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Summary of Contents for Motoman HP3JC
- Page 1 Motoman NXC100 Controller HP3JC Manipulator Manual Part Number: 151562-1CD 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 COMPLETE OUR ONLINE SURVEY Motoman is committed to total customer satisfaction! Please give us your feedback on the technical manuals you received with your Motoman robotic solution. To participate, go to the following website: http://www.motoman.com/forms/techpubs.asp The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman, Inc.
- Page 3 • Vendor manuals for system components not manufactured by Motoman Customer Service Information If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please have the following information ready before you call: • Robot Type (HP3JC) •...
- Page 4 User’s Manual Chapter 1 Introduction Notes page 2 Final...
- Page 5 We recommend that all personnel who intend to operate, program, repair, or use the robot system be trained in an approved Motoman training course and become familiar with the proper operation of the system.
- Page 6 User’s Manual Chapter 2 Safety This safety section addresses the following: • Standard Conventions (Section 2.2) • General Safeguarding Tips (Section 2.3) • Mechanical Safety Devices (Section 2.4) • Installation Safety (Section 2.5) • Programming, Operation, and Maintenance Safety (Section 2.6) Standard Conventions This manual includes the following alerts in descending order of severity...
- Page 7 HP3JC* 151562-1 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.
- Page 8 User’s Manual Chapter 2 Safety Installation Safety Safe installation is essential for protection of people and equipment. The 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 9 Motoman will VOID YOUR WARRANTY! • Some operations require standard passwords and some require special passwords. Special passwords are for Motoman 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 10 User’s Manual Chapter 2 Safety Notes page 8 Final...
- Page 11 MOTOMAN-HP3J INSTRUCTIONS TYPE: YR-HP3J-J00 Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-HP3J INSTRUCTIONS NXC100 INSTRUCTIONS NX100 OPERATOR’S MANUAL NXC100 MAINTENANCE MANUAL The NX100 operator’s manual above corresponds to specific usage.
- Page 12 MANDATORY • This instruction manual is intended to explain operating instructions and maintenance procedures primarily for the MOTOMAN-HP3J. • General items related to safety are listed in the Section 1: Safety of the NXC100 Instructions. To ensure correct and safe operation, carefully read the NXC100 Instructions before reading this manual.
- Page 13 HW0483547 Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the NXC100. In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”. Indicates a potentially hazardous situation which, if not WARNING avoided, could result in death or serious injury to personnel.
- Page 14 HW0483547 WARNING • Before operating the manipulator, check that servo power is turned OFF when the emergency stop buttons on the front face of the NXC100 and on the right side of the programming pendant are pressed. When the servo power is turned OFF, the SERVO ON LED on the program- ming pendant is turned OFF.
- Page 15 HW0483547 WARNING • Observe the following precautions when performing teaching opera- tions: -Always follow the predetermined operating procedure. -Ensure that you have a safe place to retreat in case of emergency. Improper operation or unintended manipulator motion may result in injury. •...
- Page 16 • For safety, operate under the proper lighting. Definition of Terms Used Often in This Manual The MOTOMAN manipulator is the YASKAWA industrial robot product. The manipulator usually consists of the controller, the programming pendant, and supply cables.
- Page 17 Also, an identification label with important information is placed on the body of the manipula- tor. Prior to operating the manipulator, confirm the contents. Warning label B Warning label B Nameplate Warning label A Nameplate Warning Label A: WARNING MOTOMAN TYPE Moving parts MASS PAYLOAD may cause ORDER NO. DATE injury SERIAL NO.
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Page 18: Table Of Contents
HW0483547 Product Confirmation 1.1 Contents Confirmation ......1 1.2 Order Number Confirmation . - Page 19 HW0483547 Allowable Load for Wrist Axis and Wrist Flange 6.1 Allowable Wrist Load ......6 6.2 Wrist Flange .
