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YASKAWA MOTOMAN-NX100
CONTROLLER MANUAL
FOR HD DRIVE MODULE
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
YASKAWA MOTOMAN INSTRUCTIONS
YASKAWA MOTOMAN-NX100 CONTROLLER INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR'S MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operator's manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number:
151521-1CD
Revision:
2
1 of 47
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Summary of Contents for YASKAWA MOTOMAN-NX100
- Page 1 FOR HD DRIVE MODULE Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. YASKAWA MOTOMAN INSTRUCTIONS YASKAWA MOTOMAN-NX100 CONTROLLER INSTRUCTIONS NX100 INSTRUCTIONS NX100 OPERATOR’S MANUAL NX100 MAINTENANCE MANUAL The NX100 operator’s manual above corresponds to specific usage.
- Page 2 YASKAWA Motoman robots, related equipment and software This manual is copyrighted property of YASKAWA and may not be sold or redistributed in any way. You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files to another website, blog, cloud storage site or any other means of storing or distributing online content.
- Page 3 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.
- Page 4 151521-1CD Definition of Terms Used Often in This Manual Definition of Terms Used Often in This Manual MOTOMAN is a YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables. In this manual, the equipment is designated as follows.
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Page 5: Table Of Contents
3.3.2 Mounting ............3-4 3.4 Connection to YASKAWA NX100 Controller ..... . . 3-4 3.4.1 Conducting a Safety/Operation Check . - Page 6 151521-1CD Table of Contents Appendix B Illustrated Parts List B.1 Introduction ..........B-3 B.1.1 Explanation of Parts List .
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Page 7: Chapter 1 Introduction
This manual is intended as an introduction and overview for personnel who have received operator training from YASKAWA, and who are familiar with the operation of their YASKAWA robot model. For more detailed information, refer to the manuals listed in section 1.3 "Reference to Other Documentation". - Page 8 151521-1CD This manual is for a standard YASKAWA Motoman system. If your system is a custom or NOTE modified system, please use the drawing and Bill of Material (BOM) provided with the system for troubleshooting and spares provisioning. The secondary reduction gear (radial bearing) is driven by an AC servo motor through an RV reducer and primary reduction gear (pinion).
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Page 9: Dimensions
151521-1CD 1.2.1 Dimensions 513 mm 407 mm (20.2 in.) (16.0 in.) 1140 mm (44.9 in.) Approximate C.G. Location Mass Est. = 1700 kg as shown 663 mm (26.1 in.) 288 mm (11.3 in.) 1325 mm (52.2 in.) 1436 mm (56.5 in.) 1436 mm 20 mm Dowel Hole (56.5 in.) -
Page 10: Specifications
For additional information refer to the following: • YASKAWA Motoman Manipulator Manual • YASKAWA Motoman NX100 Controller Manual (P/N 149201-1CD) • YASKAWA Motoman Concurrent I/O Parameter Manual (P/N 149230-1CD) • Vendor manuals for system components not manufactured by YASKAWA 10 of 47 151521-1CD... -
Page 11: Customer Support Information
151521-1CD Customer Support Information If you need assistance with any aspect of your NX100 Controller 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... -
Page 12: Chapter 2 Safety
NEVER 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. -
Page 13: Notes For Safe Operations
151521-1CD Notes for Safe Operations Read this manual carefully before installation, operation, maintenance, or inspection of the YASKAWA MOTOMAN. In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”. Indicates an imminent hazardous situation which, if not DANGER avoided, could result in death or serious injury to personnel. - Page 14 151521-1CD WARNING • Before operating the manipulator, check that servo power is turned OFF when the emergency stop buttons on the front door of the NX100 and programming pendant are pressed. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
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Page 15: General Safeguarding Tips
151521-1CD CAUTION • Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed. -Check for problems in manipulator movement. -Check for damage to insulation and sheathing of external wires. •... -
Page 16: Mechanical Safety Devices
151521-1CD Mechanical Safety Devices The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's responsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-2012 safety standards, and other local codes that may pertain to the installation and use of industrial equipment. -
Page 17: Programming, Operation, And Maintenance Safety
