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Motoman NX100 Controller HP165-100* Manipulator Manual Part Number: 151780-1CD 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 * North American Naming International Naming - ES165N-100...
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HP165-100 151780-1 Chapter 1 Introduction About This Document This manual provides information for the HP165-100 manipulator and contains the following sections: CHAPTER 1 - INTRODUCTION Provides general information about the structure of this manual, a list of reference documents, and customer service information.
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HP165-100 151780-1 Chapter 2 Safety Introduction It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed. We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems.
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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...
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HP165-100 151780-1 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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HP165-100 151780-1 • Any modifications to PART 1, System Section, of the robot controller concurrent I/O program can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to PART 1, System Section. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY! •...
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YASKAWA MOTOMAN-ES165N-100 INSTRUCTIONS YR-ES165N-A10 (STANDARD SPECIFICATION) YR-ES165N-A11 (SLU-AXES WITH L.S. SPECIFICATION) Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-ES165N-100 INSTRUCTIONS NX100 INSTRUCTIONS NX100 OPERATOR’S MANUAL NX100 MAINTENACE MANUAL The NX100 operator’s manuals above correspond to specific usage.
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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 rep- resentative to order a new copy. The representatives are listed on the back cover.
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HW0481994 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.
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HW0481994 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 manipulator 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. WARNING WARNING MOTOMAN TYPE PAYLOAD MASS DATE ORDER NO. SERIAL NO. YASKAWA ELECTRIC CORPORATION JAPAN Moving parts may Do not enter cause injury robot work area 6/76...
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HW0481994 Product Confirmation 1.1 Contents Confirmation ......1 1.2 Order Number Confirmation .
HW0481994 Allowable Load for Wrist Axis and Wrist Flange 6.1 Allowable Wrist Load ....... 6 6.2 Wrist Flange .
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HW0481994 Grease Replenishment for B-Axis Speed Reducer (Refer to " Fig. 27 U-Arm Diagram ".) ....9-16 Grease Replenishment for T-Axis Speed Reducer (Refer to " Fig. 27 U-Arm Diagram ".) ....9-16 Grease Exchange for R-, B-, T-Axis Gears in the Casing (Refer to "...
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HW0481994 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.
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HW0481994 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 SHOULD HAVE SAME ORDER NUMBER. Check that the manipulator and the NX100 have the same order number.
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HW0481994 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.
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HW0481994 2.1 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 shipping bolts and brackets. Be sure the manipulator is fixed with the shipping bolts and brackets before trans- porting, and lift it in the posture as shown in "...
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HW0481994 2.2 Shipping Bolts and Brackets Shipping Bolts and Brackets The manipulator is provided with shipping bolts and brackets at position A and with the hexa- gon socket head cap screws at point B. (" Fig. 2 Transporting Position "). Shipping bracket Shipping bolt Hook...
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HW0481994 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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HW0481994 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 guid- ance. 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.
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HW0481994 3.3 Location 3.2.1 Mounting Example Fix the baseplate onto the floor. The baseplate should be rugged and durable to prevent shift- ing of the manipulator or the fixture. The thickness of the baseplate is 50mm or more, and an M20 size or larger anchor bolt is recommended.
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HW0481994 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.
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HW0481994 4.1 Grounding Grounding Follow local regulations for grounding line size. A line of 5.5mm or more is recommended. • Do not use this line in common with other ground lines or grounding electrodes for other NOTE electric power, motor power, welding devices, etc. •...
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HW0481994 4.2 Manipulator Cable Connection 4.2.2 Connection to the NX100 First connect the 2BC cable then 3BC and 1BC cables respectively after verifying the num- bers. The numbers are on both the manipulator cables and the NX100 board connectors. When connecting, insert cables adjusting the cable connector positions to the main key posi- tions of the NX100, and then set the lever until it clicks.
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HW0481994 4.2 Manipulator Cable Connection molex molex molex Connector details (Manipulator side) Fig. 7 (a) Details of the Manipulator Cable Connectors (Manipulator Side) Fig. 7 (b) Manipulator Cable Connections to the NX100 21/76...
