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MOTOMAN-MCL130

INSTRUCTIONS
TYPE: YR-MCL0130-A00

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOVAN-MCL130 INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATORS MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operators manual above corresponds to specific usage.
Be sure to use the appropriate manual.

Part Number: 158869-1CD


Revision: 0

YASKAWA ELECTRIC CORPORATION

MANUAL NO.

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MANDATORY

This instruction manual is intended to explain mainly on the


mechanical part of the MOTOMAN-MCL130 for the application to
the actual operation and for proper maintenance and inspection. It
describes on safety and handling, details on specifications,
necessary items on maintenance and inspection, to explain
operating instructions and maintenance procedures. Be sure to
read and understand this instruction manual thoroughly before
installing and operating the manipulator.

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


DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instructions before reading this manual.

CAUTION

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


representative 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
product's warranty.

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Notes for Safe Operation


Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MCL130.
In this manual, the Notes for Safe Operation are classified as
WARNING, CAUTION, MANDATORY, or PROHIBITED.

WARNING
CAUTION

MANDATORY
PROHIBITED

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 damage 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.

Even items described as CAUTION may result in a serious accident in


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

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 manipulator, check that servo power is turned


OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming 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.
Fig. : 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.


Fig. : Release of Emergency Stop
TURN

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.
Keep in mind the emergency response measures against the
manipulators unexpected motion toward you.
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 person is present in the P-point maximum envelope


of the manipulator and that you are in a safe location before:
Turning ON the power for the DX100.
Moving the manipulator with the programming pendant.
Running the system in the check mode.
Performing automatic operations.

Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.

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CAUTION

Perform the following inspection procedures prior to conducting


manipulator 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 cabinet


of the DX100 after use.

The programming pendant can be damaged if it is left in the


manipulator's work area, on the floor, or near fixtures.

Read and understand the Explanation of Warning Labels in the


DX100 Instructions before operating the manipulator:

Definition of Terms Used Often in This Manual


The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.
In this manual, the equipment is designated as follows:
Equipment

Manual Designation

DX100 controller

DX100

DX100 programming pendant

Programming pendant

Cable between the manipulator and the


controller

Manipulator cable

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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 manipulator. Prior to operating the manipulator, confirm the
contents.
Fig. : Warning Label Locations

WARNING Label B
WARNING Label A

Nameplate

WARNING Label B

WARNING Label A

Nameplate:

WARNING Label A:

WARNING
Moving parts
may cause
injury

WARNING Label B:

WARNING
Do not enter
robot
work area.

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Contents

1 Receiving ........................................................................................................................................ 1-1


1.1 Checking Package Contents ............................................................................................. 1-1
1.2 Checking the Order Number.............................................................................................. 1-2
2 Transporting.................................................................................................................................... 2-1
2.1 Transporting Method.......................................................................................................... 2-1
2.1.1 Using the Crane ................................................................................................... 2-1
2.2 Shipping Bolts and Brackets.............................................................................................. 2-3
2.3 After Removing the Shipping Bolts and Brackets .............................................................. 2-4
3 Installation....................................................................................................................................... 3-1
3.1 Installation of Safeguarding ............................................................................................... 3-2
3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2
3.2.1 When the Manipulator and Mounting Fixture are
Installed on a Common Base ............................................................................... 3-3
3.2.2 When the Manipulator is Mounted Directly on the Floor....................................... 3-3
3.3 Mounted Type.................................................................................................................... 3-5
3.4 Location ............................................................................................................................. 3-5
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-2
4.2 Cable Connection .............................................................................................................. 4-2
4.2.1 Connection to the Manipulator.............................................................................. 4-2
4.2.2 Connection to the DX100 ..................................................................................... 4-3
5 Basic Specifications ........................................................................................................................ 5-1
5.1 Basic Specifications........................................................................................................... 5-1
5.2 Manipulator Clean Specifications ...................................................................................... 5-2
5.3 Part Names and Working Axes.......................................................................................... 5-3
5.4 Manipulator Installation Base Dimensions......................................................................... 5-3
5.5 Dimensions and P-point Maximum Envelope .................................................................... 5-4
5.6 B-axis Working Range ....................................................................................................... 5-5
5.7 Alterable Working Range................................................................................................... 5-5
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-2

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7 System Application.......................................................................................................................... 7-1


7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.2 Internal User I/O Wiring Harnesses and Air Line ............................................................... 7-2
8 HMOTOMAN Construction.............................................................................................................. 8-1
8.1 Position of S-axis Limit Switch ........................................................................................... 8-1
8.2 Internal Connections .......................................................................................................... 8-2
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-2
9.2 Notes on Maintenance Procedures.................................................................................... 9-6
9.2.1 Battery Pack Replacement ................................................................................... 9-6
9.2.2 Grease Replenishment/Replacement for S-axis Speed Reducer and Gear......... 9-8
9.2.2.1 Grease Replenishment (Refer to fig. 9-5 S-axis Speed
Reducer and Gear Diagram ) ................................................................. 9-8
9.2.2.2 Grease Replacement (Refer to fig. 9-5 S-axis Speed
Reducer and Gear Diagram at page 9-8)............................................... 9-9
9.2.3 Grease Replenishment/Replacement for L-axis Speed Reducer ....................... 9-10
9.2.3.1 Grease Replenishment (Refer to fig. 9-6 L-axis Speed
Reducer Diagram ) ............................................................................... 9-10
9.2.3.2 Grease Replacement (Refer to fig. 9-6 L-axis Speed
Reducer Diagram at page 9-10)........................................................... 9-11
9.2.4 Grease Replenishment/Replacement for U-axis Speed Reducer ...................... 9-12
9.2.4.1 Grease Replenishment (Refer to fig. 9-7 U-axis Speed
Reducer Diagram ) ............................................................................... 9-12
9.2.4.2 Grease Replacement (Refer to fig. 9-7 U-axis Speed
Reducer Diagram at page 9-12)........................................................... 9-13
9.2.5 Grease Replenishment/Replacement for R-axis Speed Reducer ...................... 9-14
9.2.5.1 Grease Replenishment (Refer to chapter Fig. 9-8: R-axis Speed
Reducer Diagram) ................................................................................ 9-14
9.2.5.2 Grease Replacement (Refer to fig. 9-8 R-axis Speed
Reducer Diagram at page 9-14)........................................................... 9-15
9.2.6 Grease Replenishment/Replacement for B-axis Speed Reducer and Gear....... 9-16
9.2.6.1 Grease Replenishment (Refer to fig. 9-9 B-axis Speed
Reducer and Gear Diagram ) ............................................................... 9-16
9.2.6.2 Grease Replacement (Refer to fig. 9-9 B-axis Speed
Reducer and Gear Diagram at page 9-16)........................................... 9-17
9.2.7 Grease Replenishment/Replacement for T-axis Speed Reducer and Gear....... 9-18
9.2.7.1 Grease Replenishment (Refer to fig. 9-10 T-axis Speed
Reducer and Gear Diagram ) ............................................................... 9-18
9.2.7.2 Grease Replacement (Refer to fig. 9-10 T-axis Speed
Reducer and Gear Diagram at page 9-18)........................................... 9-19
9.2.8 Grease Replenishment for Balancer Connection Part........................................ 9-20
9.2.9 Notes for Maintenance........................................................................................ 9-21
9.2.9.1 Battery Pack Connection for S-, L-, and U-axes Motors........................ 9-21

