EPL500 Manipulator Manual Motoman NX100 Controller Part Number:

Transcription

Motoman NX100 Controller
EPL500 Manipulator
Manual
Part Number:
Revision:
150776-1CD
0
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
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.
©2007 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
EPL500
150776-1
Chapter 1
Introduction
1.1
About This Document
This manual provides information for the EPL500 manipulator and contains the following chapters:
CHAPTER 1 - INTRODUCTION
Provides general information about the structure of this manual, a list of reference documents, and
customer service information.
CHAPTER 2 - SAFETY
This section provides information regarding the safe use and operation of Motoman products.
CHAPTER 3 - EPL500 INSTRUCTIONS
Provides detailed instructions for the EPL500.
1.2
Reference to Other Documentation
For additional information refer to the following:
1.3
•
NX100 Controller Manual (P/N 149201-1)
•
Concurrent I/O Manual (P/N 149230-1)
•
Operator’s Manual for your application
•
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 (EPL500, HP50, etc.)
•
Application Type (handling, welding, etc.)
•
Robot Serial Number (located on back side of robot arm)
•
Robot Sales Order Number (located on back of controller)
Final
page 1
Manipulator Manual
Chapter 1 Introduction
Notes
page 2
Final
EPL500
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Chapter 2
Safety
2.1
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. This information can be obtained from the Robotic Industries
Association by requesting ANSI/RIA R15.06-1999. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
INTERNET: www.roboticsonline.com
Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel
who are adequately trained to operate, program, and maintain the robot cell. The robot must not be
operated by personnel who have not been trained!
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.
Final
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Manipulator Manual
Chapter 2 Safety
This safety section addresses the following:
2.2
•
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 – 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.
DANGER!
Information appearing in a DANGER concerns the protection of personnel from the immediate
and imminent hazards that, if not avoided, will result in immediate, serious personal injury or
loss of life in addition to equipment damage.
WARNING!
Information appearing in a WARNING concerns the protection of personnel and equipment from
potential hazards that can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing in a CAUTION concerns the protection of personnel and equipment,
software, and data from hazards that can result in minor personal injury or equipment damage.
Note: Information appearing in a Note provides additional information which is helpful in understanding the item being
explained.
page 4
Final
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2.3
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. General safeguarding tips are as follows:
2.4
•
Improper operation can result in personal injury and/or damage to the equipment. Only
trained personnel familiar with the operation of this robot, the operator's manuals, the system
equipment, and options and accessories should be permitted to operate this robot system.
•
Do not enter the robot cell while it is in automatic operation. Programmers must have the
teach pendant when they enter the robot cell.
•
Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).
•
The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in use.
•
In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of Energy, use
lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147
(29CFR, Part 1910), Occupational Safety and Health Standards for General Industry
(OSHA).
Mechanical Safety Devices
The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's
responsibility. The conditions under which the equipment will be operated safely should be reviewed
by the user. The user must be aware of the various national codes, ANSI/RIA R15.06-1999 safety
standards, and other local codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required depending on system
installation, operation, and/or location. The following safety equipment is provided as standard:
•
Safety fences and barriers
•
Light curtains and/or safety mats
•
Door interlocks
•
Emergency stop palm buttons located on operator station, robot controller, and
programming pendant
Check all safety equipment frequently for proper operation. Repair or replace any non-functioning
safety equipment immediately.
Final
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Manipulator Manual
Chapter 2 Safety
2.5
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. Installation tips are as follows:
2.6
•
Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06-1999 safety standards are permitted to install the equipment.
•
Identify the work envelope of each robot with floor markings, signs, and barriers.
•
Position all controllers outside the robot work envelope.
•
Whenever possible, install safety fences to protect against unauthorized entry into the work
envelope.
•
Eliminate areas where personnel might get trapped between a moving robot and other
equipment (pinch points).
•
Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.
Programming, Operation, and Maintenance Safety
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. Improper
operation can result in personal injury and/or damage to the equipment. Only trained personnel
familiar with the operation, manuals, electrical design, and equipment interconnections of this robot
should be permitted to program, operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of operation.
page 6
•
Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be
sure the area is clean and free of water, oil, debris, etc.
•
Be sure that all safeguards are in place. Check all safety equipment for proper operation.
Repair or replace any non-functioning safety equipment immediately.
•
Do not enter the robot cell while it is in automatic operation. Be sure that only the person
holding the programming pendant enters the workcell.
•
Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
•
Back up all programs and jobs onto suitable media before program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.
Final
EPL500
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•
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!
•
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. Great
care must be taken when making these modifications. All modifications made to the
controller will change the way the robot operates and can cause severe personal injury or
death, as well as damage the robot and other parts of the system. Double-check all
modifications under every mode of robot operation to ensure that you have not created
hazards or dangerous situations.
•
Check and test any new or modified program at low speed for at least one full cycle.
•
This equipment has multiple sources of electrical supply. Electrical interconnections are
made between the controller and other equipment. Disconnect and lockout/tagout all
electrical circuits before making any modifications or connections.
•
Do not perform any maintenance procedures before reading and understanding the proper
procedures in the appropriate manual.
•
Use proper replacement parts.
•
Improper connections can damage the robot. All connections must be made within the
standard voltage and current ratings of the robot I/O (Inputs and Outputs).
Final
page 7
Manipulator Manual
Chapter 2 Safety
Notes
page 8
Final
YASKAWA
MOTOMAN-EPL500
INSTRUCTIONS
TYPE: YR-EPL500-A00 (STANDARD SPECIFICATION)
TYPE: YR-EPL500-A10 (FOR INTEGRATED WRIST AXIS CABLE ROUTING PACKAGE)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-EPL500 INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENACE MANUAL
The NX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
YASKAWA
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MANDATORY
• This instruction manual explains operating instructions and maintenance procedures primarily for MOTOMAN-EPL500.
• 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.
CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples
and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. 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.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your product’s warranty.
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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”.
WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury to personnel.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury to personnel and damage to equipment. It may also be used to alert against unsafe
practices.
MANDATORY
Always be sure to follow explicitly the items listed under this
heading.
PROHIBITED
Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations. At
any rate, be sure to follow these important items.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.
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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 programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.
Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator. Then turn
ON the servo power.
Injury may result from unintentional or unexpected manipulator motion.
TURN
Release of Emergency Stop
• Observe the following precautions when performing teaching operations
within the working envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the manipulator’s work envelope
and that you are in a safe location before:
- Turning ON the NX100 power.
- Moving the manipulator with the programming pendant.
- Running check operations.
- Performing automatic operations.
Injury may result if anyone enters the working envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem. The
emergency stop button is located on the right of the front door of the NX100 and the programming pendant.
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CAUTION
• Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the NX100 cabinet after use.
The programming pendant can be damaged if it is left in the manipulator’s work area, on
the floor, or near fixtures.
• 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.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
NX100 Controller
NX100
NX100 Programming Pendant
Programming Pendant
Cable between the manipulator and the controller
Manipulator Cable
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Explanation of Warning Labels
The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the manipulator. Prior to operating the manipulator, confirm the contents.
Warning label A
Nameplate
WARNING
Do not enter
robot
work area.
Warning label B
Nameplate:
MOTOMAN
Warning Label A:
Warning Label B:
WARNING
WARNING
TYPE
MASS
PAYLOAD
kg
kg
ORDER NO.
DATE
SERIAL NO.
YASKAWA ELECTRIC CORPORAION JAPAN
Moving parts
may cause
injury
Do not enter
robot
work area.
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1
Product Confirmation
1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Order Number Confirmation
2
. . . . . . . . . . . . . . . . . . . . . . . 1-2
Transporting
2.1 Transporting Method
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Shipping Bolts and Brackets . . . . . . . . . . . . . . . . . . . . . . . 2-3
3
Installation
3.1 Installation of the Safeguarding . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . 3-2
3.2.1 Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4
Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Manipulator Cable Connection . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.2 Connection to the NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
5
Basic Specifications
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 T-Point Maximum Envelope
5.5 Alterable Operating Range
. . . . . . 5-3
. . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5.1 Components for Altering Operating Range . . . . . . . . . . . . . . . .5-6
5.5.2 Installation of the S-Axis Mechanical Stopper . . . . . . . . . . . . . .5-7
5.5.3 Adjustment to the S-axis Pulse Limitation . . . . . . . . . . . . . . . . .5-8
Installation of the S-axis Mechanical Stopper at
Configurable Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
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6
Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange
7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
System Application
7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Internal User I/O Wiring Harness and Air Line
8
. . . . . . 7-2
Electrical Equipment Specification
8.1 Locations of Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections
9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Maintenance and Inspection
9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-6
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.2 Grease Replenishment/Exchange for S-axis Speed Reducer and
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Grease Replenishment (Refer to " Fig. 24 S-axis Speed
Reducer and Gear Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . 9-8
Grease Exchange (Refer to " Fig. 24 S-axis Speed Reducer and
Gear Diagram ".). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.2.3 Grease Replenishment/Exchange for L-axis Speed Reducer 9-10
Grease Replenishment (Refer to " Fig. 25 L-axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Grease Exchange (Refer to " Fig. 25 L-axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.2.4 Grease Replenishment/Exchange for U-axis Speed Reducer 9-13
Grease Replenishment (Refer to " Fig. 26 U-axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Grease Exchange (Refer to " Fig. 26 U-axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.2.5 Grease Replenishment/Exchange for T-axis Speed Reducer 9-15
Grease Replenishment (Refer to " Fig. 27 T-axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Grease Exchange (Refer to " Fig. 27 T-axis Speed Reducer
Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
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9.2.6 Grease Replenishment for U-axis Cross Roller
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
9.2.7 Grease Replenishment for Links . . . . . . . . . . . . . . . . . . . . . .9-19
9.2.8 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21
Battery Pack Connection for Motors . . . . . . . . . . . . . . . . . .9-21
10
Recommended Spare Parts
11
Parts List
11.1 S-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1
11.2 L-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
11.3 U-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-6
11.4 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-8
11.5 Balancer Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
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1.1 Contents Confirmation
1 Product Confirmation
CAUTION
• Confirm that the manipulator and the NX100 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.
