YASKAWA Motoman MH Series User manual

Motoman, Incorporated

805 Liberty Lane

West Carrollton, OH 45449

TEL: (937) 847-6200

FAX: (937) 847-6277

24-Hour Service Hotline: (937) 847-3200

Motoman

MH-series

Positioner Manual

with MotoMount and

Drive Assemblies

Part Number: 146703-1CD

Revision: 0

The information contained within this document is the proprietary property of Motoman, Inc., and may not be

copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

Inc.

Because we are constantly improving our products, we reserve the right to change specifications without

notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

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http://www.motoman.com/forms/techpubs.asp

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i MH-Series Positioner Manual with MotoMount

TABLE OF CONTENTS

Section Page

INTRODUCTION

1.1 About this Document .................................................................................................... 1-1

1.2 System Overview ..........................................................................................................1-2

1.2.1 NS600 Module ............................................................................................... 1-2

1.2.2 MotoMount ..................................................................................................... 1-2

1.2.3 System Layout – Type I .................................................................................. 1-3

1.2.4 System Layout – Type II ................................................................................. 1-3

1.3 Reference to Other Documentation................................................................................ 1-4

1.4 Customer Service Information ......................................................................................1-4

2 SAFETY

2.1 Introduction .................................................................................................................. 2-1

2.2 Standard Conventions ..................................................................................................2-2

2.3 General Safeguarding Tips............................................................................................ 2-3

2.4 Safety Devices ..............................................................................................................2-3

2.5 Installation Safety .........................................................................................................2-4

2.6 Programming Safety ..................................................................................................... 2-4

2.7 Operation Safety ...........................................................................................................2-5

2.8 Maintenance Safety....................................................................................................... 2-6

3 EQUIPMENT DESCRIPTION

3.1 MH-Series Drive Assemblies – Type I .......................................................................... 3-1

3.1.1 Type I Specifications ....................................................................................... 3-2

3.2 MH-series Drive Assembly – Type II ............................................................................3-3

3.2.1 Type II Specifications ...................................................................................... 3-4

3.3 MotoMount................................................................................................................... 3-5

3.4 NS600 Module .............................................................................................................3-6

4 INSTALLATION

4.1 Materials Required........................................................................................................ 4-1

4.1.1 Customer-Supplied Items ............................................................................... 4-1

4.1.2 List of Tools .................................................................................................... 4-1

4.2 Installing the MH-Series Drive Assembly – Type I........................................................ 4-2

4.2.1 Site Preparation .............................................................................................. 4-2

4.2.2 Unpacking ...................................................................................................... 4-2

4.2.3 Headstock Assembly Mounting Hole Pattern – MH75/175/450/1500 ............4-3

4.2.4 Column Assembly Mounting – Type I Drive Assembly ................................... 4-5

4.2.5 Connecting the Cables .................................................................................... 4-7

4.2.6 Home Position ................................................................................................ 4-7

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TABLE OF CONTENTS

4.3 Installing the MH-Series Drive Assembly – Type II....................................................... 4-8

4.3.1 Site Preparation .............................................................................................. 4-8

4.3.2 Unpacking ...................................................................................................... 4-8

4.3.3 Floor Mounting – Type II ................................................................................ 4-9

4.3.4 Connecting the Cables .................................................................................. 4-11

4.3.5 Home Position .............................................................................................. 4-11

4.4 Tailstock Column Installation .....................................................................................4-12

4.4.1 Type I Installation ......................................................................................... 4-12

4.4.2 Type II Installation ........................................................................................ 4-13

4.4.3 Leveling the Tailstock ................................................................................... 4-14

4.4.4 Installing the MotoMount Tailstock Adapter ................................................. 4-16

4.4.5 Installing the Bearing Housing Base ............................................................. 4-17

4.4.6 Tooling Fixture Installation (initial) ............................................................... 4-17

4.4.7 Tooling Fixture Installation (regular) ............................................................. 4-19

4.4.8 Final Alignment Check .................................................................................. 4-19

4.4.9 Tooling Fixture Removal ............................................................................... 4-22

4.5 MotoMount Installation ..............................................................................................4-22

4.5.1 Preparation ................................................................................................... 4-22