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9.2.9.2 Battery Pack Connection for R-, B-, and T-axes Motors ....................... 9-21

10 Recommended Spare Parts........................................................................................................ 10-1

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1.1

MCL130

Receiving
Checking Package Contents

Receiving

CAUTION
Confirm that the manipulator and the DX100 have
the same order number. Special care must be
taken when more than one manipulator is to be
installed.
If the numbers do not match, manipulators may not perform as
expected and cause injury or damage.

1.1

Checking Package Contents


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

Manipulator
DX100
Programming pendant
Manipulator cables (three cables)
Accessories

Accessories

Quantity

Hexagon socket head cap bolt M20 90mm: Anti-corrosive

Flat washer M20: Anti-corrosive

Spring washer M20: Anti-corrosive

Flat washer M12: Anti-corrosive

Hexagon socket head cap bolt M12 35mm: Anti-corrosive

Hexagon socket head cap bolt M8 20mm: Anti-corrosive

Plate A: Anti-corrosive

Plate B: Anti-corrosive

Plate C: Anti-corrosive

Hexagon wrench 17mm

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1.2

Receiving
Checking the Order Number

Checking the Order Number


Check that the order number of the manipulator corresponds to the
DX100. The order number is located on a label as shown below.
Fig. 1-1: Location of Order Number Labels
Label (Enlarged View)

THE MANIPULATOR AND THE CONTROLLER


SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.

AC200V
AC220V

50/60Hz
60Hz

kVA
kVA
kA

PEAK
AVERAGE

ER

GE N
Y

3PHASE

INTERRUPT CURRENT

ERDR-

POWER SUPPLY

EM

DX100
TYPE

Check that the manipulator


and the DX100 have the
same order number.

SERIAL No.
DATE

MADE IN JAPAN

NJ2960-1

T O P

RE

SE

OFF

TR

IP

PE

ON

WARNING
Do not open the door
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.

ORDER NO.
NJ1529

PROGRAMMING PENDANT

X81

(a) DX100 (Front View)

(b) Manipulator (Side View)

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2.1

MCL130

Transporting
Transporting Method

Transporting

CAUTION
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.

2.1
2.1.1

Transporting Method

Using the Crane


As a rule, when removing the manipulator from the package and moving
it, a crane should be used. The manipulator should be lifted using wire
rope threaded through attached eyebolts. Be sure the manipulator is fixed
with shipping bolts and brackets before transporting, and lift it in the
posture as shown in fig. 2-1 Transporting Position at page 2-2.

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2.1

Transporting
Transporting Method

Fig. 2-1: Transporting Position

Check that the eyebolts are securely fastened.


The mass of the manipulator is approximately 1400kg
including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.
Attached eyebolts are designed to support the manipulator

NOTE

weight. Do not use them for anything other than transporting the manipulator.
Mount the shipping bolts and brackets for transporting the
manipulator.
Avoid external 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.

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2.2

Transporting
Shipping Bolts and Brackets

Shipping Bolts and Brackets


The manipulator is provided with shipping bolts and brackets at points A,
B, and C (fig. 2-1 Transporting Position at page 2-2).

The shipping bolts and brackets are painted yellow.


Installing
Location

Anti-corrosive Bolt

Quantity

Hexagon socket head cap bolt M8 20mm


(Tensile strength: 1200N/mm2 or more)

Hexagon socket head cap bolt M12 50mm


(Tensile strength: 1200N/mm2 or more)
Hexagon socket head cap bolt M12 35mm
(Tensile strength: 1200N/mm2 or more)

Hexagon socket head cap bolt M12 50mm


(Tensile strength: 1200N/mm2 or more)

NOTE

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 manipulator must be moved again.

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2.3

Transporting
After Removing the Shipping Bolts and Brackets

After Removing the Shipping Bolts and Brackets


After removing the shipping bolts and brackets, install the parts described
in the following table on each installing location in fig. 2-2 After Removing
the Shipping Bolts and Brackets for preventing corrosion.

Fig. 2-2: After Removing the Shipping Bolts and Brackets


D

A (4 locations)

Installing
Location

Anti-corrosive Bolt

Quantity

A
(Four locations)

Flat washer M12


Hexagon socket head cap bolt
M12 35mm

1 (Four locations)
1 (Four locations)

B
(Two locations)

Plate A
Hexagon socket head cap bolt
M12 35mm

1 (Two locations)
2 (Two locations)

Plate B
Hexagon socket head cap bolt
M12 35mm

1
2

Plate C
Hexagon socket head cap bolt
M8 20mm

1
2

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Installation

Installation

WARNING
Install the safeguarding.
Failure to observe this warning may result in injury or damage.
Install the manipulator in a location where the
fully extended arm and tool will not reach the wall,
safeguarding, or DX100.
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.

CAUTION
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 have been
removed.
Failure to observe this caution may result in damage to the driving parts.

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3.1

MCL130

3.1

Installation
Installation of Safeguarding

Installation of Safeguarding
To insure safety, be sure to install the safeguarding. It prevents
unforeseen accidents with personnel and damage to equipment. The
following is quoted for your information and guidance.
(ISO10218)
Responsibility for Safeguarding
The user of a manipulator or robot system shall ensure that the
safeguarding is provided and used in accordance with Sections 6, 7, and
8 of this standard. The means and degree of safeguarding, 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 base or foundation strong
enough to support the manipulator and withstand repulsion forces during
acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand
maximum repulsion forces of the manipulator as shown in table 3-1
Maximum Repulsion Forces of the Manipulator
During installation, if the flatness is not right, the manipulator shape may
change and its functional ability may be compromised. The flatness for
installation must be kept at 0.5mm or less. Mount the manipulator base in
either of the following ways: chapter 3.2.1 When the Manipulator and
Mounting Fixture are Installed on a Common Base at page 3-3 or
chapter 3.2.2 When the Manipulator is Mounted Directly on the Floor at
page 3-3
Table 3-1: Maximum Repulsion Forces of the Manipulator
Horizontal rotating maximum torque
( S-axis moving direction)

32000N m

Vertical rotating maximum torque


(LU-axis moving direction)

78500N m

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3.2.1

3
3.2

Installation
Mounting Procedures for Manipulator Base

When the Manipulator and Mounting Fixture are Installed on a Common Base
The common base should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. The thickness of the common base is
50mm or more and an M20 size or larger anchor bolt is recommended.
For the installation dimensions of the manipulator installation base, refer
to the dimensions in fig. 3-2 Direct Mounting on the Floor at page 3-4
Affix the manipulator securely with the hexagon head bolts M20 (90mm
long recommended). Tighten the bolts and anchor bolts securely so that
they will not work loose during operation. See "Fig. 3-1 Mounting on the
Common Base" for the method.

