ROBOTICS

MH180
YR-MH180-A00

Operating and Maintenance Manual

Created on: 2018-11
Revision: 13
Document number: E1101000180GB13 Author: WOE

Modifications made:
Rev. 01: Revised version of the original HW1482326.0 in YEU-style (2014-04)
Rev. 02: Revision of the quantity of grease (2014-06).
Rev. 03: Revised version of the original HW1482326.2 (2014-08)
Rev. 04: Revised version of chapter "Notes on how to refill grease" (2014-09)
Rev. 05: Revision of table "Inspection intervals" and review of chapter "Grease replenish-
ment/exchange" (2015-03)
Rev. 06: Revised version of the original HW1482326.3 (2015-03)
Rev. 07: Revised version of chapter "Notes on how to refill grease" (2015-08)
Rev. 08: Revised version of the original HW1482326.5 (Fig.: Internal connection diagram
(a)) (2015-08)
Rev. 09: Revised version of chapter "Internal cables and compressed air lines" and "Rec-
ommended spare parts" (DX200 Rev. 1.5 01.05.2015)
Rev. 10: Revised version of the original HW1482326.6 (2016-03)
Rev. 11: Addition of the chapter "Zeroing (optional)" (2016-08)
Rev. 12: Revised of chapter “Inspection schedule” (2016-09)
Rev. 13: Revision of chapter: 8 "Internal cables and compressed air lines")

© Copyright 2018
This documentation (or parts of it) must not be reproduced or made available to third parties without
the express approval of YASKAWA Europe "Robotics Division GmbH”.
We have checked the content of this publication for compatibility with the hardware described.
Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.
However, the information given in this publication is checked regularly and any necessary corrections
will be made in subsequent editions.
Subject to technical modifications.
Table of contents

Table of contents

1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.8 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Position type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Transporting method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.1 Using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 Using a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Shipping brackets and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Damping material during transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Ambient conditions and installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.1 Connecting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.2 Connection of the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.3 Connecting the programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Parts and work axis label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Robot base dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Dimensions and defined working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.4 Adjustable working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4.1 Components for Changing the Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.4.2 Adjusting the S-Axis Pulse Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.5 Stopping Angle and Time at the Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.5.1 Stop category 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5.2 Stop category 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7 Allowable load for wrist axis and wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.1 Wrist flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3
Table of contents

8 Internal cables and compressed air lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.1 Inspection schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.2 Note on battery unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2.1 Battery pack replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2.2 Battery pack connector (including warning note) . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.3 Note on maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.4 Refill/Replace grease.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.4.1 Grease filling the main axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.4.2 Grease filling the wrist axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.4.3 Grease replenishment for balancer link part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.5 Gas maintenance procedure in the gas balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.5.1 Notes on gas maintenance procedure in the gas balancer . . . . . . . . . . . . . . . . . 66
9.5.2 Gas pressure inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.5.3 Gas discharging procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.5.4 Gas injecting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.6 Home position calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.6.1 Registering all axes at the time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.6.2 Registering individual axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.6.3 Changing the absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.6.4 Clearing absolute data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.7 Setting the second home position (check point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.7.1 Purpose of position check operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.7.2 Procedure for the second home position setting . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.7.3 Procedure after alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.8 Zeroing Function (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.8.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.8.2 Overview and operation Reset to zero device YasXzero. . . . . . . . . . . . . . . . . . . 83
9.8.3 Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.8.4 Positions for the reset sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.8.5 Error and solutions during resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10 Recommended spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

11 Parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.1 S-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.2 L-axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.3 For R-, B- and T-axes drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
11.4 U arm unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
11.5 Wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4
General

1 General

1.1 Notes for safe operation

DANGER!
Indicating immediate danger at high risk, hazard that can cause death or serious bodily
injuries if no precautions are taken.

WARNING!
Indicating possible medium risk hazard situation which can cause death or serious bodily
injuries if it is not avoided.

CAUTION!
Indicating potentially dangerous situation with low risk of minor or moderate bodily injuries
result if it is not avoided. This signal word can also be used for property damage warnings.

NOTICE
Indicates important background information and application advice.