4.5.2 Unpack and Assemble .................................................................................. 4-22

4.5.3 Securing MotoMount Drive Components onto Faceplate .............................. 4-24

4.5.4 Retrofitting the Tailstock Assembly ............................................................... 4-25

4.6 MotoMount HD Adjustments ...................................................................................... 4-25

4.6.1 Tooling Fixture Installation – MotoMount HD .............................................. 4-27

4.6.2 Tooling Fixture Removal ............................................................................... 4-27

4.6.3 Variable Tooling Size Accommodations ........................................................ 4-27

4.7 Conducting a Safety/Operation Check ........................................................................4-28

5 TOOLING RECOMMENDATIONS

5.1 Headstock Only – Tooling Recommendations ..............................................................5-1

5.1.1 Customer-supplied Tooling Fixture ................................................................ 5-2

5.2 Headstock/Tailstock with MotoMount........................................................................... 5-4

5.2.1 Multiple Tooling Fixtures ................................................................................ 5-4

5.2.2 Specifications ................................................................................................. 5-4

6 NS600 OPERATION

6.1 Operating the NS600 ....................................................................................................6-1

6.1.1 E-Stop ............................................................................................................ 6-1

6.1.2 I/O Sequencing ............................................................................................... 6-1

6.1.3 Sequencing I/O for Motion ............................................................................. 6-1

6.1.4 Alarms ............................................................................................................ 6-6

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iii MH-Series Positioner Manual with MotoMount

7 MAINTENANCE

7.1 Spare Parts ................................................................................................................... 7-1

7.2 Servomotor................................................................................................................... 7-1

7.3 Weld Ground Brush Replacement – Type I ...................................................................7-2

7.3.1 MH75/150/450/1500 ...................................................................................... 7-2

7.4 Weld Ground Brush Replacement – Type II ..................................................................7-4

7.4.1 MH1000/3000 ................................................................................................ 7-4

7.5 Reset Headstock To Home Position .............................................................................. 7-8

7.5.1 Jogging Procedure ......................................................................................... 7-8

7.5.2 Homing ......................................................................................................... 7-10

7.6 Adjusting Position Limit Switches .............................................................................. 7-12

7.7 NS600 List of Spares.................................................................................................. 7-14

7.7.1 Spare Parts ................................................................................................... 7-14

7.8 Maintenance Schedule................................................................................................ 7-15

7.8.1 MH-series Positioners .................................................................................. 7-15

7.8.2 MotoMount ................................................................................................... 7-15

7.9 Troubleshooting ......................................................................................................... 7-16

7.9.1 MH-series Positioners .................................................................................. 7-16

7.9.2 MotoMount ................................................................................................... 7-16

A PERFORMANCE CHARTS

B ILLUSTRATED PARTS LIST

C ALARM CODES

MH-Series Positioner Manual with MotoMount iv

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LIST OF FIGURES

Figure Page

Figure 1-1 MHT System Layout – Type I.................................................................................... 1-3

Figure 1-2 MHT System Layout – Type II................................................................................... 1-4

Figure 3-1 MH-series Type I Drive Assembly............................................................................. 3-1

Figure 3-2 MH-Series, Type II Drive Assembly .......................................................................... 3-3

Figure 3-3 MotoMount Layout.................................................................................................... 3-5

Figure 3-4 MotoMount HD Layout.............................................................................................. 3-6

Figure 4-1 Unbolting the Drive Assembly................................................................................... 4-2

Figure 4-2 MH75/175 Mounting Hole Pattern............................................................................ 4-3

Figure 4-3 MH450 Mounting Hole Pattern ................................................................................. 4-4

Figure 4-4 MH1500 Mounting Hole Pattern ............................................................................... 4-4

Figure 4-5 Column-Mounting Hole Pattern – Type I .................................................................. 4-5

Figure 4-6 Leveling Hardware..................................................................................................... 4-6

Figure 4-7 Ground Cable Connections MH75/150/450/1500..................................................... 4-7

Figure 4-8 Unbolting the Drive Assembly................................................................................... 4-8

Figure 4-9 MH1000/3000 Mounting Hole Pattern...................................................................... 4-9

Figure 4-10 Leveling Hardware................................................................................................... 4-10

Figure 4-11 Ground Cable Connections MH1000/3000............................................................. 4-11

Figure 4-12 Strike Chalk Line..................................................................................................... 4-12

Figure 4-13 Tailstock Placement without Tooling – Type I......................................................... 4-12

Figure 4-14 Strike Chalk Line..................................................................................................... 4-13

