MANUAL NO.
1
163475-1CD
Part Number: 163475-1CD
Revision: 1
MHTH POSTIONER
SIGMA 5 Instructions
FOR DX100 or DX200
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN INSTRUCTIONS
DX100 or DX200 INSTRUCTIONS
DX100 or DX200 OPERATOR’S MANUAL
DX100 or DX200 MAINTENANCE MANUAL
The DX100 or DX200 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
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MANDATORY
General items related to safety are listed in Section 2 of the DX100 or
DX200 Controller Manual. To ensure correct and safe operation,
carefully read the DX100 or DX200 Controller Manual before reading
this manual.
CAUTION
• 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 a modification is made, the manual number will also be
re
vised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
r
epresentative 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
m
odification of its products. Unauthorized modification voids the
products warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the MHTH Positioner SIGMA V.
In this manual, the Notes for Safe Operation are classified as “WARNING,”
“CA
UTION,” “MANDATORY,” or “PROHIBITED.”
Even items described as “CAUTION” may result in a serious accident in
s
ome situations. At any rate, be sure to follow these important items.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
MANDATORY
Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED
Must never be performed.
NOTE
To ensure safe and efficient operation at all times, be sure to
follow all instructions, even if not designated as "CAUTION"
and "WARNING."
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WARNING
• Before operating the MHTH Positioner SIGMA V, check that servo
power is turned OFF by pressing the EMERGENCY STOP buttons
on the operator station or Programming Pendant (refer to
Fig. 1).
When servo power is turned OFF, the SERVO ON LED on the
P
rogramming Pendant is turned OFF.
Injury or damage to machinery may result if the Emergency Stop circuit
c
annot stop the positioner during an emergency. The positioner should
not be used if the EMERGENCY STOP buttons do not function.
Figure 1: EMERGENCY STOP Button
• Release the EMERGENCY STOP button (refer to Fig. 2). Once this
button is released, clear the cell of all items which could interfere
w
ith the operation of the positioner then, turn servo power ON.
Injury may result from unintentional or unexpected positioner motion.
Figure 2 : Release of EMERGENCY STOP Button
TURN
• Observe the following precautions when performing teaching
operations within the working envelope of the positioner:
– View the positioner from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that there is a safe place to retreat to in case of
em
ergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the working envelope of the
p
ositioner and that you are in a safe location before:
– Turning on the power for the DX100 or DX200 controller.
– Moving the positioner with the Programming Pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the working envelope of the
p
ositioner during operation. Always press an EMERGENCY STOP
button immediately if there is a problem. The EMERGENCY STOP
buttons are located on the operator station and on the Programming
Pendant.
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Definition of Terms Used Often in This Manual
The positioner usually consists of the controller, the Programming
Pendant, and supply cables.
In this manual, the equipment is designated as follows:
CAUTION
• Perform the following inspection procedures prior to conducting
positioner teaching. If problems are found, repair them immediately
and be sure that all other necessary processing has been
performed.
– Check for problems in positioner movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the Programming Pendant to the hook on the cabinet
of th
e DX100 or DX200 controller after use.
• The Programming Pendant can be damaged if it is left in the work
ar
ea, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX1
00 or DX200 Controller Manual before operating the MHTH
Positioner SIGMA V.
