Motoman NX100 Controller EPL500 Manipulator Manual

Motoman NX100 Controller

EPL500 ManipulatorManual

Part Number: 150776-1CDRevision: 0

Motoman, Incorporated 805 Liberty LaneWest Carrollton, OH 45449TEL: (937) 847-6200FAX: (937) 847-627724-Hour Service Hotline: (937) 847-3200

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 MOTOMANAll 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.

COMPLETE OUR ONLINE SURVEYMotoman 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

EPL500150776-1

Chapter 1

Introduction

1.1 About This Document

This manual provides information for the EPL500 manipulator and contains the following chapters:

CHAPTER 1 - INTRODUCTIONProvides general information about the structure of this manual, a list of reference documents, and customer service information.

CHAPTER 2 - SAFETYThis section provides information regarding the safe use and operation of Motoman products.

CHAPTER 3 - EPL500 INSTRUCTIONSProvides detailed instructions for the EPL500.

1.2 Reference to Other Documentation

For additional information refer to the following:

• 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

1.3 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)

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Manipulator Manual Chapter 1 Introduction

Notes

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EPL500150776-1

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 Association900 Victors WayP.O. Box 3724

Ann Arbor, Michigan 48106TEL: (734) 994-6088FAX: (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.

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Manipulator Manual Chapter 2 Safety

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming, Operation, and Maintenance Safety (Section 2.6)

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.

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EPL500150776-1

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:

• 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).

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 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 page 5


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 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.

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.

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EPL500150776-1

• Any modifications to PART 1, System Section, of the robot controller concurrent I/O program can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to PART 1, System Section. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY!

• 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).

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Notes

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YASKAWA

MOTOMANINSTRUCTITYPE: YR-EPL500-ATYPE: YR-EPL500-A

Upon receipt of the producfor future reference.

MOTOMAN INSTRUCTIOMOTOMAN-EPL500 INSNX100 INSTRUCTIONSNX100 OPERATOR’S MNX100 MAINTENACE M

The NX100 operator’s manualBe sure to use the appropriate

YASKAWA

-EPL500
ONS00 (STANDARD SPECIFICATION)10 (FOR INTEGRATED WRIST AXIS CABLE ROUTING PACKAGE)
t and prior to initial operation, read these instructions thoroughly, and retain

NSTRUCTIONS

ANUALANUAL

above corresponds to specific usage. manual.

MANUAL NO.

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• This instruction manual explains operating instructions and mainte-nance 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.

• 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 rep-resentative 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 prod-uct’s warranty.

MANDATORY

CAUTION

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Notes for Safe OperationRead 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”.

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

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 dam-age to equipment. It may also be used to alert against unsafe practices.

Always be sure to follow explicitly the items listed under this heading.

Must never be performed.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “CAUTION” and “WARNING”.

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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• Before operating the manipulator, check that servo power is turned OFF when the emergency stop buttons on the front door of the NX100 and programming pendant are pressed.When the servo power is turned off, the SERVO ON LED on the program-ming pendant is turned OFF.

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

• 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 opera-tion. 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 pro-gramming pendant.

WARNING

TURN

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Definition of Terms Used Often in This ManualThe 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:

• Perform the following inspection procedures prior to conducting manip-ulator 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 cabi-net 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.

Equipment Manual Designation

NX100 Controller NX100

NX100 Programming Pendant Programming Pendant

Cable between the manipulator and the controller Manipulator Cable

CAUTION

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Explanation of Warning LabelsThe 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 manipula-tor. Prior to operating the manipulator, confirm the contents.

MOTOMANTYPE

PAYLOAD

ORDER NO.

SERIAL NO.

MASS

DATE

YASKAWA ELECTRIC CORPORAION JAPAN

kgkg

WARNING

Do not enterrobot work area.

Warning Label A: Warning Label B:

WARNING

Moving partsmay causeinjury

Nameplate:

WARNING

Do not enterrobot work area.

Warning label A

Warning label BNameplate

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1 Product Confirmation1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 Transporting2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Shipping Bolts and Brackets . . . . . . . . . . . . . . . . . . . . . . . 2-3

3 Installation3.1 Installation of the Safeguarding . . . . . . . . . . . . . . . . . . . . 3-23.2 Mounting Procedures for Manipulator Base . . . . . . . . 3-2

3.2.1 Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4 Wiring4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.2 Manipulator Cable Connection . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-34.2.2 Connection to the NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

5 Basic Specifications5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . 5-25.3 Manipulator Base Dimensions . . . . . . . . . . . . . . . . . . . . . 5-25.4 Dimensions and T-Point Maximum Envelope . . . . . . 5-35.5 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.5.1 Components for Altering Operating Range . . . . . . . . . . . . . . . .5-65.5.2 Installation of the S-Axis Mechanical Stopper . . . . . . . . . . . . . .5-75.5.3 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 Flange6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

7 System Application7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . . 7-17.2 Internal User I/O Wiring Harness and Air Line . . . . . . 7-2

8 Electrical Equipment Specification8.1 Locations of Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . 8-18.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

9 Maintenance and Inspection9.1 Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-6

9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69.2.2 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 ".). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-99.2.3 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 ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-149.2.5 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 . . . . . . . . . . . . . . . . . . . . . .9-199.2.8 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21

Battery Pack Connection for Motors . . . . . . . . . . . . . . . . . .9-21

10 Recommended Spare Parts

11 Parts List11.1 S-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-111.2 L-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-311.3 U-Axis Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-611.4 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811.5 Balancer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

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1.1 Contents ConfirmationHW0483366

1 Product Confirmation

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)

• Confirm that the manipulator and the NX100 have the same order num-ber. Special care must be taken when more than one manipulator is to be installed.

If the numbers do not match, manipulators may not perform as expected and cause injury or damage.

CAUTION

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1.2 Order Number ConfirmationHW0483366

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.

Fig. 1 Location of Order Number Labels

THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER.

ORDER. No.

Label (Enlarged View)

N

PO

E

T

R G

YCM

S

E

E

SELECTSELECTSELECT

PLAYTEACHREMOTE

SERVOPOWER

S-X+S+

MAINMENU

R-x

R+x

ASSIST

COORD.MULTIDISPLAYSWITCH

X-

yy

64 5

AUXILIARY

AUXILIARY

TIMER1

WEAVINGCOMPLETE

VOLTAGE CURRENT2

WELDCOMPLETE

3RETRUCT

DELETE

BACK

INSERT

NEXT

L+L-

R-

LOCKINTER

WEAVINGSTART

7

+R+

B+B-

zT-

WELDSTART

8FEED9 TEST RUN SHIFT

zT+

EX-AXISSWITCH

ROBOT SWITCH

-

SHIFT

Y+Y-

0 ENTERCABCEK INTER. REF.POINT MODIFY

. -VOLTAGE CURRENT

SHORTCUTMENU

NX100200V 50Hz

kVA3PHASE220V 50/60Hz

NJ2484-1MADE IN JAPAN

DATE

SERIAL No.

ERCR-TYPE

POWER SUPPLY

******

ORDER NO.NJ1529

THE MANIPULATOR AND THE CONTROLLERSHOULD HAVE SAME ORDER NUMBER.

WARNINGDo not open the door

RESETO

FFTR

IPPED

ON

(a) NX100 (Front View) (b) Manipulator (Side View)

Check that the manipulatorand the NX100 have thesame order number.

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2.1 Transporting MethodHW0483366

2 Transporting

2.1 Transporting Method

2.1.1 Using a Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be used. The manipulator should be lifted using wire rope threaded through shipping bolts and brackets. Be sure the manipulator is fixed with the shipping bolts and brackets before transporting, and lift it in the posture as shown in " Fig. 2 Posture for Transportation ".

• Sling applications and crane or forklift operations must be performed by authorized personnel only.

Failure to observe this caution may result in injury or damage.

• Avoid excessive vibration or shock during transporting.

Failure to observe this caution may adversely affect the performance as the system con-sists of precision components.

• 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.

