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- Page 1 Motoman NX100 Controller DA20C Manipulator Manual Part Number: 151528-1CD 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 (DA20C, HP50, etc.) •...
- Page 4 Manipulator 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 Manipulator 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 DA20C 151528-1 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 Manipulator 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 Manipulator Manual Chapter 2 Safety Notes page 8 Final...
- Page 11 MOTOMAN-DA20 INSTRUCTIONS TYPE: YR-DA20-A00 (STANDARD SPECIFICATION) Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-DA20 INSTRUCTIONS NX100 INSTRUCTIONS NX100 OPERATOR’S MANUAL NX100 MAINTENACE MANUAL The NX100 operator’s manual above corresponds to specific usage.
- Page 12 HW0483402 MANDATORY • This instruction manual explains operating instructions and mainte- nance procedures primarily for MOTOMAN-DA20. • General items related to safety are listed in Section 1: Safety of the NX100 Instructions. To ensure correct and safe operation, carefully read the NX100 instructions before reading this manual.
- Page 13 HW0483402 Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the NX100. In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”. Indicates a potentially hazardous situation which, if not avoided, WARNING could result in death or serious injury to personnel.
- Page 14 HW0483402 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 program- ming pendant is turned OFF.
- Page 15 • Read and understand the Explanation of the Warning Labels in the NX100 instructions before operating the manipulator. 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 manipulator cables.
- Page 16 Prior to operating the manipulator, confirm the contents. Warning label A Warning label A Nameplate Warning label B Warning label B Warning Label A: Nameplate: WARNING MOTOMAN TYPE Moving parts MASS PAYLOAD may cause DATE injury ORDER NO. SERIAL NO.
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Page 17: Table Of Contents
HW0483402 Product Confirmation 1.1 Contents Confirmation ......1 1.2 Order Number Confirmation . - Page 18 HW0483402 System Application 7.1 Peripheral Equipment Mounts ..... . 7 7.2 Internal User I/O Wiring Harness and Air Line ..7 Electrical Equipment Specification 8.1 Internal Connections .
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Page 19: Contents
HW0483402 1.1 Contents Confirmation 1 Product Confirmation CAUTION • Confirm that the manipulator and the NX100 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 20: Order Number
HW0483402 1.2 Order Number Confirmation Order Number Confirmation Check that the order number of the manipulator corresponds to the NX100. 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 21: Shipping Bolts And
HW0483402 2.1 Transporting Method 2 Transporting CAUTION • Sling applications and crane or forklift operations must be performed by authorized personnel only. Failure to observe this caution may result in injury or damage. • Avoid excessive vibration or shock during transporting. Failure to observe this caution may adversely affect the performance as the system con- sists of precision components. - Page 22 HW0483402 2.1 Transporting Method Eyebolt M16 (4 places) (Fixed to the manipulator) 1045 mm Fig. 2 Posture for Transportation HW0483402 12/59...
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Page 23: Using A Forklift
HW0483402 2.1 Transporting Method 2.1.2 Using a Forklift When using a forklift, the manipulator should be fixed on a pallet with shipping bolts 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 24: Wrist
HW0483402 2.2 Shipping Bolts and Brackets Shipping Bolts and Brackets As shown in the figure below, the shipping bolts and brackets are fixed to the wrist flanges of the manipulator to minimize the external force during transportation. • The shipping bracket is painted yellow, and fixed with four hexagon socket head cap screws M6. - Page 25 HW0483402 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 NX100 when the arm is fully extended.
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Page 26: Mounting Procedures For Manipulator
HW0483402 3.1 Installation of the Safeguarding Installation of the Safeguarding To insure safety, be sure to install the safeguarding. They prevent unforeseen accidents with personnel and damage to equipment. The following is quoted for your information and guidance. Responsibility for Safeguarding (ISO 10218) The user of a manipulator or robot system shall ensure that safeguarding is provided and used in accordance with Sections 6, 7, and 8 of this standard. - Page 27 HW0483402 3.3 Location 3.2.1 Mounting Example Fix the baseplate firmly to the floor. The baseplate should be durable enough to prevent shifting of the manipulator and mounting fixture. It is recommended to prepare a baseplate of 32 mm or more in thickness, and the anchor bolts of size M16 or more for the baseplate fixation.