Figure 4-15 Tailstock Placement – Type II.................................................................................. 4-13

Figure 4-16 Leveling the Tailstock – Type I................................................................................ 4-14

Figure 4-17 Leveling the Tailstock – Type II............................................................................... 4-15

Figure 4-18 Allowable Axial Leveling - Side View ...................................................................... 4-16

Figure 4-19 Installing the MotoMount Tailstock Adapter............................................................ 4-16

Figure 4-20 Install Pillow Block Base......................................................................................... 4-17

Figure 4-21 Tooling Fixture Installation-Headstock.................................................................... 4-18

Figure 4-22 Install the Bearing Cap............................................................................................ 4-18

Figure 4-23 Measurement Point for Horizontal Alignment, Bottom View.................................... 4-20

Figure 4-24 Vertical Position - Drive Bushing on Bottom........................................................... 4-20

Figure 4-25 Vertical Position - Drive Bushing on Top................................................................ 4-21

Figure 4-26 MotoMount Mounting Hole Pattern......................................................................... 4-23

Figure 4-27 Dowel Pin Installation ............................................................................................. 4-24

Figure 4-28 MotoMount Fixture Installation............................................................................... 4-25

Figure 4-29 Nominal Center Position - Side View...................................................................... 4-26

Figure 4-30 Allowable Misalignment - Top View........................................................................ 4-26

Figure 4-31 Adapter Shaft Position............................................................................................. 4-28

Figure 5-1 Headstock Assembly – Type I ................................................................................... 5-1

Figure 5-2 Headstock Assembly – Type II .................................................................................. 5-1

Figure 5-3 Mounting Holes on Faceplate MH75/150.................................................................. 5-2

Figure 5-4 Mounting Holes on Faceplate MH450....................................................................... 5-3

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v MH-Series Positioner Manual with MotoMount

Figure 5-5 Mounting Holes on Faceplate MH1500..................................................................... 5-3

Figure 5-6 Mounting Holes on Faceplate MH1000/3000............................................................ 5-4

Figure 5-7 Tooling Fixture Inspection......................................................................................... 5-5

Figure 5-8 Tooling Template – MotoMount................................................................................ 5-5

Figure 5-9 Tooling Template – MotoMount HD.......................................................................... 5-5

Figure 5-10 Drive Component Clearance – MotoMount............................................................... 5-6

Figure 5-11 Drive Component Clearance – MotoMount HD......................................................... 5-6

Figure 5-12 Tailstock Adapter – MotoMount................................................................................ 5-7

Figure 5-13 Tailstock Adapter – MotoMount HD.......................................................................... 5-7

Figure 5-14 Tailstock Component Clearance - MotoMount HD.................................................... 5-8

Figure 7-1 Brush Cable Removal................................................................................................ 7-2

Figure 7-2 Brush Assembly........................................................................................................ 7-3

Figure 7-3 Brush Removal MH75/150/450/1500 ....................................................................... 7-3

Figure 7-4 Brush Cable Post ...................................................................................................... 7-5

Figure 7-5 Brush Assembly........................................................................................................ 7-6

Figure 7-6 Brush Removal MH1000/3000.................................................................................. 7-7

Figure 7-7 Home Position – Type I........................................................................................... 7-10

Figure 7-8 Home Position – Type II.......................................................................................... 7-11

Figure 7-9 Position Limit Switch Setting – Type I .................................................................... 7-13

Figure 7-10 Position Limit Switch Setting – Type II ................................................................... 7-13

Figure A-1 MH75 Performance Charts........................................................................................A-1

Figure A-2 MH150 Performance Charts......................................................................................A-2

Figure A-3 MH450 Performance Charts......................................................................................A-3

Figure A-4 MH1000 Performance Charts....................................................................................A-4

Figure A-5 MH1500 Performance Charts....................................................................................A-5

Figure A-6 MH3000 Performance Charts....................................................................................A-6

Figure B-1 MH75/150 Drive Assembly Components..................................................................B-3

Figure B-2 MH450 Drive Assembly Components .......................................................................B-5

Figure B-3 MotoMount Tailstock Components – 75/150/450 kg................................................B-7

Figure B-4 MH1500 Drive Assembly Components .....................................................................B-9

Figure B-5 MH1000/3000 Headstock Components ..................................................................B-11

Figure B-6 MotoMount HD Tailstock Components – 1000/1500/3000 kg................................B-13

