. 4: "Transporting Position" at Page 11)

With any transportation equipment, make sure to avoid external force on the arm or motor unit when transporting the robot.

NOTE

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2.1.1 Using a Crane

As a rule, the robot should be lifted by a crane with two wire ropes when removing it from the package and moving it. Be sure that the robot is fixed with the shipping bolts and brackets before transport, and lift it in the posture as shown in Fig. 4: "Transporting Position".

Fig. 4: Transporting Position

Table 1: Transporting Position

1 Eyebolt M12 (2 eyebolts), delivered with the robot

2 View E

3 View F

4 Eyebolt M12 (2 eyebolts), delivered with the robots

F

E

C

B

A

D

1

2

3

4

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2.1.2 Using a Forklift

When using a forklift, the robot should be fixed on a pallet with shipping bolts as shown in Fig. 5: "Using a Forklift". Insert claws under the pallet and lift it. The pallet must be strong enough to support the robot. Transport the robot slowly with due caution in order to avoid overturning or slippage.

Fig. 5: Using a Forklift

2.2 Shipping Bolts and Brackets

The robot is provided with shipping bolts and brackets at sections A and B. (See Fig. 6: "Shipping Bolts and Brackets" at Page 13).

Table 2: Using a Forklift

1 Bolt M16 (4 places)

2 Palleet

3 Forklift claw entry

1

2

3

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Fig. 6: Shipping Bolts and Brackets

● The brackets in the sections A and B are painted yellow.

● The section A is fixed with a hexagon socket head cap screw M8, and the section B is fixed with two hexagon socket head cap screws M6.

● A rubber cushion is respectively wedged at the sections C and D.

Table 3: Shipping Bolts and Brackets

1 Eyebolt M12 (2 eyebolts), delivered with the robot

2 Enlarged View: Sections B and D

3 Parts Drawing for Section B

4 Enlarged View: Section C

5 Parts Drawing for Section A

6 Enlarged View: Section A

Before turning ON the power, check to be sure that the shipping bolts and brackets are removed. The shipping bolts and brackets then must be stored for future use, in the event that the robot must be moved again.

B

A C

D

1

2

3

46

5

NOTE

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3 Installation

WARNINGInstall the safeguarding.

Failure to observe this warning may result in injury or damage.

Install the robot in a location where the fully extended arm and tool will not reach the wall, safeguarding, or controller.

Failure to observe this warning may result in injury or damage.

Do not start the robot or even turn ON the power before it is firmly anchored.

The robot may overturn and cause injury or damage.

When mounting the robot on the wall, the base section must have sufficient strength and rigidity to support the weight of the robot. Also, it is necessary to consider countermeasures to prevent the robot from falling.

Failure to observe these warnings may result in injury or damage.

CAUTIONDo not install or operate the robot that is damaged or lacks parts.

Failure to observe this caution may cause injury or damage.

Before turning ON the power, check to be sure that the shipping bolts and brackets explained in Fig. 6: "Shipping Bolts and Brackets" at Page 13 are removed.

Failure to observe this caution may result in damage to the driving parts.

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3.1 Safeguarding Installation

To insure safety, be sure to install safeguarding. It prevents unforeseen accidents with personnel and damage to equipment. Refer to the quoted clause for your information and guidance:

Responsibility for Safeguarding (ISO10218)

The user of a robot or robot system shall ensure that safeguards are provided and used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safeguarding, including any redundancies, shall correspond directly to the type and level of hazard presented by the robot system consistent with the robot application. Safeguarding may include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter guarding, awareness barriers, and awareness signals.

3.2 Mounting Procedures for Robot Base

The robot should be firmly mounted on a baseplate or foundation strong enough to support the robot and withstand repulsion forces during acceleration and deceleration.

Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the robot referring to Table 4: "Maximum Repulsion Forces of the Robot at Emergency Stop" and Table 5: "Endurance Torque in Operation".

A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness of installation surface may deform the robot shape and affect its functional abilities. Mount the robot base as instructed in 3.2.1 "Mounting Example".

Table 4: Maximum Repulsion Forces of the Robot at Emergency Stop

Maximum torque in horizontal rotation

(S-axis moving direction)

8000 Nm

Maximum torque in vertical rotation

(LU-axes moving direction)

5000 Nm

Table 5: Endurance Torque in Operation

Endurance torque in horizontal operation

(S-axis moving direction)

1700 Nm

Endurance torque in vertical operation

(LU-axes moving direction)

3775 Nm

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3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The baseplate should be rugged and durable to prevent shifting of the robot or the mounting fixture. It is recommend to prepare a baseplate of 32 mm or more thick, and anchor bolts of M16 or larger size.

The robot base is tapped for four mounting holes; securely fix the robot base to the baseplate with four hexagon head bolts M16 (60 mm long is recommended). Next, fix the robot base to the baseplate. Tighten the hexagon head bolts and anchor bolts firmly so that they will not work loose during the operation (Refer to Fig. 7: "Mounting the Robot on Baseplate").

Fig. 7: Mounting the Robot on Baseplate

Table 6: Mounting the robot an baseplate

1 Screw M16 (4 screws) 5 Baseplate

2 Spring washer 6 Anchor bolt M16 or more

3 Washer 7 Baseplate

4 Robot base 8 Robot base

25

21

3

4

5

6

7

8

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Fig. 8: Baseplate

3.3 Types of Mounting

The YASKAWA-HP20D-C09 is available in two types: floor-mounted type (standard), wall-mounted type. For wall-mounted type, the three points listed below are different from the floor-mounted type.

● S-Axis Operating Range

● Fixing the Robot Base

● Precautions to Prevent the Robot from Falling

● IP (International Protection) for Main Part of the Robot

3.3.1 S-Axis Operating Range

For wall-mounted type, the S-axis operating range is ±30° (Set before the shipment).

3.3.2 Fixing the Robot Base

For wall- and ceiling-mounted types, be sure to use four hexagon socket head cap screws M16 (tensile strength: 1200 N/mm2 or more) when fixing the robot base. Use a torque of 206 Nm when tightening the screws.

Table 7: Baseplate

1 t = 25 mm up to 50 kg of robots

5

5

80

580

580

520

520

335

260

335

260

36 (4

x)

24 (8

x)

3

1

2

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3.3.3 IP (International Protection) for Main Part of the Robot

For wall-mounted or ceiling mounted types, environmental resistance for main part of the robot does not conform to IP54; environmental resistance for IP65 is optionally available. However, the wrist part conforms to IP67.

3.4 Location

When the robot is installed, it is necessary to satisfy the following environmental conditions:

● Ambient temperature: 0° to +45°C

● Humidity: 20 to 80%RH (at constant temperature)

● Free from dust, soot, or water

● Free from corrosive gases or liquids, or explosive gases

● Free from excessive vibration (Vibration acceleration: 4.9 m/s2 or less [0.5 G] or less)

● Free from large electrical noise (plasma)

● Flatness for installation: 0.5 mm or less

In case of using the wall-mounted type, inform Yaskawa of the matter when placing an order. Be sure to contact YASKAWA europe GmbH representative (listed on the back cover of this instruction manual) to execute a wall installation on site.

NOTE

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4 Wiring

4.1 Grounding

Follow local regulations for grounding line size. A line of 6.0 mm2 or more is recommended. Refer to Fig. 9: "Grounding Methode" at Page 20 to connect the ground line directly to the robot.

WARNINGGround resistance must be 0.1 Ω or less.

Failure to observe this warning may result in fire or electric shock.

Before wiring, make sure to turn the primary power supply off, and put up a warning sign. (ex. DO NOT TURN THE POWER ON).

Failure to observe this warning may result in fire or electric shock.

CAUTIONWiring must be performed by authorized or certified personnel. Failure to observe this caution may result in fire or electric shock.

Never use this line sharing with other ground lines or grounding electrodes for other electric power, motor power, welding devices, etc.

Where metal ducts, metallic conduits, or distributing racks are used for cable laying, ground in accordance with Electric Equipment Technical Standards.

NOTE

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Fig. 9: Grounding Methode

4.2 Cable Connection

Two robot cables are delivered with the robot; an encoder cable and a power cable (2BC). (Refer to Fig. 10: "Robot Cables" at Page 21).

Connect the robot cables to the connectors on the robot connector base and connectors on the DX100. Refer to Fig. 11: "Robot Cable Connectors (Robot Side)" at Page 22, Fig. 12: "Robot Cable Connection to the DX100" at Page 22.

4.2.1 Connection to the Robot

Before connecting the cables to the robot, verify the numbers on robot cables and the connectors on the connector base of the robot. When connecting, adjust the cable connector positions to the main key positions of the robot, and insert cables in the order of 2BC, then 1BC, and set each lever low until it clicks.

Table 8: Grounding Methode

1 5.5 mm² or more

2 Section A-A

3 Bolt M8 (for grounding), delivered with the robot

AA

1

23

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4.2.2 Connection to the DX100

Before connecting two cables to the DX100, verify the numbers on both robot cables and the connectors on the DX100. When connecting, insert the cables in the order of X21, then X11, and set each lever low until it clicks.

Fig. 10: Robot Cables

Table 9: Robot Cables

1 The robot side

2 Encoder cables

3 Power cables

4 The DX100 Side

X1

X2

X1

X2

2BC

1BC

4 1

2

3

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Fig. 11: Robot Cable Connectors (Robot Side)

Fig. 12: Robot Cable Connection to the DX100

Table 10: Robot cable connectors (Robot side)

1 1 BC 4 Union

2 2 BC 5 Grease hose

3 Connector base fixing screw (M4)

Table 11: Robot cableconnection to the DX100

1 Back view

1BC 2BC

1BC

2BC

1

2

3

4

5

X 11

X 21X 1

X 2

1

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5 Basic Specifications

5.1 Basic Specifications

Table 12: Basic Specifications

Item Model YASKAWA-HP20D-C09

Structure Vertically Articulated

Degree of Freedom 6

Payload 20 kg

Repeatability1) ±0.06 mm

Range of Motion S-Axis (turning) -180° - 180°

L-Axis (lower arm) -110° - 155°

U-Axis (upper arm) -165° - 255°

R-Axis (wrist roll) -200° - 200°

B-Axis (wrist pitch/yaw)

-50° - 230°

T-Axis (wrist twist) -360° - 360°

Maximum Speed S-Axis 3.44 rad/s, 197°/s

L-Axis 3.05 rad/s, 175°/s

U-Axis 3.26 rad/s, 187°/s

R-Axis 6.98 rad/s, 400°/s

B-Axis 6.98 rad/s, 400°/s

T-Axis 10.47 rad/s, 600°/s

Allowable Moment2) R-Axis 39.2 Nm

B-Axis 39.2 Nm

T-Axis 19.6 Nm

Allowable Inertia

(GD2/4)

R-Axis 1.05 kgm2

B-Axis 1.05 kgm2

T-Axis 0.75 kgm2 3)

Approx. Mass 273 kg

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Ambient Conditions Temperature 0°C to 45°C

Humidity 20 to 80% RH (non-condensing)

Vibration Acceleration 4.9 m/s2 or less (0.5 G)

Others Free from corrosive gasses or liquids, or explosive gasses. Free from dust, soot, and substances that spoil sealing performance of the lips of nitrile rubber oil seals used in the manipulator. Free from excessive electrical noise (plasma)

Power Requirements 2.0 kVA

1. Conformed to ISO92832. Refer to chapter „6 "Allowable Load for Wrist Axis and Wrist Flange"“ for details on the permissible moment of

inertia.3. The allowable inertia of T-axis varies depending on the added value of the moment. Refer to 6 "Allowable Load

for Wrist Axis and Wrist Flange" for the details.

