YASKAWA MOTOMAN-PH130F Bedienungsanleitung

MANUAL NO.

HW1485471

MOTOMAN-PH130F

MAINTENANCE MANUAL

TYPE:

YR-1-06VXF130-A00

(MOTOMAN-PH130F STANDARD SPECIFICATION)

Procedures described in this maintenance manual should be carried out by the person who took

the maintenance-relevant trainings offered by YASKAWA.

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and

retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN-PH130F INSTRUCTIONS

YRC1000 INSTRUCTIONS

YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)

YRC1000 MAINTENANCE MANUAL

YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)

The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”.

The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.

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187273-1CD

Contents

HW1485471

1 Introduction ..................................................................................................................................... 1-1

2 Notes for Maintenance .................................................................................................................... 2-1

2.1 Details of Internal Connections.......................................................................................... 2-1

2.2 Multi-Port Connector.......................................................................................................... 2-3

3 Home Position Return..................................................................................................................... 3-1

3.1 Home Position Posture of Manipulator .............................................................................. 3-1

3.2 Types of Methods for Home Position Return ..................................................................... 3-2

3.2.1 Using a Teaching Point for Setting the Home Position......................................... 3-2

3.2.2 Using Keys............................................................................................................ 3-2

3.2.3 Using Encoder Backup Error Recovery Function ................................................. 3-2

3.2.4 Robot Calibration (MOTOCALV EG) .................................................................... 3-2

3.2.5 Table of Suitable Methods for Home Position Return........................................... 3-2

3.3 Methods for Home Position Return.................................................................................... 3-3

3.3.1 Using a Teaching Point for Setting the Home Position......................................... 3-3

3.3.1.1 Preparation .............................................................................................. 3-3

3.3.1.2 Replacement of Motor or Speed Reducer ............................................... 3-3

3.3.1.3 Home Position Adjustment ...................................................................... 3-4

3.3.2 Using Keys............................................................................................................ 3-5

3.3.3 Using Encoder Backup Error Recovery Function ................................................. 3-8

3.3.4 Robot Calibration (MOTOCALV EG) .................................................................... 3-8

4 L-Axis Fixing Jig .............................................................................................................................. 4-1

4.1 Fixing Jig............................................................................................................................ 4-1

4.1.1 Recommended Installation Posture of the Specified Fixing Jig............................ 4-2

4.1.2 Range of L-Arm Postures to Avoid ....................................................................... 4-3

4.2 Installation and Removal of the L-axis Fixing Jig............................................................... 4-4

4.3 Mechanism......................................................................................................................... 4-8

5 Notes on Grease Replenishment/Exchange Procedures................................................................ 5-1

5.1 Grease Exchange Procedures for Each Axis Speed Reducer........................................... 5-1

5.1.1 Notes on Grease Exchange Procedures .............................................................. 5-1

5.1.2 Grease Exchange Procedure ............................................................................... 5-3

5.1.3 Grease Replenishment for Balancer Link Part ..................................................... 5-8

5.2 Removing, Applying, Assembling of Sealing Bond ............................................................ 5-9

5.2.1 Removing Sealing Bond from Sealing Surface and Cleaning .............................. 5-9

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Contents

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5.2.2 Applying Sealing Bond to Sealing Surface ......................................................... 5-10

5.2.3 Assembling After Applying Sealing Bond ........................................................... 5-11

6 Disassembly and Reassembly of the Motors.................................................................................. 6-1

6.1 Disassembly and Reassembly of the S-Axis Motor ........................................................... 6-2

6.2 Disassembly and Reassembly of the L-Axis Motor ........................................................... 6-6

6.3 Disassembly and Reassembly of U-Axis Motor............................................................... 6-11

6.4 Disassembly and Reassembly of the R-, B-, T-Axis Motors ............................................ 6-16

7 Disassembly and Reassembly of the Speed Reducers .................................................................. 7-1

7.1 Disassembly and Reassembly of S-Axis Speed Reducer ................................................. 7-1

7.2 Disassembly and Reassembly of L-Axis Speed Reducer.................................................. 7-5

7.3 Disassembly and Reassembly of U-Axis Speed Reducer ................................................. 7-9

7.4 Disassembly and Reassembly of R-Axis Speed Reducer ............................................... 7-13

7.5 Disassembly and Reassembly of B-Axis Speed Reducer ............................................... 7-16

7.6 Disassembly and Reassembly of T-Axis Speed Reducer ............................................... 7-20

8 Disassembly and Reassembly of Wrist Unit ................................................................................... 8-1