1.1
Contents Confirmation
Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following four items (Information for the content of optional
goods is given separately):
• Manipulator
• NX100
• Programming Pendant
• Manipulator Cables (Three cables, between manipulator and NX100)
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1.2 Order Number Confirmation
1.2
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.
ORDER. No.
Check that the manipulator
and the NX100 have the
same order number.
NX100 ******
TYPE
ERCR-
POWER SUPPLY
50Hz
50/60Hz
3PHASE
kVA
ER
MADE IN JAPAN
GE N
Y
DATE
C
EM
200V
220V
SERIAL No.
NJ2484-1
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
S
T O P
ORDER NO.
NJ1529
WARNING
Do not open the door
TEACH
REMOTE
PLAY
ED
ET
RES
OFF
TR
IPP
ON
MULTI
DISPLAY
SWITCH
SHIFT
R-
L+
R+
INTER
LOCK
ROBOT
SWITCH
AUXILIARY
EX-AXIS
SWITCH
AUXILIARY
CABCEK
ASSIST
x
S+
Y+
-
INTER.
SELECT
SHORTCUT
MENU
X+
S-
L-
R-
SERVO
POWER
COORD.
MAIN
MENU
XY-
+
7
WEAVING
START
4
WEAVING
COMPLETE
1
TIMER
0
REF.
POINT
y
B+
z
z
8
WELD
START
5
WELD
COMPLETE
2
VOLTAGE
.
VOLTAGE
9
FEED
6
x
R+
y
BT-
T+
TEST RUN
SHIFT
RETRUCT
BACK
NEXT
CURRENT
3
DELETE
INSERT
-CURRENT
MODIFY
ENTER
(a) NX100 (Front View)
(b) Manipulator (Side View)
Fig. 1 Location of Order Number Labels
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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 consists of precision components.
2.1
NOTE
2.1.1
Transporting Method
• The weight of the manipulator is approximately 2350 kg including the shipping bolts and
brackets. Use a wire rope strong enough to withstand the weight.
• Be sure to mount the shipping bolts and brackets to transport the manipulator.
The shipping bolts and brackets are designed to transport the manipulator: do not use
them for anything other than transporting the manipulator.
• Avoid exerting force on the arm or motor unit when transporting, and use caution when
using transporting equipment other than a crane or forklift, as injury may occur.
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
transporting, and lift it in the posture as shown in " Fig. 2 Posture for Transportation ".
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45°
25°
Fig. 2 Posture for Transportation
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2.2 Shipping Bolts and Brackets
2.2
Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets at positions A, B, and C to minimize the external force during transportation. (" Fig. 3 Shipping Bolts and Brackets ").
• The shipping brackets are painted yellow.
Position
NOTE
Bolt Type
Pcs
A
Hexagon socket head cap screw M20
4
B and C
4
Before turning ON the power, check to be sure that the shipping bolts and brackets are
removed. The shipping bolts and brackets then must be stored for future use, in the event
that the robot must be moved again.
C
B
A
Fig. 3 Shipping Bolts and Brackets
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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.
Failure to observe this warning may result in injury or damage.
• Do not start the manipulator or even turn on the power before it is firmly
anchored.
The manipulator may overturn and cause injury or damage.
CAUTION
• Do not install or operate the manipulator which is damaged or lacks
parts.
Failure to observe this caution may cause injury or damage.
• Before turning on the power, check to be sure that the shipping bolts
and brackets explained in " Fig. 3 Shipping Bolts and Brackets " are
removed.
Failure to observe this caution may result in damage to the driving parts.
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3.1 Installation of the Safeguarding
3.1
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. The means and degree of
safeguarding, including any redundancies, shall correspond directly to the type and level of
hazard presented by the robot system consistent with the robot application. Safeguarding may
include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter
guarding, awareness barriers, and awareness signals.
3.2
Mounting Procedures for Manipulator Base
The manipulator should be firmly mounted on a baseplate or a foundation strong enough to
support the manipulator and withstand repulsion forces during acceleration and deceleration.
Refer to " Table 1 Maximum Repulsion Forces of the Manipulator in an Emergency Stop " and
" Table 2 Endurance Torque in Operation " to construct a solid foundation with the appropriate
thickness to withstand maximum repulsion forces of the manipulator.
A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness of installation surface
may deform the manipulator shape and affect its functional abilities. Mount the manipulator
base as described in " 3.2.1 Mounting Example ".
Table 1 Maximum Repulsion Forces of the Manipulator in an Emergency Stop
Maximum torque in horizontal rotation
(S-axis moving direction)
39200 N·m
(4000 kgf·m)
Maximum torque in vertical rotation
(L-, U-axis moving direction)
88300 N·m
(9000 kgf·m)
Table 2 Endurance Torque in Operation
Endurance torque in horizontal operation
(S-axis moving direction)
11800 N·m
(1200 kgf·m)
Endurance torque in vertical operation
(L-, U-axis moving direction)
26500 N·m
(2700 kgf·m)
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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
50 mm or more in thickness, and the anchor bolts of size M24 or more for the baseplate
fixation. The anchor bolts should be inserted at least 200 mm deep into the floor.
There are eight mounting holes on the manipulator base. Securely fix the manipulator to the
baseplate with hexagon socke head cap screws M20 (80 mm long is recommended). Tighten
the hexagon socket head cap screws and anchor bolts firmly so that they will not be loosened
during the operation. See " Fig. 4 Mounting the Manipulator on Baseplate ".
Hexagon socket head
cap screw M20
(8 screws)
Spring washer
Washer
Manipulator base
28 dia. drilled hole
(12 holes)
Baseplate
1000
540
180
540
1000
180
50 mm
or more
180
180
Floor
Anchor bolt M24 or more
Flatness: 0.5 mm or less
Baseplate (reference)
200 mm or more
Units: mm
Fig. 4 Mounting the Manipulator on Baseplate
3.3
Location
When the manipulator is installed, it is necessary to satisfy the undermentioned environmental
conditions:
• Ambient temperature: 0° to 45°C
• Humidity: 20 to 80%RH at constant temperature
• Free from exposure to water, oil, or dust
• Free from corrosive gas or liquid, or explosive gas
• Free from excessive shock or vibration (less than 4.9 m/s2 [0.5 G])
• Free from large electrical noise (plasma)
• Flatness for installation is 0.5 mm or less
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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.
CAUTION
• Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
• Do not cover the cable or allow it to tangle. Keep the cable as straight
as possible.
Failure to observe this caution may result in preventing heat of the cable from being discharged.
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4.1 Grounding
4.1
Grounding
Follow the local regulations for grounding line size. A line of 5.5 mm2 or more is
recommended.
NOTE
• Never use this line sharing with other ground lines or grounding electrodes for other electric power, motor power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
grounding should be performed in accordance with Electric Equipment Technical Standards.
Bolt M8 (for grounding)
Installed before shipment.
A
Enlarged View A
5.5 mm2 or more
Fig. 5 Grounding Method
4.2
Manipulator Cable Connection
Three manipulator cables are provided: an encoder cable 1BC and two power cables 2BC
and 3BC (refer to " Fig. 6 Manipulator Cable Connections "). Connect these cables to the
connectors on the manipulator connector base and the NX100 by referring to " Fig. 7 (a)
Details of the Manipulator Cable Connectors (Manipulator Side) " and " Fig. 7 (b) Manipulator
Cable Connections to the NX100 ".
NOTE
Do not cover the cables with heat insulating material, and avoid multiple cabling.
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4.2 Manipulator Cable Connection
4.2.1
Connection to the Manipulator
Before connecting the manipulator cables to the manipulator, confirm the numbers on both the
manipulator cables and the connectors on the manipulator connector base. Then, connect
the cables in the order of 2BC, 3BC, 1BC. Insert the connectors adjusting the cable connector
positions to the main key positions of the manipulator, and then set the lever until it clicks.
4.2.2
Connection to the NX100
Before connecting the manipulator cables to the NX100, confirm the numbers on both the
manipulator cables and the NX100 board connectors. Then, connect the cables in order of
X21, X22, X11. Insert the connectors adjusting the cable connector positions to the main key
positions of the NX100, and set the lever until it clicks.
NX100 side
Manipulator side
X11
1BC
X11
1BC
1BC
Encoder Cable
NX100 side
Manipulator side
X21
2BC
2BC
X21
2BC
Power Cable
NX100 side
Manipulator side
X22
3BC
3BC
X22
3BC
Power Cable
Fig. 6 Manipulator Cable Connections
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4.2 Manipulator Cable Connection
A
Key positions
Enlarged View A
Connector Details (Manipulator Side)
Fig. 7 (a) Details of the Manipulator Cable Connectors (Manipulator Side)
X11
X21
X22
Fig. 7 (b) Manipulator Cable Connections to the NX100
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5.1 Basic Specifications
5 Basic Specifications
5.1
Basic Specifications
Table 3 Basic Specifications*1
Item
Model
YR-EPL500-A00
YR-EPL500-A10
Configuration
Vertically Articulated
Degree of Freedom
4
Payload
500 kg
Repetitive Positioning Accuracy*2
±0.5 mm
Range of
Motion
S-axis (turning)
±180°
L-axis (lower arm)
+90°, -45°
U-axis (upper arm)
+15.5°, -120°
T-axis (wrist twist)
Maximum
Speed
±360°
±180°
S-axis
1.40 rad/s (80 °/s)
L-axis
1.48 rad/s (85 °/s)
U-axis
1.48 rad/s (85 °/s)
T-axis
3.40 rad/s (195 °/s)
Allowable Inertia (GD2/4)*3
200 kg•m2
Mass
2300 kg
Ambient
Conditions
Temperature
0° to 45°C
Humidity
20 to 80% RH at constant temperature
Vibration acceleration
Less than 4.9 m/s2 (0.5 G)
• Free from corrosive gas or liquid, or explosive gas
Others
• Free from exposure to water, oil, or dust
• Free from excessive electrical noise (plasma)
Power Capacity
*1
*2
*3
11 kVA
SI units are used in this table. However, gravitational unit is used in ( ).
