YASKAWA YYR-1-06VXH25-A10 Operating And Maintenance Manual
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YASKAWA YYR-1-06VXH25-A10 Operating And Maintenance Manual

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ROBOTICS
YYR-1-06VXH25-A10
GP25-12 (Standard)
Operating and Maintenance Manual

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Summary of Contents for YASKAWA YYR-1-06VXH25-A10

  • Page 1 ROBOTICS YYR-1-06VXH25-A10 GP25-12 (Standard) Operating and Maintenance Manual...
  • Page 2 Modifications made: Rev 01: Revised version of the original HW1484890.0 in YEU R style (2017-11) Rev. 02: Add a new chapter 1.3 "YASKAWA manual list" Rev. 03: Revision of the chapter 4.3 "Installation example" Rev 04: Revised version of the original HW1484890.1 (Chapter: 6.4.1 "Instructions for In- stalling the Mechanical Limit", 9.1 "Inspection schedule"...

  • Page 3: Table Of Contents

    YASKAWA manual list........
  • Page 4 Table of contents Allowable load for wrist axis and wrist flange ........40 Wrist flange .

  • Page 5: General

    General General Notes for safe operation DANGER! Indicating immediate danger at high risk, hazard that can cause death or serious bodily injuries if no precautions are taken. WARNING! Indicating possible medium risk hazard situation which can cause death or serious bodily injuries if it is not avoided.

  • Page 6: Frequently Used Terms

    YASKAWA manual list NOTICE It is important to have all the manuals of the YASKAWA control or robot available and to know their contents. Please make sure you have all these manuals. If any manuals are missing, contact your salesman from YASKAWA local branch office.

  • Page 7: Target Group

    For optimal use of our products, we recommend our customers to take part in a training session at the YASKAWA Academy. For more detailed information on the training programs, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA branch office.

  • Page 8: About This Manual

    If your copy of the operating and maintenance instructions is damaged or lost, please contact the local YASKAWA branch office to order a new copy. The official branch offices are listed on the last page. Please mention the manual number in your order.

  • Page 9: Safety

    General Safety Programming pendant Emergency stop button WARNING! Danger of death or injury from crushing If the emergency stop button is not working properly, the robot cannot be stopped in the event of an emergency.  The robot should not be used if the emergency stop button is not working. ...
  • Page 10 General WARNING! Danger of death or injury from crushing Before you release the emergency stop button (see ), note the following.  Make sure there is no one within the maximum operating range of the robot.  Clear the cell of all items with which the robot could collide. ...

  • Page 11: Manufacturer

    General Manufacturer Address: YASKAWA ELECTRIC CORPORATION 2-1 KUROSAKISHIROISHI YAHATANISHI-KU KITAKYUSHU JAPAN 1.10 Authorized representative Address: YASKAWA Europe GmbH Robotics Division Yaskawastr. 1 85391 Allershausen Germany...

  • Page 12: Supply

    Supply Supply Checking the scope of delivery The standard delivery includes the following items: Scope of delivery Programming pendant Robot controller Robot Cable The present assembly instruc- tions READ ONLY MEMORY...

  • Page 13: Position Type Plate

    Supply Position type plate NOTICE Please contact the local YASKAWA branch office if the serial numbers do not match the information on the delivery note. Verify whether the serial number of the robot, the robot controller and the programming pendant with the delivery.

  • Page 14: Transportation

    Transportation Transportation Transporting method CAUTION! Damage to persons and damage to property due to external force influences  External forces must not be exerted on the robot or the motors. • Check that the eyebolts are securely fastened. • The robot weights approximately 260 kg. Use load carrying devices strong enough to withstand the weight.

  • Page 15: Using A Crane

    Transportation 3.1.1 Using a crane Adequate load handling devices must be used to transport the robot. Make sure that the robot is lifted as shown in the diagram "Transport by crane". Transport with crane Wire rope (at least 1200 mm long) Shipping brackets and bolts 2 screws M12 x 30, 2 washers...