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Page 20: Product Confirmation
HW0483547 1.1 Contents Confirmation 1 Product Confirmation CAUTION • Confirm that the manipulator and the NXC100 have the same order num- ber. 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. -
Page 21: Order Number Confirmation
HW0483547 1.2 Order Number Confirmation Order Number Confirmation Check that the order number of the manipulator corresponds to the NXC100. The order number is located on a label as shown below. Label (Enlarged View) THE MANIPULATOR AND THE CONTROLLER Check that the manipulator SHOULD HAVE SAME ORDER NUMBER. -
Page 22: Transporting
HW0483547 2 Transporting CAUTION • Sling 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, so failure to observe this caution may adversely affect performance. -
Page 23: Transporting Method
HW0483547 2.1 Transporting Method Transporting Method 2.1.1 Using a Crane As a rule, when removing the manipulator from the package and moving it, a crane should be used. The manipulator should be lifted using wire rope threaded through attached eyebolts. Be sure the manipulator is fixed with shipping bolts and brackets before transportation, and lift it in the posture as shown in "... -
Page 24: Using A Forklift
HW0483547 2.1 Transporting Method 2.1.2 Using a Forklift When using a forklift, the manipulator should be fixed on a pallet as shown in " Fig. 3 Using a Forklift ". Insert claws under the pallet and lift it. The pallet must be strong enough to support the manipulator. -
Page 25: Installation
HW0483547 3 Installation WARNING • Install the safeguarding. Failure to observe this warning may result in injury or damage. • Install the manipulator in a location where the manipulator’s tool or the workpiece held by the manipulator will not reach the wall, safeguarding, or NXC100 when the arm is fully extended. -
Page 26: Installation Of Safeguarding
HW0483547 3.1 Installation of Safeguarding Installation of Safeguarding To insure safety, be sure to install the safeguarding. It prevents 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 the safeguarding is provided and used in accordance with Sections 6, 7, and 8 of this standard. - Page 27 HW0483547 3.2 Mounting Procedures for Manipulator Base 3.2.1 When the Manipulator and Mounting Fixture are Installed on a Baseplate For the first process, anchor the baseplate firmly to the ground. The baseplate should be rug- ged and durable to prevent shifting of the manipulator or the mounting fixture. It is recom- mended to prepare a baseplate in 25 mm in thickness, and anchor bolts in M8 or larger size.
- Page 28 HW0483547 3.2 Mounting Procedures for Manipulator Base 3.2.2 When the Manipulator is Mounted Directly on the Floor without the Mounting Fixture The floor should be strong enough to support the manipulator. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the manipulator as shown in "Table.
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Page 29: Installation Method
HW0483547 3.3 Installation Method Installation Method The manipulator can be mounted in three different ways: floor-mounted (standard), wall- mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the three points listed below are different from the floor-mounted types. 1. -
Page 30: Location
HW0483547 3.4 Location Location When the manipulator is installed, it is necessary to satisfy the undermentioned environmental conditions: • Ambient temperature: 0° to +40°C (ambient temperature) • Humidity: 20 to 80%RH (no moisture, at constant temperature) • Free from dust, soot, or water •... -
Page 31: Wiring
HW0483547 4 Wiring WARNING • Ground resistance must be 100 Ω 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. (ex. DO NOT TURN THE POWER ON.) Failure to observe this warning may result in fire or electric shock. -
Page 32: Grounding
HW0483547 4.1 Grounding Grounding Follow the local regulations and electrical installation standards for grounding. The recom- mended grounding wire size is 5.5 mm at minimum. For grounding, connect the ground wire directly to the manipulator as shown in "Fig. 7 Grounding Method". -
Page 33: Manipulator Cable Connection
HW0483547 4.2 Manipulator Cable Connection Manipulator Cable Connection There are two manipulator cables; an encoder cable for detection (1BC) and power cable (2BC). (See "Fig. 8 Manipulator Cables (1BC and 2BC)".) Connect these cables respectively to the connectors at the manipulator connector base and the NXC100. Refer to "Fig. 9 (a) Manipulator Cable Connectors (Manipulator Side)"... - Page 34 HW0483547 4.2 Manipulator Cable Connection Connector details (Manipulator side) Fig. 9 (a) Manipulator Cable Connectors (Manipulator Side) FAN3 FAN2 PPESP PPESP X64-X63 Connector details (NXC100 side) Fig. 9 (b) Manipulator Cable Connectors (NXC100 Side) HW0483547 24/50...