Conformed to ISO9283
Refer to " 6.1 Allowable Wrist Load " for details on the permissible moment of inertia.
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5.2 Part Names and Working Axes
5.2
Part Names and Working Axes
U+
UL-
Wrist
Upper arm
(U-arm)
Wrist flange
T+
L+
Lower arm
L-arm
T-
Turning head
S-head
S+
Base
S-
Fig. 8 Part Names and Working Axes
Manipulator Base Dimensions
640
540
220±0.1
220±0.1
+0.021
dia. 0
hole
300±0.1
320±0.1
540
640
22 dia. hole
(8 places)
350
710
360±0.1
20
(2 places)
40
5.3
320±0.1
12 dia.
A
+0.018
0
hole
360±0.1
519
879
Units: mm
View A
Fig. 9 Manipulator Base Dimensions
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5.4
Dimensions and T-Point Maximum Envelope
1600
1300
42
1600
1300
R7
R3159
7
03
R1
2776
614
R1124
270
2162
1400
250
15.5°
300
2204
P-point
45°
1356
678
678
2529
1250
2363
2624
°
90
T -Point
0°
880
12
0
820
0
1037
3159
Units: mm
T -point maximum envelope
Fig. 10 (a) Dimensions and T-Point Maximum Envelope (YR-EPL500-A00)
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1600
1300
42
1600
1300
R7
R3159
7
03
R1
2776
614
R1124
270
2162
1400
250
15.5°
300
2204
P-point
45°
1356
678
T -Point
2529
1250
2363
2624
°
90
678
0°
880
12
0
820
0
1037
3159
Units: mm
T -point maximum envelope
Fig. 10 (b) Dimensions and T-point Maximum Envelope (YR-EPL500-A10)
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5.5
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 S-axis Operating Range
Item
S-Axis
Operating
Range
Specifications
±180° (standard)
±165°
±150°
±135°
±120°
±105°
±90°
±75°
±60°
±45°
±30°
±15°
NOTE The stoppers must be installed with more than 60° of interval.
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5.5.1
Components for Altering Operating Range
Prepare the components shown in the " Fig. 11 Components of S-axis Stopper " referring to
the following list.
No.
Item
Pcs
c
Pin (Drawing No. HW0407007-1)
1
d
Stopper (Drawing No. HW0307574-1)
2
e
(length: 70 mm) (tensile strength: 1200 N/mm2 or more)
3
f
Flat washer M20
3
(3 screws) (tensile strength: 1200 N/mm2
or more)
Flat washer M20 (3 washers)
Stopper
(HW0307574-1)
Section A-A
Pin
(HW0407007-1)
A
A
Fig. 11 Components of S-axis Stopper
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5.5.2
Installation of the S-Axis Mechanical Stopper
1. Apply the LOCTITE 242 to the thread part of the pin HW0407007-1, and install the pin
bottom up into the S-axis mechanical stopper HW0307574-1 as shown in " Fig. 11
Components of S-axis Stopper ".
2. Mount the stopper to the S-head with three hexagon head screws M20 (length: 70 mm)
and tighten the screws to the tightening torque of 402 Nm (tensile strength: 1200 N/
mm2 or more). The stopper is to be installed as shown in the Fig. 11 when the operating range is ±180°.
Notes on S-Axis Mechanical Stopper Installation
• The S-axis mechanical stopper can be installed every 15 degrees. However, to avoid the
mechanical troubles caused by interference between stoppers, install the stopper referring to " Table 5 Configurable Angles for S-axis Stopper Installation " to avoid mechanical
troubles.
• To ensure the stopper strength, make sure to fix both sides of the protrusion with screws
as shown in properly mounted example in " Fig. 12 Properly-installed Image ". Do not fix
only one side of the stopper as shown in the Fig. 12 on account of the limitation of the
stopper strength.
• As in the figures: Fig. 13 (a) to Fig. 13 (m), the S-axis mechanical stopper is reversible
that either side of the stopper can be used and installed to the S-axis driving unit except
for the installation at the angles: ±30, ±60, ±120, ±150 degrees. If the stopper cannot be
installed in the range as shown in " Table 5 Configurable Angles for S-axis Stopper Installation ", flip the stopper and retry installing the stopper.
Hexagon head
screws M20
Hexagon head
screws M20
Improper Installation
Proper Installation
Fig. 12 Properly-installed Image
NOTE
1. Use the specified components to install the S-axis mechanical stopper.
2. Turn OFF the electric power supply before installing the S-axis mechanical stopper.
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5.5.3
Adjustment to the S-axis Pulse Limitation
To confine the S-axis operating range, refer to "NX100 Concurrent I/O (manual No. RE-CKIA442)" and change the following parameters with the programming pendant.
The limitation to the pulse (Pulse Soft Limit + 1st Axis ) : SICxG200
The limitation to the pulse (Pulse Soft Limit - 1st Axis ) : SICxG208
NOTE
Degree
Number of Pulse
0°
0
± 15°
± 34092
± 30°
± 68183
± 45°
± 102275
± 60°
± 136367
± 75°
± 170458
± 90°
± 204550
± 105°
± 238642
± 120°
± 272733
± 135°
± 306825
± 150°
± 340917
± 165°
± 375008
± 180°
± 409100
Limitation of the S-axis operating range must be made with both the software and mechanical stopper in the same setting: the operating range cannot be limited only with the software modification.
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Negative (-) Direction Angles
180
165
150
135
120
105
90
75
60
45
30
15
0
-15
-30
-45
-60
-75
-90
-105
-120
-135
-150
-165
-180
180
165
135
120
105
90
60
30
15
0
-15
Positive (+) Direction Angles
45
-30
-45
-60
-75
-90 -105 -120 -135 -150 -165 -180
Exception: The top left cell (180°, -180°) indicates the mountability of one stopper.
This table can be used when installing two mechanical stoppers on the S-axis.
The vertical axis of the table shows the angles in the positive direction, and the horizontal axis of the table
shows the angles in the negative direction.
For example, if one stopper is to be installed at a 180 degree angle in the positive direction, the other one
can be installed within the range of +/-105 degree angles: since more than 60 degrees of interval is required
to mount two stoppers, the chart indicates that the other angles are inappropriate for the installation.
75
Table 5 Configurable Angles for S-axis Stopper Installation
Disabled angle
Configurable angle
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Installation of the S-axis Mechanical Stopper at Configurable Angles
180°
The stopper is reversible.
Either side of the stopper
can be used.
Hexagon head screw M20
(3 screws) (length: 70 mm)
with three washers M20
Installation at +180°
165°
can be used.
Fig. 13 (a) Stopper Installation at Configurable Angles
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150°
The stopper is irreversible.
Only this side of the stopper can
be used at this angle.
135
°
can be used.
Fig. 13 (b) Stopper Installation at Configurable Angles
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0°
12
Only this side of the stopper can
be used at this angle.
can be used.
5°
10
Fig. 13 (c) Stopper Installation at Configurable Angles
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Either side of the stopper can be used.
90
°
75
°
Fig. 13 (d) Stopper Installation at Configurable Angles
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Only this side of the stopper can be used at this angle.
60
°
45°
Installation at + 45°
Fig. 13 (e) Stopper Installation at Configurable Angles
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30°
Only this side of the stopper
can be used at this angle.
15 °
can be used.
Fig. 13 (f) Stopper Installation at Configurable Angles
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can be used.
Fig. 13 (g) Stopper Installation at Configurable Angles
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180°
Installation at -180°
can be used.
165°
Fig. 13 (h) Stopper Installation at Configurable Angles
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150°
135
°
can be used.
Fig. 13 (i) Stopper Installation at Configurable Angles
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12
0°
10
5°
can be used.
Fig. 13 (j) Stopper Installation at Configurable Angles
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90
°
can be used.
°
75
can be used.
Fig. 13 (k) Stopper Installation at Configurable Angles
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°
60
45°
Installation at - 45°
Fig. 13 (l) Stopper Installation at Configurable Angles
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30°
15°
can be used.
Fig. 13 (m) Stopper Installation at Configurable Angles
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6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist Flange
6.1
Allowable Wrist Load
The allowable wrist load including the weight of the mount/gripper is 500 kg.
The constraint conditions of the wrist axis are described below:
1. The total inertia (GD2/4) of T-axis is to be set at the value in the following table or less.
Table 6 Allowable Total Inertia
Model
Axis
GD2/4 Inertia kg•m2
EPL500
T-axis
200
2. When the inertia of the volume load on the flange is small, the eccentricity of load center measured from T-axis flange rotation center is in the range shown in " Fig. 14
Moment Arm Rating ".
When the inertia of the volume load on the flange is large, use the following formula to
calculate the eccentricity LT.
Formula:
J=Ji+WLT 2
J : Total inertia (GD2/4) of the T-axis (kgxm2)
Ji : Inertia of the volume load on the flange (kgxm2)
W : Payload (kg)
LT : Eccentricity (mm)
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LB
6.1 Allowable Wrist Load
LT
Center of T-axis flange rotation
600 500 400 300 200 100
100 200 300 400 500 600 LT (mm)
100
200
300
400
500
600
m=500 kg
700
m=450 kg
m=400 kg
800
LB (mm)
Fig. 14 Moment Arm Rating
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6.2 Wrist Flange
6.2
Wrist Flange
8
The wrist flange dimensions are shown in " Fig. 15 Wrist Flange ". In order to see the
alignment mark, it is recommended that the attachment be mounted inside the fitting. Fitting
depth of inside and outside must be 8 mm or less.
+0.035
100 dia. 0
0
250 dia. -0.046
30°
0
.
.D
20
80
0.05
C
P.
Tapped hole M12
(depth: 18) (6 holes)
+0.015
10 dia. 0 hole
Units: mm
Fig. 15 Wrist Flange
NOTE Wash off anti-corrosive paint (Yellow) on the wrist flange surface with thinner or light oil
before mounting the tools.