CAUTION

NOTE

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2.1 Transporting MethodHW0483366

Fig. 2 Posture for Transportation

45° 25°

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2.2 Shipping Bolts and BracketsHW0483366

2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at positions A, B, and C to mini-mize the external force during transportation. (" Fig. 3 Shipping Bolts and Brackets ").

• The shipping brackets are painted yellow.

Fig. 3 Shipping Bolts and Brackets

Position Bolt Type Pcs

A Hexagon socket head cap screw M20 4

B and C Hexagon socket head cap screw M10 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.

NOTE

A

C

B

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3 Installation

• 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.

• 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.

WARNING

CAUTION

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3.1 Installation of the SafeguardingHW0483366

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 2 Endurance Torque in Operation

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)

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 LocationHW0483366

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 ".

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

Hexagon socket head cap screw M20(8 screws) Spring washer

Manipulator base

Baseplate

Anchor bolt M24 or more

Flatness: 0.5 mm or less

Washer

50 mmor more

180 5401000

180

180

540

180

1000

Baseplate (reference)200 mm or more

Floor

28 dia. drilled hole(12 holes)

Units: mm

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HW0483366

4 Wiring

• 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.

• 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 dis-charged.

WARNING

CAUTION

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4.1 GroundingHW0483366

4.1 Grounding

Follow the local regulations for grounding line size. A line of 5.5 mm2 or more is recommended.

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 ".

• Never use this line sharing with other ground lines or grounding electrodes for other elec-tric 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 Stan-dards.

Do not cover the cables with heat insulating material, and avoid multiple cabling.

NOTE

A

Bolt M8 (for grounding)Installed before shipment.

Enlarged View A5.5 mm2 or more

NOTE

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4.2 Manipulator Cable ConnectionHW0483366

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.

Fig. 6 Manipulator Cable Connections

2BCX21

1BC

2BC

3BC

3BCX22

3BC

X22

2BCX21

Power Cable

Power Cable

NX100 side

Encoder Cable

Manipulator side

X11

1BC

X11 1BC

NX100 side

NX100 side

Manipulator side

Manipulator side

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4.2 Manipulator Cable ConnectionHW0483366

Fig. 7 (a) Details of the Manipulator Cable Connectors (Manipulator Side)

Fig. 7 (b) Manipulator Cable Connections to the NX100

Enlarged View AConnector Details (Manipulator Side)

Key positions

A

X22X21

X11

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5.1 Basic Specifications

5 Basic Sp

5.1 Basic Sp

*1 SI units are used in*2 Conformed to ISO9*3 Refer to " 6.1 Allow

Item

Configuratio

Degree of Free

Payload

Repetitive Positioning

Range of Motion

S-axi

L-axis

U-axis

T-axis

Maximum Speed

S

L

U

T

Allowable Inertia (G

Mass

AmbientConditions

Tem

Hu

Vibration

O

Power Capac

HW0483366

ecifications

ecifications

Table 3 Basic Specifications*1

Model YR-EPL500-A00 YR-EPL500-A10

n Vertically Articulated

dom 4

500 kg

Accuracy*2 ±0.5 mm

s (turning) ±180°

(lower arm) +90°, -45°

(upper arm) +15.5°, -120°

(wrist twist) ±360° ±180°

-axis 1.40 rad/s (80 °/s)

-axis 1.48 rad/s (85 °/s)

-axis 1.48 rad/s (85 °/s)

-axis 3.40 rad/s (195 °/s)

D2/4)*3 200 kg•m2

2300 kg

perature 0° to 45°C

midity 20 to 80% RH at constant temperature

acceleration Less than 4.9 m/s2 (0.5 G)

thers• Free from corrosive gas or liquid, or explosive gas• Free from exposure to water, oil, or dust• Free from excessive electrical noise (plasma)

ity 11 kVA

5-1

HW0483366

this table. However, gravitational unit is used in ( ).283able Wrist Load " for details on the permissible moment of inertia.

22/77

5.2 Part Names and Working AxesHW0483366

5.2 Part Names and Working Axes

Fig. 8 Part Names and Working Axes

5.3 Manipulator Base Dimensions

Fig. 9 Manipulator Base Dimensions

T-

T+

U+

U-

S-

S+

L+L-

Lower armL-arm

Base

Upper arm(U-arm)

Wrist

Wrist flange

Turning headS-head

40

540220±0.1220±0.1

300±

0.1

320±

0.1

360±0.1

320±0.1

360±

0.1

540

A

+0.021 020 dia. hole

(2 places)

12 dia. hole+0.018 0

710

350

879

519

640

640

Units: mm

View A

22 dia. hole(8 places)

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5.4 Dimensions and T-Point Maximum EnvelopeHW0483366

5.4 Dimensions and T-Point Maximum Envelope

Fig. 10 (a) Dimensions and T-Point Maximum Envelope (YR-EPL500-A00)

300

2776

0

0

120°

45°

90°

R1037

R742

820

2204

2624

2363

31591037

R11242162614

2501400270

2529

1250

880

6781356678

1600

1300

1600

1300

R3159

300

300

300

15.515.515.5°

Units: mm

T -Point

-point maximum envelopeT

P-point

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5.4 Dimensions and T-Point Maximum EnvelopeHW0483366

Fig. 10 (b) Dimensions and T-point Maximum Envelope (YR-EPL500-A10)

R11242162614

2501400270

1600

R742

1300

R3159

R1037

1300

1600

2204

6781356

678

0

90°

120°

2363

2624

820

31591037

45°

1250

2529

880

0

2776

300

300

300

Units: mm

T -Point

-point maximum envelopeT

P-point

15.5°

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5.5 Alterable Operating RangeHW0483366

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 Specifications

S-Axis OperatingRange

±180° (standard) ±165° ±150° ±135° ±120° ±105° ±90° ±75° ±60° ±45° ±30° ±15°

The stoppers must be installed with more than 60° of interval.NOTE

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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.

Fig. 11 Components of S-axis Stopper

No. Item Pcs

Pin (Drawing No. HW0407007-1) 1

Stopper (Drawing No. HW0307574-1) 2

Hexagon socket head cap screw M20(length: 70 mm) (tensile strength: 1200 N/mm2 or more)

3

Flat washer M20 3

AA

Stopper(HW0307574-1)

Pin(HW0407007-1)

Section A-A

Hexagon socket head cap screw M20(3 screws) (tensile strength: 1200 N/mm2

or more)Flat washer M20 (3 washers)

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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 N m (tensile strength: 1200 N/mm2 or more). The stopper is to be installed as shown in the Fig. 11 when the operat-ing 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 refer-ring 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 Instal-lation ", flip the stopper and retry installing the stopper.

Fig. 12 Properly-installed Image

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.

Improper Installation Proper Installation

Hexagon headscrews M20

Hexagon headscrews M20

NOTE

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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-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

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 mechan-ical stopper in the same setting: the operating range cannot be limited only with the soft-ware modification.

NOTE

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180

165

150

135

120

105

9075

6045

3015

0-1

5-3

0-4

5-6

0-7

5-9

0-1

05-1

20-1

35-1

50-1

65-1

80-1

80-1

65-1

50-1

35-1

20-1

05 -90

-75

-60

-45

-30

-15 0 15 30 45 60 75 90 105

120

135

150

165

180

�C

onfig

urab

le a

ngle

�D

isab

led

angl

e

Pos

itive

(+)

Dire

ctio

n A

ngle

s

Negative (-) Direction Angles

Thi

s ta

ble

can

be u

sed

whe

n in

stal

ling

two

mec

hani

cal s

topp

ers

on th

e S

-axi

s.T

he v

ertic

al a

xis

of th

e ta

ble

show

s th

e an

gles

in th

e po

sitiv

e di

rect

ion,

and

the

horiz

onta

l axi

s of

the

tabl

e sh

ows

the

angl

es in

the

nega

tive

dire

ctio

n.F

or e

xam

ple,

if o

ne s

topp

er is

to b

e in

stal

led

at a

180

deg

ree

angl

e in

the

posi

tive

dire

ctio

n, th

e ot

her

one

can

be in

stal

led

with

in th

e ra

nge

of +

/-10

5 de

gree

ang

les:

sin

ce m

ore

than

60

degr

ees

of in

terv

al is

req

uire

d to

mou

nt tw

o st

oppe

rs, t

he c

hart

indi

cate

s th

at th

e ot

her

angl

es a

re in

appr

opria

te fo

r th

e in

stal

latio

n.

