Table of Contents
Related Manuals for YASKAWA Motoman MH Series
Summary of Contents for YASKAWA Motoman MH Series
- Page 1 Motoman MH-series Positioner Manual with MotoMount and Drive Assemblies Part Number: 146703-1CD Revision: Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200...
- Page 2 Motoman, Inc. ©2007 by MOTOMAN All Rights Reserved Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
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Page 3: Table Of Contents
TABLE OF CONTENTS Section Page INTRODUCTION About this Document ....................1-1 System Overview ......................1-2 1.2.1 NS600 Module ....................1-2 1.2.2 MotoMount ..................... 1-2 1.2.3 System Layout – Type I .................. 1-3 1.2.4 System Layout – Type II ................. 1-3 Reference to Other Documentation................ - Page 4 TABLE OF CONTENTS Installing the MH-Series Drive Assembly – Type II............4-8 4.3.1 Site Preparation ....................4-8 4.3.2 Unpacking ...................... 4-8 4.3.3 Floor Mounting – Type II ................4-9 4.3.4 Connecting the Cables .................. 4-11 4.3.5 Home Position ....................4-11 Tailstock Column Installation ..................
- Page 5 MAINTENANCE Spare Parts ........................7-1 Servomotor ........................7-1 Weld Ground Brush Replacement – Type I ..............7-2 7.3.1 MH75/150/450/1500 ..................7-2 Weld Ground Brush Replacement – Type II ..............7-4 7.4.1 MH1000/3000 ....................7-4 Reset Headstock To Home Position ................7-8 7.5.1 Jogging Procedure ..................
- Page 6 LIST OF FIGURES Figure Page Figure 1-1 MHT System Layout – Type I ..................1-3 Figure 1-2 MHT System Layout – Type II ................... 1-4 Figure 3-1 MH-series Type I Drive Assembly ................3-1 Figure 3-2 MH-Series, Type II Drive Assembly ................3-3 Figure 3-3 MotoMount Layout....................
- Page 7 Figure 5-5 Mounting Holes on Faceplate MH1500..............5-3 Figure 5-6 Mounting Holes on Faceplate MH1000/3000............5-4 Figure 5-7 Tooling Fixture Inspection..................5-5 Figure 5-8 Tooling Template – MotoMount................5-5 Figure 5-9 Tooling Template – MotoMount HD................5-5 Figure 5-10 Drive Component Clearance – MotoMount............... 5-6 Figure 5-11 Drive Component Clearance –...
- Page 8 LIST OF TABLES Table Page Table 3-1 MH-series Type I Specifications .................. 3-2 Table 3-2 MH-series Type II Specifications ................. 3-4 Table 4-1 Drive Assembly Mounting Specification – Type I ............4-3 Table 4-2 Floor Anchoring Specifications – Type I ..............4-5 Table 4-3 Column Installation –...
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Page 9: About This Document
SECTION 1 INTRODUCTION This manual provides instructions for Motoman’s Type I and Type II drive assemblies – MH75, MH150, MH450, MH1000, MH1500, and MH3000, headstocks, and headstock/tailstock combinations with MotoMount. MH-Series drive assemblies are used universally throughout Motoman’s product line. Appendix A and B of this manual contain parts lists with exploded views and performance specifications for the MH-Series. -
Page 10: System Overview
1.2.1 NS600 Module The NS600 control solution uses Yaskawa Electric America (YEA) components; specifically an amplifier and the NS600 motion control option. The NS600 selects motions via a binary input pattern received from standard XRC outputs. Motion progress/status is transmitted to the XRC via outputs from the NS600. This handshaking interaction of the inputs and outputs creates the loss of coordinated motion, a feature that can be desirable in certain applications. -
Page 11: System Layout - Type I
INTRODUCTION 1.2.3 System Layout – Type I The Type I MH-Series positioner kits include four drive assemblies: MH75, MH150, MH450, and MH1500. The kits are available in four basic mechanical configurations: the drive assembly, the drive assembly with MotoMount, the headstock positioner assembly, and the head and tailstock positioner assembly. -
Page 12: Reference To Other Documentation
INTRODUCTION MOTOMOUNT HEADSTOCK COMPONENTS HOUSING STANDARD TOOL RADIUS (SEE TABLE 3-2) MOTOMOUNT TAILSTOCK COMPONENTS HEADSTOCK COLUMN Figure 1-2 MHT System Layout – Type II Reference to Other Documentation For additional information refer to the following: • Sigma II User’s Manual (NS600 Alarms) - Motoman P/N 147237-1 •... -
Page 13: Safety
SECTION 2 SAFETY Introduction It is the purchaser's responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed. We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems. -
Page 14: Standard Conventions
SAFETY Standard Conventions This manual includes information essential to the safety of personnel and equipment. As you read through this manual, be alert to the four signal words: • DANGER • WARNING • CAUTION • NOTE Pay particular attention to the information provided under these headings which are defined below (in descending order of severity). -
Page 15: General Safeguarding Tips
SAFETY General Safeguarding Tips All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot 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: •... -
Page 16: Installation Safety