Fig. 3-1: Mounting on the Common Base

Spring washer

Hexagon socket head cap bolts M20 (8 bolts)


Manipulator installation base

50

Flat washer

Flatness: 0.5mm or less

3.2.2

When the Manipulator is Mounted Directly on the Floor


The floor should be strong enough to support the manipulator. Construct a
solid foundation with the appropriate thickness to withstand maximum
repulsion forces of the manipulator. As a rough standard, when there is a
concrete thickness (floor) is 200mm or more, the manipulator base can be
fixed directly to the floor with anchor bolts M20. Before mounting the
manipulator, however, check that the floor is level and that all cracks, etc.
are repaired. A non-concrete floor or a floor less than 200mm thick is
insufficient for installation, even if the floor is concrete.

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3.2

Installation
Mounting Procedures for Manipulator Base

Fig. 3-2: Direct Mounting on the Floor


640

880

1200

410

960

Tapped holes M20 (8 holes)


(Bolt A)

540

40

1100

Manipulator installation base

640
540
500
460
28 dia. through holes (4 holes)
(Base B)
160
320

160
320

440

28 dia. through holes (4 holes) (Base A)


Tapped holes M24 (4 holes) (Base B) (Bolt B)
10 Weld these portions after
installation and adjustment.
(Base A)

250

FL

350

32

50

(Base B)
The surface must be
level and even.

36

Dimensions in mm

200

JA type anchor bolts


200
100
M24 315mm
Bolt A: Bolts M20 (length: 90mm) (8 bolts), spring washers, flat washers
Bolt B: Bolts M24 (length: 70mm) (8 bolts), spring washers
Bolts, base A and B should be equipped by user.
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3.3

MCL130

3.3

Installation
Mounted Type

Mounted Type
The MOTOMAN-MCL130 is floor-mounted type.

3.4

Location
The MOTOMAN-MCL130 is used in the clean room.
When the manipulator is installed, it is necessary to satisfy the
undermentioned environmental conditions:

15 to +45C (ambient temperature)


20 to 80%RH (no moisture, non-condensing)
Free from water
Free from corrosive gases or liquid, or explosive gases
Free from excessive impact or vibration
(less than 4.9m/s2 (0.5G)
Free from large electrical noise
The flatness for installation is 0.5mm or less

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Wiring

Wiring

WARNING
Ground resistance must be 100 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.

CAUTION
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 discharged.

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4.1

MCL130

4.1

Wiring
Grounding

Grounding
Follow local regulations for grounding line size. A line of 5.5mm2 or more
is recommended. Refer to fig. 4-1 Grounding Method to connect the
ground line directly to the manipulator.

NOTE

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.

Fig. 4-1: Grounding Method

  

4.2

   
    
 

Cable Connection
There are three manipulator cables; an encoder cable for detection (1BC)
and power cables (2BC and 3BC). Connect these cables to the
manipulator base connectors and the DX100. Refer to fig. 4-3(a)
Manipulator Cable Connection to the Manipulator at page 4-4 and
fig. 4-3(b) Manipulator Cable Connection to the DX100 at page 4-4.

4.2.1

Connection to the Manipulator


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

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Wiring
Cable Connection

Connection to the DX100


Remove the cover on the DX100 side. Pass the encoder cable for
detection (1BC), the power cables (2BC and 3BC), through the opening
for the cables, and then fasten bolts on the opening.
Connect the 2BC and 3BC cables to the terminals inside of the DX100.
Be sure to verify the numbers on both the cable and board connectors
before connecting.
Connect the 1BC cable to the boards. Be sure to verify the numbers on
both the cable and board connectors before connecting, and to fasten the
bolts on connectors to prevent cables from loosening.

Fig. 4-2: Manipulator Cables

The DX100 Side

The Manipulator Side

1BC

X11

X11

1BC

1BC

Encoder Cable

The DX100 Side

The Manipulator Side


X21

2BC

2BC

X21

2BC

Power Cable

The DX100 Side

The Manipulator Side


X22

3BC

3BC

3BC

X22

4.2.2

4
4.2

Power Cable

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4.2

Wiring
Cable Connection

Fig. 4-3(a): Manipulator Cable Connection to the Manipulator

2BC

3BC

1BC

Key positions

Connector Details
(Manipulator Side)

Fig. 4-3(b): Manipulator Cable Connection to the DX100

;
;
;

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5.1

MCL130

Basic Specifications
Basic Specifications

Basic Specifications
5.1

Basic Specifications

Table 5-1: Basic Specifications1)


Item

Model

MOTOMAN-MCL130

Configuration

Vertically Articulated

Degree of Freedom

Payload

130 kg

Repeatability

2)

0.2 mm

Range of Motion

Maximum Speed

Allowable Moment

Allowable Inertia
(GD2/4)

3)

S-axis (turning)

-150 - +150

L-axis (lower arm)

-60 - +76

U-axis (upper arm)

-130 - +240

R-axis (wrist roll)

-360 - +360

B-axis (wrist pitch/yaw)

-130 - +130

T-axis (wrist twist)

-360 - +360

S-axis

2.27 rad/s, 130/s

L-axis

2.27 rad/s, 130/s

U-axis

2.27 rad/s, 130/s

R-axis

3.75 rad/s, 215/s

B-axis

3.14 rad/s, 180/s

T-axis

5.24 rad/s, 300/s

R-axis

735Nm (75 kgfm)

B-axis

735Nm (75 kgfm)

T-axis

421 Nm (43 kgfm)

R-axis

45 kgm2

B-axis

45 kgm2

T-axis

15 kgm2

Mass
Ambient
Conditions

1300 kg
Temperature

15 C to 45 C

Humidity

20 to 80% RH (non-condensing)

Vibration

4.9 m/s2 or less (0.5 G)

Others

Free from corrosive gasses or liquids, or explosive


gases or liquids
Free from exposure to water, oil, or dust
Free from excessive electrical noise (plasma)
A baseplate flatness must be kept at 0.5 mm or
less.

Power Capacity

7.5 kVA

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


2 Conformed to ISO9283
3

Refer to chapter 6.1 Allowable Wrist Load at page 6-1 for details on the allowable inertia.