  • Page 16: Using A Forklift

    Transportation 3.1.2 Using a forklift If the robot is transported using a forklift, it should be fixed on a pallet with transport securing devices and shipping bolts. Make sure that the forklift and the transportation route have sufficient bearing capacity. Always take due care when transporting the robot.

  • Page 17: Shipping Brackets And Bolts

    Transportation Shipping brackets and bolts NOTICE Before turning ON the power, check to be sure that the shipping bolts and brackets are removed. After removing the transport securing devices and the shipping bolts, keep them at a safe place. The transport securing devices and shipping bolts will be required again if the system is transported again.

  • Page 18: Installation

    Installation Installation CAUTION! Personal injury and damage to property The following precautions must be taken.  Check that the robot controller is complete and not damaged.  Do not put into operation a robot controller that is damaged or incomplete. ...

  • Page 19: Ambient Conditions And Installation Location

    Installation Ambient conditions and installation location When installing a robot, it is necessary to satisfy the undermentioned environmental conditions: • Ambient temperature: From 0°C to +45°C. • Air humidity: 20% to 80% relative humidity (non-condensing). • Free of corrosive gases, liquids, or explosive gases. No water, oil or dust and free from excessive electrical noise (plasma).

  • Page 20: Installation Example

    Installation example NOTICE  YASKAWA Europe recommends to use the robot only with a base plate.  Please contact the manufacturer of the mounting material you use 1. At the first set out, anchor the base plate firmly onto the floor.
  • Page 21 Installation 260 ±0,3 335 ±0,3 Fig. 4-1: Base plate Thread desig- Strength Maximum tightening torque M in Nm nation category Sliding friction coefficient μ 0.10 0.15 0.20 10.9 12.9 12.9 10.9 12.9 10.9 12.9 1. μ = 0.10: very good surface, lubricated; μ = 0.15: good surface, lubricated or dry; μ = 0.20: Surface, black or phosphatized dry...
  • Page 22 Installation Direction of move- Horizontal Vertical ment Force F Moment M Force F Torque M Emergency stop 8829 N 6700 Nm 11282 N 13734 Nm (Stop category 0) Acceleration/Decelera- 2943 N 2011 Nm 4905 N 5150 Nm tion (Stop category 1) Tab.
  • Page 23 In case of suspended mounting, take measures to prevent the robot from falling down. NOTICE If the setup is changed, please contact the local YASKAWA branch office. Fastening the robot base With suspended mounting, the robot must be fastened with 4 screws M16 (strength class...

  • Page 24: Notes On Dust-Proof/Water-Poof Specifications

    Installation Notes on dust-proof/water-poof specifications The MOTOMAN-GP25-12 (YR-1-06VXH25-A10) conforms to: • IP67 for the wrist part • IP54 for the main part of the robot NOTICE < Definition of IP (protection class) > • Definition of IP67 IP6□: Protection from the entry of dust IP □7: Protection from immersion in water with being submerged for a specified duration and pressure.

  • Page 25: Wiring

    Wiring Wiring DANGER! Danger to life due to electric shock, risk of fire due to short circuit. Wiring must be performed by authorized or certified personnel. Follow the instructions given below before wiring.  Make sure that the earthing resistance does not exceed 0.1 Ω. ...

  • Page 26: Cable Connections

    Wiring Cable connections Fig. 5-1: Connecting the robot system One cable are delivered with the robot (refer to Fig. Robot cable). • Encoder cable / power cable (1BC) Before connecting the robot cable, check the marking on the robot cable and the connections on the connector plate of the robot (see the following diagram "Robot cable").

  • Page 27: Connecting The Robot

    Wiring 5.2.1 Connecting the robot 1. Check the cable. 2. Connect the cable 1BC with the connection 1BC to the connector plate of the robot. Make sure that you hear each locking clip snap into place (clicking sound). Distance between A Outside diameter Minimum bending radius and B...

  • Page 28: Connection Of The Robot Controller

    Wiring 5.2.2 Connection of the robot controller 1. Check the cable 2. Connect the cable X1 at connection X1 to the robot controller. Make sure that you hear the locking clips snap into place (clicking sound). Fig. 5-4: Connection robot controller 5.2.3 Connecting the programming pendant Connect the programming pendant cable to the connection (X81) (see diagram...