Exc

eptio

n: T

he to

p le

ft ce

ll (1

80°,

-18

0°)

indi

cate

s th

e m

ount

abili

ty o

f one

sto

pper

.

Tabl

e 5

Con

figur

able

Ang

les

for S

-axi

s St

oppe

r Ins

talla

tion

5-9

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Installation of the S-axis Mechanical Stopper at Configurable Angles　

Fig. 13 (a) Stopper Installation at Configurable Angles

165°

Installation at +165°

The stopper is reversible.Either side of the stoppercan be used.

Hexagon head screw M20(3 screws) (length: 70 mm)with three washers M20




180°

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Fig. 13 (b) Stopper Installation at Configurable Angles

135°

150°





The stopper is irreversible.Only this side of the stopper canbe used at this angle.


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Fig. 13 (c) Stopper Installation at Configurable Angles

105°




The stopper is irreversible.Only this side of the stopper canbe used at this angle.

120°



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Fig. 13 (d) Stopper Installation at Configurable Angles

75°

90°

The stopper is reversible.Either side of the stopper can be used.






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Fig. 13 (e) Stopper Installation at Configurable Angles

45°

60°




The stopper is irreversible.Only this side of the stopper can be used at this angle.


Installation at + 45°

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Fig. 13 (f) Stopper Installation at Configurable Angles

15°

30°




The stopper is irreversible.Only this side of the stoppercan be used at this angle.



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Fig. 13 (g) Stopper Installation at Configurable Angles




5-16

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Fig. 13 (h) Stopper Installation at Configurable Angles

165°

180°

Installation at -180°






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Fig. 13 (i) Stopper Installation at Configurable Angles

150°

135°







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Fig. 13 (j) Stopper Installation at Configurable Angles

105°

120°





Hexagon head screw M20(3 screws) (length: 70 mm)with three washers M20 Installation at -105°

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Fig. 13 (k) Stopper Installation at Configurable Angles

90°

75°

Installation at -90°The stopper is reversible.Either side of the stoppercan be used.


Hexagon head screw M20(3 screws) (length: 70 mm)with three washers M20Installation at -75°


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Fig. 13 (l) Stopper Installation at Configurable Angles

60°

45°






Installation at - 45°

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Fig. 13 (m) Stopper Installation at Configurable Angles

15°30°







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6.1 Allowable Wrist LoadHW0483366

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist LoadThe 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.

2. When the inertia of the volume load on the flange is small, the eccentricity of load cen-ter 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.

Table 6 Allowable Total Inertia

Model Axis GD2/4 Inertia kg•m2

EPL500 T-axis 200

J=Ji+WL 2T

JJiWLT

: Total inertia (GD2/4) of the T-axis (kg m2): Inertia of the volume load on the flange (kg m2): Payload (kg): Eccentricity (mm)

Formula:

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6.1 Allowable Wrist LoadHW0483366

Fig. 14 Moment Arm Rating

m=500 kgm=450 kg

m=400 kg

Center of T-axis flange rotation

600 500 400 300 200 100 100 200 300 400 500 600

100

200

300

400

500

600

700

800

LB (mm)

LB

LT (mm)

LT

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6.2 Wrist FlangeHW0483366

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.

Fig. 15 Wrist Flange

Wash off anti-corrosive paint (Yellow) on the wrist flange surface with thinner or light oil before mounting the tools.

P.C.D. 2000.

0580

8

30°

Tapped hole M12(depth: 18) (6 holes)

10 dia. hole(depth: 8) (2 holes)

+0.015 0

Units: mm

100 dia.+0.035

0

0-0.046250 dia.

NOTE

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7.1 Peripheral Equipment MountsHW0483366

7 System Application

7.1 Peripheral Equipment Mounts

Peripheral equipment mounts or tapped holes are provided to the wrist unit for easier installa-tion 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.

Fig. 16 Location of Peripheral Equipment Mounts/Tapped Holes

Table 7 Constraint for Attaching

Application Note

Cable Processing andValve Load

Up to 500 kg including the mass of the peripheral equipment attached to the wrist unit.

A

Tapped hole M8(depth: 15) (4 holes)

110

40

Enlarged View A

Units: mm

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7.2 Internal User I/O Wiring Harness and Air LineHW0483366

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.)

Fig. 17 (a) Internal User I/O Wiring Harness and Air Lines for YR-EPL500-A00

A

B

D A

E B

F C

4BC

Exhaust port D:Tapped hole PT3/8 with a pipe plug

Exhaust port E:Tapped hole PT3/8 with a pipe plug

Exhaust port F:Tapped hole PT3/8 with a pipe plug

Exhaust port A:Tapped hole PT3/8 with a pipe plug

Exhaust port B:Tapped hole PT3/8 with a pipe plug

Exhaust port C:Tapped hole PT3/8 with a pipe plug

Connector for internal user I/O wiringharness on the wrist side: JL05-2A24-28SC (socket connector with a cap).Prepare pin connector: JL05-6A24-28P.View B

1BC

A

4BC

2BC

3BC

D FE

B CA

View A

Air inlet A:Tapped hole PT3/8 with a pipe plug

Air inlet B:Tapped hole PT3/8 with a pipe plug

Air inlet D:Tapped hole PT3/8 with a pipe plug

Air inlet C:Tapped hole PT3/8 with a pipe plug

Air inlet E:Tapped hole PT3/8 with a pipe plug

Air inlet F:Tapped hole PT3/8 with a pipe plug

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.

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7.2 Internal User I/O Wiring Harness and Air LineHW0483366

Fig. 17 (b) Internal User I/O Wiring Harness and Air Lines for YR-EPL500-A10

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.

A

B Exhaust port A:Tapped hole PT3/8 with a pipe plug

Exhaust port B:Tapped hole PT3/8 with a pipe plug

Exhaust port C:Tapped hole PT3/8 with a pipe plug

Exhaust port D:Tapped hole PT3/8 with a pipe plug

Connector for internal user I/Owiring harness on the wrist side:JL05-2A24-28SC(socket connector with a cap).Prepare pin connector:JL05-6A24-28P.

View BExhaust port E:Tapped hole PT3/8 with a pipe plug

Exhaust port F:Tapped hole PT3/8 with a pipe plug

Air inlet D:Tapped hole PT3/8 with a pipe plug

Air inlet A:Tapped hole PT3/8 with a pipe plug

Air inlet B:Tapped hole PT3/8 with a pipe plug

Air inlet C:Tapped hole PT3/8 with a pipe plug

Air inlet E:Tapped hole PT3/8 with a pipe plug

Air inlet F:Tapped hole PT3/8 with a pipe plug

Connector for internal user I/O wiring harnesson the base side: JL05-2A24-28PC(pin connector with a cap).Prepare socket connector: JL05-6A24-28S.

1BC

A

4BC

2BC

3BC

D FE

B CA

View A

12

431 25

76

43

2116

2318 19 2017

22

141311 1210

1211

9 10

15

1716

1413

15

202122

19

23

18

85 7 8 96

Pins used

Internal user I/O wiringharness:23 wires, size 0.5 mm2

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8.1 Locations of Limit SwitchesHW0483366

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 ".

Fig. 18 Locations of Limit Switches

1BC

A

4BC

2BC

3BC

D FE

B CA

LU-axis intereference limit switch(option)

L-axis overrun limit switch(option)

S-axis overrun limit switch(option)

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8.2 Internal ConnectionsHW0483366

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 ".

