YASKAWA SIGMA 5 Instructions Manual

Brand: YASKAWA

Model: SIGMA 5

Type: Instructions Manual

MANUAL NO.

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

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

vised.

• If your copy of the manual is damaged or lost, contact a YASKAWA

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

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

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

rogramming Pendant is turned OFF.

Injury or damage to machinery may result if the Emergency Stop circuit

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

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

ergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no person is present in the working envelope of the

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

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

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

ntroller

Power cables

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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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Table of Contents

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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

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 Introduction

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

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

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

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

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 Introduction

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

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

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

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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

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

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

ogramming Pendant’s LCD

display screen by selecting {MAIN

MENU} - {SYSTEM INFO} -

{VERSION}

• Serial Number Located on the positioner data

ate

• Sales Order Number Located on the positioner data

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

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

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

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

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

Ø 400

Ø 5 THRU

FOR HOMING PIN

8X M16 X2 X 22

Ø 300

2X 572X 57

138138

138

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

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

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

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

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

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

leaning

as required Clean with dry cloth or compressed air

Insulation

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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YASKAWA SIGMA 5 Instructions Manual

YASKAWA SIGMA 5 Instructions Manual

YASKAWA SIGMA 5 Instructions Manual

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