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7.1 Peripheral Equipment Mounts
7 System Application
7.1
Peripheral Equipment Mounts
Peripheral equipment mounts or tapped holes are provided to the wrist unit for easier installation of the user’s system application as shown in " Fig. 16 Location of Peripheral Equipment
Mounts/Tapped Holes ".
When peripheral equipment is attached to the manipulator, the following conditions should be
observed.
A
110
40
Tapped hole M8
Enlarged View A
Units: mm
Fig. 16 Location of Peripheral Equipment Mounts/Tapped Holes
Table 7 Constraint for Attaching
Application
Note
Cable Processing and
Valve Load
Up to 500 kg including the mass of the peripheral
equipment attached to the wrist unit.
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7.2
Internal User I/O Wiring Harness and Air Line
An internal user I/O wiring harness (0.5 mm2 x 23 wires) and six air lines are incorporated in
the manipulator for drives of the peripheral devices mounted on the upper arm as shown in
" Fig. 17 (a) Internal User I/O Wiring Harness and Air Lines for YR-EPL500-A00 " and " Fig.
17 (b) Internal User I/O Wiring Harness and Air Lines for YR-EPL500-A10 ".
The connector pins and the terminals are assigned as shown in " Fig. 17 (c) Connectors for
Internal User I/O Wiring Harness and Air Lines (Pin Details) ". Wiring must be performed by
user.
• The allowable current for wires: 2.0 A or less for each wire
(The total current value for pins 1 to 23 must be 44 A or less.)
• The maximum pressure for the air line is 784 kPa (8 kgf/cm2) or less
(The air line inside diameter: 7.5 mm.)
B
Exhaust port D:
Tapped hole PT3/8
with a pipe plug
Exhaust port A:
Tapped hole PT3/8 with a pipe plug
D
A
E
B
Exhaust port E:
Tapped hole PT3/8
with a pipe plug
C
F
A
View B
Air inlet D:
D
E
F
1BC
A
Exhaust port C:
4BC
Exhaust port F:
Tapped hole PT3/8
with a pipe plug
Exhaust port B:
B
C
Air inlet A:
4BC
A
Air inlet E:
Air inlet F:
2BC
Air inlet B:
Connector for internal user I/O wiring
harness on the wrist side: JL05-2A24-28SC
(socket connector with a cap).
Prepare pin connector: JL05-6A24-28P.
3BC
Connector for internal user I/O wiring harness
on the base side: JL05-2A24-28PC
(pin connector with a cap).
Prepare socket connector: JL05-6A24-28S.
Air inlet C:
View A
Fig. 17 (a) Internal User I/O Wiring Harness and Air Lines for YR-EPL500-A00
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Exhaust port A:
B
Exhaust port B:
Tapped hole PT3/8
with a pipe plug
Connector for internal user I/O
wiring harness on the wrist side:
JL05-2A24-28SC
(socket connector with a cap).
Prepare pin connector:
JL05-6A24-28P.
Exhaust port C:
Tapped hole PT3/8
with a pipe plug
Exhaust port E:
Tapped hole PT3/8
with a pipe plug
View B
Exhaust port F:
Tapped hole PT3/8
with a pipe plug
A
Air inlet D:
D
E
Exhaust port D:
Tapped hole PT3/8
with a pipe plug
Air inlet E:
Tapped hole PT3/8
with a pipe plug
F
1BC
A
B
Air inlet A:
C
4BC
2BC
3BC
A
Air inlet F:
Tapped hole PT3/8
with a pipe plug
Air inlet B:
Connector for internal user I/O wiring harness
on the base side: JL05-2A24-28PC
(pin connector with a cap).
Prepare socket connector: JL05-6A24-28S.
Air inlet C:
View A
Fig. 17 (b) Internal User I/O Wiring Harness and Air Lines for YR-EPL500-A10
Pins used
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1 2 3 4
5 6 7 8
9
10 11 12 13 14 15
16 17 18 19 20
21 22 23
Internal user I/O wiring
harness:
23 wires, size 0.5 mm2
Fig. 17 (c) Connectors for Internal User I/O Wiring Harness and Air Lines (Pin Details)
The same pin numbers (1 to 23) of two connectors is connected in the lead line of single 0.5
mm2.
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8.1 Locations of Limit Switches
8 Electrical Equipment Specification
8.1
Locations of Limit Switches
The limit switches are optional. For the S, L, and U-Axes with limit switch specifications, the
limit switches are located on the S-axis, L-axis, and U-axis respectively. For the locations,
refer to " Fig. 18 Locations of Limit Switches ".
LU-axis intereference limit switch
(option)
L-axis overrun limit switch
(option)
S-axis overrun limit switch
(option)
D
E
F
1BC
A
B
C
4BC
2BC
A
3BC
Fig. 18 Locations of Limit Switches
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8.2
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. 19 (a)
Locations of Connectors for YR-EPL500-A00 " and " Fig. 19 (b) Locations of Connectors for
YR-EPL500-A10 ", and " Table 8 List of Connector Types ".
B
D
A
E
B
C
F
Connector for internal user
I/O wiring harness
4BC
Enlarged View B
A
D
E
F
I/O wiring harness
1BC
A
B
C
4BC
2BC
3BC
1BC
2BC
3BC
Enlarged View A
Fig. 19 (a) Locations of Connectors for YR-EPL500-A00
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B
4BC
B
A
C
D
E
F
Enlarged View B
I/O wiring harness
A
D
E
F
1BC
A
B
C
I/O wiring harness
4BC
2BC
3BC
1BC
2BC
3BC
Enlarged View A
Fig. 19 (b) Locations of Connectors for YR-EPL500-A10
Table 8 List of Connector Types
Name
Type of Connector
Connector Base
wiring harness
JL05-2A24-28PC
(JL05-6A24-28S: Optional)
Wrist Base
wiring harness
JL05-2A24-28SC
(JL05-6A24-28P: Optional)
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Note:
For the limit switch specification, the connection of the section A is changed as follows:
ENCODER POWER BOARD
0BT
K R P BAT
0BT
K R P BAT
1
2
3
4
0BAT11
BAT11
0BAT12
BAT12
0BT
K R P BAT
0BT
K R P BAT
5
6
7
8
0BAT21
BAT21
0BAT22
BAT22
1
2
3
4
5
6
7
8
NX100
CN1-5
CN1-4
+24V
0V
P
CN1-10
CN1-9
+24V
0V
P
1BC(10PX4)
CN1-5
CN1-4
CN1-10
CN1-9
+24V
0V
No.20CN
X
-1
+24V
-3
0V
1
3
+24V
0V
-2
-4
2
4
+24V
0V
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
S-AXIS LIMIT SWITCH SPECIFICATION
0BAT1
BAT1
0BAT2
BAT2
0BAT3
BAT3
LA1
LB1
S-AXIS OVERRUN LIMIT SWITCH
LA1
LB1
SPG+1
SPG-1
CN1-3
FG1
P
CN1-1
CN1-2
SPG+1
SPG-1
CN1-3
FG1
LA3
LA4
LB1
A
LC1
LC2
LB1
LC3
L-AXIS LIMIT SWITCH SPECIFICATION (OPTIONAL)
0BAT6
BAT6
LA1
LB1
PG0V1
PG5V1
PG0V2
PG5V2
PG0V3
PG5V3
LB1
LA1
LB1
LB1
LA3
LA4
LA3
LA4
LA3
LA4
LA4
LA4
A
L-AXIS OVERRUN LIMIT SWITCH
LC1
LC2
LB1
LC3
LU-AXIS LIMIT SWITCH SPECIFICATION (OPTIONAL)
PG0V6
PG5V6
LA1
LB1
LB1
LA1
LC3
LB1
LA3
LA4
LA3
LA4
LA3
LA4
LA4
LA4
A
L-AXIS OVERRUN LIMIT SWITCH
LB1
CN1-1
CN1-2
LB1
LC1
LC2
LB1
No,16CN
S
BAT1
-1
OBAT1
-2
PG5V1
-3
PG0V1
-4
No.6CN
6CN-1
-2
-6
-5
-4
-9
-7
P
P
P
LU-AXIS INTERFERENCE LIMIT SWITCH
LC1
LC2
DATA+1
DATA-1
BAT
OBT
+5V
PG S-AXIS
0V
FG1
OBT
BAT
SPG+2
SPG-2
CN1-6
CN1-7
P
CN1-8
FG2
CN1-8
CN1-6
CN1-7
SPG+2
SPG-2
L
No,17CN
BAT2
-1
OBAT2
-2
PG5V2
-3
PG0V2
-4
FG2
No.7CN
7CN-1
-2
-6
-5
-4
-9
-7
P
P
P
DATA+2
DATA-2
BAT
OBT
+5V
PG L-AXIS
0V
FG2
OBT
BAT
SPG+3
SPG-3
CN2-1
CN2-2
P
FG3
CN2-3
CN2-1
CN2-2
CN2-3
SPG+3
SPG-3
U
No,18CN
BAT3
-1
OBAT3
-2
PG5V3
-3
PG0V3
-4
FG3
No.8CN
8CN-1
-2
-6
-5
-4
-9
-7
P
P
P
DATA+3
DATA-3
BAT
OBT
+5V
PG U-AXIS
0V
FG3
OBT
BAT
SPG+6
SPG-6
CN3-6
CN3-7
P
FG6
CN3-8
CN3-6
CN3-7
CN3-8
SPG+6
SPG-6
T
No,19CN
BAT6
-1
OBAT6
-2
PG5V6
-3
PG0V6
-4
FG6
No.1CN
1CN-1
-2
-6
-5
-4
-9
-7
P
P
P
+24V
LB1
SS2
AL1
CN4-2
CN4-7
P
CN4-1
CN4-6
No.12CN
B1
12CN-1
-2
SS1
BC1
-3
LA1
-4
LB1
-5
-6
BC2
+24
LB1
P
CN4-2
CN4-7
SS2
AL1
P
CN4-3
CN4-8
BC2
AL2
SS2
LA1
LB1
LB1
LB1
LA3
LA4
LA3
LA4
LB1
LC3
BC2
AL2
FOR LAMP (OPTIONAL)
FOR S-AXIS FAN (OPTIONAL)
E
E
A
LC1
LC2
BC1
BC2
CN4-3
CN4-8
PG T-AXIS
0V
FG6
OBT
BAT
SS1
B1
CN4-1
CN4-6
DATA+6
DATA-6
BAT
OBT
+5V
E
BASE
E E E
AL1
AL2
AC1
AC2
S
FAN
Fig. 20 (a) Internal Connection Diagram
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2BC(8X5)
X21(8X5)
E
E
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
