Page 1
YR-MH00080-A01 (WITH LIMIT SWITCHES FOR SLU-AXES) Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-MH80 INSTRUCTIONS DX100 INSTRUCTIONS DX100 OPERATOR’S MANUAL DX100 MAINTENANCE MANUAL The DX100 operator’s manual above corresponds to specific usage.
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
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. Failure to observe these safety precautions may result in death or serious injury from unexpected turning of the manipulator's arm.
Page 5
158813-1CD MH80 Manipulator WARNING • Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the front door of the DX100 and programming pendant are pressed. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.
Page 6
Read and understand the Explanation of Warning Labels in the DX100 instructions before operating the manipulator. Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and manipulator cables.
Page 7
WARNING WARNING MOTOMAN MODEL MOTOMAN- TYPE PAYLOAD MASS ORDER NO. DATE SERIAL NO. YASKAWA ELECTRIC CORPORATION 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan Do not enter NJ3247 MADE IN JAPAN Moving parts may cause robot injury work area. 7 of 77...
158813-1CD MH80 Manipulator Table of Contents Table of Contents 1 Product Confirmation ........................1-1 1.1 Contents Confirmation ....................... 1-1 1.2 Order Number Confirmation....................1-2 2 Transport............................2-1 2.1 Transporting Method......................2-1 2.1.1 Using a Crane....................... 2-2 2.1.2 Using a Forklift...................... 2-3 2.2 Shipping Bolts and Brackets ....................
Page 9
158813-1CD MH80 Manipulator Table of Contents 5 Basic Specifications ........................5-1 5.1 Basic Specifications......................5-1 5.2 Part Names and Working Axes..................5-2 5.3 Manipulator Base Dimensions ................... 5-2 5.4 Dimensions and P-Point Maximum Envelope..............5-3 5.5 Alterable Operating Range ....................5-4 6 Allowable Load for Wrist Axis and Wrist Flange ................
Page 10
158813-1CD MH80 Manipulator Table of Contents 9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ......9-13 9.3.3.1 Grease Replenishment................9-13 9.3.3.2 Grease Exchange.................. 9-14 9.3.4 Grease Replenishment/Exchange for R-Axis Speed Reducer ......9-16 9.3.4.1 Grease Replenishment................9-16 9.3.4.2 Grease Exchange.................. 9-17 9.3.5 Grease Replenishment/Exchange for B- and T-Axis Speed Reducers and Gears ......................
158813-1CD MH80 Manipulator Product Confirmation 1.1 Contents Confirmation Product Confirmation CAUTION • Confirm that the manipulator and the DX100 have the same order number. 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.
158813-1CD MH80 Manipulator Product Confirmation 1.2 Order Number Confirmation Order Number Confirmation Check that the order number of the manipulator corresponds to the DX100. The order number is indicated on a label as shown below. Fig. 1-1: Location of Order Number Label Label (Enlarged View) THE MANIPULATOR AND THE CONTROLLER Check that the manipulator...
158813-1CD MH80 Manipulator Transport 2.1 Transporting Method 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.
158813-1CD MH80 Manipulator Transport 2.1 Transporting Method 2.1.1 Using a Crane As a rule, when uncrating the manipulator and moving it, a crane should be used. Lift the manipulator with a four-leg bridle sling using the shipping bolts and brackets. Be sure that the manipulator is fixed with the shipping bolts and brackets before transport, and lift it in the posture as shown in Fig.
158813-1CD MH80 Manipulator Transport 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. 2-2 “Transport Using a Forklift”. Insert claws into the folklift claw entries of the pallet and lift it. The pallet must be strong enough to support the manipulator.
158813-1CD MH80 Manipulator Transport 2.2 Shipping Bolts and Brackets Shipping Bolts and Brackets The manipulator is provided with shipping bolts and brackets at positions as shown in the figures in section 2.1 “Transporting Method” on page 2-1, to protect its driving units from various external force during transport. The shipping brackets are painted yellow.
158813-1CD MH80 Manipulator Installation 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 DX100 when the arm is fully extended.
158813-1CD MH80 Manipulator Installation 3.1 Installation of Safeguarding Installation of 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.
158813-1CD MH80 Manipulator Installation 3.2 Mounting Procedures for Manipulator Base 3.2.1 Mounting the Manipulator on the Baseplate The baseplate should be rugged and durable to withstand maximum repulsion force of the manipulator and to ensure that the manipulator and fixture are in the correct relative position. The thickness of the baseplate is 50 mm or more and an M20 size or larger anchor bolt is recommended.
158813-1CD MH80 Manipulator Installation 3.2 Mounting Procedures for Manipulator Base 3.2.2 Mounting the Manipulator on the Floor The floor should be strong enough to support the manipulator. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion force of the manipulator shown in Table 3-1 "Maximum Repulsion Force of the Manipulator at Emergency Stop"...