SAFETY Installation Safety Safe installation is essential for protection of people and equipment. following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. -
Page 17: Operation Safety
SAFETY • Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to operate the system. • Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. -
Page 18: Maintenance Safety
SAFETY Maintenance Safety All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Maintenance tips are as follows: •... -
Page 19: Equipment Description
SECTION 3 EQUIPMENT DESCRIPTION The MH-series, Type I and Type II drive assemblies consist of an AC servo motor and gear reducer with an integral output bearing mounted in a cast iron housing. Weld ground brushes and position switches are included as standard features. The drive assembly provides programmable motion about the central axis, and endless rotation can be purchased as an option. -
Page 20: Type I Specifications
EQUIPMENT DESCRIPTION 3.1.1 Type I Specifications See Table 3-1 for Type I drive assembly specifications. Table 3-1 MH-series Type I Specifications Series Component MH75 MH150 MH450 MH1500 Motoman P/N 145878-1 145878-2 145881-1 146615-1 Axis Type Rotation Rated Load – kgf 1500 Rated MHT Load @ CG Off Center –... -
Page 21: Mh-Series Drive Assembly - Type Ii
EQUIPMENT DESCRIPTION MH-series Drive Assembly – Type II The appearance of the two available Type II drive assemblies is the same; capacity is the primary difference. The Type II drive assembly is designed for vertical mounting configurations. The Type II drive assembly positioners (see Figure 3-2) are available in two configurations: •... -
Page 22: Type Ii Specifications
EQUIPMENT DESCRIPTION 3.2.1 Type II Specifications See Table 3-2 for MH-series Type II drive assembly specifications. Table 3-2 MH-series Type II Specifications Series Component MH1000 MH3000 Motoman P/N 146356-3 146356-4 Axis Type Rotation Rotation Rated Load – kgf 1000 3000 Rated MHT Load @ CG Off Center –... -
Page 23: Motomount
EQUIPMENT DESCRIPTION MotoMount MotoMount (see Figure 3-3) is a flexible tool fixture mounting system which improves tool repeatability and reduces loads on the headstock/tailstock bearing systems. MotoMount accommodates combined headstock/tailstock/tooling misalignments up to two (2) degrees. MotoMount is required for use with all Motoman MHT-series (headstock/ tailstock) positioners. -
Page 24: Ns600 Module
Figure 3-4 MotoMount HD Layout NS600 Module The NS600 motion-controlling package consists of a Yaskawa Electric America stand-alone servo amplifier with NS600 motion controller. This electrical sub- system can be interfaced with motors in the range of 550W – 1.5kW and 4.0kW –... -
Page 25: Installation
SECTION 4 INSTALLATION CAUTION! Installation of MotoMount and the MH–Series positioners is not a task for the novice. These components are not fragile, but should still be handled with care. Rough handling can damage system electronic components. Installation of the MH–Series positioner and MotoMount should be performed by personnel who are familiar with this Motoman product. -
Page 26: Installing The Mh-Series Drive Assembly - Type I
INSTALLATION Installing the MH-Series Drive Assembly – Type I 4.2.1 Site Preparation Each MH-Series drive assembly should be firmly mounted on a machine base or foundation rigid enough to withstand static and dynamic forces. 4.2.2 Unpacking The headstock and optional tailstock are shipped on a wood shipping skid. To unpack the equipment, proceed as follows: WARNING! See the specification tables in Section 3 for drive assembly weight. -
Page 27: Headstock Assembly Mounting Hole Pattern - Mh75/175/450/1500
INSTALLATION 4.2.3 Headstock Assembly Mounting Hole Pattern – MH75/175/450/1500 The headstock assembly may be mounted to the column assembly (see Section 4.2.4) or mounted to a customer-supplied machine base. For custom orientations, auxiliary mounting holes are provided on top of the drive assembly housing, and may be used in addition to the base mounting holes. -
Page 28: Figure 4-3 Mh450 Mounting Hole Pattern
INSTALLATION 350.0 MM 13.77 IN 2 X SF FOR M12 DOWEL 4 X CLEARANCE 56.9 MM FOR M10 SCREW 2.29 IN 2 X M10 X 1.5 THRU 135.0 MM AUXILARY MOUNTING 5.31 IN HOLES 190.0 MM 76.2 MM 7.48 IN 3.00 IN 190.0 MM 7.48 IN... -
Page 29: Column Assembly Mounting - Type I Drive Assembly
INSTALLATION 4.2.4 Column Assembly Mounting – Type I Drive Assembly Hole Patterns The column assembly for the MHT-Series positioner may be mounted to the floor or on a base. For accurate placement information, cross reference the hole pattern in Figure 4-5 with the specifications shown in Table 4-2. C –... -
Page 30: Figure 4-6 Leveling Hardware
INSTALLATION ANCHOR (CUSTOMER SUPPLIED) HEADSTOCK COLUMN FACEPLATE LEVELING BOLT LOCK NUT COLUMN BASE LEVELING SHIM Figure 4-6 Leveling Hardware Leveling the Type I Headstock The headstock must be leveled two directions: parallel to the faceplate and perpendicular to the faceplate. Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. -
Page 31: Connecting The Cables
INSTALLATION 4.2.5 Connecting the Cables Do not connect the encoder, power, and ground cables until after the drive assembly is securely in place. NOTE: When installing stand-alone drive assemblies, the user needs to mount the junction boxes close to the drive assembly for motor cables. Connection to Motoman Controller When the MH-series drive assembly is delivered with a Motoman robot, connections between the two usually have been made at the factory, or if not,... -
