EPL160/EPL300 Manipulator Manual

Transcription

1 Motoman NX100 Controller EPL160/EPL300 Manipulator Manual Part Number: CD Revision: 0 Motoman, Incorporated 805 Liberty Lane West Carrollton, OH TEL: (937) FAX: (937) Hour Service Hotline: (937)

2 COMPLETE OUR ONLINE SURVEY Motoman is committed to total customer satisfaction! Please give us your feedback on the technical manuals you received with your Motoman robotic solution. To participate, go to the following website: 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 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.

3 EPL160/EPL Chapter 1 Introduction 1.1 About This Document This manual provides information for the EPL160/EPL300 manipulator and contains the following sections: SECTION 1 - INTRODUCTION Provides general information about the structure of this manual, a list of reference documents, and customer service information. SECTION 2 - SAFETY This section provides information regarding the safe use and operation of Motoman products. SECTION 3 - EPL160/EPL300 INSTRUCTIONS Provides detailed instructions for the EPL160/EPL Reference to Other Documentation For additional information refer to the following: NX100 Controller Manual (P/N ) Concurrent I/O Manual (P/N ) Operator s Manual for your application Vendor manuals for system components not manufactured by Motoman 1.3 Customer Service Information If you are in need of technical assistance, contact the Motoman service staff at (937) Please have the following information ready before you call: Robot Type (EA1400, 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

4 Manipulator Manual Chapter 1 Introduction Notes page 2 Final

5 EPL160/EPL 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 R The address is as follows: Robotic Industries Association 900 Victors Way P.O. Box 3724 Ann Arbor, Michigan TEL: (734) FAX: (734) INTERNET: 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 page 3

6 Manipulator Manual Chapter 2 Safety This safety section addresses the following: Standard Conventions (Section 2.2) General Safeguarding Tips (Section 2.3) Mechanical Safety Devices (Section 2.4) Installation Safety (Section 2.5) Programming, Operation, and Maintenance Safety (Section 2.6) 2.2 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

7 EPL160/EPL 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: 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 R , section 4.2.5, Sources of Energy, use lockout/tagout procedures during equipment maintenance. Refer also to Section (29CFR, Part 1910), Occupational Safety and Health Standards for General Industry (OSHA). 2.4 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 R 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 page 5

8 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: Be sure that only qualified personnel familiar with national codes, local codes, and ANSI/RIA R 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. 2.6 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. 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. page 6 Final

9 EPL160/EPL 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

10 Manipulator Manual Chapter 2 Safety Notes page 8 Final

11 MOTOMAN-EPL300, EPL160 INSTRUCTIONS YASKAWA TYPE: YR-EPL300-A00 (STANDARD SPECIFICATION) YR-EPL160-A00 (STANDARD SPECIFICATION) YR-EPL300-A10 (FOR INTEGRATED WRIST AXIS CABLE ROUTING PACKAGE) YR-EPL160-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-EPL300, EPL160 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 MANUAL NO. 2 1/95

12 MANDATORY This instruction manual explains operating instructions and maintenance procedures primarily for the MOTOMAN-EPL300 and EPL160. 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. ii 2/95

13 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 CAUTION MANDATORY Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel. 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. 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. iii 3/95

14 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. Release of Emergency Stop TURN 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. iv 4/95

15 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 Programming Pendant Cable between the manipulator and the controller NX100 Programming pendant Manipulator cable v 5/95

16 WARNING Do not enter robot work area. 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. Nameplate WARNING label A WARNING label B Nameplate: MOTOMAN TYPE WARNING label A: WARNING WARNING label B: WARNING PAYLOAD ORDER NO. kg MASS DATE kg SERIAL NO. YASKAWA ELECTRIC CORPORAION JAPAN Do not enter robot work area. Moving parts may cause injury vi 6/95

17 1 Product Confirmation 1.1 Contents Confirmation Order Number Confirmation Transporting 2.1 Transporting Method Using a Crane Shipping Bolts and Brackets Installation 3.1 Installation of the Safeguarding Mounting Procedures for Manipulator Base Mounting Example Location Wiring 4.1 Grounding Manipulator Cable Connection Connection to the Manipulator Connection to the NX Basic Specifications 5.1 Basic Specifications Part Names and Working Axes Manipulator Base Dimensions Dimensions and T-Point Maximum Envelope Alterable Operating Range Components for Altering Operating Range Installation of the S-Axis Mechanical Stopper Adjustment to the S-axis Pulse Limitation Installation of the S-axis Mechanical Stopper at Configurable Angles vii 7/95

