Instructions: Motoman-Hp20D/Hp20F

MOTOMAN-HP20D/HP20F
INSTRUCTIONS
TYPE: YR-HP0020D-A00 (STANDARD SPECIFICATION FOR DX100) TYPE: YR-HP0020D-A01 (SLU-AXES WITH LIMIT SWITCHES FOR DX100) YR-HP0020F-A00 (STANDARD SPECIFICATION FOR FS100) YR-HP0020F-A01 (SLU-AXES WITH LIMIT SWITCHES FOR FS100)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-HP20D/HP20F INSTRUCTIONS DX100 INSTRUCTIONS DX100 OPERATORS MANUAL DX100 MAINTENANCE MANUAL FS100 INSTRUCTIONS FS100 OPERATORS MANUAL FS100 MAINTENANCE MANUAL
The HP20D/HP20F operators manual above corresponds to specific usage. Be sure to use the appropriate manual.
Part Number: Revision:
156192-1CD 5
MANUAL NO.
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MANDATORY
This instruction manual is intended to explain mainly on the mechanical part of the MOTOMAN-HP20D/HP20F for the application to the actual operation and for proper maintenance and inspection. It describes on safety and handling, details on specifications, necessary items on maintenance and inspection, to explain operating instructions and maintenance procedures. Be sure to read and understand this instruction manual thoroughly before installing and operating the manipulator. General items related to safety are listed in Chapter 1: Safety of the DX100/FS100 Instructions. To ensure correct and safe operation, carefully read the DX100/FS100 Instructions before reading this manual.
CAUTION
Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before operating this product. The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product. YASKAWA may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications. If such modification is made, the manual number will also be revised. If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover. YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product's warranty.
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the MOTOMAN-HP20D/HP20F. In this manual, the Notes for Safe Operation are classified as WARNING, CAUTION, MANDATORY, or PROHIBITED.
WARNING CAUTION
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.
MANDATORY
PROHIBITED
Must never be performed.
Even items described as CAUTION may result in a serious accident in some situations. At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as CAUTION and WARNING.
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<DX100>
WARNING
Before operating the manipulator, check that servo power is turned OFF pressing the emergency stop buttons on the front door of the DX100 and the programming pendant. 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. Figure 1: 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 the servo power ON.
Injury may result from unintentional or unexpected manipulator motion. Figure 2: Release of Emergency Stop
TURN
Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator: View the manipulator from the front whenever possible. Always follow the predetermined operating procedure. Keep in mind the emergency response measures against the manipulators unexpected motion toward you. 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 person is present in the P-point maximum envelope of the manipulator and that you are in a safe location before: Turning ON the power for the DX100. Moving the manipulator with the programming pendant. Running the system in the check mode. Performing automatic operations. Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem. The emergency stop buttons are located on the right of front door of the DX100 and the programming pendant.
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<FS100>
WARNING
Before operating the manipulator, check that servo power is turned OFF when the emergency stop button on the programming pendant is 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. Figure 3: Emergency Stop Button
In the case of not using the programming pendant, be sure to supply the emergency stop button on the equipment. Then before operating the manipulator, check to be sure that the servo power is turned OFF by pressing the emergency stop button. Connect the external emergency stop button to the 5-6 pin and 1617 pin of the robot system signal connector (CN2). Upon shipment of the FS100, this signal is connected by a jumper cable in the dummy connector. To use the signal, make sure to supply a new connector, and then input it.
If the signal is input with the jumper cable connected, it does not function, which may result in personal injury or equipment damage. Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator. Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion. Figure 4: Release of Emergency Stop
Turn
Observe the following precautions when performing teaching operations within the manipulators operating range: Always follow the predetermined operating procedure. Keep in mind the emergency response measures against the manipulators unexpected motion toward you. 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 person is present in the manipulators operating range and that you are in a safe location before: Turning ON the FS100 power. Moving the manipulator with the programming pendant. Running the system in the check mode. Performing automatic operations. Injury may result if anyone enters the manipulators operating range during operation. Always press the emergency stop button immediately if there is a problem. The emergency stop button is located on the right of the programming pendant.
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CAUTION
Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed. Check for problems in manipulator movement. Check for damage to insulation and sheathing of external wires. For the DX100, always return the programming pendant to the hook on the cabinet of the DX100 after use. For the FS100, always return the programming pendant to a safe place 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 Warning Labels in the DX100/FS100 Instructions before operating the manipulator:
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Definition of Terms Used Often in This Manual (DX100)

The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables. In this manual, the equipment is designated as follows:
Equipment DX100 controller DX100 programming pendant Cable between the manipulator and the controller Manual Designation DX100 Programming pendant Manipulator cable
Definition of Terms Used Often in This Manual (FS100)

The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the FS100 controller, manipulator cables, the FS100 programming pendant (optional), and the FS100 programming pendant dummy connector (optional). In this manual, the equipment is designated as follows:
Equipment FS100 controller FS100 programming pendant Cable between the manipulator and the controller FS100 programming pendant dummy connector Manual Designation FS100 Programming pendant Manipulator Cable Programming pendant dummy connector
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Explanation of Warning Labels

The following warning labels are attached to the manipulator. Always follow the warnings on the labels. Also, an identification label with important information is placed on the body of the manipulator. Prior to operating the manipulator, confirm the contents. Figure 5: Warning Labels Locations
WARNING Label B WARNING Label A WARNING Label B
Nameplate
Nameplate:
WARNING Label A:
WARNING
Moving parts may cause injury
WARNING Label B:
WARNING
Do not enter robot work area.
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HP20D/HP20F Table of Contents 1 Product Confirmation ...................................................................................................................... 1-1 1.1 Contents Confirmation ....................................................................................................... 1-1 1.2 Order Number Confirmation .............................................................................................. 1-2 2 Transport......................................................................................................................................... 2-1 2.1 Transport Method .............................................................................................................. 2-1 2.1.1 Using a Crane ...................................................................................................... 2-2 2.1.2 Using a Forklift...................................................................................................... 2-3 2.2 Cushioning Material for Transport ..................................................................................... 2-4 3 Installation....................................................................................................................................... 3-1 3.1 Safeguarding Installation ................................................................................................... 3-2 3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2 3.2.1 Mounting Example................................................................................................ 3-3 3.3 Ways of Mounting .............................................................................................................. 3-4 3.3.1 S-Axis Operating Range....................................................................................... 3-4 3.3.2 Fixing Manipulator Base ....................................................................................... 3-4 3.3.3 Precautions to Prevent Manipulator from Falling.................................................. 3-4 3.3.4 IP (International Protection) for Main Part of Manipulator .................................... 3-5 3.4 Location ............................................................................................................................. 3-5 4 Wiring.............................................................................................................................................. 4-1 4.1 Grounding .......................................................................................................................... 4-1 4.2 Cable Connection .............................................................................................................. 4-2 4.2.1 Connection to Manipulator.................................................................................... 4-2 4.2.2 Connection to DX100/FS100................................................................................ 4-2 5 Basic Specifications ........................................................................................................................ 5-1 5.1 Basic Specifications........................................................................................................... 5-1 5.2 Part Names and Working Axes.......................................................................................... 5-2 5.3 Manipulator Base Dimensions ........................................................................................... 5-3 5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-4 5.5 Alterable Operating Range ................................................................................................ 5-5 6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1 6.1 Allowable Wrist Load ......................................................................................................... 6-1 6.2 Wrist Flange....................................................................................................................... 6-3
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HP20D/HP20F Table of Contents 7 System Application.......................................................................................................................... 7-1 7.1 Peripheral Equipment Mounts............................................................................................ 7-1 7.1.1 Allowable Load ..................................................................................................... 7-1 7.1.2 Installation Position............................................................................................... 7-1 7.2 Internal User I/O Wiring Harness and Air Line................................................................... 7-2 8 Electrical Equipment Specification .................................................................................................. 8-1 8.1 Position of Limit Switch ...................................................................................................... 8-1 8.2 Internal Connections .......................................................................................................... 8-2 9 Maintenance and Inspection ........................................................................................................... 9-1 9.1 Inspection Schedule........................................................................................................... 9-2 9.2 Notes on Maintenance Procedures.................................................................................... 9-6 9.2.1 Battery Pack Replacement ................................................................................... 9-6 9.3 Notes on Grease Replenishment and Exchange Procedures ........................................... 9-8 9.3.1 Grease Replenishment and Exchange for S-Axis Speed Reducer ...................... 9-9 9.3.1.1 Grease Replenishment (Refer to Fig.9-4 S-Axis Speed Reducer Diagram.) ................................ 9-9 9.3.1.2 Grease Exchange (Refer to Fig. 9-4 S-Axis Speed Reducer Diagram on page 9-9.) ......... 9-10 9.3.2 Grease Replenishment and Exchange for L-Axis Speed Reducer..................... 9-11 9.3.2.1 Grease Exchange (Refer to Fig.9-5 L-Axis Speed Reducer Diagram.)............................... 9-11 9.3.2.2 Grease Exchange (Refer to Fig. 9-5 L-Axis Speed Reducer Diagram on page 9-11.) ....... 9-12 9.3.3 Grease Replenishment and Exchange for U-Axis Speed Reducer .................... 9-13 9.3.3.1 Grease Replenishment (Refer to Fig.9-6 U-Axis Speed Reducer Diagram.) .............................. 9-13 9.3.3.2 Grease Exchange (Refer to Fig. 9-6 U-Axis Speed Reducer Diagram on page 9-13.) ....... 9-14 9.3.4 Grease Replenishment for R-Axis Speed Reducer ............................................ 9-15 9.3.5 Grease Replenishment for B- and T-Axis Speed Reducers ............................... 9-16 9.3.6 Grease Replenishment for T-Axis Gear.............................................................. 9-17 9.3.7 Grease Replenishment for R-Axis Cross Roller Bearing .................................... 9-18 9.3.8 Notes for Maintenance........................................................................................ 9-19 9.3.8.1 Wrist Unit ............................................................................................... 9-19 9.3.8.2 Battery Pack Connection ....................................................................... 9-20 10 Recommended Spare Parts........................................................................................................ 10-1
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HP20D/HP20F Table of Contents 11 Parts List .................................................................................................................................... 11-1 11.1 S-Axis Unit ..................................................................................................................... 11-1 11.2 L-Axis Unit ..................................................................................................................... 11-3 11.3 U-Axis Unit..................................................................................................................... 11-5 11.4 Wrist Unit ..................................................................................................................... 11-10
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1 Product Confirmation 1.1 Contents Confirmation
Product Confirmation
CAUTION
Confirm that the manipulator and the DX100/FS100 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 five (six or seven) items (Information for the content of optional goods is given separately.): For DX100: Manipulator DX100 (including spare parts) Programming pendant Manipulator cable (between the DX100 and the manipulator, 4 cables) Set of instruction manuals For FS100: Manipulator FS100 (including spare parts) 2 units (for R1 and R2) Manipulator cable (between the FS100 and the manipulator, 4 cables) Set of instruction manuals Programming pendant (optional) Programming pendant dummy connector (optional)
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1 Product Confirmation 1.2 Order Number Confirmation
1.2
Order Number Confirmation

Check that the order number of the manipulator corresponds to the DX100/FS100. The order number is located on a label as shown below.
Fig. 1-1: Location of Order Number Labels

Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
Check that the manipulator and the DX100/FS100 have the same order number.
EM
DX100
TYPE
ERDR-
ER
GE N
C
Y
POWER SUPPLY
3PHASE
AC200V AC220V
50/60Hz 60Hz
PEAK AVERAGE
INTERRUPT CURRENT SERIAL No. DATE
kVA kVA kA
MADE IN JAPAN
NJ2960-1
T O P
ON
IP
RE SE T
OFF
TR
PE
US
ORDER NO.
NJ1529
CN
FBB CN210 CN211
(c) FS100 (Front View)
PROGRAMMING PENDANT
(a) DX100 (Front View)
(b) Manipulator (Top View)
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2 Transport 2.1 Transport Method
Transport
CAUTION
Sling applications and crane or forklift operations must be performed by authorized personnel only. Avoid 3G or more vibration or shock during transport. Failure to observe this caution may result in injury or damage. The system consists of precision components. Failure to observe this caution may adversely affect performance. In case a message PULSE LIMIT appeared on the programming pendant window after the manipulator is installed and the power supply is turned ON, execute the following procedures for restoration. 1. From the alarm message, confirm that which axis has exceeded its motion range. 2. Select VALID to {SOFT LIMIT RELEASE} on LIMIT RELEASE window. (Refer to 8.10 Soft LImit Release Function in DX100 INSTRUCTIONS (162536-1CD) and 8.10 Soft LImit Release Function in FS100 INSTRUCTIONS (159644-1CD) . 3. Move the axis mentioned in step one to return it into its motion range. 4. Select INVALID to {SOFT LIMIT RELEASE} on LIMIT RELEASE window. In case a message OUT OF RANGE(ABSO DATA) appeared, take measures by following the instructions mentioned in 6.4 Setting the Second Home Position (Check Point) in DX100 MAINTENANCE MANUAL (155492-1CD) and 7.4 Setting the Second Home Position (Check Point) in FS100 MAINTENANCE MANUAL (159645-1CD).
2.1
Transport Method
Check that the eyebolts are securely fastened. The weight of the manipulator is approximately 280 kg including the cushioning material for transport. Use a wire rope strong enough to withstand the weight.
NOTE
Attached eyebolts are designed to support the manipulator mass. Do not use them for anything other than transporting the manipulator. Mount the cushioning material for transport to the manipulator. Avoid putting external force on the arm or motor unit when transporting by a crane, forklift, or other equipment. Failure to observe this instruction may result in injury.
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2.1.1
Using a Crane As a rule, the manipulator should be lifted by a crane with two wire ropes when removing it from the package and moving it. Be sure that the manipulator is fixed with the cushioning material for transport, and lift it in the posture as shown in Fig.2-1 Transporting Position. Fig. 2-1: Transporting Position
Eyebolt M12 (2 eyebolts) (Delivered with the manipulator) Factory setting for angle and pulse of each axis Axis Angle Pulse 0 -196244 -111514 81920 0 0 S L U R B T
Eyebolt M12 (2 eyebolts) (Delivered with the manipulator)
View E
B
View F
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2.1.2
Using a Forklift When using a forklift, the manipulator should be fixed on a pallet with shipping bolts as shown in Fig.2-2 Using a Forklift. Insert claws under the pallet and lift it. The pallet must be strong enough to support the manipulator. Transport the manipulator slowly with due caution in order to avoid overturning or slippage. Fig. 2-2: Using a Forklift
Bolt M16 (4 places) Pallet
Forklift claw entries
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2 Transport 2.2 Cushioning Material for Transport
2.2
Cushioning Material for Transport

The manipulator is provided with the cushioning materials for transport at sections A and B. (See Fig.2-3 Cushioning Materials for Transport.) Fig. 2-3: Cushioning Materials for Transport
Eyebolts M12 (2 eyebolts) (delivered with the manipulator)
B A
Enlarged View: Section A
Enlarged View: Section B
A rubber cushion is respectively wedged at the sections A and B. Before turning ON the power, check to be sure that the cushioning materials for transport are removed. In the event that the manipulator must be moved again, to avoid its main body from being damaged, the cushioning materials such as rubber plate, etc. must be used.
NOTE
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Installation
Installation
WARNING
Install the safeguarding. Install the manipulator in a location where the tool or the workpiece held by its fully extended arm will not reach the wall, safeguarding, or controller. Do not start the manipulator or even turn ON the power before it is firmly anchored. When mounting the manipulator on the wall, the base section must have sufficient strength and rigidity to support the weight of the manipulator. Also, it is necessary to consider countermeasures to prevent the manipulator from falling. Failure to observe this warning may result in injury or damage.
Failure to observe this warning may result in injury or damage.
The manipulator may overturn and cause injury or damage.
Failure to observe these warnings may result in injury or damage.
CAUTION
Do not install or operate the manipulator that is damaged or lacks parts. Before turning ON the power, check to be sure that the cushioning materials for transport explained in Fig. 2-3 Cushioning Materials for Transport on page 2-4 are removed. Failure to observe this caution may cause injury or damage.
Failure to observe this caution may result in damage to the driving parts.
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3 Installation 3.1 Safeguarding Installation
3.1
Safeguarding Installation
To insure safety, be sure to install safeguarding. It prevents unforeseen accidents with personnel and damage to equipment. Refer to the quoted clause for your information and guidance. Responsibility for Safeguarding (ISO10218) The user of a manipulator or robot system shall ensure that safeguards are 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 3-1 Maximum Repulsion Forces of Manipulator at Emergency Stop and Table 3-2 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 instructed in chapter 3.2.1 Mounting Example at page 3-3. Table 3-1: Maximum Repulsion Forces of Manipulator at Emergency Stop
Maximum torque in horizontal rotation (S-axis moving direction) Maximum torque in vertical rotation (L-,U-axes moving direction) 8000 Nm (815 kgfm) 5000 Nm (510 kgfm)
Table 3-2: Endurance Torque in Operation

Endurance torque in horizontal operation (S-axis moving direction) Endurance torque in vertical operation (L-,U-axes moving direction) 1700 Nm (171 kgfm) 3775 Nm (385 kgfm)
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3 Installation 3.2 Mounting Procedures for Manipulator Base
3.2.1
Mounting Example For the first process, anchor the baseplate firmly to the ground. The baseplate should be rugged and durable to prevent shifting of the manipulator or the mounting fixture. It is recommend to prepare a baseplate of 32 mm or more thickness, and anchor bolts of M16 or larger size. Next, fix the manipulator base to the baseplate. The manipulator base is tapped for four mounting holes; securely fix the manipulator base to the baseplate with four hexagon head bolts M16 (60 mm long is recommended). Tighten the hexagon head bolts and anchor bolts firmly so that they will not work loose during the operation. Refer to Fig.3-1 Mounting Manipulator on Baseplate. Fig. 3-1: Mounting Manipulator on Baseplate
Bolt M16 (4 bolts) Spring washer Washer Manipulator base 25 40 mm or more Baseplate
Manipulator base Anchor bolt (M16 or larger) Baseplate
375 335 18 dia. holes (4 holes) 2000.1 313 2000.1 60
250
335
Baseplate
+0.018 0 dia.
1700.1
2600.1
12
holes (2 holes)
Manipulator Base
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3 Installation 3.3 Ways of Mounting
3.3
Ways of Mounting
The MOTOMAN-HP20D/HP20F is available in three ways of mounting: floor-mounted way (standard), wall-mounted way, and ceiling-mounted way. For wall-mounted and ceiling-mounted ways, the three points listed below are different from the floor-mounted way. S-Axis Operating Range Fixing the Manipulator Base Precautions to Prevent the Manipulator from Falling IP (International Protection) for Main Part of the Manipulator
3.3.1
S-Axis Operating Range For wall-mounted type, the S-axis operating range is 30. (The range is adjusted prior to the shipment)
3.3.2
Fixing Manipulator Base For wall- and ceiling-mounted types, be sure to use four hexagon socket head cap screws M16 (tensile strength: 1200 N/mm2 or more) when fixing the manipulator base. Use a torque of 206 Nm when tightening the screws.
3.3.3
Precautions to Prevent Manipulator from Falling For the wall- or ceiling-mounted types, take appropriate measures to avoid the falling of the manipulator in case of emergency. Refer to Fig.3-2 Precaution Against Falling for details. Fig. 3-2: Precaution Against Falling
Support for fall prevention Manipulator base Hexagon socket head cap screw M16 (4 places) (Tensile strength: 1200 N/mm2 or more)
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3 Installation 3.4 Location
3.3.4
IP (International Protection) for Main Part of Manipulator For wall-mounted or ceiling mounted ways, environmental resistance for main part of the manipulator does not conform to IP54; environmental resistance for IP65 is optionally available. However, the wrist part conforms to IP67. In case of using the wall-mounted or the ceiling-mounted way, inform Yaskawa of the matter when placing an order. Be sure to contact Yaskawa representative (listed on the back cover of this instruction manual) to execute a wall or ceiling installation on site. Also, thoroughly read the instructions described in 8.4 ARM Control in both DX100 INSTRUCTIONS (1625361CD) and FS100 INSTRUCTIONS (159644-1CD) before installing and using the manipulator.
NOTE
3.4
Location
When the manipulator is installed, it is necessary to satisfy the following environmental conditions: Ambient temperature: 0 to + 45C Humidity: 20 to 80%RH (non-condensing) Free from dust, soot, oil, or water Free from corrosive gas or liquid, or explosive gas or liquid. Free from excessive vibration (Vibration acceleration: 4.9 m/s2 [0.5G] or less) Free from large electrical noise (plasma) Flatness for installation: 0.5 mm or less
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4 Wiring 4.1 Grounding
Wiring
WARNING
Ground resistance must be 100 or less. Before wiring, make sure to turn the primary power supply off, and put up a warning sign. (e.g. DO NOT TURN THE POWER ON.) Failure to observe this warning may result in fire or electric shock.
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.
4.1
Grounding
Follow electrical installation standards and wiring regulations for grounding. A ground wire of 5.5 mm2 or more is recommended. Refer to Fig. 4-1 Grounding Method on page 4-2 to connect the ground line directly to the manipulator.
NOTE
Never use this wire 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, ground in accordance with electrical installation standards.
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4 Wiring 4.2 Cable Connection Fig. 4-1: Grounding Method
5.5 mm2 or more
Bolt M8 (For grounding) Delivered with the manipulator
Section A-A
4.2
Cable Connection
Two manipulator cables are delivered with the manipulator; an encoder cable (1BC) and a power cable (2BC). (Refer to fig. 4-2(a) Manipulator Cables (DX100) on page 4-3 and fig. 4-2(b) Manipulator Cables (FS100) on page 4-3.) Connect these cables to the manipulator base connectors and to the DX100/FS100. Refer to fig. 4-3(a) Manipulator Cable Connectors (Manipulator Side) on page 4-4, fig. 4-3(b) Manipulator Cable Connection (DX100 Side) on page 4-4 and fig. 4-3(c) Manipulator Cable Connection (FS100 Side) on page 4-4.
4.2.1
Connection to Manipulator Before connecting cables to the manipulator, verify the numbers on both manipulator cables and the connectors on the connector base of the manipulator. When connecting, adjust the cable connector positions to the main key positions of the manipulator, and insert cables in the order of 2BC, then 1BC. After inserting the cables, depress the lever until it clicks.
4.2.2
Connection to DX100/FS100 Before connecting cables to the DX100/FS100, verify the numbers on both manipulator cables and the connectors on the DX100/FS100. When connecting, connect the cables in the order of X21, then X11. For the DX100, after inserting the connectors, depress each lever until it clicks. For the FS100, insert each connector until it clicks.
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4 Wiring 4.2 Cable Connection Fig. 4-2(a): Manipulator Cables (DX100)
DX100 side
X11
Manipulator side
1BC
X11
1BC
1BC
Encoder cable DX100 side Manipulator side
2BC
X21
2BC X21
2BC
Power cable
Fig. 4-2(b): Manipulator Cables (FS100)
FS100 side
Manipulator side
1BC
X11
1BC X11
1BC
molex
Encoder cable Manipulator side
FS100 side
2BC
X21
X21
2BC
2BC
Power cable
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4 Wiring 4.2 Cable Connection Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)
2BC 1BC
3BC
Connector Details (Manipulator Side)
Fig. 4-3(b): Manipulator Cable Connection (DX100 Side)
X21
X11
Fig. 4-3(c): Manipulator Cable Connection (FS100 Side)
X21
X11
Back View
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5 Basic Specifications 5.1 Basic Specifications
Basic Specifications
5.1 Basic Specifications
Model MOTOMAN-HP20D/HP20F Vertically articulated 6 20 kg
2)
Table 5-1: Basic Specifications1)