Page 32: Installing The Mh-Series Drive Assembly - Type Ii
INSTALLATION Installing the MH-Series Drive Assembly – Type II 4.3.1 Site Preparation Each MH-Series drive assembly should be firmly mounted on a machine base or foundation rigid enough to withstand static and dynamic forces. 4.3.2 Unpacking The headstock and optional tailstock are shipped on a wood shipping skid. To unpack the equipment, proceed as follows: WARNING! The MH-series headstock can weigh as much as 1200 kg (2650 lbs). -
Page 33: Floor Mounting - Type Ii
INSTALLATION 4. Remove top cover and attach eye bolts to top of the housing and lift. 5. Place headstock in position. NOTE: Make sure there is adequate room on all sides of the positioner for parts fixturing. 4.3.3 Floor Mounting – Type II Figure 4-9 provides dimensions for accurately floor mounting the MH1000/3000 headstocks. -
Page 34: Figure 4-10 Leveling Hardware
INSTALLATION ANCHOR (CUSTOMER HEADSTOCK SUPPLIED) RISER FACEPLATE LEVELING BOLT LOCK-NUT COLUMN BASE LEVELING SHIM Figure 4-10 Leveling Hardware Leveling the Type II Headstock The headstock must be leveled in two directions, parallel to the faceplate and perpendicular to the faceplate. Since it only takes three points to define a plane, use only three of the four leveling bolts to level the positioner. -
Page 35: Connecting The Cables
INSTALLATION 4.3.4 Connecting the Cables Do not connect the encoder, power, and ground cables until after the drive assembly is securely in place. Connection to Motoman Controller When the MH-series drive assembly is delivered with a Motoman robot, connections between the two usually have been made at the factory, or if not, instructions for making connections can be found in the system manual. -
Page 36: Tailstock Column Installation
INSTALLATION Tailstock Column Installation 4.4.1 Type I Installation Before proceeding to install the tailstock, make sure the Type I headstock is already anchored to the floor. If it is not, refer to Section 4.2. To install the tailstock onto a cell base or floor, proceed as follows: 1. -
Page 37: Type Ii Installation
INSTALLATION 4.4.2 Type II Installation To install the tailstock of a Type II assembly onto a cell base or floor, proceed as follows: 1. Ensure the proper position the headstock assembly per system layout. The headstock must be permanently anchored to the floor/base. 2. -
Page 38: Leveling The Tailstock
INSTALLATION 4.4.3 Leveling the Tailstock Type I Leveling Procedures The tailstock must be leveled in two directions, axially and cross-axially. Since it only taks three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts throughout each process. -
Page 39: Figure 4-17 Leveling The Tailstock - Type Ii
INSTALLATION Type II Leveling Procedures The Type II tailstock must be leveled in two directions, axially and cross-axially. Since it only takes three points to define a plane, use only three of the four leveling bolts to level the system. It is important to consistently use the same three leveling bolts through out each process. -
Page 40: Installing The Motomount Tailstock Adapter
INSTALLATION LEVELING DEVICE 0 – 0.5 DEGREE MAX. Figure 4-18 Allowable Axial Leveling - Side View 4.4.4 Installing the MotoMount Tailstock Adapter The MotoMount tailstock adapter mounts to the tailstock end of the customer- supplied tooling fixture (see Figure 4-19). 1. -
Page 41: Installing The Bearing Housing Base
INSTALLATION 4.4.5 Installing the Bearing Housing Base The pillow block base (see Figure 4-20) is mounted on top of the tailstock column. Install the mounting bolts finger tight. Tighten to prescribed torque, 76 N • m (56 lbf-ft). NOTE: THE MH450 TAILSTOCK IS SHOWN. THE MH75/150 VERSIONS USE 2 BOLTS. -
Page 42: Figure 4-21 Tooling Fixture Installation-Headstock
INSTALLATION CUSTOMER SUPPLIED BOLTS M12 GRADE 8.8 HARDENED WASHERS (MOTOMAN SUPPLIED) CUSTOMER SUPPLIED TOOLING FIXTURE Figure 4-21 Tooling Fixture Installation-Headstock 4. Locate the tailstock bearing and center it in the pillow block base while lowering (see Figure 4-22). PILLOW BLOCK CAP TAILSTOCK BEARING TAILSTOCK COLUMN TOOLING... -
Page 43: Tooling Fixture Installation (Regular)
INSTALLATION 9. Tighten the tailstock bearing gland nut to the tailstock adapter shaft per the bearing manufacture’s literature. 10. Remove the hoisting straps. 4.4.7 Tooling Fixture Installation (regular) 1. Jog the headstock until MotoMount is horizontal. The tooling mounting holes and locating pin must be pointing up. WARNING! Make certain servo power is OFF for the remainder of the installation, or serious operator injury and/or equipment damage... -
Page 44: Figure 4-23 Measurement Point For Horizontal Alignment, Bottom View
INSTALLATION c) Ensure the bearing housing is perpendicular to the tailstock adapter within 1/2 degree (a visual check with a square is acceptable). d) Repeat this process until the gap at both positions is within 1 mm (.039 in.). If moving the bearing housing cannot provide the desired results, the columns are out of basic alignment and must be repositioned. -
Page 45: Figure 4-25 Vertical Position - Drive Bushing On Top