CN1-7
CN1-8
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
CN2-7
CN2-8
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
CN3-7
CN3-8
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN4-7
CN4-8
CN 6-1
CN 6-2
CN 6-3
CN 6-4
CN 6-5
CN 6-6
MU1
MU1
MU1
MU1
MV1
MV1
MV1
MV1
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
CN1-7
CN1-8
MU1
MU1
MU1
MU1
MV1
MV1
MV1
MV1
MW1
MW1
MW1
MW1
ME1
ME1
ME1
ME1
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
CN2-7
CN2-8
MW1
MW1
MW1
MW1
ME1
ME1
ME1
ME1
MU2
MU2
MU2
MU2
MV2
MV2
MV2
MV2
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
CN3-7
CN3-8
MU2
MU2
MU2
MU2
MV2
MV2
MV2
MV2
MW2
MW2
MW2
MW2
ME2
ME2
ME2
ME2
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN4-7
CN4-8
MW2
MW2
MW2
MW2
ME2
ME2
ME2
ME2
BA1
BA2
BA3
BA6
BB1
BB6
CN 6-1
CN 6-2
CN 6-3
CN 6-4
CN 6-5
CN 6-6
BA1
BA2
BA3
BA6
BB1
BB6
No.9CN
9CN-A
-B
-C
-D
-E
-F
No.10CN
10CN-A
-B
-C
-D
MU1
MV1
SM
MW1
ME1
BA1
BB1
S-AXIS
YB
MU2
MV2
MW2
ME2
No.14CN
14CN-A
-B
BA2
BB2
No.11CN
11CN-A
-B
MU3
MV3
SM
L-AXIS
YB
3BC(6X5)
X22(6X5)
E
CN 1-1
CN 1-2
CN 1-3
CN 1-4
CN 1-5
CN 1-6
CN 2-1
CN 2-2
MU3
MU3
MU3
MU3
MV3
MV3
MV3
MV3
CN 1- 1
CN 1-2
CN 1-3
CN 1-4
CN 1-5
CN 1-6
CN 2- 1
CN 2-2
MU3
MU3
MU3
MU3
MV3
MV3
MV3
MV3
CN 2-3
CN 2-4
CN 2-5
CN 2-6
CN 3-1
CN 3-2
CN 3-3
CN 3-4
MW3
MW3
MW3
MW3
ME3
ME3
ME3
ME3
CN 2- 3
CN 2-4
CN 2- 5
CN 2-6
MW3
MW3
MW3
MW3
ME3
ME3
ME3
ME3
CN3-1
CN3-2
CN3-3
CN3-4
CN 4-1
CN 4-2
CN 4-3
CN 4-4
CN 4-5
CN 4-6
MU6
MU6
MV6
MV6
MW6
MW6
CN 4- 1
CN 4-2
CN 4-3
CN 4-4
CN 4-5
CN 4-6
MU6
MU6
MV6
MV6
MW6
MW6
CN 5-1
CN 5-2
ME6
ME6
CN 5-1
CN 5-2
ME6
ME6
AC1
AC2
CN5-3
CN5-4
-C
-D
No.15CN
15CN-A
-B
MW3
ME3
SM
BA3
BB3
No.2CN
2CN-A
-B
-C
-D
-E
-F
U-AXIS
YB
MU6
MV6
MW6
ME6
BA6
BB6
WRIST
SM
E
T-AXIS
YB
PE
CN 5-3
CN 5-4
AC1
AC2
4BC (24-28)
E
4BC-1
-2
-3
-4
-5
-6
PE
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22
-23
4BC (24-28)
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
7
8
9
10
11
12
11
12
13
14
15
16
17
13
14
15
16
17
18
18
19
19
20
21
22
23
POWER CABLE
20
21
22
23
INTERNAL WIRES IN S-AXIS
INTERNAL WIRES IN LU-AXES
INTERNAL WIRES IN U-ARM
E
4BC-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22
-23
FOR SPARE CABLE
Fig. 20 (b) Internal Connection Diagram
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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
• 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.
Failure to observe this caution may result in injury from unexpected turning of the manipulator’s arm.
• The battery pack must be connected before removing encoder connector when maintenance and inspection.
Failure to observe this caution may result in the loss of home position data.
9.1
Inspection Schedule
Proper inspections are essential not only to assure that the mechanism will be able to function
for a long period, but also to prevent malfunctions and assure safe operation. Inspection intervals are classified into six levels as shown in " Table 9 Inspection Items ". Conduct periodical
inspections according to the inspection schedule in Table 9.
In Table 9, the inspection items are categorized by three types of operations: operations which
can be performed by personnel authorized by the user, operations which can be performed by
personnel being trained, and operations which can be performed by service company personnel. Only the specified personnel are to do the inspection work.
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NOTE
• The inspection interval depends on the total servo operation time.
• The following inspection schedule is based on the case that each axis is used under normal conditions. For axes which are used very frequently (in handling applications, etc.), it
is recommended that inspections be conducted at intervals of 1/2 of the schedule indicated in " Table 9 Inspection Items ".
• From the standpoint of the preventive maintenance, it is recommended that the following
parts be replaced at the secondary inspection (18000 H).
• Speed reducers for the S-, L-, U-, and T-axes
• Cross roller bearing for the U-axis
• Oil seal for the L-, U-, and T-axis motor units
Table 9 Inspection Items
Inspection Charge
Schedule
Items*4
Daily
1000
H
Cycle
5000
H
Cycle
9000
H
Cycle
Method
18000
H
Operation
Service
Specified
Licensee
Company
Person
36000
H
c
Alignment
mark
{
Visual
Check alignment
mark accordance
and damage at the
home position.
{
{
{
d
External lead
{
Visual
Check for damage
and deterioration of
leads.
{
{
{
e
Working area
and whole
exterior of
manipulator
{
Visual
Clean the work
area if dust or spatter is present.
Check for damage
and outside cracks.
{
{
{
f
LU-axis
motors
{
Visual
{
{
{
g
Baseplate
mounting
bolts
{
Spanner,
Wrench
Tighten loose bolts.
Replace if necessary.
{
{
{
h
Connector
base
{
Manual
Check for loose
connectors and
tighten if necessary.
{
{
{
i
LU-axis connectors
{
Manual
Check for loose
connectors and
tighten if necessary.
{
{
{
j
Connectors in
S-head
{
Manual
Check for loose
connectors.
{
{
{
k
L-axis balancer
{
Grease
Gun,
Visual
Supply grease.
Check for loose
screw nuts and
shafts, and tighten
if necessary.
{
{
Check for grease
leakage.*5
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Table 9 Inspection Items
Inspection Charge
Schedule
Items*4
Daily
l
1000
H
Cycle
5000
H
Cycle
Wire harness
in manipulator
(Lead wires
for SLU-axes)
(Lead wire for
T-axis)
9000
H
Cycle
Method
18000
H
Service
Specified
Licensee
Company
Person
Check for conduction between the
main connector of
base and intermediMultimeter, ate connector with
Visual
manually shaking
the wire. Check for
wear of protective
{
{
{
spring*1
Replace*2
{
11
Operation
36000
H
Links/Connections
Visual,
Manual
{
{
Move the L- and Uaxes back and
forth, up and down
to check any backlash.
{
{
{
{
{
{
{
{
{
{
{
{
Replenish grease*3
See Par.9.2.7
12
Battery pack
in manipulator
{
Screwdriver,
Wrench
Replace the battery pack when the
battery alarm
occurs or the
manipulator drove
for 36000H.
See Par.9.2.1
Check for malfunction. (Replace if
necessary.)
13
S-axis speed
reducer
{
Grease
Gun
{
Replenish grease*3
(5000H cycle).
See Par. 9.2.2
*3
Exchange grease
(9000H cycle).
See Par. 9.2.2
necessary.)
14
LU-axis
speed reducers
{
Grease
Gun
{
Replenish grease*3
(5000H cycle).
See Par. 9.2.3 and
9.2.4
Exchange grease*3
(9000H cycle). See
Par. 9.2.3 and 9.2.4
necessary.)
15
T-axis speed
reducer
{
Grease
Gun
{
Replenish grease*3
(5000H cycle).
See Par. 9.2.5
Exchange grease*3
(9000H cycle). See
Par. 9.2.5
Replenish
16
Bearing
17
Overhaul
Grease
Gun
{
{
grease*3, *6
Exchange grease*3
{
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*1
When checking for conduction with a multimeter, connect the battery to “BAT” and “OBT” of connectors on
the motor side for each axis, and then remove connectors on detector side for each axis from the motor.
Otherwise, the home position may be lost. (Refer to " 9.2.8 Notes for Maintenance ")
*2
*3
*4
*5
Wire harness in manipulator to be replaced at 18000 H inspection.
*6
Replenish grease to the U-axis cross-roller bearing at 5000 H or after a year, whichever comes first.
For the grease, refer to " Table 10 Inspection Parts and Grease Used ".
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.
Table 10 Inspection Parts and Grease Used
No.
13 14 15
9 16
Grease Used
Inspected Parts
VIGO Grease RE No.0
Speed reducers for S-, L-, U-, and T-axes
Alvania EP Grease 2
L-axis balancer, bearings
Inspection numbers correspond to the numbers in " Table 9 Inspection Items ".