Equipment Manual Designation
DX100 or DX200 controller DX100 or DX200
DX100 or DX200 Programming
Pend
ant
Programming Pendant
Cable between the positioner and the
co
ntroller
Power cables
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Table of Contents
Table of Contents
1 Introduction ..................................................................................................................................... 1-1
1.1 About This Document ........................................................................................................ 1-1
1.2 Overview............................................................................................................................ 1-1
1.2.1 MHTH-305............................................................................................................ 1-1
1.2.2 MHTH-605............................................................................................................ 1-2
1.2.3 MHTH-905............................................................................................................ 1-2
1.2.4 Dimensions........................................................................................................... 1-3
1.2.5 Specifications ....................................................................................................... 1-4
1.3 Reference to Other Documentation................................................................................... 1-7
1.4 Customer Support Information........................................................................................... 1-8
2 Installation....................................................................................................................................... 2-1
2.1 Materials Required............................................................................................................. 2-1
2.1.1 Customer-Supplied Items ..................................................................................... 2-1
2.1.2 List of Tools .......................................................................................................... 2-1
2.2 Lifting Instructions.............................................................................................................. 2-2
2.3 Installation Safety .............................................................................................................. 2-3
2.3.1 Dimensions........................................................................................................... 2-3
2.3.2 Mounting............................................................................................................... 2-3
2.4 Connection to Motoman Controller.................................................................................... 2-4
2.4.1 Conducting a Safety/Operation Check ................................................................. 2-4
2.5 Installation of Tooling and Fixtures .................................................................................... 2-4
3 Maintenance ................................................................................................................................... 3-1
3.1 Ordering Parts ................................................................................................................... 3-1
3.2 Drive Motor Maintenance...................................................................................................3-1
3.2.1 Servopack ............................................................................................................ 3-1
3.3 Lubrication and Maintenance Schedule............................................................................. 3-2
3.4 Resetting Axis To Home Position ...................................................................................... 3-2
3.5 Troubleshooting................................................................................................................. 3-3
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Appendix A Illustrated Parts List ........................................................................................................A-1
A.1 Introduction........................................................................................................................A-1
A.1.1 Explanation of Parts List.......................................................................................A-1
A.2 Parts List............................................................................................................................A-2
A.2.1 Explanation of Parts List Arrangement.................................................................A-2
A.2.2 Symbols and Abbreviations..................................................................................A-2
Appendix B Revision History..............................................................................................................B-1
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1 Introduction
1.1 About This Document
1 Introduction
1.1 About This Document
This manual is intended as an introduction and overview for personnel
who have received operator training from Yaskawa Motoman, and who
are familiar with the operation of their Yaskawa Motoman robot model. For
more detailed information, refer to the manuals listed in Section 1.4
“Customer Support Information”. This manual contains the following
chapters:
C
HAPTER 1 - INTRODUCTION
Provides general information about the MHTH Headstock and its
components, a list of reference documents, and customer service
information.
CHAPTER 3 - INSTALLATION
Provides instructions for set up and installation of the MHTH
Headstock.
CHAPTER 4 - MAINTENANCE
Contains a table listing periodic maintenance requirements for the
components of the MHTH Headstock.
APPENDIX A - ILLUSTRATED PARTS LIST
Appendix A provides exploded views and illustrated parts lists for
the MHTH Headstock.
1.2 Overview
The MHTH Positioner SIGMA V uses an AC servo drive module designed
for use in a variety of applications including high capacity headstocks, and
high-capacity positioning tables. The simple design provides high
reliability and ease of installation and maintenance, while the compact,
low-profile configuration provides increased application flexibility. The
MHTH drive units feature Sigma 5 motors. The 110 mm thru-hole allows
pneumatic, hydraulic, or electrical connections for end-user tooling to pass
through the center of the positioner. The MHTH-series drive assembly
modules are available in three different configurations:
1.2.1 MHTH-305
The MHTH-305 has a load capacity of 305 kg at 152 mm from the center
o
f rotation. Weld ground capacity is rated at 800 amps, with options to
increase ground capacity to either 1,200 or 1,600 amps. The MHTH-305
indexes 180 degrees in 1.4 seconds.
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1.2 Overview
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1.2.2 MHTH-605
The MHTH-605 has load capacity of 605 kg at 152 mm from the center of
r
otation. Weld ground capacity is rated at 800 amps, with options to
increase ground capacity to either 1,200 or 1,600 amps. The MHTH-605
indexes 180 degrees in 2.1 seconds.
1.2.3 MHTH-905
The MHTH-905 has load capacity of 905 kg at 152 mm from the center of
r
otation. Weld ground capacity is rated at 800 amps, with options to
increase ground capacity to either 1,200 or 1,600 amps. The MHTH-905
indexes 180 degrees in 2.9 seconds.
Fig. 1-1: Layout
Headstock assembly with external axis kits include:
• Servo amplifier with mounting hardware
• 7-meter cables
• Appropriate MHTH drive assembly
• External axis daughter board
• Cooling fan
• Power harnesses and terminal strip
The external axis kit mounts inside the controller. The controller has
provisions for three external axis kits.