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HW0481994 5.1 Basic Specifications 5 Basic Specifications Basic Specifications Table.3 Basic Specifications MOTOMAN-ES165N-100 Item Model MOTOMAN-ES165N-100 with external cabling for SRBT-axes Configuration Vertically Articulated Degree of Freedom Payload 100kg ±0.2mm Repeatability S-Axis (turning) ±180° L-Axis (lower arm) +76°, -60° Range of U-Axis (upper arm) +230°, -142.5°...
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HW0481994 5.2 Part Names and Working Axes Part Names and Working Axes Wrist Upper arm (U arm) Wrist flange Rotary head Lower arm (L arm) (S head) Base Fig. 8 Part Names and Working Axes Manipulator Base Dimensions +0.021 290 0.1 290 0.1 Fitting surface dia.
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HW0481994 5.4 Dimensions and P-Point Maximum Envelope Dimensions and P-Point Maximum Envelope 3410 5330 2320 3010 P-point maximum envelope 1590 P-point Units: mm Fig. 10 Dimensions and P-Point Maximum Envelope 24/76...
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5.5 Alterable Operating Range Alterable Operating Range The operating 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...
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HW0481994 5.5 Alterable Operating Range 5.5.1 Components for Altering Operating Range Arrange the components listed in " Fig. 11 The Components of the S-Axis Stopper ", when modifying the angle of S-axis. Pin (drawing No. HW0402104-1, 1 pin) Stopper (drawing No. HW0302424-2, 1 stopper) Hexagon socket head cap screw M20 (length;...
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HW0481994 5.5 Alterable Operating Range 5.5.2 Notes on the Mechanical Stopper Installation • For S-Axis mechanical stopper, install the stopper (drawing No. HW0302424-2) with the pin which is used bottom up (drawing No. HW0402104-1) as in " Fig. 11 The Components of the S-Axis Stopper ".
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HW0481994 5.5 Alterable Operating Range 5.5.3 Adjustment to the Pulse Limitation of S-Axis Apply the Instruction for NX100 Concurrent I/O Parameter (Manual No.:RE-CKI-A442) as part of reference materials for adjusting the programming pendant when modifying the range of motion of S-Axis. + 1st Axis ) : SICxG200 The limitation to the pulse (Pulse Soft Limit - 1st Axis ) : SICxG208...
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HW0481994 5.5 Alterable Operating Range 29/76...
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HW0481994 5.5 Alterable Operating Range Mounting the S-Axis Stopper by Settable Angles Hexagon socket head cap screws The stopper could be utlized by either side. The Settled Model of +180 Degree Hexagon socket head cap screws The stopper could be utlized by either side.
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HW0481994 5.5 Alterable Operating Range The stopper only utlized by one side with this angle Hexagon socket head cap screws The Settled Model of +150 Degree The stopper could be utlized by either side. Hexagon socket head cap screws The Settled Model of +135 Degree Fig.
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HW0481994 5.5 Alterable Operating Range The stopper is only utlized by one side with this angle Hexagon socket head cap screws The Settled Model of +120 Degree Hexagon socket The stopper could head cap screws be utlized by either side. The Settled Model of +105 Degree Fig.
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HW0481994 5.5 Alterable Operating Range The stopper could be utlized by either side. Hexagon socket head cap screws The Settled Model of + 90 Degree The stopper could be utlized by either side. Hexagon socket head cap screws The Settled Model of + 75 Degree Fig.
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HW0481994 5.5 Alterable Operating Range Hexagon socket The stopper is only utlized head cap screws by one side with this angle The Settled Model of + 60 Degree The stopper could be utilized by either side. Hexagon socket head cap screws The Settled Model of +45 Degree Fig.
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HW0481994 5.5 Alterable Operating Range The stopper is only utlized Hexagon socket by one side with this angle head cap screws The Settled Model of +30 Degree The stopper could be utlized by either side. Hexagon socket head cap screws The Settled Model of +15 Degree Fig.
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HW0481994 5.5 Alterable Operating Range The stopper could be utlized by either side. Hexagon socket head cap screws The Settled Model of 0 Degree Fig. 13 (g) The Properly-Mounted Models for S-Axis Stopper 5-15 36/76...
