YASKAWA motoman NX100 Instructions Manual

MANUAL NO.

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YASKAWA ELECTRIC CORPORATION

MOTOMAN-ES200RN

INSTRUCTIONS

TYPE: YR-ES200RN-A00 (STANDARD SPECIFICATION)

YR-ES200RN-A01 (SLU-AXES WITH L.S. SPECIFICATION)

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

for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN-ES200RN INSTRUCTIONS

NX100 INSTRUCTIONS

NX100 OPERATOR’S MANUAL

NX100 MAINTENANCE MANUAL

The NX100 operator’s manual above corresponds to specific usage.

Be sure to use the appropriate manual.

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Part Number: 149539-1CD

Revision: 2

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• This instruction manual is intended to explain operating instructions

and maintenance procedures primarily for the MOTOMAN-ES200RN.

• General items related to safety are listed in Section 1: Safety of the

NX100 Instructions. To ensure correct and safe operation, carefully

read the NX100 instructions before reading this manual.

• Some drawings in this manual are shown with the protective covers or

shields removed for clarity. Be sure all covers and shields are replaced

before operating this product.

• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.

• YASKAWA may modify this model without notice when necessary due to

product improvements, modifications, or changes in specifications. If

such modification is made, the manual number will also be revised.

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

resentative to order a new copy. The representatives are listed on the

back cover. Be sure to tell the representative the manual number listed

on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-

uct’s warranty.

MANDATORY

CAUTION

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the

NX100.

In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,

“MANDATORY”, or “PROHIBITED”.

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

any rate, be sure to follow these important items.

Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided,

could result in minor or moderate injury to personnel and dam-

age to equipment. It may also be used to alert against unsafe

practices.

Always be sure to follow explicitly the items listed under this

heading.

Must never be performed.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if

not designated as “CAUTION” and “WARNING”.

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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• Before operating the manipulator, check that servo power is turned off

when the emergency stop buttons on the front door of the NX100 and

programming pendant are pressed.

When the servo power is turned off, the SERVO ON LED on the program-

ming pendant is turned off.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the

manipulator during an emergency. The manipulator should not be used if the emergency

stop buttons do not function.

Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items

which could interfere with the operation of the manipulator. Then turn

the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Stop

• Observe the following precautions when performing teaching operations

within the P-point maximum envelope of the manipulator :

- View the manipulator from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of

the manipulator and that you are in a safe location before:

- Turning on the NX100 power

- Moving the manipulator with the programming pendant

- Running check operations

- Performing automatic operations

Injury may result if anyone enters the P-point maximum envelope of the manipulator dur-

ing operation. Always press an emergency stop button immediately if there are prob-

lems.The emergency stop button is located on the right of front door of the NX100 and the

programming pendant.

WARNING

TURN

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Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.

The manipulator usually consists of the controller, the programming pendant, and supply

cables.

In this manual, the equipment is designated as follows:

• Perform the following inspection procedures prior to conducting manip-

ulator teaching. If problems are found, repair them immediately, and be

sure that all other necessary processing has been performed.

-Check for problems in manipulator movement.

-Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the NX100 cabi-

net after use.

The programming pendant can be damaged if it is left in the P-point maximum envelope

of the manipulator, on the floor, or near fixtures.

• Read and understand the Explanation of Warning Labels in the NX100

instructions before operating the manipulator.

Equipment Manual Designation

NX100 Controller NX100

NX100 Programming Pendant Programming Pendant

Cable between the manipulator and the controller Manipulator cable

CAUTION

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MOTOMAN

TYPE



ORDER NO.



PAYLOAD

 kg MASS

 kg

SERIAL NO.



DATE



YASKAWA ELECTRIC CORPORATION JAPAN

Explanation of Warning Labels

The following warning labels are attached to the manipulator.

Always follow the warnings on the labels.

Also, an identification label with important information is placed on the body of the manipula-

tor. Prior to operating the manipulator, confirm the contents.

WARNING label A

Nameplate

WARNING label B

WARNING

Do not enter

robot

work area.

WARNING label A WARNING label B

WARNING

Moving parts

may cause

injury

Nameplate:

MOTOMAN

TYPE



ORDER NO.



PAYLOAD

 kg MASS

 kg

SERIAL NO.