  • Page 29: Technical Data

    Technical data Technical data Type: Types of Mounting: Floor, ceiling, wall and angle mounting Degree of freedom: Wrist: 12 kg / U arm 9 kg Payload: ±0.08 mm Repeatability: Power consumption: 2.0 kVA 260 kg Weight: Working area of main axes: S-axis (turning) -180°...

  • Page 30: Parts And Work Axis Label

    Technical data Parts and work axis label Parts and work axis label Wrist Wrist unit Robot base Rotary head of the S-axis Lower arm (L arm) Upper arm (U arm) Robot base dimension Robot base dimensions 4 x Ø18 ±0.1 2 x Ø12 ±0.1...

  • Page 31: Dimensions And Defined Working Area

    Technical data Dimensions and defined working area 2365 1082 227 139 1309 1284 Fig. 6-1: Dimensions and maximum working range of the P-point P point Maximum P-point range All dimensions in mm...

  • Page 32: Adjustable Working Area

    Technical data Adjustable working area The work area of the s-axis may be changed depending on the type of application. If any modification is necessary, please contact the local YASKAWA branch office. Item Specifications S-axis working range ± 180° (standard) ±...

  • Page 33: Components For Changing The Working Area

    Technical data 6.4.2 Components for Changing the Working Area If you change the working area of S-axis, the following components are required (see the following figure). Fig. 6-2: Components of the S-axis limitation 10 x M16 mounting positions Screws M16 x 25, 2 washers M16 (Tightening torque: 206 Nm) S-axis working range Stop position ±180°...

  • Page 34: Adjusting The S-Axis Pulse Limit

    Technical data 6.4.3 Adjusting the S-Axis Pulse Limit NOTICE To change the movement range of the machine, set both the pulse limit and the angle of the mechanical S-axis limit. For altering the range of motion of S-Axis, refer to “YRC1000 GENERAL OPERATOR'S MANUAL chapter ”Softlimit setting function (Document No.: E1102000220XX01 or higher)”.

  • Page 35: Stopping Angle And Time At The Emergency Stop

    Technical data Stopping Angle and Time at the Emergency Stop The definition of the coastdown times is important for determining the safety distance for protective devices. The overrun time is the time that elapses from the point of time when the stop signal is triggered until the robot comes to a complete stop.

  • Page 36: Stop Category 0

    Technical data 6.5.1 Stop category 0 Measurement condition by category 0 • Maximum load • Maximum speed • Posture of maximum inertia Axis Overrun distance (degrees°) Overrun time (second) S-axis 20.6 0.292 L-axis 0.153 U-axis 13.48 0.185...

  • Page 37: Stop Category 1

    Technical data 6.5.2 Stop category 1 6.5.2.1 Stop position S-axis • 100% deflection • 66% deflection • 33% deflection...
  • Page 38 Technical data 6.5.2.2 Stop position L-axis • 100% deflection • 66% deflection • 33% deflection...
  • Page 39 Technical data 6.5.2.3 Stop position U-axis • 100% deflection...

  • Page 40: Allowable Load For Wrist Axis And Wrist Flange

    Allowable load for wrist axis and wrist flange Allowable load for wrist axis and wrist flange Wrist flange The dimensions of the wrist flange are shown in the following figure "Wrist flange". To ensure that the home position marks can be seen at all times, the tool may only be flange- mounted with the inner diameter.

  • Page 41: Allowable Wrist Load

    Thus, in the case when only the inertia load is applied, when the moment load is small while the inertia load is large or when the load is not applied as mass but applied as force, etc.,contact your YASKAWA representative in advance.