18 6 Allowable Load for Wrist Axis and Wrist Flange 6.1 Allowable Wrist Load Wrist Flange System Application 7.1 Peripheral Equipment Mounts Internal User I/O Wiring Harness and Air Line Electrical Equipment Specification 8.1 Position of Limit Switch Internal Connections Maintenance and Inspection 9.1 Inspection Schedule Notes on Maintenance Procedures Battery Pack Replacement Grease Replenishment/Exchange for S-axis Speed Reducer and Gear Grease Replenishment (Refer to " Fig. 24 S-axis Speed Reducer and Gear Diagram ".) Grease Exchange (Refer to " Fig. 24 S-axis Speed Reducer and Gear Diagram ".) Grease Replenishment/Exchange for L-axis Speed Reducer 9-11 Grease Replenishment (Refer to " Fig. 25 (a) L-axis Speed Reducer Diagram " and " Fig. 25 (b) L-axis Grease Replenishment ".) Grease Exchange (Refer to " Fig. 25 (a) L-axis Speed Reducer Diagram ".) Grease Replenishment/Exchange for U-axis Speed Reducer 9-15 Grease Replenishment (Refer to " Fig. 26 U-axis Speed Reducer Diagram ".) Grease Exchange (Refer to " Fig. 26 U-axis Speed Reducer Diagram ".) Grease Replenishment/Exchange for T-axis Speed Reducer 9-17 Grease Replenishment (Refer to " Fig. 27 T-axis Speed Reducer Diagram ".) Grease Exchange (Refer to " Fig. 27 T-axis Speed Reducer Diagram ".) viii 8/95

19 9.2.6 Grease Replenishment for U-axis Cross Roller Bearing Grease Replenishment for Links Notes for Maintenance Battery Pack Connection for S-, L-, U-, T-axis Motors Recommended Spare Parts 11 Parts List 11.1 S-Axis Unit L-Axis Unit U-Axis Unit Wrist Unit Balancer Unit ix 9/95

20 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 (the information for the content of optional goods is given separately): Manipulator NX100 Programming Pendant Manipulator Cables (Three cables, between manipulator and NX100) /95

21 TYPE ERCR- POWER SUPPLY 200V 50Hz 220V 50/60Hz 3PHASE kva SERIAL No. DATE MADE IN JAPAN NJ THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER. ORDER NO. NJ1529 OFF RESET Do not open the door ON REMOTE TEACH PLAY MULTI DISPLAY SWITCH MAIN MENU E M SERVO COORD. POWER SELECT SHORTCUT ASSIST MENU x x R- R+ y y X- X+ S- S+ Y- Y+ L- L+ B- B+ - + z z R- R+ T- T+ SHIFT INTER WEAVING WELD LOCK START START FEED TEST RUN SHIFT ROBOT AUXILIARY WEAVING WELD SWITCH COMPLETE COMPLETE RETRUCT BACK NEXT EX-AXIS SWITCH AUXILIARY TIMER VOLTAGE CURRENT DELETE INSERT CABCEK 0 INTER. REF. ENTER POINT VOLTAGE CURRENT MODIFY E S R G T E O N P C Y 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 ****** WARNING TRIPPED. - (a) NX100 (Front View) (b) Manipulator (Side View) Fig. 1 Location of Order Number Labels /95

22 2.1 Transporting Method 2 Transporting CAUTION Sling applications and crane or forklift operations must be performed by authorized personnel only. Failure to observe this caution may result in injury or damage. Avoid excessive vibration or shock during transporting. Failure to observe this caution may adversely affect the performance as the system consists of precision components. 2.1 Transporting Method NOTE The weight of the manipulator including the shipping bolts and brackets is as follows: Manipulator Type Mass EPL300 Approx kg EPL160 Approx kg Use a wire rope strong enough to withstand the weight. Mount the shipping bolts and brackets for transporting 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 /95

23 2.1 Transporting Method 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 Transporting Position " Fig. 2 Transporting Position /95

24 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 Bolt Type Pcs A Hexagon socket head cap screw M20 4 B and C Hexagon socket head cap screw M10 4 NOTE Before turning ON the power, check to be sure that the shipping bolts and brackets have been 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 /95