DATE



YASKAWA ELECTRIC CORPORATION JAPAN

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1 Product Confirmation

1.1 Contents Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 Transporting

2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Shipping Bolts and Brackets. . . . . . . . . . . . . . . . . . . . . . . 2-3

3 Installation

3.1 Installation of the Safeguarding. . . . . . . . . . . . . . . . . . . . 3-2

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

3.2.1 Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.3 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

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

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

4.2.2 Connection to the NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

5 Basic Specifications

5.1 Basic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

5.3 Manipulator Base Dimensions . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 Dimensions and P-Point Maximum Envelope . . . . . . 5-3

5.5 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5.1 Components for Altering Operating Range . . . . . . . . . . . . . . . .5-5

5.5.2 Notes on the Mechanical Stopper Installation. . . . . . . . . . . . . .5-6

5.5.3 Adjustment to the Pulse Limitation of S-Axis. . . . . . . . . . . . . . .5-7

 Mounting the S-Axis Stopper by Settable Angles . . . . . . . . .5-9

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6 Allowable Load for Wrist Axis and Wrist Flange

6.1 Allowable Wrist Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

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

7 System Application

7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . .7-1

7.2 Internal User I/O Wiring Harness and Air Lines . . . . .7-2

8 Motoman Construction

8.1 Position of S-Axis Limit Switch . . . . . . . . . . . . . . . . . . . . .8-1

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

9 Maintenance and Inspection

9.1 Inspection Schedule

(Manipulator in the Home Position: Refer to “Fig.21.”) . . . . . . . . . . 9-1

9.2 Notes on Maintenance Procedures. . . . . . . . . . . . . . . . .9-6

9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9.2.2

Grease Replenishment/Exchange for S-Axis Speed Reducer

. . . . . . 9-8

 Grease Replenishment

(Refer to " Fig. 24 S-Axis Speed Reducer and Gear Diagram ".)

. . 9-8

 Grease Exchange

(Refer to " Fig. 24 S-Axis Speed Reducer and Gear Diagram ".)

. . 9-9

9.2.3 Grease Replenishment/Exchange for L-Axis Speed Reducer 9-10

 Grease Replenishment

(Refer to " Fig. 25 L-Axis Speed Reducer Diagram ".) . . . . 9-10

 Grease Exchange

(Refer to " Fig. 25 L-Axis Speed Reducer Diagram ".) . . . . 9-11

9.2.4 Grease Replenishment/Exchange for U-Axis Speed Reducer9-12

 Grease Replenishment

(Refer to " Fig. 26 U-Axis Speed Reducer Diagram ".). . . . 9-12

 Grease Exchange

(Refer to " Fig. 26 U-Axis Speed Reducer Diagram ".). . . . 9-13



Grease Replenishment for R-, B-, T- Gears in the Casing

(Refer to " Fig. 27 U-Arm Diagram ".). . . . . . . . . . . . . . . . . 9-15

 Grease Replenishment for R-Axis Speed Reducer

(Refer to " Fig. 27 U-Arm Diagram ".). . . . . . . . . . . . . . . . . 9-15

 Grease Replenishment for B-Axis Speed Reducer

(Refer to " Fig. 27 U-Arm Diagram ".). . . . . . . . . . . . . . . . . 9-16

 Grease Replenishment for T-Axis Speed Reducer

(Refer to " Fig. 27 U-Arm Diagram ".). . . . . . . . . . . . . . . . . 9-16

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

Grease Exchange for R-, B- T-Axis Gears in the Casing

(Refer to " Fig. 27 U-Arm Diagram ".) . . . . . . . . . . . . . . . . .9-17

 Grease Exchange for R-Axis Speed Reducer

(Refer to " Fig. 27 U-Arm Diagram ".) . . . . . . . . . . . . . . . . .9-17

 Grease Exchange for B-Axis Speed Reducer

(Refer to " Fig. 27 U-Arm Diagram ".) . . . . . . . . . . . . . . . . .9-18

 Grease Exchange for T-Axis Speed Reducer

(Refer to " Fig. 27 U-Arm Diagram ".) . . . . . . . . . . . . . . . . .9-19

9.2.5 Grease Replenishment for Balancer Connection Part. . . . . . .9-20

9.2.6 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22

 Battery Pack Connections. . . . . . . . . . . . . . . . . . . . . . . . . .9-22

10 Recommended Spare Parts

11 Parts List

11.1 S-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.2 L-Axis Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11.3 URBT-Axis Link Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

11.4 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

11.5 Balancer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

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1.1 Contents Confirmation

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1Product Confirmation

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (Information for the content of optional

goods is given separately):

• Manipulator

• NX100

• Programming Pendant

• Manipulator cables (3 cables, between the NX100 and the manipulator)

• Confirm that the manipulator and the NX100 have the same order num-

ber. Special care must be taken when more than one manipulator is to

be installed.

If the numbers do not match, manipulators may not perform as expected and cause injury

or damage.

CAUTION

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1.2 Order Number Confirmation

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1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the NX100. The order number

is located on a label as shown below.

(a) NX100 (Front View) (b) Manipulator (Side View)

Fig. 1 Location of Order Number Labels

Label (Enlarged view)

THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.