Table 12: Basic Specifications

Item Model YASKAWA-HP20D-C09

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5.2 Part Names and Working Axes

Fig. 13: Part Names and Working Axes

Table 13: Part names and working axes

1 U-arm 4 S-head

2 Wrist flange 5 Robot base

3 L-arm

T+

T-B-

B+R+

R-U-

U+

L- L+

S-

S+

1

2

3

4

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5.3 Robot Base Dimensions

Fig. 14: Robot Base Dimensions

Table 14: Robot base dimensions

1 Fitting surface

2 Units: mm

3 12 dia. holes (2 holes)

4 View A

5 18 dia. holes (4 holes) (for robot fixing)

395,

519

5,5

60

60

200 0,1

200

0,1

260

170

0,1

0,1

335

375

250

313335375

A

25

1

1

23

5

4

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5.4 Dimensions and P-Point Maximum Envelope

Fig. 15: Dimensions and P-Point Maximum Envelope

Table 15: Dimension and P-point maximum envelope

1 P-point maximum envelope

2 P-point

3 View A

1717

807

105

413

349

288

459

635

514

0

79515087,5

1417

1323

8014

0

1003

768

505

334

0

524

255

110

165

155

917

991

807

471

260 0

1485

760

505

505

0

238

559

81

2072

R421

157

138,5

421

180

180

A

150

264264264

R31

4

R1717

1

2

3

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5.5 Alterable Operating Range

The operating range of the S-axis can be altered according to the operating conditions as shown in Table 16: "S-Axis Operating Range". If alteration is necessary, contact your YASKAWA europe GmbH representative in advance.

Table 16: S-Axis Operating Range

Item Specifications

S-Axis Operating Range

±180°(standard)

±150°

±120°

± 90°

± 60°

± 30°

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

The allowable wrist load is 20 kg maximum. If force is applied to the wrist instead of the load, force on R-, B-, and T-axes should be within the value shown in Table 17: "Moment and Total Moment of Inertia". Contact your YASKAWA Europe GmbH representative for further information or assistance.

The allowable moments of inertia for R-axis and B-axis are calculated when the moment is at the maximum. The allowable moment of inertia for T-axis varies depending on the moment, as shown in Fig. 16: "T-axis Allowable Moment of Inertia Diagram (Measured Value from the Rotation Center of the T-axis Flange Surface)". Use the robot to meet those conditions. For example, with YASKAWA-HP20D C09, the allowable moment of inertia for the T-axis is 0.25 kgm2 when the moment is 19.6 Nm, and 0.75 kgm2 when 0 Nm. When the volume load is small, refer to the moment arm rating shown in Fig. 17: "Moment Arm Rating" at Page 30.

Fig. 16: T-axis Allowable Moment of Inertia Diagram (Measured Value from the Rotation Center of the T-axis Flange Surface)

Table 17: Moment and Total Moment of Inertia

Axis Moment Nm GD2/4 Total Moment of Inertia kgm2

R-Axis 39.2 1.05

B-Axis 39.2 1.05

Table 18: T-axis allowable moment of inertia diagram

1 Total Inertia GD²/4 Kgm²

2 Moment (Nm)

0.9

20

0.60.30.750.25

19.6

15

10

5

0

0

Mom

ent

Mom

ent

NNmm

1

2

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Fig. 17: Moment Arm Rating

Table 19: Moment arm rating

1 Load gravity position

2 R-, T-axis rotation center

3 B-axis rotation center

L

L

105

T

B

400

300

W=6Kg

W=10Kg

200100

200

100

0

W=20Kg

W=16Kg

300

L m

m

L mmB

T

1

2

3

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6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 18: "Wrist Flange". In order to see the alignment marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth of inside and outside fittings must be 5 mm or less.

Fig. 18: Wrist Flange

Table 20: Wirst flange

1 Alignment mark

2 Tapped hole M8 (depth:10) (pitch:1.0) (4 holes)

3 6 dia. +0,012 / 0 hole (depth: 6)

4 Units: mm

5 View A

6 50 dia 0 / -0,039

7 25 dia 0.023 / 0

Wash off anti-corrosive paint (yellow color) on the wrist flange surface with thinner or light oil before mounting the tools.

Mount the attachment with the mounting bolts (length: 10 mm or less). Failure to observe this instruction may affect the robot performance.

6

45

P.C.D406

0,5

A

1

2

34

5

67

NOTE

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7 System Application

7.1 Peripheral Equipment Mounts

The peripheral equipment mounts are provided on the U-axis (upper arm) and S-axis (rotary head) as shown in Fig. 19: "Installing Peripheral Equipment" at Page 32 for easier installation of the users’s system applications. The following conditions shall be observed to attach or install peripheral equipment.

7.1.1 Allowable Load

The maximum allowable load on the U-axis is 31 kg, including the wrist load. For instance, when the mass installed on the wrist point is 20 kg, the mass which can be installed on the upper arm is 11 kg.

7.1.2 Installation Position

There is a limitation on the installation position. Fig. 20: "Allowable Load on U-axis" at Page 33 shows the distance between the center of U-axis rotation and the load gravity.

Fig. 19: Installing Peripheral Equipment

Table 21: Installing peripheral equipment

1 Z-coordinate direction 5 View A

2 X-coordinate direction 6 Units: mm

3 Center of U-axis rotation 7 Limited dimension of Z-coordinate: 400 at a maximum

4 Rotating Base

7070

220

W2W1

A

1

2

3

4

56

7

2 E1101000130GB03

HP20D-C09

Fig. 20: Allowable Load on U-axis

7.2 Internal User I/O Wiring Harness and Air Line

Internal user I/O wiring harness (14 wires: 0.2 mm2 x 8 wires and 1.25 mm2 x 6 wires), and an air lines are incorporated in the robot for the drive of peripheral devices mounted on the upper arm as shown in Fig. 21: "Connectors for Internal User I/O Wiring Harness and Air Line". The connector pins 1 to 16 are assigned as shown in Fig. 22: "Details of the Connector Pin Numbers" at Page 35 on the following page. Wiring must be performed by users.

Table 22: Allowable load on u-axis

1 In this case, unbalanced moment is not permitted

2 Distance between Center of U-axis Rotation and Load Gravity (‚w direction)

3 Weight W2

The allowable current for internal user I/O wiring harness

3 A or less for each wire (The total current value for pins 1 to 16 must be 40 A or less.)

The maximum pressure for the air line 490 kPa or less (The air line inside diameter: 8.0 mm)

(mm)500200 300 400

30(kg)

W1=16kg20

10W1=20kg

10000

-200 -100

W1=10kg

W1=6kg

*1 *1 1

2

3

E1101000130GB03 33

3

HP20D-C09

Fig. 21: Connectors for Internal User I/O Wiring Harness and Air Line

Table 23: Connectors for internal user I/O wiring harness and air line

1 Connector for internal user I/O wiring harness: JL05-2A204-29SC Order no. 104072 (socket connector with a cap). Prepare pin connector JL05-6A20-29P, Order no. 104073

2 View A

3 Connector for internal user I/O wiring harness: JL05-2A204-29PC Order no. 104064 (socket connector with a cap). Prepare pin connector JL05-6A20-29S, Order no. 104065

4 Air inlet Tapped hole PT3/8 with pipe plug

5 Exhaust port Tapped hole PT3/8 with pipe plug

2BC

1BC

3BC

A

1

2

1

3

5

4

4 E1101000130GB03

HP20D-C09

Fig. 22: Details of the Connector Pin Numbers

The same pin number (1 to 16) of two connectors is connected in the wire lead of single 0.2 mm2 or 1.25 mm2.

Table 24:

1 Connector for Internal User I/O Wiring Harness on the Connector Base

2 Open

3 Internal user I/O wiring harness : 0.20 mm², 8 wires, 1.25 mm², 6 wires

4 Connector for Internal User I/O Wiring Harness on the U-arm

5 +24V: for shock sensor (1A) (Shock sensor signal input)

6 Internal user I/O wiring harness : 0.20 mm², 8 wires, 1.25 mm², 6 wires

7 Pins used

For the standard specification, the pins No. 7 and No. 8 of 3BC connector on the U-arm are respectively connected with the shock sensor power supply and shock sensor signal input port of the DX100 controller.

The pins No.7 and No.8 of respective 3BC connectors on the connector base side and the U-arm side are not connected with each other.

1

6

10

14

8

12

7

11

5

1615

4

9

13

2 3

345

12

91011

1615

1314

12

6

(1,25 mm2)(1,25 mm2)(1,25 mm2)(1,25 mm2)(1,25 mm2)

78

1

6

10

14

8

12

7

11

5

1615

4

9

13

2 3

345

12

91011

1615

1314

12

6

(1,25 mm2)(1,25 mm2)(1,25 mm2)(1,25 mm2)(1,25 mm2)

78

1

22

3

4

5

6

7

7

NOTE

E1101000130GB03 35

3

HP20D-C09

8 Electrical Equipment Specification

8.1 Position of Limit Switch

The limit switches are optional. See Fig. 23: "Location of Limit Switches". The robot with S- and L-axis overrun limit switches, and LU-axis interference limit switch is the type YR-HP0020D-A01 (standard specification).

Fig. 23: Location of Limit Switches

8.2 Internal Connections

Highly reliable connectors are equipped on each connection part of the robot to enable easy removal and installation for maintenance and inspection. For the number and location of connectors, see Fig. 24: "Locations and Numbers of Connectors". Diagrams for Internal connections of the robot are shown in Fig. 25: "(a) Internal Connection Diagramm" at Page 38 and Fig. 26: "(b) Internal Connection Diagramm" at Page 39.

Table 25: Location of limit switches

1 L- and U-axes interference limit switch (optional)

2 L-axis interference limit switch (optional)

3 S-axis overrun limit switch (optional)

1

2

3

6 E1101000130GB03

HP20D-C09

Fig. 24: Locations and Numbers of Connectors

Table 26: Locations and numbers of connectors

1 3BC (for internal user I/O wiring harness) on the U-arm

2 3BC (for internal user I/O wiring harness) on the connector base

Table 27: List of Connector Types

Name Type of Connector Order No.