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5.2

MCL130

5.2

Basic Specifications
Manipulator Clean Specifications

Manipulator Clean Specifications


The MOTOMAN-MCL130 is ISO-14644 rated, cleanliness class 6*1
(equivalent to the FEDERAL STANDARD 209E, cleanliness class 1000).
1. Under the condition that the manipulator is in the downflow of 0.4m/s
or more (vertically rectified state) and exhausted (exhausted amount of
400 liter/min) inside from the exhaust port A for the manipulator
internal air, and the balancer is exhausted (exhausted amount of 150
liter/min) inside from the exhaust port B for the manipulator internal air.
Refer to fig. 5-1 Exhaust Ports for Manipulator Internal Air

Fig. 5-1: Exhaust Ports for Manipulator Internal Air

Exhaust port B for manipulator internal air


(Tapped hole PT1/8:with pipe plug)

2BC

3BC

1BC

Exhaust port A for manipulator internal air


(Outer diameter: 34mm)

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5.3

MCL130

5.3

Basic Specifications
Part Names and Working Axes

Part Names and Working Axes

Fig. 5-2: Part Names and Working Axes


Upper arm
U-arm

U+

R+

B+

Wrist T+

U-

R-

B-

T-

Wrist flange

L+

L-

Lower arm
L-arm

S+
Rotary head
S-head
Manipulator installation base
S-

Manipulator Installation Base Dimensions

Fig. 5-3: Manipulator Base Dimensions


22 dia. holes (12 holes)

12

+0.018
0

dia. hole

0.1

640

725

540

320

365

0.1

0.1

320

50

5.4

540
640
365

855

0.1

Dimensions in mm

View A

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5.5

Dimensions and P-point Maximum Envelope

Fig. 5-4: Dimensions and P-point Maximum Envelope

150

R7
29

25
R5
R265

150

4611
1961

2650

P-point maximum envelope


1250

230

60
20.8

76

?P-point

3130

69

.2

189

285

2069
1150

90

36

13

50

242

222

5.5

Basic Specifications
Dimensions and P-point Maximum Envelope

730

MCL130

Dimensions in mm

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5.6

MCL130

5.6

Basic Specifications
B-axis Working Range

B-axis Working Range


The working range of the B-axis maintaining a constant angle to the
center of the U-arm is shown in fig. 5-5 B-axis Working Range

Fig. 5-5: B-axis Working Range

13

Center of
U-axis
rotation

130

Center of
B-axis
rotation

Center of
L-axis
rotation
Center of S-axis
rotation

5.7

Alterable Working Range


The working range of the S-axis can be altered according to the operating
conditions as shown in table 5-2 S-axis Working Range If alteration is
necessary, contact your Yaskawa representative in advance.
Table 5-2: S-axis Working Range
Item

Specifications

S-axis Working
Range

-150 - + 150 (standard)


-120 - + 120
-90 - + 90
-60 - + 60
-30 - + 30

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6.1

MCL130

Allowable Load for Wrist Axis and Wrist Flange


Allowable Wrist Load

Allowable Load for Wrist Axis and Wrist Flange


6.1

Allowable Wrist Load


The allowable wrist load including the mass of the mount/gripper is:

YR-MCL0130-A00 : 130kg maximum


If force is applied to the wrist instead of the load, force on R-, B-, and Taxes should be within the value shown in table 6-1 Moment and Total
Inertia Contact your Yaskawa representative for further information or
assistance.
Table 6-1: Moment and Total Inertia
Axis

Moment Nm (kgfm)1)

Total Inertia kgm2

R-axis
B-axis
T-axis

735 (75)
735 (75)
421 (43)

45
45
15

1 ( ): Gravitational unit

When the volume load is small, refer to the moment arm rating shown in
"Fig. 6-1 Moment Arm Rating."
The allowable total inertia is calculated when the moment is at the
maximum. Contact your Yaskawa representative when only inertia
moment, or load moment is small and inertia moment is large. Also, when
the load is combined as a force but a mass, contact your Yaskawa
representative.

Fig. 6-1: Moment Arm Rating


L T(mm)
600

P-point

40Kg

Center
line of
T-and
R-axes
rotation

60Kg

400
130Kg

200

100Kg
80Kg
400

600

800 1000

L B(mm)

200
400
600
L T(mm)
Center line of B-axis rotation
YR-MCL0130-A00

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6.2

Wrist Flange
If the fitting is used to mount the attachment, the fitting depth inside the
fitting must be 8mm or less; outside 5mm or less.

Fig. 6-2: Wrist Flange


+0.015
0
+0.015
0

dia. holes (depth: 8mm) (2 holes)

dia. holes (depth: 8mm) (2 holes)

PC
D1
25

10

92

171 dia.

PCD

160-0.025 dia.

6.2

Allowable Load for Wrist Axis and Wrist Flange


Wrist Flange

63 +0.030
dia. hole
0

MCL130

Tapped holes M10 (depth: 12mm)


(6 holes)

Tapped holes M10 (depth: 12mm) (6 holes)

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7.1

MCL130

System Application
Peripheral Equipment Mounts
When peripheral equipment is attached to the U-axis, the following
conditions described in table 7-1 Constraint for Attaching at page 7-2
should be observed.

Fig. 7-1: Clamp and Trapped Holes


B Cap bolts M8 (length: 15mm) (pitch: 1.25mm) (4 bolts)
126 160

100

60

A1 Cap bolts M8 (length: 15mm) (pitch: 1.25mm) (4 bolts)

497.5

85

85

200
189

552.5

A2 Cap bolts M8 (length: 15mm) (pitch: 1.25mm) (4 bolts)

120
80

7.1

100

System Application
Peripheral Equipment Mounts

C Hexagon socket head cap bolts M12


(length: 25mm) (pitch: 1.75mm) (4 bolts)
With flat washer (WSSM35-12-10)
Dimensions in mm

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7.2

MCL130

System Application
Internal User I/O Wiring Harnesses and Air Line

Table 7-1: Constraint for Attaching

7.2

Application

Note

A1
A2

Cable Processing

Attaching load mass is


130kg max. for YR-MCL0130-A00
including wrist load.

Cable Processing
and Valve Load

30kg max.
49Nm (5kgf.m) max. for moment
increase amount of upper arm

Others

200kg max.

Internal User I/O Wiring Harnesses and Air Line


Internal user I/O wiring harnesses (0.75mm2, 23 cables) and two air lines
are used in the manipulator for the drives of the peripheral devices
mounted on the upper arm and the connector pins (1 to 23) are assigned
as shown in fig. 7-2 Internal User I/O Wiring Harnesses and Air Line at
page 7-3. Wiring must be performed by user.
The allowable current for internal user
I/O wiring harness

6.6 A or less / wire.


(The total current value for pins 1 to 23
must be 60A or less.)