Figure B-7 Type II Drive Assembly Components.......................................................................B-15

Figure B-8 MotoMount Drive Components...............................................................................B-17

Figure B-9 MotoMount HD Drive Components.........................................................................B-19

Figure B-10 Slip Ring Kit for MotoMount HD.............................................................................B-21

MH-Series Positioner Manual with MotoMount vi

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LIST OF TABLES

Table Page

Table 3-1 MH-series Type I Specifications .................................................................................. 3-2

Table 3-2 MH-series Type II Specifications ................................................................................. 3-4

Table 4-1 Drive Assembly Mounting Specification – Type I ........................................................ 4-3

Table 4-2 Floor Anchoring Specifications – Type I ...................................................................... 4-5

Table 4-3 Column Installation – X value .................................................................................... 4-12

Table 6-1 Outputs/Inputs – 2-position Continuous Rotation ....................................................... 6-2

Table 6-2 Outputs/Inputs – 3-position Continuous Rotation ....................................................... 6-3

Table 6-3 Outputs/Inputs – 4-position Continuous Rotation ....................................................... 6-4

Table 6-4 Outputs/Inputs – 2-position Reciprocating Rotation .................................................... 6-5

Table 7-1 Recommended Spare Parts .......................................................................................... 7-1

Table 7-2 Spare Parts 750 kW – Kit P/N 146732-1 ................................................................... 7-14

Table 7-3 Spare Parts 1.5 kW – Kit P/N 146732-2 .................................................................... 7-14

Table 7-4 Spare Parts 5.0 kW – Kit P/N 146732-3 .................................................................... 7-14

Table 7-5 Maintenance Schedule ............................................................................................... 7-15

Table 7-6 Periodic Maintenance ................................................................................................ 7-15

Table 7-7 Troubleshooting ........................................................................................................ 7-16

Table B-1 Parts List – MH75/150 Common Components ............................................................B-4

Table B-2 Parts List – Headstock, 450 kg ....................................................................................B-6

Table B-3 Parts List – Tailstock Assembly, 75/150/450 kg ..........................................................B-8

Table B-4 Parts List – Headstock, 1500 kg ................................................................................B-10

Table B-5 Parts List – Headstock 1000/3000 kg ........................................................................B-12

Table B-6 Parts List – Tailstock Assembly, MotoMount HD ......................................................B-14

Table B-7 Parts List – Type II Drive Assembly Components ......................................................B-16

Table B-8 Parts List – MotoMount Drive Components ..............................................................B-18

Table B-9 Parts List – MotoMount HD Drive Components ........................................................B-20

Table B-10 Part List - Slip Ring Kit Components .........................................................................B-22

Table C-1 Alarm Identification ......................................................................................................C-1

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1-1 MH-Series Positioner Manual with MotoMount

SECTION 1

INTRODUCTION

This manual provides instructions for Motoman’s Type I and Type II drive

assemblies – MH75, MH150, MH450, MH1000, MH1500, and MH3000,

headstocks, and headstock/tailstock combinations with MotoMount.

MH-Series drive assemblies are used universally throughout Motoman’s product

line. Appendix A and B of this manual contain parts lists with exploded views and

performance speciﬁcations for the MH-Series. Use this manual as a supplement

with other system manuals to identify parts and locate performance speciﬁcations

of all MH-Series components, regardless of their application.

The MotoMount information in this manual also covers systems with the MH340/

680/680/1360 drive assemblies.

1.1 About this Document

This manual provides general information about MotoMount and the MH-Series

positioners, and contains the following sections:

SECTION 1 - INTRODUCTION

This section provides general information about MotoMount and its components,

the MH-Series positioners and their components, a list of reference documents,

and customer service information.

SECTION 2 - SAFETY

This section provides information regarding the safe use and operation of

MotoMount and the MH-Series positioners.

SECTION 3 - EQUIPMENT DESCRIPTION

This section provides detailed descriptions of the major components of

MotoMount and the MH-Series positioners. This section also includes component

speciﬁcations.

SECTION 4 - INSTALLATION

This section provides instructions for installing MotoMount and MH-Series

components.

SECTION 5 - TOOLING RECOMMENDATIONS

This section provides guidelines for customer-suppled tooling design.

SECTION 6 - MAINTENANCE

This section provides instructions for maintaining MotoMount and each MH-

Series positioner.