INSTALLATION The vertical alignment is checked by measuring the gap between the mounting fixture and mounting block. The measurement of this gap must not change more than 1 mm (.039 in.) after the headstock is rotated 180 degrees. To align MotoMount vertically, proceed as follows: 1. -
Page 46: Tooling Fixture Removal
INSTALLATION d) Recheck the alignment gap and verify that both gaps are within 1 mm (.039 in.). If multiple attempts fail to reduce the gap difference below 1 mm (.039 in.), contact Motoman Customer Service. e) Recheck the horizontal alignment. f) Insure ground cable is installed and properly secured. -
Page 47: Figure 4-26 Motomount Mounting Hole Pattern
INSTALLATION Installing Fixture Dowel Pins The dowel pins must be installed into the back of the mounting block before the assembly is mounted onto the faceplate. There are four holes in the back of the mounting block. See Figure 4-27 to determine which holes to use for your application. -
Page 48: Securing Motomount Drive Components Onto Faceplate
INSTALLATION MOUNTING HOLES MH75/150 ARBOR PRESS DOWEL PIN MOUNTING BLOCK INSERT SPACER MH450 MOUNTING HOLES ARBOR PRESS BASE FIXTURE BLOCK Figure 4-27 Dowel Pin Installation 3. Use an arbor press to force the dowel pins into the appropriate dowel pin hole in the mounting block. -
Page 49: Retrofitting The Tailstock Assembly
INSTALLATION M16 LOCATING PIN MOUNTING BLOCK FIXTURE BLOCK MOUNTING BOLT GROUND CABLE HEADSTOCK FACEPLATE DRIVE BUSHING Figure 4-28 MotoMount Fixture Installation 4.5.4 Retrofitting the Tailstock Assembly The tailstock assembly, with faceplate, must be removed and replaced with the new tailstock bearing assembly. It is not necessary to remove the tailstock column from the cell base. -
Page 50: Figure 4-29 Nominal Center Position - Side View
INSTALLATION TRAVEL 14 MM 14 MM (.55 IN.) (.55 IN.) TOOLING 37 MM NOMINAL FIXTURE (1.45 IN.) 5 MM NOMINAL ADAPTER (.196 IN.) CLAMP ADAPTER SHAFT TAILSTOCK COLUMN TAILSTOCK ADAPTER TAILSTOCK COLUMN Figure 4-29 Nominal Center Position - Side View Allowable Misalignment The flexibility of MotoMount allows for misalignment between the tailstock and the tooling fixture without affecting performance. -
Page 51: Tooling Fixture Installation - Motomount Hd
INSTALLATION 4.6.1 Tooling Fixture Installation – MotoMount HD Both the headstock and tailstock must be permanently anchored to the floor and leveled prior to installation of the tooling fixture. 1. Jog the headstock until MotoMount HD is horizontal. The tooling mounting holes and locating pin must be pointing up. -
Page 52: Conducting A Safety/Operation Check
INSTALLATION Changing Adapter Shaft Position The preferred way change the adapter shaft position is to simply slide the tailstock adapter either way along the adapter shaft. If more adjustment is needed, loosen the four tailstock bolts and slide the adapter shaft and the tailstock adapter until a suitable position is acquired. -
Page 53: Tooling Recommendations
SECTION 5 TOOLING RECOMMENDATIONS Installation of tooling and fixtures should be performed by personnel who are familiar with the operation of this system. Tooling and fixtures are supplied by the customer. There are two system configurations possible with the MH-series positioners: headstock only and headstock/tailstock with MotoMount. -
Page 54: Customer-Supplied Tooling Fixture
TOOLING RECOMMENDATIONS 5.1.1 Customer-supplied Tooling Fixture The customer-supplied tooling hangs from the faceplate as it supports production parts for welding. Customers control/change the design of tooling fixtures to match the design of the production parts. Recommendations To ensure optimum performance from the customer-supplied tooling fixture, please read the following recommendations: •... -
Page 55: Figure 5-4 Mounting Holes On Faceplate Mh450
TOOLING RECOMMENDATIONS 100 MM 100 MM (3.93 IN.) (3.93 IN.) 4 X M12 x 1.75 100 MM (3.93 IN.) 100 MM (3.93 IN.) 2 X SLIP FIT FOR M12 DOWEL 125 MM (4.92 IN.) 250 MM (9.84 IN.) Figure 5-4 Mounting Holes on Faceplate MH450 CAUTION! To properly secure fixture, rated loads require the use of all M16 mounting holes. -
Page 56: Headstock/Tailstock With Motomount
TOOLING RECOMMENDATIONS (4.42 IN) (4.42 IN) 112.5 MM 112.5 MM (7.67 IN) (7.67 IN) 194.9 MM 194.9 MM (8.85 IN) (8.85 IN) 225.0 MM 225.0 MM (8.85 IN) 200 MM (7.87 IN.) 225.0 MM 5 MM (.20 IN) DEEP (7.67 IN) 194.9 MM 4 X M10 1.5 THRU (4.42 IN) -
Page 57: Figure 5-7 Tooling Fixture Inspection
TOOLING RECOMMENDATIONS 1/4-DEGREE ANGLE OF MISALIGNMENT FLANGE 1/4-DEGREE TOOLING FIXTURE ANGLE OF MISALIGNMENT Figure 5-7 Tooling Fixture Inspection Hole Pattern on MotoMount The tooling fixture flange that attaches to MotoMount must have the following hole pattern (see Figure 5-8). 177.8 MM (7 IN.) 2 X DIAM. -
Page 58: Figure 5-10 Drive Component Clearance - Motomount
TOOLING RECOMMENDATIONS Headstock Flange Specifications Figure 5-10 shows the specifications for the tooling fixture flange that is secured to MotoMount. Figure 5-11 shows the specifications for the tooling fixture flange that is secured to MotoMount and MotoMount HD. 40 MM (1.57 IN.) MAXIMUM 40 MM (1.57 IN.) MINIMUM... -
Page 59: Figure 5-12 Tailstock Adapter - Motomount
TOOLING RECOMMENDATIONS Tailstock Flange Specifications Figure 5-12 shows the specifications for the tooling fixture flange that is secured to the MotoMount tailstock adapter. Figure 5-13 shows the specifications for the tooling fixture flange that is secured to the MotoMount tailstock adapter. MotoMount 16 MM (.629 IN.) MINIMUM... -