Connector for the internal user I/O wiring harness on the connector base

JL05-2A20-29PC

(JL05-6A20-29S: Optional)

104072

104065

Connector for the internal user I/O wiring harness on the U-arm

JL05-2A20-29SC

(JL05-6A20-29P: Optional)

104072

104065

Cable grommet 107261

Pin male 104120

Pin female 104117

1

1

E1101000130GB03 37

3

HP20D-C09

Fig

.25

: (a)

Inte

rna

l Co

nne

ctio

n D

iagr

amm

-3-21E 32

3BC

-1 -6 -7-5 -10

-11

-9-8 -13

-15

-14

-16

-12

76 1198 105 1613 151412

-44

31 21 32

SS

1S

S2

SS

1S

S24

4

E

SS

2S

S1

87

42 31

E

E

E

3 41

E

E

2

E

-2 -3 -442 31

3BC

-1

66

-6 -8 -9-76 987

-11

-12

-13

-14

11 1312 1410-1

0

-16

1615-1

5

55

5-5

Sec

tion

A f

or IP

65 S

peci

ficat

ion

1 2E

-2

654 118 9 107

-10

-7 -11

-9-8-6-5-4-33

3BC

-1

13 151412 16

-13

-15

-14

-16

-12

7 8

1 2 654 SS

2S

S1

3

1 2 654

SS

2S

S13

-2 -10

-7 -11

-9-8-6-5-4-3

1E 2 6 117 1098543

3BC

-1 -13

-15

-14

-16

-12

1613 151412

21 2

4 SS

2S

S1

433

SS

1S

S2

E

E E

E

E

E

Bas

e3B

C(2

0-29

)

P PP

P P

3BC

(20-

29)

P P P

P PS-

AXIS

OVE

RRUN

L.S

LD

1L

D1

LD

1

L A

ND

U-A

XIS

INTE

RFE

RE

NC

E L

.SL

D3

LD

3

L-A

XIS

OV

ER

RU

N L

.SL

C2

LD

2L

C2 L

C3

LD

1P

LC

2L

C2

LD

1L

D1

LC

1L

D1

LC

1S

-AX

IS O

VE

RR

UN

L.S

LD

3L

AN

D U

-AX

IS IN

TER

FER

EN

CE

L.S

LD

3

LD

2

PL

C3

L-A

XIS

OV

ER

RU

N L

.S

S-AX

IS O

VERR

UN L.

SL

B1

LB

1L

B1

L A

ND

U-A

XIS

INTE

RFE

RE

NC

E L

.SL

B3

LB

3

L-A

XIS

OV

ER

RU

N L

.SL

A2

LB

2L

A2 LA

3L

B1

P

LA

2L

A2

LB

1L

B1

LA

1L

B1

LA

1S

-AX

IS O

VE

RR

UN

L.S

LB

3L

AN

D U

-AX

IS IN

TER

FER

EN

CE

L.S

LB

3

LB

2

PL

A3

L-A

XIS

OV

ER

RU

N L

.S

LD

1L

D1

LD

1

LD

3L

C2

LD

1L

C2

LD

3

LB

1L

B1

LB

1

LB

3L

A2

INTE

RN

AL

CA

BLE

IN B

T-A

XIS

INTE

RNAL

CAB

LE IN

L-AX

ISIN

TER

NA

L C

AB

LE IN

S-A

XIS

PO

WE

R C

AB

LE

LA

2L

B3

LB

1

Bas

e

Cas

ing

C

1BC

(10X

4)D

X10

0

SS

224

V(1A

)C

N4-

2C

N4-

1C

N4-

2C

N4-

1S

S1

SS

2

LD

1L

C1

LC

1

LC

1L

C1

LB

1L

A1

LA

1

LA

1L

A1

A

A

PP

LD

1L

C1

PL

C1

LC

1P

LD

1+2

4V

FG

7

SS

2A

L1

C

0VCN

4-10

CN4-

10

LB

1L

A1

PL

A1

3BC

(20-

29)

P PP PP

B

3BC

(20-

29)

Cas

ing

P P P

P

No

.6C

N

0V

DA

TA

-3B

AT

+5

V

FG

3

OB

T

DA

TA

+35

CN

-1 -2 -3 -4 -3-26

CN

-1

No

.5C

N

PG

DA

TA

+1D

AT

A-1

FG

10

V

OB

T+

5V

BA

T

S-A

XIS

PG

U-A

XIS

B-A

XIS

PG

R-A

XIS

PG

No

.14

CN

0V

BA

T

+5

VO

BT

-2-3 -4-2

OB

TB

AT

-3F

G5

16

CN

-1N

o.1

6C

N

15

CN

-1

14

CN

-1

DA

TA

+6

DA

TA

+5D

AT

A-5

22

CN

-1

-6 -5-2

No

.22

CN

-10

-9-4PP P

PG

DA

TA+2

BA

TD

AT

A-2

BA

T

OB

TF

G2

0V

OB

T+

5V

BA

T

L-A

XIS

23

CN

-1

24

CN

-1-4-2 -3 -3-2

PPP

P

No

.7C

N

-9-3-8-2-7 -4D

AT

A+

6

0V

DA

TA

-5

+5

V

BA

TO

BT

DA

TA

+5

7C

N-1

No

.23

CN

DA

TA

+4

0V

BA

TO

BT

FG

4

DA

TA

-4

+5

VO

BT

BA

T

DA

TA

+3

OB

TB

AT

FG

3

DA

TA

-3B

AT

0V

OB

T+

5V

T-A

XIS

PG

FG

60

V

BA

TO

BT

+5

V

-3-2-3 -4

BA

TO

BT

17

CN

-1

A

P-6-1

1-5

FG

60

V+

5V

U VFO

R L

AM

P(O

PTI

ON

AL)

DA

TA

-6D

AT

A-6

-10

P-2

OB

T

-22

0C

N-1

No

.20

CN

-10

-9-5 -4-6P PP

BA

T1

0B

AT

2

0B

AT

11

81

9

17

0B

AT

4

BA

T3

0B

AT

3

23

25

24

22

21

27

28

30

31

29

26

BA

T4

20

BA

T2

BAT1

10B

AT12

0BAT

112 31

0BAT

215

0BAT

22BA

T22

7 8 16BA

T21

4BA

T12

PG

0V

1

PG

0V

3

PG

0V

2P

G5

V2

PG

5V

11 53 42

PG

5V

6

PG

0V

5

PG

0V

6P

G5

V5

PG

0V

4P

G5

V4

12

9 11

10

7 86P

G5

V3

16

13

14

15

3 4 75 6

1

8

3 2 4

23

2

P PPP

0V+24V

CN

1-4

CN

1-5

1BC(

10X4

)

SPG

+1S

PG

-1

0V+24V

FG

1

CN

1-2

CN

1-1

CN

1-9

CN

1-10

CN

1-3

P PP

CN

1-4

CN

1-5

CN

1-1

CN

1-2

CN

1-10

CN

1-9

CN

1-3

DX

100

0B

TB

AT

BA

T0

BT

BA

T0

BT

BA

T

0B

T

-6-22

1C

N-1

No

.21

CN

-10

-9-4-5

P PP

PP P PP P

P

PP P

P

PL

A1

P

SP

G+2

SP

G-2

FG

2

CN

1-6

CN

1-7

CN

1-8

SP

G+3

SP

G-3

FG

3

CN

2-1

CN

2-2

CN

2-3

P P

SP

G+4

SP

G-4

FG

4

CN

2-6

CN

2-7

CN

2-8

SP

G-5

SP

G+6

FG

5C

N3-

3

CN

3-2

CN

3-6

SP

G+5

CN

3-1

P P

CN

1-6

CN

1-7

CN

1-8

CN

2-1

CN

2-2

CN

2-3

CN

2-6

CN

2-7

CN

2-8

CN

3-3

CN

3-2

CN

3-6

CN

3-1

1BC

(10X

4)

FG

6

+24V

CN

3-8

CN

4-1

AL2

BC

2

CN

4-7

CN

4-2

CN

2-4

CN

4-8

CN

4-3

CN

4-6

LB1

P PP

SP

G-7

+5V

0V

CN

2-10

CN

2-9

CN

3-5

CN

3-4

0V +5V

CN3-

10C

N3-

9

CN

4-9

CN

4-5

CN

4-4

P P P P

CN

2-5

P

SP

G+

7

CN

3-8

CN

4-1

CN

4-7

CN

4-2

CN

2-4

CN

4-8

CN

4-3

CN

4-6

CN2-

10C

N2-

9

CN

3-5

CN

3-4

CN3-

10C

N3-

9

CN

4-9

CN

4-5

CN

4-4

CN

2-5

CN

3-7

CN

3-7

PS

PG

-6

EE

FOR

SP

AR

E C

AB

LESH

OCK

SENS

OR(O

PTIO

NAL)

- For

the

limit

switc

h sp

ecifi

catio

n, th

e co

nnec

tion

of th

e se

ctio

n A

is

chan

ged

as fo

llow

s:- F

or th

e IP

65 s

peci

ficat

ion,

the

conn

ectio

n of

the

sect

ion

A a

nd B

are

cha

nged

as

follo

ws:

<NO

TES

> SLU

-axe

s w

ith O

verr

un L

imit

Sw

itch

Spe

cific

atio

n

SLU

-axe

s w

ith O

verr

un L

imit

Sw

itch

Spe

cific

atio

n (IP

65 s

peci

ficat

ion)

- For

the

stan

dard

spe

cific

atio

n, th

e pi

ns N

o.7

and

No.

8 of

3B

C c

onne

ctor

on

the

U-a

rm a

re

res

pect

ivel

y co

nnec

ted

with

the

shoc

k se

nsor

pow

er s

uppl

y an

d th

e sh

ock

sens

or s

igna

l inp

ut

por

t of t

he D

X10

0 co

ntro

ller.

Pin

No.

7 8

D

X10

0 C

onne

ctio

n P

ort

Sho

ck s

enso

r pow

er s

uppl

y; +

24V

(1A

)S

hock

sen

sor s

igna

l inp

ut

- Whe

n co

nnec

ting

the

pin

No.

7 an

d N

o.8

of th

e co

nnec

tor b

ase

resp

ectiv

ely

with

the

pin

No.

7 an

d N

o.8

of 3

BC

con

nect

ors

on th

e U

-arm

, the

con

nect

ion

of c

rimpe

d co

ntac

t-pin

s (S

S1,

SS

2) s

houl

d be

cha

nged

a

s sh

own

in th

e se

ctio

n C

bel

ow.