- Page 28 HW0483402 4.1 Grounding 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 OFF the primary power supply, and put up a warning sign.
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Page 29: Connection To The Manipulator
HW0483402 4.2 Manipulator Cable Connection Section A-A 5.5 mm or more Bolt M8 (for grounding) Installed before shipment. Fig. 6 Grounding Method Manipulator Cable Connection Five manipulator cables are provided: two encoder cables (1BC and 3BC) and three power cables (2BC, 4BC, and 5BC). (Refer to " Fig. 7 Manipulator Cables "). Connect these cables to the connectors on the manipulator connector base and the NX100 by referring to "... - Page 30 HW0483402 4.2 Manipulator Cable Connection Manipulator (Back View) AIR-1 AIR-2 AIR-3 GREAS AIR-4 AIR-5 AIR-6 NX100 side Manipulator side NX100 Manipulator Connector No. Connector No. 1BC: Encoder Cable 2BC: Power Cable 3BC: Encoder Cable 4BC: Power Cable 5BC: Power Cable Fig.
- Page 31 HW0483402 4.2 Manipulator Cable Connection AIR-R1 AIR-R1 AIR-R2 AIR-R2 GREAS GREAS AIR-1 AIR-2 AIR-3 GREAS AIR-4 AIR-5 AIR-6 AIR-1 AIR-2 AIR-3 GREAS AIR-4 AIR-5 AIR-6 Fig. 8 (a) Details of the Manipulator Cable Connectors (Manipulator Side) NX100 ****** TYPE ERCR- 200V POWER SUPPLY 50Hz...
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Page 32: Allowable Wrist
HW0483402 5.1 Basic Specifications 5 Basic Specifications Basic Specifications Table 3 Basic Specifications Item Model MOTOMAN-DA20 Configuration Articulated 6 axes for the left arm (R1); 6 axes for the right arm (R2); Degree of Freedom 1 turning axis Payload 20 kg/arm ±0.1 mm... -
Page 33: Part Names And Working
HW0483402 5.2 Part Names and Working Axes Part Names and Working Axes T-axis B-axis U-axis L-axis Reference coordinates of base/robot axes S-axis R-axis View C (when the S-axis angle is 90°.) S-axis B-axis L-axis T-axis U-axis R-axis Reference coordinates of base/robot axes T-axis B-axis U-axis... - Page 34 HW0483402 5.3 Manipulator Base Dimensions Manipulator Base Dimensions (505) +0.018 12 dia. hole ± ± 0.05 0.05 (2 places) 18 dia. hole (8 places) Units: mm View A Fig. 10 Manipulator Base Dimensions HW0483402 24/59...
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Page 35: Dimensions And P-Point Maximum
HW0483402 5.4 Dimensions and P-Point Maximum Envelope Dimensions and P-Point Maximum Envelope (1279) 136.5 P-point maximum envelope P-point P-point P-point maximum envelope View C (when the S-axis angle is 90°.) P-point P-point maximum envelope 383.5 704.5 P-point P-point P-point maximum maximum envelope envelope... -
Page 36: Alterable Operating
HW0483402 5.5 Alterable Operating Range Optimum Range of Motion Motoman-DA20 operates most smoothly and efficiently in the shaded area shown in the fol- lowing figure. Fig. 12 Optimum Range of Motion Alterable Operating Range The operating range of the rotation-axis can be altered according to the operating conditions as shown in "... - Page 37 HW0483402 6.1 Allowable Wrist Load 6 Allowable Load for Wrist Axis and Wrist Flange Allowable Wrist Load The allowable wrist load is 20 kg; however, consider the limitations shown in " Table 5 Allow- able Moment and Total Inertia of the Wrist Axis " to fulfill this condition. If force is applied to the wrist instead of the load, the forces on R-, B-, and T-Axes should be within the values shown in Table 5.