25 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 /95

26 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 foundation strong enough to support the manipulator and withstand repulsion forces during acceleration and deceleration. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the manipulator referring to " Table 1 Maximum Repulsion Forces of the Manipulator in an Emergency Stop " and " Table 2 Endurance Torque in Operation ". 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 " Mounting Example ". Table 1 Maximum Repulsion Forces of the Manipulator in an Emergency Stop Maximum torque in horizontal rotation (S-axis moving direction) Maximum torque in vertical rotation (L-, U-axis moving direction) N m (4000 kgf m) N m (6400 kgf m) Table 2 Endurance Torque in Operation Endurance torque in horizontal operation (S-axis moving direction) Endurance torque in vertical operation (L-, U-axis moving direction) N m (1200 kgf m) N m (1920 kgf m) /95

27 Location 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 socket 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 Baseplate dia. drilled hole (12 holes) mm or more Floor Anchor bolt M24 or more Flatness: 0.5 mm or less 200 mm or more Baseplate (reference) 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/s 2 [0.5 G]) Free from large electrical noise (plasma) Flatness for installation is 0.5 mm or less /95

28 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 /95

29 4.1 Grounding 4.1 Grounding Follow the local regulations for grounding line size. A line of 5.5 mm 2 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 mm 2 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 " Connection to the Manipulator Before connecting the manipulator cables to the manipulator, confirm the numbers on both the cables and the connectors on the manipulator connector base. Then, connect the cables in the order of 2BC, 3BC, 1BC. Insert cables adjusting the cable connector positions to the main key positions of the manipulator, and then set the lever until it clicks /95

30 4.2 Manipulator Cable Connection 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 cables 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 1BC X11 Encoder Cable 1BC NX100 side Manipulator side X21 2BC 2BC X21 Power Cable 2BC NX100 side Manipulator side X22 3BC 3BC X22 Power Cable 3BC Fig. 6 Manipulator Cable Connections /95

31 4.2 Manipulator Cable Connection D E F 4BC A B C 2BC 1BC A 3BC Key positions Enlarged View A Connector Details (Manipulator Side) A Fig. 7 (a) Details of the Manipulator Cable Connectors (Manipulator Side) X22 X21 X11 Fig. 7 (b) Manipulator Cable Connections to the NX /95

32 5.1 Basic Specifications 5 Basic Specifications 5.1 Basic Specifications Table 3 Basic Specifications *1 Item Model YR-EPL300-A00 YR-EPL300-A10 YR-EPL160-A00 YR-EPL160-A10 Configuration Vertically Articulated Degree of Freedom 4 Payload 300 kg 160 kg Repetitive Positioning Accuracy *2 ±0.5 mm S-axis (turning) ±180 Range of Motion L-axis (lower arm) +90, -45 U-axis (upper arm) +15.5, -120 T-axis (wrist twist) ±360 ±180 ±360 ±180 S-axis 1.57 rad/s (90 /s) 2.44 rad/s (140 /s) Maximum Speed L-axis 1.66 rad/s, (95 /s) 2.37 rad/s (136 /s) U-axis 1.83 rad/s (105 /s) 2.37 rad/s (136 /s) T-axis 3.40 rad/s (195 /s) 5.32 rad/s (305 /s) Allowable Inertia (GD 2 /4) *3 140 kg m 2 80 kg m 2 Mass 1820 kg 1700 kg Temperature 0 to 45 C Humidity 20 to 80% RH at constant temperature Ambient Conditions Vibration acceleration Less than 4.9 m/s 2 (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 11 kva *1 SI units are used in this table. However, gravitational unit is used in ( ). *2 Conformed to ISO9283 *3 Refer to " 6.1 Allowable Wrist Load " for details on the permissible moment of inertia /95

33 5.2 Part Names and Working Axes 5.2 Part Names and Working Axes U+ L- U- Upper arm (U-arm) T+ Wrist Wrist flange L+ Lower arm L-arm T- Rotary head S-head S+ Base S- Fig. 8 Part Names and Working Axes /95

34 5.3 Manipulator Base Dimensions 5.3 Manipulator Base Dimensions ± dia. 0 hole (2 places) 220± dia. hole (8 places) ± ± ±0.1 A ± ± dia. 0 hole 879 View A Units: mm Fig. 9 Manipulator Base Dimensions /95

35 5.4 Dimensions and T-Point Maximum Envelope 5.4 Dimensions and T-Point Maximum Envelope R1037 R3159 R R T -point maximum envelope T -Point P-point Units: mm Fig. 10 (a) Dimensions and T-Point Maximum Envelope (YR-EPL300-A00) /95

36 5.4 Dimensions and T-Point Maximum Envelope R1037 R3159 R R T -point maximum envelope P-point T -point Units: mm Fig. 10 (b) Dimensions and T-point Maximum Envelope (YR-EPL300-A10) /95