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12
6
S-axis 1
1BC
A
D
B
E
A
2BC
C
F
3BC
4BC
2
8
11 16
11 16
11 16
11 16
A
U-axis
1
11 16
1
T-axis
13
The figure in the circle shows
the detailed view for the
L-axis
1
11 16
11 16
Fig. 21 Inspection Parts and Inspection Numbers
The figure below shows that the manipulator
is in the home position.
9
2
7
2
14
4
15
11 16
5
View A
4
14
2
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9.2 Notes on Maintenance Procedures
9.2
9.2.1
Notes on Maintenance Procedures
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:
D
E
F
1BC
A
B
C
4BC
Plate mounting screw M4
2BC
Plate
A
3BC
Base
Connector base
Fig. 22 (a) Battery Location (Back View)
Battery pack
Board
Fig. 22 (b) Battery Location (Top View)
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Battery pack before replacement
See the step 5.
Connector
Board
See the step 4.
New battery pack
(HW0470360-A)
Fig. 23 Battery Connection
1. Turn OFF the NX100 main power supply.
2. Unscrew the plate mounting screws M4 to remove the plate on the connector base and
pull out the battery pack for replacement.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connectors on the board.
5. Remove the old battery pack from the board.
NOTE
Remove the old battery pack after connecting the new one so that the encoder absolute
data does not disappear.
6. Mount the new battery pack on the battery holder.
7. Reinstall the plate.
NOTE
Make sure not to pinch the cable when putting the plate back into place.
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9.2.2
Grease Replenishment/Exchange for S-axis Speed
Reducer and Gear
Grease exhaust port
(Hexagon socket head plug)
D
E
F
1BC
A
B
C
4BC
S-axis speed
reducer
2BC
3BC
Grease inlet
Fig. 24 S-axis Speed Reducer and Gear Diagram

Grease Replenishment (Refer to " Fig. 24 S-axis Speed Reducer
and Gear Diagram ".)
1. Remove the hexagon socket head plug from the grease exhaust port.
NOTE
If grease is added with the plug on, the grease will go inside the motor and may cause a
damage. Never fail to remove the plug before the grease injection.
2. Remove the hexagon socket head plug from the grease inlet and install the grease
zerk A-PT1/4. Inject the grease into the grease inlet using a grease gun. (The grease
zerk is delivered with the manipulator.)
Grease type: VIGO Grease RE No.0
Amount of grease: Approx. 2100 cc
(4200 cc for the 1st supply)
3. Move the S-axis for a few minutes to discharge excess grease.
4. Wipe the discharged grease with a cloth and reinstall the plug on the grease exhaust
port. Tighten the plug to a tightening torque of 24.5 N·m (2.5 kgf·m). (Apply Three
Bond 1206C to the thread part of the plug.)
5. Remove the grease zerk from the grease inlet and reinstall the plug. Tighten the plug
to a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond 1206C to the thread
part of the plug.)
9-8
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Grease Exchange (Refer to " Fig. 24 S-axis Speed Reducer and
Gear Diagram ".)
NOTE
3. The grease exchange is complete when new grease appears in the grease exhaust
port. The new grease can be distinguished from the old grease by color.
4. Move the S-axis for a few minutes to discharge excess grease.
NOTE
If the plug is installed while the grease is being exhausted, the grease will go inside the
motor and may cause a damage. Make sure to install the plug when the grease exhaust is
complete.
part of the plug.)
9-9
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9.2.3
Grease Replenishment/Exchange for L-axis Speed
Reducer
L-axis speed reducer
Grease exhaust port
Grease inlet
Fig. 25 L-axis Speed Reducer Diagram

Grease Replenishment (Refer to " Fig. 25 L-axis Speed Reducer
Diagram ".)
NOTE
3. Move the L-axis for a few minutes to discharge excess grease.
port. Tighten the plug to a tightening torque of 24.5 N·m (2.5 kgf·m) for the plug PT3/8.
(Apply Three Bond 1206C to the thread part of the plug.)
5. Remove the grease zerk from the grease inlet and reinstall the plug. Tighten the plug to
a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond 1206C to the thread part
of the plug.)
9-10
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CAUTION
• If the L-arm is tilted over 80 degrees, the link-C interferes with the plug
for air exhaust.
90
°
Do not tilt the L-arm over 80 degrees when verifying the manipulator operation.
170°
°
80
Link-C
Plug for air exhaust
Link-C
Plug for air exhaust
Link-C
9-11
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65/77
HW0483366

Grease Exchange (Refer to " Fig. 25 L-axis Speed Reducer Diagram ".)
NOTE
4. Move the L-axis for a few minutes to discharge excess grease.
Bond 1206C to the thread part of the plug.
NOTE
complete.
part of the plug.)
9-12
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9.2.4
Grease Replenishment/Exchange for U-axis Speed
Reducer
Grease exhaust port
U-axis speed reducer
Grease inlet
Fig. 26 U-axis Speed Reducer Diagram

Grease Replenishment (Refer to " Fig. 26 U-axis Speed Reducer
Diagram ".)
NOTE
3. Move the U-axis for a few minutes to discharge excess grease.
NOTE
complete.
of the plug.)
9-13
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HW0483366

Grease Exchange (Refer to " Fig. 26 U-axis Speed Reducer Diagram ".)
NOTE
4. Move the U-axis for a few minutes to discharge excess grease.
NOTE
complete.
part of the plug.)
9-14
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9.2.5
Grease Replenishment/Exchange for T-axis Speed
Reducer
Grease exhaust port
Grease inlet
T-axis speed reducer
Grease exhaust port
T-axis speed reducer
Grease inlet
Fig. 27 T-axis Speed Reducer Diagram
9-15
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68A/77
HW0483366

Grease Replenishment (Refer to " Fig. 27 T-axis Speed Reducer
Diagram ".)
NOTE
3. Move the T-axis for a few minutes to discharge excess grease.
port. Tighten the plug to a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond
1206C to the thread part of the plug.)
NOTE
complete.
part of the plug.)

Grease Exchange (Refer to " Fig. 27 T-axis Speed Reducer Diagram ".)
NOTE
4. Move the T-axis for a few minutes to discharge excess grease.
9-16
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69/77
HW0483366
port. Tighten the plug to a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond
NOTE
complete.
of the plug.)
9-17
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70/77
HW0483366
9.2.6
Grease Replenishment for U-axis Cross Roller
Bearing
U-axis cross roller bearing
Grease inlet
Exhaust port
Fig. 28 U-axis Cross Roller Bearing Diagram
1. Remove the hexagon socket head plug from the exhaust port. (Refer to " Fig. 28 Uaxis Cross Roller Bearing Diagram ".)
zerk A-PT1/8. Inject grease into the grease inlet using a grease gun. (The grease zerk
is delivered with the manipulator.)
Grease type: Alvania EP Grease 2
NOTE
The exhaust port is for AIR flow: the grease is not exhausted from the exhaust port.
Do not inject excessive grease into the gear grease inlet.
3. Reinstall the plug into the exhaust port. Tighten the plug to a tightening torque of 4.9
N·m (0.5 kgf·m). (Apply Three Bond 1206C to the thread part of the plug.)
part of the plug.)
9-18
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Link 10
Link 3
Link 2
Link 2
Exhaust port with
a plug PT1/8
Link 5
Exhaust port with
a plug PT1/8
Link 1
Exhaust port with a plug PT1/8
Link 10
Grease inlet with a plug PT1/8
Link 8
Link 7
Grease inlet with
a plug PT1/8
Link 6
Exhaust port with
a plug PT1/8
Link 10
Link 10
Link 3
Link 9
Exhaust port with
Link 9
a plug PT1/8
Grease inlet with
a plug PT1/8
Link 4
Link 6
Link 7
Link 8
Fig. 29 Grease Replenishment for Links
Link 9
Exhaust port with
a plug PT1/8
Link 9
Link 10
Link 3
Exhaust port with
a plug PT1/8
Link 1
Link 7
Link 11
Link 8
Link 11
A
A
Link 5
Link 2
Exhaust port with
a plug PT1/8
Link 6
Grease inlet with
a plug PT1/8
Link 10
Link 4
A
B
D
1BC
C
AE
D
BF
E
A
Link 5
Grease inlet with
a plug PT1/8
F
C
2BC
3BC
4BC
Link 3
Grease inlet with
a plug PT1/8
Link 6
Section A-A
Link 1
9.2.7
Link 11
Link 4
Grease inlet with
a plug PT1/8
Note: The plugs indicated as "plug PT1/8" are
hexagon socket head plugs PT1/8.
HW0483366
Grease Replenishment for Links
9-19
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72/77
HW0483366
1. Remove the hexagon socket head plug PT1/8 from the exhaust port of each link.
(Refer to " Fig. 29 Grease Replenishment for Links ".)
2. Remove the hexagon socket head plug PT1/8 from the grease inlet of each link and
install the grease zerk A-PT1/8. Inject grease into the grease inlet using a grease gun.
(The grease zerk is delivered with the manipulator.)
Grease type
Amount of grease
NOTE
Alvania EP Grease 2
Links 1 2 3 6
6 cc (12 cc for the 1st supply)
Links 4 5 9
Links 7 8
Links 10 11
The exhaust port is for AIR flow: the grease is not exhausted from the exhaust port.
Do not inject excessive grease into the gear grease inlet.
3. Reinstall the plug into the exhaust port of each link. Tighten the plug to a tightening
torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond 1206C to the thread part of the plug.)
4. Remove the grease zerk from the grease inlet of each link and reinstall the plug.
Tighten the plug to a tightening torque of 4.9 N·m (0.5 kgf·m). (Apply Three Bond
9-20
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9.2.8
NOTE

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.
Removing the encoder connector without connecting the battery pack leads to disappearance of the encoder absolute data.
For the battery pack connection, refer to " Fig. 30 Battery Pack Connection for SLUT-axis
Motors ".
Battery Pack Connection for Motors
A motor is equipped with connectors (crimped contact-pins; each marked with "BAT, "OBT) for
battery backup. Connect the battery pack and connectors with the same marks respectively
by following the procedure below.