The MHTH headstock is designed to be mounted with the faceplate
at
the top. Custom pinion covers are used for this application. The
tabletop drive module is designed to mount flat or in the same
orientation as the headstock positioner.
NOTE
Neither the motomount or tailstock column assembly is
available for the MHTH headstock at this time.
HEADSTOCK ASSEMBLY
FACEPLATE
MHTH DRIVE MODULE
W/ HEADSTOCK ASSEMBLY
MHTH DRIVE MODULE
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1 Introduction
1.2 Overview
1.2.4 Dimensions
Fig. 1-2: Dimensions
440 mm
434 mm
434 mm
595 mm
CENTER OF GRAVITY
MASS = 293.7 kg
169679 MHTH Drive Module
598.4 mm
456 mm
288 mm
256 mm
53 mm
280 mm
560 mm
391 mm
169680 MHTH Drive Assembly
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1.2 Overview
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1.2.5 Specifications
Table 1-1: MHTH 305 Drive Module Specifications
Axis Type Rotation
Rated Load kgf 305
Max MHTH Load @ CG Off Center kgf @ mm 969 @ 50
Headstock Speed rpm 33.3
180 Degree Sweep Time sec 1.40
Rated CG Off Center mm 152
Rated CG Overhang mm 2750
Load @ 500 mm CG Overhang kgf 1578
Rated Intertia kg*m2 66
Rated Holding Torque Nm 475
Rated Weld Current
(STD Optional)
Amps 800/1600
Allowable Thrust kgf 800
Motor Power kW 1.3
* Motor PN, YEC SGMRV-13ANA-YR11
* Motor Speed rpm 3800
* Rated Acceleration Time sec 0.5
Motor PN, Yaskawa Motoman 156009-3
* Total Reduction Ratio R 114
Repeatability mm/mm 0.000028
E-Stop Response sec 0.449
E-Stop Response deg 12.8
**In Position Maximum Motion deg 15.47
Face Plate Through Hole mm 110
Drive Assy Weight kgf/lbs 293/645
** The ‘In Position Maximum Motion’ is the maximum motion expected if the
c
ycle 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
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1 Introduction
1.2 Overview
Table 1-2: MHTH 605 Drive Module Specifications
Axis Type Rotation
Rated Load kgf 605
Max MHTH Load @ CG Off Center kgf @ mm 1717 @ 50
Headstock Speed rpm 18.8
180 Degree Sweep Time sec 2.09
Rated CG Off Center mm 152
Rated CG Overhang mm 1375
Load @ 500 mm CG Overhang kgf 1578
Rated Intertia kg*m2 208
Rated Holding Torque Nm 842
Rated Weld Current
(STD Optional)
Amps 1200/1600
Allowable Thrust kgf 800
Motor Power kW 1.3
* Motor PN, YEC SGMRV-13ANA-YR11
* Motor Speed rpm 3800
* Rated Acceleration Time sec 0.5
Motor PN, Yaskawa Motoman 156009-3
* Total Reduction Ratio R 202
Repeatability mm/mm 0.000028
E-Stop Response sec 0.449
E-Stop Response deg 12.8
**In Position Maximum Motion deg 15.47
Face Plate Through Hole mm 110
Drive Assy Weight kgf/lbs 293/645
** The ‘In Position Maximum Motion’ is the maximum motion expected if the
c
ycle 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
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Table 1-3: MHTH 905 Drive Module Specifications
Axis Type Rotation
Rated Load kgf 905
Max MHTH Load @ CG Off Center kgf @ mm 2601 @ 50
Headstock Speed rpm 12.4
180 Degree Sweep Time sec 2.92
Rated CG Off Center mm 152
Rated CG Overhang mm 925
Load @ 500 mm CG Overhang kgf 1578
Rated Intertia kg*m2 477
Rated Holding Torque Nm 1276
Rated Weld Current
(STD Optional)
Amps 1200/1600
Allowable Thrust kgf 800
Motor Power kW 1.3
* Motor PN, YEC SGMRV-13ANA-YR11
* Motor Speed rpm 3800
* Rated Acceleration Time sec 0.5
Motor PN, Yaskawa Motoman 156009-3
* Total Reduction Ratio R 306
Repeatability mm/mm 0.000028
E-Stop Response sec 0.449
E-Stop Response deg 12.8
**In Position Maximum Motion deg 15.47
Face Plate Through Hole mm 110
Drive Assy Weight kgf/lbs 293/645
** The ‘In Position Maximum Motion’ is the maximum motion expected if the
c
ycle 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
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1 Introduction
1.3 Reference to Other Documentation
1.3 Reference to Other Documentation
For additional information refer to the following:
• Motoman Manipulator Manual
• Motoman Controller Manual
• Motoman Concurrent I/O Parameter Manual
• Vendor manuals for system components not manufactured by
Yaskawa Motoman
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1 Introduction
1.4 Customer Support Information
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1.4 Customer Support Information
If assistance is needed with any aspect of the MHTH Postioner
SIGMA V, contact Yaskawa Motoman Customer Support at the following
24-hour telephone number:
For routine technical inquiries, feel free to contact Yaskawa Motoman
Customer Support at the following e-mail address:
When using e-mail to contact Yaskawa Motoman Customer Support,
please provide a detailed description of the issue, along with complete
contact information. Please allow approximately 24 to 36 hours for a
response to your inquiry.
