MOTOMAN-UP20M INSTRUCTIONS

YASKAWA

MOTOMAN-UP20MINSTRUCTIONSYR-UP20M-A00YR-UP20M-A01 (WITH LU-AXIS LIMIT SWITCH)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN SETUP MANUAL MOTOMAN-UP20M INSTRUCTIONSYASNAC XRC INSTRUCTIONSYASNAC XRC OPERATORS MANUALYASNAC XRC OPERATORS MANUAL for BEGINNERS

The YASNAC XRC operators manuals above correspond to specific usage. Be sure to use the appropriate manual.

Do not submit this electronic data to the customer.

THIS MATERIAL IS FOR STUDY PURPOSE ONLY.YOU MUST READ THE MANUAL WHICH ENCLOSEDWITH A ROBOT.

YASKAWA MANUAL NO. HW0480368

This instruction manual is intended to explain operating instructions and maintenance procedures primarily for the MOTOMAN-UP20M.

General items related to safety are listed in the Safety Manual Section 1: Safety. To ensure correct and safe operation, carefully read the Setup Manual before reading this manual.

Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before operating this product.

The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.

YASKAWA may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications.If such modification is made, the manual number will also be revised.

If your copy of the manual is damaged or lost, contact a YASKAWA rep-resentative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your prod-ucts warranty.

MANDATORY

CAUTION

ii

NOTES FOR SAFE OPERATIONRead this manual carefully before installation, operation, maintenance, or inspection of the YASNAC XRC. In this manual, the Notes for Safe Operation are classified as WARNING, CAUTION, MANDATORY, or PROHIBITED.

Even items described as CAUTION may result in a serious accident in some situations.

At any rate, be sure to follow these important items.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to personnel and dam-age to equipment. It may also be used to alert against unsafe practices.

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

Must never be performed.

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

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

iii

Before operating the manipulator, check that servo power is turned off when the emergency stop buttons on the playback panel or program-ming pendant are pressed.When the servo power is turned off, the SERVO ON READY lamp on the playback panel and the SERVO ON LED on the programming pendant are turned off.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.

Emergency Stop Button

Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator.Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Stop

Always set the Teach Lock before entering the robot work envelope to teach a job.

Operator injury can occur if the Teach Lock is not set and the manipulator is started from the playback panel.

Observe the following precautions when performing teaching operations within the working envelope of the manipulator :- View the manipulator from the front whenever possible.- Always follow the predetermined operating procedure.- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

Confirm that no persons are present in the manipulators work envelope and that you are in a safe location before:- Turning on the YASNAC XRC power- Moving the manipulator with the programming pendant- Running check operations- Performing automatic operations

Injury may result if anyone enters the working envelope of the manipulator during opera-tion. Always press an emergency stop button immediately if there are problems.The emergency stop button is located on the right side of both the YASNAC XRC play-back panel and programming pendant.

WARNING

TURN

iv

Definition of Terms Used Often in This ManualThe MOTOMAN manipulator is the YASKAWA industrial robot product.The manipulator usually consists of the controller, the playback panel, the programming pen-dant, and supply cables.In this manual, the equipment is designated as follows:

Perform the following inspection procedures prior to conducting manip-ulator teaching. If problems are found, repair them immediately,and be sure that all other necessary processing has been performed.-Check for problems in manipulator movement.-Check for damage to insulation and sheathing of external wires.

Always return the programming pendant to the hook on the XRC cabinet after use.

The programming pendant can be damaged if it is left in the manipulators work area, on the floor, or near fixtures.

Read and understand the Explanation of the Alarm Display in the Setup Manual before operating the manipulator:

Equipment Manual Designation

YASNAC XRC Controller XRC

YASNAC XRC Playback Panel Playback Panel

YASNAC XRC Programming Pendant Programming Pendant

CAUTION

v

AN EXPLANATION OF WARNING LABELSThe following warning labels are attached to the manipulator.Always follow the warnings on the labels.Also, an identification label with important information is placed on the body of the manipula-tor. Prior to operating the manipulator, confirm the contents.

MOTOMAN

TYPE!!!!!!

ORDER NO. !!!!!!

PAYLOAD !! kg

MASS !!! kg

SERIAL NO. !!!!!!

DATE !!

YASKAWA ELECTRIC CORPORATION JAPAN

Do not enterrobot work area

WARNING

Moving parts maycause injury

WARNING

vi

1 Receiving1.1 Checking Package Contents. . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Checking the Order Number . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

2.1.1 Using the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12.1.2 Using the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.2 Shipping Bolts and Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

3 Installation3.1 Safety Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.2 Mounting Procedures for Manipulator Baseplate . . . .3-2

3.2.1 When the Manipulator and Mounting Fixture areInstalled on a Common Flat Steel Plate . . . . . . . . . . . . . . . . . .3-3

3.2.2 When the Manipulator is Mounted Directly on the Floor . . . . . .3-4

3.3 Types of Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.3.1 S-Axis Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53.3.2 Affixing the Manipulator Base . . . . . . . . . . . . . . . . . . . . . . . . . .3-53.3.3 Precautions to Prevent the Manipulator from Falling. . . . . . . . .3-5

3.4 After Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.5 IP (International Protection) for Main Part of the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3.6 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

4 Wiring4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-24.2.2 Connection to the XRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

5 Basic Specifications5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . .5-2

vii

5.3 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 Dimensions and Working Range . . . . . . . . . . . . . . . . . . . 5-3

5.5 B-Axis Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.6 Alterable Working Range. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

6 Allowable Load for Wrist Axis and Wrist Flange6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

7 System Application7.1 Mounting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Incorporated Wire and Airduct . . . . . . . . . . . . . . . . . . . . . . 7-2

8 Motoman Construction8.1 Position of S-Axis Limit Switch . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

9 Maintenance and Inspection9.1 Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-5

9.2.1 Battery Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59.2.2 Grease Replenishment/Replacement for S-Axis Speed Reducer

and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7# Grease Replenishment (Refer to " Fig. 25 S-Axis Speed

Reducer and Gear Diagram " . . . . . . . . . . . . . . . . . . . . . . . . 9-7# Grease Replacement (Refer to " Fig. 25 S-Axis Speed Reducer

and Gear Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89.2.3 Grease Replenishment/Replacement for L-Axis Speed Reducer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8# Grease Replenishment (Refer to " Fig. 26 L-Axis Speed

Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8# Grease Replacement (Refer to " Fig. 26 L-Axis Speed Reducer

Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-99.2.4 Grease Replenishment/Replacement for U-Axis Speed Reducer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10# Grease Replenishment (Refer to " Fig. 28 U-Axis Speed

Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

viii

# Grease Replacement (Refer to " Fig. 28 U-Axis Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

9.2.5 Grease Replenishment for R-Axis Speed Reducer . . . . . . . . .9-11# Grease Replenishment (Refer to " Fig. 29 R-Axis Speed

Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-129.2.6 Grease Replenishment for B- and T-Axis Speed Reducers and

B-Axis Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-129.2.7 Grease Replenishment for T-Axis Gear(Refer to " Fig. 31 T-Axis

Gear Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-139.2.8 Grease Replenishment for R-Axis Taper Roller Bearing(Refer to"

Fig. 32 R-Axis Tapered Roller Bearing Diagram ".) . . . . . . . .9-149.2.9 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15

# Battery Unit Connection for S-and L-axes motors . . . . . . . .9-15# Battery Unit Connection for U-,R-,B-,and T-Axes Motors . .9-15# Wrist Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17

10 Recommended Spare Parts

ix

1.1 Checking Package Contents

1 Receiving

1.1 Checking Package Contents

When the package arrives, check the contents for the following standard items (Any additional options ordered should be checked as well.):

Manipulator XRC Programming Pendant Power supply Cables(3 cables) Between Controller and Manipulator

Confirm that the manipulator and the XRC 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.

