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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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ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR REPAIR THE EQUIPMENT! We recommend approved Yaskawa training courses for all personnel involved with the operation, programming, or repair of the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules.
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Failure to observe this caution may result in electric shock or injury. • For disassembly or repair, contact your YASKAWA representative. • 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.
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171469-1CD Notes for Safe Operation WARNING • Before operating the manipulator, check that servo power is turned OFF pressing the emergency stop buttons on the front door of the DX100/NXC100 and the programming pendant. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
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Read and understand the Explanation of Warning Labels in the DX100/NXC100 Instructions before operating the manipulator: Definition of Terms Used In this Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the programing pendant, and supply cables.
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171469-1CD Description of the Operation Procedure Description of the Operation Procedure In the explanation of the operation procedure, the expression “Select • • •” means that the cursor is moved to the object item and the SELECT key is pressed, or that the item is directly selected by touching the screen. Registered Trademark In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or...
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Moving parts MOTOMAN- TYPE may cause injury PAYLOAD MASS ORDER NO. DATE SERIAL NO. WARNING Label B: WARNING YASKAWA ELECTRIC CORPORATION 2-1 Kurosakishiroishi, Yahatanishi-ku, Do not enter Kitakyushu 806-0004 Japan NJ3878 MADE IN JAPAN robot work area. 9 of 74 HW0485750...
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171469-1CD Safeguarding Tips Safeguarding Tips All operators, programmers, maintenance personnel, supervisors, and anyone working near the system must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows: •...
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Do not make any modifications to the controller unit. Making any changes without the written permission from Yaskawa will void the warranty. • Some operations require standard passwords and some require special passwords.
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Turn the power OFF and disconnect and lockout/tagout all electrical circuits before making any modifications or connections. Perform only the maintenance described in this manual. Maintenance other than specified in this manual should be performed only by Yaskawa- trained, qualified personnel. Summary of Warning Information This manual is provided to help users establish safe conditions for operating the equipment.
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If you need assistance with any aspect of your MH5 system, please contact YASKAWA Customer Support at the following 24-hour telephone number: (937) 847-3200 For routine technical inquiries, you can also contact YASKAWA Customer Support at the following e-mail address: techsupport@motoman.com When using e-mail to contact YASKAWA Customer Support, please provide a detailed description of your issue, along with complete contact information.
171469-1CD Table of Contents Table of Contents 1 Product Confirmation ........................1-1 1.1 Contents Confirmation ....................... 1-1 1.2 Order Number Confirmation....................1-2 2 Transporting ............................ 2-1 2.1 Transporting Method......................2-1 2.1.1 Using a Crane....................... 2-2 2.1.2 Using a Forklift...................... 2-3 2.2 Shipping Bolts and Brackets ....................
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171469-1CD Table of Contents 7 System Application ......................... 7-1 7.1 Peripheral Equipment Mounts ................... 7-1 7.1.1 Allowable Load ..................... 7-1 7.2 Internal User I/O Wiring Harness and Air Lines..............7-2 8 Electrical Equipment Specification....................8-1 8.1 Internal Connections......................8-1 9 Maintenance and Inspection ......................9-1 9.1 Inspection Schedule ......................
171469-1CD Product Confirmation 1.1 Contents Confirmation Product Confirmation CAUTION • Confirm that the manipulator and the DX100/NXC100 have the same order number. Special care must be taken when more than one manipulator is to be installed. If the numbers do not match, manipulators may not perform as expected and cause injury or damage.
171469-1CD Product Confirmation 1.2 Order Number Confirmation Order Number Confirmation Check that the order number of the manipulator corresponds to the DX100/NXC100. The order number is located on a label as shown below. Fig. 1-1: Location of Order Number Labels Label (Enlarged View) THE MANIPULATOR AND THE CONTROLLER Check that the manipulator...
171469-1CD Transporting 2.1 Transporting Method Transporting CAUTION • Sling 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 transportation. The system consists of precision components.