Please have the following information ready before calling:
techsupport@motoman.com
NOTE
Please use e-mail for routine inquiries only. If there is an
urgent or emergency need for service, replacement parts,
or information, contact Yaskawa Motoman Customer
Support at the telephone number shown above.
• Positioner MHTH Positioner SIGMA V
• Controller DX100 or DX200
• Software Version Access this information on the
Pr
ogramming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Serial Number Located on the positioner data
pl
ate
• Sales Order Number Located on the positioner data
pl
ate
(937) 847-3200
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2 Installation
2.1 Materials Required
2 Installation
Installation of the MHTH Headstock should be performed by personnel
who are familiar with this Motoman product. Follow established safety
procedures at all times throughout the installation process. Failure to use
safe work practices can result in damage to the equipment and injury to
the workers.
Due to the variety of installation applications, it is not possible to provide
d
etailed installation instructions for the MHTH Drive Module. However,
general installation guidelines are provided. Contact the Yaskawa
Motoman Service Staff for help integrating the MHTH Drive Module into
your system.
2.1 Materials Required
This section identifies customer-supplied items and tools required to
complete installation.
2.1.1 Customer-Supplied Items
• Incoming power supply to controller – 240/480/575 volts
• Appropriate mounting hardware
2.1.2 List of Tools
CAUTION
Installation of the MHTH Headstock is not a task for the novice. The
positioner is not fragile, but it is a highly sophisticated positioning
system. Handle components with care. Rough handling can damage
system electronic components.
• Safety Glasses • Socket Set
• Gloves • Forklift and/or Overhead Crane
• Level • Air-impact gun with 3/4-in socket
• Ratchet with 3/4-in socket • Open-end Wrench Set
• Adjustable Wrench Set • Wrench Sets (Standard and Metric)
• Phillips and Flat Screwdrivers • 255 Nm (188 ft-lb) Torque Wrench
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2 Installation
2.2 Lifting Instructions
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2.2 Lifting Instructions
The MHTH Headstock is shipped on a wooden shipping skid. The
customer is responsible for removing the positioner from the shipping skid
and inspecting for shipping damage.
The MHTH Headstock can be
moved by forklift, or by overhead crane and straps using M16
eyebolts.
To install the MHTH Headstock, proceed as follows:
1. Carefully remove protective plastic wrapping from drive assembly.
2. Inspect drive assembly for shipping damage.
3. Unbolt the positioner from the shipping skid using a ¾-inch socket.
4. Attach slings from lifting device to the four M16 lifting eyes
(see Fig.2-3 "Shipping").
Fig. 2-3: Shipping
5. Using the lifting device, lift the drive assembly or headstock and place
i
n desired location.
WARNING
Forklift truck operation should be performed only by licensed
personnel. Never place any part of your body under a suspended load
or move a suspended load over any part of another person’s body.
Careless handling may result in severe personal injury or death.
NOTE
If any equipment is damaged, notify the shipper
immediately.
TO LIFTING DEVICE TO LIFTING DEVICE
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2 Installation
2.3 Installation Safety
2.3 Installation Safety
Warning signs and restrictive devices such as fencing, chains, safety
mats, or light beams must be placed around the working area of the robot/
positioner. Warning signs should indicate hazardous conditions and
results that may occur if the warning is disregarded. Refer to local
regulations regarding Machine Safety.