Item Structure Degree of Freedom Payload Repeatability Range of Motion S-Axis (turning) L-Axis (lower arm) U-Axis (upper arm) R-Axis (wrist roll) B-Axis (wrist pitch/yaw) T-Axis (wrist twist) Maximum Speed S-Axis L-Axis U-Axis R-Axis B-Axis T-Axis Allowable Moment
3)
0.06 mm -180 - +180 -110 - +155 -165 - +255 -200 - +200 -50 - +230 -360 - +360 3.44 rad/s, 197/s 3.05 rad/s, 175/s 3.58 rad/s, 205/s 6.98 rad/s, 400/s 6.98 rad/s, 400/s 10.47 rad/s, 600/s 39.2 Nm (4 kgfm) 39.2 Nm (4 kgfm) 19.6 Nm (2 kgfm) 1.05 kgm2 1.05 kgm2 0.75 kgm2 5) 257 kg
4)
R-Axis B-Axis T-Axis
Allowable Inertia (GD
2/4)
R-Axis B-Axis T-Axis
Approx. Mass Ambient Conditions Temperature Humidity Vibration Acceleration Others
0C to 45C 20 to 80% RH (non-condensing) 4.9 m/s2 or less (0.5G) Free from corrosive gas or liquid, or explosive gas or liquid Free from exposure to water, oil, or dust Free from excessive electrical noise (plasma) 2.0 kVA
Power Requirements
1 SI units are used in this table. However, gravitational unit is used in ( ). 2 Conformed to ISO9283 3 Refer to table chapter 6.1 Allowable Wrist Load on page 6-1 for details on the permissible moment of inertia. 4 Conformed to IP54 for the main part of the manipulator (only floor-mounted type). Conformed to IP67 for the wrist part (IP65 for the main part is optional.) 5 The allowable inertia of T-axis varies depending on the added value of the moment. Refer to chapter 6.1 Allowable Wrist Load on page 6-1 for the details.
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5 Basic Specifications 5.2 Part Names and Working Axes
5.2
Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes
U+ U-arm R+ B+ T+ Wrist flange URBT-
L-
L+ L-arm S-head
Manipulator base S+
S-
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5 Basic Specifications 5.3 Manipulator Base Dimensions
5.3
Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions
2000.1 Fitting surface 2000.1 60
25
Fitting surface
375 335 18 dia. holes (4 holes) (for manipulator fixing) 313
335 375
195.5 395.5
250
View A
12 +0.018 dia. holes 0 (2 holes)
1700.1
2600.1 Units: mm
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5 Basic Specifications 5.4 Dimensions and P-Point Maximum Envelope
5.4
Dimensions and P-Point Maximum Envelope

Fig. 5-3: Dimensions and P-Point Maximum Envelope
180
R1
71
7
150
R 42
R31
1417 1323
View A
180
1717
514 459
635
349 413
288
807
2072
Lamp (optional) 150 80
P-point 795 87.5 138.5 105
140
81
1485
L-axis 760
1003 768
421 264 157
11
155
505 334
505 238 0 31
255
0 P-point maximum envelope
559
165
524
917 260 471 807 991 0
Note: This figure shows the standard specification manipulator in the home position.
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5 Basic Specifications 5.5 Alterable Operating Range
5.5
Alterable Operating Range

The operating range of the S-axis can be altered in accordance with the operating conditions as shown in Table 5-2 S-Axis Operating Range. If alteration is necessary, contact your Yaskawa representative in advance. Table 5-2: S-Axis Operating Range
Item S-Axis Operating Range Specifications -180 - +180 (standard) -150 - +150 -120 - +120 -90 - +90 -60 - +60 -30 - +30
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6 Allowable Load for Wrist Axis and Wrist Flange 6.1 Allowable Wrist Load
Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load
The allowable wrist load is 20 kg maximum. If force is applied to the wrist instead of the load, force on R-, B-, and T-axes should be within the value shown in Table 6-1 Allowable Wrist Load. Contact your Yaskawa representative for further information or assistance. Table 6-1: Allowable Wrist Load
Axis R-Axis B-Axis Moment Nm (kgfm)1) GD2/4 Total Moment of Inertia kgm2 39.2 (4) 39.2 (4) 1.05 1.05
1 ( ): Gravitational unit
The allowable moments of inertia for R-axis and B-axis are calculated when the moment is at the maximum. The allowable moment of inertia for T-axis varies depending on the moment, as shown in Fig.6-1 T-axis Allowable Moment of Inertia (Value from Rotation Center of T-axis Flange Surface). Use the manipulator to meet those conditions. For example, with MOTOMAN-HP20D/HP20F, the allowable moment of inertia for the T-axis is 0.25 kgm2 when the moment is 19.6 Nm, and 0.75 kgm2 when 0 Nm. When the volume load is small, refer to the moment arm rating shown in Fig. 6-2 Moment Arm Rating on page 6-2. Fig. 6-1: T-axis Allowable Moment of Inertia (Value from Rotation Center of T-axis Flange Surface)
20
19.6
Moment (Nm)
15
10
0 0
0.25 0.3
0.75 0.6 0.9
Total Inertia GD2 /4 Kgm 2
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6 Allowable Load for Wrist Axis and Wrist Flange 6.1 Allowable Wrist Load Fig. 6-2: Moment Arm Rating
LB Load gravity position
105 LT R-, T-axis rotation center B-axis rotation center 300 T L (mm) 200 W=10Kg 100 W=16Kg W=20Kg W=6Kg 0 100 200 LB (mm) 300 400
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6 Allowable Load for Wrist Axis and Wrist Flange 6.2 Wrist Flange
6.2
Wrist Flange
The wrist flange dimensions are shown in Fig.6-3 Wrist Flange. In order to see the alignment marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth of inside and outside fittings must be 5 mm or less. Fig. 6-3: Wrist Flange
Alignment mark
0.5
45
Tapped holes M6 (depth: 10) (pitch: 1.0) (4 holes)
25
50 -0.039 dia.
+0.021 dia. 0
P.C
.D4
Units: mm
6 +0.012 dia. hole 0 (depth: 6)
View A
Wash off anti-corrosive paint (yellow) on the wrist flange surface with thinner or light oil before mounting the tools.
NOTE
Mount the attachment with the mounting bolts (length: 10 mm or less). Failure to observe this instruction may affect the manipulator performance.
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7 System Application 7.1 Peripheral Equipment Mounts
System Application
7.1 Peripheral Equipment Mounts
The peripheral equipment mounts are provided on the U-axis (upper arm) and S-axis (rotary head) as shown in Fig. 7-4 Installing Peripheral Equipment on page 7-1 for easier installation of the userss system applications. The following conditions shall be observed to attach or install peripheral equipment.
7.1.1
Allowable Load The maximum allowable load on the U-axis is 31 kg, including the wrist load. For instance, when the mass installed on the wrist point is 20 kg, the mass which can be installed on the upper arm is 11 kg.
7.1.2
Installation Position There is a limitation on the installation position. Fig. 7-5 Allowable Load on U-axis on page 7-1 shows the distance between the center of U-axis rotation and the load gravity. Fig. 7-4: Installing Peripheral Equipment
220
Limited dimension of Z-coordinate: 400 at a maximum
W2
Z-coordinate direction
Units: mm
W1 70
X-coordinate direction
Center of U-axis rotation 70 Rotating base
View A
Fig. 7-5: Allowable Load on U-axis

(kg) 30 W1=6kg W1=10kg 20 Weight W2 10 W1=16kg W1=20kg*1 *1 In this case, unbalanced moment is not permitted.
-200 -100 0 100 200 300 400 500 (mm) Distance between Center of U-axis Rotation and Load Gravity (X direction)
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7 System Application 7.2 Internal User I/O Wiring Harness and Air Line
7.2
Internal User I/O Wiring Harness and Air Line

Internal user I/O wiring harness (14 wires: 0.2 mm2 x 8 wires and 1.25 mm2 x 6 wires), and an air line are incorporated in the manipulator for the drive of peripheral devices mounted on the upper arm as shown in Fig.7-6 Connectors for Internal User I/O Wiring Harness and Air Line. The connector pins 1 to 16 are assigned as shown in Fig. 7-7 Details of the Connector Pin Numbers on page 7-3 on the following page. Wiring must be performed by users.
The allowable current for internal user I/O wiring harness 3 A or less for each wire (The total current value for pins 1 to 16 must be 40 A or less.)
The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less (The air line inside diameter: 8.0 mm)
Fig. 7-6: Connectors for Internal User I/O Wiring Harness and Air Line
Exhaust port (air flow): Tapped hole PT3/8 with pipe plug
A
Connector for internal user I/O wiring harness: JL05-2A20-29SC (socket connector with a cap) Prepare pin connector JL05-6A20-29P.
2BC
Air inlet: Tapped hole PT3/8 with pipe plug
1BC
3BC
Connector for internal user I/O wiring harness: JL05-2A20-29PC (pin connector with a cap) Prepare socket connector JL05-6A20-29S.
View A
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7 System Application 7.2 Internal User I/O Wiring Harness and Air Line Fig. 7-7: Details of the Connector Pin Numbers
Connector for Internal User I/O Wiring Harness on the Connector Base
1 2 3 4 5 6 7 (Open) 8 (Open) 9 10 11 (1.25 mm2) 12 (1.25 mm2) 13 (1.25 mm2) 14 2 15 (1.25 mm ) 16 (1.25 mm2)
2 4 9 13 7 11 15
1 5 3 8 12 16 6 10 14
Pins used
Internal user I/O wiring harness: 0.2 mm2, 8 wires : 1.25 mm2, 6 wires
Connector for Internal User I/O Wiring Harness on the U-arm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Pins used
(+24V: for shock sensor) 4 (For DX100: shock sensor signal input 7 9 For FS100: Not used)
2
1 5
3 8 12
6 10
13 14 (1.25 mm ) (1.25 mm2) 16 15 (1.25 mm2) (1.25 mm2) (1.25 mm2) Internal user I/O wiring harness: 0.2 mm2, 8 wires : 1.25 mm2, 6 wires
11
For the standard specification, the pins No.7 and No.8 of 3BC connector on the U-arm are respectively connected with the shock sensor power supply and shock sensor signal input port of the DX100/FS100 controller.
NOTE
The pins No.7 and No.8 of respective 3BC connectors on the connector base side and the U-arm side are not connected with each other. For wiring, refer to fig. 8-3(a) Internal Connection Diagram (DX100) on page 8-3 and fig. 8-3(c) Internal Connection Diagram (FS100) on page 8-5.
The same numbered pins (1 to 16) of the two connectors are connected with a single lead wire of 0.2 mm2 or 1.25 mm2.
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8 Electrical Equipment Specification 8.1 Position of Limit Switch
Electrical Equipment Specification