YASKAWA will VOID YOUR WARRANTY! • Some operations require standard passwords and some require special passwords. Special passwords are for YASKAWA use only. YOUR WARRANTY WILL BE VOID if you use these special passwords. • The robot controller allows modifications of PART 2, User Section, of the concurrent I/O program and modifications to controller parameters for maximum robot performance. -
Page 18: Chapter 3 Installation
Due to the variety of installation applications, it is not possible to provide detailed installation instructions in this manual. However, general installation guidelines are provided. Contact the YASKAWA customer service for help integrating the HD Drive Module into your system. CAUTION Installation of the HD Drive Module is not a task for the novice. -
Page 19: Lifting Instructions
151521-1CD Lifting Instructions The HD Drive Module is shipped on a wooden shipping skid. The customer is responsible for removing the positioner from the shipping skid and inspecting for shipping damage. The HD Drive Module can be moved by forklift, or by overhead crane and straps using the M16 eyebolts provided. To install the HD Drive Module, proceed as follows: DANGER Forklift truck operation should be performed only by licensed personnel. -
Page 20: Installation Safety
151521-1CD Installation Safety Warning signs and restrictive devices such as fencing, chains, safety mats, or light beams must be placed around the working area of the robot/positioner. Warning signs should indicate hazardous conditions and results that may occur if the warning is disregarded. Refer to local regulations regarding Machine Safety. -
Page 21: Mounting
The surface should be level and even. If it is uneven, grind the swell and flatten the surface. If installing on concrete, YASKAWA recommends the use of an adapter plate (P/N 150903-1) with grout. All floor requirements are application specific and must be determined by the project engineer overseeing the installation. -
Page 22: Conducting A Safety/Operation Check
Your HD Drive Module is now ready for power-up. This system should be operated only by personnel who have received operator training from YASKAWA and who are familiar with the operation of this YASKAWA Motoman robot model. Turn the main power ON, and continue the safety/operation check. -
Page 23: Drive Pinion Adjustment
151521-1CD Drive Pinion Adjustment Drive pinion adjustment is performed at the factory. The following procedure should be used for maintenance or as required during installation. Properly adjusted gear alignment and engagement provide smooth and reliable drive operation. 3.5.1 List of Tools •... -
Page 24: Coarse Adjustment/Gear Alignment
151521-1CD 3.5.2 Coarse Adjustment/Gear Alignment Loosen the three M20 bolts locking the levelling bolts. M20 LOCKING BOLT LEVELING BOLT Fig. 3-4 Leveling Bolts Loosen the four M20 bolts securing the spring assembly. M20 SPRING ASSEMBLY BOLTS Fig. 3-5 Spring Assembly Bolts 24 of 47 151521-1CD... - Page 25 151521-1CD Loosen the jam nut and back off the spring assembly adjuster bolt. JAM NUT SPRING ASSEMBLY ADJUSTER BOLT Fig. 3-6 Spring Assembly Adjuster Bolt Using a pry bar, back the pinion away from the ring gear providing a loose engagement. Fig.
- Page 26 151521-1CD Snug the four M20 spring assembly securing bolts. Adjust the three levelling bolts to provide a uniform gap (approximately 3 mm) between the drive assembly plate and support structures. 3 mm GAP 3 mm GAP Fig. 3-8 Uniform Gap Locate a digital level on the lower surface of the ring gear, near the pinion gear, and oriented in the 'X' direction.
- Page 27 151521-1CD Place the level on the top surface of the pinion gear in the 'X' direction. Raise B and C levelling bolts as required to zero the level. Turn levelling bolt 'B' clockwise to raise the front of the pinion gear (away from the ring gear). Turn levelling bolt 'C' clockwise to raise the back of the pinion gear towards the ring gear.
- Page 28 151521-1CD Place the digital level on the lower surface of the ring gear, near the pinion gear, and oriented in the 'Y' direction. Zero the level. Place the level on the top surface of the pinion gear in the 'Y' direction. Turn levelling screw 'A' clockwise to tip the top of the pinion to the right.
- Page 29 151521-1CD Once the pinion has been firmly seated into the ring gear, back off the adjusting screw until loose and re-tighten until the bolt just touches the assembly. Tighten the spring assembly securing bolts. Fine Adjustment, Checking Gear Mesh: Using the programming pendent, slowly rotate the ring gear in both the forward and reverse directions to create an engagement pattern on the teeth of the ring gear.
- Page 30 151521-1CD Table 3.1 Gear Mesh Pattern Engagement Pattern Description Remedy Proper Tooth Contact Full contact is achieved. Final torque the Pattern is visibly equal on both three locking bolts to 370 Nm. top and bottom. Top Too Tight Turn levelling screw 'B' clockwise to tip the Pattern is visibly equal only top of the pinion gear away from the ring gear (Loosen and re-tighten locking bolt as...