The allowable total inertia is calculated when the moment is at the maximum. Contact your Yaskawa representative when only inertia, or load moment is small and inertia is large. Also, when the load mass is combined with an outside force, contact your Yaskawa representative.
HW0481994 6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the align- ment mark, it is recommended that the attachment be mounted inside the fitting. Fitting depth of inside and outside must be 8mm or less.
HW0481994 7.2 Internal User I/O Wiring Harness and Air Line Internal User I/O Wiring Harness and Air Line 3 cables for valves (0.75mm ), 18 internal user I/O wires (0.5mm x 6 wires, 0.75mm x 12 wires), the cables for the external axis (1.0mm x 4 cables, 0.5mm x 2 cables) , and an air line are used in the manipulator for the drives of the peripheral devices mounted on the upper...
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HW0481994 7.2 Internal User I/O Wiring Harness and Air Line Connector for the external axis (Encoder cable): JL05-2A20-29SC Exhaust port (air flow) (socket connector with cap). Tapped holes PT3/8 Prepare pin connector: JL05-6A20-29P. with pipe plug Connector for internal user I/O wiring harness (Casing): JL05-2A22-14SC (socket connector with cap).
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HW0481994 7.2 Internal User I/O Wiring Harness and Air Line 0.5mm (6 pins) 0.5mm (6 pins) Pins used 0.75mm (12 pins) 0.75mm (12 pins) Pins used 0.75mm (3 pins) 17 18 Pin details for internal user I/O wiring harness (Casing side) 32 33 Pin details for internal user I/O wiring harness (Base side)
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HW0481994 7.2 Internal User I/O Wiring Harness and Air Line 0.5mm (6 pins) 0.5mm (6 pins) Pins used 0.3mm (12 pins) 0.3mm (12 pins) Pins used (6 pins) 0.75mm 17 18 Pin details for internal user I/O wiring harness (Casing side) 32 33 1.25mm (4 pins)
HW0481994 8.1 Position of S-Axis Limit Switch 8 Motoman Construction Position of S-Axis Limit Switch The limit switches are optional. For the S, L, and U-Axes with limit switches specifications, L.S. are located on S-Axis, L-Axis, and U-Axis respectively. For the location, refer to " Fig. 18 Location of Limit Switches ".
HW0481994 8.2 Internal Connections Internal Connections High reliability connectors which can be easily put on and removed are used with each con- nector part. For the numbers, types, and locations of connectors, see " Fig. 19 Location of Connectors " and “Table.8 List of Connector Types”. Connector for external axis (Power cable) Connector for external axis...
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HW0481994 8.2 Internal Connections 0BAT11 0BAT1 BAT11 BAT1 0BAT12 0BAT2 Note) BAT12 BAT2 0BAT3 BAT3 1. This diagram is for the MOTOMAN-ES165N-100. 0BAT21 0BAT4 BAT21 BAT4 For the limit switch specification, the connection of the section A was changed. 0BAT22 0BAT5 BAT22 BAT5...
• Maintenance and inspection must be performed by specified personnel. Failure to observe this caution may result in electric shock or injury. • For disassembly or repair, contact your Yaskawa representative. • Do not remove the motor, and do not release the brake.
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• For any different or special applications, the inspection process should be developed on an case-by-case basis. • For axes which are used very frequently (in handling applications, etc.), it is recom- mended that inspections be conducted at shorter intervals. Contact your Yaskawa repre- sentative. Table. 9...
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Inspection numbers correspond to the numbers in “ Fig. 21 Inspection Parts and Inspection Numbers “. The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa representative. 49/76...
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HW0481994 9.1 Inspection Schedule Table. 10 Inspection Parts and Grease Used Grease Used Inspected Parts Molywhite RE No.00 Speed Reducers for all Axes 12 13 14 R-, B-, and T-Axes gears 15 16 Alvania EP Grease 2 L-Axis Balancer Inspection numbers correspond to the numbers in " Table. 9 Inspection Items ". 50/76...
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HW0481994 9.1 Inspection Schedule R-axis B-axis T-axis S-axis Note: The manipulator is in the home position. U-axis L-axis Fig. 21 Inspection Parts and Inspection Numbers 51/76...