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Page 35: Basic Specifications
HW0483547 5.1 Basic Specifications 5 Basic Specifications Basic Specifications Table. 3 Basic Specifications MOTOMAN-HP3J Item Model YR-HP3J-J00 Configuration Vertically Articulated Degree of Freedom Payload 3 kg ± 0.03 mm Repeatability S-axis (turning) ± 160 ° L-axis (lower arm) +90 ° , -85 °... -
Page 36: Part Names And Working Axes
HW0483547 5.2 Part Names and Working Axes Part Names and Working Axes Upper arm Wrist (U-arm) Lower arm (L-arm) Rotary head (S-head) Base Fig. 10 Part Names and Working Axes Manipulator Base Dimensions +0.012 6 dia. hole (reference hole) 50±0.1 9 dia. -
Page 37: Dimensions And P-Point Maximum Envelope
HW0483547 5.4 Dimensions and P-Point Maximum Envelope Dimensions and P-Point Maximum Envelope 99.5 99.5 68 68 P-point P-point maximum envelope (*2) (*1) (*1) Shows the LU-axes working envelope within the range of S-axis motion: -40 to 40 . (*2) Shows the LU-axes working envelope within the range of S-axis motion: -160 to 125 or 125 to 160 . Refer to "... -
Page 38: Special Interference Area
HW0483547 5.5 Special Interference Area Special Interference Area Shows the LU-axes working envelope within the range of S-axis motion: -160 to 125 or 125 to 160 . U-axis does not move the S-axis is in area of the slash part in above figure. Shows the LU-axes working envelope within the range of S-axis motion: -40 to 40 . -
Page 39: B-Axis Operating Range
HW0483547 5.6 B-Axis Operating Range B-Axis Operating Range " Fig. 13 B-axis Operating Range " shows the operating range of the B-axis maintaining a constant angle to the center of U-axis. B-axis rotation center U-axis rotation center Wrist U-axis rotation center S-axis rotation center Fig. -
Page 40: Allowable Load For Wrist Axis And Wrist Flange
HW0483547 6.1 Allowable Wrist Load 6 Allowable Load for Wrist Axis and Wrist Flange Allowable Wrist Load The allowable wrist load is up to 3 kg. If force is applied to the wrist instead of the load, force on R-, B-, and T-axes should be within the value shown in " Table. 5 Allowable Moment and Inertia ". -
Page 41: Wrist Flange
HW0483547 6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the alignment marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth of inside and outside fittings must be 5 mm or less. Tapped hole M5 (4 places) (Depth: 9) (Pitch: 0.8) 5 (fitting depth) -
Page 42: System Application
HW0483547 7.1 Peripheral Equipment Mount 7 System Application Peripheral Equipment Mount The peripheral equipment mount is on the upper arm for easier installation of the user’s system application as shown in " Fig. 16 Installing Peripheral Equipment Mounts ". When peripheral equipment is attached to the U-axis, the following conditions should be observed. -
Page 43: Internal User I/O Wiring Harness And Air Lines
HW0483547 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 (0.2 mm x 10 wires) and four air lines are used in the manipulator for the drives of the peripheral devices mounted on the upper arm as shown in " Fig. -
Page 44: Electrical Equipment Specification
HW0483547 8.1 Internal Connections 8 Electrical Equipment Specification Internal Connections High reliability connectors which can be easily put on and removed are used with each connector part. For the numbers, types, and locations of connectors, see " Fig. 18 Location Connectors "... - Page 45 8.1 Internal Connections 0BAT11 0BAT1 BAT11 BAT1 0BAT12 0BAT2 BAT12 BAT2 Note: 0BAT21 0BAT4 BAT21 BAT4 The figure below shows the internal connection diagram for MOTOMAN-HP3J. 0BAT22 0BAT5 BAT22 BAT5 PG0V1 PG5V1 PG0V2 PG5V2 PG0V3 PG5V3 PG0V4 PG5V4 NXC100 1BC(10X4)
- Page 46 HW0483547 8.1 Internal Connections Base 3BC-1 3BC-1 For spare (X) 2BC(6X6) No.13CN CN1-1 13CN-1 CN1-2 S-axis CN1-3 CN1-4 CN1-5 14CN-1 No.14CN No.15CN CN2-1 15CN-1 CN2-2 L-axis CN2-3 CN2-4 CN2-5 16CN-1 CN2-6 No.16CN No.17CN 17CN-1 U-axis CN3-4 CN3-5 18CN-1 CN3-6 2BC(6X6) No.18CN No.19CN CN4-1...
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Page 47: Maintenance And Inspection
HW0483547 9.1 Inspection Schedule 9 Maintenance and Inspection WARNING • Before maintenance or inspection, be sure to turn the main power sup- ply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.) Failure to observe this warning may result in electric shock or injury. CAUTION •... - Page 48 HW0483547 9.1 Inspection Schedule NOTE • The inspection interval must be based on the servo power supply ON time. Table. 7 Inspection Items Schedule Inspection Charge Items Operation Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Person Company Cycle Cycle Cycle...
- Page 49 HW0483547 9.1 Inspection Schedule Table. 7 Inspection Items Schedule Inspection Charge Items Operation Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Person Company Cycle Cycle Cycle Check for malfunc- tion. (Replace if nec- R-axis speed Grease essary.) Supply reducer grease (6000H...