ORDER. No. 

Check that the manipulator

and the NX100 have the

same order number.

NX100

200V 50Hz

kVA

3PHASE220V 50/60Hz

NJ2484-1

MADE IN JAPAN

DATE

SERIAL No.

ERCR-

TYPE

POWER SUPPLY

******

ORDER NO.

NJ1529

THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.

WARNING

Do not open the door

RESET

OFF

TRIPPED

ON

N

P

O

E

T

R

G

Y

C

M

S

E

SELECT

PLAY

TEACH

REMOTE

SERVO

POWER

S-

X+

S+

MAIN

MENU

R-

x

R+

x

ASSIST

COORD.

MULTI

DISPLAY

SWITCH

X-

yy

645

AUXILIARY

TIMER

1

WEAVING

COMPLETE

VOLTAGE CURRENT

2

WELD

COMPLETE

3

RETRUCT

DELETE

BACK

INSERT

R-

LOCK

INTER

WEAVING

START

7

+

R+

B+B-

z

T-

WELD

START

8

FEED

9

T

EST RUN

SHIFT

z

T+

EX-AXIS

SWITCH

ROBOT

SWITCH

-

SHIFT

Y+Y-

0

ENTER

CABCEK

INTER.

REF.

POINT

MODIFY

.

-

VOLTAGE CURRENT

SHORTCUT

MENU

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2.1 Transporting Method

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2Transporting

2.1 Transporting Method

2.1.1 Using a Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be

used. The manipulator should be lifted using wire rope threaded through shipping bolts and

brackets. Be sure the manipulator is fixed with the shipping bolts and brackets before trans-

porting, and lift it in the posture as shown in " Fig. 2 Transporting Position ".

• Sling and crane or forklift operations must be performed by authorized

personnel only.

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

• Avoid excessive vibration or shock during transporting.

The system consists of precision components, so failure to observe this caution may

adversely affect performance.

• The weight of the manipulator is approximately 1620kg including the shipping bolts and

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

• Shipping bolts and brackets are designed to support the manipulator weight. Do not use

them for anything other than transporting the manipulator.

• Mount the shipping bolts and brackets for transporting the manipulator.

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

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

CAUTION

NOTE

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2.1 Transporting Method

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Fig. 2 Transporting Position

A

B

Electrical tape

painted yellow

Rubber plate

Details of shipping bolt

Shipping bolt

(1 piece)

Hexagon socket head

cap screw M20

(length: 50mm) (8 screws)

Shipping bracket (2 pieces)

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2.2 Shipping Bolts and Brackets

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2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at position A and with the hexa-

gon socket head cap screws at point B. (" Fig. 2 Transporting Position ")

Fig. 3 Shipping Bolts and Brackets

• The shipping brackets are painted yellow.

Position Bolt Type Pcs

AHexagon socket head cap bolt M20 X 50 mm

(Tensile strength: 1200 N/mm2 or more) 8

BHexagon socket head cap bolt M16 X 20 mm

(Tensile strength: 1200 N/mm2 or more) 1

Before turning ON the power, check to be sure that the shipping bolts and brackets have

been removed. The shipping bolts and brackets then must be stored for future use, in the

event that the robot must be moved again.

BShipping bolt Rubber plate

Electrical tape painted yellow

AShipping bracket

Front View Side View

NOTE

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3Installation

• Install the safeguarding.

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

• Install the manipulator in a location where the manipulator’s tool or the

workpiece held by the manipulator will not reach the wall, safeguarding,

or NX100 when the arm is fully extended.

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

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

anchored.

The manipulator may overturn and cause injury or damage.

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

Failure to observe this caution may cause injury or damage.

• Before turning on the power, check to be sure that the shipping bolts

and brackets explained in “ Fig. 3 Shipping Bolts and Brackets ” are

removed.

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

WARNING

CAUTION

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3.1 Installation of the Safeguarding

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3.1 Installation of the Safeguarding

To insure safety, be sure to install the safeguarding. They prevent unforeseen accidents with

personnel and damage to equipment. The following is quoted for your information and guid-

ance.

Responsibility for Safeguarding (ISO 10218)

The user of a manipulator or robot system shall ensure that safeguarding is provided and

used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safe-

guarding, including any redundancies, shall correspond directly to the type and level of hazard

presented by the robot system consistent with the robot application. Safeguarding may

include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter

guarding, awareness barriers, and awareness signals.

3.2 Mounting Procedures for Manipulator Base

The manipulator should be firmly mounted on a baseplate or foundation strong enough to sup-

port the manipulator and withstand repulsion forces during acceleration and deceleration.