CAUTION

1-1

1.2 Checking the Order Number

1.2 Checking the Order Number

Check that the order number of the manipulator corresponds to the XRC. The order number is located on a label as shown below.

Fig. 1 Location of Order Number Labels

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

Label(Enlarged view)

THE MANIPULATOR AND THE CONTROLLER SHOULD HAVE SAME ORDER NUMBER.

ORDER. No. !!!!!!

Check that the manipulator and the XRC have the same order number.

YASNAC XRC

TYPE

POWER SUPPLY

DATE P/N

MADE IN JAPAN

SERIAL NO.

ERCR-

NJ2063-1

200/220V 50/60Hz 3PHASE KVA

ON

TRIP

RES

ETO

FF

UP20

T-Z

T+Z

XR+

B-Y

B+Y

R-X

Z+U+

L+

-0 .

9

3

6

7 8

1

4

2

5

Z-U-

X-S-

Y-L-

Y+

X+S+

ORDER NO.NJ1530

1-2

2.1 Transporting Method

2 Transporting

2.1 Transporting Method

2.1.1 Using the Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be used. The manipulator should be lifted using wire rope threaded through attached eyebolts.

Be sure the manipulator is fixed with jigs before transporting, and lift it in the posture as shown in " Fig. 2 Transporting Position ".

Fig. 2 Transporting Position

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

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

Avoid excessive vibration or shock during transporting.

The system consists of precision components, so failure to observe this caution may adversely affect performance.

CAUTION

2-1

2.2 Shipping Bolts and Jigs

2.1.2 Using the Forklift

When using a forklift, the manipulator should be fixed on a pallet with shipping bolts and jigs as shown in " Fig. 3 Using the Forklift ". Insert claws under the pallet and lift it. The pallet must be strong enough to support the manipulator. Transporting of the manipulator must be per-formed slowly in order to avoid overturning or slippage.

Fig. 3 Using the Forklift

2.2 Shipping Bolts and Jigs

The manipulator is provided with shipping bolts and jigs at points A (" Fig. 2 Transporting Position ").

The jigs are painted yellow. The number of hexagon socket head cap screws are: A: M8 X2.

Check that the eyebolts are securely fastened.

The weight of the manipulator is approximately 550kg including the shipping bolts and

jigs. Use a wire rope strong enough to withstand the weight.

Attached eyebolts are designed to support the manipulator weight. Do not use them for

anything other than transporting the manipulator.

Mount the shipping bolts and jigs for transporting the manipulator.

Avoid exerting force on the arm or motor unit when transporting, use caution when using

transporting equipment other than a crane or forklift, as injury may occur.

Before turning on the power, check to be sure that the shipping bolts and jigs have been removed. The shipping bolts and jigs then must be stored for future use, in the event that the manipulator must be moved again.

Pallet

M20 bolts(8 bolts)

Forklift claw entry

NOTE

NOTE

2-2

3 Installation

Install the safety guards.

Failure to observe this warning may result in injury or damage. Install the manipulator in a location where the fully extended arm and

tool will not reach the wall, safety guards, or controller.

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

Do not start the manipulator or even turn on the power before it is firmly anchored.

The manipulator may overturn and cause injury or damage.

When mounting the manipulator on the ceiling or 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 pre-vent the manipulator from falling.

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

Do not install or operate a manipulator that is damaged or lacking parts.

Failure to observe this caution may cause injury or damage.

Before turning on the power, check to be sure that the shipping bolts and jigs have been removed.

Failure to observe this caution may result in damage to the driving parts.

WARNING

CAUTION

3-1

3.1 Safety Guard Installation

3.1 Safety Guard Installation

To insure safety, be sure to install safety guards. They prevent unforeseen accidents with per-sonnel and damage to equipment. The following is quoted for your information and guidance.(ISO10218)

Responsibility for SafeguardingThe 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 safeguard-ing, including any redundancies, shall correspond directly to the type and level of hazard pre-sented 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 Baseplate

The manipulator should be firmly mounted on a common installation 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 as shown in " Table. 1 Maximum Repulsion Forces of the Manipula-tor ".During installation, if the flatness is not right, the manipulator shape may change and its func-tional ability may be compromised.Common installation base flatness must be kept at 0.5mm or less. Mount the manipulator base in either of the following was:" 3.2.1 When the Manipula-tor and Mounting Fixture are Installed on a Common Flat Steel Plate " or " 3.2.2 When the Manipulator is Mounted Directly on the Floor ".

Table. 1 Maximum Repulsion Forces of the Manipulator

Horizontal rotating maximum torque(S-axis moving direction)

19600N m(2000kgf･m)

Vertical rotating maximum torque(LU-axis moving direction)

51500N m(5250kgf･m)

3-2


3.2.1 When the Manipulator and Mounting Fixture areInstalled on a Common Flat Steel Plate

The common base should be rugged and durable to prevent shifting of the manipulator or the mounting fixture. The thickness of the common base is 50mm or more and an M20 size or larger anchor bolt is recommended.There are 8 mounting holes on the manipulator base. Affix the manipulator by fastening the plate with the M20 anchor bolts. The plate is tapped for M20 (70mm length) bolts. Tighten the bolts and anchor bolts securely so that they will not work loose during operation. See " Fig. 4 Mounting the Manipulator Baseplate " for the method.

Fig. 4 Mounting the Manipulator Baseplate

Manipyulator basewasherSpring

Washer

Common base

Flatness 0.5mm and below

Common base

8 M20 bolts

Anchor bolt(M20 or more)

3-3


3.2.2 When the Manipulator is Mounted Directly on the Floor

The floor should be strong enough to support the manipulator. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the manipulator as shown in " Table. 1 Maximum Repulsion Forces of the Manipulator ". As a rough standard, when there is a concrete thickness (floor) is 200mm or more, the base of the manipulator can be fixed directly to the floor with M20 anchor bolts. Before mounting the manipulator, however, check that the floor is level and that all cracks, etc. are repaired. Any thickness less than 200mm is insufficient for mounting, even if the floor is concrete.