- Page 50 HW0483547 9.1 Inspection Schedule Fig. 20 Inspection Parts and Inspection Numbers HW0483547 40/50...
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Page 51: Notes On Maintenance Procedures
HW0483547 9.2 Notes on Maintenance Procedures Notes on Maintenance Procedures 9.2.1 Battery Pack Replacement The battery packs are installed in the two positions indicated in " Fig. 21 (a) Battery Pack Location ". • Battery Pack Type: HW0470360-B If the battery alarm occurs in the NXC100, replace the battery pack in accordance with the following procedure: Connector base fixing screw Connector base... - Page 52 HW0483547 9.2 Notes on Maintenance Procedures 1. Turn the NXC100 main power supply OFF. 2. Remove the connector base fixing screws and pull out the connector base. 3. Remove the INSULOK-tie that ties the battery pack. 4. Connect the new battery pack to an unconnected connector. 5.
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Page 53: Grease Replenishment For S-Axis Speed Reducer
HW0483547 9.2 Notes on Maintenance Procedures 9.2.2 Grease Replenishment for S-axis Speed Reducer Si: Grease inlet Hexagon socket head plug PT1/8 S-axis speed reducer So: Exhaust port Hexagon socket head plug PT1/8 Fig. 22 S-axis Speed Reducer Diagram Grease Replenishment (Refer to " Fig. 22 S-axis Speed Reducer Diagram ".) 1. -
Page 54: Grease Replenishment For L-Axis Speed Reducer
HW0483547 9.2 Notes on Maintenance Procedures 9.2.3 Grease Replenishment for L-axis Speed Reducer Lo: Exhaust port Plug Cover L-axis speed reducer Li: Grease inlet Hexagon socket head cap screw M6×6 Fig. 23 L-axis Speed Reducer Diagram Grease Replenishment (Refer to " Fig. 23 L-axis Speed Reducer Diagram ".) 1. -
Page 55: Grease Replenishment For Speed Reducers Of U- And R-Axes
HW0483547 9.2 Notes on Maintenance Procedures 9.2.4 Grease Replenishment for Speed Reducers of U- and R-axes Ro: Exhaust port R-axis speed reducer Plug Cover Li: Grease inlet Hexagon socket head cap screw M6×6 Ri: Grease inlet Uo: Exhaust port Hexagon socket head cap Plug screw M6×6 Cover... -
Page 56: B- And T-Axes, And T-Axis Gear
HW0483547 9.2 Notes on Maintenance Procedures 9.2.5 Grease Replenishment for Speed Reducers of B- and T-axes, and T-axis Gear T-axis speed reducer To: Exhaust port Plug Ti: Grease inlet Bo: Exhaust port Hexagon socket head Plug cap screw M6×6 B-axis speed reducer Cover Bi: Grease inlet Hexagon socket ehad cap screw M6×6... -
Page 57: Notes For Maintenance
HW0483547 9.2 Notes on Maintenance Procedures 9.2.6 Notes for Maintenance Battery Pack Connection The connectors (crimped contact-pin) for the battery backup are installed at the end point of the motors (marked as BAT and OBT). Connect the battery pack according to the following procedure. - Page 58 It is recommended that the following parts and components be kept in stock as spare parts for the MOTOMAN-HP3J. The spare parts list for the MOTOMAN-HP3J is shown below. Check the serial number and contact your Yaskawa representative for preparing lead wires for internal wiring, etc.
- Page 59 HW0483547 Table. 9 Spare Parts for the MOTOMAN-HP3J Parts Rank Name Type Manufacturer Remarks Unit U-axis Yaskawa Electric HW0385338-A Speed Reducer Corporation R-axis Yaskawa Electric HW0385323-A Speed Reducer Corporation B-axis Yaskawa Electric HW0385324-A Speed Reducer Corporation T-axis Yaskawa Electric HW0385325-A...
- Page 60 60-3-6092-6377 YASKAWA ELECTRIC TAIWAN CORPORATION 9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan Phone 886-2-2502-5003 886-2-2505-1280 SHOUGANG MOTOMAN ROBOT CO., LTD. 7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China Phone 86-10-6788-0541 86-10-6788-2878 YASKAWA ELECTRIC CORPORATION YASKAWA...