1. Remove the cap attached to the battery backup connector of the motor.
2. Connect the battery pack (HW9470932-A) with the battery backup connector. With the
battery pack connected to the battery backup connectors, disconnect the encoder connector and conduct the maintenance.
3. After the maintenance, verify that all connectors are connected, then disconnect the
battery pack from the battery backup connector.
4. Install the cap to the battery backup connector.
NOTE
Do not remove the battery pack in the connector base.
Motor
Motor power connector
Connector for motor encoder
0BT
b
a 0BT*
BAT
a
b BAT*
Battery backup connector
Battery pack: HW9470932-A
a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)
Fig. 30 Battery Pack Connection for SLUT-axis Motors
9-21
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HW0483366
10 Recommended Spare Parts
It is recommended to keep the parts and components in the following table in stock as spare
parts for the MOTOMAN-EPL500 (see " Table 11 Spare Parts for the Motoman-EPL500 ").
Product performance may not be guaranteed when using spare parts recommended by
companies other than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts
• 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-EPL500
Qty
Qty
per
Unit
Remarks
Yaskawa
Electric
Corporation
16kg
-
For speed reducers
Alvania EP
Grease 2
Showa Shell
Sekiyu K.K.
16kg
-
For links and
bearings
Battery Pack
HW0470360-A
Yaskawa
Electric
Corporation
1
1
4
Battery Pack
HW9470932-A
Yaskawa
Electric
Corporation
1
-
A
5
Liquid Gasket
Three Bond 1206C
ThreeBond Co.,
Ltd.
1
1
B
6
S-axis
Speed Reducer
HW0281280-A
Yaskawa
Electric
Corporation
1
1
B
7
Gear Unit
HW0172031-B
Yaskawa
Electric
Corporation
1
1
B
8
Speed Reducers for
LU-axes
HW9381442-B
Yaskawa
Electric
Corporation
1
2
B
9
Input Gears for LUaxes
HW9482358-A
Yaskawa
Electric
Corporation
1
2
B
10
T-axis
Speed Reducer
HW9380961-C
Yaskawa
Electric
Corporation
1
1
Rank
Parts
No.
A
1
Grease
VIGO Grease RE
No.0
A
2
Grease
A
3
A
Name
Type
Manufacturer
10-1
HW0483366
75/77
HW0483366
Table 11 Spare Parts for the Motoman-EPL500
Qty
Qty
per
Unit
Yaskawa
Electric
Corporation
1
1
HW9381003-1
Yaskawa
Electric
Corporation
1
1
AC Servomotor for
S-axis
HW0383523-A
SGMRS-44A2A-YR2*
Yaskawa
Electric
Corporation
1
1
14
AC Servomotors for
LU-axes
HW0383524-A
SGMRS-55A2A-YR2*
Yaskawa
Electric
Corporation
1
2
B
15
AC Servomotor for
T-axis
HW0382156-A
SGMRS-13A2A-YR1*
Yaskawa
Electric
Corporation
1
1
B
16
Wire Harness in
Manipulator
HW0172434-A
Yaskawa
Electric
Corporation
1
1
C
17
Wire Harness in
Manipulator
HW0372044-A
Yaskawa
Electric
Corporation
1
1
C
18
Wire Harness in
Manipulator
HW0271718-A
Yaskawa
Electric
Corporation
1
1
Rank
Parts
No.
B
11
T-axis Input Gear
HW0300074-1
B
12
U-axis Cross Roller
Bearing
B
13
B
Name
Type
Manufacturer
Remarks
Only for
YR-EPL500-A10
10-2
HW0483366
76/77
HW0483366
11.1 S-Axis Unit
11 Parts List
11.1 S-Axis Unit
1005
1032
1006
1033
1034
1001
1021
1029
1035
1008
1015
1017
1011
1018
1030
1020
1019
1024
1007
1010
1023
1012
1056
1036
1055
1026
1054
1027
1003
1037
1004
1028
1025
1002
1031
1062
1063
1059
1022
1061
1041
1040
1039
1061
1060
1049
1046
1038
1053
1039
1041
1042
1045
1044
1043
1052
1051
1049
1050
1044
1043
1009
1058
1057
1048
1047
1013
1016
1014
11-1
HW0483366
76A/77
HW0483366
11.1 S-Axis Unit
No.
DWG No.
Name
1001
SGMRS-44A2A-YR2*
Motor
1002
HW0281280-A
1003
M8X100
1004
2H-8
Spring washer
1005
M16X70
1006
2H-16
Pcs
No.
DWG No.
Name
Pcs
1
1059
M12X20
Socket screw
1
Speed reducer
1
1060
HW0307564-1
Gear
1
Socket screw
10
1061
IRTW-72
Retaining ring
2
10
1062
M6X16
Socket screw
1
Socket screw
12
1063
2H-6
Spring washer
1
Spring washer
12
1007
TC8511013
Oil seal
1
1008
HW0101153-1
S-head
1
1009
HW0101142-1
Base
1
1010
G415
O-ring
1
1011
M20X160
Socket screw
9
1012
2H-20
Spring washer
9
1013
HW0308465-1
Shaft
1
1014
M6X20
GT-SA Bolt
4
1015
HW0308464-1
Flange
1
1016
G135
O-ring
1
1017
HW0407533-1
Fry wheel
1
1018
HW0307565-3
Shaft
1
1019
M8X115
Socket screw
1
1020
2H-8
Spring washer
1
1021
HW0407007-1
Pin
1
1022
HW0403903-1
Plate
1
1023
M20X70(12.9)
Bolt
3
1024
M20
Washer
3
1025
HW0402102-1
Stopper
1
1026
M8X40
(DACROTIZED coating)
Socket screw
1
1027
2H-8
Spring washer
1
1028
HW9404486-1
Shaft
1
1029
M5X16
GT-SA Bolt
11
1030
S180
O-ring
1
1031
MSTM6-20
Pin
2
1032
M12X40
Socket screw
4
1033
2H-12
Spring washer
4
1034
HW0307574-1
Stopper
1
1035
HW0402627-2
Washer
1
1036
HW0101152-2
Gear case
1
1037
PT3/8
Plug
1
1038
HW9381477-B
Gear
1
1039
6207ZZ
Bearing
2
1040
CIMR35-1
Shim
2
2
1041
ISTW-35
Retaining ring
1042
HW9405051-1
Cover
1
1043
M5X16
Socket screw
14
1044
2H-5
Washer
14
1045
HW9405047-1
Shaft
1
1046
HW0307563-1
Gear
1
1047
M8X25
Socket screw
8
1048
2H-8
Washer
8
1049
HR33206J
Bearing
2
1050
HW9405048-1
Housing
1
1051
G85
O-ring
1
1052
HW9405304-*
Shim
*
1053
HW0307562-1
Gear
1
1054
6828ZZ
Bearing
1
1055
WR140
Circlip
1
1056
AR175
Circlip
1
1057
M6X20
Socket screw
10
1058
2H-6
Washer
10
11-2
HW0483366
76B/77
HW0483366
11.2 L-Axis Unit
11.2 L-Axis Unit
2059
2080
2057
2058
2077
2062
2079
2062
2069
2064
2007
2078
2054
2020
2001
2053
2080
2016
2062
2015
2008
2002
2021
2018
2080
2017
2014
2062
2062
2054
2019
2077
2079
2013
2078
2062
2080
2059
2070
2064
2056
2055
2071
2080
2020
2006
2012
2053
2013
2011
2001
2062
2080
2062
2019
2058
2057
2018
2014
2009
2080
2015
2016
2004
2052
2075
2064
2068
2010
2005
2021
1008
2072
2080
11-3
HW0483366
76C/77
HW0483366
11.2 L-Axis Unit
2046
2045
2031
2003
2080
2061
2047
2033 2035
2045
2034
2066 2065
2060
2032
2046
2008
2062
2002
2060
2064
2030
2063
2036
2041
2039
2044
2043
2042
2024
2056
2074
2029
2080
2022
2067
2076
2037
2056
2038
2028 2062
2023
2049
2048
5005
2073
2051
2052
2027
2062
2050 2024
2025
2074
2026
2056
2040
2062
1008
2052
2051
2037
2028
2048
2038
2027
2056
2062
2076
11-4
HW0483366
76D/77
HW0483366
11.2 L-Axis Unit
No.
DWG No.
Name
Pcs
No.
DWG No.