8.1 Position of Limit Switch
The limit switches are optional. See Fig.8-1 Location of Limit Switches. The manipulators with S- and L-axis overrun limit switches, and LU-axis interference limit switch are the types YR-HP0020D-A01 and YRHP0020F-A01. Fig. 8-1: Location of Limit Switches
LU-axes interference limit switch (optional)
L-axis interference limit switch (optional)
S-axis overrun limit switch (optional)
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8 Electrical Equipment Specification 8.2 Internal Connections
8.2
Internal Connections
Highly reliable connectors are equipped on each connection part of the manipulator to enable easy removal and installation for maintenance and inspection. For the number and location of connectors, see Fig.8-2 Locations and Numbers of Connectors. Diagrams for Internal connections of the manipulator are shown in fig. 83(a) Internal Connection Diagram (DX100) on page 8-3, fig. 8-3(b) Internal Connection Diagram (DX100) on page 8-4, fig. 8-3(c) Internal Connection Diagram (FS100) on page 8-5, and fig. 8-3(d) Internal Connection Diagram (FS100) on page 8-6. Fig. 8-2: Locations and Numbers of Connectors
3BC (For internal user I/O wiring harness)
3BC (For internal user I/O wiring harness)
Table 8-1: List of Connector Types

Name Type of Connector Connector for the internal user I/O JL05-2A20-29PC wiring harness on the connector base (JL05-6A20-29S: Optional) Connector for the internal user I/O wiring harness on the U-arm JL05-2A20-29SC (JL05-6A20-29P: Optional)
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8 Electrical Equipment Specification 8.2 Internal Connections Fig. 8-3(a): Internal Connection Diagram (DX100)
POWER CABLE INTERNAL CABLE IN S-AXIS INTERNAL CABLE IN L-AXIS INTERNAL CABLE IN BT-AXIS
<NOTES>
- For the limit switch specification, the connection of the section A is changed as follows:
0BT P BAT 0BT P BAT 1 2 3 4 0BAT11 BAT11 0BAT12 BAT12 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0BAT1 BAT1 0BAT2 BAT2 0BAT3 BAT3 0BAT4 BAT4
- For the IP65 specification, the connection of the section A and B are changed as follows:
LA1 LB1 LA1
S-AXIS OVERRUN L.S

LB1 LA2 LA2 LB2
0BT P BAT 0BT P BAT
5 6 7 8 1 2 3 4 5 6 7 8
0BAT21 BAT21 0BAT22 BAT22
LB1
L-AXIS OVERRUN L.S

LB3 LB3
P
LC1 LD1 LC1
LA3
A
L AND U-AXIS INTERFERENCE L.S
S-AXIS OVERRUN L.S

LD1 LD1 LC2 LC2 LD2
DX100
CN1-5 CN1-4 CN1-10 CN1-9 CN1-1 CN1-2 P P P
1BC(10X4) CN1-5 CN1-4 CN1-10 CN1-9 CN1-1 CN1-2

+24V 0V +24V 0V SPG+1 SPG-1
1 3 2 4
PG0V1 PG5V1 PG0V2 PG5V2 PG0V3 PG5V3 PG0V4 PG5V4 PG0V5 PG5V5 PG0V6 PG5V6
L-AXIS OVERRUN L.S

LD3 LD3
LC3
SLU-axes with Overrun Limit Switch Specification

LB1 LA1 LB1
No.20CN 20CN-1 -2 -6 -5 -4 -9 -10 DATA+1 DATA-1 BAT OBT +5V 0V FG1 OBT BAT
LB1 LA1
LB1
LB1
LA1
LA1
LA2
S-AXIS OVERRUN L.S
LA2 LB2
L-AXIS OVERRUN L.S

LB3 LB3
A
LA3
P P
LD1
PG
LD1 LC1
LD1
LD1
LC1
LC1
LC2
S-AXIS
CN1-3
CN1-3
P
FG1
LC1 LD1
S-AXIS OVERRUN L.S
LC2 LD2
L-AXIS OVERRUN L.S

LD3 LD3
LC3
SLU-axes with Overrun Limit Switch Specification (IP65 specification) - For the standard specification, the pins No.7 and No.8 of 3BC connector on the U-arm are respectively connected with the shock sensor power supply and the shock sensor signal input port of the DX100 controller.
No.22CN 22CN-1 -2 -6 -5 -4 -9 -10 DATA+3 DATA-3 BAT OBT +5V 0V FG3 OBT BAT No.23CN 23CN-1 -2 -3 -4 24CN-1 -2 -3 DATA+4 DATA-4 BAT OBT +5V 0V FG4 OBT BAT PG
CN1-6 CN1-7
CN1-6 CN1-7
SPG+2 SPG-2
P P
CN1-8
CN1-8
P
FG2
No.21CN 21CN-1 -2 -6 -5 -4 -9 -10
DATA+2 DATA-2 BAT OBT +5V 0V FG2 OBT BAT
PG
L-AXIS
CN2-1 CN2-2
CN2-1 CN2-2
SPG+3 SPG-3
P P P
CN2-3
CN2-3
FG3
No.5CN 5CN-1 -2 -3 -4 6CN-1 -2 -3 No.6CN
DATA+3 DATA-3 BAT OBT +5V 0V FG3
P P P
U-AXIS
DX100 Connection Port Pin No. Shock sensor power supply; +24V (1A) 7 Shock sensor signal input 8
1BC(10X4)
CN2-6 CN2-7
CN2-6 CN2-7
SPG+4 SPG-4
P P P
PG
R-AXIS
CN2-8
CN2-8
P
FG4
CN3-1 CN3-2
CN3-1 CN3-2
SPG+5 SPG-5
P P
CN3-3
CN3-3
P
FG5
No.7CN 7CN-1 -7 -2 -8 -3 -9
DATA+5 DATA-5 BAT OBT +5V 0V
P P P
No.14CN 14CN-1 -2 -3 -4 15CN-1 -2 -3
PG
B-AXIS
CN3-6 CN3-7
CN3-6 CN3-7
SPG+6 SPG-6
-4 -10 -5 -11 -6
DATA+6 DATA-6 +5V 0V FG6
P P
CN3-8
CN3-8
P
FG6
No.16CN 16CN-1 -2 -3 -4 17CN-1 -2 -3
PG
T -AXIS
CN4-1 CN4-6 CN4-2 CN4-7 CN4-3 CN4-8 CN4-10 CN2-4 CN2-5
P P
CN4-1 CN4-6 CN4-2 CN4-7 CN4-3 CN4-8 CN4-10
+24V LB1 SS2 AL1 BC2 AL2 0V
LA1
LB1
LB3
LA2
A
LC1
LD1
LD3
LC2
- When connecting the pin No.7 and No.8 of the connector base respectively with the pin No.7 and No.8 of 3BC connectors on the U-arm, the connection of crimped contact-pins (SS1, SS2) should be changed as shown in the section C below. (Contact your Yaskawa representative when modifying the wiring before use.)
POWER CABLE CONNECTOR BASE INTERNAL CABLE U-ARM
CN2-4 CN2-5
P
SPG+7 SPG-7
FOR LAMP(OPTION)
CN2-9 CN2-10
CN2-9 CN2-10
+24V
CN3-4 CN3-5
CN3-4 CN3-5
LB1 LA1
0V +5V
LB1 LA1
LB1
LB1
P
LD1
LD1
LB3
LA2
DX100
1BC(10X4)
CN3-9 CN3-10 CN4-4 CN4-5 CN4-9

E
CN3-9 CN3-10 CN4-4 CN4-5 CN4-9
0V +5V +24V LD1 FG7 E
LD1 LC1
LD1 LC1
LD3
LC2
E E E
Section A for IP65 Specification
CN4-1 CN4-2
CN4-1 CN4-2
24V(1A) SS2
SS1 SS2
Casing
Crimped Contact-Pin
E
3BC(20-29)
E
E E
3BC(20-29)
Base
E E
Casing
3BC(20-29)
Base
E E
1 2 3 4 5 6 7 8 1 2 3 4 5 6 SS1 SS2
UNUSED
3BC(20-29)
E
E
1 2 3 4 5 6 SS1 SS2 1 2 3 4 5 6 SS1 SS2
P P P P P
E 1 2 3 4 SS1 SS2 2 3 4 SS1 SS2

P P
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
FOR SPARE CABLE
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P P P P P
1 2 3 4 SS1 SS2
1 2 3 4 SS1 SS2
P P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
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8 Electrical Equipment Specification 8.2 Internal Connections Fig. 8-3(b): Internal Connection Diagram (DX100)
2BC(6X6) E
CN1-1 CN1-2 CN1-3 CN1-4 CN1-5 CN1-6 CN2-1 CN2-2 CN2-3 CN2-4 CN2-5 CN2-6 CN1-1 CN1-2 CN1-3 CN1-4 CN1-5 CN1-6 CN2-1 CN2-2 CN2-3 CN2-4 CN2-5 CN2-6
E ME1 ME2 ME2 MU1 MV1 MW1 MU2 MV2 MW2 MU2 MV2 MW2
3CN-3 -2 -1 -PE -4 -5
No.3CN
Casing
E
MU1 MV1 MW1 ME1 BA1 BB1
No.8CN
FOR SPARE CABLE

3BC(20-29)
E
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6
P P
SM YB
S-AXIS
4CN-1-A -B -C -D -1 -2
No.4CN
SM YB
L-AXIS
8CN-1 2 3 4 5 6 7 8 9 10 9CN-1 2 3 4 5 6
1 2 3 4
1 2 3 4
P P P
SS1 SS2
SS1 SS2
P P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
No.9CN
Section B for IP65 Specification

CN3-1 CN3-2 CN3-3 CN3-4 CN3-5 CN3-6 CN4-1 CN4-2 CN4-3 CN4-4 CN4-5 CN4-6 CN3-1 CN3-2 CN3-3 CN3-4 CN3-5 CN3-6 CN4-1 CN4-2 CN4-3 CN4-4 CN4-5 CN4-6
2BC(6X6)
MU3 MV3 MW3 MU4 MV4 MW4 MU5 MV5 MW5 MU6 MV6 MW6 ME3 ME4 ME5 ME6 BA1 BB1 BA2 BA3 BA4 BB4 BA5 BA6
No.10CN
26CN-3 -2 -1 -PE -4 -5 25CN-1 -2 -3 -4 -1 -2

No.35CN
No.26CN
MU3 MV3 MW3 ME3 BA3 BB3 MU4 MV4 MW4 ME4 BA4 BB4
SM YB
U-AXIS
No.25CN
SM YB
R-AXIS
No.18CN
CN5-1 CN5-2 CN5-3 CN5-4 CN5-5 CN5-6 CN6-1 CN6-2 CN6-3 CN6-4 CN6-5 CN6-6
CN5-1 CN5-2 CN5-3 CN5-4 CN5-5 CN5-6 CN6-1 CN6-2 CN6-3 CN6-4 CN6-5 CN6-6
10CN-1 -2 -3 -4
MU5 MV5 MW5 ME5