- Page 61 RE-MTO-A235 9.2 Notes on Maintenance Procedures 9.2.6 Notes for Maintenance Connect the battery with reference to the following figure before removing the encoder con- nector (with WARNING label). Motor Encoder Motor cable, etc. Power connector Internal cable Battery Encoder connector WARNING label a: Insertion-type pin terminal (female) b: Insertion-type pin terminal (male)
- Page 62 RE-MTO-A235 9.2 Notes on Maintenance Procedures 9-12...
- Page 63 It is recommended that the following parts and components be kept in stock as spare parts for the MOTOMAN-UPJ. The spare parts list for the MOTOMAN-UPJ is shown below. Product performance cannot be guaranteed when using spare parts from any company other than Yaskawa.
- Page 64 RE-MTO-A235 Table. 8 Spare Parts for the MOTOMAN-UPJ Parts Rank Name Type Manufacturer Remarks Unit R-axis HW9381721-A Yaskawa Electric Only for YR- Speed Reducer Corporation UPJ3-B00 B-axis HW9381726-A Yaskawa Electric Speed Reducer Corporation T-axis HW9381727-A Yaskawa Electric Speed Reducer Corporation...
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Page 65: Parts List
RE-MTO-A235 11.1 S-axis Driving Unit 11 Parts List 11.1 S-axis Driving Unit 2056 1026 1027 1004 1054 1055 1012 1049 1053 1011 1043 1051 1044 1052 1046 1042 1050 1048 1041 1047 1045 1001 1040 1002 1032 1029 1037 1038 1006 1005 1003... - Page 66 RE-MTO-A235 11.1 S-axis Driving Unit DWG No. Name M3 × 20 1001 Socket screw 1002 2H-3 Spring washer 1003 UE10257 Oil seal 1004 HW0100064-1 S head M3 × 30 1005 Socket screw 1006 2H-3 Spring washer M4 × 20 1007 Socket screw 1008 2H-4...
- Page 67 RE-MTO-A235 11.2 L-axis Driving Unit 11.2 L-axis Driving Unit 2023 2015 2043 2038 2044 2045 2015 2037 2001 2042 2039 2036 2040 2035 2042 2034 2042 2032 2041 2033 2058 2023 2002 2029 2030 2057 2059 2028 2013 2016 2031 2014 2058 2017...
- Page 68 RE-MTO-A235 11.2 L-axis Driving Unit DWG No. Name GT-SA M5 × 10 2001 Socket screw 2002 HW9481967-A Sheet A-MT6 × 1 2008 Grease nipple 2009 HW9482887-A Pulley GT-SA M4 × 12 2010 Socket screw 2013 HW9482888-A Pulley GT-SA M4 × 12 2014 Socket screw 2015...
- Page 69 RE-MTO-A235 11.3 Wrist Unit 11.3 Wrist Unit 3049 3062 3063 3001 3065 3061 2055 3066 3007 3064 3003 3009 3005 3067 3046 2060 3068 3006 3047 3053 3052 3008 3048 3057 3052 3056 3053 3055 3031 3032 3030 3043 3058 3041 3060 3050...
- Page 70 RE-MTO-A235 11.3 Wrist Unit DWG No. Name DWG No. Name M4 × 8 2048 HW9201033-1 Cover 3056 Round head screw 2049 M 4×10 Cross recessed head screw 3057 T30R Insulok’tie 2055 HW9101029-1 U Arm 3058 HW9406288-1 Support M3 × 8 2060 LP-M5 Plug...
- Page 71 RE-MTO-A235 11.4 U(R)-axis Driving Unit 11.4 U(R)-axis Driving Unit 4015 4008 4010 4011 4020 4004 4019 4002 4017 4006 4003 4018 4016 4022 4009 4005 4012 4029 4013 4027 4026 4030 4007 4025 4024 4028 4023 4021 4001 4014 2030 2028 2027 2004...
- Page 72 RE-MTO-A235 11.4 U(R)-axis Driving Unit DWG No. Name GT-SA M3 × 12 2003 Socket screw 2004 6913DDU Bearing GT-SA M4 × 12 2005 Socket screw GT-SA M4 × 12 2006 Socket screw 2007 6900ZZ Bearing A-MT6 × 1 2008 Grease nipple 2009 HW9482887-A Pulley...
- Page 73 60-3-6092-6377 YASKAWA ELECTRIC TAIWAN CORPORATION 9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan Phone 886-2-2502-5003 886-2-2505-1280 SHOUGANG MOTOMAN ROBOT CO., LTD. 7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China Phone 86-10-6788-0541 86-10-6788-2878 YASKAWA ELECTRIC CORPORATION YASKAWA MANUAL NO.
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