9 Cable Wiring ................................................................................................................................... 9-1

9.1 Disassembly and Reassembly of Internal Wiring Harness ................................................ 9-1

10 Disassembly and Reassembly of Balancer Unit ......................................................................... 10-1

10.1 Notes when Disassembling and Reassembling the Balancer Unit ................................ 10-1

10.2 Disassembly and Reassembly of Balancer Unit ............................................................ 10-2

10.3 Unit Assembly................................................................................................................ 10-8

10.3.1 Balancer Unit Assembly ................................................................................... 10-8

10.3.2 Shaft Assembly (Knuckle Part)......................................................................... 10-9

10.3.3 Shaft Assembly (Support Part 1) .................................................................... 10-10

10.3.4 Shaft Assembly (Support Part 2) .................................................................... 10-10

10.3.5 Unit Assembly Parts Checklist........................................................................ 10-11

11 Battery Pack Replacement ......................................................................................................... 11-1

11.1 Battery Pack Replacement ............................................................................................ 11-1

12 Parts List..................................................................................................................................... 12-1

12.1 S-Axis Unit ..................................................................................................................... 12-1

12.2 L-Axis Unit ..................................................................................................................... 12-4

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Contents

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12.3 U-, R-, B-, T-Axis Unit ....................................................................................................12-7

12.4 U-arm unit .................................................................................................................... 12-10

12.5 Wrist unit...................................................................................................................... 12-12

12.6 Balancer Unit ............................................................................................................... 12-15

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1 Introduction

1-1

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1Introduction

DANGER

• This maintenance manual is intended to describe safety measures,

necessary items on maintenance and inspection, and maintenance

procedures for proper maintenance and inspection of the

mechanical part of this manipulator. Be sure to read and

understand this instruction manual thoroughly before installing and

operating the manipulator. Any matter not described in this manual

must be regarded as “prohibited” or “improper”.

• General information related to safety are described in “Chapter 1.

Safety” of the YRC1000 INSTRUCTIONS. To ensure correct and

safe operation, carefully read “Chapter 1. Safety” of the YRC1000

INSTRUCTIONS.

CAUTION

• In some drawings in this manual, protective covers or shields are

removed to show details. Make sure that all the covers or shields

are installed in place 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 is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids the

product warranty.

NOTICE

• The drawings and photos in this manual are representative

examples and differences may exist between them and the

delivered product.

• YASKAWA 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

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.

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1 Introduction

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or

inspection of your manipulator.

In this manual, the Notes for Safe Operation are classified as “DANGER”,

“WARNING”, “CAUTION”, or “NOTICE”.

Even items described as “CAUTION” may result in a serious

accident in some situations. At any rate, be sure to follow these

important items.

DANGER

Indicates an imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Safety Signs identified by the signal

word DANGER should be used

sparingly and only for those

situations presenting the most

serious hazards.

WARNING

Indicates a potentially hazardous

situation which, if not avoided, will

result in death or serious injury.

Hazards identified by the signal

word WARNING present a lesser

degree of risk of injury or death than

those identified by the signal word

DANGER.

CAUTION

Indicates a hazardous situation,

which if not avoided, could result in

minor or moderate injury. It may

also be used without the safety alert

symbol as an alternative to

“NOTICE”.

NOTICE

NOTICE is the preferred signal word

to address practices not related to

personal injury. The safety alert

symbol should not be used with this

signal word. As an alternative to

“NOTICE”, the word “CAUTION”

without the safety alert symbol may

be used to indicate a message not

related to personal injury.

NOTE

To ensure safe and efficient operation at all times, be sure

to follow all instructions, even if not designated as “DAN-

GER”, “WARNING” and “CAUTION”.

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1 Introduction

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DANGER

• Do not remove the motor, and do not release the brake.

Failure to observe these safety precautions may result in death or

serious injury from unexpected turning of the manipulator’s arm.

WARNING

• Maintenance 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 representative.

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1 Introduction

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DANGER

• Before operating the manipulator, make sure the servo power is

turned OFF by performing the following operations. When the servo

power is turned OFF, the SERVO ON LED on the programming

pendant is turned OFF.