No.36CN
18CN-1 -2 -3 -4 -1 -2 19CN-1 -2 -3 -4 -1 -2
No.37CN No.19CN
SM YB
B-AXIS
-5 -6 -7 -8
MU6 MV6 MW6 ME6
SM YB
T-AXIS
PE
12CN-1 -2 -3 -4
No.12CN
BA5 BB5 BA6 BB6
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8 Electrical Equipment Specification 8.2 Internal Connections Fig. 8-3(c): Internal Connection Diagram (FS100)
<NOTES>
- For the limit switch specification, the connection of the section A is changed as follows:
LA1 LB1 S-AXIS OVERRUN L.S LA1 LB1 LB1 LA2 LA2 LB2 L-AXIS OVERRUN L.S LB3 LB3 L AND U-AXIS INTERFERENCE L.S
0BT K R P BAT 0BT K R P BAT
1 2 3 4
0BT K R P BAT 0BT K R P BAT
5 6 7 8 1 2 3 4 5 6 7 8
FS100
B2 B1 B4 B3 A1 A2 P P P
1BC(10X4) CN1-5 CN1-4 CN1-10 CN1-9 CN1-1 CN1-2

+24V 0V +24V 0V SPG+1 SPG-1
1 3 2 4
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0BAT1 BAT1 0BAT2 BAT2 0BAT3 BAT3 0BAT4 BAT4
P
LC1 LD1 S-AXIS OVERRUN L.S LC1 LD1 LD1
LA3
LC2
LC2 LD2
L-AXIS OVERRUN L.S LD3 LD3 L AND U-AXIS INTERFERENCE L.S
LC3
Section A SLU-axes with Overrun Limit Switch Specification

LB1 LB1
LA1
LB1
PG0V1 PG5V1 PG0V2 PG5V2 PG0V3 PG5V3 PG0V4 PG5V4 PG0V5 PG5V5 PG0V6 PG5V6
LA1 LB1
P
LD1
LB1 LA1 S-AXIS OVERRUN L.S
LA1
LA2
P
LD1 LC1 S-AXIS OVERRUN L.S LC1
LA2 LB2
L-AXIS OVERRUN L.S LB3 LB3 L AND U-AXIS INTERFERENCE L.S
LA3
LD1
LC1 LD1
LD1
LC1
LC2
LC2 LD2
L-AXIS OVERRUN L.S LD3 LD3 L AND U-AXIS INTERFERENCE L.S
LC3
Section A SLU-axes with Overrun Limit Switch Specification (IP65 specification)

P P No.20CN 20CN-1 -2 -6 -5 -4 -9 -10 DATA+1 DATA-1 BAT OBT +5V 0V FG1 OBT BAT
PG S-AXIS
A3
CN1-3
P
FG1
A4 A5
CN1-6 CN1-7
SPG+2 SPG-2
P P
A6
CN1-8
P
FG2
No.21CN 21CN-1 -2 -6 -5 -4 -9 -10
PG L-AXIS
C1 C2
CN2-1 CN2-2
SPG+3 SPG-3
P P P
C3
CN2-3
FG3
No.5CN 5CN-1 -2 -3 -4 6CN-1 -2 -3 No.6CN
DATA+3 DATA-3 BAT OBT +5V 0V FG3
P P P
No.22CN 22CN-1 -2 -6 -5 -4 -9 -10
PG U-AXIS
1BC
C4 C5
CN2-6 CN2-7
SPG+4 SPG-4
P P P R K
C6
CN2-8
P
FG4
No.23CN 23CN-1 -2 -3 -4 24CN-1 -2 -3
PG
R-AXIS
E1 E2
CN3-1 CN3-2
SPG+5 SPG-5
P P R K
E3
CN3-3
P
FG5
No.7CN 7CN-1 -7 -2 -8 -3 -9
DATA+5 DATA-5 BAT OBT +5V 0V
P P P
No.14CN 14CN-1 -2 -3 -4 15CN-1 -2 -3
PG B-AXIS
E4 E5
CN3-6 CN3-7
SPG+6 SPG-6
-4 -10 -5 -11 -6
DATA+6 DATA-6 +5V 0V FG6
P P
E6
CN3-8
P
FG6
No.16CN 16CN-1 -2 -3 -4 17CN-1 -2 -3
PG T-AXIS
D3 D4 B5 D1 F6 D2 F2 D5 D6 B6
P P
CN4-1 CN4-6 CN4-2 CN4-7 CN4-3 CN4-8 CN4-10
+24V OT_1+ NC NC LAMPNC 0V
LA1
LB1
LB3
LA2
A
LC1
LD1
LD3
LC2
CN2-4 CN2-5 CN2-9
P
NC NC NC
U V
FOR LAMP(OPTION)
F1
CN2-10
OT_1-
G1 G2
CN3-4 CN3-5
LB1 LA1
NC NC
LB1 LA1
LB1
LB1
P
LD1
LD1
LB3
LA2
G3 F3 G4 G5 G6
E
CN3-9 CN3-10 CN4-4 CN4-5 CN4-9
NC NC OT_2+ OT_2NC E
LD1 LC1
LD1 LC1
LD3
LC2
Section A for IP65 specification
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8 Electrical Equipment Specification 8.2 Internal Connections Fig. 8-3(d): Internal Connection Diagram (FS100)
E E E
Base
E E
Casing
E
1 2 3 4 5 6 SS1 SS2 1 2 3 4 5 6 SS1 SS2
P P P P P
FOR SPARE CABLE

3BC(20-29)
E 1 2 3 4 2 3 4
K R K R
3BC(20-29)
E
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P P
7 8
SS1 SS2
SS1 SS2
K R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
C
2BC(6X6) E
A5 H6 G6 A2 A3 A4 CN1-1 CN1-2 CN1-3 CN1-4 CN1-5 CN1-6
Item-A
B
Casing
3CN-3 -2 -1 -PE -4 -5
No.3CN
FOR SPARE CABLE

3BC(20-29)
E
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6
K R K R K R K R K R
E ME1 ME2 ME2 MU1 MV1 MW1 MU2 MV2 MW2 MU2 MV2 MW2
E
SM YB S-AXIS
8CN-1 2 3 4 5 6 7 8 9 10 9CN-1 2 3 4 5 6
No.8CN P P
1 2 3 4
1 2 3 4
K R K R
P P P
B6 D6 F6 A6 C6 E6
CN2-1 CN2-2 CN2-3 CN2-4 CN2-5 CN2-6
4CN-1 -A -B -C -D -1 -2
No.4CN
SS1 SS2
SS1 SS2
K R
P P
SM YB
L-AXIS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3BC-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16
No.9CN
Section B for IP65 Specification

H5 H4 H3 H1 G1 CN3-1 CN3-2 CN3-3 CN3-4 CN3-5 CN3-6
2BC
F1
MU3 MV3 MW3 MU4 MV4 MW4 MU5 MV5 MW5 MU6 MV6 MW6 ME3 ME4 ME5 ME6 BA1 BB1 BA2 BA3 BA4 BB4 BA5 BA6
No.10CN
26CN-3 -2 -1 -PE -4 -5 25CN-1 -2 -3 -4 -1 -2

No.35CN
No.26CN
SM U-AXIS YB
No.25CN
D1 C1 B1 C2 C3 C4
CN4-1 CN4-2 CN4-3 CN4-4 CN4-5 CN4-6
SM R-AXIS YB
No.18CN
H2 E1 A1 C5 D5 D4
CN5-1 CN5-2 CN5-3 CN5-4 CN5-5 CN5-6
10CN-1 -2 -3 -4
MU5 MV5 MW5 ME5

No.36CN
18CN-1 -2 -3 -4 -1 -2 19CN-1 -2 -3 -4 -1 -2
No.37CN No.19CN
SM B-AXIS YB
D3 E5 E3 E2 F5 F3
CN6-1 CN6-2 CN6-3 CN6-4 CN6-5 CN6-6
-5 -6 -7 -8
MU6 MV6 MW6 ME6
SM T-AXIS YB
PE
12CN-1 -2 -3 -4
No.12CN
BA5 BB5 BA6 BB6
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8 Electrical Equipment Specification 8.2 Internal Connections
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Maintenance and Inspection
Maintenance and Inspection
WARNING
Before maintenance or inspection, be sure to turn the main power supply OFF, and put up a warning sign. (e.g. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in electric shock or injury.
CAUTION
Maintenance and inspection must be performed by specified personnel. For disassembly or repair, contact your Yaskawa representative. The battery pack must be connected before removing detection connector when maintenance and inspection. Failure to observe this caution may result in electric shock or injury.
Failure to observe this caution may result in the loss of home position data.
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9 Maintenance and Inspection 9.1 Inspection Schedule
9.1
Inspection Schedule
Proper inspections are essential not only to assure that the mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. Inspection intervals are classified into six levels as shown in Table 9-1 Inspection Items on page 9-3. In Table 9-1 Inspection Items on page 9-3, the inspection items are categorized by three types of operations: operations which can be performed by personnel authorized by the user, operations to be performed by trained personnel, and operations to be performed by service company personnel. Only specified personnel shall perform the inspection work.
The inspection interval depends on the total servo operation time. The following inspection schedule is based on the case where the manipulator is used for arc welding application. If the manipulator is used for other application or if it is used under special conditions, a case-by-case examination is required. The inspection may be conducted at shorter intervals if the manipulator is used very frequently for the application such as handling; in this case, contact your Yaskawa representative. In Table 9-2 Inspection Parts and Grease Used on page 96, the speed reducers which use VIGO grease RE No.0 may make noises at the initial operation or at the first operation after a long interval. These noises are eliminated after the running-in period of one or two days.
NOTE
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Table 9-1: Inspection Items (Sheet 1 of 2)

Items1) Schedule 12000 H Cycle Method Operation Inspection Charge
1000 H Cycle
6000 H Cycle
Specified Personnel
1 2 3 4 5
Alignment mark External lead Working area and manipulator Motors for S-, L-, U-axes Baseplate mounting bolts Cover mounting screws Connector base Timing belts for B- and T-axes Wire harness in manipulator (SLEU-axis wires) (RBT-axis wires)
Visual Visual Visual Visual
Check alignment mark accordance and damage at the home position. Check for damage and deterioration of leads. Clean the work area if dust or spatter is present. Check for damage and outside cracks. Check for grease leakage.2) Tighten loose bolts. Replace if necessary. Tighten loose bolts. Replace if necessary. Check for loose connectors. Check for belt tension and wear. Check for conduction between the main connector of base and intermediate connector with manually shaking the wires. Check for wear of protective spring.3) Replace.4) Check for conduction between terminals and wear of protective spring.3) Replace4)
Spanner, wrench Screwdriver, wrench Manual Manual Visual, multimeter
6 7 8 9
Service Company
Licensee
24000 H
36000 H
Daily
9 9.1 Maintenance and Inspection Inspection Schedule
9-3
10 Wire harness in manipulator (BT-axis wires) 11 Battery pack in manipulator 12 S-axis speed reducer
Visual, multimeter
Replace the battery pack when the battery alarm occurs or the manipulator drove for 36000 H. Grease gun Check for malfunction. (Replace if necessary.) Supply grease5) (6000 H cycle). See chapter 9.3.1 at page 9-9 . Replace grease5). (12000 H cycle) See chapter 9.3.1 at page 9-9 .
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Table 9-1: Inspection Items (Sheet 2 of 2)