1.2 Frequently used terms

The YASKAWA robot is a product of YASKAWA Electric Corporation GmbH. The robot is
normally supplied with the robot controller, programming pendant, and robot cable.
The terms are designated as follows in this manual:

Terms Designation
Controller Robot controller
Industrial robot Robot
Programming pendant (teach box) Programming pendant or PP
Cable between the robot and the robot con- Cable
troller
Robot, robot controller, and cable Robot system
Yaskawa Electric Corporation YEC
YASKAWA Europe “Robotics Division” YEU-R
Movement, calibration, and setup of the ro- Teach
bot
Sequence of movements of the robot JOB
Technical Customer Service TCS
Personal Computer PC

1 -5
General

1.3 Target group

This manual is directed at users with the following knowledge:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• System knowledge of the robot control
• Specially trained staff

NOTICE
According to the international DIN EN ISO 10218-1 standard, operators of a robot system
must receive training before they operate the robot.
For optimal use of our products, we recommend our customers to take part in a training
session at the YASKAWA Academy. For more detailed information on the training
programs, please visit www.yaskawa.eu.com or directly get in touch with your YASKAWA
branch office.

1.4 Intended use

Typical applications:
• Flange-mounting tools
• Installation of spot welding guns
• Installation of arc welding equipment
• Installation of grippers
• Machining and transporting workpieces or products

1 -6
General

1.5 Improper use

Any use that deviates from the intended use shall be regarded as impermissible misuse.
This includes:
• Transport of people and animals
• Use as ascending aid.
• Use outside the permissible operating limits.
• Use in environments with risk of explosion (except for ATEX-approved robots).
• Overload
• Use without protective equipment.

NOTICE
Modifications to the robot, e.g. drilling holes or similar modifications, can damage parts.
This will be regarded as improper use (i.e. use that deviates from the intended use) and will
lead to loss of warranty and liability claims as well as loss of the declaration of incorporation.

CAUTION!
The robot system is an incomplete machine.
The robot system may be put into operation only after it has been determined that the
incomplete or complete machine in which the robot system is being installed:
 Corresponds to the provisions of the machinery directive.
 Complies with all relevant (harmonized) standards.
 Corresponds to the state of the art.

1 -7
General

1.6 About this manual

NOTICE
• This manual describes the mechanics of the robot for the purpose of operation,
maintenance and inspection. It contains information on safety and handling, technical
data, the tools and materials required for maintenance and inspection and instructions
for operation and maintenance. Read this manual carefully and make sure you are
familiar with its contents before installing and operating the robot..
• To ensure correct and safe operation, carefully read the operating instructions of the
robot controller ("Basic Information," "Setup," and "Connection and System Setup").
• In order to illustrate details clearly, some drawings are shown with the protective covers
or shields removed. All protective covers and shields must be mounted before the robot
is operated.
• The drawings and figures in this manual are representative illustrations. They may differ
from the product delivered.
• YEU-R reserves the right to make technical changes. These changes may include
product improvements, modifications or changes in specifications
• If your copy of the operating and maintenance instructions is damaged or lost, please
contact the local YASKAWA branch office to order a new copy. The official branch
offices are listed on the last page. Please mention the manual number in your order.
• YASKAWA Europe GmbH is not responsible for damage caused due to unauthorised
modification of the system. If any impermissible modifications are made to the system
and to the robot, all warranty and liability claims as well as the declaration of
incorporation will expire.

1 -8
General

1.7 Safety

REMOTE TEACH
START HOLD
1
PLAY

JOB EDIT DISPLAY UTILITY

JOB CONTENT
-TEST01 S:0000
CONTROL GROUP:R1 TOOL:
0000 NOP
0001 SET B000 1
0002 SET B001 0
0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
MOVJ VJ=0.78

Main Menu Short Cut Turn on servo power

LAYOUT TOOL SEL GO BACK

DIRECT
COORD OPEN
Multi PAGE AREA
ENTRY
SERVO
SELECT
MAIN SIMPLE ON CANCEL
MENU MENU READY ASSIST

SERVO ON
X- X+ X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
Z- Z+ MANUAL SPEED
Z- Z+
U- U+ T- T+
SLOW
E- E+ 8- 8+

INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

ROBOT INFORM 4 5 6 BWD FWD

LIST

EX.AXIS
WELD 1 2 3 DELETE INSERT
ON/OFF

MOTION 0 . -
AUX MODIFY ENTER
TYPE

Fig. 1-1: Programming pendant

1 Emergency Stop button

WARNING!
Death or injury because of danger of crushing
If the emergency stop button does not function properly, the robot cannot be stopped in the
event of an emergency.
 The robot should not be used if the emergency stop button does not function.
 Before operating the robot check the function of the emergency stop button. The
SERVO power has to immediately go off once the emergency stop button on the
programming pendant has been pressed (see).
 When the SERVO power is turned OFF, the SERVO ON LED on the programming
pendant goes off (see ).