- Page 38 HW0483402 6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in " Fig. 14 Wrist Flange ". In order to see the alignment mark, it is recommended that the attachment be mounted inside the fitting. The depths of inside and outside fittings must be respectively 5 mm or less and 6 mm or less. +0.012 6 dia.
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Page 39: System Application
HW0483402 7.1 Peripheral Equipment Mounts 7 System Application Peripheral Equipment Mounts The manipulator is equipped with peripheral equipment mounts and tapped holes on the top and front of the S-head for easier installation of the user’s system application as shown in "... -
Page 40: Internal User I/O Wiring Harness And Air Line
HW0483402 7.2 Internal User I/O Wiring Harness and Air Line Internal User I/O Wiring Harness and Air Line An internal user I/O wiring harness (0.1 mm x 12 wires) and six air lines are incorporated in the manipulator for drives of the peripheral devices mounted on the arms as shown in " Fig. 16 Internal User I/O Wiring Harness and Air Lines ". - Page 41 HW0483402 7.2 Internal User I/O Wiring Harness and Air Line System Connection Diagram: System Connection Diagram: Air Lines Internal User I/O Wiring Harness Base S-head Base S-head AIR-1 AIR-1 S2-1 AIR-2 AIR-2 S2-2 AIR-3 AIR-3 AIR-4 AIR-4 AIR-5 AIR-5 S3-1 S3-2 AIR-6 AIR-6...
- Page 42 HW0483402 7.2 Internal User I/O Wiring Harness and Air Line Pin details for internal user I/O wiring harness Pin details for internal user I/O wiring harness (S1, S2, S3 on the base; S1 on the S-head) (S2, S3 on the arms) Pin No.
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Page 43: Electrical Equipment Specification
HW0483402 8.1 Internal Connections 8 Electrical Equipment Specification Internal Connections Manipulator Power Cable Lead Wires in Rotation-Axis Lead Wires for IF Board Power Lead Wires in Arm Board for Encoder Power 0BAT11 0BAT1 BAT11 BAT1 0BAT12 0BAT2 BAT12 BAT2 0BAT3 BAT3 0BAT4 BAT4... - Page 44 HW0483402 8.1 Internal Connections Braided Wire 3BC(JL05,18-1) Drain Wire No.11CN CN1-2 11CN-1 CN1-3 CN1-4 CN1-1 -Axis CN1-5 BO7+ BO7+ CN1-6 BO7- BO7- Braided Wire Drain Wire 2BC(6X6) No.24CN No.6CN CN1-2 CN1-2 6CN-1 24CN-1 CN1-3 CN1-3 CN1-4 CN1-4 CN1-1 CN1-1 S-Axis No.25CN CN1-5 CN1-5...
- Page 45 HW0483402 8.1 Internal Connections Manipulator Power Cable Lead Wires in Rotation-Axis Lead Wires for IF Board Power Lead Wires in Arm Board for Encoder Power 0BAT11 0BAT1 BAT11 BAT1 0BAT12 0BAT2 BAT12 BAT2 0BAT3 BAT3 0BAT4 BAT4 0BAT21 0BAT5 BAT21 BAT5 0BAT22 0BAT6...
- Page 46 HW0483402 8.1 Internal Connections Braided Wire Drain Wire 2BC(6X6) No.6CN No.24CN CN1-2 CN1-2 6CN-1 24CN-1 CN1-3 CN1-3 CN1-4 CN1-4 CN1-1 CN1-1 S-Axis No.25CN CN1-5 CN1-5 BO1+ BO1+ 25CN-1 BO1+ BO1- CN1-6 CN1-6 BO1- BO1- No.26CN CN2-2 CN2-2 26CN-1 CN2-3 CN2-3 CN2-4 CN2-4 CN2-1...