– Press the emergency stop buttons on the front door of the

YRC1000, on the programming pendant, on the external control

device, etc.

– Disconnect the safety plug of the safety fence.

(when in the play mode or in the remote mode)

If operation of the manipulator cannot be stopped in an emergency,

personal injury and/or equipment damage may result.

Fig. : Emergency Stop Button

• Before releasing the emergency stop, make sure to remove the

obstacle or error caused the emergency stop, if any, and then turn

the servo power ON.

Failure to observe this instruction may cause unintended movement of

the manipulator, which may result in personal injury.

Fig. : Release of Emergency Stop

TURN

• Observe the following precautions when performing a teaching

operation within the manipulator's operating range:

– Be sure to perform lockout by putting a lockout device on the

safety fence when going into the area enclosed by the safety

fence. In addition, the operator of the teaching operation must

display the sign that the operation is being performed so that no

other person closes the safety fence.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Always keep in mind emergency response measures against the

manipulator’s unexpected movement toward a person.

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

Failure to observe this instruction may cause improper or unintended

movement of the manipulator, which may result in personal injury.

• Confirm that no person is present in the manipulator's operating

range and that the operator is in a safe location before:

– Turning ON the YRC1000 power

– Moving the manipulator by using the programming pendant

– Running the system in the check mode

– Performing automatic operations

Personal injury may result if a person enters the manipulator's

operating range during operation. Immediately press an emergency

stop button whenever there is a problem. The emergency stop buttons

are located on the front panel of the YRC1000 and on the right of the

programming pendant.

• Read and understand the Explanation of the Warning Labels before

operating the manipulator.

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1 Introduction

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Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the YRC1000, the

programming pendant, and supply cables.

In this manual, the equipment is designated as follows.

Registered Trademark

In this manual, names of companies, corporations, or products are

trademarks, registered trademarks, or brand names for each company or

corporation. The indications of (R) and TM are omitted.

WARNING

• Perform the following inspection procedures prior to conducting

manipulator teaching. If there is any problem, immediately take

necessary steps to solve it, such as maintenance and repair.

– Check for a problem in manipulator movement.

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

• Always return the programming pendant to the hook on the

YRC1000 cabinet after use.

If the programming pendant is left unattended on the manipulator, on a

fixture, or on the floor, etc., the Enable Switch may be activated due to

surface irregularities of where it is left, and the servo power may be

turned ON. In addition, in case the operation of the manipulator starts,

the manipulator or the tool may hit the programming pendant left

unattended, which may result in personal injury and/or equipment

damage.

NOTICE

• When performing maintenance and inspection, make sure to

connect the battery unit before removing the encoder connector.

Failure to observe this instruction may result in the loss of home

position data.

Equipment Manual Designation

YRC1000 controller YRC1000

YRC1000 programming pendant Programming pendant

Cable between the manipulator and the

YRC1000

Manipulator cable

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1 Introduction

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Explanation of Warning Labels

The following warning labels are attached to the manipulator.

Always follow the warnings on the labels.

Also, an identification label with important information is placed on the

body of the manipulator. Prior to operating the manipulator, confirm the

contents.

Note: Taking the maintenance-relevant trainings offered by YASKAWA is

indispensable for replacing the L-axis of the balancer-equipped

manipulator.

Fig. 1-1: Warning Label Locations

NJ3884-*

NJ4175

MADE IN JAPAN

YASKAWA ELECTRIC CORPORATION

Kitakyushu 806-0004 Japan

2-1 Kurosakishiroishi, Yahatanishi-ku,

MASS

TYPE

PAYLOAD

NJ4030

SERIAL NO.

DATE

NJ4032

NJ4036

NJ4040

NJ4032

NJ4175

NJ4176

NJ4036

Motor removing prohibited label

Nameplate

Balancer disassembly

prohibited label

Crush hazard label

Fall down

hazard label

Collision hazard label

Crush hazard label

Motor removing prohibited label

1BC

OUT

Nameplate

MADE IN JAPAN

YASKAWA ELECTRIC CORPORATION

Kitakyushu 806-0004 Japan

2-1 Kurosakishiroishi, Yahatanishi-ku,

MASS

TYPE

PAYLOAD

NJ4030

SERIAL NO.

DATE

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