171469-1CD Transporting 2.1 Transporting Method 2.1.1 Using a Crane As a rule, the manipulator should be lifted by a crane with two wire ropes when removing it from the package and moving it. Be sure the manipulator is fixed with the shipping bolts and brackets before transport, and lift it in the posture as shown in "Fig.
171469-1CD Transporting 2.1 Transporting Method 2.1.2 Using a Forklift When using a forklift, the manipulator should be fixed on a pallet with shipping bolts and brackets as shown in Fig. 2-2 “Using a Forklift”. Insert claws under the pallet and lift it. The pallet must be strong enough to support the manipulator.
171469-1CD Transporting 2.2 Shipping Bolts and Brackets Shipping Bolts and Brackets The manipulator is equipped with shipping bolts and brackets at A and B as shown in Fig. 2-1 “Transporting Position” to minimize external force during the transportation. • The shipping bolts and brackets are painted yellow Before turning ON the power, make sure that the shipping bolts and brackets are removed.
171469-1CD Installation Installation WARNING • Install the safeguarding. Failure to observe this warning may result in injury or damage. • Install the manipulator in a location where the tool or the workpiece held by its fully extended arm will not reach the wall, safeguarding, or controller.
171469-1CD Installation 3.1 Installation of the Safeguarding Installation of the Safeguarding To insure safety, be sure to install safeguarding. They prevent unforeseen accidents with personnel and damage to equipment. The following is quoted for your information and guidance. Responsibility for Safeguarding (ISO10218) The user of a manipulator or robot system shall ensure that safeguarding is provided and used in accordance with Sections 6, 7, and 8 of this standard.
171469-1CD Installation 3.2 Mounting Procedures for Manipulator Base 3.2.1 Mounting Example For the first process, anchor the base plate firmly to the ground. The baseplate should be rugged and durable to prevent shifting of the manipulator or the mounting fixture. It is recommended to be prepare a balseplate of 30 mm or more thick , and anchor bolts of M10 or larger size.
Conical spring washer In case of using the wall-/ceiling-mounted type, inform YASKAWA of the matter when placing an order. Be sure to NOTE contact YASKAWA representative (listed on the back cover of this instruction manual) to execute a wall/ceiling installation on site.
171469-1CD Installation 3.4 Location Location When installing the manipulator, it is necessary to satisfy the following environmental conditions: • Ambient Temperature: 0° to +45°C • Humidity: 20 to 80%RH (non-condensing) • Free from dust, soot, oil, or water • Free from corrosive gas or liquid, or explosive gas or liquid. •...
171469-1CD Wiring 4.1 Grounding Wiring WARNING • Ground resistance must be 100 W 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.
171469-1CD Wiring 4.2 Cable Connection Fig. 4-1: Grounding Method 5.5 mm or more Bolts M8 (for grounding) Delivered with the manipulator Cable Connection Two manipulator cables are delivered with the manipulator; an encoder cable (1BC) and a power cable (2BC). (Refer to Fig. 4-2(a) “Manipulator Cables for DX100”...
171469-1CD Wiring 4.2 Cable Connection 4.2.2 Connection to the DX100/NXC100 Before connecting cables to the DX100/NXC100, verify the numbers on both manipulator cables and the connectors on the DX100/NXC100. • DX100 When connecting, insert the cables in the order of X21, then X11, and depress each lever low until they click.
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171469-1CD Wiring 4.2 Cable Connection Fig. 4-2(b): Manipulator Cables for NXC100 The NXC100 side The Manipulator side 1BC Encoder cable The NXC100 side The Manipulator side 2BC Power cable 30 of 74 HW0485750...
171469-1CD Basic Specifications 5.2 Part Names and Working Axes Part Names and Working Axes Fig. 5-1: Part Names and Working Axes Wrist Upper arm (U-arm) Lower arm (L-arm) Wrist flange Rotary head Manipulator base Baseplate Dimensions Fig. 5-2: Manipulator Base Dimensions ±...
171469-1CD Basic Specifications 5.4 Dimensions and P-Point Maximum Envelope Dimensions and P-Point Maximum Envelope Fig. 5-3: Dimensions and P-Point Maximum Envelope (mm) 59.5 50.5 34 of 74 HW0485750...