(C

onta

ct y

our M

OTO

MA

N ro

bote

c G

mbH

repr

esen

tativ

e w

hen

mod

ifyin

g th

e w

iring

bef

ore

use.

)

PO

WE

R C

AB

LEIN

TER

NA

L C

AB

LECO

NNEC

TOR

BASE

U-A

RM

UN

US

ED

Crim

ped

Con

tact

-Pin

8 E1101000130GB03

HP20D-C09

Fig

.26

: (b)

Inte

rna

l Co

nne

ctio

n D

iagr

amm

ME

1M

E2

ME

2M

U1

MV

1M

W1

MV

2

MU

2M

W2

MW

2

MU

3

MV

2

MU

2

MW

3

MV

4M

U4

MV

5M

U5

MW

4

MU

6

MW

6M

V6

ME

3

ME

5M

E4

MW

5

BA

1

BA

2

BB

1

BA

3B

A4

BB

4B

A5

BA

6

ME

6

MV

3

-2 -3

3BC

-121 3E

21 321 3

-5 -6 -7 -9 -11

-10

-8

4 5 6 7 109 118 14 1513 1612

4 SS

1S

S2

SS

14

SS

2

-4 -12

-16

-14

-15

-13

E

MU

5

ME

5M

W5

MV

5

MV

6

ME

6M

W6

MU

6

BA

6B

B6

BB

5

BA

5

-4-3

12C

N-1 -2-7 -8

10C

N-1 -3 -4 -5 -6-2

-2-1-D-C-A -B

SM

SM

MU

3

ME

3B

A3

MW

3M

V3

MU

4

MW

4

BA

4M

E4

MV

4

YB

BB

3

SM

SMYB

26C

N-3

-4-PE

-1-2

25C

N-1 -3 -1-4-2-5

YB

SM YB

SMYB

MU

5

MW

5M

E5

BA

5

MV

5

18C

N-1 -3 -4 -1-2

MV

6

MU

6

MW

6

BA

6B

B6

ME

6

-219

CN

-1 -3 -1 -2-4-2B

B5

BB

4

-2Y

B

MU

1

BA

1

MV

1

ME

1M

W1

3CN

-3 -4-2 -PE

-1

BB

1

MU

2

BA

2M

E2

MW

2M

V2

-5

4CN

-1

BB

2

E

E

PE

No.

12C

N

No.

10C

N

U-A

XIS

R-A

XIS

S-A

XIS

L-A

XIS

No.

25C

N

No.

26C

N

B-A

XIS

T-A

XIS

No.

18C

N

No.

19C

N

No.

35C

N

No.

37C

N

No.

36C

N

No.

3CN

No.

4CN

2BC

(6X

6)

P

3BC

(20-

29)

P

P P PP

P P

212N

o.8C

N

Cas

ing

8CN-

1

64 5 8 9 10 17654 10987

52 43 6

3 42 5 6 No.

9CN

9CN-

1

33

CN

1-1

CN

1-5

CN

1-2

CN

1-3

CN

1-4

CN

2-1

CN

1-6

CN

2-5

CN

2-4

CN

2-3

CN

2-2

CN

3-1

CN

2-6

CN

3-5

CN

3-4

CN

3-3

CN

3-2

CN

4-2

CN

4-1

CN

3-6

CN

4-3

CN

4-5

CN

4-4

CN

1-1

CN

1-5

CN

1-2

CN

1-3

CN

1-4

CN

2-1

CN

1-6

CN

2-5

CN

2-4

CN

2-3

CN

2-2

CN

3-1

CN

2-6

CN

3-5

CN

3-4

CN

3-3

CN

3-2

CN

4-1

CN

4-2

CN

3-6

CN

4-3

CN

4-5

CN

4-4

2BC

(6X

6)

CN

5-1

CN

5-3

CN

5-5

CN

5-4

CN

5-2

CN

6-2

CN

6-1

CN

6-3

CN

6-6

CN

6-4

CN

6-5

CN

5-6

CN

5-1

CN

5-3

CN

5-5

CN

5-4

CN

5-2

CN

6-2

CN

6-1

CN

6-3

CN

6-6

CN

6-4

CN

6-5

CN

5-6

CN

4-6

CN

4-6

FOR

SP

AR

E C

AB

LE

Sec

tion

B f

or IP

65 S

peci

ficat

ion

E1101000130GB03 39

4

HP20D-C09

9 Maintenance and Inspection

WARNINGBefore maintenance or inspection, be sure to turn the main power supply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON).

Failure to observe this warning may result in electric shock or injury.

CAUTIONMaintenance and inspection 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 Europe GmbH representative.

The battery pack must be connected before removing detection connector when maintenance and inspection.

Failure to observe this caution may result in the loss of home position data.

SYS MONI T ORING TIME

DAT A EDIT DISPL A Y UTILITY

Main Men u ShortCut

CONTRO L POWER TIME (1998/07/06 10:00 ) 2385:42'02

SE R VO POWER TIME (1998/07/06 10:30 ) 36000:00'00

PL A YBACK TIME (1998/10/22 1 1:12 ) 2210:00'20

MOVING TIME (1998/10/22 15:30 ) 1875:15'30

OPER A TING TIME (1998/10/22 16:12 ) 0:0'0

1

HOLD START PLAY TEACH REMOTE

T- Z-

T+ Z+

B+ Y+

R+ X+

B- Y-

R- X-

. .

HIGH SPEED

FAST

SLOW MANUAL SPEED

U- Z-

U+ Z+

L+ Y+

S+ X+

L- Y-

S- X- SERVO ON

M M O O T T O O M M A A N N

S S E E L L E E C C T T SERVO ON

READY

MAIN MENU

SHORT CUT

GO BACK

PAGE AREA

LAYOUT

Multi

C C A A N N C C E E L L

COORD DIRECT OPEN

INFORM LIST

BACK SPACE

S S H H I I F F T T I I N N T T E E R R L L O O C C K K

ROBOT

EX.AXIS

MOTION TYPE

T T E E S S T T S S T T A A R R T T

B B W W D D

INSERT

MODIFY ENTER

F F W W D D

DELETE

S S H H I I F F T T 7

4

2 3

. -

5 . 6

0

8

1

9

JOB UTILITY EDIT DISPLAY

Main Menu ShortCut

JOB CONTENT JOB NAME: TEST01

0000 NOP 0001 SET B000 0 0002 SET B001 1 0003 MOVJ VJ=80.00 0004 MOVJ VJ=80.00 0005 DOUT OGH#(13) B002 0006 DOUT OT#(41) ON 0007 MOVL C00002 V=880.0 CV#(1) CTP=0.662 0008 DOUT OT#(44) ON 0009 TIMER T=3.0 0010 MOVL V=880.0 0011 MOVL V=880.0 0012 MOVL V=880.0 0013 MOVL V=880.0

!Turn on servo power

ASSIST

!?

TOOL: 00 CONTROL GROUP: R1 STEP NO: 0003

0 E1101000130GB03

HP20D-C09

9.1 Inspection Schedule

Proper inspections are essential not only to assure that the mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. Inspection intervals are classified into six levels as shown in Table 28: "Inspection Items".

In Table 28: "Inspection Items", the inspection items are categorized by three types of operations: operations which can be performed by personnel authorized by the user, operations to be performed by trained personnel, and operations to be performed by service company personnel. Only specified personnel shall perform the inspection work.

The inspection interval depends on the total servo operation time.

The following inspection schedule is based on the case where the robot is used for arc welding application. If the robot is used for other application or if it is used under special conditions, a case-by-case examination is required. The inspection may be conducted at shorter intervals if the robot is used very frequently for the application such as handling; in this case, contact your YASKAWA europe GmbH representative.

NOTE

E1101000130GB03 41

4

HP20D-C09

Ta

ble

28

: In

spe

ctio

n It

ems

(S

hee

t 1

of

2)

Item

sa)

Sc

hed

ule

Me

tho

dO

per

ati

on

Ins

pe

cti

on

C

har

ge

Daily

1000HCycle

6000HCycle

12000HCycle

24000H

36000H

Specified Personnel

Licensee

Service Company

Alig

nme

nt

mar

k•

Vis

ual

Ch

eck

alig

nm

ent

ma

rk a

ccor

dan

ce a

nd d

am

ag

e a

t the

ho

me

po

sitio

n.•

••

Ext

ern

al l

ead

•V

isua

lC

he

ck f

or

da

ma

ge a

nd

de

teri

ora

tion

of l

ead

s.•

••

Wor

kin

g ar

ea a

nd

ro

bo

t•

Vis

ual

Cle

an

the

wo

rk a

rea

if d

ust

or

spa

tter

is p

rese

nt.

Ch

eck

fo

r d

am

age

an

d

out

sid

e c

rack

s.•

••

Mo

tors

fo

r S

-, L

-, U

-axe

s•

Vis

ual

Ch

eck

fo

r g

rea

se le

aka

ge

.b)•

••

Ba

sep

late

mou

ntin

g bo

lts•

Spa

nne

r W

renc

hT

igh

ten

loos

e b

olts

. R

ep

lace

if n

ece

ssar

y.•

••

Cov

er

mou

ntin

g s

cre

ws

•S

crew

driv

er,

Wre

nch

Tig

hte

n lo

ose

bo

lts.

Re

pla

ce if

nec

ess

ary.

••

•C

onn

ect

or

ba

se•

Ma

nu

al

Ch

eck

fo

r lo

ose

co

nne

cto

rs.

••

•T

imin

g b

elts

for

B-

and

T-a

xes

•M

an

ua

lC

he

ck f

or

be

lt te

nsi

on

an

d w

ea

r.•

•W

ire

harn

ess

in r

obot

(SL

EU

-axi

s w

ire

s)

(RB

T-a

xis

wire

s)

•V

isua

l, M

ulti

met

erC

he

ck f

or

con

duc

tion

bet

we

en

the

ma

in c

on

nect

or

of b

ase

and

in

term

ed

iate

co

nn

ecto

r w

ith m

an

ually

sh

aki

ng

the

wir

es.

Ch

eck

for

we

ar o

f

pro

tect

ive

sp

ring

.c)

••

•R

ep

lace

d)•

Wir

e ha

rnes

s in

rob

ot

(BT

-axi

s w

ire

s)

•V

isua

l, M

ulti

met

erC

he

ck f

or

con

duc

tion

bet

we

en

term

ina

ls a

nd

wea

r of

pro

tect

ive

spri

ng.

c)•

••

Re

pla

ced)

•B

att

ery

pack

in r

obot

•R

ep

lace

the

ba

ttery

pa

ck w

he

n th

e b

att

ery

ala

rm o

ccur

s o

r th

e r

obo

t dro

ve

for

360

00H

.•

•S

-axi

s sp

eed

red

uce

r•

•G

reas

e G

unC

he

ck f

or

ma

lfun

ctio

n. (

Re

pla

ce if

nec

ess

ary.