  • Page 42: Maximum Capacity Load

    Failure to observe this instruction may adversely affect the safety and/or performance of the robot. YASKAWA provides no guarantee against damages, malfunctions, failures, etc. caused by using any means other than the tapped holes shown in the following figure. The tightening bolts used for the mechanical parts of the manipulator must be used only to secure the mechanical parts.
  • Page 43 Allowable load for wrist axis and wrist flange 77.5 77.5 300 60 28.5 135 255 Fig. 7-1: Installing peripheral devices 4 M6 x 12 threaded holes Dimension of the casting 4 M5 x 11 threaded holes 2 M5 x 10 threaded holes* 4 M6 x 12 threaded holes 8 M5 through tap* Center of gravity of accessories mount on...

  • Page 44: Internal Cables And Compressed Air Lines

    Internal cables and compressed air lines Internal cables and compressed air lines Internal cables (4 wires 1.25 mm², 2 wires 0.75 mm², 8 wires 0.20 mm²) and air hoses are used in order to use peripheral devices (e.g. gripper). They are mounted on the upper arm as shown in the following diagram "Connector for internal cables and compressed air lines".
  • Page 45 Internal cables and compressed air lines Wire harness location Wire harness Detailed drawing of connector ● = used (0.2 mm (0.2 mm ○ = not used (0.2 mm (0.2 mm (0.2 mm Pins used (0.2 mm Open Open Detailed drawing connector on casing (0.2 mm (0.2 mm (0.75 mm...
  • Page 46 Internal cables and compressed air lines When operating, be careful not to let the connector and/or the cable touch the robots body. Mating connector for internal user I/O wiring harness (straight type) Base part: Straight U-arm part: Straight Elbow type The appearance of the robot with the connector installed is shown in figure "Mating connector for internal user I/O wiring harness (elbow type)”.

  • Page 47: Maintenance And Inspection

     Put up the required warning sign, e.g "Do not turn the power on!".  Install a switch-on guard as prescribed. If you have any questions regarding disassembly or repair, please contact the local YASKAWA branch office. NOTICE Home position data is lost Before removing the connector of the encoder cable to perform maintenance or inspection, ...

  • Page 48: Inspection Schedule

    In the table of „Inspection intervals“, the inspections are divided according to three levels of requirement: • Works, carried out by trained staff. • Work carried out by staff trained by YASKAWA. • Works, carried out by YASKAWA staff. Inspections are only carried out by trained staff. NOTICE ...
  • Page 49 1 Trained staff 2 YASKAWA trained staff 3 YASKAWA personnel Item numbers Schedule (h) Method Operation To be per- formed by: Alignment marks  Visual inspection Check alignment mark correspondence and dam-    age at the zero position.
  • Page 50 Item numbers Schedule (h) Method Operation To be per- formed by: Battery unit in robot  If a battery alarm appears or after the robot has   been operated for 24,000 hours, the battery must be replaced. S, L, U, R, axes gear ...
  • Page 51 Maintenance and inspection Fig. 9-2: Inspection intervals...

  • Page 52: Note On Battery Unit

    Maintenance and inspection Note on battery unit NOTICE The absolute encoder data will be lost Removing the battery unit, make sure you not to remove the plug from circuit board. The battery units are installed as shown in picture "The location of the battery unit". If battery alarm occuring in the robot controller, battery unit has to be changed in the following form.
  • Page 53 Maintenance and inspection 3. Remove the connector from the “IN” port of the multi-port connector. Connect the lead for battery replacement to the “IN” port of the multi-port connector. 4. Connect the battery pack for backup to the lead for battery replacement. 5.
  • Page 54 Maintenance and inspection Fig. 9-3: Battery unit location Cable tie 6 screws M4 x 12 (Tightening torque 2.8 Nm) Protective tube 13 screws M4 x 12 (Tightening torque 2.8 Nm) Battery unit for U- and R-axes Battery unit for B- and T-axes Multi-port connector (board) 10 screws M6 x 15 (Tightening torque 10 Nm) Cover...

  • Page 55: Multiple Connection

    Maintenance and inspection 9.2.2 Multiple connection The multi-port connector includes 4 terminals. • 2 connections for the motor • 2 connections for the cable harness NOTICE The absolute encoder data will be lost Absolute encoder data are lost if you remove the plug between engine and multi-port connector during battery replacement.