Fig. 5 Direct Mounting on the Floor

10

FL

900

720

385

320

600

400

230

300

32

3625

0

35020

0

300

870

100 100200

800

M20 Tapped holes (8 holes)(Bolt A)

28 Dia. drilled holes (4 holes)(Base B)

M24 Tapped holes (4 holes)(Base B)(Bolt B)28 Dia. drilled holes (4 holes)(Base A)

Manipulator base

Base A

Base B

Weld these portions afterinstallation and adjustment.

Bolt A: M20·70 mm bolts (8 bolts), spring washers, plane washersBolt B: M24·70 mm bolts (4 bolts), spring washersBolts, base A and B should be equipped by user.

JA type anchor boltsM24·315 mm

The surfase mustbe level and even.

Dimensions in mm

3-4

3.3 Types of Mounting

3.3 Types of Mounting

The manipulator can be mounted in three different ways: floor-mounted (standard), wall-mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the three points listed below are different from the floor-mounted types.

S-Axis Working Range Affixing the Manipulator Base Precautions to Prevent the Manipulator from Falling

3.3.1 S-Axis Working Range

When performing a wall installation, the S-Axis movable range must be ±30°.

3.3.2 Affixing the Manipulator Base

When performing a wall or ceiling installation, be sure to use eight M20 hexagon socket head

cap bolts (tensile strength: 1200N/mm2 or more). Use a torque of 402N• m(41kgf ･ m) when screwing in the bolts.

3.3.3 Precautions to Prevent the Manipulator from Falling

When performing wall or ceiling installations, for safety purposes, take measures to keep the manipulator from falling. Refer to " Fig. 6 When Using Ceiling and Wall-Mounted Types " for details.

Fig. 6 When Using Ceiling and Wall-Mounted Types

When using wall-mounted or ceiling mounted types, contact your Yaskawa representative.

Support

M20 Hexagon socket head cap bolts (8 bolts)(tensile strength: 1200 N/mm or more)

Manipulator base 2

NOTE

3-5

3.4 After Installation

3.4 After Installation

When the manipulator shipped is the floor mounting type, yet is to mounted on the ceiling, the grease cap should be replaced with the air breezer (shipped with the manipulator) after instal-lation in the following procedure.

1. After installation of the manipulator in ceiling-mounted position, remove the grease cap installed in the L-axis motor, as shown in (a) of " Table. 7 Replasement of Grease Cap with Air Breezer ".

2. Install the air breezer (shipped with the manipulator) in the hole where the cap is removed in above 1, as shown in (b) of " Table. 7 Replasement of Grease Cap with Air Breezer ".

Fig. 7 Replacement of Grease Cap with Air Breezer

A

(a) Before Changing

L-Axis motor base

Hexagon socket head

Air breezer

Air breezer

Grease cap

Grease cap

Nipple

NippleHexagon socket head

PT 1/8 plug

PT 1/8 plug

View A

(b) After Changing

3-6

3.5 IP (International Protection) for Main Part of the Manipulator

3.5 IP (International Protection) for Main Part of the Manipulator

For standard type, environmental resistance for main part of the manipulator conforms to IP54. For wall-mounted or ceiling mounted types, it does not conform to IP54. Environmental resistance for IP65 is optional. For wrist part, the resistance conforms to IP67.

3.6 Location

When the manipulator is installed, it is necessary to satisfy the undermentioned environmental conditions:

0° to +45°C (Ambient temperature) 20 to 80%RH (no moisture) Free from dust, soot, or water Free from corrosive gases or liquid, or explosive gases

Free from excessive vibration (less than 4.9m/s2 (0.5G)) Free from large electrical noise (plasma) Out of the plane for installation is 0.5mm or less

When using wall-mounted or ceiling mounted types, contact your Yaskawa representative.NOTE

3-7

3.6 Location

3-8

4.1 Grounding

4 Wiring

4.1 Grounding

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

Refer to " Fig. 8 Grounding Method "to connect the ground line directly to the manipulator.

Fig. 8 Grounding Method

Ground resistance must be 100 Ω or less.

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

Before wiring, make sure to turn the primary power supply off, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

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

Wiring must be performed by authorized or certified personnel.

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

Do not use this line in common 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 Electric Equipment Technical Standards.

WARNING

CAUTION

NOTE

A

25.5mm or more

M8 Bolt (for grounding) provided at factory

View A

4-1

4.2 Cable Connection


There are three cables for the power supply; a signal cable for detection (1BC) and a power cable (2BC and 3BC). Connect these cables to the manipulator base connectors and the XRC. Refer to " Fig. 10 " .

4.2.1 Connection to the Manipulator

Before connecting three cables to the manipulator, verify the numbers: 1BC, 2BC and 3BC on both power supply cables and the manipulator base connectors. When connecting, adjust the cable connector positions to the main key positions of the manipulator, and insert cables in the order of 2BC, 3BC,1BC, and then set the lever until hearing a click.

4.2.2 Connection to the XRC

Remove the three entrance cable covers on the XRC side. Pass the signal cable for detection (1BC) and the power cables (2BC and 3BC) through the entrance, and then fasten the bolts on the entrances.Connect the 2BC and 3BC cables to the board and the terminals inside of the XRC. Be sure to verify the number on both cables and terminals before connecting.Connect the 1BC cable to the boards. Be sure to verify the numbers on cable and board con-nectors before connecting.

4-2


Fig. 9 Power supply Cables

Fig. 10 (a) Power supply Cable Connection to the Manipulator

Connection to the manipulator

1 BC

2BC

3BC

Connection to the XRC

WRCA01-CNPG123

E

ECN1-1CN1-2CN3

WRCA01-CNPG456

XIU01-CN25

CN4

XIU01-CN29

E

CN6U21U21

CN5

U22U22V21V21

V22V22

W21W21W22W22

E22

E21E21

E22

Power cable (2BC)

Power cable (3BC)

Signal cable for detection (1BC)

Connector details(Manipulator side)

4-3


Fig. 10 (b) Power Cable Connection to the XRC

Connector No.XIU01-CN25

Signal Cable

Connector No.XIU01-CN29

Power Cable

Grounding platefor Signal and power lineTerminal No.: E

Signal Cable

Connector No.WRCA01-CNPG456 (upper)WRCA01-CNPG123 (lower)

Power Cable

U21 to E22

Power Cable

Connector No. (from left side)CN1-1CN1-2CN3CN4CN5CN6

Tighten the screws withscrew driver(+).

4-4

5.1 Basic Specifications

5 Basic Specifications

5.1 Basic Specifications

*1 SI units are used in this table. However, gravitational unit is used in ( ).

*2 Conformed to ISO9283

*3 For UP20M-A01, the working range is restricted with limit switches, For details, refer to MOTOMAN-UP20M L-,U-axes overrun limit switch instructions

*4 Refer to " 6.1 Allowable Wrist Load " for details on the permissible moment of inertia.