) S

up

ply

gre

ase

e) (

60

00

H

cycl

e).

Se

e 9

.3.1

"G

rea

se R

epl

enis

hme

nt/

Exc

han

ge

for

S-A

xis

Sp

eed

Re

duc

er"

at P

age

49

. R

ep

lace

gre

ase

e).

(12

000

H c

ycle

) S

ee

9.3

.1 "

Gre

ase

Rep

len

ishm

en

t/E

xcha

ng

e fo

r S

-Axi

s S

pee

d R

edu

cer"

at

Pa

ge

49

.

••

2 E1101000130GB03

HP20D-C09

Sp

eed

red

uce

rs fo

r L-

and

U

-axe

s•

•G

reas

e G

unC

he

ck f

or

ma

lfun

ctio

n.

(Re

pla

ce if

ne

cess

ary

.) S

upp

ly g

rea

see)

(6

000

H

cycl

e).

Se

e 9

.3.2

"G

rea

se R

epl

enis

hme

nt/

Exc

han

ge

for

L-A

xis

Sp

eed

R

ed

uce

r" a

t Pa

ge 5

1,

9.3

.3 "

Gre

ase

Rep

len

ish

me

nt/

Exc

han

ge

for

U-A

xis

Spe

ed

Re

du

cer"

at P

ag

e 53

. R

ep

lace

gre

ase

e) (

12

000

H c

ycle

).

Se

e 9

.3.2

"G

rea

se R

ep

len

ish

men

t/E

xch

ang

e f

or L

-Axi

s S

pee

d R

ed

uce

r"

at P

age

51

, 9

.3.3

"G

reas

e R

eple

nis

hm

en

t/E

xcha

ng

e fo

r U

-Axi

s S

pee

d

Re

duc

er"

at P

age

53

.

••

R-,

B-

and

T-a

xes

spe

ed

re

du

cer

•G

reas

e G

unC

he

ck f

or

ma

lfun

ctio

n.

(Re

pla

ce if

ne

cess

ary

.) S

upp

ly g

rea

see)

(6

000

H

cycl

e).

Se

e 9

.3.4

"G

rea

se R

epl

enis

hme

nt

for

R-A

xis

Sp

ee

d R

ed

uce

r" a

t P

ag

e 5

5, 9

.3.5

"G

rea

se R

ep

len

ish

men

t fo

r B

-, T

-Axe

s S

pe

ed R

edu

cer"

at

Pa

ge

56

.

••

T-a

xis

gea

r•

Gre

ase

Gun

Ch

eck

fo

r m

alfu

nct

ion

. (R

ep

lace

if n

ece

ssa

ry.)

Sup

ply

gre

ase

e) (

600

0H

cy

cle

). 9

.3.6

"G

rea

se R

ep

len

ish

me

nt f

or T

-Axi

s G

ea

r" a

t P

ag

e 5

7•

•R

-axi

s cr

oss

ro

ller

be

arin

g•

Gre

ase

Gun

Ch

eck

fo

r m

alfu

nct

ion

. (R

ep

lace

if n

ece

ssa

ry.)

Sup

ply

gre

ase

e) (

600

0H

cy

cle

). S

ee

9.3

.7 "

Gre

ase

Re

ple

nis

hm

ent f

or

R-a

xis

Cro

ss R

olle

r B

eari

ng"

at P

age

58

••

Ove

rha

ul

••

a.In

spec

tion

No

. cor

resp

ond

to th

e nu

mbe

rs in

Fig

.27:

"In

spec

tion

item

s" a

t Pag

e 45

.b.

The

occ

urre

nce

of a

gre

ase

leak

age

indi

cate

s th

e po

ssib

ility

that

gre

ase

has

seep

ed

into

the

mot

or. T

his

can

caus

e a

mot

or b

reak

dow

n. C

ont

act y

our

YA

SK

AW

A e

uro

pe G

mbH

re

pres

enta

tive.

c.W

hen

chec

king

for

cond

uctio

n w

ith m

ultim

eter

, con

nect

the

bat

tery

to “

BA

T”

and

“OB

T”

of c

onne

cto

rs o

n th

e m

otor

sid

e fo

r ea

ch a

xis,

and

then

rem

ove

conn

ecto

rs o

n de

tect

or s

ide

for

each

axi

s fr

om th

e m

otor

. Oth

erw

ise,

the

hom

e p

ositi

on m

ay b

e lo

st. (

Ref

er t

o 9.

3.8

"Not

es fo

r M

aint

enan

ce"

at P

age

59)

d.W

ire h

arne

ss in

rob

ot to

be

rep

lace

d at

240

00H

insp

ectio

n.e.

For

the

gre

ase,

ref

er t

o Ta

ble

29:

"Ins

pect

ion

Par

ts a

nd G

reas

e U

sed"

at P

age

44.

Ta

ble

28

: In

spe

ctio

n It

ems

(S

hee

t 2

of

2)

Item

sa)

Sc

hed

ule

Me

tho

dO

per

ati

on

Ins

pe

cti

on

C

har

ge

Daily

1000HCycle

6000HCycle

12000HCycle

24000H

36000H

Specified Personnel

Licensee

Service Company

E1101000130GB03 43

4

HP20D-C09

The numbers in the above table correspond to the numbers in Table 28: "Inspection Items" at Page 42

Table 29: Inspection Parts and Grease Used

No. Grease Used Order no. Qty Inspected Parts

12, 13 VIGO Grease RE No. 0 101839 16 kg Speed reducers for S-, L- and U-axes

14, 15 Harmonic Grease SK-1A 127609 2.5 kg Speed reducers for R-, B- and T-axes

T-axis gear

16 Alvania EP Grease 2 127606 16 kg R-axis cross roller bearing

4 E1101000130GB03

HP20D-C09

Fig

.27

: In

spe

ctio

n ite

ms

Th

e nu

mbe

rs in

the

abo

ve F

ig.

27:

"In

spec

tion

item

s" c

orr

espo

nd to

the

nu

mb

ers

in T

abl

e 2

8: "

Insp

ect

ion

Ite

ms"

at

Pag

e 4

2

1711

13

74

4

16

114 15

13

1

12

11

9

110

882

41

5

E1101000130GB03 45

4

HP20D-C09

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

The battery packs are installed in the position shown in Fig. 28: "Battery Location". If the battery alarm occurs in the DX100, replace the battery according to the following procedure:

Fig. 28: Battery Location

Table 30: Battery location

1 Cover fixing screw (M4)

2 Battery pack

3 Plate fixing screw (M4)

1BC 2BC

1

2

3

6 E1101000130GB03

HP20D-C09

Fig. 29: Battery Connection

1. Turn OFF the DX100 main power supply.

2. Remove the plate fixing screws and the plate on the connector base, then pull the battery pack out to replace 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 the new battery pack to the holder.

7. Reinstall the plate.

Table 31: Battery connection

1 Battery pack before replacement

2 Connector

3 New battery pack (HW0470360-A) Order No.: 105548

4 See step 4 below

5 Board

6 See step 5 below

Remove the old battery pack after connecting the new one so that the encoder absolute data does not disappear.

Do not allow plate to pinch the cables when reinstalling the plate.

1

2

4

3

5

6

NOTE

NOTE

E1101000130GB03 47

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HP20D-C09

9.3 Notes on Grease Replenishment/Exchange Procedures

Make sure to follow the instructions listed below at grease replenishment/exchange. Failure to observe the following notes may result in damage to motor and speed reducer.

If grease is added without removing the plug/screw from the grease exhaust port, the grease will leak inside a motor or an oil seal of a speed reducer will come off, which may result in damage to the motor. Make sure to remove the plug.

Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

Make sure to use a grease pump to inject grease. Set air supply pressure to the grease pump at 0.3 MPa or less, and the grease injection rate at 8 g/s or less.

Make sure to fill the hose on the grease inlet with grease beforehand to prevent air from leaking into the speed reducer.

NOTE

8 E1101000130GB03

HP20D-C09

9.3.1 Grease Replenishment/Exchange for S-Axis Speed Reducer

Fig. 30: S-Axis Speed Reducer Diagram

9.3.1.1 Grease Replenishment (Refer to Fig. 30: "S-Axis Speed Reducer Diagram").

Replenish the grease according to the following procedure:

1. Remove the hexagon socket head plugs PT1/8 from the grease inlet and grease exhaust port.

Table 32: S-axis speed reducer diagram

1 Grease exhaust port Hexagon socket head plug PT1/8

2 S-axis speed reducer

3 Grease inlet Hexagon socket head plug PT1/8

For the ceiling-mounted robot, the grease exhaust port and the grease inlet are inverted.

If grease is injected with the plug on, the grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.

1

2

3

NOTE

NOTE

E1101000130GB03 49

5

HP20D-C09

2. Install a grease zerk PT1/8 to the grease inlet (The grease zerk is delivered with the robot).

3. Inject the grease into the grease inlet using a grease gun.

– Grease type: VIGO Grease RE No.0Order no. 101839.

– Amount of grease: 360 cc

– Air supply pressure of grease pump: 0.3 MPa or less

– Grease injection rate: 8 g/s or less.

4. Move the S-axis for a few minutes to discharge excess grease.

5. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply Fluit Plast on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm.

6. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply Fluit Plast on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm.

9.3.1.2 Grease Exchange (Refer to fig. 31 “S-Axis Speed Reducer Diagram” at page 49.)

1. Remove the hexagon socket head plugs PT1/8 from the grease inlet and grease exhaust port.

2. Install a grease zerk PT1/8 to the grease inlet (The grease zerk is delivered with the robot).

3. Inject the grease into the grease inlet using a grease gun.

– Grease type: VIGO Grease RE No. 0Order no. 101839

– Amount of grease: approx. 1800 cc


– Grease injection rate: 8 g/s or less.

4. The grease exchange is completed when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color).

5. Move the S-axis for a few minutes to discharge excess grease.

6. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply Fluid Plast on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm.


NOTE

0 E1101000130GB03

HP20D-C09

7. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply Fluid Plast on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm.

9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

Fig. 31: L-Axis Speed Reducer Diagram

9.3.2.1 Grease Exchange (Refer to Fig. 31: "L-Axis Speed Reducer Diagram").

1. Make the L-arm vertical to the ground.

2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.

3. Remove the hexagon socket head cap screw M6 from the grease inlet.

4. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the robot).

5. Inject grease into the grease inlet using a grease gun.

– Grease type: VIGO Grease RE No. 0Order no. 101839.

Table 33: L-axes speed reducer diagram

1 Grease exhaust port Hexagon socket head plug PT1/8

2 L-axis speed reducer

3 Grease inlet Hexagon socket head cap screw M6

4 L-arm



1

2

3

4

NOTE

NOTE

E1101000130GB03 51

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HP20D-C09


– Air supply pressure of grease pump: 0.3 MPa or less.