(Tensile strength: 1200 N/mm or more) In case of using the wall-/ceiling-mounted way, inform Yaskawa of the matter when placing an order. Be sure to NOTE contact your Yaskawa representative (listed on the back cover of this instruction manual) to perform a wall/ceiling installation on site.
158813-1CD MH80 Manipulator Installation 3.4 Notes in Mounting the Manipulators on the Ceiling Notes in Mounting the Manipulators on the Ceiling In the case if the manipulator shipped is the floor-mounted way, yet is to be mounted on the ceiling, mounting positions of each part on the view A in the figure below should be changed after installing the manipulator on the ceiling, to prevent a grease leakage from an air breather.
Page 23
158813-1CD MH80 Manipulator Installation 3.4 Notes in Mounting the Manipulators on the Ceiling Notes in Mounting the Manipulators on the Wall In the case if the manipulator shipped is the floor-mounted way, yet is to be mounted on the wall, mounting positions of each part on the view A in the figure below should be changed after installing the manipulator on the wall, to prevent a grease leakage from an air breather.
158813-1CD MH80 Manipulator Installation 3.6 IP (International Protection) IP (International Protection) For the standard type, environmental resistance for main part of the manipulator conforms to IP54; the wrist part conforms to IP67. However, for wall-mounted or ceiling mounted ways, environmental resistance for main part of the manipulator does not conform to IP54;...
158813-1CD MH80 Manipulator Wiring 4.1 Grounding Wiring WARNING • Ground resistance must be 100Ω 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.
158813-1CD MH80 Manipulator Wiring 4.2 Manipulator Cable Connection Manipulator Cable Connection Two manipulator cables are delivered with the manipulator: an encoder cable (1BC) and a power cable (2BC). Refer to Fig. 4-2 “Manipulator Cables” on page 4-3. Connect these cables to the connectors on the manipulator connector base and the DX100 board connectors.
158813-1CD MH80 Manipulator Basic Specifications 5.2 Part Names and Working Axes Part Names and Working Axes Fig. 5-1: Part Names and Working Axes Upper arm Wrist (U-arm) Wrist flange Lower arm (L-arm) Rotary head (S-head) Base Manipulator Base Dimensions Fig. 5-2: Manipulator Base Dimensions +0.018 12 dia.
158813-1CD MH80 Manipulator Basic Specifications 5.4 Dimensions and P-Point Maximum Envelope Dimensions and P-Point Maximum Envelope Fig. 5-3: Dimensions and P-Point Maximum Envelope 31 of 77 HW1480080...
Alterable Operating Range The operating range of the S-axis can be altered according to the operating conditions as shown in Fig. 5-2 “S-Axis Operating Range”. If alteration is necessary, contact your Yaskawa representative in advance. Table 5-2: S-Axis Operating Range Item...
Fig. 6-1 “Moment Arm Rating”. 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.
158813-1CD MH80 Manipulator Allowable Load for Wrist Axis and Wrist Flange 6.2 Wrist Flange Wrist Flange The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. To make the alignment mark visible and to enable an easy grease exchange for the B- and T-axis gears, mount the attachment inside the fitting.
158813-1CD MH80 Manipulator System Application 7.1 Peripheral Equipment Mounts 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. 7-1 “Installing Peripheral Equipment”. Observe the conditions in the figure and table below in mounting the peripheral equipment on the U-axis.
158813-1CD MH80 Manipulator System Application 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 (0.5 mm x 23 wires) and an air line are incorporated in the manipulator for the drive of peripheral devices mounted on the upper arm as shown in Fig.
In case of re-adjusting the operating range of each subject axis, it is also required to change the dog location and limit NOTE values in software. Contact your Yaskawa representative if re-adjustment is required. 8.1.2 Location of Limit Switches Limit switches are optional. The limit switches (the S- and L-axis overrun limit switches and the LU-axes interference limit switch) can be mounted only if the manipulator type is YR-MH00080-A01.
158813-1CD MH80 Manipulator Electrical Equipment Specification 8.1 Position of Limit Switch 8.1.3 Setting of Operation Range 8.1.3.1 S-Axis Operation Range By the S-axis limit switch, S-axis operation range can be set to those ranges mentioned in Table 5-2 "S-Axis Operating Range" on page 5-4. 8.1.3.2 L-Axis Operation Range By the L-axis limit switch, the L-axis operation range can be set to any angles within -91°...
158813-1CD MH80 Manipulator Electrical Equipment Specification 8.1 Position of Limit Switch 8.1.3.3 Setting Range of LU-Axes Interference Angle L- and U-axes interference limit switches are designed to check the interference angle of L- and U-axes. As shown in Fig. 8-3 “LU-Axes Interference Angle”, the operation range of U-axis can be set to any angles within +9°...