Table. 2 Basic Specifications*1

Operation Mode Vertically Articulated

Degree of Freedom 6

Payload 20kg

Repetitive Positioning Accuracy*2 ±0.15mm

MotionRange

S-Axis (turning) ±180°

L-Axis (lower arm) +135°, -90°

U-Axis (upper arm) +251°, -160°

R-Axis (wrist roll) ±190°

B-Axis (wrist pitch/yaw) +230°, -50°

T-Axis (wrist twist) ±360°

MaximumSpeed

S-Axis 2.97 rad/s, 170°/s

L-Axis 2.97 rad/s, 170°/s

U-Axis 2.97 rad/s, 170°/s

R-Axis 5.85 rad/s, 335°/s

B-Axis 5.85 rad/s, 335°/s

T-Axis 8.90 rad/s, 510°/s

Allowable

Moment*4

R-Axis 31.4Nm(3.2kgf ･ m)

B-Axis 31.4Nm(3.2kgf ･ m)

T-Axis 15.7Nm(1.6kgf ･ m)

AllowableInertia

R-Axis 0.7kgm2

B-Axis 0.7kgm2

T-Axis 0.2kgm2

Mass 495kg

Ambient

Conditions*4

Temperature 0° to 45C°

Humidity 20 to 80% RH (non-condensing)

Vibration Less than 4.9m/s2 (0.5G)

Others

Free from corrosive gasses or liquids, or

explosive gasses

Clean and dry

Free from excessive electrical noise (plasma)

Power Capacity 5.0kVA

5-1

5.2 Part Names and Working Axes

5.2 Part Names and Working Axes

Fig. 11 Part Names and Working Axes

5.3 Baseplate Dimensions

Fig. 12 Baseplate Dimensions (mm)

Wrist flange

Wrist

(U arm)

Upper arm

Lower arm(L arm)

(S head)Rotary head

Base

320

195±

0.2

230±

0.2

385

455

230

400

195±0.2

455156.2

230±0.2

30

A

8-f22

2-f12+0.0250

195±

0.2

195±0.2

611.2

View ADimensions in mm

5-2

5.4 Dimensions and Working Range

5.4 Dimensions and Working Range

Fig. 13 Dimensions and Working Range

Note: For UP20M-A01, the working range is restricted with limit switches. For details, refer to MOTOMAN-UP20M L-,U-axes overrun limit switch instructions.

3501

2070

314.5

24255

85

1140

0

348

244414

12271077

2084

3106

3075

R965

120

R370

28.5

1051800

R3106

Point P

145

5377206

90

Point PWorking Range

100

200

135

160

704

3850

592236665

965

1990

71

540

1065

1396

1402

2816

45 30

1150

5-3

5.5 B-Axis Working Range

5.5 B-Axis Working Range

The working range of the B-Axis maintaining a constant angle to the center of the U-arm is shown in " Fig. 14 B-Axis Working Range ".

Fig. 14 B-Axis Working Range

5.6 Alterable Working Range

The working range of the S-Axis can be altered according to the operating conditions as shown in " Table. 3 S-Axis Working Range ". If alteration is necessary, contact your Yaskawa representative in advance.

Table. 3 S-Axis Working Range

Item Specifications

S-AxisWorkingRange

±180°(standard)±150°±120°±90°±60°±30°

140°

140°

B-Axis Rotation CenterU-Axis Rotation Center

S-Axis Rotation Center

L-Axis Rotation Center

5-4

6.1 Allowable Wrist Load

6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load

The allowable wrist load is 20kg. 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. 4 Moment and Total Inertia ". Con-tact your Yaskawa representative for further information or assistance.

When the volume load is small, refer to the moment arm rating shown in " Fig. 15 Moment Arm Rating ".The allowable total inertia is calculated when the moment is at the maximum. Contact your Yaskawa representative when only inertia moment, or load moment is small and inertia moment is large. Also, when the load mass is combined with an outside force, contact your Yaskawa representative.

Fig. 15 Moment Arm Rating

Table. 4 Moment and Total Inertia

Axis Moment Nm Total Inertia kgm2

R-AxisB-AxisT-Axis

31.431.415.7

0.70.70.2

LB(mm)

R-,T-axisrotation center

300

10kg

20kg

100 200

B-axis rotation center

LT(mm)

100

100

200

200

6-1

6.2 Wrist Flange

6.2 Wrist Flange

The wrist flange dimensions are shown in " Fig. 16 Wrist Flange ". In order to see the tram marks, it is recommended that the attachment be mounted inside the fitting. Fitting depth of inside and outside fittings must be 5mm or less.

Fig. 16 Wrist Flange

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

P.C.D.40

6 45

50h8

(

)

25H

7(

)+0

.021

0 0 -0.0

39

M8 tapped holes(4 holes)

Depth:10mm pitch:1.25mm

6H7( )+0.0120

Depth:6mm

NOTE

6-2

7.1 Mounting Equipment

7 System Application

7.1 Mounting Equipment

When peripheral equipment is attached to the U-axis, the following conditions should be observed.

Fig. 17 Installing Peripheral Equipment

Table. 5 Constraint for Attaching

Application Notes

A Cable processing 20kg max. including wrist load

B Cable processing and valve load

10kg max.49N･m(5kgf･m)max.for moment increase amount of upper arm (only for floor-and ceiling-mounted type)

C Others 30kg max.(only for floor-and ceiling-mounted type)

28.5120581.5

100

75

4018

7

8087

53

B

AM8 tapped holes(2x2 holes)Depth:15mm pitch:1.25mm

C

400

30

M8 tapped holes(2 2 holes)Depth:15mm pitch:1.25mm

M12 tapped holes(4 holes)Depth:18mm pitch:1.75mm

7-1

7.2 Incorporated Wire and Airduct

7.2 Incorporated Wire and Airduct

23 wires (0.75mm2) and an air hose are used in the manipulator for the drives of the periph-eral devices mounted on the upper arm as shown in " Fig. 18 Incorporated Wire and Airduct ".The connector pins 1 to 23 are assigned as shown in " Fig. 18 Incorporated Wire and Airduct ". Wiring must be performed by user.

The allowable current for user cable:6.6A or less for each cable (The total current value for pins 1 to 23 must be 60A or less.)

The maximum pressure for the air hose:490kpa(5kgf/cm2) or less

(The air hose inside diameter: Φ8mm.)

Fig. 18 Incorporated Wire and Airduct

The same pin number (1-23) of two connectors is connected in the lead line of single0.75mm2.