Name
Pcs
2001
SGMRS-55A2A-YR2*
Motor
2
2059
M12X80
Socket screw
44
2002
HW0101154-1
L-arm
1
2060
M6X15
GT-SA Bolt
8
2003
HW0101146-1
Link A
1
2061
M12X70
Socket screw
1
2004
HW9381003-1
Cross roller
bearing
1
2062
PT1/8
Plug
13
2005
HW9301454-1
B-cover
1
2063
M16X50
Socket screw
6
2006
HW0200394-1
M-base
1
2064
2H-16
Spring washer
36
1
2007
HW9200895-1
M-base
1
2065
M6X6
Socket screw
2008
HW0101145-2
Link-B
1
2066
2H-6
Spring washer
1
2009
HW9482506-G
Bolt
1
2067
M12X50
Socket screw
12
2010
HW0300930-1
Shaft
1
2068
M16X80
Socket screw
6
2011
HW0303231-1
Spacer
1
2069
M16X65
Socket screw
18
2012
HW0403590-1
Fly wheel
1
2070
M16X75
Socket screw
6
2013
HW9381442-B
Speed reducer
2
2071
M12X60
Socket screw
21
2014
HW9482358-A
Gear
2
2072
M12X30
Socket screw
21
2015
HW9481343-A
Shaft
2
2073
M6X20
GT-SA Bolt
3
2016
HW9482339-A
Shaft
2
2074
M10X25
Socket screw
2
2017
HW9482506-A
Bolt
1
2075
M8X20
Socket screw
12
2018
ISTW-12
Retaining ring
2
2076
M10X50
Socket screw
18
2019
G300
O-ring
2
2077
EZ0094-A0
Air-breather
2
2020
Y507212.5
Oil seal
2
2078
TSH6-01M
Union
2
2021
V-220L
V-Ring
2
2079
UB-0640-0.1C
Tube
2
2022
HW0307641-1
Shaft
1
2080
2H-12
Spring washer
105
2023
HW0406922-1
B-cover
1
5005
HW0100477-1
Case
1
1008
HW0101153-1
S-head
1
2024
HW0406923-1
Pup washer
2
2025
HW0406926-1
Collar
1
1
2026
HW0406925-1
Collar
2027
HW9405055-1
Shaft
2
2028
HW9405699-1
B-cover
2
1
2029
HW9302054-1
Shaft
2030
HW0308094-1
Link-C
1
2031
HW0400016-1
Shaft
1
2032
HW0400008-1
B-cover
1
2033
HW0406931-1
B-cover
1
1
2034
HW0400015-1
Shaft
2035
HW0400012-*
Shim
*
2036
HW0200692-1
Counter wait
1
2037
S105
O-ring
2
2038
HR32916J
Bearing
2
2039
AG3217A4
Oil seal
1
2040
VB60789
Oil seal
1
2041
WR60
Circlip
1
1
2042
VB75956
Oil seal
2043
AR-85
Circlip
1
2044
NA6912
Needle bearing
1
2045
AG3512E1
Oil seal
2
2046
HR32011XJ
Bearing
2
2047
G85
O-ring
1
2048
KE901107
Oil seal
2
2049
G75
O-ring
1
2050
HW9481646-A
Bearing
1
2051
M8X20
Socket screw
8
2052
2H-8
Spring washer
20
2053
M12X65
Socket screw
4
2054
PT3/8
Plug
2
2055
M10X30
Socket screw
6
2056
2H-10
Spring washer
26
2057
M12X35
Socket screw
8
2058
2H-12
Spring washer
8
11-5
HW0483366
76E/77
HW0483366
11.3 U-Axis Unit
11.3 U-Axis Unit
3030 3029
3015
2030
3015
3021 3030
3029
3014
3027
3017
3039 3028
3041
3029
3027
3014
3055
3040 3030
3021
3042
3030
3029
3028
3015
3018
3017
3020
3016
3019
3018
3010
3035
3028
3028
3012 3034
3013
3011
3028
3023
3009
3008
3007
3013
3012
3028
3019
3016
3031
3030
3036
3036
3043
3032
3033
3005
3004
3006
3028
3044
3001
3028
3025
3028
3020
3015
3029 3030
3022
3024
3037
3030
3035
3038
3028
2003
3026
3028
3030
3037
3001
3028
3004
3005
3028
2002
3003
3002
3030
3031
11-6
HW0483366
76F/77
HW0483366
11.3 U-Axis Unit
No.
DWG No.
Name
Pcs
3001
HW9403571-2
Shaft
2
3002
HW9301405-1
B-cover
1
3003
HW9403656-*
Shim
*
3004
AG4059E0
Oil seal
2
3005
HR32016XJ
Bearing
2
3006
HW0400016-1
Shaft
1
3007
HW0400008-1
B-cover
1
3008
HW0406931-1
B-cover
1
3009
G85
O-ring
1
3010
HW0400015-1
Shaft
1
3011
HW0400012-*
Shim
*
3012
AG3512E1
Oil seal
2
3013
HR32011XJ
Bearing
2
3014
HW0406922-1
B-cover
2
3015
HW0406923-1
Pup washer
4
3016
HW0307641-1
Shaft
2
3017
HW0406925-1
Collar
2
3018
HW0406926-1
Collar
2
3019
HW9481646-A
Bearing
2
3020
AG3217A4
Oil seal
2
3021
G75
O-ring
2
3022
MSTH6-10
Pin
2
3023
HW0200691-1
Link-D
1
3024
HW0308095-1
Link-E
1
3025
HW0101147-1
Casing
1
3026
HW0101155-1
U-arm
1
3027
M6X20
GT-SA Bolt
6
3028
PT1/8
Plug
13
3029
M10X25
Socket screw
5
3030
2H-10
Spring washer
21
3031
M10X30
Socket screw
8
3032
M6X6
Socket screw
1
3033
2H-6
Spring washer
1
3034
M12X70
Socket screw
1
3035
2H-12
Spring washer
11
3036
M6X15
GT-SA Bolt
8
3037
M10X50
Socket screw
8
3038
M12X45
Socket screw
10
3039
HW0406822-1
B-cover
1
3040
HW0406759-1
Pup washer
1
3041
G95
O-ring
1
3042
HW0483232-A
Bearing
1
3043
HW0306239-1
Shaft
1
3044
VC70X92X7
Oil seal
1
3055
M6X20
GT-SA Bolt
6*1
M6X20
GT-SA Bolt
3*2
2002
HW0101154-1
L-arm
1
2003
HW0101146-1
Link-A
1
2030
HW0308094-1
Link-C
1
*1
Component parts
S5Q569-1 and after
*2
Component parts before
S5Q569-1
11-7
HW0483366
76G/77
HW0483366
11.4 Wrist Unit
11.4 Wrist Unit
4033
4048
4032
4019
4029
4039
4032
4001
4028
4020
4023
4031
4044
4040
4032
4032
4024
4030
4014
4022
4013
4025
4012
3024
4017
4026
4004
4016
4037
4015
3026
4041
4042
4044
4036
4008
4044
4011
4003
4032
4040
4007
4015
4010
4016
4045
4017
4021
4038
4018
4032
4009
4004
4042
4041
4044
4032
4039
4005
4043
4006
4002
4032
4033
4027
4035
4044
4034
11-8
HW0483366
76H/77
HW0483366
11.4 Wrist Unit
No.
4001
DWG No.
SGMRS-13A2A-YR1*
Name
Pcs
Motor
1
1
4002
HW9380961-C
Speed reducer
4003
HW0101156-1
Wrist base
1
4004
HW0406923-1
Pup washer
2
4005
G75
O-ring
1
4006
HW0406922-1
B-cover
1
4007
HW9481646-A
Bearing
1
4008
HW0307641-1
Shaft
1
4009
HW0406925-1
Collar
1
4010
HW0406926-1
Collar
1
4011
AG3217A4
Oil seal
1
4012
S90
O-ring
1
4013
HW9404246-*
Shim
*
4014
HW0405915-1
B-cover
1
4015
AG3584A0
Oil seal
2
4016
HW9404245-1
Shaft
2
4017
HR32012XJ
Bearing
2
4018
HW9404383-1
B-cover
1
4019
HW0407406-1
Pipe
1
4020
HW0308088-1
M-base
1
4021
ARP568-263
O-ring
1
4022
HW0300074-1
Gear
1
4023
HW0300073-1
Gear
1
4024
HW9481950-A
Shaft
1
4025
HW0400073-1
Pipe
1
4026
HW9404651-1
Washer
1
4027
HW0308090-1
Flange
1
1
4028
AE2085K4
Oil seal
4029
HW0400017-1
Fly-wheel
1
4030
HW0308089-1
Spacer
1
4031
M8X35
Socket screw
4
4032
2H-8
Spring washer
44
4033
M8X30
Socket screw
20
4034
M8X50
Socket screw
18
4035
2H-8
Spring washer
18
4036
M6X95
Socket screw
1
4037
2H-6
Spring washer
1
4038
M8X90
Socket screw
6
4039
M8X25
Socket screw
6
4040
M8X65
Socket screw
8
4041
M10X25
Socket screw
2
4042
2H-10
Spring washer
2
4043
M6X20
GT-SA Bolt
3
4044
PT1/8
Plug
6
4045
LP-M5
Plug
1
4048
PT3/8
Plug
1
3024
HW0308095-1
Link-E
1
3026
HW0101155-1
U-arm
1
11-9
HW0483366
76I/77
HW0483366
11.5 Balancer Unit
11.5 Balancer Unit
5018
5012
5005
5008
5006
5001
5002
5007
5017
5003
5016
5013
5004
5009
5014
5004
5013
5014
5015
5011
5010
11-10
HW0483366
76J/77
HW0483366
11.5 Balancer Unit
No.
DWG No.
Name
Pcs
5001
HW0481740-A
Coil spring
1
5002
HW0481741-A
Coil spring
1
5003
HW0481742-A
Coil spring
1
5004
SOB607440
Oiless
2
5005
HW0100477-1
Case
1
5006
HW0306033-1
Flange
1
5007
HW0200420-1
Flange
1
5008
HW0401112-1
Flange
1
5009
HW0303581-1
Rod
1
5010
HW9405057-1
Clevis
1
5011
FD3187A0
Dust seal
1
5012
EZ2228B0
Cap
1
2
5013
IRTW-75
Retaining ring
5014
M6X8
Magic screw
2
5015
PT1/8
Plug
3
5016
M10X40
Socket screw
8
5017
2H-10
Spring washer
8
5018
M8X16
GT-SA Bolt
3
11-11
HW0483366
76K/77
MOTOMAN-EPL500
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Y ahatanishi-ku, Kitaky usy u-shi, 806-0004, Japan
Phone 81-93-645-7745
Fax
81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200
Fax
1-937-847-6277
Y ASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686
Fax
1-905-813-5911
MOTOMAN ROBOTICSEUROPEAB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800
Fax
46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerf eld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100
Fax
49-8166-90103
Y ASKAWAELECTRIC KOREACORPORATION
1F Samy ang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844
Fax
82-2-784-8495
Y ASKAWAELECTRIC (SINGAPORE)PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003
Fax
65-6289-3003
Y ASKAWAELECTRIC (MALAY SIA)SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malay sia
Phone 60-3-6092-1377
Fax
60-3-6092-6377
Y ASKAWAELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003
Fax
886-2-2505-1280
SHOUGANGMOTOMAN ROBOTCO., LTD.
7,Y ongchang-North Road, Beijing Economic & Technological Dev elopment Area, Beijing 100076, China
Phone 86-10-6788-0541
Fax
86-10-6788-2878
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice
for ongoing product modifications and improvements.
C
Printed in Japan September 2006 06-03
MANUAL NO.
HW0483366
2
77/77