Contact your YASKAWA representative beforehand when moment of inertia is the only load, or load moment is smaller than moment of inertia . Also contact your YASKAWA representative in advance in a case where the load mass is combined with an external force.
171469-1CD Allowable Load for Wrist Axis and Wrist Flange 6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. It is recommended that the attachment be mounted inside the fitting in order to identify the alignment marks. Fitting depth shall be 5 mm or less. Fig.
171469-1CD System Application 7.1 Peripheral Equipment Mounts System Application Peripheral Equipment Mounts The peripheral equipment mounts are provided on the U-axis (upper arm) as shown in Fig. 7-1 “Installing Peripheral Equipment” for easier installation of the user’s system applications. The following conditions shall be observed to attach or install peripheral equipment.
171469-1CD System Application 7.2 Internal User I/O Wiring Harness and Air Lines Internal User I/O Wiring Harness and Air Lines Internal user I/O wiring harness (16 wires :0.2 mm ) and two air lines are incorporated in the manipulator for the drive of the peripheral devices mounted on the upper arm as shown in Fig.
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171469-1CD System Application 7.2 Internal User I/O Wiring Harness and Air Lines Fig. 7-2: Connectors for Internal User I/O Wiring Harness and Air Line Exhaust port 2: Exhaust port 1: Tapped hole M5 Tapped hole M5 with pipe plug with pipe plug Connector for internal user I/O wiring harness: HR10A-10R-10S (2 socket connectors ) Prepare pin connector HR10A-10P-10P*HIROSE*...
171469-1CD Electrical Equipment Specification 8.1 Internal Connections Electrical Equipment Specification Internal Connections High reliability connectors are equipped on each connection part of the manipulator to enable easy removal and installation for maintenance and inspection. For the number and location of connectors, see Fig. 8-1 “Locations and Numbers of Connectors”.
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171469-1CD 8 Electrical Equipment Specification 8.1 Internal Connections Fig. 8-1(a): Internal Connection Diagram for DX100 POWER CABLE INTERNAL CABLE IN S-AXIS INTERNAL CABLE IN L-AXIS INTERNAL CABLE IN BT-AXIS Encoder power supply board 0BAT11 0BAT1 BAT11 BAT1 0BAT12 0BAT2 BAT12 BAT2 0BAT3 BAT3...
The inspection may be conducted at shorter intervals if the manipulator is used very frequently for the application such as handling, in this case, contact your YASKAWA representative. 45 of 74 HW0485750...
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Table 9-1: Inspection Items (Sheet 1 of 2) Items Schedule Method Operation Inspection Charge • • • • Alignment mark Visual Check tram mark accordance and damage at the home position. • • • • Working area and Visual Clean the work area if dust or spatter is present. Check for manipulator damage and outside cracks.
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Table 9-1: Inspection Items (Sheet 2 of 2) Items Schedule Method Operation Inspection Charge • • • R-axis speed reducer Grease Gun Check for malfunction. (Replace if necessary.) Supply grease (6000H cycle). See section 9.3.5 • • • BT-axes speed reducers Grease Gun Check for malfunction.
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Fig. 9-1: Inspection Items R-axis B-axis Note: This figure shows the standard specification manipulator in the home position. T-axis R-axis U-axis T-axis U-axis B-axis L-axis S-axis S-axis AIR1 AIR2 48 of 74...
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171469-1CD Maintenance and Inspection 9.1 Inspection Schedule Table 9-2: Inspection Parts and Grease Used Grease Used Inspected Parts 9,10,11, Harmonic Grease SK-1A S, L, U, R, B and T-axes speed reducers, T- and S-axes gears The numbers in the above table correspond to the numbers in Table 9-1 "Inspection Items".
171469-1CD Maintenance and Inspection 9.2 Notes on Maintenance Procedures Notes on Maintenance Procedures 9.2.1 Battery pack Replacement The battery packs are installed in the position shown in Fig. 9-2 “Battery Location”. If the battery alarm occurs in the DX100/NXC100, replace the battery in accordance with the following procedure: Fig.