Air outlet

With plugPT3/8 tapped hole

User cable connectorJL05-2A24-28SC(with cap)Mating plug type isJL05-6A24-28P

View B

B

Air inlet

With plugPT3/8 tapped hole

User cable connectorJL05-2A24-28PC(with cap)Mating plug type is JL05-6A24-28S

9

2015

8713

1912

18

51110

16 17

6

22 2321

14

4321231

456897

131211

141615

10

AView A

Detailed drawing of connector pin numbers

Pins used number

171918

222120

23

Internal wires:0.75mm2,23wires

7-2

8.1 Position of S-Axis Limit Switch

8 Motoman Construction

8.1 Position of S-Axis Limit Switch

The limit switches for the S-, L-, and U-Axes are located as shown in " Fig. 19 Location of Limit Switches ". The limit switch for the S-Axis is standard. The limit switch for the L- and U-Axes are optional (model UP20M-A01).

Fig. 19 Location of Limit Switches

L-axis overrun L.S.(YR-UP20M-A01)

(YR-UP20M-A01)LU-axis interference L.S.

S-axis overrun L.S.

8-1

8.2 Internal Connections


High reliability connectors which can be easily removed are used with connector part. For the number and location of connectors, see " Fig. 20 Location and Numbers of Connec-tors ".

Fig. 20 Location and Numbers of Connectors

Table. 6 List of Connector Types

Name Type of Connector

Base Connectorfor Internal Wire

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

U-arm Connectorfor Internal Wire

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

No,1 6

No,20 25

No,7 19

1BC

2BC3BC

4BC(User cable connector)

No,26

User cable connector

8-2


Fig. 21 (a) Internal wireFig. 21 (b) Internal wire

8-3


8-4

9.1 Inspection Schedule

9 Maintenance and Inspection


Proper inspections are essential not only to assure that the mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. Inspection inter-vals are displayed in six levels. Conduct periodical inspections according to the inspection schedule in " Table. 7 Inspection Items ".In " Table. 7 Inspection Items ", the inspection items are classified into three types of opera-tion: operations which can be performed by personnel authorized by the user, operations which can be performed by personnel being trained, and operations which can be performed by service company personnel. Only specified personnel are to do inspection work.

Before maintenance or inspection, be sure to turn the main power sup-ply off, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

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

Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

For disassembly or repair, contact your Yaskawa representative.

Do not remove the motor, and do not release the brake.

Failure to observe this caution may result in injury from unexpected turning of the manipu-lators arm.

The battery unit must be connected before removing detection connec-tor when maintenance and inspection.

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

WARNING

CAUTION

9-1


The inspection interval must be based on the servo power supply on time.

For any different or special applications, the inspection process should be developed on

an case-by-case basis.

For axes which are used very frequently (in handling applications, etc.), it is recom-

mended that inspections be conducted at shorter Intervals. Contact your Yaskawa repre-

sentative.

Table. 7 Inspection Items

Items*4

Schedule

Method Operation

Inspection Charge

Daily1000

HCycle

6000H

Cycle

12000H

Cycle

24000H

36000H

Specified Person

LicenseeService

Company

$ Tram mark % Visual

Check tram mark accordance and damage at the home position.

% % %

& External lead % VisualCheck for damage and deterioration of leads.

% % %

'Working area andmanipulator

% Visual

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

% % %

( S,L,U-axes motor

% VisualCheck for grease

leakage.*5% % %

)Baseplate mounting bolts

% SpannerWrench

Tighten loose bolts. Replace if necessary. % % %

* Cover mount-ing screws

%Screw-driver,

Wrench

Tighten loose bolts. Replace if necessary. % % %

+SLU-axismotorconnector

% Manual

Check for loose con-nectors and tighten if necessary.

% % %

⑧Base connec-tors

% ManualCheck for loose con-nectors. % % %

, RBT-axes timing belt

% ManualCheck for belt tension and wear. % %

-

Wire harness in manipulator(SLURBT-axes leads))

% Visual Multimeter

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

% %

% Replace.*2 %

NOTE

9-2


⑪

Wire harness In manipulator(BT-axes leads)

% Visual Multimeter

Check for conduc-tion between termi-nals and wear of protective spring.*1

% %

% Replace*2 %

⑫

SLU-axes limit switch, dog

%Screw-driver,

Wrench, Multimeter

Check for stain, dam-age, and looseness. Tighten and check the dog movement.

% %

⑬Battery unit in manipulator

%

Replace the battery unit when the battery alarm occurs or the manipulator drove for 36000H.

% %

⑭S-axis speed reducer

% % Grease Gun

Check for malfunc-tion. (Replace if nec-essary.) Supply

grease*3 (6000H cycle). Replace

grease*3 (12000H cycle).See Par. 9.2.2.

% %

⑮

LU-axes speed reduc-ers

% % Grease Gun



grease*3 (12000H cycle). See Par. 9.2.3(L) and 9.2.4(U).

% %

⑯

RBT-axes speed reduc-ers

% % Grease Gun



grease*3 (12000H cycle). See Par. 9.2.5(R). and 9.2.6(BT).

% %

⑰ T-axis gear % Grease Gun


grease*3 (6000H cycle).See Par.9.2.7.

% %

⑱

R-axis tapered roller bearing

% Grease Gun


grease*3 (6000H cycle).See Par.9.2.8.

% %

⑲ Overhaul % %

Table. 7 Inspection Items

Items*4

Schedule

Method Operation

Inspection Charge

Daily1000

HCycle

6000H

Cycle

12000H

Cycle

24000H

36000H

Specified Person

LicenseeService

Company

9-3


*1 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. Other-wise, the home position may be lost. (Refer to " 9.2.9 Notes for Maintenance ")

*2 Wire harness in manipulator to be replaced at 24000H inspection.

*3 For the grease, refer to " Table. 8 Inspection Parts and Grease Used ".

*4 Inspection No. correspond to the numbers in " Fig. 22 Inspection Parts and Inspection Numbers ".

*5 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa representative.

Fig. 22 Inspection Parts and Inspection Numbers

The numbers in the above table correspond to the numbers in " Table. 7 Inspection Items ".

Table. 8 Inspection Parts and Grease Used

No. Grease Used Inspected Parts

14,15 Molywhite RE No. 00 S-, L-, and U-axis speed reducers.

16,17Harmonic Grease SK-1A R-, B-, and T-axis speed reducers,

T-axis gear

18 Alvania EP Grease 2 R-axis tapered roller bearings

17

1616

1510

7

1 B-axis

6

1T-axis

69

T-axis

B-axis9

11

6

414

1R-axis

1

16

6

s-axis

18

1U-axis

15

612

5

613

1 L-axis

2

6 8

4

9-4

9.2 Notes on Maintenance Procedures


9.2.1 Battery Unit Replacement

The battery units are attached in the two positions indicated in " Fig. 23 (a Battery Loca-tion(Back view) " and " Fig. 23 (b Battery Location(Top view) ".SLU-axes battery unit type:HW9470932-ARBT-axes battery unit type:HW9470932-BIf the battery alarm occurs in the XRC, replace the battery according to the following proce-dure:

Fig. 23 (a) Battery Location (Back view)

Fig. 23 (b) Battery Location (Top view)

Battery unit

M6 Screws (4 screws)

Connector base

Connector base part

HW9470932-A HW9470932-B

Internal cable

RBT-axesbattery unit

SLU-axesbattery unit

M5 Screw M5 Screw

9-5


Fig. 24 (a) Battery Connection for SLU-axes

Fig. 24 (b) Battery Connection for RBT-axes

1. Turn the XRC main power supply off.2. Remove the connector base, and grease tube from the union.3. Remove the battery unit mounting screw on the support.4. Remove the plastic tape (insulation tape) protecting the connection part of the battery

unit in the manipulator.5. Connect the new battery.