Page 60: Figure 5-14 Tailstock Component Clearance - Motomount Hd
TOOLING RECOMMENDATIONS 31.8 MM (1.25 IN.) TOOLING PIN 63.5 MM (2.50 IN.) TAILSTOCK ADAPTER TAILSTOCK DIAM. 90 MM ADAPTER (3.54 IN.) THRU 90 MM DIAM X 40 MM DEEP SHAFT CLEARANCE REQUIRED Figure 5-14 Tailstock Component Clearance - MotoMount HD Welding NOTE: This does not apply to MotoMount HD. -
Page 61: Ns600 Operation
SECTION 6 NS600 OPERATION This section deals with I/O sequencing with the positioner. This section assumes the electrical interface of the NS600 was wired as dictated for part number 146732-1, -2, -3 (all three dash numbers represent the standard package for this product). -
Page 62: Table 6-1 Outputs/Inputs - 2-Position Continuous Rotation
NS600 OPERATION Table 6-1 Outputs/Inputs – 2-position Continuous Rotation XRC Outputs XRC Inputs Index Motions Speed (% of Rated) Home 100% IN #13 IN #9 Move to 0 100% IN #13 IN #9 Move to 180 100% IN #13 IN #10 Jog CW IN #13 -none-... -
Page 63: Table 6-2 Outputs/Inputs - 3-Position Continuous Rotation
NS600 OPERATION Table 6-2 Outputs/Inputs – 3-position Continuous Rotation XRC Outputs XRC Inputs Index Motions Speed (% of Rated) Home 100% IN #13 IN #9 Move to 0 100% IN #13 IN #9 Move to 120 100% IN #13 IN #10 Move to 240 100% IN #13... -
Page 64: Table 6-3 Outputs/Inputs - 4-Position Continuous Rotation
NS600 OPERATION Table 6-3 Outputs/Inputs – 4-position Continuous Rotation XRC Outputs XRC Inputs Index Motions Speed (% of Rated) Home 100% IN #13 IN #9 Move to 0 100% IN #13 IN #9 Move to 90 100% IN #13 IN #10 Move to 180 100% IN #13... -
Page 65: Table 6-4 Outputs/Inputs - 2-Position Reciprocating Rotation
NS600 OPERATION Table 6-4 Outputs/Inputs – 2-position Reciprocating Rotation XRC Outputs XRC Inputs Index Motions Speed (% of Rated) Home 100% IN #13 IN #9 Move to 0 100% IN #13 IN #9 Move to 180 100% IN #13 IN #10 Jog CW IN #13 -none-... -
Page 66: Alarms
NS600 OPERATION 6.1.4 Alarms Controller Input #16 will remain turned on while no errors on present. This will be different than what you expect, when errors occur this input will go low. When this input is low, look at the NS600 amplifier display and cross reference it with the Alarm table in Appendix C to identify the problem. -
Page 67: Maintenance
SECTION 7 MAINTENANCE Maintenance of the MH-Series components should be performed only by authorized personnel who are familiar with the design and construction of this positioner. The following procedures should be performed only as needed. Read through the instructions completely before performing any maintenance procedure. -
Page 68: Weld Ground Brush Replacement - Type I
MAINTENANCE Weld Ground Brush Replacement – Type I 7.3.1 MH75/150/450/1500 To replace the grounding brush(s) proceed as follows: 1. Shut down cell using main disconnect. 2. Use a flathead screwdriver to disconnect the brush cable(s) from the ground post (see Figure 7-1). GROUND POST GROUND BRUSH CABLE... -
Page 69: Figure 7-2 Brush Assembly
MAINTENANCE BRUSH NUT RETAINING FACE PLATE EDGE BRUSH BRUSH HOLDER VERIFY FULL CONTACT WITH HOUSING FACEPLATE SERVO MOTOR FACE PLATE Figure 7-2 Brush Assembly NOTE: When pulling the brush holder out, identify and secure the nut plate that slides in the top side of the case. -
Page 70: Weld Ground Brush Replacement - Type Ii
MAINTENANCE 7. Slide the old brush out of the housing and replace it with the new one. 8. Put the brush holder back into housing compartment until the both holes on the nut plate are aligned with holes in the housing. 9. -
Page 71: Figure 7-4 Brush Cable Post
MAINTENANCE GROUND BRUSH CABLE DRIVE ASSEMBLY HEADSTOCK Figure 7-4 Brush Cable Post 4. Release the spring tensioner on the back of the brush by squeezing both black spring levers and pulling away from the faceplate. 5. Reach in and steady the brush case with one hand. 6. -
Page 72: Figure 7-5 Brush Assembly
MAINTENANCE BRUSH NUT VERIFY FULL CONTACT WITH PLATE BRUSH BRUSH HOLDER HOUSING Figure 7-5 Brush Assembly NOTE: When pulling the brush holder out, identify and secure the nut plate that slides in the top side of the case. 7. Lower the case below the retaining edge, and slowly pull the brush holder out of the housing (see Figure 7-6). -
Page 73: Figure 7-6 Brush Removal Mh1000/3000
MAINTENANCE MOTOR HOUSING DRIVE ASSEMBLY BRUSH HEADSTOCK Figure 7-6 Brush Removal MH1000/3000 8. Slide the old brush out of the housing and replace it with the new one. 9. Put the brush holder back into housing compartment until the both holes on the nut plate are aligned with holes in the housing. -
Page 74: Reset Headstock To Home Position
MAINTENANCE Reset Headstock To Home Position The home position on the drive assembly is set in the controller by the operator. Any position of the headstock can be programmed as home. The factory setting of home position is found using the alignment hole, an alignment tool, and the programming pendant. - Page 75 MAINTENANCE Programming Home position is now found and the homing pin is inserted, programming is next: Without NS600 Module 1. Switch the programming pendant to MAINTENANCE MODE and proceed: a) Press TOP MENU key on programming pendant. b) Cursor to ROBOT and press SELECT. c) Cursor to HOME POSITION and press SELECT.