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171469-1CD Maintenance and Inspection 9.2 Notes on Maintenance Procedures Fig. 9-3: Battery Connection Battery pack before replacement See replacing step 5 Connector Board See replacing step 4 New battery pack 1. Turn OFF the DX100/NXC100 main power supply. 2. Remove the plate fastening screws and the plate on the connector base, then pull the battery pack put to replace it with the new one.
171469-1CD Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 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. •...
171469-1CD Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.6.2 Grease Replenishment for T-axis (Refer to Fig. 9-9 “B- and T-Axes Speed Reducers Diagram”.) 1. Remove the plug M5 from the exhaust port and the low head socket head cap screw M6 from the grease inlet. •...
171469-1CD Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.7 Notes for Maintenance 9.3.7.1 Wrist Unit The motor and encoder units are provided with the wrist unit. To prevent fumes from penetrating into the wrist unit, the jointed faces are sealed with sealing bond.
10 Recommended Spare Parts It is recommended to keep the parts and components in the following table in stock as spare parts for the MOTOMAN-MH5. Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA. The spare parts are ranked as follows: •...
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Recommended Spare Parts Table 10-1: Spare Parts for the YR-MH00005-C00/YR-MH0005N-C00 (Sheet 2 of 2) Rank Parts Name Type Manufacturer Remarks Unit T-Axis HW0388710-A YASKAWA Speed Reducer Wire Harness in HW0175096-A YASKAWA Manipulator S-and L-Axes HW0388651-A YASKAWA AC Servomotor SGMAV-04ANA-YR1* U-Axis...
171469-1CD Parts List 11.1 S-Axis Unit 11 Parts List 11.1 S-Axis Unit Fig. 11-1: S-Axis Unit 1027 1026 1020 1023 1023 1003 1001 1020 1049 1048 1013 1023 1040 1002 1005 1039 1025 1015 1024 1028 1029 1011 1034 1012 1017 1033 1009...
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171469-1CD Parts List 11.1 S-Axis Unit Table 11-1: S-Axis Unit (Sheet 1 of 2) DWG No. Name 1001 HW0102487-1 Base 1002 HW0102486-1 S head 1003 HW0314329-1 Cover 1004 HW0314328-1 Cover 1005 HW0414024-1 Collar 1006 HW0414025-1 B holder 1007 HW0414034-1 M base 1008 HW0314319-1 Shaft...
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171469-1CD Parts List 11.1 S-Axis Unit Table 11-1: S-Axis Unit (Sheet 2 of 2) DWG No. Name 1047 SGMAV-04ANA-YR11 Motor 1048 HW0414483-1 Cover 1049 HW0414484-1 Packing 11-3 65 of 74 HW0485750...
171469-1CD Parts List 11.4 Wrist Unit 11.4 Wrist Unit Fig. 11-4: Wrist Unit 4023 4042 4098 4083 4096 4097 4085 4089 4090 4086 4081 4092-94 4075 3007 4091 4076 4071 4072 4053 4005 4080 4070 4082 4052 4054 4056 4051 4091 4082 4032...
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171469-1CD Parts List 11.4 Wrist Unit Table 11-4: Wrist Unit (Sheet 1 of 2) DWG No. Name 4001 HW0102483-1 U arm 4002 HW0313997-1 Wrist base 4003 HW0388712-A Gear 4004 HW0388711-A Gear 4005 HW0414075-A Pulley 4006 HW0414076-A Pulley 4007 HW0414078-A Pulley 4008 HW9406260-1 Housing...
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171469-1CD Parts List 11.4 Wrist Unit Table 11-4: Wrist Unit (Sheet 2 of 2) DWG No. Name 4045 M3X10 Socket screw 4046 2H-3 Spring washer 4047 M4X10 GT-SA bolt 4048 M3X12 Socket screw 4049 2H-3 Spring washer 4050 M4X20 Socket screw 4051 2H-4 Spring washer...
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INSTRUCTIONS HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802 YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Europe GmbH Robotics Divsion ) Yaskawastrasse 1, 85391 Allershausen, Germany...
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