6. Remove the old battery.

7. Protect the connection part of the battery unit in the manipulator with plastic tape (insu-lation tape).

8. Mount the battery unit with the screws, connect the grease tube to the union, and then

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

b

a

BAT1

0BT1

0BT1

b BAT1

a

a

0BT1 b

a

b

BAT1

0BT1

BAT1

See step 6 below

See step 7 below

See step 4 belowSee step 5 below

New battery unit

Battery unit before replacement

a: Insertion-type pin terminal (male)b: Insertion-type pin terminal (female)

SLU-axesinternal cable

b

a

BAT4

0BT4

0BT4

b BAT4

a

a

0BT4 b

a

b

BAT4

0BT4

BAT4

See step 6 below

See step 7 below

See step 4 belowSee step 5 below

New battery unit

Battery unit before replacement


RBT-axesinternal cable

NOTE

9-6


mount the connector base. Apply silicon sealant (modifer silicon caulk, refer to " Table. 9 Spare Parts for the Motoman-UP20M ") on fitting surfaces of connector base.

9.2.2 Grease Replenishment/Replacement for S-Axis Speed Reducer and Gear

Fig. 25 S-Axis Speed Reducer and Gear Diagram

# Grease Replenishment (Refer to " Fig. 25 S-Axis Speed Reducer and Gear Diagram "

Replenish the grease according to the following procedure:

1. Remove the So exhaust plug.

2. Remove the plug in the Si grease inlet and install the G Nipple PT1/4.3. Inject the grease into the Si grease inlet using a grease gun.

4. Move the S-axis for a few minutes to discharge the excess grease.5. Wipe the So exhaust port with a cloth and reinstall the plug.(Spread the threebond

1211 on the screw of the plug).6. Remove the G Nipple and reinstall the plug in the Si grease inlet.

For ceiling mounted manipulators, the exhaust port and the grease inlet are inverted.

If grease is added without removing the exhaust plug, the grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug.

Grease type: Molywhite RE No. 00Amount of grease: 700cc(1400cc for 1st supply)

So :Exhaust portHexagon socket head PT1/8 plug

Si :Grease inlet Hexagon socket head PT1/4 plug

S-axis speed reducer

NOTE

NOTE

9-7


# Grease Replacement (Refer to " Fig. 25 S-Axis Speed Reducer and Gear Diagram ".)

1. Remove the So exhaust plug.

2. Remove the plug in the Si grease inlet and install the G Nipple PT1/4.

3. Inject the grease into the Si grease inlet a grease gun.

4. The grease replacement is complete when new grease appears in the So 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 the excess grease.6. Wipe the So exhaust port with a cloth and reinstall the plug. (Spread the Three Bond

1211 on screw of the plug).7. Remove the G Nipple and reinstall the plug in the Si grease inlet.

9.2.3 Grease Replenishment/Replacement for L-Axis Speed Reducer

Fig. 26 L-Axis Speed Reducer Diagram

# Grease Replenishment (Refer to " Fig. 26 L-Axis Speed Reducer Diagram ".)

1. Make the L-Arm vertical for ground.

If grease is added without removing the exhaust plug, the grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug.

Grease type: Molywhite RE No. 00Amount of grease:3400cc

For ceiling mounted manipulators, the exhaust port and the grease inlet are inverted.

NOTE

Lo : Exhaust portHexagon socket head PT1/8 plug

L-axis speed reducerLi :Grease inlet

Hexagon socket head PT1/8 plug

NOTE

9-8


2. Remove the Lo exhaust plugs.

3. Remove the plug in the Li grease inlet and install the G Nipple PT1/8.

4. Inject the grease into the Li grease inlet using a grease gun.

5. Move the L-Axis for a few minutes to discharge the excess grease.6. Wipe the Lo exhaust port with a cloth and reinstall the plug. (Spread the Three Bond

1211 on screwed parts).7. Remove the G Nipple and reinstall the plug in the Li grease inlet.

# Grease Replacement (Refer to " Fig. 26 L-Axis Speed Reducer Dia-gram ".)

1. Make the L-Arm vertical for ground.

2. Be sure to remove the Lo exhaust plug.3. Remove the plug in the Li grease inlet and install the G Nipple PT1/8

4. Inject the grease into the Li grease inlet using a grease gun.

5. The grease replacement is complete when new grease appears in the Lo exhaust ports. The new grease can be distinguished from the old grease by color.

6. Move the L-Axis for a few minutes to discharge the excess grease.7. Wipe the Lo exhaust plugs with a cloth and reinstall the plug.(Spread the Three Bond

1211 on screw of the plug).8. Remove the G Nipple and reinstall the plug in the Li grease inlet.

If grease is added without removing the exhaust plugs, the grease will go inside the motor and may damage it. It is absolutely necessary to remove the plugs.

Grease type: Molywhite RE No. 00Amount of grease: 250cc

(500cc for 1st supply)

If grease is added without removing the exhaust plugs, the grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug.

Grease type: Molywhite RE No. 00Amount of grease: approx. 1650cc

NOTE

NOTE

9-9


9.2.4 Grease Replenishment/Replacement for U-Axis Speed Reducer

Fig. 27 Grease Injection Posture of the U-Axis

Fig. 28 U-Axis Speed Reducer Diagram

# Grease Replenishment (Refer to " Fig. 28 U-Axis Speed Reducer Diagram ".)

1. Tilt the U-arm to the angle as shown in " Fig. 27 Grease Injection Posture of the U-Axis ". The L-arm must be vertical for ground.

2. Remove the Uo exhaust plug.

3. Remove the plug in the Ui grease inlet and install the G Nipple PT1/8.

4. Inject the grease into the Ui grease inlet using a grease gun.


Grease type: Molywhite RE No. 00Amount of grease: 170cc


U-arm

U-axis speed reducerGrease inlet Ui

(Hexagon socket head PT1/8 plug)

Grease exhast plug Uo

(Hexagon socket head PT1/8 plug)

NOTE

9-10


5. Move the U-Axes for a few minutes to discharge the excess grease.6. Wipe the Uo exhaust plugs with a cloth and reinstall the plug.(Spread the Three Bond

1211 on screw of the plug).7. Remove the G Nipple and reinstall the plug in the Ui grease inlet.