APPENDICES

Appendix A

provides performance charts for each of the drive assembly models

(MH75, MH150, MH450, MH1000, MH1500, and MH3000).

Appendix B

provides exploded views with illustrated parts lists for MH-Series

models and components.

Appendix C

provides NS600 Alarm codes and descriptions for them.

INTRODUCTION

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1.2 System Overview

The Motoman Type I and Type II MH-Series drive assemblies provide precision-

controlled rotary motion and can be mounted in any orientation the welding,

material handling, or dispensing application may require. The standard

conﬁguration uses an AC servo motor, a high-ratio gear reducer with integral

output bearing, faceplate, and a cast iron housing. It also includes dual integral

position switches and one or more weld ground brushes rated at 400 amps per

brush.

The MotoMount tool mounting system is a modular accessory for MHT (Motoman

Headstock/Tailstock) positioners and provides improved repeatability as compared

to hard-mounted tooling systems. It eliminates headstock bearing loads induced by

tooling and head/tailstock misalignments, up to a maximum of two (2) degrees.

MotoMount also decreases moment forces on the headstock bearing by up to 70

percent on a 3-meter (118.1-inch) span, and affords even higher reductions on

longer spans. This improves headstock life by minimizing wear on the reducer gear

and bearings. MotoMount eliminates the need for costly machine bases or use of

surveying tools (transits) for precise headstock/tailstock alignment, thus reducing

overall positioner cost and installation time. The system includes a headstock

ﬁxture assembly, a compliant tailstock bearing, a tailstock tooling adapter, and

mounting hardware.

1.2.1 NS600 Module

The NS600 control solution uses Yaskawa Electric America (YEA) components;

speciﬁcally an ampliﬁer and the NS600 motion control option. The NS600 selects

motions via a binary input pattern received from standard XRC outputs. Motion

progress/status is transmitted to the XRC via outputs from the NS600. This

handshaking interaction of the inputs and outputs creates the loss of coordinated

motion, a feature that can be desirable in certain applications.

1.2.2 MotoMount

MotoMount is standard equipment with all MHT positioner assemblies. It may be

purchased for any MH-Series drive assembly for applications requiring custom

headstock/tailstock supporting structures.

WARNING!

Do not use MotoMount with stand-alone headstock (no tailstock)

applications. Use in a stand-alone application will result in

uncontrolled tooling motion.

NOTE: If customers want to integrate a Motoman drive assembly or headstock assembly with their own

tailstock, they must order the MotoMount system. Failure to use MotoMount with a Motoman

drive assembly or headstock assembly will void the warranty.

INTRODUCTION

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1-3 MH-Series Positioner Manual with MotoMount

1.2.3 System Layout – Type I

The Type I MH-Series positioner kits include four drive assemblies: MH75,

MH150, MH450, and MH1500. The kits are available in four basic mechanical

conﬁgurations: the drive assembly, the drive assembly with MotoMount, the

headstock positioner assembly, and the head and tailstock positioner assembly.

These are combined with the appropriate single or multiple external axis control

packages to provide a complete positioner kit.

The major components of a typical Type I headstock and tailstock positioner

assembly (MHT) are shown in Figure 1-1.

Figure 1-1 MHT System Layout – Type I

1.2.4 System Layout – Type II

The Type II MH-Series positioner kits include two drive assemblies: MH1000 and

MH3000. The kits are available in four basic mechanical conﬁgurations: the drive

assembly, the drive assembly with motomount, the head stock positioner assembly,

and the head and tailstock positioner assembly. These are combined with the

appropriate single or multiple external axis control packages to provide a complete

positioner kit.

The major components of a typical Type II headstock and tailstock positioner

assembly (MHT) are shown in Figure 1-2.

DRIVE

ASSEMBLY

MOTOMOUNT

HEADSTOCK

COMPONENTS

AC SERVO

MOTOR

MOTOMOUNT

TAILSTOCK

COMPONENTS

TAILSTOCK

COLUMN

STANDARD

TOOL RADIUS

(SEE SPEC.