Fig. 19 (a) Locations of Connectors for YR-EPL500-A00

B

A

Connector for internal userI/O wiring harness

Enlarged View B


Enlarged View A

F C

E B

4BC

AD

1BC4BC

2BC

3BC

D FE

B CA

1BC

3BC2BC

8-2

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8.2 Internal ConnectionsHW0483366

Fig. 19 (b) Locations of Connectors for YR-EPL500-A10

Table 8 List of Connector Types

Name Type of Connector

Connector Base Connector for internal user I/O wiring harness

JL05-2A24-28PC(JL05-6A24-28S: Optional)

Wrist Base Connector for internal user I/O wiring harness

JL05-2A24-28SC(JL05-6A24-28P: Optional)

A

B

B

DF

A

C

4BC

E



Enlarged View B

Enlarged View A

1BC4BC

2BC

3BC

D FE

B CA

2BC

1BC

3BC

8-3

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8-4

HW0483366

HW0483366

Fig. 20 (a) Internal Connection Diagram

BASE

LA4

AL1

P

P

CN4-7PCN4-7 AL1

FG6

SPG+6SPG-6P

CN3-6CN3-7

CN3-8FG6

SPG+6SPG-6CN3-6

CN3-7

CN3-8

FG3

SPG+3SPG-3P

CN2-1CN2-2

CN2-3FG3

SPG+3SPG-3CN2-1

CN2-2

CN2-3

SPG+2SPG-2P

CN1-6CN1-7

FG2CN1-8

SPG+2SPG-2CN1-6

CN1-7

FG2CN1-8

FG1CN1-3FG1CN1-3

SPG+1SPG-1CN1-2

CN1-1PSPG-1CN1-2

SPG+1CN1-1

PG T-AXISBAT

OBT

0V

BAT

+5V

FG6

OBT-6-2

1CN-1

-7-9-4-5

No.1CN

P

P

P

T-1

-4-3-2

No,19CNBAT6

PG5V6PG0V6

OBAT6

DATA+6DATA-6

U-AXISPGBAT-6

-28CN-1No.8CN

FG3

OBT

0V+5V

BAT

-7-9-4-5 OBT

P

P

P

U-1No,18CN

BAT3

-3-4

PG5V3PG0V3

OBAT3-2

DATA-3DATA+3

PG L-AXIS+5VOBTBAT

0V

-2

-4-5-6

-9

7CN-1No.7CN

P

P

PL-1

-4-3-2

PG0V2

BAT2

PG5V2OBAT2

No,17CN

OBTBAT

-7 FG2

DATA+2DATA-2

S-AXIS

DATA+1DATA-1-2

FG10V+5VOBT

OBTBAT

-4-5

-9-7

BAT-6PG

P

P

P

No.6CN6CN-1

S

OBAT1PG5V1PG0V1

BAT1-2-3-4

-1No,16CN

XNo.20CN1BC(10PX4)

-4-2

-3-1 +24V

0V

+24V0V

0V

0V

+24V

+24VCN1-9

CN1-5CN1-4

CN1-10P

P

CN1-10CN1-9 0V

+24V

+24V0VCN1-4

CN1-5 PG0V6PG5V6

9

1110

1615141312

1

42

3

PG0V2

PG0V3PG5V2

3

54

78

PG5V36

5

76

8

0BAT2BAT10BAT1

0BAT3BAT3

BAT2

1819

17

2122

2425

23

20

0BAT6BAT6

PG5V1PG0V1

2829

27

3031

2132

26

23

1

5

4

BAT110BAT12BAT12

0BAT21

0BAT11

87

1

432

BAT220BAT22BAT216

P BAT0BT

0BT

0BT

P BAT

K

K R

R

P0BTBATK R

PK R BAT

NX100

A

A

LA3LA4

LA4LA4

ALA3LA4

LA4

A

LA4LA3

LA4LA3

LA3

LC1LC2

LA4

LB1 LB1

LB1LB1

LA1LB1

LB1LA1

LB1LC3

LC2LC1

LA4LA3

LC1LC2

LA3LA4

LC2

LA4LA3

LC1LC2

BC1BC2

LB1 LB1

LB1

LA1LC3

LB1

LB1LC3

LB1LB1

LA3LA4

LC1

LC3

LB1

LB1

LA1

E

No.12CN

2

4

65-

-

3--

SS1B1

12CN-1- SS1

SS2

LA1

BC2LB1

BC1

B1

CN4-8CN4-3

E

CN4-1CN4-6

CN4-2

AL2BC2

+24LB1

SS2

E E E

LA1LB1

LB1LA1

LA1LB1

CN4-3CN4-8

CN4-2

CN4-6CN4-1

AL2BC2

E

+24V

SS2

LB1

FANS

AC2

AL2 AC1

AL1

S-AXIS LIMIT SWITCH SPECIFICATION

L-AXIS LIMIT SWITCH SPECIFICATION (OPTIONAL)

LU-AXIS LIMIT SWITCH SPECIFICATION (OPTIONAL)

S-AXIS OVERRUN LIMIT SWITCH



L-AXIS OVERRUN LIMIT SWITCH

L-AXIS OVERRUN LIMIT SWITCHLU-AXIS INTERFERENCE LIMIT SWITCH

Note:For the limit switch specification, the connection of the section A is changed as follows:

ENCODER POWER BOARD

FOR LAMP (OPTIONAL)

FOR S-AXIS FAN (OPTIONAL)

53/77


8-5

HW0483366

HW0483366

Fig. 20 (b) Internal Connection Diagram

WRIST

YB-E-F

-D-C

BA1BB1

ME1MW1

BA3BB3-B

No.15CN15CN-A

BB2BA2

-B14CN-ANo.14CN

PE

E

S-AXISSM

L-AXIS

YB

SM

9CN-ANo.9CN

-BMU1MV1

10CN-ANo.10CN

-B

-C-D

MV2

MW2ME2

MU2

U-AXIS

YB

SM

T-AXISSM

YB

MU6MV6

ME6

BB6BA6

MW6

11CN-ANo.11CN

-B

-D-C

MV3

ME3MW3

MU3

No.2CN2CN-A

-F

-B

-E-D-C

CN2-6CN2-5CN2-4CN2-3

CN1-6

CN1-8CN1-7

CN2-1CN2-2

CN1-4CN1-3

CN1-5

CN1-2CN1-1

2BC(8X5)

MW1

ME1ME1

MW1

MV1

MW1

MV1MV1

MW1

MU1MU1

MV1MU1

MU1

E

CN3-3

CN4-5

CN 6-2CN 6-1

CN4-7CN4-8

CN4-6

CN4-4

CN4-1CN4-2

CN3-8

CN4-3

CN3-7CN3-6

CN3-4CN3-5

CN3-2

CN2-8

CN3-1

MU2

BA2BA1

MW2

ME2ME2

ME2ME2

MW2

MV2

MW2MW2

MU2

MV2MV2

MV2

MU2

ME1

MU2

ME1CN2-7

CN3-2

CN3-4CN3-3

CN 1-4

CN 2-6CN3-1

CN 2- 1CN 2-2

CN 2- 3CN 2-4CN 2- 5

CN 1-5CN 1-6

CN 6-6

CN 1-3CN 1-2CN 1- 1

3BC(6X5)

CN 6-4CN 6-5

ME3

ME3ME3

BB6

ME3MW3

MV3MV3

MW3MW3MW3

MU3

MV3MU3

MV3

MU3MU3

E

BA6BB1

AC1AC2

CN5-3CN5-4

4BC (24-28)

CN 5-1CN 5-2

CN 4-4CN 4-5CN 4-6

CN 4- 1CN 4-2CN 4-3

MU6

ME6ME6

MU6MV6MV6MW6MW6

BA3CN 6-3

4BC-1

11

2019

1415

181716

12

13

910

34

87

65

21 E

-10

-19-20

-14-15-16-17-18

-12

-13

-11

-6

-9-8-7

-5-4-3-2

2322

-23

-21-22

21

1112

11

1920

14

161718

15

13

12

10

789

6

2

543

1

-10

-19-20

-14-15-16-17-18

-12

-13

-11

4BC-1

-6

-7-8-9

-2-3-4-5

E

2322

-23

-21-22

21

CN1-1

CN1-8

CN2-5CN2-4CN2-3CN2-2CN2-1

CN1-6CN1-7

CN1-5CN1-4CN1-3CN1-2

ME1ME1

MW1

MV1

MW1

MW1MW1

MV1

MU1

MV1

MU1MV1

MU1MU1

EX21(8X5)