  • Page 56: Wrist Unit

    Maintenance and inspection Wrist unit Sealing part U-arm Cover Gasket U-arm...

  • Page 57: Home Position Check

    There are alignment marks on each axis to check the home position (Refer to figure “Alignment mark check” below). With those alignment marks, check for home position deviation on regular basis. When home position is disappeared or deviated, contact YASKAWA representative. Alignment mark check S-axis alignment mark...

  • Page 58: Seeped Oil Check

    Maintenance and inspection Seeped oil check Check for seeped oil and/or oil spot periodically. Especially the parts indicated in figure “Inspection parts for seeped oil check” must be inspected carefully. Wipe off seeped oil or oil spot with a cloth before use. Fig.

  • Page 59: Axis Motors

    For these procedures of each axis, refer to figure “Positions of grease-leakage detection hole". When grease leakage is detected, contact YASKAWA representative. Positions of grease-leakage detection hole (S-,L-axis) 1 screw M4 x 6 mm* screw (Tighten- ing torque: 0.75 Nm)

  • Page 60: Refill/Replace Grease

    Maintenance and inspection Refill/Replace grease. Make sure to follow the instructions. If the following instructions are not followed, it might cause damage to motor or gear. CAUTION! Burns from heated grease The grease may be under pressure and may spray out of the threaded hole when opening the threaded hole.
  • Page 61 Maintenance and inspection Designation Tightening torque (Nm) 0.15 PT1/8 PT3/8 16.5 Tab. 9-2: Tightening torque of sealing plug 1. Remove plug from grease exhaust port (OUT) and grease inlet (IN) port. 2. Mount the lubricating nipple to the grease inlet opening. 3.

  • Page 62: Grease Filling The Main Axes

    Maintenance and inspection 9.7.1 Grease filling the main axes Figure the axes S-axis gear PT3/8 PT3/8 L-axis gear PT3/8 PT3/8 U-axis gear PT3/8 PT3/8 Grease inlet opening Grease outlet opening 1. In ceiling-mounted robots the grease outlet and the grease inlet are located the other way around...

  • Page 63: Grease Filling The Wrist Axes

    Maintenance and inspection 9.7.2 Grease filling the wrist axes Figure the axes R-axis gear PT1/8 PT1/8 R-axis pinion PT1/8 PT1/8 B-axis gear PT1/8 PT1/8 T-axis pinion Grease inlet opening Grease outlet opening 1. In ceiling-mounted robots the grease outlet and the grease inlet are located the other way around...

  • Page 64: 10 Recommended Spare Parts List

    It is recommended to keep in stock parts and components in the following table as spare parts. Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA. NOTICE Please contact your YASKAWA branch office if you need spare or replacement parts. Part List robot Designation Type Material no.
  • Page 65 Recommended spare parts list Part List robot Designation Type Material no. Connection cable (Motor) HW1372597-F 191620...
  • Page 66 Recommended spare parts list Part List robot Designation Type Material no. R-axis: Gear HW1382521-A 164748 Motor SGM7J-02APK-YR1* 186762 Power cable for motor HW1372917-B 191683 O-ring Motor 191684 Shaft seal on the motor TC20305-FKM 144564 Conical gear set motor/gear HW1304319-1/20-2 173371 O-ring conical gear 189634 Shim conical gear motor (0.05 mm)
  • Page 67 Recommended spare parts list Part List robot controller Designation Type Material Control power supply CSRA-CPS01KA 186782 CPU Rack JZNC-ARK01-E 186783 CPU board JANCD-ACP01-E 186785 Robot I/F board (STANDARD 2 MB) JANCD-AIF01-1E 186786 Robot I/F board (Optional 4 MB) JANCD-AIF01-1E 186787 General I/O board (PNP Type) JANCD-AIO02-E 186782...