– Grease injection rate: 8 g/s or less

6. Move the L-axis for a few minutes to discharge excess grease.

7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply Fluit Plast on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm.

8. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply Fluit Plast on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm.

9.3.2.2 Grease Exchange (Refer to Fig. 31: "L-Axis Speed Reducer Diagram" at Page 51.)

1. Make the L-arm vertical to the ground.

2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.


4. Install a grease zerk A-MT6X1 to the grease inlet (The grease zerk is delivered with the robot).






6. The grease exchange is completed when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color).

7. Move the L-axis for a few minutes to discharge excess grease.




NOTE

2 E1101000130GB03

HP20D-C09

9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

Fig. 32: U-Axis Speed Reducer Diagram

9.3.3.1 Grease Replenishment (Refer to Fig. 32: "U-Axis Speed Reducer Diagram").

1. Make the U-arm horizontal to the ground.

2. Remove the hexagon socket head cap screw M6 from grease exhaust port.

3. Remove the hexagon socket head plug PT1/8 from the grease inlet.

Table 34: U-axis speed reducer diagram

1 U-arm

2 Grease inlet Hexagon socket head

3 Grease exhaust port Hexagon socket head cap screw M6

4 U-axis speed reducer



1

2

4

3

NOTE

NOTE

E1101000130GB03 53

5

HP20D-C09







6. Move the U-axis for a few minutes to discharge excess grease.



9.3.3.2 Grease Exchange (Refer to Fig. 32: "U-Axis Speed Reducer Diagram" at Page 53.)

1. Make the U-arm horizontal to the ground.

2. Remove the hexagon socket head cap screw M6 from the grease exhaust port.







5. The grease exchange is complete when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color.)

6. Move the U-axis for a few minutes to discharge excess grease.


Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.

NOTE

4 E1101000130GB03

HP20D-C09



9.3.4 Grease Replenishment for R-Axis Speed Reducer

Fig. 33: R-Axis Speed Reducer Diagram

1. Remove the hexagon socket head cap screw M6 from the exhaust port.

2. Inject grease into the grease inlet using a grease gun (Refer to Fig. 33: "R-Axis Speed Reducer Diagram").

– Grease type: Harmonic grease SK-1AOrder no. 100148

– Amount of grease: 8cc

3. Reinstall the screw on the exhaust port. Before installing the screw, apply Fluid Plast on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm.

Table 35: R-axis speed reducer diagram

1 Grease inlet Grease zerk A-MT6 x 1

2 Cap

3 Exhaust port screw M6

The exhaust port is used for air exhaust, and the grease is not exhausted from the exhaust port. Do not inject excessive grease into the grease inlet.

1

23

NOTE

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9.3.5 Grease Replenishment for B-, T-Axes Speed Reducer

Fig. 34: B-, T-Axes Speed Reducers Diagram

1. Remove the plug LP-M5 from the exhaust port.



4. Inject grease into the grease inlet using a grease gun (Refer to Fig. 34: "B-, T-Axes Speed Reducers Diagram").


– Amount of grease: For B-axis: 10 cc

– For T-axis: 5 cc)

Table 36: B-, T-axes speed reducer diagram

1 Exhaust port (B-axis) Plug LP-M5

2 T-axis speed reducer

3 Exhaust port (T-axis) screw M6

4 Grease inlet (T-axis) screw M6

5 Grease inlet (B-axis) screw M6

6 B-axis speed reducer

Remove the cover for the B-axis speed reducer.

4

5

6

32

1

NOTE

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5. Reinstall the plug/screw to the exhaust ports. Before installing the plug/screw, apply Fluid Plast on the thread part of the plug/screw, then tighten the plug/screw with a tightening torque of 5 Nm.

6. Remove the grease zerk from the grease inlets, and reinstall the screws. Before installing the screws, apply Fluid Plast on the thread part of the screws, then tighten the screws with a tightening torque of 5 Nm.

9.3.6 Grease Replenishment for T-Axis Gear

Fig. 35: T-Axis Gear Diagram




4. Inject grease into the gear grease inlet using a grease gun. (Refer to Fig. 35: "T-Axis Gear Diagram").




Mount the cover for the B-axis speed reducer (Refer to 9.3.8 "Notes for Maintenance" at Page 59).

Table 37:

1 Exhaust port Plug LP-M5

2 Grease inlet screw M6

NOTE

NOTE

Exhaust portExhaust port1

2

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5. Reinstall the plug to the exhaust port. Before installing the plug, apply Fluit PlastFluit Plast on the thread part of the plug, then tighten the screw with a tightening torque of 5 Nm.

6. Remove the grease zerk from the gear grease inlet, and reinstall the screw. Before installing the screw, apply Fluit Plast on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm.

9.3.7 Grease Replenishment for R-axis Cross Roller Bearing

Fig. 36: R-axis Cross Roller Bearing Diagram




4. Inject grease into the grease inlet using a grease gun (Refer to Fig. 36: "R-axis Cross Roller Bearing Diagram" at Page 58).


Table 38: R-axis cross roller bearing diagram

1 Exhaust port Plug LP-M5

2 R-axis cross roller bearing

3 Grease inlet screw M6

NOTE

12

3

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– Grease type: Alvania EP grease 2Order no. 127606


5. Reinstall the plug to the exhaust port. Before installing the plug, apply Fluit Plast on the thread part of the plug, then tighten the screw with a tightening torque of 5 Nm.

6. Remove the grease zerk from the gear grease inlet, and reinstall the screw. Before installing the screw, apply Fluit Plast on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm.

9.3.8 Notes for Maintenance

9.3.8.1 Wrist Unit

The motor and encoder units are provided with the wrist unit. To prevent fumes from penetrating into the wrist unit, the matched parts are sealed with sealing bond. If the wrist cover is disassembled, make sure to reseal with Fluit Plast.

Fig. 37: Sealing Part of Wrist Unit


Table 39: Sealing part of wrist unit

1 Cover jointing face

2 Cover

NOTE

1

1

2

2

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9.3.9 Home Position Calibration

WARNINGBefore operating the robot, check that the SERVO ON lamp goes out when the emergency stop buttons on the right of the front door of the DX100 and the programming pendant are pressed.

Injury or damage to machinery may result if the robot cannot be stopped in case of an emergency.




– Always prepare your reactions to a robot’s unexpected approach toward you.


Improper or unintended robot operation may result in injury.

Prior to performing the following operations, be sure that no one is in the P-point maximum envelope of the robot, and be sure that you are in a safe place when:

– Turning ON the DX100 power.

– Operating the robot with the programming pendant.

Injury may result from contact with the robot if persons enter the P-point maximum envelope of the robot.

Always press the emergency stop button immediately if there are problems.

Emergency stop buttons are located on the right of the front door of the DX100 and the programming pendant.

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9.3.10 Home Position Calibration

Home position calibration is an operation in which the home position and absolute encoder position coincide. 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 of the robot and DX100.

● Replacement of the motor or absolute encoder.

● Clearing stored memory (by replacement of NIF01 circuit board, weak battery, etc.).

● Home position deviation caused by hitting the robot against a workpiece, etc.

To calibrate the home position, use the axis keys to calibrate the home position mark on each axis so that the robot can take its posture for the home position. There are two operations for home position calibration:

● All the axes can be moved at the same time: Recalibrate the home position by moving all the axes together if changing the combination of robot and circuit board.

● Axes can be moved individually: Recalibrate the home position for the individual axes that were affected by the replacement, if replacing the motor or absolute encoder.

If the absolute data of its posture for the home position is already known, set the absolute data again after completing home position registration.

CAUTIONPerform the following inspection procedures prior to teaching the robot. If problems are found, correct them immediately, and be sure that all other necessary tasks have been performed.

– Check for problems in robot movement.

– Check for damage to the insulation and sheathing of external wires.

– Always return the programming pendant to its hook on the DX100 cabinet after use.

If the programming pendant is inadvertently left on the robot, a fixture, or on the floor, the robot or a tool could collide with it during robot movement, possibly causing injury or equipment damage.

Teaching and playback are not possible before the completion of the home position calibration.

In a system with two or more robots, the home position of all the robots must be calibrated before starting teaching or playback.

NOTE

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9.3.11 Calibrating Operation

9.3.11.1 Registering All Axes at One Time

1. Select {ROBOT} under the main menu.

– The sub menu appears.

2. Select {HOME POSITION}.

– The HOME POSITIONING window appears.

Home Position: The home position is the pulse value "0" for each axis and its posture.

Home position calibration screen is displayed only in security mode or management mode.

SUPPLE-MENT

NOTE

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3. Select {DISPLAY} under the menu.

– The pull-down menu appears.

– The same operation as the instruction 3 can also be performed by selecting {PAGE}, and selection box appears.

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4. Select the desired control group.

– Select the control group for HOME POSITIONING.

– The control group can also be selected by pressing page key .

5. Select {EDIT} under the menu.


6. Select {SELECT ALL AXES}.

– The confirmation dialog box appears.

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7. Select {YES}.

– Displayed position data of all axes are registered as home position. When {NO} is selected, the registration will be canceled.

9.3.11.2 Registering Individual Axes





– Perform the step 3 and 4 of the “Registering All Axes at One Time” to select the desired control group.

4. Select the axis to be registered.

– Move the cursor to the axis to be registered, and select it.

– A confirmation dialog box appears.

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5. Select {YES}.

– Displayed position data of the axis is registered as home position. When {NO} is selected, the registration will be canceled.

9.3.11.3 Changing the Absolute Data

To change the absolute data of the axis when home position calibration is completed, perform the following:





4. Select the absolute data to be registered.

– The number can now be entered.

5. Enter the absolute data using the numeric keys.

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6. Press [ENTER].

– Absolute data is modified.

9.3.11.4 Clearing Absolute Data


– The sub menu appears



3. Select {DATA} under the main menu.


4. Select [CLEAR ALL DATA].

– A confirmation dialog box appears.

5. Select {YES}.

– All absolute data are cleared.

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– When {NO} is selected, the registration will be canceled.

9.3.12 Home Position of the Robot

In case of ES165D, the home position are as follows.

Fig. 38: Home Positon

Table 40: Home position

1 B-axis center line angle against, U-axis center line (0°)

2 U-axis angle against horizontal line on the ground (0°)

3 L-axis angle against vertical line to the ground (0°)

1 2

3

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9.4 Setting the Second Home Position (Check Point)

Other robot models have different positions. Always refer to "ROBOT INSTRUCTIONS" for the correct robot model.

WARNINGBe aware of safety hazards when performing the position confirmation of the second home position (check point).