# Grease Replacement (Refer to " Fig. 28 U-Axis Speed Reducer Diagram ".)

1. Tilt the U-arm to the angle as shown in " Fig. 28 U-Axis Speed Reducer Diagram ". The L-arm must be vertical for ground.

2. Remove the Uo exhaust plugs.

3. Remove the plug in the Ui grease inlet and install the G Nipple PT1/8.

4. Inject the grease into the Ui grease inlet using a grease gun.

5. The grease replacement is complete when new grease appears in the Uo exhaust ports. The new grease can be distinguished from the old grease by color.

6. Move the U-Axes for a few minutes to discharge the excess grease.7. Wipe the Uo exhaust plugs with a cloth and reinstall the plug.(Spread the Three Bond

1211 on screw of the plug).8. Remove the G Nipple and reinstall the plug in the Ui grease inlet.

9.2.5 Grease Replenishment for R-Axis Speed Reducer

Fig. 29 R-Axis Speed Reducer Diagram


Grease type: Molywhite RE No. 00Amount of grease: approx. 850cc

NOTE

U-arm

(Cap:EZ5013B0)

(Cap:EZ5013B0)

R-axis speed reducer

(Hexagon socket head plug:PT1/8)

Ro:Plug for air flow

(Hexagon socket head plug:PT1/8)

Ri:Grease inlet

9-11


# Grease Replenishment (Refer to " Fig. 29 R-Axis Speed Reducer Diagram ".)

1. Remove the Ro exhaust plug.

2. Remove the plug in the Ri grease inlet and install the G Nipple PT1/8.3. Inject the grease into the Ri grease inlet using a grease gun.

4. Move the R-axis for a few minutes to discharge the excess by grease.5. Wipe the Ro exhaust port with a cloth and reinstall the plug.(Spread the three-bond

1211 on the screw of the plug.)6. Remove the G Nipple and reinstall the plug in the Ri grease inlet.

9.2.6 Grease Replenishment for B- and T-Axis Speed Reducers and B-Axis Gear

Fig. 30 B- and T-Axis Speed Reducers Diagram

1. Remove the Bo and To plug for air flow.

If grease is added without removing the exhaust plugs, the grease will go inside the motor and may damage it, It is absolutely necessary to remove the plugs.

Grease type: Harmonic grease SK-1AAmount of grease: 8cc(16cc for first supply)

Remove the U-arm cover side of the B-axis speed reducer..

NOTE

Ti:Grease inlet

Bi:Grease inlet

T-axis speed reducer

To:Plug for air flow

(G Nipple A-MT6 1)

B-axis speed reducer

Bo:Plug for air flow(Plug)

(Hexagon socket head bolt M6)


NOTE

9-12


2. Remove the hexagon socket bolts in the Bi and Ti grease inlet and install the G Nipple A-MT6x1.

3. Inject the grease into the Bi and Ti grease inlet using a grease gun..

4. Wipe the Bo and To plug for air flow with a cloth and reinstall the plug.(Spread the three-bond 1211 on the screw of the plug.)

5. Wipe the Bi and Ti exhaust port with a cloth and reinstall the hexagon socket

bolt.(Spread the three-bond 1211 on the screw of the hexagon socket bolt.)

9.2.7 Grease Replenishment for T-Axis Gear (Refer to " Fig. 31 T-Axis Gear Diagram ".)

Fig. 31 T-Axis Gear Diagram

1. Remove the Bo plug for air flow.2. Remove the hexagon socket bolt from the part of gear grease inlet and install the

G nipple A-MT6×1.

Grease type: Harmonic grease SK-1AAmount of grease:

For B-axis (Bi): 10cc (20cc for 1st supply)For T-axis (Ti): 5cc (10cc for 1st supply)

The Bo, To exhaust ports are used for air flow . Do not inject excessive grease into the Bi and Ti grease inlets.

Mount the U-arm cover side of the B-axis speed reducer.

NOTE

NOTE

Bo:Plug for air flow

(Plug)

Gear grease inlet


9-13


3. Inject grease into the gear grease inlet using a grease gun.

4. Wipe the Bo plug for air flow with a cloth and reinstall the plug.(Spread the three bond 1211 on the screw of the plug.)

5. Wipe the part of gear grease inlet with a cloth and reinstall the hexagon socket bolt on the Bi grease inlet. (Spread the three-bond 1211 on the hexagon socket bolt.)

9.2.8 Grease Replenishment for R-Axis Tapered Roller Bearing (Refer to" Fig. 32 R-Axis Tapered Roller Bearing Diagram ".)

Fig. 32 R-Axis Tapered Roller Bearing Diagram

1. Remove the Co plug for air flow.2. Remove the hexagon socket bolt from the Ci grease inlet and install the G nipple A-

MT6×1.

3. Inject grease into the Ci grease inlet using a grease gun..

Grease type: Harmonic grease SK-1AAmount of grease: 5cc


The Bo exhaust port is used for air flow . Do not inject excessive grease into the gear grease inlet.

Grease type: Alvania EP grease 2Amount of grease: 8cc


NOTE

Co:Plug for air flow

(plug:PT1/8)

Grease inlet Ci

bearing

R-axis tapered roller


9-14


4. Wipe Co plug for air flow with a cloth and reinstall the plug.(Spread the three-bond 1211 on the screw of the plug.)

5. Wipe Ci exhaust port with a cloth and reinstall the hexagon socket bolt.(Spread the three-bond 1211 on the screw of the hexagon socket bolt.)

9.2.9 Notes for Maintenance

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

# Battery Unit Connection for S-and L-axes motors

The connector (insertion-type pin terminal) for the battery backup is installed in the cap located on the encoder of the S-and L-axes motors (BAT and OBT are marked). Connect the battery unit according to the following procedure.

1. Remove the cap attached to the battery backup connector of the motor.2. Connect the S-,L-,and U-axes battery unit (HW9470932-A) for the motor.(Under such a

condition, remove the encoder connector and do the maintenance check work.)3. Confirm all connectors connection after the maintenance check ends, and remove the

battery unit.4. Install the cap attached to the battery backup connector of the motor.

# Battery Unit Connection for U-,R-,B-,and T-Axes Motors

The connector (insertion-type pin terminal) for the battery backup is installed in the end point of the cable for the encoder of the U-,R-,B-,and T-axes motors (BAT and OBT are marked). Connect the battery unit according to the following procedure.

1. Connect battery unit (HW9470932-B) for the R-,B-,and T-axes with the battery backup connector (BAT and OBT are marked) located in the end point of the cable for the encoder.(Under such a condition, remove the encoder connector and do the mainte-nance check work.)

2. Confirm all connectors connection after the maintenance check ends, and remove the battery unit.

The Co exhaust port is used for air flow. Do not inject excessive grease into the gear grease inlet.

Do not remove the battery unit in the base connector.