The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0mm )

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7
7.2

System Application
Internal User I/O Wiring Harnesses and Air Line

Fig. 7-2: Internal User I/O Wiring Harnesses and Air Line
Cable connector provided on
U-axis is type JL05-2A24-28SC
(with cap).
Mating connector type is
JL05-6A24-28P.

Air A outlet:
tapped hole PT 3/8
with pipe plug
Air B outlet:
tapped hole PT 3/8
with pipe plug

Air B inlet:
tapped hole
PT 3/8 with
pipe plug

Air A inlet:
tapped hole PT 3/8
with pipe plug

A
View A

Cable connector provided on


U-axis is type JL05-2A24-28PC
(with cap).
Mating connector type is
JL05-6A24-28S.

Pins used

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

1 2 3 4
5 6 7 8 9
10 11 12 13 14 15
16 17 18 19 20
21 22 23

Internal user I/O


wiring harness
(23 lead wires,
size:0.75mm2)

The same pin number (1-23) of two connectors is connected in the lead
wire of single 0.75mm2.

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8.1

MCL130

HMOTOMAN Construction
Position of S-axis Limit Switch

HMOTOMAN Construction
8.1

Position of S-axis Limit Switch


The limit switch is mounted on the S-axis as shown in fig. 8-1 Location of
Limit Switch

Fig. 8-1: Location of Limit Switch

S-axis overrun L.S.

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8.2

MCL130

8.2

HMOTOMAN Construction
Internal Connections

Internal Connections
High reliability connectors which can be easily removed are used with
each connector part. For the number and location of connectors, refer to
fig. 8-2 Location and Numbers of Connectors

Fig. 8-2: Location and Numbers of Connectors


Connector for internal
user I/O wiring harness

1BC
2BC
3BC

4BC (for internal user I/O


wiring harness)

Table 8-1: List of Connector Types


Name

Type of Connector

Connector for internal user I/O wiring


harness on base

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

Connector for internal user I/O wiring


harness on U-arm

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

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8 Electrical Equipment Specification


8.2 Internal Connections
Fig. 8-3(a): Internal Connection Diagram
(HQFRGHU3RZHUVXSSO\ERDUG

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8 Electrical Equipment Specification


8.2 Internal Connections
Fig. 8-3(b): Internal Connection Diagram

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Maintenance and Inspection

Maintenance and Inspection

WARNING
Before maintenance or inspection, be sure to turn
the main power supply OFF, and put up a warning
sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in electric shock or
injury.

CAUTION
Maintenance and inspection must be performed by
specified personnel.
Failure to observe this caution may result in electric shock or
injury.
For disassembly or repair, contact your Yaskawa
representative.
Do not remove the motor, and do not release the
brake.
Failure to observe this caution may result in injury from unexpected turning of the manipulators arm.
The battery pack must be connected before
removing detection connector when maintenance
and inspection.
Failure to observe this caution may result in the loss of home
position data.

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9.1

MCL130

9.1

Maintenance and Inspection


Inspection Schedule

Inspection Schedule
Proper inspections are essential not only to assure that the mechanism
will be able to function for a long period, but also to prevent malfunctions
and assure safe operation. Inspection intervals are displayed in six levels.
Conduct periodical inspections according to the inspection schedule in
table 9-1 Inspection Items at page 9-3
In table 9-1 Inspection Items at page 9-3 the inspection items are
classified into three types of operation: operations which can be
performed by personnel authorized of the user, operations which can be
performed by personnel being trained, and operations which can be
performed by service company personnel. Only specified personnel are to
do inspection work.
The inspection interval must be based on the servo power
supply on time.

NOTE

For axes which are used very frequently (in handling applications, etc.), it is recommended that inspections be conducted at shorter Intervals. Contact your Yaskawa
representative.

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External lead
Manipulator

L,U-axes motor
Base mounting bolts

Cover mounting screws

SLU-axes motor connectors


Base connectors
Balancer
RBT-axes timing belt
SLURBT-axes internal wires

2
3

4
5

7
8
9
10
11

Daily

1000H Cycle

12000H Cycle

Grease Gun

Grease Gun
Manual
Visual
Multimeter

Visual
Spanner
Wrench
Screwdriver,
Wrench
Manual

Visual
Visual

Visual

14 L-axis speed reducer

18000H

Grease Gun

24000H

6000H Cycle

Tighten loosen bolts.


Check for loose connectors.
Supply grease (6000H cycle). See chapter 9.2.8 at page 9-20
Check for belt tension and wear.
Check for conduction between the main connector of base and intermediate
connector with manually shaking the wire. Check for wear of protective
spring.4)
Replace.5)
Replace the battery pack when the battery alarm occurs or the manipulator
drove for 24000H.6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.2 at page 9-8 .6)
Replace grease (12000H cycle). See chapter 9.2.2 at page 9-8 6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.3 at page 9-10 6)
Replace grease (12000H cycle). See chapter 9.2.3 at page 9-10 6)

Tighten loose bolts. Replace if necessary.

Check alignment mark accordance and damage at the


home position.
Check for damage and deterioration of leads.
Clean the exterior.
Check for damage, exterior cracks, and grease leakage.2)
Check for grease leakage.3)
Tighten loose bolts. Replace if necessary.

Inspection
Charge

9
9.1

13 S-axis speed reducer


and gear

Operation

MCL130

12 Battery pack in manipulator

Alignment mark

Method

Specified
Person

Schedule

Licensee

Items1)

Service
Company

Table 9-1: Inspection Items (Sheet 1 of 2)

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Inspection Schedule

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Inspection No. correspond to the numbers in fig. 9-1 Inspection Parts and Inspection Numbers at page 9-5
If a grease leakage occurs, contact your Yaskawa representative as soon as possible.
The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa representative.
IWhen checking for conduction with multimeter, connect the battery pack to BAT and OBT of connectors on the motor side for each axis, and then remove connectors on
detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer to chapter 9.2.9 Notes for Maintenance at page 9-21)
5 Internal cables to be replaced at 18000H inspection.
6 For the grease, refer to fig. 9-2(a Battery Pack Location (Rear View) at page 9-6

Inspection
Charge

9
9.1

1
2
3
4

Check for malfunction. (Replace if necessary.)


