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® Motoman NX100 Controller EA1800N Manipulator Manual Part Number: 154992-1CD Revision: Motoman, Incorporated 805 Liberty Lane West Carrollton, Ohio 45449 USA 937.847.6200 (Voice) 937.847.6277 (Fax) 937.847.3200 (24-Hour Support) www.motoman.com info@motoman.com...
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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.
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• 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 (EA1800N) •...
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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. This safety section addresses the following: •...
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Manipulator Manual Chapter 2 Safety • 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 that are essential to the – – safety of personnel and equipment. As you read this manual, pay close attention to these alerts to insure safety when installing, operating, programming, and maintaining this equipment.
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EA1800N 154992-1 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.
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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.
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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.
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YASKAWA MOTOMAN-EA1800N INSTRUCTIONS TYPE: YR-EA1800N-A00 (STANDARD SPECIFICATIONS) TYPE: YR-EA1800N-A01 (WITH SLU-AXIS LIMIT SWITCHES) Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-EA1800N INSTRUCTIONS NX100 INSTRUCTIONS NX100 OPERATOR’S MANUAL NX100 MAINTENANCE MANUAL The NX100 operator’s manuals above correspond to specific usage.
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MANDATORY • This instruction manual is intended to explain operating instructions and maintenance procedures primarily for the MOTOMAN-EA1800N. • General items related to safety are listed in the Section 1: Safety of the NX100 Instructions. To ensure correct and safe operation, carefully read the NX100 Instructions before reading this manual.
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HW0484074 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 WARNING avoided, could result in death or serious injury to personnel.
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HW0484074 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.
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• 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 supply cables.
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Also, an identification label with important information is placed on the body of the manipula- tor. Prior to operating the manipulator, confirm the contents. Nameplate Warning label B Warning label A Warning label A Nameplate Warning Label A: WARNING MOTOMAN TYPE Moving parts MASS PAYLOAD may cause DATE ORDER NO. injury SERIAL NO.
HW0484074 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.
HW0484074 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.
HW0484074 2.1 Transporting Method 2 Transport 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 transport. The system consists of precision components.
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HW0484074 2.1 Transporting Method View E Eyebolt M16 (2 eyebolts) Fixed to the manipulator before shipment Eyebolt M16 (2 eyebolts) Fixed to the manipulator before shipment Fig. 2 Transporting Position HW0484074 13/59...
HW0484074 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 and brackets as shown in "Fig. 3 Using a Forklift". Use a pallet strong enough to support the manipulator.
HW0484074 2.2 Shipping Bolts and Brackets Shipping Bolts and Brackets To protect the driving units of the manipulator from various external force during transport, a shipping bracket ("A" in "Fig. 2 Transporting Position") is attached to the manipulator. Eyebolt M16 (2 eyebolts) Fixed to the manipulator before shipment Enlarged View A Enlarged View B...
HW0484074 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.
HW0484074 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.
HW0484074 3.2 Mounting Procedures for Manipulator Base 3.2.1 Installation Example 1. Fix the baseplate to the floor with anchor bolts. The baseplate should be rugged and durable. It is recommended to prepare a base- plate of 40 mm or more thick, and anchor bolts of size M16 or larger size. 2.
HW0484074 3.3 Installation Method Installation Method The MOTOMAN-EA1800N-A00/-A01 manipulator is available in floor-mounted (standard) and wall-mounted types. For installation of the ceiling-mounted type, the following points are different from the floor-mounted type. • S-axis Operating Range • Fixing the Manipulator Base •...
HW0484074 3.4 Location Location When installing the manipulator, satisfy the undermentioned environmental conditions: • 0° to +45°C (ambient temperature) • 20 to 80% RH (non-condensing) • Free from dust, soot, or water • Free from corrosive gases or liquid, or explosive gases •...
HW0484074 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. (ex. DO NOT TURN THE POWER ON.) Failure to observe this warning may result in fire or electric shock.
HW0484074 4.1 Grounding Grounding Follow local regulations for grounding line size. A line of 5.5 mm or more is recommended. Refer to "Fig. 5 Grounding Method" to connect the ground line directly to the manipulator. • Never use this line sharing with other ground lines or grounding electrodes for other elec- NOTE tric power, motor power, welding devices, etc.