158813-1CD MH80 Manipulator Electrical Equipment Specification 8.2 Internal Connections Internal Connections Highly reliable connectors are equipped on each connection part of the manipulator to enable easy removal and installation for maintenance and inspection. For the numbers, types, and locations of connectors, see Fig. 8-4 “Location of Connectors”...
Page 41
158813-1CD MH80 Manipulator 8 Electrical Equipment Specification 8.1 Internal Connections Fig. 8-5(a): Internal Connection Diagram <Notes> 1.For the limit switch specification, the connection of the section A B are changed as follows: S-AXIS OVERRUN L.S. Connected to A1 L-AXIS OVERRUN L.S. Connected to A2 L- AND U-AXES INTERFERENCE L.S.
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. Failure to observe these safety precautions may result in death or serious injury from unexpected turning of the manipulator's arm.
Page 44
Table 9-1: Inspection Items Items Schedule Method Operation Inspection Charge • • • • • • • • • Alignment marks Visual Check alignment mark accordance at the home position. Check for damage. • • • • • • • •...
Page 45
Table 9-1: Inspection Items Items Schedule Method Operation Inspection Charge • • • • • • • • • Wire harness in manipulator Visual, Check for conduction between the main connector of base Multimeter and intermediate connector by manually shaking the wire. Check for wear of protective spring.
Page 46
4 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used" on page 9-6. 5 The application that requires highly frequent operation such as handling may cause grease leakage of air breather or the internal pressure rise of speed reducer. Contact your Yaskawa representative. 46 of 77...
Page 47
158813-1CD MH80 Manipulator Maintenance and Inspection 9.1 Inspection Schedule Fig. 9-1: Inspection Parts and Inspection Numbers 47 of 77 HW1480080...
158813-1CD MH80 Manipulator Maintenance and Inspection 9.2 Notes on Maintenance Procedures Table 9-2: Inspection Parts and Grease Used Grease Used Inspected Parts 13, 14, 15, 16 Molywhite RE No.00 Speed reducers for all axes B-, T-axis gears Inspection numbers correspond to the numbers in Fig. 9-1 “Inspection Items”...
Page 49
158813-1CD MH80 Manipulator Maintenance and Inspection 9.2 Notes on Maintenance Procedures Fig. 9-3: Battery Connection Battery pack before replacement See step 5 below. Connector See step 4 below. Circuit Board (Type: SGDR-EFBA02A) New battery pack (HW0470360-A) 1. Turn OFF the DX100 main power supply. 2.
158813-1CD MH80 Manipulator Maintenance and Inspection 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.
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 2. Remove the hexagon socket head plug PT1/4 from the grease inlet and install the grease zerk PT1/4. (The grease zerk is delivered with the manipulator.) 3. Inject grease into the grease inlet using a grease gun. –...
Page 52
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 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 plug with a tightening torque of 4.9 N·m (0.5 kgf·m).
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.2.2 Grease Exchange (Refer to Fig. 9-5 “L-Axis Speed Reducer”.) 1. Tilt the L-arm vertical to the ground. 2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port..
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 4. Inject grease into the grease inlet using a grease gun. – Grease type: Molywhite RE No. 00 – Amount of grease: 140 cc (280 cc for 1st supply) –...
Page 57
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 7. 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 plug with a tightening torque of ·...
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.4.2 Grease Exchange (Refer to Fig. 9-8 “R-Axis Speed Reducer” 1. Remove the hexagon socket head plug PT1/8 from the grease exhaust port. • If grease is injected with the plug on, the grease will go inside the motor and may cause a damage.
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.5 Grease Replenishment/Exchange for B- and T-Axis Speed Reducers and Gears Fig. 9-9: B- and T-Axis Speed Reducers and Gears Grease exhaust port (Hexagon socket head plug PT1/8) Grease inlet (Hexagon socket head plug PT1/8) B-axis speed reducer and gear...
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.5.2 Grease Exchange (Refer to Fig. 9-9 “B- and T-Axis Speed Reducers and Gears”.) 1. Remove the hexagon socket head set screw M6 from the grease exhaust port. •...
158813-1CD MH80 Manipulator Maintenance and Inspection 9.3 Notes on Grease Replenishment/Exchange Procedures 9.3.6 Notes for Maintenance When performing maintenance such as replacement of a wire harness in the manipulator, 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 To replace parts in Rank B or Rank C, contact your NOTE Yaskawa representative. Table 10-1: Spare Parts for the MOTOMAN-MH80 (Sheet 1 of 2) Rank Parts Name Type Manufacturer Remarks...