37 Dimensions and T-Point Maximum Envelope 1300 R1037 R R R T -point maximum envelope P-point T -point Units: mm Fig. 10 (c) Dimensions and T-point Maximum Envelope (YR-EPL160-A00) /95

38 Dimensions and T-Point Maximum Envelope 1300 R1037 R T -point maximum envelope P-point T -point R R Units: mm Fig. 10 (d) Dimensions and T-point Maximum Envelope (YR-EPL160-A10) /95

39 5.5 Alterable Operating Range 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 /95

40 5.5 Alterable Operating Range Components for Altering Operating Range Arrange the components listed in " Fig. 11 Components of S-axis Stopper ", when modifying the angle of S-axis. No. Item Pcs Pin (Drawing No. HW ) 1 Stopper (Drawing No. HW ) 2 Hexagon socket head cap screw M20 (length: 70 mm) (tensile strength: 1200 N/mm 2 or more) Flat washer M Hexagon socket head cap screw M20 (3 screws) (tensile strength: 1200 N/mm 2 or more) Washer M20 (3 washers) Stopper (HW ) Section A-A Pin (HW ) A A Fig. 11 Components of S-axis Stopper /95

41 5.5 Alterable Operating Range Installation of the S-Axis Mechanical Stopper 1. Apply the LOCTITE 242 to the thread part of the pin HW , and install the pin bottom up into the S-axis mechanical stopper HW 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 405 N m (tensile strength: 1200 N/ mm 2 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 /95

42 5.5 Alterable Operating Range Adjustment to the S-axis Pulse Limitation To confine the operating range of the S-axis, refer to "NX100 Concurrent I/O (manual No. RE- CKI-A442)" 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 EPL300 EPL160 Degree Number of Pulse Number of Pulse ± 15 ± ± ± 30 ± ± ± 45 ± ± ± 60 ± ± ± 75 ± ± ± 90 ± ± ± 105 ± ± ± 120 ± ± ± 135 ± ± ± 150 ± ± ± 165 ± ± ± 180 ± ± NOTE Adjust both of the pulse limitation and the angle of the S-axis mechanical stopper as modifying the range of motion for the manipulator /95

43 5.5 Alterable Operating Range Direction Angles Configurable angle Disabled angle 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. Exception: The top left cell indicates the mountability of one stopper. Table 5 Configurable Angles for S-axis Stopper Installation - Direction Angles /95

44 5.5 Alterable Operating Range 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 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 Fig. 13 (a) Stopper Installation at Configurable Angles /95

45 5.5 Alterable Operating Range 150 The stopper is irreversible. Only this side of the stopper can be used at this angle. Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 Installation at 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 Fig. 13 (b) Stopper Installation at Configurable Angles /95

46 5.5 Alterable Operating Range 120 The stopper is irreversible. Only this side of the stopper can be used at this angle. Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 Installation at 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 Fig. 13 (c) Stopper Installation at Configurable Angles /95

47 5.5 Alterable Operating Range 90 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 + 90 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 75 Installation at + 75 Fig. 13 (d) Stopper Installation at Configurable Angles /95

48 5.5 Alterable Operating Range The stopper is irreversible. Only this side of the stopper can be used at this angle. Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 60 Installation at + 60 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 45 Installation at + 45 Fig. 13 (e) Stopper Installation at Configurable Angles /95

49 5.5 Alterable Operating Range The stopper is irreversible. Only this side of the stopper can be used at this angle. Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 30 Installation at + 30 Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 The stopper is reversible. Either side of the stopper can be used. 15 Installation at + 15 Fig. 13 (f) Stopper Installation at Configurable Angles /95

50 5.5 Alterable Operating Range Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 The stopper is reversible. Either side of the stopper can be used. Installation at + 0 Fig. 13 (g) Stopper Installation at Configurable Angles /95

51 5.5 Alterable Operating Range The stopper is reversible. Either side of the stopper can be used. 180 Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 Installation at Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M The stopper is reversible. Either side of the stopper can be used. Installation at Fig. 13 (h) Stopper Installation at Configurable Angles /95

52 5.5 Alterable Operating Range Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 The stopper is irreversible. Only this side of the stopper can be used at this angle. 150 Installation at Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 Installation at The stopper is reversible. Either side of the stopper can be used. Fig. 13 (i) Stopper Installation at Configurable Angles /95