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Page 76: Homing
MAINTENANCE 5. The headstock is now reset to zero. Disconnect the serial cable from the computer and from the NS600 unit. Remove the alignment tool from the faceplate. Remove the alignment tool from faceplate. 7.5.2 Homing MH75/150/450/1500 – Type I The factory home position for Type I positioners is located by aligning the homing pin against the housing, after installing the pin in the faceplate hole. -
Page 77: Figure 7-8 Home Position - Type Ii
MAINTENANCE MH1000/3000 – Type II The factory home position is located by aligning two homing pins after installing them into holes in the faceplate and housing. Once both pins are aligned, some minor programming with the programming pendant is required. To reset each a MH1000/MH3000 headstock, proceed as follows: 1. -
Page 78: Adjusting Position Limit Switches
MAINTENANCE 6. Switch the programming pendant to MAINTENANCE MODE and proceed: g) Press TOP MENU key on programming pendant. h) Cursor to ROBOT and press SELECT. i) Cursor to HOME POSITION and press SELECT. j) Press the PAGE OVER key to the desired station (indicated in the top right corner). -
Page 79: Figure 7-9 Position Limit Switch Setting - Type I
MAINTENANCE TOOLING PLATE FACTORY PRESET HOME POSITION WASHER SCREW LIMIT SWITCH Figure 7-9 Position Limit Switch Setting – Type I MH1000/3000 LIMIT SWITCH BRUSH SCREW HOLDER WASHER 30º Figure 7-10 Position Limit Switch Setting – Type II MOTOMAN 7-13 MH-Series with MotoMount Positioner Manual... -
Page 80: Ns600 List Of Spares
MAINTENANCE NS600 List of Spares 7.7.1 Spare Parts The following list contains non-mechanical parts that could require replacement for the NS600. Basic hardware and mounting equipment are not included in the parts lists See Table 7-2 for spare parts for the 750W system, Table 7-3 for spare parts for the 1.5W system, and Table 7-4 for spare parts for the 5.0 W system. -
Page 81: Maintenance Schedule
MAINTENANCE Maintenance Schedule 7.8.1 MH-series Positioners See Table 7-5 for the periodic maintenance schedule. Table 7-5 Maintenance Schedule Inspection Item Frequency Inspection Operation Physical damage Daily Check for physical damage; this indicates a load collision and is evi- dence of misuse. Excessive or Daily Listen for grinding, excessive or irregular noise. -
Page 82: Troubleshooting
MAINTENANCE Troubleshooting 7.9.1 MH-series Positioners Table 7-7 Troubleshooting Symptom Probable Cause Corrective Action Loose connection Check all wire connections. Motor does not start Incorrect wiring Check that system has been wired correctly. Overload Reduce load or reduce unbalanced load. Unstable operation Incorrect wiring Inspect and correct wiring across motor terminals L1, L2, L3, and PE. -
Page 83: Performance Charts
APPENDIX A PERFORMANCE CHARTS MH-series Drive Assemblies A.1.1 MH75 Holding Torque; Load CG Offcenter Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf) Rated W (kgf) Max W (kgf) CG Offcenter, r (mm) Load CG Overhang (from Tooling Plate) D (mm) Rated W (kgf) Max W (kgf) -
Page 84: Figure A-2 Mh150 Performance Charts
PERFORMANCE CHARTS A.1.2 MH150 Rated Holding Torque (N*m)= 212 Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf) Holding Torque; Load CG Offcenter Rated W (kgf) Max W (kgf) CG Offcenter, r (mm) Maximum Bearing Moment (N*m) = 882 Load CG Overhang (from Tooling Plate) D (mm) Rated W (kgf) -
Page 85: Figure A-3 Mh450 Performance Charts
PERFORMANCE CHARTS A.1.3 MH450 Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf) 1301 1951 1084 1626 Holding Torque; Load CG Offcenter 1219 1200 Rated W (kgf) 1000 Max W (kgf) CG Offcenter, r (mm) 2156 Load CG Overhang (from Tooling Plate) D (mm) Rated W (kgf) Max W (kgf) -
Page 86: Figure A-4 Mh1000 Performance Charts
PERFORMANCE CHARTS A.1.4 MH1000 1405 Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf) 2864 4296 Holding Torque; Load CG Offcenter 2387 3580 1790 2685 4475 1432 2148 1193 1790 3975 Rated W (kgf) 1023 1534 3475 1343 Max W (kgf) 1193 2975... -
Page 87: Figure A-5 Mh1500 Performance Charts
PERFORMANCE CHARTS A.1.5 MH1500 Load CG Offcenter Holding Torque; Load CG Offcenter r (mm) Rated W (kgf) Max W (kgf) 4082 6122 3401 5102 4100 2551 3826 Rated W (kgf) 3600 2041 3061 Max W (kgf) 1701 2551 3100 1458 2187 1275 1913... -
Page 88: Figure A-6 Mh3000 Performance Charts
PERFORMANCE CHARTS A.1.6 MH3000 Rated Holding Torque (N*m)= 4214 Holding Torque; Load CG Offcenter Load CG Offcenter 13000 r (mm) Rated W (kgf) Max W (kgf) 8592 12888 11000 7160 10740 Rated W (kgf) 5370 8055 Max W (kgf) 4296 6444 9000 3580... -
Page 89: Illustrated Parts List
APPENDIX B ILLUSTRATED PARTS LIST Introduction The Illustrated Parts List identifies, describes, and illustrates detail parts of the main assemblies for the MH-Series positioner manufactured by Motoman. This list provides parts identification and descriptive information for use in provisioning, requesting, purchasing, storing, and issuing spare parts. Contents The parts list contains a breakdown of the equipment into detail parts. - Page 90 ILLUSTRATED PARTS LIST B.1.1 Symbols and Abbreviations The following is a list of symbols and abbreviations used in the parts list. amp – ampere AC – alternating current cyl – cylinder DC – direct current fig – figure hex – hexagon ID –...