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Page 31: Adjusting Gear Engagement (Gear Lash)
151521-1CD 3.5.3 Adjusting Gear Engagement (Gear Lash) Normal adjustment of gear engagement provides zero lash at rest. The spring assembly provides proper running lash. Jog the adaptor plate to the HOME position, pointing away from the drive pinion. Set up the dial indicators to rest on a ring gear tooth face on both gears to measure tangential motion. -
Page 32: Chapter 4 Maintenance
DANGER Ensure power is off before performing the following procedures. Observe standard lockout/tagout practices. Ordering Parts Contact the YASKAWA service staff at 937.847.3200 to order spare parts. Please have the following information ready before you call: • Machine type (Positioner) •... -
Page 33: Drive Motor Maintenance
Drive Motor Maintenance The servo drive motor is virtually maintenance free. If the servo motor is physically damaged due to a load collision or misuse, or if there is grinding or excessive noise, contact YASKAWA Service Department at (937) 847-3200. -
Page 34: Resetting Axis To Home Position
Resetting the HD Drive Module axis to Home position is typically done during initial installation or after the servo motor has been serviced. These procedures assume that the customer supplied adapter plate has been design to YASKAWA Motoman specifications and includes the homing pin hole (see Fig. 1-2 Customer Adapter Plate Configuration. -
Page 35: Inspecting/Adjusting Brake Pads
Adjust brake pad by turning each of the M12 adjusting bolts counter-clockwise approximately 1/2 turn. Tighten the lock nuts. One turn maximum should be enough to adjust for normal wear. If motion is still NOTE unacceptable, there may be other problems with your system. Contact YASKAWA Service Dept. 35 of 47 151521-1CD... -
Page 36: Troubleshooting
Clean motor surface. Motor overloaded Check motor connections and correct as needed. Unusual noise Motor is going bad Call YASKAWA customer service. Brakes Inspect/replace the brake pads (see Section 4.5). NOTE Shaded text, remedies should be carried out after turning power off. -
Page 37: Appendix A Options Installation
151521-1CD Appendix A Options Installation Installing the Over Travel Limit Switch To install the over travel limit switch option, proceed as follows: Mount limit switch actuators in desired locations along the limit switch diameter of the customer supplied adapter plate using M16x70 hardware provided. CUSTOMER SUPPLIED LIMIT SWITCH DIAMETER ADAPTER PLATE... -
Page 38: Installing The Zone Ring
151521-1CD Connect the limit switch Turck cables to the hard stop limit switches. Refer to system prints for additional wiring information. Reset the soft limits to appropriate values. Refer to Concurrent I/O and Parameters manual for instructions for resetting soft limits. Installing the Zone Ring To install the optional zone ring, proceed as follows: Remove the adaptor plate and brake wear plate to provide access to the drive frame. -
Page 39: B.1 Introduction
Thus, the figure and item numbering system ties the parts list to the illustrations and vice versa. “Part Number” Column All part numbers appearing in this column are YASKAWA Motoman part numbers. “Description” Column The item nomenclature appears in this column. -
Page 40: B.2 Parts List
151521-1CD Parts List B.2.1 Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on left-hand page and the applicable parts list will appear on the opposite right-hand page. Unless the list is unusually long, the user will be able to look at the illustration and read the parts list without turning a page. - Page 41 151521-1CD Fig. B-4 Exploded View 41 of 47 151521-1CD...
- Page 42 151521-1CD Table B.1 Exploded View Item Number Description 149736-1 PLATE, WEAR 150974-1 PLATE, ADAPTOR (Optional) 148154-1 BEARING, RADIAL 150976-2 GUARD, GEAR., RH 150976-1 GUARD, GEAR, LH 149724-1 DRIVE ASSY 149824-1 PLATE WASHER 149729-1 SPRING ASSY 149819-1 BRACKET SUPPORT DRIVE ASSY 149734-1 BRAKE, MOTOSWEEP HD 150926-1...
- Page 43 151521-1CD Fig. B-5 Drive Assembly Table B.2 149724-1 Drive Assembly Item Number Description 150270-1 GUARD, WIPER (Not used on Revision 2 or newer.) 149728-1 GEAR, PINION, 21T 149726-1 RV-450E 149725-1 PLATE, MTG, DRIVE, ASSY, R1 149727-1 PINION, RV-450E 149568-1 MOTOR, 3.7 SGMRS, 37A2A 43 of 47 151521-1CD...
- Page 44 151521-1CD Fig. B-6 Optional Zone Ring Kit Table B.3 149821-1 Optional Zone Ring Kit Item Number Description 146429-1 MODULE, J-BOX, 4-PORT 151043-1 PLATE, MTG, J-BOX 143963-1 SWITCH, LIMIT, MINIATURE ROLLER 149735-1 BRACKET, MOUNTING, LIMIT SWITCH 143789-1 PLATE, MTG, SWITCH, THREADED 44 of 47 151521-1CD...
- Page 45 151521-1CD Fig. B-7 Optional Over Travel Limit Kit 45 of 47 151521-1CD...
- Page 46 151521-1CD Table B.4 149821-1 Optional Over Travel Limit Kit Item Number Description 149779-1 BLOCK, ACTUATOR, LIMIT SWITCH 143789-1 PLATE, MTG, SWITCH, THREADED 143963-1 SWITCH, LIMIT, MINIATURE ROLLER 149735-2 BRACKET, MOUNTING, LIMIT SWITCH 146548-2 SCREW, SHOULDER, M16X50 B-10 46 of 47 151521-1CD...
- Page 47 FOR HD DRIVE MODULE 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...