HW0484074 4.2 Manipulator Cable Connection 4.2.1 Connection to the Manipulator Before connecting the manipulator cables to the manipulator, verify the connector numbers: both the cables and the connectors on the manipulator base are marked with 1BC, 2BC, and 3BC. Connect the cables in the order of 3BC, 2BC, 1BC, referring to " Fig. 7 (a) Manipulator Cable Connection (To the Manipulator) ".
HW0484074 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) Manipulator base Fig. 8 Part Names and Working Axes Manipulator Base Dimensions 18 dia. hole 195±0.1 (4 holes) +0.015 12 dia.
HW0484074 5.4 Dimensions and P-Point Maximum Envelope Dimensions and P-Point Maximum Envelope 180 ° 180 ° View A 2212 P-point maximum P-point envelope 1031 Units: mm Fig. 10 Dimensions and P-Point Maximum Envelope HW0484074 27/59...
HW0484074 5.5 Alterable Operating Range Alterable Operating Range The working range of the S-axis can be altered according to the operating conditions as shown in "Table 4 S-axis Operating Range" If alteration is necessary, contact your Yaskawa representative in advance. Table 4 S-axis Operating Range Item Specifications...
HW0484074 6.1 Allowable Wrist Load 6 Allowable Load for Wrist Axis and Wrist Flange Allowable Wrist Load The allowable wrist load is 15 kg. As shown in "Table 5 Allowable Total Moment of Wrist", the moment of each axis is restricted. Observe the conditions described in this section in applying load on the wrist.
HW0484074 6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in "Fig. 12 Wrist Flange". It is recommended that the attachment is mounted inside the fitting. Fitting depth of inside and outside fittings shall be 6 mm or less. Tapped hole M4 (pitch: 0.7)(depth: 8)(6 holes) +0.025...
HW0484074 7.1 Peripheral Equipment Mounts 7 System Application Peripheral Equipment Mounts The peripheral equipment mounts are fixed on the upper arm for easier installation of the user's system application as shown in "Fig. 13 Installing Peripheral Equipment". Observe the conditions in the following sections and the figure in mounting the peripheral equipment on the U-axis.
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HW0484074 7.1 Peripheral Equipment Mounts Tapped hole M8 (pitch: 1.25)(depth: 18) (2 holes) Tapped hole M6 (pitch: 1.0)(depth: 14) (2 holes) View A Mount the peripheral equipment within this range. Gravity point of the peripheral equipment on the U-arm is to be set within this range.
HW0484074 7.2 Internal User I/O Wiring Harness and Air Line Internal User I/O Wiring Harness and Air Line Internal user I/O wiring harness (0.2 mm x 8 wires and 1.25 mm x 6 wires) and an air line are built into the manipulator for the drive of peripheral devices mounted on the upper arm as shown in "Fig.
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HW0484074 7.2 Internal User I/O Wiring Harness and Air Line Connector for Internal User I/O Wiring Harness Connector for Internal User I/O Wiring Harness (Connector Base) (U-arm) (Power for shock sensor +24 V [1 A]) (Open) (Open) (Signal input port for shock sensor) Pins Used Pins Used (1.25 mm...
Location of Limit Switches Limit switches are optional. For each location, refer to "Fig. 16 Location of Limit Switch". A manipulator type with the S- or L-axis overrun limit switch or the LU-axis interference limit switch is YR-EA1800N-A01. LU-axis interference limit switch (optional)
HW0484074 8.2 Internal Connections Internal Connections Highly reliable connectors that enable easy removal and installation for maintenance and inspection are equipped to each connection part of the manipulator. For the numbers, types, and locations of the connectors, refer to "Fig. 17 Location of Connectors" and "Table 6 Con- nector Types".
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HW0484074 8.2 Internal Connections 0BAT11 0BAT1 BAT11 BAT1 0BAT12 0BAT2 BAT12 BAT2 0BAT3 Note: BAT3 For the limit switch specification, the connection of the section A is changed as follows: 0BAT21 0BAT4 BAT21 BAT4 0BAT22 0BAT5 S-axis Overrun Limit Switch BAT22 BAT5 0BAT6...
HW0484074 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 •...
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HW0484074 9.1 Inspection Schedule Table 7 Inspection Items Schedule Inspection Charge Operation Items Method 1000 6000 12000 24000 36000 Specified Service Daily Licensee Personnel Company Cycle Cycle Cycle Check alignment Alignment mark accordance Visual mark and damage at the home position. External Check for damage Visual...