CN4-6

CN4-8CN4-7

CN4-4CN4-5

CN4-3CN4-2CN4-1

CN3-4

CN3-8

CN3-5CN3-6CN3-7

CN3-2CN3-3

CN3-1

CN2-8CN2-7

MU2

ME2

BA1BA2

ME2ME2

ME2

MW2

MW2

MW2MW2

MV2MV2

MV2MV2

MU2

MU2MU2

ME1

CN 6-1CN 6-2

CN2-6 ME1

ME3ME3ME3

MU3

MW3ME3

MW3MW3MW3

MV3MV3

MV3MV3

MU3MU3

MU3

BB6BB1BA6

CN 6-5CN 6-6

CN 3-2CN 3-3CN 3-4

CN 2-5

CN 2-3

CN 3-1CN 2-6

CN 2-4

CN 1-4

CN 2-1CN 2-2

CN 1-6CN 1-5

CN 1-2CN 1-3

CN 1-1

X22(6X5)

CN 6-4

CN 5-4CN 5-3 AC2

AC1

ME6ME6

MW6MW6MV6

MU6

MV6MU6

CN 4-3

CN 5-1CN 5-2

CN 4-6CN 4-5CN 4-4

CN 4-1CN 4-2

CN 6-3 BA3

PE

4BC (24-28)

POWER CABLE INTERNAL WIRES IN S-AXIS INTERNAL WIRES IN LU-AXES INTERNAL WIRES IN U-ARMFOR SPARE CABLE

54/77

9.1 Inspection ScheduleHW0483366

9 Maintenance and Inspection

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 inter-vals 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 person-nel. Only the specified personnel are to do the inspection work.

• 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.

• 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 manipu-lator’s arm.

• The battery pack must be connected before removing encoder connec-tor when maintenance and inspection.

Failure to observe this caution may result in the loss of home position data.

WARNING

CAUTION

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• 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 nor-

mal 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 indi-cated 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

Items*4

Schedule

Method Operation

Inspection Charge

Daily1000

HCycle

5000H

Cycle

9000H

Cycle

18000H

36000H

Specified Person Licensee Service

Company

Alignment mark Visual

Check alignment mark accordance and damage at the home position.

External lead VisualCheck for damage and deterioration of leads.

Working area and whole exterior of manipulator

Visual

Clean the work area if dust or spat-ter is present. Check for damage and outside cracks.

LU-axis motors Visual

Check for grease leakage.*5

Baseplate mounting bolts

Spanner,Wrench

Tighten loose bolts. Replace if neces-sary.

Connector base Manual

Check for loose connectors and tighten if necessary.

LU-axis con-nectors Manual

Check for loose connectors and tighten if necessary.

Connectors in S-head Manual

Check for loose connectors.

L-axis bal-ancer

Grease Gun,Visual

Supply grease. Check for loose screw nuts and shafts, and tighten if necessary.

NOTE

9-2

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Wire harness in manipula-tor(Lead wires for SLU-axes)(Lead wire for T-axis)

Multimeter, Visual

Check for conduc-tion between the main connector of base and intermedi-ate connector with manually shaking the wire. Check for wear of protective spring*1

Replace*2

Links/Con-nections

Visual, Manual

Move the L- and U-axes back and forth, up and down to check any back-lash.Replenish grease*3See Par.9.2.7

Battery pack in manipula-tor

Screw-driver,

Wrench

Replace the bat-tery pack when the battery alarm occurs or the manipulator drove for 36000H.See Par.9.2.1

S-axis speed reducer

Grease Gun

Check for malfunc-tion. (Replace if necessary.)Replenish grease*3

(5000H cycle).See Par. 9.2.2Exchange grease*3(9000H cycle).See Par. 9.2.2

LU-axis speed reduc-ers

Grease Gun


(5000H cycle).See Par. 9.2.3 and 9.2.4Exchange grease*3 (9000H cycle). See Par. 9.2.3 and 9.2.4

T-axis speed reducer

Grease Gun


(5000H cycle).See Par. 9.2.5Exchange grease*3 (9000H cycle). See Par. 9.2.5

Bearing Grease Gun

Replenish grease*3, *6

Exchange grease*3

Overhaul

Table 9 Inspection Items

Items*4

Schedule

Method Operation

Inspection Charge

Daily1000

HCycle

5000H

Cycle

9000H

Cycle

18000H

36000H

Specified Person Licensee Service

Company

11

12

13

14

15

16

17

9-3

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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 Wire harness in manipulator to be replaced at 18000 H inspection.*3 For the grease, refer to " Table 10 Inspection Parts and Grease Used ".*4 Inspection numbers correspond to the numbers in " Fig. 21 Inspection Parts and Inspection Numbers ".*5 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.*6 Replenish grease to the U-axis cross-roller bearing at 5000 H or after a year, whichever comes first.

Inspection numbers correspond to the numbers in " Table 9 Inspection Items ".

Table 10 Inspection Parts and Grease Used

No. 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

13 14 15

9 16

9-4

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1BC

A

4BC

2BC

3BC

L-ax

is1

DF

E BC

A

5

14

7

4

2

7

4

214

29

1T

-axi

s

1116

1116

U-a

xis

1

1116

1116

111611

16

1116

1611

28

A

13121

S-a

xis

6

The

figu

re b

elow

sho

ws

that

the

man

ipul

ator

is in

the

hom

e po

sitio

n.

Vie

w A

15

The

figu

re in

the

circ

le s

how

s th

e de

taile

d vi

ew fo

r th

e

Fig.

21

Insp

ectio

n P

arts

and

Insp

ectio

n N

umbe

rs

9-5

HW0483366 59/77

9.2 Notes on Maintenance ProceduresHW0483366

9.2 Notes on Maintenance Procedures

9.2.1 Battery Pack Replacement

The battery packs are attached in the two positions indicated in " Fig. 22 (a) Battery Location (Back View) " and " Fig. 22 (b) Battery Location (Top View) ".

If a battery alarm occurs in the NX100, replace the battery in accordance with the following procedure:

Fig. 22 (a) Battery Location (Back View)

Fig. 22 (b) Battery Location (Top View)

1BC

A

4BC

2BC

3BC

D FE

B CA

Base

Connector base

Plate mounting screw M4

Plate

Battery pack

Board

9-6

HW0483366 60/77


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.

6. Mount the new battery pack on the battery holder.7. Reinstall the plate.

Remove the old battery pack after connecting the new one so that the encoder absolute data does not disappear.

Make sure not to pinch the cable when putting the plate back into place.

New battery pack(HW0470360-A)

Battery pack before replacementSee the step 5.

See the step 4.

Connector

Board

NOTE

NOTE

9-7

HW0483366 61/77


9.2.2 Grease Replenishment/Exchange for S-axis Speed Reducer and Gear

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.

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.)

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.)

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.

Grease type: VIGO Grease RE No.0Amount of grease: Approx. 2100 cc

(4200 cc for the 1st supply)

1BC

2BC

3BC

D FE

B CA 4BC

Grease exhaust port(Hexagon socket head plug)

S-axis speed reducer

Grease inlet(Hexagon socket head plug)

NOTE

9-8

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Grease Exchange (Refer to " Fig. 24 S-axis Speed Reducer and Gear Diagram ".)



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.5. Wipe the discharged grease with a cloth and reinstall the plug on the grease exhaust





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.

NOTE

NOTE

9-9

HW0483366 63/77


9.2.3 Grease Replenishment/Exchange for L-axis Speed Reducer

Fig. 25 L-axis Speed Reducer Diagram

Grease Replenishment (Refer to " Fig. 25 L-axis Speed Reducer Diagram ".)



3. Move the L-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) for the plug PT3/8. (Apply Three Bond 1206C to the thread part of the plug.)





Grease exhaust port(Hexagon socket head plug)L-axis speed reducer


NOTE

9-10

HW0483366 64/77


• If the L-arm is tilted over 80 degrees, the link-C interferes with the plug for air exhaust.