Items1) Schedule 12000 H Cycle Method Operation Inspection Charge
HP20D/HP20F
1000 H Cycle
6000 H Cycle
Specified Personnel Grease gun Check for malfunction. (Replace if necessary.) Supply grease5) (6000 H cycle). See chapter 9.3.2 at page 9-11 and chapter 9.3.3 at page 9-13 . Replace grease5) (12000 H cycle). See chapter 9.3.2 at page 9-11 and chapter 9.3.3 at page 9-13 . Check for malfunction. (Replace if necessary.) Supply grease5) (6000 H cycle). See chapter 9.3.4 chapter 9.3.5 at page 9-16 . Check for malfunction. (Replace if necessary.) Supply grease5) (6000 H cycle). See chapter 9.3.6 Check for malfunction. (Replace if necessary.) Supply grease5) (6000 H cycle). See chapter 9.3.7 at page 9-15 and
13 Speed reducers for L- and U-axes

9 9.1 Maintenance and Inspection Inspection Schedule
14 R-, B- and T-axes speed reducer 15 T-axis gear
Grease gun
Grease gun Grease gun
at page 9-17 at page 9-18
16 R-axis cross roller bearing 17 Overhaul
1 Inspection No. correspond to the numbers in Fig. 9-1 Inspection Items on page 9-5. 2 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. 3 When checking for conduction with 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 chapter 9.3.8 Notes for Maintenance at page 9-19) 4 Wire harness in manipulator to be replaced at 24000 H inspection. 5 For the grease, refer to Table 9-2 Inspection Parts and Grease Used on page 9-6.
Service Company
Licensee
24000 H
36000 H
Daily
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Fig. 9-1: Inspection Items
156192-1CD
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S-AXIS 4
1 S-AXIS
T-AXIS 8
9 9.1
8 B-AXIS 14 BT-AXES 13 1 R-AXIS
10
U-AXIS
4 16 4 U-AXIS 1 L-AXIS 13
Maintenance and Inspection Inspection Schedule
9-5
15 12 4
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9 Maintenance and Inspection 9.2 Notes on Maintenance Procedures
Table 9-2: Inspection Parts and Grease Used

No. 12, 13 14, 15 16 Grease Used VIGO Grease RE No. 0 Inspected Parts Speed reducers for S-, L- and U-axes
Harmonic Grease SK-1A Speed reducers for R-, B- and T-axes T-axis gear Alvania EP Grease 2 R-axis cross roller bearing
The numbers in the above table correspond to the numbers in Table 9-1 Inspection Items on page 9-3.
9.2
9.2.1
Notes on Maintenance Procedures
Battery Pack Replacement The battery packs are installed in the position shown in Fig.9-2 Battery Location. If the battery alarm occurs in the DX100/FS100, replace the battery in accordance with the following procedure: Fig. 9-2: Battery Location
Battery pack
Connector base
Support
Connector base Connector base fixing screw
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9 Maintenance and Inspection 9.2 Notes on Maintenance Procedures Fig. 9-3: Battery Connection
See step 5 below Connector Battery pack before replacement
Board (type: SGDR-EFBA02A)
See step 4 below New battery pack (HW0470360-A)
1. Turn OFF the DX100/FS100 main power supply. 2. Remove the plate fixing screws and the plate on the connector base, then pull the battery pack out to replace it with the new one. 3. Remove the battery pack from the battery holder. 4. Connect the new battery pack to the unoccupied connector on the board. 5. Remove the old battery pack from the board.
NOTE
Remove the old battery pack after connecting the new one so that the encoder absolute data does not disappear.
6. Mount the new battery pack to the holder. 7. Reinstall the plate.
NOTE
Do not allow plate to pinch the cables when reinstalling the plate.
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9 Maintenance and Inspection 9.3 Notes on Grease Replenishment and Exchange Procedures
9.3
Notes on Grease Replenishment and Exchange Procedures

Make sure to follow the instructions listed below at grease replenishment and exchange. Failure to observe the following notes may result in damage to motor and speed reducer. If grease is added without removing the plug or screw from the grease exhaust port, the grease will leak inside a motor or an oil seal of a speed reducer will come off, which may result in damage to the motor. Make sure to remove the plug or screw.
NOTE
Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal. Make sure to use a grease pump to inject grease. Set air supply pressure to the grease pump at 0.3 MPa or less, and the grease injection rate at 8 g/s or less. Make sure to fill the hose on the grease inlet with grease beforehand to prevent air from leaking into the speed reducer.
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9.3.1
Grease Replenishment and Exchange for S-Axis Speed Reducer Fig. 9-4: S-Axis Speed Reducer Diagram
Grease exhaust port Hexagon socket head plug PT1/8
Grease inlet Hexagon socket head plug PT1/8
S-axis speed reducer
NOTE
For the ceiling-mounted manipulator, the grease exhaust port and the grease inlet are inverted.
9.3.1.1
Grease Replenishment (Refer to Fig.9-4 S-Axis Speed Reducer Diagram.) Replenish the grease according to the following procedure: 1. Remove the hexagon socket head plugs PT1/8 from the grease inlet and grease exhaust port.
NOTE
If grease is injected with the plug on, the grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection.
2. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the manipulator.) 3. Inject the grease through the grease inlet using a grease gun Grease type: Amount of grease: Air supply pressure of grease pump: Grease injection rate: VIGO Grease RE No. 0 30 cc (60 cc for 1st supply) 0.3 MPa or less 8 g/s or less
4. Move the S-axis for a few minutes to discharge excess grease.
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9 Maintenance and Inspection 9.3 Notes on Grease Replenishment and Exchange Procedures 5. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C (see Table 10-1 Spare Parts for YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 on page 10-1) on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm (0.51 kgfm). 6. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm (0.51 kgfm).
9.3.1.2
Grease Exchange (Refer to Fig. 9-4 S-Axis Speed Reducer Diagram on page 9-9.) 1. Remove the hexagon socket head plugs PT1/8 from the grease inlet and grease exhaust port.
NOTE
2. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the manipulator.) 3. Inject the grease through the grease inlet using a grease gun. Grease type: Amount of grease: Air supply pressure of grease pump: Grease injection rate: VIGO Grease RE No. 0 approx. 1800 cc 0.3 MPa or less 8 g/s or less
4. The grease exchange is completed when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color.) 5. Move the S-axis for a few minutes to discharge excess grease. 6. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm (0.51 kgfm). 7. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.2
Grease Replenishment and Exchange for L-Axis Speed Reducer Fig. 9-5: L-Axis Speed Reducer Diagram
Grease exhaust port Hexagon socket head plug PT 1/8 L-arm L-axis speed reducer
Grease inlet Hexagon socket head cap screw M6
NOTE
9.3.2.1
Grease Exchange (Refer to Fig.9-5 L-Axis Speed Reducer Diagram.) 1. Make the L-arm vertical to the ground. 2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port. 3. Remove the hexagon socket head cap screw M6 from the grease inlet.
NOTE
4. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the manipulator.) 5. Inject grease through the grease inlet using a grease gun. Grease type: Amount of grease: Air supply pressure of grease pump: Grease injection rate: VIGO Grease RE No. 0 30 cc (60 cc for 1st supply) 0.3 MPa or less 8 g/s or less
6. Move the L-axis for a few minutes to discharge excess grease. 7. Remove the grease zerk from the grease inlet, and reinstall the screw. Before installing the screw, apply ThreeBond 1206C on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm). 8. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.2.2
Grease Exchange (Refer to Fig. 9-5 L-Axis Speed Reducer Diagram on page 9-11.) 1. Make the L-arm vertical to the ground. 2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port. 3. Remove the hexagon socket head cap screw M6 from the grease inlet.
NOTE
If grease is injected with the screw on, the grease will leak inside the motor and may cause a damage. Make sure to remove the screw before the grease injection.
4. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the manipulator.) 5. Inject grease through the grease inlet using a grease gun. Grease type: Amount of grease: Air supply pressure of grease pump: Grease injection rate: VIGO Grease RE No. 0 approx. 500 cc 0.3 MPa or less 8 g/s or less
6. The grease exchange is completed when new grease appears in the grease exhaust port. (The new grease can be distinguished from the old grease by color.) 7. Move the L-axis for a few minutes to discharge excess grease. 8. Remove the grease zerk from the grease inlet, and reinstall the screw. Before installing the screw, apply ThreeBond 1206C on the thread part of the screw, then tighten the screw with a tightening torque of 10 Nm (1.0 kgfm). 9. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 4.9 Nm (0.5 kgfm).
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9.3.3
Grease Replenishment and Exchange for U-Axis Speed Reducer Fig. 9-6: U-Axis Speed Reducer Diagram
U-arm
U-axis speed reducer
Grease exhaust port Hexagon socket head cap screw M6
Grease inlet Hexagon socket head plug PT 1/8
NOTE
9.3.3.1
Grease Replenishment (Refer to Fig.9-6 U-Axis Speed Reducer Diagram.) 1. Make the U-arm horizontal to the ground. 2. Remove the hexagon socket head cap screw M6 from grease exhaust port. 3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
NOTE
4. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the manipulator.) 5. Inject grease through the grease inlet using a grease gun. Grease type: Amount of grease: Air supply pressure of grease pump: Grease injection rate: VIGO Grease RE No. 0 30 cc (60 cc for 1st supply) 0.3 MPa or less 8 g/s or less
6. Move the U-axis for a few minutes to discharge excess grease. 7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm (0.51 kgfm). 8. Wipe the discharged grease with a cloth, and reinstall the screw. Before installing the screw, apply ThreeBond 1206C on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.3.2
Grease Exchange (Refer to Fig. 9-6 U-Axis Speed Reducer Diagram on page 9-13.) 1. Make the U-arm horizontal to the ground. 2. Remove the hexagon socket head cap screw M6 from the grease exhaust port. If grease is injected with the plug on, the grease will leak inside the motor and may cause a damage. Make sure to remove the plug before the grease injection. Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this instruction may result in damage to the motor due to coming off of an oil seal.
NOTE
3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the manipulator.) 4. Inject grease through the grease inlet using a grease gun. Grease type: Amount of grease: Air supply pressure of grease pump: Grease injection rate: VIGO Grease RE No. 0 approx. 300 cc 0.3 MPa or less 8 g/s or less
5. 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.) 6. Move the U-axis for a few minutes to discharge excess grease. 7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the plug with a tightening torque of 5 Nm (0.51 kgfm). 8. Wipe the discharged grease with a cloth, and reinstall the screw to the grease exhaust port. Before installing the screw, apply ThreeBond 1206C on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.4
Grease Replenishment for R-Axis Speed Reducer Fig. 9-7: R-Axis Speed Reducer Diagram
Grease inlet Grease zerk A-MT6X1
Exhaust port Hexagon socket head cap screw M6
1. Remove the hexagon socket head cap screw M6 from the exhaust port. 2. Inject grease through the grease inlet using a grease gun. (Refer to Fig.9-7 R-Axis Speed Reducer Diagram.) Grease type: Amount of grease: Harmonic grease SK-1A 8 cc (16 cc for the first supply)
NOTE
The exhaust port is used for air exhaust, and the grease is not exhausted from the exhaust port. Do not inject excessive grease through the grease inlet.
3. Reinstall the screw on the exhaust port. Before installing the screw, apply ThreeBond 1206C on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.5
Grease Replenishment for B- and T-Axis Speed Reducers Fig. 9-8: B- and T-Axis Speed Reducers Diagram
Exhaust port (for B-axis) (Plug LP-M5)
T-axis speed reducer Exhaust port (for T-axis) (Hexagon socket set screw M6) Gease inlet (for T-axis) (Hexagon socket head cap screw M6) Gease inlet (for B-axis) (Hexagon socket head cap screw M6)
B-axis speed reducer
1. Remove the plug LP-M5 and the hexagon socket head cap screw M6 from the exhaust ports.
NOTE
Remove the cover for the B-axis speed reducer.
2. Remove the hexagon socket head cap screws M6 from the grease inlets. 3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the manipulator.) 4. Inject grease through the grease inlet using a grease gun. (Refer to Fig.9-8 B- and T-Axis Speed Reducers Diagram.) Grease type: Amount of grease: Harmonic grease SK-1A For B-axis: 10 cc (20 cc for the first supply) For T-axis: 5 cc (10 cc for the first supply)
NOTE
5. Reinstall the plug/screw to the exhaust ports. Before installing the plug/screw, apply ThreeBond 1206C on the thread part of the plug/ screw, then tighten the plug/screw with a tightening torque of 5 Nm (0.51 kgfm). 6. Remove the grease zerk from the grease inlets, and reinstall the screws. Before installing the screws, apply ThreeBond 1206C on the thread part of the screws, then tighten the screws with a tightening torque of 5 Nm (0.51 kgfm).
NOTE
Mount the cover for the B-axis speed reducer. (Refer to chapter 9.3.8 Notes for Maintenance at page 9-19.)
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9.3.6
Grease Replenishment for T-Axis Gear Fig. 9-9: T-Axis Gear Diagram
Exhaust port Plug LP-M5
Grease inlet Hexagon socket head cap screw M6
1. Remove the plug LP-M5 from the exhaust port. 2. Remove the hexagon socket head cap screw M6 from the grease inlet. 3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the manipulator.) 4. Inject grease through the gear grease inlet using a grease gun. (Refer to Fig.9-9 T-Axis Gear Diagram.) Grease type: Amount of grease: Harmonic grease SK-1A 5 cc (10 cc for the first supply)
NOTE
5. Reinstall the plug to the exhaust port. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm). 6. Remove the grease zerk from the gear grease inlet, and reinstall the screw. Before installing the screw, apply ThreeBond 1206C on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.7
Grease Replenishment for R-Axis Cross Roller Bearing Fig. 9-10: R-Axis Cross Roller Bearing Diagram
Exhaust port Plug LP-M5 R-axis cross roller bearing
Grease inlet Hexagon socket head cap screw M6 (Length: 6mm)
1. Remove the plug LP-M5 from the exhaust port. 2. Remove the hexagon socket head cap screw M6 from the grease inlet. 3. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with the manipulator.) 4. Inject grease through the grease inlet using a grease gun. (Refer to Fig.9-10 R-Axis Cross Roller Bearing Diagram.) Grease type: Amount of grease: Alvania EP grease 2 8 cc (16 cc for the first supply)
NOTE
5. Reinstall the plug to the exhaust port. Before installing the plug, apply ThreeBond 1206C on the thread part of the plug, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm). 6. Remove the grease zerk from the grease inlet, and reinstall the screw. Before installing the screw, apply ThreeBond 1206C on the thread part of the screw, then tighten the screw with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.8 9.3.8.1
Notes for Maintenance Wrist Unit The motor and encoder units are provided with the wrist unit. To prevent fumes from penetrating into the wrist unit, the matched parts are sealed with sealing bond. If the wrist cover is disassembled, make sure to reseal with sealing bond (ThreeBond 1206C, refer to Table 10-1 Spare Parts for YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 on page 10-1.) Fig. 9-11: Sealing Part of Wrist Unit
Cover Cover matching surface
Cover
Cover matching surface
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9.3.8.2
Battery Pack Connection
When performing maintenance such as replacement of a wire harness in the manipulator, the encoder connector (with CAUTION label) will be removed. In this case, be sure to connect the battery pack to the battery backup connector before removing the encoder connector.
NOTE
Removing the encoder connector without connecting the battery pack leads to disappearance of the encoder absolute data. For the battery pack connection, refer to fig. 9-12(a) Encoder Connector Diagram (for S-, L-, and U-Axes) on page 9-21 and fig. 9-12(b) Encoder Connector Diagram (for R-, B-, and T-Axes) on page 9-22.
Battery Pack Connection (for S-, L-, and U-Axis Motors) The connectors (crimped contact-pin) for the battery backup are installed at the end point of the motors (marked as BAT and OBT). Connect the battery pack according to the following procedure. 1. Remove the cap attached to the battery backup connector of the motors. 2. Connect the battery packs (HW9470932-A) with the battery backup connectors located at the end point of the cables for the encoder. (Under this condition, remove the encoder connector and carry out the maintenance checks). 3. After the maintenance check, verify that all the connectors are connected and remove the battery pack. Install the caps attached to the battery backup connector of the motor.
NOTE
Do not remove the battery pack in the connector base.
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9 Maintenance and Inspection 9.3 Notes on Grease Replenishment and Exchange Procedures Fig. 9-12(a): Encoder Connector Diagram (for S-, L-, and U-Axes)
Encoder connector Motor
CAUTION
Connect battery to encoder to save the data before removing conector.
Motor power connector
CAUTION label
0BT BAT
b a
a 0BT* b BAT*
Battery pack (HW9470932-A) Connector for the battery backup
CAUTION label (Enlarged view)
a: Crimped contact-pin (pin) b: Crimped contact-pin (socket)
CAUTION
Battery Pack Connection (for R-, B-, and T-Axis Motors) The connectors (crimped contact-pin) for the battery backup are installed at the end point of the motors (marked as BAT and OBT). Connect the battery pack according to the following procedure. 1. Connect the battery packs (HW9470932-A) with the battery backup connectors located at the end point of the cables for the encoder. (Under this condition, remove the encoder connector and carry out the maintenance checks). 2. After the maintenance check, verify that all the connectors are connected and remove the battery pack. Install the caps attached to the battery backup connector of the motor.
NOTE
Do not remove the battery pack in the connector base.
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9 Maintenance and Inspection 9.3 Notes on Grease Replenishment and Exchange Procedures Fig. 9-12(b): Encoder Connector Diagram (for R-, B-, and T-Axes)
Encoder Motor
Motor cable, etc. Wire harness in manipulator
Power connector Connection