Supply grease (6000H cycle). See chapter 9.2.4 at page 9-12 6)
Replace grease (12000H cycle). See chapter 9.2.4 at page 9-12 6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.5 at page 9-14 6)
Replace grease (12000H cycle). See chapter 9.2.5 at page 9-14 6)
Check for malfunction. (Replace if necessary.)
Supply grease (6000H cycle). See chapter 9.2.6 at page 9-16 and
chapter 9.2.7 at page 9-18 6)
Replace grease (12000H cycle). See chapter 9.2.6 at page 9-16 and
chapter 9.2.7 at page 9-18 6)

Operation

MCL130

18 Overhaul

Grease Gun

17 BT-axes speed reducers


and gears

Daily

Grease Gun

1000H Cycle

6000H Cycle

16 R-axis gear

12000H Cycle

Grease Gun

18000H

24000H

15 U-axis speed reducer

Method

Specified
Person

Schedule

Licensee

Items1)

Service
Company

Table 9-1: Inspection Items (Sheet 2 of 2)

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Inspection Schedule

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9
9.1

Maintenance and Inspection


Inspection Schedule

Fig. 9-1: Inspection Parts and Inspection Numbers


B-axis
5
1

17
16
15
4
6

U-axis
11

R-axis

T-axis

6 10

L-axis
1

14

4
7

S-axis

6
2

13
12
8

Table 9-2: Inspection Parts and Grease Used


No.

Grease Used

Inspected Parts

13, 14, 15, 16,


17

VIGO Grease
RE No.0

All axes speed reducers and


R-, B-, and T-axes gears

Alvania EP Grease 2

L-axis balancer

The numbers in the above table correspond to the numbers in table 9-1
Inspection Items at page 9-3

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9.2

MCL130

9.2
9.2.1

Maintenance and Inspection


Notes on Maintenance Procedures

Notes on Maintenance Procedures

Battery Pack Replacement


If the battery alarm occurs in the DX100, replace the battery pack
according to the following procedure:

Fig. 9-2(a): Battery Pack Location (Rear View)

Manipulator
base
2BC

3BC

1BC

Battery pack mounting


screw M4

Connector base

Fig. 9-2(b): Battery Pack Location (Top View)

Axes battery pack


HW0273162-A

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9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Fig. 9-3: Battery Pack Connection


Battery pack
before replacement

See replacing step 5.


Connector

Board

See replacing step 4.


New battery pack

1. Turn OFF the DX100 main power supply.


2. Remove the plate fixing screws and the plate on the connector base,
then pull the battery pack out to replace it with the new one.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connector on the
board.
5. Remove the old battery pack from the board.

NOTE

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

6. Mount the new battery pack to the holder.


7. Reinstall the plate.

NOTE

Do not allow plate to pinch the cables when reinstalling the


plate.

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9.2.2

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replenishment/Replacement for S-axis Speed Reducer and Gear

Fig. 9-4: S-axis Speed Reducer and Gear Diagram

So: Grease exhaust port


Hexagon socket head plug
PT1/8)

9.2.2.1

Si: Grease inlet


Hexagon socket head plug
PT1/4

S-axis speed reducer

Grease Replenishment (Refer to fig. 9-4 S-axis Speed Reducer and Gear Diagram )
Replenish the grease according to the following procedure:
1. Remove the So exhaust plug PT1/8.

NOTE

If grease is added without removing the exhaust plug, the


grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.

2. Remove the plug on the Si grease inlet and install the grease zerk APT1/4.
3. Inject the grease into the Si grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

530 cc
(1060 cc for 1st supply)

4. Move the S-axis for a few minutes to discharge the excess grease.
5. Wipe the So exhaust port with a cloth and reinstall the plug. (Confirm
that no oil adheres to the screw of the plug and spread Three Bond
1206C.)
6. Remove the grease zerk and reinstall the plug in the Si grease
inlet.(Confirm that no oil adheres to the screw of the plug and spread
Three Bond 1206C.)

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9.2.2.2

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replacement (Refer to fig. 9-4 S-axis Speed Reducer and Gear Diagram at
page 9-8)
1. Remove the So exhaust plug PT1/8.

NOTE

If grease is added without removing the exhaust plug, the


grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.

2. Remove the plug on the Si grease inlet and install the grease zerk APT1/4.
3. Inject the grease into the Si grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

approx. 3650 cc

4. The grease replacement is complete when new grease appears in the


So exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the S-axis for a few minutes to discharge the excess grease.
6. Wipe the So exhaust port with a cloth and reinstall the plug.(Confirm
that no oil adheres to the screw of the plug and spread Three Bond
1206C.)
7. Remove the grease zerk and reinstall the plug in the Si grease
inlet.(Confirm that no oil adheres to the screw of the plug and spread
Three Bond 1206C.)

NOTE

If the plug is installed when the grease is still being replaced,


the grease will go inside the motor and may damage it.
Confirm that the old grease has been completely replaced
before reinstalling the plug.

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9.2.3

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replenishment/Replacement for L-axis Speed Reducer

Fig. 9-5: L-axis Speed Reducer Diagram


L-axis speed reducer
Lo: Grease exhaust port
Hexagon socket
head plug PT1/8)

Li: Grease inlet


Hexagon socket head
plug PT1/8

9.2.3.1

Grease Replenishment (Refer to fig. 9-5 L-axis Speed Reducer Diagram )


1. Make the L-arm vertical for ground.
2. Remove the Lo exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.

3. Remove the plug on the Li grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Li grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

400 cc
(800 cc for 1st supply)

5. Move the L-axis for a few minutes to discharge the excess grease.
6. Wipe the Lo exhaust port with a cloth and reinstall the plug. (Confirm
that no oil adheres to the screw of the plug and spread Three Bond
1206C.)
7. Remove the grease zerk and reinstall the plug in the Li grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9.2.3.2

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replacement (Refer to fig. 9-5 L-axis Speed Reducer Diagram at page 9-10)
1. Make the L-arm vertical for ground.
2. Remove the Lo exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.

3. Remove the plug on the Li grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Li grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

approx 2000cc for Li

5. The grease replacement is complete when new grease appears in the


Lo exhaust port. The new grease can be distinguished from the old
grease by color.
6. Move the L-axis for a few minutes to discharge the excess grease.
7. Wipe the Lo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
8. Remove the grease zerk and reinstall the plug in the Li grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9.2.4

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replenishment/Replacement for U-axis Speed Reducer

Fig. 9-6: U-axis Speed Reducer Diagram


Uo: Grease exhaust port
Hexagon socket head plug PT1/8

Ui: Grease inlet


Hexagon socket head plug PT1/8

U-axis speed reducer

Remove the cap.

9.2.4.1

Grease Replenishment (Refer to fig. 9-6 U-axis Speed Reducer Diagram )


1. Make the U-arm horizontal for ground.
2. Remove the Uo exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.

3. Remove the plug on the Ui grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Ui grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

250cc for Ui
(500cc for 1st supply)

5. Move the U-axis for a few minutes to discharge the excess grease.
6. Wipe the Uo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the plug in the Ui grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replacement (Refer to fig. 9-6 U-axis Speed Reducer Diagram at page 9-12)
1. Make the U-arm horizontal for ground.
2. Remove the Uo exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go inside the motor and may damage it. It is
absolutely necessary to remove the plug.