Construct a solid foundation with the appropriate thickness to withstand maximum repulsion

forces of the manipulator. Refer to " Table. 1 Maximum Repulsion Forces of the Manipulator "

and " Table. 2 Endurance Torque in Operation ".

During installation, if the flatness is not right, the manipulator shape may change and its func-

tional ability may be compromised. Baseplate flatness must be kept at 0.5mm or less. Mount

the manipulator base as described in “ 3.2.1 Mounting Example “..

Table. 1 Maximum Repulsion Forces of the Manipulator

Horizontal rotating maximum torque

(S-axis moving direction) 32000N • m

(3265kgf • m)

Vertical rotating maximum torque

(LU-axis moving direction) 78500N • m

(8000kgf • m)

Table. 2 Endurance Torque in Operation

Horizontal acceleration and

deceleration maximum torque 9000N • m

(918kgf • m)

Vertical acceleration and decel-

eration maximum torque 26150N • m

(2664kgf • m)

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3.3 Location

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3.2.1 Mounting Example

The baseplate should be rugged and durable to prevent shifting of the manipulator or the fix-

ture. The thickness of the baseplate is 50mm or more and an M20 size or larger anchor bolt is

recommended.

Fix the manipulator base onto the baseplate with the hexagon socket head cap screw M20 (8

screws, length: 80mm or more is recommended) as shown in " Fig. 4 Mounting the Manipula-

tor on Baseplate ". Tighten the hexagon socket head cap screws and anchor bolts securely

so that they will not work loose during operation.

Fig. 4 Mounting the Manipulator on Baseplate

3.3 Location

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

conditions:

• Ambient temperature: 0° to 45°C

• Humidity: 20 to 80%RH at constant temperature

• Free from exposure to water, oil, or dust

• Free from corrosive gas or liquid, or explosive gas or liquid

• Free from excessive vibration (less than 4.9m/s2 [0.5G])

• Free from large electrical noise (plasma)

• Flatness for installation is 0.5mm or less

40mm

Baseplate

Manipulator base

Flat washer

Spring washer

M20 (8 screws)

Flatness:0.5mm or less

Hexagon socket head cap screw

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4.1 Grounding

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4Wiring

4.1 Grounding

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

Refer to " Fig. 5 Grounding Method " to connect the ground line directly to the manipulator.

• Ground resistance must be 100 Ω or less.

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

• Before wiring, make sure to turn the primary power supply off, and put

up a warning sign. (ex. DO NOT TURN THE POWER ON.)

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

• Wiring must be performed by authorized or certified personnel.

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

• Do not cover the cable or allow it to tangle. Keep the cable as straight

as possible.

Failure to observe this caution may result in preventing heat of the cable from being dis-

charged.

• Do not use this line in common with other ground lines or grounding electrodes for other

electric power, motor power, welding devices, etc.

• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,

ground in accordance with Electric Equipment Technical Standards.

WARNING

CAUTION

NOTE

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4.2 Manipulator Cable Connection

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Fig. 5 Grounding Method

4.2 Manipulator Cable Connection

Three manipulator cables are delivered with the manipulator: an encoder cable for detection

(1BC) and two power cables (2BC and 3BC). Refer to " Fig. 6 Manipulator Cable Connections

". The cables are connected to manipulator base connectors and NX100.

4.2.1 Connection to the Manipulator

The manipulator cables and manipulator base connectors are numbered 1BC, 2BC, and 3BC.

Verify the numbers and connect these cables to the manipulator base connectors in the order

of 2BC first, 3BC second, and 1BC last. Refer to “ Fig. 7 (a) Details of the Manipulator Cable

Connectors (Manipulator Side) “. When connecting the cables, insert them adjusting cable

connector positions to main key positions of the manipulator, and set the lever until it clicks.

4.2.2 Connection to the NX100

The manipulator cables and NX100 board connectors are numbered 1BC, 2BC, and 3BC.

Verify the numbers and connect these cables to the NX100 board connectors in the order of

2BC first, 3BC second, and 1BC last. Refer to " Fig. 7 (b)) Manipulator Cable Connections to

the NX100 ". When connecting the cables, insert them adjusting cable connector positions to

main key positions of the NX100, and set the lever until it clicks.

A

5.5mm2or more View A

Bolt M8 (for grounding)

Delivered with the manipulator

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4.2 Manipulator Cable Connection

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Fig. 6) Manipulator Cable Connections

X11

1BC

X21

2BC

X22

3BC

Power cable

X11 1BC

X21 2BC

X22 3BC

Power cable

2BC

Encoder cable

1BC

Manipulator side

NX100 side

Manipulator side

NX100 side

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YASKAWA motoman NX100 Instructions Manual

YASKAWA motoman NX100 Instructions Manual

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