HW0481994 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. 22 (a) Battery Location Back View “ and “ Fig. 22 (b) Battery Location (Top View). If a battery alarm occurs in the NX100, replace the battery in accordance with the following procedure: Plate...
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HW0481994 9.2 Notes on Maintenance Procedures Battery pack before replacement See procedure 5 Connector Board See procedure 4 New battery pack Fig. 23 Battery Connection 1. Turn the NX100 main power supply off. 2. Uninstall the plate from the base connector and pull the battery pack out to replace with a new battery pack.
HW0481994 9.2 Notes on Maintenance Procedures Grease Exchange (Refer to " Fig. 24 S-Axis Speed Reducer and Gear Diagram ".) 1. Remove the hexagon socket head plug PT1/8 from the exhaust port. If grease is added with the plug on, the grease will go inside the motor and may damage it. NOTE It is absolutely necessary to remove the plug.
HW0481994 9.2 Notes on Maintenance Procedures Grease Exchange (Refer to " Fig. 25 L-Axis Speed Reducer Dia- gram ".) 1. Tilt the L-arm vertical to ground. 2. 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 damage it. NOTE It is absolutely necessary to remove the plug.
HW0481994 9.2 Notes on Maintenance Procedures Grease Replenishment (Refer to " Fig. 26 U-Axis Speed Reducer Diagram ".) 1. Tilt the U-arm horizontal to ground. 2. 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 damage it. NOTE It is absolutely necessary to remove the plug.
HW0481994 9.2 Notes on Maintenance Procedures Grease Exchange (Refer to " Fig. 26 U-Axis Speed Reducer Dia- gram ".) 1. Tilt the L-arm horizontal to ground. 2. Remove the hexagon socket head plug PT1/8 from the exhaust port. If grease is added with the plug on, the grease will go inside the motor and may damage it. NOTE It is absolutely necessary to remove the plug.
HW0481994 9.2 Notes on Maintenance Procedures Grease Replenishment for R-, B-, T-Axis Gears in the Casing (Refer to " Fig. 27 U-Arm Diagram ".) 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 outside the grease box and may NOTE damage it.
HW0481994 9.2 Notes on Maintenance Procedures Grease Replenishment for B-Axis Speed Reducer (Refer to " Fig. 27 U-Arm Diagram ".) 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 outside the grease box and may NOTE damage it.
HW0481994 9.2 Notes on Maintenance Procedures Grease Exchange for R-, B-, T-Axis Gears in the Casing (Refer to " Fig. 27 U-Arm Diagram ".) 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 outside the grease box and may NOTE damage it.
HW0481994 9.2 Notes on Maintenance Procedures 6. Remove the grease zerk from the grease inlet and reinstall the plug PT1/8. Tighten the plug with a tightening torque of 5 N・m (0.51 kgf・m). (Apply Three Bond 1211 to the screwed part of the plug.) Grease Exchange for B-Axis Speed Reducer (Refer to "...
HW0481994 9.2 Notes on Maintenance Procedures Grease Exchange for T-Axis Speed Reducer (Refer to " Fig. 27 U- Arm Diagram ".) 1. Remove the hexagon socket head plug PT1/16 from the grease exhaust port If grease is added with the plug on, the grease will go outside the grease box and may NOTE damage it.
HW0481994 9.2 Notes on Maintenance Procedures 9.2.7 Notes for Maintenance When performing maintenance such as replacement of a wire harness in the manipulator, NOTE the encoder connector may be necessary to be removed. In this case, be sure to connect the battery pack to the battery backup connector before removing the encoder connector.
• 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. 11 Spare Parts for the Motoman-ES165N-100...
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HW0481994 Table. 11 Spare Parts for the Motoman-ES165N-100 Parts Rank Name Type Manufacturer Remarks Unit Yaskawa U-Axis Input Gear HW0303272-1 Electric Corporation Yaskawa R-Axis HW0380500-B Electric Speed Reducer Corporation Yaskawa B-Axis HW9380961-D Electric Speed Reducer Corporation Yaskawa T-Axis HW9381400-D Electric...
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