3. Remove the plug on the Ui grease inlet and install the grease zerk APT1/8.
4. Inject the grease into the Ui grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

approx. 1650cc for Ui

5. The grease replacement is complete when new grease appears in the


Uo exhaust port. The new grease can be distinguished from the old
grease by color.
6. Move the U-axis for a few minutes to discharge the excess grease.
7. Wipe the Uo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
8. Remove the grease zerk and reinstall the plug in the Ui grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

NOTE

If the plug is installed when the grease is still being replaced,


the grease will go inside the motor and may damage it.
Confirm that the old grease has been completely replaced
before reinstalling the plug.

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9.2.5

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replenishment/Replacement for R-axis Speed Reducer

Fig. 9-7: R-axis Speed Reducer Diagram


Ro: Grease exhaust port
R-axis speed reducer

Hexagon socket head plug PT1/8

Ri: Grease inlet


Hexagon socket head plug PT1/8

9.2.5.1

Grease Replenishment (Refer to fig. 9-7 R-axis Speed Reducer Diagram )


1. Remove the Ro exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.

2. Remove the plug on the Ri grease inlet and install the grease zerk APT1/8.
3. Inject the grease into the Ri grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

28cc for Ri
(56cc for 1st supply)

4. Move the R-axis for a few minutes to discharge the excess grease.
5. Wipe the Ro exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
6. Remove the grease zerk and reinstall the plug in the Ri grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replacement (Refer to fig. 9-7 R-axis Speed Reducer Diagram at page 9-14)
1. Remove the Ro exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.

2. Remove the plug on the Ri grease inlet and install the grease zerk APT1/8.
3. Inject the grease into the Ri grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

approx. 140cc for Ri

4. The grease replacement is complete when new grease appears in the


Ro exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the R-axis for a few minutes to discharge the excess grease.
6. Wipe the Ro exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the plug in the Ri grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9.2.6

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replenishment/Replacement for B-axis Speed Reducer and Gear

Fig. 9-8: B-axis Speed Reducer and Gear Diagram


Bo: Grease exhaust port
Hexagon socket head plug PT1/8

B-axis speed reducer

9.2.6.1

Bi: Grease inlet


Hexagon socket head cap bolt M6

Grease Replenishment (Refer to fig. 9-8 B-axis Speed Reducer and Gear Diagram )
1. Remove the Bo exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.

2. Remove the bolt on the Bi grease inlet and install the grease zerk AMT6.
3. Inject the grease into the Bi grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

200cc for Bi
(400 cc for 1st supply)

4. The grease replacement is complete when new grease appears in the


Bo exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the B-axis for a few minutes to discharge the excess grease.
6. Wipe the Bo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the bolt in the Bi grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9.2.6.2

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replacement (Refer to fig. 9-8 B-axis Speed Reducer and Gear Diagram at
page 9-16)
1. Remove the Bo exhaust plug.

NOTE

If grease is added without removing the exhaust plug, the


grease will go outside the grease box and may damage it. It
is absolutely necessary to remove the plug.

2. Remove the bolt on the Bi grease inlet and install the grease zerk AMT6.
3. Inject the grease into the Bi grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

approx. 900cc for Bi

4. The grease replacement is complete when new grease appears in the


Bo exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the B-axis for a few minutes to discharge the excess grease.
6. Wipe the Bo exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the bolt in the Bi grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9.2.7

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replenishment/Replacement for T-axis Speed Reducer and Gear

Fig. 9-9: T-axis Speed Reducer and Gear Diagram


T-axis speed reducer

Ti: Grease inlet


Hexagon socket head cap bolt M6
(Seal washer M6)
To: Grease exhaust port
Hexagon socket head cap bolt M5
(Seal washer M5)

9.2.7.1

Grease Replenishment (Refer to fig. 9-9 T-axis Speed Reducer and Gear Diagram )
1. Remove the hexagon socket head cap bolt M5 in the To exhaust port.

NOTE

If grease is added without removing the bolt, the grease will


go outside the grease box and may damage it. It is absolutely necessary to remove the bolt.

2. Remove the bolt on the Ti grease inlet and install the grease zerk AMT6.
3.

Inject the grease into the Ti grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

200cc for Ti
(400cc cc for 1st supply)

4. Move the T-axis for a few minutes to discharge the excess grease.
5. Wipe the To exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
6. Remove the grease zerk and reinstall the bolt in the Ti grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9.2.7.2

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replacement (Refer to fig. 9-9 T-axis Speed Reducer and Gear Diagram at
page 9-18)
1. Remove the hexagon socket head cap bolt M5 in the To exhaust port.

NOTE

If grease is added without removing the bolt, the grease will


go outside the grease box and may damage it. It is absolutely necessary to remove the bolt.

2. Remove the bolt on the Ti grease inlet and install the grease zerk AMT6.
3. Inject the grease into the Ti grease inlet using a grease gun.
Grease type:

VIGO Grease RE No.0

Amount of grease:

approx. 900 cc for Ti

4. The grease replacement is complete when new grease appears in the


To exhaust port. The new grease can be distinguished from the old
grease by color.
5. Move the T-axis for for a few minutes to discharge the excess grease.
6. Wipe the To exhaust port with a cloth and reinstall the plug.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
7. Remove the grease zerk and reinstall the bolt in the Ti grease inlet.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)

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9.2.8

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Grease Replenishment for Balancer Connection Part

Fig. 9-10: Balancer Connection Part Diagram

Exhaust port

Exhaust port
(Hexagon socket head plug
PT1/8)

Vc: Grease inlet in connection


part

Tapered roller bearings (2 bearings)


in connection part

Needle bearing
in connection part

Vc: Grease inlets in connection part


(Hexagon socket head plugs PT1/8)
(2 plugs)

1. Remove two plugs for exhaust port in 1 and 2. (Refer to fig. 9-10
Balancer Connection Part Diagram )
2. Remove two plugs on the Vc grease inlets in
grease zerk A-PT1/8.

1 and 2and install the

3. Inject the grease into the Vc grease inlets in 1 and 2 using a grease
gun.
Grease type:

Alvania EP grease 2

Amount of grease:

NOTE

5cc
(10 cc for 1st supply)

The grease is not exhausted from the exhaust ports 1 and


2. Do not inject excessive grease into the Vc grease inlets.

4. Reinstall the plugs on the exhaust ports in 1 and 2.


(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)
5. Remove the grease zerk and reinstall the bolts in the Vc grease inlets.
(Confirm that no oil adheres to the screw of the plug and spread Three
Bond 1206C.)]
6. Wipe off excess grease and abrasion power adhering to the rod with a
clean waste cloth, then lightly apply AFE grease.