HW0484074 9.2 Notes on Maintenance Procedures Notes on Maintenance Procedures 9.2.1 Battery Pack Replacement If the battery alarm occurs in the NX100, replace the battery pack according to the following procedure: Battery pack Cover plate Connector base Support Cover plate fixing screw Fig.
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HW0484074 9.2 Notes on Maintenance Procedures 3. Remove the battery pack from the battery holder. 4. Connect the new battery pack to an unconnected connector on the circuit board. 5. Remove the old battery pack from the circuit board. Make sure to connect the new battery pack before removing the old one so that the NOTE encoder absolute data will not disappear.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures Notes on Grease Replenishment/Exchange Procedures Make sure to follow the instructions listed below at grease replenishment/exchange. Failure to observe the following notes may result in damage to motor and speed reducer. • If grease is added without removing the plug/screw from the grease exhaust port, the NOTE grease will go inside a motor or an oil seal of a speed reducer will come off, which may result in damage to the motor.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 2. Remove the hexagon socket head plug PT1/8 from the grease inlet and install the grease zerk PT1/8. (The grease zerk is delivered with the manipulator.) 3. Inject grease from the grease inlet using a grease gun. Grease type: VIGO Grease RE No.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 5. Move the L-axis for a few minutes to discharge the excess grease. 6. Wipe the discharged grease with a cloth and reinstall the plug PT1/8 on the grease exhaust port. Apply Three Bond 1206C to the thread part of the plug, and tighten the m (0.5 kgf plug with a tightening torque of 4.9 N 7.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.3 Grease Replenishment/Exchange for U-axis Speed Reducer U-arm Grease exhaust port Grease inlet (Hexagon socket head cap screw M6) (Hexagon socket head plug PT1/8) U-axis speed reducer Fig. 24 U-axis Speed Reducer Grease Replenishment (Refer to "Fig. 24 U-axis Speed Reducer") 1.
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HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 2. Remove the hexagon socket head cap screw M6 from the grease exhaust port. • If grease is injected with the screw on, the grease will go inside the motor and may cause NOTE a damage.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.4 Grease Replenishment for R-axis Speed Reducer Exhaust port (Hexagon socket head plug PT1/8) R-axis speed reducer Grease inlet (Hexagon socket head cap screw M6) Fig. 25 R-axis Speed Reducer 1. Remove the hexagon socket head plug PT1/8 from the exhaust port. 2.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.5 Grease Replenishment for B-Axis Speed Reducer Exhaust port (Plug LPM5) B-axis speed reducer Grease inlet (Hexagon socket head cap screw M6) Fig. 26 B-Axis Speed Reducer 1. Remove the cover and the plug LPM5 from the exhaust port. 2.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.6 Grease Replenishment for T-axis Gear Grease inlet 2 (Hexagon socket head cap screw M6) Exhaust port (Hexagon socket set screw) Grease inlet 1 (Hexagon socket head cap screw M6) Fig. 27 T-axis Gear 1.
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HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures 6. Inject grease into the grease inlet 2 using a grease gun. Grease type: Alvania EP Grease 2 Amount of grease: 5 cc The exhaust port is used only for air flow; the grease is not exhausted from the exhaust NOTE port.
If the wrist cover is removed for some reason, make sure to reapply the sealing bond (Three Bond 1206C, refer to "Table 9 Spare Parts for the MOTOMAN-EA1800N-A00, -A01") when reassembling the cover.
HW0484074 9.3 Notes on Grease Replenishment/Exchange Procedures Encoder Connector (With CAUTION Label) Before disconnecting the encoder connector (with CAUTION label), connect the battery pack to the motor referring to the following figures. Motor Motor power connector Encoder connector 0BT* BAT* HW9470932-A (battery pack) Battery backup connector Fig.
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• Rank B: Parts for which replacement may be necessary as a result of frequent operation • Rank C: Drive unit NOTE To replace parts in Rank B or Rank C, contact your Yaskawa representative. Table 9 Spare Parts for the MOTOMAN-EA1800N-A00, -A01 Parts Rank Name...
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HW0484074 Table 9 Spare Parts for the MOTOMAN-EA1800N-A00, -A01 Parts Rank Name Type Manufacturer Remarks Unit Yaskawa Electric L-axis Input Gear HW0309830-1 Corporation U-axis Yaskawa Electric HW0385640-A Speed Reducer Corporation Yaskawa Electric U-axis Input Gear HW0309857-1 Corporation R-axis Yaskawa Electric...
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