TABLE 3-1)

INTRODUCTION

MH-Series Positioner Manual with MotoMount 1-4

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Figure 1-2 MHT System Layout – Type II

1.3 Reference to Other Documentation

For additional information refer to the following:

• Sigma II User’s Manual (NS600 Alarms) - Motoman P/N 147237-1

• Sigma II Indexer User’s Manual (NS600 Alarms) - Motoman P/N 147238-1

1.4 Customer Service Information

If you need technical assistance, contact the Motoman service staff at

937.847.3200. Please have the following information ready before you call:

• Product (MotoMount, MH75, MH150, MH450, MH1000, MH1500, or

MH3000)

• Serial Number

HOUSING

MOTOMOUNT

TAILSTOCK

COMPONENT

S

HEADSTOCK

COLUMN

MOTOMOUNT

HEADSTOCK

COMPONENTS

STANDARD

TOOL RADIUS

(SEE TABLE 3-2)

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2-1 MH–Series Positioner Manual with MotoMount

SECTION 2

SAFETY

2.1 Introduction

.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety

Standard for Industrial Robots and Robot Systems. This information can be

obtained from the Robotic Industries Association by requesting ANSI/RIA

R15.06. The address is as follows:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: (734) 994-6088

FAX: (734) 994-3338

Ultimately, the best safeguard is trained personnel. The user is responsible for

providing personnel who are adequately trained to operate, program, and maintain

the robot cell.

The robot must not be operated by personnel who have not been

trained!

We recommend that all personnel who intend to operate, program, repair, or use

the robot system be trained in an approved Motoman training course and become

familiar with the proper operation of the system.

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming Safety (Section 2.6)

• Operation Safety (Section 2.7)

• Maintenance Safety (Section 2.8)

It is the purchaser's responsibility to ensure that all local, county,

state, and national codes, regulations, rules, or laws relating to

safety and safe operating conditions for each installation are met

and followed.

SAFETY

MH–Series Positioner Manual with MotoMount 2-2

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2.2 Standard Conventions

This manual includes information essential to the safety of personnel and

equipment. As you read through this manual, be alert to the four signal words:

• DANGER

• WARNING

• CAUTION

•NOTE

Pay particular attention to the information provided under these headings which

are deﬁned below (in descending order of severity).

DANGER!

Information appearing under the DANGER caption concerns the

protection of personnel from the immediate and imminent hazards

that, if not avoided, will result in immediate, serious personal injury

or loss of life in addition to equipment damage.

WARNING!

Information appearing under the WARNING caption concerns the

protection of personnel and equipment from potential hazards that

can result in personal injury or loss of life in addition to equipment

damage.

CAUTION!

Information appearing under the CAUTION caption concerns the

protection of personnel and equipment, software, and data from

hazards that can result in minor personal injury or equipment

damage.

NOTE: Information appearing in a NOTE caption provides additional information which is helpful in

understanding the item being explained.

SAFETY

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2-3 MH–Series Positioner Manual with MotoMount

2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel,

supervisors, and anyone working near the robot must become familiar with the

operation of this equipment. All personnel involved with the operation of the

equipment must understand potential dangers of operation. General safeguarding

tips are as follows:

• Improper operation can result in personal injury and/or damage to the

equipment. Only trained personnel familiar with the operation of this robot,

the operator's manuals, the system equipment, and options and accessories

should be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmers

must have the teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be made

within the standard voltage and current ratings of the robot I/O (Inputs and

Outputs).

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is

not in use.

• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use

lockout/tagout procedures during equipment maintenance. Refer also to

Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health

Standards for General Industry (OSHA).

2.4 Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is

ultimately the user's responsibility. The conditions under which the equipment

will be operated safely should be reviewed by the user. The user must be aware of

the various national codes, ANSI/RIA R15.06 safety standards, and other local

codes that may pertain to the installation and use of industrial equipment.

Additional safety measures for personnel and equipment may be required

depending on system installation, operation, and/or location. The following safety

measures are available:

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

Check all safety equipment frequently for proper operation. Repair or replace any

non-functioning safety equipment immediately.

SAFETY

MH–Series Positioner Manual with MotoMount 2-4

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2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The

following suggestions are intended to supplement, but not replace, existing federal,

local, and state laws and regulations. Additional safety measures for personnel and

equipment may be required depending on system installation, operation, and/or

location. Installation tips are as follows:

• Be sure that only qualiﬁed personnel familiar with national codes, local

codes, and ANSI/RIA R15.06 safety standards are permitted to install the

equipment.

• Identify the work envelope of each robot with ﬂoor markings, signs, and

barriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entry

into the work envelope.

• Eliminate areas where personnel might get trapped between a moving robot

and other equipment (pinch points).

• Provide sufﬁcient room inside the workcell to permit safe teaching and

maintenance procedures.