Do not tilt the L-arm over 80 degrees when verifying the manipulator operation.

CAUTION

80°90°

170° Link-C

Plug for air exhaust

Link-C

Plug for air exhaust

Link-C

9-11

HW0483366 65/77


Grease Exchange (Refer to " Fig. 25 L-axis Speed Reducer Dia-gram ".)




4. Move the L-axis for a few minutes to discharge excess grease.5. 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.





NOTE

NOTE

9-12

HW0483366 66/77


9.2.4 Grease Replenishment/Exchange for U-axis Speed Reducer

Fig. 26 U-axis Speed Reducer Diagram

Grease Replenishment (Refer to " Fig. 26 U-axis Speed Reducer Diagram ".)



3. Move the U-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








U-axis speed reducer


NOTE

NOTE

9-13

HW0483366 67/77


Grease Exchange (Refer to " Fig. 26 U-axis Speed Reducer Dia-gram ".)




4. Move the U-axis for a few minutes to discharge excess grease.5. Wipe the discharged grease with a cloth and reinstall the plug on the grease exhaust






NOTE

NOTE

9-14

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9-15

HW0483366

HW0483366

9.2.5 Grease Replenishment/Exchange for T-axis Speed Reducer

Fig. 27 T-axis Speed Reducer Diagram







68A/77


9-16

HW0483366

HW0483366

Grease Replenishment (Refer to " Fig. 27 T-axis Speed Reducer Diagram ".)



3. Move the T-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



Grease Exchange (Refer to " Fig. 27 T-axis Speed Reducer Dia-gram ".)




4. Move the T-axis for a few minutes to discharge excess grease.5. Wipe the discharged grease with a cloth and reinstall the plug on the grease exhaust







NOTE

NOTE

NOTE

69/77


9-17

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HW0483366




NOTE

70/77


9-18

HW0483366

HW0483366

9.2.6 Grease Replenishment for U-axis Cross Roller Bearing

Fig. 28 U-axis Cross Roller Bearing Diagram

1. Remove the hexagon socket head plug from the exhaust port. (Refer to " Fig. 28 U-axis Cross Roller Bearing Diagram ".)

2. Remove the hexagon socket head plug from the grease inlet 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.)

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.)


Grease type: Alvania EP Grease 2Amount of grease: Approx. 60 cc

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.

U-axis cross roller bearing


Exhaust port(Hexagon socket head plug)

NOTE

71/77


9-19

HW0483366

HW0483366

9.2.7 Grease Replenishment for Links

1BC

A

4BC

2BC

3BC

BDF

CE

A

DF

E BC

A

1

6

5

10

6 A

6

4

A

5

26

7

9

9

1010

10

33

9

1

7

79

8

8

8

2

2

511

11

1

11

4

Link

Gre

ase

inle

t with

a

plug

PT1

/8

Link

Exha

ust p

ort w

ith

a pl

ug P

T1/8

Link

Link

Exha

ust p

ort w

ith

a pl

ug P

T1/8

Link

Exha

ust p

ort w

ith a

plu

g PT

1/8

Link

Exha

ust p

ort w

ith

a pl

ug P

T1/8

Link

Gre

ase

inle

t with

a

plug

PT1

/84

Link

Exha

ust p

ort w

ith a

plu

g PT

1/8

3Li

nkEx

haus

t por

t with

a p

lug

PT1/

8

10Li

nkEx

haus

t por

t with

a p

lug

PT1/

8

10Li

nkG

reas

e in

let w

ith a

plu

g PT

1/8

Link Link

Link

Gre

ase

inle

t with

a

plug

PT1

/8

Link

Gre

ase

inle

t with

a p

lug

PT1/

8

Link

Gre

ase

inle

t with

a p

lug

PT1/

8

Link

Exha

ust p

ort w

ith a

plu

g PT

1/8

Link

Exha

ust p

ort w

ith a

plu

g PT

1/8

Link

Exha

ust p

ort w

ith

a pl

ug P

T1/8

Link

Exha

ust p

ort w

ith

a pl

ug P

T1/8

Link

Link

Link

Link

Gre

ase

inle

t with

a

plug

PT1

/8Li

nkG

reas

e in

let w

ith a

plu

g PT

1/8

Link

Gre

ase

inle

t with

a p

lug

PT1/

8

Link

Exha

ust p

ort w

ith

a pl

ug P

T1/8

Link

Exha

ust p

ort w

ith

a pl

ug P

T1/8

Link

Exha

ust p

ort w

ith a

plu

g PT

1/8

Link

Gre

ase

inle

t with

a p

lug

PT1/

8

Link

Gre

ase

inle

t with

a

plug

PT1

/8Li

nk Link

Link

Link

Link

Link

Sect

ion

A-A

3Li

nkG

reas

e in

let w

ith

a pl

ug P

T1/8

Not

e: T

he p

lugs

indi

cate

d as

"plu

g PT

1/8"

are

hex

agon

soc

ket h

ead

plug

s PT

1/8.

Link

Exha

ust p

ort w

ith a

plug P

T1/8

Fig.

29

Gre

ase

Rep

leni

shm

ent f

or L

inks

72/77


9-20

HW0483366

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.)

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 1206C to the thread part of the plug.)

Grease type Alvania EP Grease 2

Amount of grease

Links 6 cc (12 cc for the 1st supply)




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.

1 2 3 6

4 5 9

7 8

10 11

NOTE

73/77


9-21

HW0483366

HW0483366

9.2.8 Notes for Maintenance

Battery Pack Connection for MotorsA 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 con-nector 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.

Fig. 30 Battery Pack Connection for SLUT-axis Motors

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 disappear-ance of the encoder absolute data.For the battery pack connection, refer to " Fig. 30 Battery Pack Connection for SLUT-axis Motors ".

Do not remove the battery pack in the connector base.

NOTE

NOTE

b

aab0BT

BAT BAT*0BT*

Motor

Motor power connector

Connector for motor encoder

Battery pack: HW9470932-A

Battery backup connector

a: Crimped contact-pin (pin)b: Crimped contact-pin (socket)

74/77

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

To replace parts in Rank B or Rank C, contact your Yaskawa representative.