When "OUT OF RANGE (ABSO DATA)" alarm occurs, abnormality of the PG system may be a cause of the alarm. The robot may operate in an unexpected manner, and there is a risk of damage to equipment or injury to personnel.

Before operating the robot, check that the SERVO ON lamp goes out when the emergency stop buttons on the front door of DX100 and the programming pendant are pressed.

Injury or damage to machinery may result if the robot cannot be stopped in case of an emergency.





Improper or unintended robot operation may result in injury.

Prior to performing the following operations, be sure that no one is in the P-point maximum envelope of the robot, and be sure that you are in a safe place when:

– Turning ON the DX100 power.

– Moving the robot with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result from contact with the robot if persons enter the P-point maximum envelope of the robot.

Press the emergency stop button immediately whenever there are problems.

Emergency stop buttons are attached on the front door of the DX100 and the right side of the programming pendant.

NOTE

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9.4.1 Purpose of Position Check Operation

If the absolute number of rotation detected at power supply ON does not match the data stored in the absolute encoder the last time the power supply was turned OFF, an alarm is issued when the controller power is turned ON.

There are two possible causes of this alarm:

● Error in the PG system.

● The robot was moved after the power supply was turned OFF.

If there is an error with the PG system, the robot may stall when playback is started. If the absolute data allowable range error alarm has occurred, playback and test runs will not function and the position must be checked.

CAUTIONPerform the following inspection procedures prior to teaching the robot. If problems are found, correct them immediately, and be sure that all other necessary tasks have been performed.

– Check for problems in robot movement.

– Check for damage to the insulation and sheathing of external wires.

Always return the programming pendant to its hook on the DX100 cabinet after use.

If the programming pendant is inadvertently left on the robot, a fixture, or on the floor, the robot or a tool could collide with it during robot movement, possibly causing injury or equipment damage.

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Fig. 39: Purpose of position check

Table 41:

1 "OUT OF RANGE (ABSO DATA)" alarm occurs

2 Reset alarm

3 Turn ON servo power

4 Position confirmation operation

5 Compare second home position (check point)* pulses with current position pulses

6 Alarm occurs again

7 Correct defective axis

8 Position checking point

9 Playback possible

10 Procedure After Alarm Occurs

� • •

�

NG

OK

�

1

2

4

5

6

7

8

9

3

10

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Position Check

After the "OUT OF RANGE (ABSO DATA)" alarm occurs, move to the second home position using the axis keys and perform the position confirmation. Playback, test runs, and FWD operation will not function unless "CONFIRM POSITION" is performed.

Pulse Difference Check

The pulse number at the second home position is compared with that at the current position. If the difference is within the allowable range, playback is enabled. If not, the alarm occurs again.

● The allowable range pulse is the number of pulses per rotation of the motor (PPR data).

● The initial value of the second home position is the home position (where all axes are at pulse 0). The second home position can be changed.

Alarm Occurrence

If the alarm occurs again, there may be an error in the PG system. Check the system. After adjusting the erroneous axis, calibrate the home position of the axis, then check the position again.

9.4.2 Procedure for the Second Home Position Setting (Check Point)

Apart from the "home position" of the robot, the second home position can be set up as a check point for absolute data. Use the following steps to set the specified point.

If two or more robots or stations are controlled by one controller, the second home position must be set for each robot or station.



Home position calibration of all the axes at the same time enables playback operations without having to check the position.

Sometimes in a system with a robot with 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, the robot moves as follows:

After the start, the robot moves at low speed (1/10 of the maximum speed) to the step indicated by the cursor. If it stops and restarts during this motion, the low speed setting is retained until the step at cursor is reached.

Regardless of cycle setting, the robot stops after reaching to the step indicated by cursor. Starting the robot again then moves it at the programmed speed and cycle of the job.

NOTE

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2. Select {SECOND HOME POS}.

– The SECOND HOME POS window appears. A message “Available to move to and modify specified point” is displayed.

3. Press the page key , or select {PAGE} to display the selection window for the control group.

– When there are two or more group axes, select the group axes to which the second home position is to be specified.

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4. Press the axis keys.

– Move the robot to the new second home position.

5. Press [MODIFY], then [ENTER].

– The second home position is changed.

9.4.3 Procedure after the Alarm

If the "OUT OF RANGE (ABSO DATA)" alarm occurs:

● Reset the alarm;

● Turn ON the servo power;

then confirm the second home position. After the confirmation, if the PG system is found to be the cause of the alarm, perform the necessary operation, such as replacing the PG, etc.

The robot current position data when turning main power supply OFF and ON can be confirmed in “POWER ON/OFF POS" window.

WARNINGBe aware of safety hazards when performing the position confirmation of the specified point.

Abnormality of the PG system may be the cause of the alarm. The robot may operate in an unexpected manner, and there is a risk of damage to equipment or injury to personnel.

For details on the “POWER ON/OFF POS" window, refer to " 7.7 Position Data When Power is Turned ON/OFF " in DX100 MAINTENANCE MANUAL.

SUPPLE-MENT

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2. Select {SECOND HOME POS}.

– The SECOND HOME POS window appears.

3. Press the page key , or select {PAGE} to display the selection window for the control group.

– When there are two or more group axes, select the group axes to which the second home position is to be specified.

4. Press [FWD].

– TCP moves to the second home position. The robot moving speed is set as selected manual speed.

5. Select {DATA} under the menu.

6. Select {CONFIRM POSITION}.

– A message “Home position checked” appears.

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– Pulse data of the second home position and current pulse data are compared. If the compared error is in allowed range, playback operation can be done.

– If the error is beyond the allowed range, the alarm occurs again.

9.4.3.1 Encoder Connector (with CAUTION Label)

● Battery Pack Connection (for S-, L-, U-axes Motors)

The connectors (crimped contact-pin) for the battery backup are installed at the end point of the motors (marked as BAT and OBT). Connect the battery pack according to the following procedure.

1. Remove the cap attached to the battery backup connector of the motors.

2. Connect the battery packs (HW9470932-A / Order no. 111512) with the battery backup connectors located at the end point of the cables for the encoder. (Under this condition, remove the encoder connector and carry out the maintenance checks).

3. After the maintenance check, verify that all the connectors are connected and remove the battery pack. Install the caps attached to the battery backup connector of the motor.

When performing maintenance such as replacement of a wire harness in the robot, the encoder connector (with CAUTION label) will be removed. In this case, be sure to connect the battery pack to the battery backup connector before removing the encoder connector.

Removing the encoder connector without connecting the battery pack leads to disappearance of the encoder absolute data.

For the battery pack connection, refer to Fig. 40: "Encoder connector Diagram (for S-, L- and U-Axes)" at Page 77 and Fig. 41: "Encoder Connector Diagram (for R-, B- and T-Axes)" at Page 78.

Do not remove the battery pack in the connector base.

NOTE

NOTE

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Fig. 40: Encoder connector Diagram (for S-, L- and U-Axes)

● Battery Pack Connection (for R-, B-, T-axes Motors)

The connectors (crimped contact-pin) for the battery backup are install.ed at the end point of the motors (marked as BAT and OBT). Connect the battery pack according to the following procedure.

Table 42: Encoder connector diagram (for S-, L- and U-axes)

1 Motor

2 Motor power connector

3 Battery pack HW9470932-A Order no. 111512

4 Connector for the battery backup

5 a: Crimped contact-pin (Socket)

b: Crimped contact-pin (Pin)

6 CAUTION Label (Enlarged view)

7 CAUTION label

8 Encoder connector

b

aab0BT

BAT BAT*0BT*

Connect battery to encoder to save the data before removing conector.

CAUTION

CAUTIONConnect battery to encoder to save the data before removing conector.

1

2

3

5

4

6

7

8

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1. Connect the battery packs (HW9470932-A / Order no. 111512) with the battery backup connectors located at the end point of the cables for the encoder (Under this condition, remove the encoder connector and carry out the maintenance checks).

2. After the maintenance check, verify that all the connectors are connected and remove the battery pack. Install the caps attached to the battery backup connector of the motor.

Fig. 41: Encoder Connector Diagram (for R-, B- and T-Axes)

Do not remove the battery pack in the connector base.

Table 43: Encoder connector diagram (for R-, B- and T-axes

1 Encoder 7 CAUTION Label (Enlarged view)

2 Motor cable, etc. 8 CAUTION label

3 Connection 9 Wire harness in robo

4 Battery pack HW9470932-A Order no. 111512

10 Power connector

5 Encoder connector 11 Motor

6 a: Crimped contact-pin (Socket) b: Crimped contact-pin (Pin)

NOTE

BAT0BTb

aa

b0BTBAT

BAT0BTb

aa

bBAT

0BT

CAUTION

CA

UTIO

N

Connect battery to encoder

to save the data before rem

oving conector.

Connect battery to encoder to save the data before removing conector.

1

2

3

45

67

8

9 10

11

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9.4.4 Exhaust Procedures of Dew Condensation Water

Add this item to 9.2 "Notes on Maintenance Procedures" at Page 46.

9.4.4.1 In Case of Floor Installation

Fig. 42: Dew Condensation Water Exhaust (Floor Installation)

1. Make the U-axis horizontal to the ground as shown in Fig. 42: "Dew Condensation Water Exhaust (Floor Installation)".

2. Remove the plug from the water exhaust port 1.


4. Discharge the dew condensation water.

5. Apply Fluit Plast on the thread part of each plug, and reinstall the plug on water exhaust port 1.

6. Reinstall the plug on water exhaust port 2.

Table 44: Dew condensation water exhaust

1 Dew condensation water exhaust port 2: plug PT 1/8


1

2

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9.4.4.2 In Case of Wall Installation

Fig. 43: Dew Condensation Water Exhaust (Wall Installation)

1. Make the U-axis horizontal to the ground as shown in Fig. 43: "Dew Condensation Water Exhaust (Wall Installation)".



4. Apply Fluit Plast on the thread part of the plug, and reinstall the plug on water exhaust port 1.

Table 45:

1 View A


1

2

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9.4.4.3 In Case of Ceiling Installation

Fig. 44: Dew Condensation Water Exhaust (Ceiling Installation)

1. Make the U-axis horizontal to the ground as shown in Fig. 44: "Dew Condensation Water Exhaust (Ceiling Installation)".

2. Remove each plug from the water exhaust port 1 and 2.


4. Apply Fluit Plast on the thread part of each plug, and reinstall the plugs on water exhaust port 1 and 2 respectively.

Table 46: Dew

1 Dew condensation water exhaust port 2: plug PT 1/


12

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10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table in stock as spare parts for the YASKAWA-HP20D-C09. Product performance cannot be guaranteed when using spare parts from any company other than Yaskawa. The spare parts are ranked as follows:

● Rank A: Expendable and frequently replaced parts.

● Rank B: Parts for which replacement may be necessary as a result of frequent operation.

● Rank C: Drive unit.