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Page 47: Maintenance And Inspection
HW0483402 9.1 Inspection Schedule 9 Maintenance and Inspection WARNING • Before maintenance or inspection, be sure to turn OFF the main power supply, 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 HW0483402 9.1 Inspection Schedule • The inspection interval depends on the total servo operation time. NOTE • The following inspection schedule is based on the case that each axis is used under nor- mal conditions. For axes which are used very frequently (in handling applications, etc.), it is recommended that inspections be conducted at shorter intervals.
- Page 49 HW0483402 9.1 Inspection Schedule Table 6 Inspection Items Schedule Inspection Charge Items Operation Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Person Company Cycle Cycle Cycle Wire harness Check for dam- Visual ages. in manipula- (Lead wires Replace for rotation- axis) Wire harness...
- Page 50 HW0483402 9.1 Inspection Schedule Note: The manipulator is in the home position. AIR-R1 AIR-R2 GREAS Enlarged View D AIR-1 AIR-2 AIR-3 GREAS AIR-4 AIR-5 AIR-6 Enlarged View E Fig. 19 Inspection Parts and Inspection Numbers HW0483402 40/59...
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Page 51: Notes On Maintenance Procedures
HW0483402 9.2 Notes on Maintenance Procedures Notes on Maintenance Procedures 9.2.1 Battery Pack Replacement The battery packs are attached in the two positions indicated in " Fig. 20 Battery Location ". If a battery alarm occurs in the NX100, replace the battery in accordance with the following procedure: Section B-B Battery packs... -
Page 52: Batteries In Nx100
HW0483402 9.2 Notes on Maintenance Procedures 1. Turn OFF the NX100 main power supply. 2. Unscrew four plate mounting screws to remove the plate, and pull out the battery pack for replacement attached to the battery pack holder. 3. Remove the battery pack from the battery pack holder. 4. -
Page 53: Grease Replenishment/Exchange For Rotation-Axis
HW0483402 9.2 Notes on Maintenance Procedures 9.2.3 Grease Replenishment/Exchange for Rotation-Axis Speed Reducer AIR-1 AIR-4 GREAS Grease exhaust port: Hexagon socket head plug PT1/8 Enlarged View Connector Base on the S-head AIR-1 AIR-2 AIR-3 GREAS AIR-R1 AIR-R2 GREAS AIR-4 AIR-5 AIR-6 Grease inlet: Hexagon socket... -
Page 54: Grease Exchange
HW0483402 9.2 Notes on Maintenance Procedures Grease Exchange (Refer to " Fig. 23 Grease Inlet and Grease Exhaust Port for the Rotation-Axis Speed Reducer ".) 1. Remove the hexagon socket head plug PT1/8 from the grease exhaust port. If grease is added with the plug on, the grease will go inside the motor and may cause a NOTE damage. -
Page 55: Grease Replenishment For S-, L-, U-, R-, B-, T-Axis
HW0483402 9.2 Notes on Maintenance Procedures 9.2.4 Grease Replenishment for S-, L-, U-, R-, B-, T-axis Actuators The manipulator is in the home position. : Grease inlet (Hexagon socket head cap screw) : Grease exhaust port (Hexagon socket head cap screw) L-axis B-axis T-axis... -
Page 56: Grease Replenishment Of Each Actuator (Refer To " Fig. 24 Grease Inlets And Grease Exhaust Ports For The S-, L-, U-, R-, B-, T-Axis Actuators ".)