Table 11 Spare Parts for the Motoman-EPL500

Rank PartsNo. Name Type Manufacturer Qty

QtyperUnit

Remarks

A 1 Grease VIGO Grease RE No.0

YaskawaElectricCorporation

16kg - For speed reduc-ers

A 2 Grease Alvania EPGrease 2

Showa Shell Sekiyu K.K. 16kg - For links and

bearings

A 3 Battery Pack HW0470360-AYaskawaElectricCorporation

1 1

A 4 Battery Pack HW9470932-AYaskawaElectricCorporation

1 -

A 5 Liquid Gasket Three Bond 1206C ThreeBond Co., Ltd. 1 1

B 6 S-axisSpeed Reducer HW0281280-A


1 1

B 7 Gear Unit HW0172031-BYaskawaElectricCorporation

1 1

B 8 Speed Reducers for LU-axes HW9381442-B


1 2

B 9 Input Gears for LU-axes HW9482358-A


1 2

B 10 T-axisSpeed Reducer HW9380961-C


1 1

NOTE

10-1

HW0483366 75/77

HW0483366

B 11 T-axis Input

B 12 U-axis CrossBearing

B 13 AC ServomoS-axis

B 14 AC ServomoLU-axes

B 15 AC ServomoT-axis

B 16 Wire HarnesManipulator

C 17 Wire HarnesManipulator

C 18 Wire HarnesManipulator

Rank PartsNo. Nam

Gear HW0300074-1YaskawaElectricCorporation

1 1

Roller HW9381003-1YaskawaElectricCorporation

1 1

tor for HW0383523-ASGMRS-44A2A-YR2*


1 1

tors for HW0383524-ASGMRS-55A2A-YR2*


1 2

tor for HW0382156-ASGMRS-13A2A-YR1*


1 1

s in HW0172434-AYaskawaElectricCorporation

1 1


1 1


1 1 Only for YR-EPL500-A10

Table 11 Spare Parts for the Motoman-EPL500

e Type Manufacturer QtyQtyperUnit

Remarks

10-2

HW0483366 76/77

11.1 S-Axis Unit

11-1

HW0483366

HW0483366

11 Parts List

11.1 S-Axis Unit

1005

1006

1026

1027

1031

1001

1002

1013

1015

1008

1009

10101007

1017

1018

10191020

10321033

1036

1014

1011

1012

1003

1004

1030

1029

1022

10621063

1025

1028

10611041104010391061

1038

103910411042

1049

1046

1045

1049

105210511050

1060

1053

1056

1055

1054

1059

10581057

10481047

10441043

10441043

1037

1035

1034

1021

1023

1024

1016

76A/77

11.1 S-Axis Unit

11-2

HW0483366

HW0483366

No. DWG No. Name Pcs

1001 SGMRS-44A2A-YR2* Motor 11002 HW0281280-A Speed reducer 11003 M8X100 Socket screw 101004 2H-8 Spring washer 101005 M16X70 Socket screw 121006 2H-16 Spring washer 121007 TC8511013 Oil seal 11008 HW0101153-1 S-head 11009 HW0101142-1 Base 11010 G415 O-ring 11011 M20X160 Socket screw 91012 2H-20 Spring washer 91013 HW0308465-1 Shaft 11014 M6X20 GT-SA Bolt 41015 HW0308464-1 Flange 11016 G135 O-ring 11017 HW0407533-1 Fry wheel 11018 HW0307565-3 Shaft 11019 M8X115 Socket screw 11020 2H-8 Spring washer 11021 HW0407007-1 Pin 11022 HW0403903-1 Plate 11023 M20X70(12.9) Bolt 31024 M20 Washer 31025 HW0402102-1 Stopper 11026 M8X40

(DACROTIZED coating)Socket screw 1

1027 2H-8 (DACROTIZED coating)

Spring washer 1

1028 HW9404486-1 Shaft 11029 M5X16 GT-SA Bolt 111030 S180 O-ring 11031 MSTM6-20 Pin 21032 M12X40



Spring washer 4

1034 HW0307574-1 Stopper 11035 HW0402627-2 Washer 11036 HW0101152-2 Gear case 11037 PT3/8 Plug 11038 HW9381477-B Gear 11039 6207ZZ Bearing 21040 CIMR35-1 Shim 21041 ISTW-35 Retaining ring 21042 HW9405051-1 Cover 11043 M5X16 Socket screw 141044 2H-5 Washer 141045 HW9405047-1 Shaft 11046 HW0307563-1 Gear 11047 M8X25 Socket screw 81048 2H-8 Washer 81049 HR33206J Bearing 21050 HW9405048-1 Housing 11051 G85 O-ring 11052 HW9405304-* Shim *1053 HW0307562-1 Gear 11054 6828ZZ Bearing 11055 WR140 Circlip 11056 AR175 Circlip 11057 M6X20 Socket screw 101058 2H-6 Washer 10


1059 M12X20 Socket screw 11060 HW0307564-1 Gear 11061 IRTW-72 Retaining ring 21062 M6X16 Socket screw 11063 2H-6 Spring washer 1

76B/77

11.2 L-Axis UnitHW0483366

11.2 L-Axis Unit

2013

1008

2008

2010

20192001

2011

2064

20572058

2068

2006

2012

2020

2014

20152016

2009

20692064

20592080

20722080

2021

2004

2075

2002

2013

2018

2018

20172080

2014

2015

2079

2020

2007

2021

2001

2005

20572058

20592080

2071

2062

2080

2064

2019

2080

2054

2062

2062

2062

206220542062

2078

2078

2062

2052

2070

2077

2077

2016

2079

20552056

20532080

20532080

2062

11-3

HW0483366 76C/77

11.2 L-Axis UnitHW0483366

2048

2027

2027

2048

1008

2038

2038

2076

2076

2037

2037

2028

2028

2024

2041

2029

2024

2002

2030

20742056

20672080

2022

2039

2050

20262025

2023

2073

2051

2044

2049

2051

20742056

2062

2062

2062

2036

2045

2046

2047

2031

2033

2003

2008

20452046

20612080 2034 2065

2032

2060

2060

20632064

2062

5005

2040

20422043

2062

2035

2066

2056

2052

2056

2052

11-4

HW0483366 76D/77

11.2 L-Axis Unit

11-5

HW0483366

HW0483366


2001 SGMRS-55A2A-YR2* Motor 22002 HW0101154-1 L-arm 12003 HW0101146-1 Link A 12004 HW9381003-1 Cross roller

bearing1

2005 HW9301454-1 B-cover 12006 HW0200394-1 M-base 12007 HW9200895-1 M-base 12008 HW0101145-2 Link-B 12009 HW9482506-G Bolt 12010 HW0300930-1 Shaft 12011 HW0303231-1 Spacer 12012 HW0403590-1 Fly wheel 12013 HW9381442-B Speed reducer 22014 HW9482358-A Gear 22015 HW9481343-A Shaft 22016 HW9482339-A Shaft 22017 HW9482506-A Bolt 12018 ISTW-12 Retaining ring 22019 G300 O-ring 22020 Y507212.5 Oil seal 22021 V-220L V-Ring 22022 HW0307641-1 Shaft 12023 HW0406922-1 B-cover 12024 HW0406923-1 Pup washer 22025 HW0406926-1 Collar 12026 HW0406925-1 Collar 12027 HW9405055-1 Shaft 22028 HW9405699-1 B-cover 22029 HW9302054-1 Shaft 12030 HW0308094-1 Link-C 12031 HW0400016-1 Shaft 12032 HW0400008-1 B-cover 12033 HW0406931-1 B-cover 12034 HW0400015-1 Shaft 12035 HW0400012-* Shim *2036 HW0200692-1 Counter wait 12037 S105 O-ring 22038 HR32916J Bearing 22039 AG3217A4 Oil seal 12040 VB60789 Oil seal 12041 WR60 Circlip 12042 VB75956 Oil seal 12043 AR-85 Circlip 12044 NA6912 Needle bearing 12045 AG3512E1 Oil seal 22046 HR32011XJ Bearing 22047 G85 O-ring 12048 KE901107 Oil seal 22049 G75 O-ring 12050 HW9481646-A Bearing 12051 M8X20 Socket screw 82052 2H-8 Spring washer 202053 M12X65 Socket screw 42054 PT3/8

(DACROTIZED coating)Plug 2

2055 M10X30 Socket screw 62056 2H-10 Spring washer 262057 M12X35


2058 2H-12(DACROTIZED coating)

Spring washer 8


2059 M12X80 Socket screw 442060 M6X15 GT-SA Bolt 82061 M12X70 Socket screw 12062 PT1/8


2063 M16X50 Socket screw 62064 2H-16 Spring washer 362065 M6X6 Socket screw 12066 2H-6 Spring washer 12067 M12X50 Socket screw 122068 M16X80 Socket screw 62069 M16X65 Socket screw 182070 M16X75 Socket screw 62071 M12X60 Socket screw 212072 M12X30 Socket screw 212073 M6X20 GT-SA Bolt 32074 M10X25 Socket screw 22075 M8X20 Socket screw 122076 M10X50 Socket screw 182077 EZ0094-A0 Air-breather 22078 TSH6-01M Union 22079 UB-0640-0.1C Tube 22080 2H-12 Spring washer 1055005 HW0100477-1 Case 11008 HW0101153-1 S-head 1