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Page 91: Figure B-1 Mh75/150 Drive Assembly Components
ILLUSTRATED PARTS LIST NOTE: The MH75 and MH150 drive assemblies have the same common parts except for the gear reducer and gear pinion components. Figure B-1 MH75/150 Drive Assembly Components MOTOMAN MH-Series Positioner Manual with MotoMount... -
Page 92: Table B-1 Parts List - Mh75/150 Common Components
ILLUSTRATED PARTS LIST Table B-1 Parts List – MH75/150 Common Components Figure B-1 Motoman Item Part Description Number Number 145878-1 POSITIONER ASSY, HEADSTOCK 75 kg, SERVO 145878-2 POSITIONER ASSY, HEADSTOCK 150 kg, SERVO 142182-1 MOTOR, AC SERVO, SIGMA 3 145877-1 HOUSING, MACHINED 2 (4) 144370-1... -
Page 93: Figure B-2 Mh450 Drive Assembly Components
ILLUSTRATED PARTS LIST Figure B-2 MH450 Drive Assembly Components MOTOMAN MH-Series Positioner Manual with MotoMount... -
Page 94: Table B-2 Parts List - Headstock, 450 Kg
ILLUSTRATED PARTS LIST Table B-2 Parts List – Headstock, 450 kg Figure B-2 Motoman Item Part Description Number Number 145881-1 POSITIONER ASSY, HEADSTOCK 450 kg, SERVO 142142-4 MOTOR, AC SERVO, SIGMA 3 141575-2 GEAR, INPUT, GEAR REDUCER 141577-1 SEAL, OIL SEAL, SINGLE LIP 4 (6) 144370-1 TERMINAL, QUICK, DISCONNECT... -
Page 95: Figure B-3 Motomount Tailstock Components - 75/150/450 Kg
ILLUSTRATED PARTS LIST Figure B-3 MotoMount Tailstock Components – 75/150/450 kg MOTOMAN MH-Series Positioner Manual with MotoMount... -
Page 96: Table B-3 Parts List - Tailstock Assembly, 75/150/450 Kg
ILLUSTRATED PARTS LIST Table B-3 Parts List – Tailstock Assembly, 75/150/450 kg Figure B-3 Motoman Item Part Description Number Number 146683-1 POSITIONER KIT, TAILSTOCK W/ MOTOMOUNT, 75/150 kg 146697-1 POSITIONER KIT, TAILSTOCK W/ MOTOMOUNT, 450 kg 145381-1 FIXTURE ASSY, TOOLING MOUNT, MOTOMOUNT, 450 kg 145381-2 FIXTURE ASSY, TOOLING MOUNT, MOTOMOUNT, 75/150 kg 146469-1... -
Page 97: Figure B-4 Mh1500 Drive Assembly Components
ILLUSTRATED PARTS LIST Figure B-4 MH1500 Drive Assembly Components MOTOMAN MH-Series Positioner Manual with MotoMount... -
Page 98: Table B-4 Parts List - Headstock, 1500 Kg
ILLUSTRATED PARTS LIST Table B-4 Parts List – Headstock, 1500 kg Figure B-4 Motoman Item Part Description Number Number 146615-1 POSITIONER ASSY, HEADSTOCK 1500 kg, SERVO 142142-1 MOTOR, AC SERVO, SIGMA 3 146919-1 SHAFT, GEAR, ALTERED 133890-1 SHAFT, LU AXIS DRIVE 133894-1 GEAR, PINION, STRAIGHT 146918-1... -
Page 99: Figure B-5 Mh1000/3000 Headstock Components
ILLUSTRATED PARTS LIST Figure B-5 MH1000/3000 Headstock Components MOTOMAN B-11 MH-Series Positioner Manual with MotoMount... -
Page 100: Table B-5 Parts List - Headstock 1000/3000 Kg
ILLUSTRATED PARTS LIST Table B-5 Parts List – Headstock 1000/3000 kg Figure B-5 Motoman Item Part Description Number Number 146356-3 POSITIONER, ASSY, HEADSTOCK, 1000 kg 146356-4 POSITIONER, ASSY, HEADSTOCK, 3000 kg 146365-2 COVER, BASE, CASTING 146365-1 COVER, BASE, CASTING 146295-1 RISER, HEADSTOCK 140784-1 BOLT, LEVELING... -
Page 101: Figure B-6 Motomount Hd Tailstock Components - 1000/1500/3000 Kg
ILLUSTRATED PARTS LIST Figure B-6 MotoMount HD Tailstock Components – 1000/1500/3000 kg MOTO MAN B-13 MH-Series Positioner Manual with MotoMount... -
Page 102: Table B-6 Parts List - Tailstock Assembly, Motomount Hd
ILLUSTRATED PARTS LIST Table B-6 Parts List – Tailstock Assembly, MotoMount HD Figure B-6 Motoman Item Part Description Number Number 146964-3 ADAPTER, ASSY, TAILSTOCK, MOTOMOUNT HD 131275-1 SCREW, HHC, M20 X 120 146951-1 CLAMP, SHAFT 148124-1 PIN, LOCATING, DIA16 146950-4 SHAFT, SQUARE 148136-1 BEARING, SPHERICAL, ROLLER... -
Page 103: Figure B-7 Type Ii Drive Assembly Components