2.3.1 Dimensions
Fig. 2-4: Dimensions
2.3.2 Mounting
The MHTH Headstock should be firmly mounted on a base plate or
f
oundation rigid enough to support the weight and also withstand repulsion
forces. The surface should be level and even. If it is uneven, grind the
swell and flatten the surface. All floor requirements are application specific
and must be determined by the project engineer overseeing the
installation.
6X Ø 17 THRU
MOUNTING HOLES
CENTER OF
GRAVITY LOCATION
MASS 293.7 kg
4 X M16 X 2
LIFTING HOLES
455
288
510
560
150
300
25
Ø 400
Ø 5 THRU
FOR HOMING PIN
8X M16 X2 X 22
Ø 300
2X 572X 57
138138
138
138
2X 57
2X 57
280
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2 Installation
2.4 Connection to Motoman Controller
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2.4 Connection to Motoman Controller
Installation and connection to the controller comprises hardware as well
as software installation, and must be carried out by Yaskawa Motoman
Service personnel. When the HD Module is delivered together with a
robot, this installation is complete.
See separate schematics for electrical connections:
2.4.1 Conducting a Safety/Operation Check
Before installing the tooling and fixtures for your application, take a few
m
inutes to perform a safety/operation check. To conduct a safety/
operation check:
1. Check that safeguards have been installed and are adequate for plant
c
onditions per ANSI/RIA R15.06-2012 Robot Safety Standard.
2. Verify that cable connections are tight and system is level and secure.
Your MHTH Headstock is now ready for power-up. This system should be
o
perated only by personnel who have received operator training from
Yaskawa Motoman and who are familiar with the operation of this
Yaskawa Motoman robot model. Turn the main power ON, and continue
the safety/operation check.
3. Check all system E-STOPS (pendant, op-station, controller door).
4. Check system Hold buttons.
2.5 Installation of Tooling and Fixtures
Your MHTH Headstock is now ready for the installation of tooling and
fixtures for your application. Installation of tooling and fixtures should be
performed by personnel who are familiar with the operation of this system.
Tooling and fixtures are supplied by the customer. After tooling is installed,
test the module for proper operation.
WARNING
Install all electrical cables connecting the MHTH Headstock, Controller,
and electrical supply wiring cables so that there is no possibility of
being walked on or run over. Do not put any object directly on the
cables and do not install cables across other cables.
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3 Maintenance
3.1 Ordering Parts
3 Maintenance
Maintenance of the MHTH Headstock components should be performed
by authorized personnel who are familiar with the design and construction
of this positioner. The following procedures should be performed only as
needed. Read through the instructions completely before performing any
maintenance procedure. Be sure that you understand the procedure, have
the proper tools, and observe all applicable safety precautions.
3.1 Ordering Parts
Contact the Yaskawa Motoman service staff see Section 1.4 “Customer
Support Information” on page 1-8 to order spare parts.
3.2 Drive Motor Maintenance
The servo drive motor is virtually maintenance free. If the servo motor is
physically damaged due to a load collision or misuse, or if there is grinding
or excessive noise, contact Yaskawa Motoman Service Department see
Section 1.4 “Customer Support Information” on page 1-8.
3.2.1 Servopack
The servopack does not require any special maintenance. Remove dust
a
nd tighten screws periodically.
WARNING
Ensure power is off before performing the following procedures.
Observe standard lockout/tagout practices.
NOTE
Maintenance on the motor and reducer are not
recommended for field service. The unit should be returned
t
o Yaskawa Motoman for repairs to these components.
Table 3-4: Maintenance of AC Servo Motor
Inspection Item Frequency Inspection Operation
Vibration Daily Feel manually
Noise Daily Aurally
Exterior and
c
leaning
as required Clean with dry cloth or compressed air
Insulation
r
esistance
Annually Make sure that it is more than 10M Ohm
by measuring with a 500V insulation
tester (Megger) after disconnecting the
motor from the controller
Overhaul Every 20,000
hou
rs or 5 years
If worn or damaged, replace after
disconnecting the motor from the
machine. Contact Yaskawa Motoman
Service.
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