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9.2.9

9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Notes for Maintenance


Remove the old battery pack after connecting the new one so that the
encoder absolute data does not disappear. For the battery pack
connection for the S-, L-, and U-axes motors and R-, B-, and T-axes
motors, refer to fig. 9-11 Battery Pack Connection for Motor at
page 9-22

9.2.9.1

Battery Pack Connection for S-, L-, and U-axes Motors


The connector (crimped contact-pin) for the battery backup is installed in
the end point of the cable for the encoder of the S-, L-, and U-axes motors
(BAT and OBT are marked). Connect the battery pack according to the
following procedure.
1. Connect battery pack (HW9470917-A) with the battery backup
connector (BAT and OBT are marked) located in the end point of the
cable for the encoder. (Under such a condition, remove the encoder
connector and do the maintenance check work.)
2. Confirm all connectors connection after the maintenance check ends,
and remove the battery pack.

NOTE

9.2.9.2

Do not remove the battery pack in the base connector.

Battery Pack Connection for R-, B-, and T-axes Motors


The connector (crimped contact-pin) for the battery backup is installed in
the end point of the cable for the encoder of the R-, B-, and T-axes motors
(BAT and OBT are marked). Connect the battery pack according to the
following procedure.
1. Connect battery pack (HW9470917-B) with the battery backup
connector (BAT and OBT are marked) located in the end point of the
cable for the encoder. (Under such a condition, remove the encoder
connector and do the maintenance check work.)
2. Confirm all connectors connection after the maintenance check ends,
and remove the battery pack.

NOTE

Do not remove the battery pack in the base connector.

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9
9.2

Maintenance and Inspection


Notes on Maintenance Procedures

Fig. 9-11: Battery Pack Connection for Motor


Motor

Motor power connector


Connector for the encoder

0BT

a 0BT*

BAT

b BAT*
Battery Pack: HW9470917-A
Connector for the battery backup
a:Insertion-type pin terminal (Pin)
b:Insertion-type pin terminal (Socket)

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MCL130

Recommended Spare Parts

10 Recommended Spare Parts


It is recommended that the following parts and components be kept in
stock as spare parts for the MOTOMAN-MCL130. The spare parts list for
the MOTOMAN-MCL130 is shown below. Product performance can not be
guaranteed when using spare parts from any company other than
Yaskawa. The spare parts are ranked as follows:

Rank A: Expendable and frequently replaced parts


Rank B: Parts for which replacement may be necessary as a
result of frequent operation
Rank C: Drive unit

NOTE

To replace parts in Rank B or Rank C, contact your Yaskawa


representative.

Fig. 10-1: Spare Parts for the MOTOMAN-MCL130 (Sheet 1 of 2)


Rank

Parts
No.

Name

Type

Manufacturer

Qty

Qtyp
er
Unit

Remarks

Grease

VIGO Grease
RE NO.0

Yaskawa
Electric
Corporation

16kg

For all axes speed


reducers and wrist
units

Grease

Alvania EP
Grease 2

Showa Oil
Co., Ltd.

16kg

For balancer joint


parts

Liquid Gasket

Three Bond 1206C THREE BOND


CO., LTD.

Battery Pack

HW9470917-A

Yaskawa
Electric
Corporation

For SLU-axes

Battery Pack

HW9470917-B

Yaskawa
Electric
Corporation

For RBT-axes

R-axis Timing Belt

200S8M976

Mitsuboshi
Belting Limited

B-axis Timing Belt

200S8M800

Mitsuboshi
Belting Limited

T-axis Timing Belt

200S8M656

Mitsuboshi
Belting Limited

S-axis
Speed Reducer

HW9381388-F

Yaskawa
Electric
Corporation

Drawing number
for painting
HW0300979-1

10

L-axis
Speed Reducer

HW9381442-F

Yaskawa
Electric
Corporation

Drawing number
for painting
HW0300983-1

11

U-axis
Speed Reducer

HW9381465-F

Yaskawa
Electric
Corporation

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MCL130

Recommended Spare Parts

Fig. 10-1: Spare Parts for the MOTOMAN-MCL130 (Continued) (Sheet 2 of 2)


Rank

Parts
No.

Name

Type

Manufacturer

Qty

Qtyp
er
Unit

Remarks

12

R-axis
Speed Reducer

HW0380815-F

Yaskawa
Electric
Corporation

Drawing number
for painting
HW0300989-1

13

B-axis
Speed Reducer

HW9380961-F

Yaskawa
Electric
Corporation

Drawing number
for painting
HW0301816-1

14

T-axis
Speed Reducer

HW1380173-A

Yaskawa
Electric
Corporation

Drawing number
for painting
HW0300994-1

15

Wrist Unit

HW0175514-A

Yaskawa
Electric
Corporation

16

AC Servomotor for
S-axis

HW0389698-A

Yaskawa
Electric
Corporation

17

AC Servomotors for HW0388670-A


L-and U-axes

Yaskawa
Electric
Corporation

18

AC Servomotor for
R-axis

HW0388933-A

Yaskawa
Electric
Corporation

19

AC Servomotors for HW0388934-A


B-and T-axes

Yaskawa
Electric
Corporation

20

Internal Wiring

Yaskawa
Electric
Corporation

HW0175541-A

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MOTOMAN-MCL130

INSTRUCTIONS

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan
Phone +81-93-645-7745
Fax +81-93-645-7746
YASKAWA America Inc. MOTOMAN Robotics Division
805 Liberty Lane, West Carrollton, OH 45449, U.S.A.
Phone +1-937-847-6200
Fax +1-937-847-6277
YASKAWA Nordic AB
Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden
Phone +46-480-417800
Fax +46-480-417999
YASKAWA Europe GmbH Robotics Division
Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100
Fax +49-8166-90-103
YASKAWA Electric Korea Co., Ltd.
7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA
Phone +82-2-784-7844
Fax +82-2-784-8495
YASKAWA Electric (Singapore) PTE Ltd.
151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003
Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.
252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek Road, Huaykwang Bangkok, 10320 Thailand
Phone +66-2-693-2200
Fax +66-2-693-4200
Shougang MOTOMAN Robot Co. Ltd.
No.7, Yongchang-North Road, Beijing E&T Development Area, China 100176
Phone +86-10-6788-2858
Fax +86-10-6788-2878
MOTOMAN Motherson Robotics Ltd.
Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana
Phone +91-124-475-8500
Fax +91-124-414-8016

Specifications are subject to change without notice


for ongoing product modifications and improvements.

YASKAWA ELECTRIC CORPORATION

Printed in Japan Junuary 2011 11-01

MANUAL NO.

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