53 Alterable Operating Range 120 Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 The stopper is irreversible. Only this side of the stopper can be used at this angle. Installation at The stopper is reversible. Either side of the stopper can be used. Installation at Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 Fig. 13 (j) Stopper Installation at Configurable Angles /95

54 5.5 Alterable Operating Range 90 The stopper is reversible. Either side of the stopper can be used. Installation at - 90 Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 75 The stopper is reversible. Either side of the stopper can be used. Installation at - 75 Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 Fig. 13 (k) Stopper Installation at Configurable Angles /95

55 5.5 Alterable Operating Range Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 60 The stopper is irreversible. Only this side of the stopper can be used at this angle. Installation at - 60 Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 45 The stopper is reversible. Either side of the stopper can be used. Installation at - 45 Fig. 13 (l) Stopper Installation at Configurable Angles /95

56 Alterable Operating Range Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 30 The stopper is irreversible. Only this side of the stopper can be used at this angle. Installation at - 30 Hexagon head screw M20 (3 screws) (length: 70 mm) with three washers M20 The stopper is reversible. Either side of the stopper can be used. Installation at - 15 Fig. 13 (m) Stopper Installation at Configurable Angles /95

57 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: YR-EPL300-A00, -A10: 300 kg at a maximum YR-EPL160-A00, -A10: 160 kg at a maximum 1. The total inertia (GD 2 /4) of T-axis should be the value as shown in " Table 6 Allowable Total Inertia " or less. Table 6 Allowable Total Inertia Model GD 2 /4 Inertia kg m 2 YR-EPL300-A00, -A YR-EPL160-A00, -A 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 (a) Moment Arm Rating for EPL300 " and " Fig. 14 (b) Moment Arm Rating for EPL160 ". When the inertia of the volume load on the flange is large, use the following formula to calculate the eccentricity L T. Formula: J=Ji+WL 2 T J : Total inertia (GD 2 /4) of the T-axis (kg m 2 ) Ji : Inertia of the volume load on the flange (kg m 2 ) W : Payload (kg) LT: Eccentricity (mm) /95

58 6.1 Allowable Wrist Load LB LT Center of T-axis flange rotation LT (mm) m=300 kg m=250 kg 1000 m=200 kg 1100 LB (mm) Fig. 14 (a) Moment Arm Rating for EPL300 LB LT Center of T-axis flange rotation LT (mm) LB (mm) m=160 kg m=100 kg m=80 kg Fig. 14 (b) Moment Arm Rating for EPL /95

59 6.2 Wrist Flange 6.2 Wrist Flange 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 dia dia PCD 125 Tappled hole M10 (10 places)(depth: 16) dia. 0 hole (2 places)(depth: 8) 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 /95

60 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 Tapped hole M8 (4 places)(depth: 16) 40 View A Units: mm Fig. 16 Location of Peripheral Equipment Mounts/Tapped Holes Table 7 Constraint for Attaching Application Manipulator Type Note Cable Processing and Valve Load YR-EPL300-A00, -A10 YR-EPL160-A00, -A10 Up to 300 kg including the peripheral equipment mass attached to the wrist unit. Up to 160 kg including the peripheral equipment mass attached to the wrist unit /95

61 A 7.2 Internal User I/O Wiring Harness and Air Line 7.2 Internal User I/O Wiring Harness and Air Line An internal user I/O wiring harness (0.5 mm 2 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-EPL300-A00 and YR- EPL160-A00 " and " Fig. 17 (b) Internal User I/O Wiring Harness and Air Lines for YR- EPL300-A10 and YR-EPL160-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: 2.2 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/cm 2 ) or less (The air line inside diameter: 8 mm dia.) B A Exhaust port D Tapped hole PT3/8 with pipe plug Exhaust port E Tapped hole PT3/8 with pipe plug Air inlet D Tapped hole PT3/8 with pipe plug Air inlet B Tapped hole PT3/8 with pipe plug Air inlet A Tapped hole PT3/8 with pipe plug Exhaust port F Tapped hole PT3/8 with pipe plug D E F 4BC S1 D E F A B C View B Exhaust port A Tapped hole PT3/8 with pipe plug Exhaust port B Tapped hole PT3/8 with pipe plug Exhaust port C Tapped hole PT3/8 with 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. Air inlet E Tapped hole PT3/8 with pipe plug Air inlet F Tapped hole PT3/8 with pipe plug A B C 2BC Air inlet C Tapped hole PT3/8 with pipe plug 1BC 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. View A Fig. 17 (a) Internal User I/O Wiring Harness and Air Lines for YR-EPL300-A00 and YR-EPL160-A /95