2.6 Programming Safety

All operators, programmers, plant and tooling engineers, maintenance personnel,

supervisors, and anyone working near the robot must become familiar with the

operation of this equipment. All personnel involved with the operation of the

equipment must understand potential dangers of operation. Programming tips are

as follows:

• Any modiﬁcations to PART 1 of the controller PLC can cause severe

personal injury or death, as well as damage to the robot! Do not make any

modiﬁcations to PART 1. Making any changes without the written

permission of Motoman will

VOID YOUR WARRANTY!

• Some operations require standard passwords and some require special

passwords. Special passwords are for Motoman use only.

YOUR

WARRANTY WILL BE VOID

if you use these special passwords.

• Back up all programs and jobs onto a ﬂoppy disk whenever program changes

are made. To avoid loss of information, programs, or jobs, a backup must

always be made before any service procedures are done and before any

changes are made to options, accessories, or equipment.

• The concurrent I/O (Input and Output) function allows the customer to

modify the internal ladder inputs and outputs for maximum robot

performance. Great care must be taken when making these modiﬁcations.

Double-check all modiﬁcations under every mode of robot operation to

ensure that you have not created hazards or dangerous situations that may

damage the robot or other parts of the system.

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2-5 MH–Series Positioner Manual with MotoMount

• Improper operation can result in personal injury and/or damage to the

equipment. Only trained personnel familiar with the operation, manuals,

electrical design, and equipment interconnections of this robot should be

permitted to operate the system.

• Inspect the robot and work envelope to be sure no potentially hazardous

conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place.

• Check the E-STOP button on the teach pendant for proper operation before

programming.

• Carry the teach pendant with you when you enter the workcell.

• Be sure that only the person holding the teach pendant enters the workcell.

• Test any new or modiﬁed program at low speed for at least one full cycle.

2.7 Operation Safety

All operators, programmers, plant and tooling engineers, maintenance personnel,

supervisors, and anyone working near the robot must become familiar with the

operation of this equipment. All personnel involved with the operation of the

equipment must understand potential dangers of operation. Operation tips are as

follows:

• Be sure that only trained personnel familiar with the operation of this robot,

the operator's manuals, the system equipment, and options and accessories

are permitted to operate this robot system.

• Check all safety equipment for proper operation. Repair or replace any non-

functioning safety equipment immediately.

• Inspect the robot and work envelope to ensure no potentially hazardous

conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Ensure that all safeguards are in place.

• Improper operation can result in personal injury and/or damage to the

equipment. Only trained personnel familiar with the operation, manuals,

electrical design, and equipment interconnections of this robot should be

permitted to operate the system.

• Do not enter the robot cell while it is in automatic operation. Programmers

must have the teach pendant when they enter the cell.

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is

not in use.

• This equipment has multiple sources of electrical supply. Electrical

interconnections are made between the controller, external servo box, and

other equipment. Disconnect and lockout/tagout all electrical circuits before

making any modiﬁcations or connections.

• All modiﬁcations made to the controller will change the way the robot

operates and can cause severe personal injury or death, as well as damage the

robot. This includes controller parameters, ladder parts 1 and 2, and I/O

(Input and Output) modiﬁcations. Check and test all changes at slow speed.

SAFETY

MH–Series Positioner Manual with MotoMount 2-6

MOTO

MAN

2.8 Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel,

supervisors, and anyone working near the robot must become familiar with the

operation of this equipment. All personnel involved with the operation of the

equipment must understand potential dangers of operation. Maintenance tips are

as follows:

• Do not perform any maintenance procedures before reading and

understanding the proper procedures in the appropriate manual.

• Check all safety equipment for proper operation. Repair or replace any non-

functioning safety equipment immediately.

• Improper operation can result in personal injury and/or damage to the

equipment. Only trained personnel familiar with the operation, manuals,

electrical design, and equipment interconnections of this robot should be

permitted to operate the system.

• Back up all your programs and jobs onto a ﬂoppy disk whenever program

changes are made. A backup must always be made before any servicing or

changes are made to options, accessories, or equipment to avoid loss of

information, programs, or jobs.

• Do not enter the robot cell while it is in automatic operation. Programmers

must have the teach pendant when they enter the cell.

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is

not in use.

• Be sure all safeguards are in place.

• Use proper replacement parts.