  • Page 68: 11 Parts Lists

    Parts lists 11 Parts lists 11.1 S-axis unit 1005 1003 1006 1010 1014 1025 1013 1043 1022 1007 1042 1021 1046 1008 1024 1045 1002 1044 1040 1041 1009 YR-06VXH25-A01 1015 1060 1037 1016 1059 1036 1039 1039 1038 1038 1048 1050 1026...
  • Page 69 Parts lists DWG no. Designation Piece 1007 M8 × 50 Screw 1008 2L-8 Washer 1009 HW1306670-1 Housing 1010 HW0313491-2 Pinion 1011 M10 × 40 Screw 1012 2H-10 Washer 1013 M6 × 60 Screw 1014 2L-6 Washer 1015 M12 × 45 Screw 1016 2H-12...
  • Page 70 Parts lists DWG no. Designation Piece 1048 M5 × 12 Screw 1049 CD31 Saddle 1050 M5 × 8 Screw 1051 TA1-S10 Clamp 1052 M5 × 8 Screw 1053 HW1405589-1 Support 1054 M5 × 12 Screw 1055 CD39 Saddle 1056 M5 × 8 Screw 1057 TA1-S10...

  • Page 71: R-Axis Unit

    Parts lists 11.2 R-axis unit 5003 4067 4055 4062 4063 4064 4054 4065 4057 4066 4013 4060 4056 4059 4061 4058 4060 4061 4047 4048 4049 4014 4015 4016 4050 4010 4011 4012 4035 4036 4052 4053 4045 4046 4051 4043 4044 4037...
  • Page 72 Parts lists DWG no. Designation Piece 4004 HW1200370-2 Housing 4005 M5 x 45 Screw 4006 2L-5 Washer 4007 HW1303257-2 Shaft 4008 M3 × 12 Screw 4009 TC52647 Oil seal 4010 M6 × 40 Screw 4011 2L-6 Washer 4012 HW1304069-2 Shaft 4013 TC1151306 Oil seal...
  • Page 73 Parts lists DWG no. Designation Piece 4045 HW1408200-1 Support 4046 M4 × 12 Screw 4047 HW1405430-1 Support 4048 M4 × 12 Screw 4049 HW1405459-1 Cover 4050 M4 × 10 Screw 4051 HW1404786-1 Sealing 4052 Connecting terminal A 2-5 Terminal 4053 M4 ×...

  • Page 74: Wrist Unit

    Parts lists 11.3 Wrist unit 5006 5073 5063 5074 5076 5028 5062 5072 5046 5074 5064 5004 5034 5075 5010 5077 5036 5058 5005 5043 5039 5009 5033 5035 5032 5058 5048 5002 5045 5026 5044 5058 5027 5008 5057 5042 5031 5056...
  • Page 75 Parts lists DWG no. Designation Piece 5002 HW1382522-A Gear 5003 HW1100926-1 U-arm 5004 HW1100619-1 Wrist 5005 HW1303250-1 Pinion 5006 D-HW1371294-B Subassembly pinion 5007 HW1305901-1 Shaft 5008 HW1303260-1 Shaft 5009 HW1303261-1 Flange 5010 HW1303262-1 Cover 5011 HW1407201-A Pulley 5012 HW1404037-A Pulley 5013 HW1404038-B Pulley...
  • Page 76 Parts lists DWG no. Designation Piece 5043 NA4902 Needle roller bearing 1 5044 RA9008C0 Cross roller bearing 5045 HW1404059-6 Spring 5046 HW1404060-1 Sealing 5047 HW1484045-A (HW1305902-1) Pinion set (pinion 1) 5048 HW1484045-A (HW1306568-1) Pinion set (pinion 2) 5049 M4 x 18 Screw 5050 2L-4...
  • Page 77 Parts lists...
  • Page 78 Rosh Ha’ayin +972-3-9004114 ROBOPLAN Lda YASKAWA Benelux B.V. Aveiro +351-234 943 900 Son +31-40-2895500 RO Sam Robotics srl YASKAWA Polska Sp. z o.o. Timisoara +40-720-279-866 Wrocław +48-71-7928670 RO MPL Automation S.R.L. RUS YASKAWA Nordic AB Satu Mare +40 (0) 261 750 741...

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Gp25-12

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