ILLUSTRATED PARTS LIST High-speed Low-speed High-speed MH-series Low-speed Low-speed MSR-series Figure B-7 Type II Drive Assembly Components Low speed - low speed (slower turning) references the MSR1000 and MH3000 models. High speed - high speed (faster turning) references the MSR500 and MH1000 models. MOTOMAN B-15 MH-Series Positioner Manual with MotoMount... -
Page 104: Table B-7 Parts List - Type Ii Drive Assembly Components
ILLUSTRATED PARTS LIST Table B-7 Parts List – Type II Drive Assembly Components Figure B-7 Motoman Item Part Description Number Number 146356-1 POSITIONER ASSY, MSR500 146356-2 POSITIONER ASSY, MSR1000 146356-3 POSITIONER ASSY, MH1000 146356-4 POSITIONER ASSY, MH3000 146008-1 PLATE, MTG, MOTOR DRIVE ASSY 146975-1 CAP, LOCKING, PINION 133970-1... -
Page 105: Figure B-8 Motomount Drive Components
ILLUSTRATED PARTS LIST Figure B-8 MotoMount Drive Components MOTOMAN B-17 MH-Series Positioner Manual with MotoMount... -
Page 106: Table B-8 Parts List - Motomount Drive Components
ILLUSTRATED PARTS LIST Table B-8 Parts List – MotoMount Drive Components Figure B-8 Motoman Item Part Description Number Number 145381-1 ADAPTER, ASSY, MOTOMOUNT, MH 340/450 145381-2 ADAPTER, ASSY, MOTOMOUNT, MH 75/150 146503-1 PLATE, SIDE, BLOCK 145710-1 BLOCK, GUIDE 146497-1 COVER, DUST, CAM BLOCK 146496-1 PLATE, CAM BLOCK 132652-8... -
Page 107: Figure B-9 Motomount Hd Drive Components
ILLUSTRATED PARTS LIST Figure B-9 MotoMount HD Drive Components MOTOMAN B-19 MH-Series Positioner Manual with MotoMount... -
Page 108: Table B-9 Parts List - Motomount Hd Drive Components
ILLUSTRATED PARTS LIST Table B-9 Parts List – MotoMount HD Drive Components Figure B-9 Motoman Item Part Description Number Number 146200-1 ADAPTER, ASSY, MOTOMOUNT HD 146193-1 HUB, MOUNTING, 146195-1 BLOCK, GUIDE 146928-1 BEARING, CAM FOLLOWER 148124-1 PIN, LOCATING, DIA. 16 MM HEAD 146196-1 BLOCK, MOUNTING, FIXTURE 146927-1... -
Page 109: Figure B-10 Slip Ring Kit For Motomount Hd
ILLUSTRATED PARTS LIST Figure B-10 Slip Ring Kit for MotoMount HD MOTOMAN B-21 MH-Series Positioner Manual with MotoMount... -
Page 110: Table B-10 Part List - Slip Ring Kit Components
ILLUSTRATED PARTS LIST Table B-10 Part List - Slip Ring Kit Components Figure B-10 Motoman Item Part Description Number Number 148634-1 Accessory, Slip Ring, MotoMount HD 148636-1 SUPPORT, GUARD, SLIP RING 148635-1 GUARD, SLIP RING, 148848-1 SLIP RING ASSY, MOTOMOUNT HD 146913-2 FITTING, NIPPLE, PIPE, BRASS, 3/8-INCH 148847-1... - Page 111 APPENDIX C ALARM CODES Use Table C-1 to identify NS600 controller alarms. Once the alarm is identified, refer to the following manuals to resolve it: • Sigma II User’s Manual - Motoman P/N 147237-1 • Sigma II Indexer User’s Manual - Motoman P/N 147238-1 Table C-1 Alarm Identification Panel Alarm Detail...
- Page 112 ALARM CODES Table C-1 Alarm Identification Panel Alarm Detail Display Absolute Encoder Backup Error - All the power supplies for the absolute encoder have A.81 failed and position data was cleared. Encoder Checksum Error - The checksum results of encoder memory is abnormal. A.82 Absolute Encoder Battery Error - Battery voltage for the absolute encoder has dropped.
- Page 113 ALARM CODES Table C-1 Alarm Identification Panel Alarm Detail Display “Amplifier initial access error. Amplifier power on start up confirmed, but response is A.Eb absent or faulty.” “Watch dog timer error, amplifier ran away or watch dog timer abnormal.” A.EC Command execution incomplete.
- Page 114 ALARM CODES NOTES MH-Series Positioner Manual with MotoMount MOTOMAN...
- Page 115 INDEX About This Document NS600 ALARM CODES, NS600 Alarms E-Stop ANSI/RIA I/O Sequencing Sequencing I/O for Motion Brush Replacement Operation Connecting the Cables 4-11 Operation Safety Connection to Motoman Controller 4-11 Customer Service Information Programming Safety Equipment Description Reference to Other Documentation Robotic Industries Association General Safeguarding Tips Safety...
- Page 116 NOTES MH-Series Positioner Manual with MotoMount MOTOMAN...