b 0BT BAT
0BT BAT
a b
CAUTION
Encoder connector
Battery pack (HW9470932-A)
CAUTION label
0BT BAT a b b a 0BT BAT
CAUTION label (Enlarged view)
CAUTION
a: Crimped contact-pin (pin) b: Crimped contact-pin (socket)
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10
Recommended Spare Parts
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-HP20D/HP20F. Product performance cannot be guaranteed when using spare parts from any company other than Yaskawa. The spare parts are ranked as follows: Rank A: Expendable and frequently replaced parts Rank B: Parts for which replacement may be necessary as a result of frequent operation Rank C: Drive unit
NOTE
For replacing parts in Rank B or Rank C, contact your Yaskawa representative.
Table 10-1: Spare Parts for YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 (Sheet 1 of 2)
Rank Parts Name No. A A A A A 1 2 3 4 5 Grease Grease Grease Liquid Seal Battery Pack Type Manufacturer Qty. Qty. per Unit Remarks
VIGO Grease RE No. 0 Harmonic Grease SK-1A ThreeBond 1206C HW0470360-A
Yaskawa Harmonic Drive Systems Inc. ThreeBond Co., Ltd. Yaskawa
16 kg
2.5 kg 16 kg 1 1 for connector base for wire harness in manipulator replacing
Alvania EP Grease 2 Showa Shell Sekiyu K.K.
Battery Pack
HW9470932-A
Yaskawa
B B B B B B B B B B B
7 8 9 10 11 12 13 14 15 16 17
B-Axis Timing Belt 80S4.5M653 T-Axis Timing Belt 80S4.5M518 S-Axis Speed Reducer S-Axis Input Gear L-Axis Speed Reducer L-Axis Input Gear U-Axis Speed Reducer R-Axis Speed Reducer B-Axis Speed Reducer T-Axis Speed Reducer Internal Wire Harness HW0387753-B HW0313491-1 HW0387753-C HW0313492-1 HW9280880-G HW0381463-A HW9381633-A HW0382140-A HW0174855-A
Mitsuboshi Belting Limited 1 Mitsuboshi Belting Limited 1 Yaskawa Yaskawa Yaskawa Yaskawa Yaskawa Yaskawa Yaskawa Yaskawa Yaskawa 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1
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Recommended Spare Parts
Table 10-1: Spare Parts for YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 (Sheet 2 of 2)
Rank Parts Name No. B C 18 19 Internal Cable for B- and T-Axes S-Axis AC Servomotor L-Axis AC Servomotor U-Axis AC Servomotor AC Servo Motor for R-, B- and TAxes Board Type Manufacturer Qty. Qty. per Unit 1 1 Remarks
HW0270954-A HW0388665-A SGMRV-09ANAYR1* HW0388667-A SGMRV-13ANAYR2* HW0388663-A SGMRV-05ANAYR1* HW0389298-A SGMPH-02ANAYR1* SGDR-EFBA02A
Yaskawa Yaskawa
1 1
20
Yaskawa
21
Yaskawa
22
Yaskawa
23
Yaskawa
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11 Parts List 11.1 S-Axis Unit
11
Parts List
11.1 S-Axis Unit
1008 1001 1010 1034 1013 1020 1022 1021 1024 1023 1027 1030 1033 1014 1024 1023 1026 1009 1036 1035 1031 1032
1011 1012
1030
1002
1016 1015 1017 1018 1025
1004 1003 1006 1005
1014 1020
1007
1028 1029
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11 Parts List 11.1 S-Axis Unit
Table 11-1: S-axis Unit

No. 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 DWG No. SGMRV-09ANA-YR1* HW0100545-2 M16X20 2H-16 HW0387753-B M10X40 HW0100544-2 M8X30 HW0305306-2 M5X10 PT1/8 UKM6-01 HW0305809-1 NB-0640-0.3 HW0304221-1 M6X15 MSB8-15 HW0400645-1 M5X10 TSH6-01M CD-31 M6X10 TA1-S10 M5X10 EZ5036A0 M6X15 HW0305812-1 HW9406775-1 M6X8 M12 M8X60 2H-8 M12X35 HW0313491-1 M6X60 2H-6 Name Motor S head Socket screw Spring washer Speed reducer GT-SA bolt Base GT-SA bolt M base APS bolt Plug Union Cover Tube Cover GT-SA bolt Shoulder Lever APS bolt Union Saddle Socket screw Clamp Screw with spring washer Cap GT-SA bolt Holder Cover APS bolt Eye bolt Socket screw Spring washer GT-SA bolt Gear Socket screw Spring washer Pcs. 1 1 1 1 1 16 1 3 1 1 1 1 1 2 1 2 1 1 6 2 1 2 2 2 1 2 1 1 1 2 3 3 12 1 1 1
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11 Parts List 11.2 L-Axis Unit
11.2
L-Axis Unit
2024 2025 2001 2023 2017 2005
2004 2011 2012 2010 2009 2008 2003 2006 2002
2019
2018
2007
2028 2026 2027 2014 2013 2014 2013 2016 2015 2022 2021 2020
2032
2029 2031 2030 2033 2034
1002
2035 2036
2031
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11 Parts List 11.2 L-Axis Unit
Table 11-2: L-Axis Unit