HW0483402 9.2 Notes on Maintenance Procedures Grease Replenishment of Each Actuator (Refer to " Fig. 24 Grease Inlets and Grease Exhaust Ports for the S-, L-, U-, R-, B-, T-Axis Actuators ".) 1. Remove the hexagon socket head cap screw from the exhaust port. (Refer to " Fig. 24 Grease Inlets and Grease Exhaust Ports for the S-, L-, U-, R-, B-, T-Axis Actuators ".) If grease is added with the screw on, the grease will go inside the motor and may cause a NOTE... -
Page 57: Actuator Replacement
HW0483402 9.2 Notes on Maintenance Procedures 9.2.5 Actuator Replacement As shown in the following table, when an actuator needs to be replaced due to a failure, etc., there are three methods (which are different by replacement parts) according to the time that may be consumed to recover the manipulator. -
Page 58: Actuator Replacement (Example Of The B-Axis Replacement Procedure)
HW0483402 9.2 Notes on Maintenance Procedures Actuator Replacement (Example of the B-Axis Replacement Proce- dure) Refer to the " Table 9 Parts Checklist " and " Fig. 26 Disassembly/Reassembly for the B-Axis Actuator Replacement ". Disassembly to Remove the B-Axis Actuator 1. -
Page 59: Hw0483402
HW0483402 9.2 Notes on Maintenance Procedures 9. Fix the harness with the cable ties 10. If necessary, apply the sealing bond Three Bond 1206C to the cover joint faces with the hexagon socket head cap screws (nineteen 11. Install the covers screws). - Page 60 HW0483402 9.2 Notes on Maintenance Procedures View A Screw installation position View C View B Fig. 26 Disassembly/Reassembly for the B-Axis Actuator Replacement 9-14 HW0483402 50/59...
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Page 61: Interface Board
HW0483402 9.2 Notes on Maintenance Procedures 9.2.6 Interface Board The interface boards are connected to their respective actuators, and the specific data of each actuator is stored in the respective interface boards. Therefore, when replacing an actuator, it is also required to replace its corresponding interface board; connecting the interface board to the other actuator may cause a malfunction. -
Page 62: Brake Driver Board
HW0483402 9.2 Notes on Maintenance Procedures 9.2.7 Brake Driver Board The brake driver boards JARCH-DKB01-2 are used for the MOTOMAN-DA20. NX100/ DA20 TYPE ERCR- POWER SUPPLY 200V 50/60Hz 220V 60Hz 3PHASE SERIAL No. DATE MADE IN JAPAN NJ2521-1 55XT 55XT... - Page 63 HW0483402 9.2 Notes on Maintenance Procedures Major Errors The green LED turns OFF while the orange LED blinks. The blink patterns of the orange LED indicate error diagnostics as follows: Green LED: OFF Orange LED: single blink 0.25 sec 2 sec Status Reference voltage failure: detected when the reference voltage in the brake driver board is approx.
- Page 64 HW0483402 9.2 Notes on Maintenance Procedures Green LED: OFF Orange LED: continuous blink 0.25 sec Status CPU failure. Cause • Brake driver board failure. Corrective Action • Replace the brake driver board. Minor Errors The green LED lights up while the orange LED blinks. The blink patterns of the orange LED indicate error diagnostics as follows: Green LED: ON Orange LED: double blink...
- Page 65 HW0483402 9.2 Notes on Maintenance Procedures Green LED: ON Orange LED: triple blink 0.25 sec 2 sec Status Electrical load failure. Cause (a) Disconnection between the brake driver board and the brake. (b) Short circuit between the brake driver board and the brake. Corrective Action (a) Reconnect the connectors.
- Page 66 HW0483402 9.2 Notes on Maintenance Procedures When the Orange LED Does Not Light Up Status Unable to power ON the brake driver board. Cause (a) Insufficient power supply voltage. (b) Improper connection of the wires for power supply (CN2). (c) Improper connection of the wires for power supply (CN2) to the 24 V power supply unit.
- Page 67 It is recommended to keep the parts and components in the following table in stock as spare parts for the MOTOMAN-DA20 (see " Table 10 Spare Parts for the Motoman-DA20 "). Product performance may not be guaranteed when using spare parts recommended by companies other than Yaskawa.
- Page 68 HW0483402 Table 10 Spare Parts for the Motoman-DA20 Parts Rank Name Type Manufacturer Remarks Unit Yaskawa SGAGS-112F-A7AC- L-Axis Actuator Electric YR11 Corporation Yaskawa SGAGS-112F-A7AC- U-Axis Actuator Electric YR11 Corporation Yaskawa SGAGS-451E-A7AC- R-Axis Actuator Electric YR11 Corporation Yaskawa SGAGS-451E-A7AC- B-Axis Actuator...
- Page 69 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...
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