For replacing parts in Rank B or Rank C, contact your YASKAWA europe GmbH representative.

Table 47: Spare Parts for the YR-HP0020D-C09 (Sheet 1 of 2)

Rank PartsNo.

Name Type Order Nr. Manufacturer Qty QtyperUnit

Remarks

A Grease VIGO Grease RE No. 0

Yaskawa Electric Corporation

16 kg -

A Grease Harmonic Grease SK-1A

Harmonic Drive Systems Co., Ltd.

2.5 kg -

A Grease Alvania EP Grease 2

Showa Shell Sekiyu K.K. 16 kg -

A Liquid Seal Fluit Plast - -

A Battery Pack HW0470360-A Yaskawa Electric Corporation

1 1 for connector base

A Battery Pack HW9470984-A Yaskawa Electric Corporation

1 1 for wire harness in manipulator replacing

B B-Axis Timing Belt

80S4.5M653 Mitsuboshi Belting Limited 1 1

B T-Axis Timing Belt

80S4.5M518 Mitsuboshi Belting Limited 1 1

B S-Axis Speed Reducer

HW0387753-B Yaskawa Electric Corporation

1 1

B S-Axis Input Gear

HW0313491-1 Yaskawa Electric Corporation

1 1

B L-Axis Speed Reducer

HW0387753-C Yaskawa Electric Corporation

1 1

B L-Axis Input Gear

HW0313492-1 Yaskawa Electric Corporation

1 1

B U-Axis Speed Reducer

HW9280880-G Yaskawa Electric Corporation

1 1

B R-Axis Speed Reducer

HW0381463-A Yaskawa Electric Corporation

1 1

NOTE

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B B-Axis Speed Reducer


1 1

B T-Axis Speed Reducer


1 1

B Internal Wire Harness


1 1

B Internal Cable for B- and T-Axes


1 1

C S-Axis AC Servomotor

HW0388665-A

SGMRV-09ANA-YR1*


1 1

C L-Axis AC Servomotor

HW0388666-A

SGMRV-13ANA-YR2*


1 1

C U-Axis AC Servomotor

HW0388663-A

SGMRV-05ANA-YR1*


1 1

C AC Servo Motor for R-, B- and T-Axes

HW0389298-A

SGMPH-02ANA-YR1*


1 3

Table 47: Spare Parts for the YR-HP0020D-C09 (Sheet 2 of 2)

Rank PartsNo.

Name Type Order Nr. Manufacturer Qty QtyperUnit

Remarks

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11 Parts List

11.1 S-Axis Unit

1007

1005

1020

1025

1014

1006

1016

1017

1018

1015 1037

1028

1029

1038

1039

1040

1002

1004

1003

1030

1009

1030

1031

1032

1033

1035

1036

1034

1001

1008

1027

1024

10241023

1026

1020

1023

1022

1041

1041

1012

1013

1010

1014

1011

1021

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Table 48 S-axis Unit

No. DWG No. Name Order Nr.: Pcs

1001 SGMRV-09ANA-YR1* Motor 1

1002 HW0100545-2 S head 1

1003 M16X20 Socket screw 1

1004 2H-16 Spring washer 1

1005 HW0387753-B Speed reducer 1

1006 M10X40 GT-SA bolt 16

1007 HW0100544-2 Base 1


1009 HW0305306-2 M base 1

1010 M5X10 APS bolt 4

1011 PT1/8 Plug 1

1012 UKM6-01 Union 1

1013 HW0305809-1 Cover 1

1014 NB-0640-B Tube 2

1015 HW0304221-1 Cover 1


1017 MSB8-15 Shoulder 1

1018 HW0400645-1 Lever 1

1020 TSH6-01M Union 2

1021 CD-31 Saddle 1


1023 TA1-S10 Clamp 2

1024 M5X10 Screw with spring washer

2

1025 EZ5036A0 Cap 1


1027 HW0305812-1 Holder 1

1028 HW9406775-1 Cover 1


1030 M12 Eye bolt 2




1034 HW0313491-1 Gear 1



1037 V-375L V ring 1

1038 HW0405277-1 Plate 1



1041 T50R Cable tie 2

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11.2 L-Axis Unit

Table 49 L-Axis Unit

No. DWG No. Name Order Nr. Pcs




2004 HW0313492-1 Gear 1

2005 HW0304229-1 M base 1

2006 Y426012.5 Oil seal 1

2007 HW0401506-1 Plate 1

2008 HW0304226-1 Support 1

1002

20122011 2018 2006

2032

2002

2003

2004

2005

200120232024

20072019

20162008

2010

2017

2009

2027

2037

2013

2013

2014

2014

20262028

20152016

2020

2031

2030

2029

2031

20362035

2037

2037

20332034

20212022

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2011 HW0304227-1 Cover 1






2017 HW0100546-2 L arm 1

2018 HW0387753-C Speed reducer 1




2022 HW0404196-4 Washer 2





4


2029 HW0305813-1 Holder 1

2030 HW0305698-1 Cover 1


2032 PT1/8

*STAINLESS*

Plug 1

2033 CD-31 Saddle 1




2

2037 T50L Cable tie 6

1002 HW0100545-2 S head 1

Table 49 L-Axis Unit


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11.3 U-Axis Unit

Table 50 U-Axis Unit



3002 HW0313490-1 Cover 1


3005 HW0102379-1 Casing 1

3006 HW9280880-G Speed reducer 1

2017

3011

3006

3019

3007

3016

3016

30053020

3001

3012

3002 3003

3018

3018

3017

301730083009

3010

3015 30143013

3019

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3011 GT-SH-14 GT-SH washer 6





3016 HW0404196-2 Washer 2



3019 PT1/8 Plug 2

3020 EZ2940A0 Cap 1

2017 HW0100546-2 L arm 1

Table 50 U-Axis Unit


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11.4 R-Axis Unit

4005

40584077

4033

4004

40074006

40314012

40324008

4009

4007

4010

4029

4030

4042

4057

4044

4011

4062

4060

4013

4019

4014

4020

4021

4024

4024

4024

40394040

4055

4022

40234076

4079

4037

4025

4082

4072

4070

40454046

4075

4034

4083

4022

40234016

4024

40234034

4017

4002

4001

50464078

4018

4034

4035

4036

3005

4056

4003

4011

4074

4074

4073

4073

40804069

0 E1101000130GB03

HP20D-C09

Table 51 R-Axis Unit (Sheet 1 of 2)



4002 2H-6 Spring Washer 8



4005 HW0305305-3 M cover 1



4008 HW0404196-5 Washer 1




4012 A-MT6X1 G Nipple 1

4013 HW0381872-A Cross roller bearing 1


4016 TC941045*FKM* Oil seal 1

4017 HW0403857-1 Shaft 1

4018 HW0405201-2 Block 1

4019 HW0304318-1 Housing 1

4020 HW0304085-1 Shaft 1

4021 HW0304914-1 Support 1

4022 HW0404503-1 Saddle 2



4025 HW0200540-1 S cover 1

4029 HW0381463-A Speed reducer 1

4030 HW0404403-1 Shaft 1

4031 AE1314A0 Oil seal 1

4032 HW0304932-1 M base 1

4033 HW0404402-1 Shaft 1


4035 HW0411398-1 N base 1



4039 TA1-S8 Clamp 1

4040 M4X8 Pan screw with spring washer

1


4044 LP-M5 Plug 1



4055 HW0404918-1 Support 1

4056 SGMPH-02ANA-YR1* Motor 1

4057 EZ5036A0 Cap 1


E1101000130GB03 91

9

HP20D-C09

4060 HW0304930-1 Support 1

4062 6811LLU Bearing 1

4069 HW9405817-1 Cover 1

4070 HW9302603-1 Support 1

4072 HW9406148-1 Plate 1



4075 TA1-S8 Clamp 3


3

4077 PT1/8 *STAINLESS* Plug 1

4078 MS4-10 Pin 2


4080 CMBG8+9+10X2P+12-42 Union 1



3005 HW0102379-1 Casing 1

5046 HW0100623-1 Uarm 1

Table 51 R-Axis Unit (Sheet 2 of 2)


2 E1101000130GB03

HP20D-C09

11.5 Wrist Unit

3005

5046

5001

5002

5045

5005

5044

5067

5008

5006

5003

5007

5003

5045

5005

5006

5067

5007

50115008 50575055

5072

5071

5073

5039

50385040

50415016

5070

5049

5017

5068

5036

5040

5048

5043

5012

50265064

5062

50425023

5033

5020

5022

5032

50475069

5047

5060

50655026

5025

50275028

5052

5030

5066

5069

5021

5068

5053

5037

5034

5063

5014

5019

5013

5035

5068

5018

5061

5030

5031

50295031

5024

E1101000130GB03 93

9

HP20D-C09

Table 52 Wrist Unit (Sheet 1 of 2)


5001 HW9406556-1 Support 1



5005 HW9200798-1 Cover 2

5006 SGMPH-02ANA-YR1* Motor 2


5008 HW9482727-A Pulley 2

5011 80S4.5M518 Belt 1

5012 HW9381658-A Gear 1


5014 HW9405452-1 B cover 1

5016 HW9482725-A Pulley 1



5019 HW9482218-A Bearing 1

5020 HW9405199-1 B nut 1

5021 SP-0120** Shim 1

5022 HW9481180-A Bearing 1



5025 HW0304232-1 Shaft 1

5026 TC60747*FKM* Oil seal 2

5027 HW9481187-A Bearing 1

5028 HW0304233-1 Shaft 1

5029 S75 O ring 1

5030 HW0304087-1 Housing 1


5032 HW0304086-1 Housing 1

5033 HW9381659-A Gear 1

5034 HW9482726-A Pulley 1


5036 6002ZZ Bearing 1



5039 TC74.5X90X7*FKM* Oil seal 1


5041 HW9405792-1 Housing 1

5042 HW0200451-1 Wrist base 1


5044 80S4.5M653 Belt 1


5046 HW0100623-1 U arm 1



4 E1101000130GB03

HP20D-C09





5057 M6 Washer 1



5062 LP-M5 Plug 1

5063 HW9405791-3 Housing 1

5064 6811LLU Bearing 1

5065 HW0404606-1 Cover 1

5066 HW0404605-1 Plug 1



5069 M6 Washer 2


5071 TA1-S8 Clamp 1

5072 M4X8 Pan screw with spring washer

1


3005 HW0102379-1 Casing 1

Table 52 Wrist Unit (Sheet 2 of 2)


E1101000130GB03 95

9

HP20D-C09

6 E1101000130GB03

HP20D-C09

E1101000130GB03 97

YASKAWA in Ihrer Nähe / YASKAWA near You

Y ASK AW A Elec tric Co rporation JP

MO T OMAN EU A

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Date post:	13-May-2017
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Operating and Mantenance HP20D

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