• This equipment has multiple sources of electrical supply. Electrical

interconnections are made between the controller, external servo box, and

other equipment. Disconnect and lockout/tagout all electrical circuits before

making any modiﬁcations or connections.

• All modiﬁcations made to the controller will change the way the robot

operates and can cause severe personal injury or death, as well as damage the

robot. This includes controller parameters, ladder parts 1 and 2, and I/O

(Input and Output) modiﬁcations. Check and test all changes at slow speed.

• Improper connections can damage the robot. All connections must be made

within the standard voltage and current ratings of the robot I/O (Inputs and

Outputs).

MOTO

MAN

3-1 MH-Series Positioner Manual with MotoMount

SECTION 3

EQUIPMENT DESCRIPTION

The MH-series, Type I and Type II drive assemblies consist of an AC servo motor

and gear reducer with an integral output bearing mounted in a cast iron housing.

Weld ground brushes and position switches are included as standard features. The

drive assembly provides programmable motion about the central axis, and endless

rotation can be purchased as an option. Holes in the faceplate provide for mounting

MotoMount drive components or parts ﬁxtures in stand-alone (cantilevered)

applications.

3.1 MH-Series Drive Assemblies – Type I

The design of the four available drive assemblies is very similar; size is the

primary difference. The ﬂexibility of the Type I drive assembly allows for any

mounting orientation including vertical (typical), horizontal, or other.

The Type I drive assembly positioners (see Figure 3-1) are available in four

different models:

• MH75

• MH150

• MH450

• MH1500

Figure 3-1 MH-series Type I Drive Assembly

CASTING

FACEPLATE

AC SERVO

MOTOR

EQUIPMENT DESCRIPTION

MH-Series Positioner Manual with MotoMount 3-2

MOTO

MAN

3.1.1 Type I Speciﬁcations

See Table 3-1 for Type I drive assembly speciﬁcations.

* External axis default settings

** Weld capacity is at 100% duty cycle.

*** The In-position Maximum Motion is the maximum motion expected if the

cycle start command is given while the safety zone is violated. This assumes

utilizing the position switches in the safety circuit, and includes the motion

required to clear the switch actuators and implement an E-Stop.

See Appendix A for drive series component performance charts.

See Section 4.2 for installation instructions.

Table 3-1 MH-series Type I Speciﬁcations

Series Component MH75 MH150 MH450 MH1500

Motoman P/N 145878-1 145878-2 145881-1 146615-1

* Axis Type Rotation

Rated Load – kgf 75 150 450 1500

Rated MHT Load @ CG Off Center – kgf @ mm 550 @ 20 550 @ 40 1075 @ 60 3000 @ 70

Headstock Speed – rpm 24.7 12.4 9.8 10.6

180-Degree Sweep Time – sec 1.72 2.92 3.56 3.32

Rated CG Off Center – mm 152

Rated CG Overhang – mm 500 200 100 50

Load @ 500 mm CG Overhang – kgf 75 175 500

Rated Inertia – kg*m

2

15 58 119 680

Rated Holding Torque – Nm 112 224 671 2236

**

Rated Weld Current (Standard/Optional) – Amps 400/800 800/1200 800/1600

Allowable Thrust – kgf 400 800 2000

Motor Power – kW 0.60 1.3 4.5

* Motor P/N, YEC

SGMDH-06A2A-YR13

SGMGH-

13A2A-

YR13

SGMDH-

45A2B-

YR14

* Motor Speed – rpm 2000 1500

* Rated Acceleration – sec 0.3 0.3 0.3 0.5

Motor P/N, Motoman 142182-2 142142-4 142142-1

Reducer RV-20E-

81-1B

RV-20E-

161-1B

RV-80E-

153-1B

RV-320E-

141

* Total Reduction Ratio – R 81 161 153 141

Repeatability – mm/mm 0.00003 0.00004 0.00003 0.00002

Repeatability w/MotoMount – mm/mm 0.00005 0.00005 0.0002 0.0001

E-Stop Response – sec 0.15 0.14 0.2

E-Stop Response – deg 6 6 8

*** In-position Maximum Motion – deg 8 7 7

Face Plate Through Hole none none none none

Tail Stock Through Hole Dia. – mm 38 41 45

Drive Assy Weight – kgf/lbs 54/118 100/220 390/860

Standard Tool Radius – mm 815 815 815 1000

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YASKAWA Motoman MH Series User manual

YASKAWA Motoman MH Series User manual

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