NOTE

NOTE

9-15


Fig. 33 Encoder Connector Diagram

b

a

BAT1

0BT1

a

b0BT

BAT

b

0BT4

BAT4

ab0BT

BAT a

Connector for the battery backup

S- and L-axes motors

Battery unit for S- and L-axes (HW9470932-A)

Connector fore the battery backup

U-, R-, B-, and T-axes motors

Battery unit for U-, R-, B-, and T-axes (HW9470932-B)

Connector for the battery backup

Encoder cable


U-, R-, B-, and T-Axes

S- and L-Axes

9-16


# Wrist Axes

The motor and encoder units are provided with the wrist unit. To prevent fumes from penetrat-ing into the wrist unit, the matched parts are sealed with silicon sealant. Therefore, if the wrist cover is disassembled, reseal with silicon sealant (modifier silicon caulk, refer to " Table. 9 Spare Parts for the Motoman-UP20M ").

Fig. 34 Sealing Part of Wrist Unit

Cover Cover joining face

Cover joining faceCover

9-17


9-18

10 Recommended Spare Parts

It is recommended that the following parts and components be kept in stock as spare parts for the Motoman-UP20M. The spare parts list for the Motoman-UP20M is shown below. Product performance can not 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

For replacing parts in Rank B or Rank C, contact your Yaskawa representative.

Table. 9 Spare Parts for the Motoman-UP20M

RankPartsNo.

Name Type Manufacturer QtyQtyperUnit

Remarks

A 1Grease Molywhite

RE No. 00Yaskawa ElectricCorporation

16kg -SLU-axes speed reducer

A 2Grease Harmonic Grease

SK-1AHarmonic DriveSystem Co., Ltd.

2.5kg -RBT-axes speed reducer

A 3Grease Alvania EP

Grease 2Showa Oil Co.,Ltd.

16kg -

A 4Silicon RubberCompound Tube

Modifier Silicon Caulk

Konishi Co., Ltd.- -

A 5Liquid gasket Three Bond 1211 Three Bond Co.,

Ltd.- -

A 6Battery Unit HW9470932-A Yaskawa Electric

Corporation1 1

for SLU-axes

A 7Battery Unit HW9470932-B Yaskawa Electric

Corporation1 1

for RBT-axes

B 8R-Axis Timing Belt 60S4.5M468 Mitsuboshi Belt-

ing Limited1 1

B 9B-Axis Timing Belt 80S4.5M729 Mitsuboshi Belt-

ing Limited1 1

B 10T-Axis Timing Belt 80S4.5M518 Mitsuboshi Belt-

ing Limited1 1

B 11S-AxisSpeed Reducer

HW9381671-B Yaskawa ElectricCorporation

1 1

B 12L-AxisSpeed Reducer

HW9381465-B Yaskawa ElectricCorporation

1 1

NOTE

10-1

B 13U-AxisSpeed Reducer

HW9381670-A Yaskawa ElectricCorporation

1 1

B 14R-AxisSpeed Reducer


1 1

B 15B-AxisSpeed Reducer


1 1

B 16T-AxisSpeed Reducer


1 1

C 17

S-AxisAC Servomotor


1 1

With brake, with key, lead terminal treatment comple-tion

C 18

L-AxisAC Servomotor


1 1

With brake, with key, lead terminal treatment comple-tion

C 19U-AxisAC Servomotor

HW9380938-A Yaskawa ElectricCorporation 1 1

Lead terminal treatment comple-tion

C 20

R-, B- and T-AxesAC Servomotor


1 3

With brake, no key, lead terminal treatment comple-tion

C 21Internal cable HW9171977-A Yaskawa Electric

Corporation1 1

C 22Internal cable HW9371373-A Yaskawa Electric

Corporation1 1

C 23Wrist unit HW9171670-A Yaskawa Electric

Corporation1 1

Table. 9 Spare Parts for the Motoman-UP20M

RankPartsNo.

Name Type Manufacturer QtyQtyperUnit

Remarks

10-2

MOTOMAN-UP20MINSTRUCTIONS

TOKYO OFFICENew Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo 105-0022, Japan

MOTOMAN INC. HEADQUARTERS805 Liberty Lane West Carrollton, OH 45449, U.S.A.

MOTOMAN INC. TROY FACILITY1050 S. Dorset, Troy, OH 45373, U.S.A.

MOTOMAN INC. CANADA OFFICEDublin Tech Mart 5000 Blazer Memonal Parkway Dublin, OH 43017-3359, U.S.A.

YASKAWA ELECTRIC EUROPE GmbHAm Kronberger Hang 2, 65824 Schwalbach,Germany.

Motoman Robotics ABBox 504 S38525 Torsås, Sweden

Motoman Robotec GmbHKammerfeldstraβe1,85391 Allershausen, Germany

YASKAWA ELECTRIC KOREA CORPORATIONKfpa Bldg. #1201, 35-4 Youido-dong, Yeongdungpo-Ku, Seoul 150-010, Korea

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.151 Lorong Chuan, #04-01, New Tech Park Singapore 556741, Singapore

YATEC ENGINEERING CORPORATIONShen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road, Taipei, Taiwan

BEIJING OFFICERoom No. 301 Office Building of Beijing Intonational Club, 21 Jianguomenwai Avenue, Beijing 100020, China

SHANGHAI OFFICE27 Hui He Road Shanghai 200437 China

YASKAWA JASON (HK) COMPANY LIMITEDRm. 2909-10, Hong Kong Plaza, 186-191 Connaught Road West, Hong Kong

TAIPEI OFFICEShen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan

BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD.30 Xue Yuan Road, Haidian, B eijing P.R. China Post Code: 100083

SHOUGANG MOTOMAN ROBOT CO., LTD.7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area,Beijing 100076, P.R. China

Phone 81-3-5402-4511 Fax 81-3-5402-4580

Phone 1-937-847-6200 Fax 1-937-847-6277

Phone 1-937-440-2600 Fax 1-937-440-2626

Phone 1-614-718-4200 Fax 1-614-718-4222

Phone 49-6196-569-300 Fax 49-6196-888-301

Phone 46-486-48800 Fax 46-486-41410

Phone 49-8166-900 Fax 49-8166-9039

Phone 82-2-784-7844 Fax 82-2-784-8495

Phone 65-282-3003 Fax 65-289-3003

Phone 886-2-2563-0010 Fax 886-2-2567-4677

Phone 86-10-6532-1850 Fax 86-10-6532-1851

Phone 86-21-6553-6600 Fax 86-21-6531-4242

Phone 852-2803-2385 Fax 852-2547-5773

Phone 886-2-2563-0010 Fax 886-2-2567-4677

Phone 86-10-6233-2782 Fax 86-10-6232-1536

Phone 86-10-6788-0551 Fax 86-10-6788-2878

YASKAWA

YASKAWA ELECTRIC CORPORATION

Specifications are subject to change without noticefor ongoing product modifications and improvements.

MANUAL NO. HW0480368Printed in Japan October 2000 00-10C

MOTOMAN-UP20M INSTRUCTIONS

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