Page 64
158813-1CD MH80 Manipulator Recommended Spare Parts Table 10-1: Spare Parts for the MOTOMAN-MH80 (Sheet 2 of 2) Rank Parts Name Type Manufacturer Remarks Unit AC Servomotor SGMRV-44ANA-YR2* Yaskawa for L-axis HW0388671-A AC Servomotor SGMRV-20ANA-YR1* Yaskawa for U-axis HW0388668-A AC Servomotors...
158813-1CD MH80 Manipulator Parts List 11.1 S-Axis Unit 11 Parts List 11.1 S-Axis Unit Fig. 11-1: S-Axis Unit 1013 1014 1010 1002 1011 1009 1021 1007 1022 1005 1008 1003 1001 1004 1012 11-1 65 of 77 HW1480080...
Page 66
158813-1CD MH80 Manipulator Parts List 11.1 S-Axis Unit Table 11-1: S-Axis Unit DWG No. Name 1001 HW0387752-A Speed reducer HW1382898-A Speed reducer (For the manipulator assembled after Apr.2, 2014) 1002 SGMRV-30ANA-YR1* Motor 1003 HW9404486-1 Shaft 1004 HW0400405-1 Stopper 1005 6310 Bearing 1007 M8X45...
158813-1CD MH80 Manipulator Parts List 11.2 L-Axis Unit 11.2 L-Axis Unit Fig. 11-2: L-Axis Unit 2021 2001 2022 2027 2023 2024 2018 2027 2025 2025 2019 2027 2010 2011 2020 2012 2014 2017 2013 2026 2016 1009 2005 2004 2026 2003 2009 2008...
Page 68
158813-1CD MH80 Manipulator Parts List 11.2 L-Axis Unit Table 11-2: L-Axis Unit DWG No. Name 2001 SGMRV-44ANA-YR2* Motor 2002 HW0102644-1 L arm 2003 M12X55 Socket screw 2004 2H-12 Spring washer 2005 HW9381465-A Speed reducer 2006 M10X40 Socket screw 2007 2H-10 Spring washer 2008 M16X45...
158813-1CD MH80 Manipulator Parts List 11.4 R-, B-, T-Axis Unit 11.4 R-, B-, T-Axis Unit Fig. 11-4: R-, B-, T-Axis Unit 4018 4006 4020 4045 4024 4016 4019 4025 4001 4033 4044 4031 4029 4028 4037 4037 4007 4036 4013 4012 4007 4040...
Page 72
158813-1CD MH80 Manipulator Parts List 11.4 R-, B-, T-Axis Unit Table 11-4: R-, B-, T-Axis Unit DWG No. Name 4001 HW0387754-A Speed reducer 4002 SGMRV-09ANA-YR1* Motor 4003 AC1306-G00X6 Oil seal 4004 AE1017Q0 Oil seal 4005 ISTW-17 Retaining Ring 4006 HR32913J Bearing 4007 HR32005XJ...
Page 73
158813-1CD MH80 Manipulator Parts List 11.4 R-, B-, T-Axis Unit Table 11-4: R-, B-, T-Axis Unit DWG No. Name 4044 M6X35 GT-SA bolt 4045 M8X30 GT-SA bolt 4046 M8X25 Socket screw 4047 2H-8 Spring washer 4048 M8X20 Socket screw 4049 M4X6 Socket screw 4050...
158813-1CD MH80 Manipulator Parts List 11.5 Wrist Unit 11.5 Wrist Unit Fig. 11-5: Wrist Unit 5058 5015 5093 5115 5094 5016 5095 5096 5005 5115 5113 5114 5060 5040 5039 5005 5039 5055 5013 5014 5039 5008 5033 5057 5007 5022 5039 5053...
Page 75
158813-1CD MH80 Manipulator Parts List 11.5 Wrist Unit Table 11-5: Wrist Unit DWG No. Name 5001 HW0387737-B Speed reducer 5002 HW0389043-A Speed reducer 5002A HW0389043-A Washer 5002B HW0389043-A Fine U nut 5003 HW9405880-1 B cover 5004 HW9405445-1 B nut 5005 HW9405881-1 B nut 5006...
Page 76
158813-1CD MH80 Manipulator Parts List 11.5 Wrist Unit Table 11-5: Wrist Unit DWG No. Name 5053 HW0312773-1 Flange 5054 HW0312775-1 Flange 5055 HW9302630-3 Housing 5056 HW0102233-1 U arm 5057 HW0102491-1 Wrist 5058 HW0201226-1 Cover 5059 HW0414884-1 Cover 5060 HW0412694-* 5068 HW0412683-* 5075 HW0412695-*...
Page 77
INSTRUCTIONS 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...