76E/77

11.3 U-Axis Unit

11-6

HW0483366

HW0483366

11.3 U-Axis Unit

3001

3005

30053032

3033

30363036

3006

3007

30083009

3010

30343035

3031

3037

3043

3021

3041

3023

30243025

3026

3011

30123013

30023003

3004

3028

30013004

30123013

3015

3015

3015

3029 3030

3030

30293030

3016

3020

30173018

30193016

3020

3042

3044

30143014

3015 3029

302930303030

3039

3022

30383035

3027

2002

30183017

3019

2030

30553027

30293030

3030

3040

30303031

30303037

3021

3028

3028

3028

3028

3028

30283028

3028

3028

3028

3028

3028

2003

76F/77

11.3 U-Axis Unit

11-7

HW0483366

HW0483366


3001 HW9403571-2 Shaft 23002 HW9301405-1 B-cover 13003 HW9403656-* Shim *3004 AG4059E0 Oil seal 23005 HR32016XJ Bearing 23006 HW0400016-1 Shaft 13007 HW0400008-1 B-cover 13008 HW0406931-1 B-cover 13009 G85 O-ring 13010 HW0400015-1 Shaft 13011 HW0400012-* Shim *3012 AG3512E1 Oil seal 23013 HR32011XJ Bearing 23014 HW0406922-1 B-cover 23015 HW0406923-1 Pup washer 43016 HW0307641-1 Shaft 23017 HW0406925-1 Collar 23018 HW0406926-1 Collar 23019 HW9481646-A Bearing 23020 AG3217A4 Oil seal 23021 G75 O-ring 23022 MSTH6-10 Pin 23023 HW0200691-1 Link-D 13024 HW0308095-1 Link-E 13025 HW0101147-1 Casing 13026 HW0101155-1 U-arm 13027 M6X20 GT-SA Bolt 63028 PT1/8


3029 M10X25 Socket screw 53030 2H-10 Spring washer 213031 M10X30 Socket screw 83032 M6X6 Socket screw 13033 2H-6 Spring washer 13034 M12X70 Socket screw 13035 2H-12 Spring washer 113036 M6X15 GT-SA Bolt 83037 M10X50 Socket screw 83038 M12X45 Socket screw 103039 HW0406822-1 B-cover 13040 HW0406759-1 Pup washer 13041 G95 O-ring 13042 HW0483232-A Bearing 13043 HW0306239-1 Shaft 13044 VC70X92X7 Oil seal 13055 M6X20 GT-SA Bolt 6*1

M6X20 GT-SA Bolt 3*2

2002 HW0101154-1 L-arm 12003 HW0101146-1 Link-A 12030 HW0308094-1 Link-C 1

*1 Component partsS5Q569-1 and after

*2 Component parts before S5Q569-1

76G/77

11.4 Wrist Unit

11-8

HW0483366

HW0483366

11.4 Wrist Unit

4032

4030

4039

4001

4003

4004

40054006

4007

4008

40094010

4011

4013

4014

4019

4021

4022

4023

4024

4025

4026

4028

4036

4037

4040

4041

4041

4042

4042

4039

4033

4043

4045

4004

4020

4002

4033

4032

4027

4038

4032

4034

4035

4044

4016

4016

4015

4015

4017

4017

40404032

4032

4012

4018

3026

4044

4044

4044

4044

40484032

4029

4031

4032

4032

3024

76H/77

11.4 Wrist Unit

11-9

HW0483366

HW0483366


4001 SGMRS-13A2A-YR1* Motor 14002 HW9380961-C Speed reducer 14003 HW0101156-1 Wrist base 14004 HW0406923-1 Pup washer 24005 G75 O-ring 14006 HW0406922-1 B-cover 14007 HW9481646-A Bearing 14008 HW0307641-1 Shaft 14009 HW0406925-1 Collar 14010 HW0406926-1 Collar 14011 AG3217A4 Oil seal 14012 S90 O-ring 14013 HW9404246-* Shim *4014 HW0405915-1 B-cover 14015 AG3584A0 Oil seal 24016 HW9404245-1 Shaft 24017 HR32012XJ Bearing 24018 HW9404383-1 B-cover 14019 HW0407406-1 Pipe 14020 HW0308088-1 M-base 14021 ARP568-263 O-ring 14022 HW0300074-1 Gear 14023 HW0300073-1 Gear 14024 HW9481950-A Shaft 14025 HW0400073-1 Pipe 14026 HW9404651-1 Washer 14027 HW0308090-1 Flange 14028 AE2085K4 Oil seal 14029 HW0400017-1 Fly-wheel 14030 HW0308089-1 Spacer 14031 M8X35 Socket screw 44032 2H-8 Spring washer 444033 M8X30 Socket screw 204034 M8X50



Spring washer 18

4036 M6X95 Socket screw 14037 2H-6 Spring washer 14038 M8X90 Socket screw 64039 M8X25 Socket screw 64040 M8X65 Socket screw 84041 M10X25 Socket screw 24042 2H-10 Spring washer 24043 M6X20 GT-SA Bolt 34044 PT1/8


4045 LP-M5 Plug 14048 PT3/8


3024 HW0308095-1 Link-E 13026 HW0101155-1 U-arm 1

76I/77

11.5 Balancer Unit

11-10

HW0483366

HW0483366

11.5 Balancer Unit

5001

5002

5003

5004

5005

5006

5007

5008

5009

5010

5011

5012

5018

5013

5013

50145015

5016

5017

5004

5014

76J/77

11.5 Balancer Unit

11-11

HW0483366

HW0483366


5001 HW0481740-A Coil spring 15002 HW0481741-A Coil spring 15003 HW0481742-A Coil spring 15004 SOB607440 Oiless 25005 HW0100477-1 Case 15006 HW0306033-1 Flange 15007 HW0200420-1 Flange 15008 HW0401112-1 Flange 15009 HW0303581-1 Rod 15010 HW9405057-1 Clevis 15011 FD3187A0 Dust seal 15012 EZ2228B0 Cap 15013 IRTW-75 Retaining ring 25014 M6X8 Magic screw 25015 PT1/8 Plug 35016 M10X40 Socket screw 85017 2H-10 Spring washer 85018 M8X16 GT-SA Bolt 3

76K/77

YASKAWA

YASKAWA EL

Specifications are subject to change wfor ongoing product modifications and

MOTOMANINSTRUCT

HEAD OFFICE2-1 Kurosaki-Shiroishi, YahataPhone 81-93-645-7745

MOTOMAN INC. HEADQUART805 Liberty Lane West CarrollPhone 1-937-847-6200YASKAWA MOTOMAN CANA3530 Laird Road, Unit 3, MissiPhone 1-905-569-6686MOTOMAN ROBOTICS EUROFranska Vagen 1039854, KalmPhone 46-480-417800MOTOMAN ROBOTEC GmbHKammerf eld strasse 1, DE-85Phone 49-8166-90100YASKAWA ELECTRIC KOREA1F Samy ang Bldg. 89-1, ShincPhone 82-53-745-7844

YASKAWA ELECTRIC (SINGA151 Lorong Chuan, #04-01, NPhone 65-6282-3003YASKAWA ELECTRIC (MALAYNo.71, Jalan Bandar Rawang Phone 60-3-6092-1377YASKAWA ELECTRIC TAIWA9F, 16 Nanking E. Rd., Sec. 3Phone 886-2-2502-5003SHOUGANG MOTOMAN ROB7,Yongchang-North Road, BePhone 86-10-6788-0541

-EPL500IONS

nishi-ku, Kitaky usy u-shi, 806-0004, JapanFax 81-93-645-7746

ERSton, OH 45449, U.S.A.

Fax 1-937-847-6277DA LTD.ssauga, Ontario, L5L 5Z7, Canada

Fax 1-905-813-5911PE AB

ar, SwedenFax 46-480-417999

391 Allershausen, GermanyFax 49-8166-90103

CORPORATIONhun-dong, Donk-Ku, Daegu, KoreaFax 82-2-784-8495

PORE) PTE. LTD.ew Tech Park, Singapore 556741, Singapore

Fax 65-6289-3003SIA) SDN. BHD.

2, 48000 Rawang, Selangor D.E., Malay siaFax 60-3-6092-6377

N CORPORATION, Taipei, Taiwan

Fax 886-2-2505-1280OT CO., LTD.ijing Economic & Technological Dev elopment Area, Beijing 100076, China

Fax 86-10-6788-2878

ECTRIC CORPORATION

ithout notice improvements. Printed in Japan September 2006 06-03C

HW0483366MANUAL NO.

2 77/77

Documents

Motoman NX100 Controller EPL500 Manipulator Manual