No. 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 1002 DWG No. SGMRV-13ANA-YR2* M6X90 2H-6 HW0313492-1 HW0304229-1 Y426012.5 HW0401506-1 HW0304226-1 M6X10 2H-6 HW0304227-1 M6X8 M12X40 2H-12 M10X35 2H-10 HW0100546-2 HW0387753-C M10X40 M12X40 2H-12 HW0404196-4 M8X30 M8X25 *DACROTIZED coating* 2H-8 *DACROTIZED coating* TA1-S10 M5X10 M6X10 HW0305813-1 HW0305698-1 M5X12 PT1/8 *DACROTIZED coating* CD-31 M5X12 TA1-S10 M5X10 HW0100545-2 Name Motor Socket screw Spring washer Gear M base Oil seal Plate Support Socket screw Spring washer Cover APS bolt Socket screw Spring washer Socket screw Spring washer L arm Speed reducer Socket screw Socket screw Spring washer Washer GT-SA bolt Socket screw Spring washer Clamp Screw with spring washer Socket screw Holder Cover GT-SA bolt Plug Saddle GT-SA bolt Clamp Screw with spring washer S head Pcs. 1 1 1 1 1 1 1 1 2 2 1 4 12 12 6 6 1 1 16 2 2 1 4 4 4 4 4 1 1 1 6 1 1 2 2 2 1
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11 Parts List 11.3 U-Axis Unit
11.3
U-Axis Unit
3003 3004 3002 3003 3004 3001 3020 3005
3002 3019 3019 3012 3006 3016 3018 3017
2017
3009 3008
3016 3018 3017
3011 3010 3007 3013 3014
3015
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Table 11-3: U-Axis Unit

No. 3001 3002 3003 3004 3005 3006 3007 3008 3009 3010 3011 3012 3013 3014 3015 3016 3017 3018 3019 3020 2017 DWG No. SGMRV-05A3A-YR1* HW0313489-1 M4X10 M4 HW0102378-1 HW9280880-G M8X45 M5X65 2H-5 M14X35 GT-SH-14 M8X30 M10X20 H-10 M6X10 HW0404196-2 M10X35 2H-10 PT1/8 EZ2940A0 HW0100546-2 Name Motor Cover APS bolt Washer Casing Speed reducer GT-SA bolt Socket screw Spring washer Socket screw GT-SH washer GT-SA bolt Socket screw Spring washer Socket screw Washer Socket screw Spring washer Plug Cap L arm Pcs. 1 1 7 7 1 1 16 1 1 6 6 4 1 1 1 2 2 2 2 1 1
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11 Parts List 11.3 U-Axis Unit R-Axis Unit
4033 4012 4031
4032 4029
4074
4071 4010 4008 4030 4029 4042 4009 4056 4006 4007 3005 4057
4036
4072 4066
4058
4005
4035 4043 4044 4011
4003
4028 4027 4026

4076 4075 4037 4034 4023 4039 4025 3014 4040 4051 4022
4073
4060 4055
4062 3012 4046 4045 4020
4013 4024 4019 4021
4017
4067 4065
4015
4014 4016 4004 4069 4068 5046 4018 4002 4070 4001
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Table 11-4: R-Axis Unit (Sheet 1 of 2)

No. 4001 4002 4003 4004 4005 4006 4007 4008 4009 4010 4011 4012 4013 4014 4015 4016 4017 4018 4019 4020 4021 4022 4023 4024 4025 4026 4027 4028 4029 4030 4031 4032 4033 4034 4035 4036 4037 4039 4040 4042 4043 4044 DWG No. M6X65 2H-6 M5X20 M4X12 HW0305305-1 M4X20 2H-4 HW0404196-5 M6X20 M4X45 M6X6 A-MT6X1 HW0381872-A M6X35 HW0403879-1 TC941045*A727* HW0403857-1 HW0405201-2 HW0304318-1 HW0304085-1 HW0304914-1 HW0403879-1 M4X20 M4X12 HW0200530-1 HW0404919-1 M5X16 2H-5 HW0381463-A HW0404403-1 AE1314A0 HW0304932-1 HW0404402-1 2H-4 HW0404900-1 M4X10 M5X16 TA1-S8 M4X8 M5X8 M6X6 LP-M5 Name Socket screw Spring Washer GT-SA bolt GT-SA bolt M cover Socket screw Spring Washer Washer GT-SA bolt Socket screw Socket screw G Nipple Cross roller bearing GT-SA bolt Saddle Oil seal Shaft Block Housing Shaft Support Saddle Socket screw GT-SA bolt S cover Support Socket screw Spring washer Speed reducer Shaft Oil seal M base Shaft Spring Washer N base Screw with spring washer GT-SA bolt Clamp Screw with spring washer APS bolt Socket screw Plug Pcs. 8 8 4 4 1 12 12 1 8 1 1 1 1 8 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 1 1 1 1 2 1 4 4 4 4 1 1 1
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11 Parts List 11.3 U-Axis Unit Table 11-4: R-Axis Unit (Sheet 2 of 2)
No. 4045 4046 4051 4055 4056 4057 4058 4060 4062 4065 4066 4067 4068 4069 4070 4071 4072 4073 4074 4075 4076 3005 3012 3014 5046 DWG No. M5X35 2H-5 M4X12 HW0404918-1 SGMPH-02A2A-YR1* EZ5036A0 M6X20 HW0304930-1 6811LLU M4X20 KQE12-03 2H-4 M4X20 2H-4 MS4-10 2H-4 PT 3/8 M4X12 M6X30 TA1-S8 M4X8 HW0102378-1 M4X16 HW0404179-1 HW0100623-1 Name Socket screw Spring Washer GT-SA bolt Support Motor Cap GT-SA bolt Support Bearing Socket screw Union Spring Washer Socket screw Spring Washer Pin Spring Washer Plug GT-SA bolt GT-SA bolt Clamp Screw with spring washer Casing GT-SA bolt Support U arm Pcs. 2 2 2 1 1 1 6 1 1 2 1 2 2 2 2 1 1 2 3 3 3 1 4 2 1
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11 Parts List 11.4 Wrist Unit
11.4
3005
Wrist Unit
5045
5046
5001 5002
5005 5003 5006 5007
5011 5008 5008 5007
5045 5044 5003 5043 5005 5048 5039 5049 5036 5041 5047 5031 5032 5050 5024 5029 5028 5027 5025 5026 5065 5066 5052 5053 5033 5021 5017 5016 5062 5063 5040 5012 5018 5038 5014 5019 5006 5037
5026 5064 5035 5071
5013
5034
5042
5023 5071 5020 5022
5030
5060
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11 Parts List 11.4 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)

No. 5001 5002 5003 5005 5006 5007 5008 5011 5012 5013 5014 5016 5017 5018 5019 5020 5021 5022 5023 5024 5025 5026 5027 5028 5029 5030 5031 5032 5033 5034 5035 5036 5037 5038 5039 5040 5041 5042 5043 5044 5045 5046 5047 5048 DWG No. HW9406556-1 M4X12 M5X20 HW9200798-1 SGMPH-02A2A-YR12 M4X16 HW9482727-A 80S4.5M518 HW9381658-A M4X12 HW9405452-1 HW9482725-A M5X16 M4X16 HW9482218-A HW9405199-1 SP-0120** HW9481180-A M5X16 M5X12 HW0304232-1 TC60747 HW9481187-A HW0304233-1 S75 HW0304087-1 HW0382140-A HW0304086-1 HW9381659-A HW9482726-A M5X16 6002ZZ 6901ZZ 6814ZZ HW9482668-A HW9381633-A HW9405792-1 HW0200451-1 M5X16 80S4.5M653 M5X12 HW0100623-1 M6X6 M4X16 Name Support GT-SA bolt GT-SA bolt Cover Motor Socket screw Pulley Belt Gear GT-SA bolt B cover Pulley GT-SA bolt GT-SA bolt Bearing B nut Shim Bearing GT-SA bolt GT-SA bolt Shaft Oil seal Bearing Shaft O ring Housing Speed reducer Housing Gear Pulley Socket screw Bearing Bearing Bearing Oil seal Speed reducer Housing Wrist base GT-SA bolt Belt GT-SA bolt U arm Socket screw GT-SA bolt Pcs. 1 2 4 2 2 2 2 1 1 4 1 1 1 4 1 1 1 1 1 8 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 11 1 24 1 1 13
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11 Parts List 11.4 Wrist Unit Table 11-5: Wrist Unit (Sheet 2 of 2)
No. 5049 5050 5052 5053 5057 5062 5063 5064 5065 5066 3005 DWG No. M4X12 M6X6 M5X16 M6X6 M6 LP-M5 HW9405791-3 6811LLU HW0404606-1 HW040605-1 HW0102378-1 Name GT-SA bolt Socket screw GT-SA bolt Socket screw L Washer Plug Housing Bearing Cover Plug Casing Pcs. 4 1 5 1 1 1 1 1 1 1 1
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INSTRUCTIONS
Specifications are subject to change without notice for ongoing product modifications and improvements.
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Instructions: Motoman-Hp20D/Hp20F

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MOTOMAN-HP20D/HP20F

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Notes for Safe Operation

Must never be performed.

Definition of Terms Used Often in This Manual (DX100)

Definition of Terms Used Often in This Manual (FS100)

Explanation of Warning Labels

WARNING Label B WARNING Label A WARNING Label B

1 Product Confirmation 1.1 Contents Confirmation

1 Product Confirmation 1.2 Order Number Confirmation

Order Number Confirmation

Fig. 1-1: Location of Order Number Labels

INTERRUPT CURRENT SERIAL No. DATE

FBB CN210 CN211

(c) FS100 (Front View)

(a) DX100 (Front View)

(b) Manipulator (Top View)

2 Transport 2.1 Transport Method

2 Transport 2.1 Transport Method

Eyebolt M12 (2 eyebolts) (Delivered with the manipulator)

2 Transport 2.1 Transport Method

Bolt M16 (4 places) Pallet

Forklift claw entries

2 Transport 2.2 Cushioning Material for Transport

Cushioning Material for Transport

Enlarged View: Section A

Enlarged View: Section B

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

The manipulator may overturn and cause injury or damage.

Failure to observe these warnings may result in injury or damage.

3 Installation 3.1 Safeguarding Installation

Mounting Procedures for Manipulator Base

Table 3-2: Endurance Torque in Operation

3 Installation 3.2 Mounting Procedures for Manipulator Base

Manipulator base Anchor bolt (M16 or larger) Baseplate

375 335 18 dia. holes (4 holes) 2000.1 313 2000.1 60

3 Installation 3.3 Ways of Mounting

3 Installation 3.4 Location

4 Wiring 4.1 Grounding

Failure to observe this warning may result in fire or electric shock.

4 Wiring 4.2 Cable Connection Fig. 4-1: Grounding Method

5.5 mm2 or more

Bolt M8 (For grounding) Delivered with the manipulator

4 Wiring 4.2 Cable Connection Fig. 4-2(a): Manipulator Cables (DX100)

Encoder cable DX100 side Manipulator side

Encoder cable Manipulator side

Connector Details (Manipulator Side)

Fig. 4-3(b): Manipulator Cable Connection (DX100 Side)

Fig. 4-3(c): Manipulator Cable Connection (FS100 Side)

5 Basic Specifications 5.1 Basic Specifications

Table 5-1: Basic Specifications1)

R-Axis B-Axis T-Axis

Allowable Inertia (GD

R-Axis B-Axis T-Axis

Approx. Mass Ambient Conditions Temperature Humidity Vibration Acceleration Others

5 Basic Specifications 5.2 Part Names and Working Axes

Part Names and Working Axes

5 Basic Specifications 5.3 Manipulator Base Dimensions

Manipulator Base Dimensions