SERVO ON
Fig. 1-2: LED SERVO ON

Fig. 1-3: Emergency Stop button

1 -9
General

WARNING!
Death or injury because of danger of crushing
Before you release the emergency stop button (see ) note the following:
 Make sure that there is no one within the maximum working range of the robot.
 Clear the cell of all items which could collide with the robot.
 Now you can switch ON the SERVO power by pressing the enable switch on the
programming pendant.

Fig. 1-4: Release of emergency stop button by turning

WARNING!
Death or injury because of danger of crushing
if anyone enters the working area of the robot during operation or any problems occur,
always press the emergency stop button immediately. The emergency stop button is
located on the programming pendant (see ).
Observe the following precautions when performing teaching operations within the robot’s
working range:
 View the Robot from the front whenever possible.
 Always follow the prescribed operating procedure (see the instructions on robot control
as well as the operating instructions on "Handling" or "Universal Application").
 An area must be left clear so that the operator can retreat to it in case of emergency.

The following inspection procedures must be performed prior to teaching the robot. If
problems are found, correct them immediately, and be sure that all other necessary
measures have been performed.
• Check for problems in robot movement.
• Check the connectors for tight fit and all cables for damage.
• Hang the programming pendant back on the robot control after use.
• Make sure that the key for the key switch (Teach/Automatic) of the programming
pendant is kept by a skilled person who has been specially trained.
• The key may be inserted in the key switch of the programming pendant only during
teach operation; after the teach operation it must be immediately removed and kept in
a safe place.

1 - 10
General

1.8 Manufacturer
Address:
YASKAWA ELECTRIC CORPORATION
2-1 KUROSAKISHIROISHI
YAHATANISHI-KU
KITAKYUSHU
JAPAN

1.9 Authorized representative

Address:
YASKAWA Europe GmbH
Robotics Division
Yaskawastr. 1
85391 Allershausen
Germany

1 - 11
Supply

2 Supply

2.1 Checking the scope of delivery

The standard delivery includes the following items:

1 2

DX200

MOTOMAN
MANUAL

4 5

Fig. 2-1: Scope of delivery

1 Programming pendant 4 Assembly instruction

2 Robot controller 5 Cable
3 Robot

2 - 12
Supply

2.2 Position type plate

Verify whether the serial number of the robot, the robot controller and the programming
pendant with the delivery. The serial number can be found on the type plate as shown
below.

S/N. □ □ □ □ □ □ □ □

YASAKAW XXXXX
Part No.
Power Supply Peak kVA
AC XXXXXXXX Average kVA
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen
DX200

Fig. 2-2: Position type plate

NOTICE
Please contact the local YASKAWA branch office if the serial numbers do not match the
information on the delivery note.

2 - 13
Transportation

3 Transportation
CAUTION!
Personal injury or material damage
The system consists of precision components. Failure to observe this caution may
adversely affect performance.
 Crane and forklift trucks must be performed only by authorised personnel. The same
applies to the application of loops.
 Avoid excessive vibration or shock during transportation.
 No external forces may be exercised on the robot control, the robot or other
components.

3.1 Transporting method

CAUTION!
Damage to persons and damage to property due to external force influences
 External forces must not be exerted on the robot or the motors.

• Check that the eyebolts are securely fastened.

• The robot weights approximately 970 kg. Use load carrying devices strong enough to
withstand the weight.
• The transport safety devices support the robot; therefore, use them exclusively for the
transport of the robot.
• Before transport, be sure to mount the shipping bolts and brackets to the robot.

3 - 14
Transportation

3.1.1 Using a crane

Adequate load handling devices must be used to transport the robot. Make sure that the
robot is lifted as shown in the diagram "Transport by crane".

Using a crane
1 Position of the center of grav-
ity
2 Wire rope (length: 2000 mm
or longer)
3 Shipping brackets and bolts1
4 8 screws M20 x 701, 8 spring
washers M20

1102 1539

1610
1. Must be mounted prior to transportation.

The robot is equipped with transport securing devices and shipping bolts to reduce external
forces to a minimum during transport

3 - 15
Transportation

3.1.2 Using a forklift

If the robot is transported using a forklift, it should be fixed on a pallet with transport securing
devices and shipping bolts. Make sure that the forklift and the transportation route have
sufficient bearing capacity.
Always take due care when transporting the robot.

Using a forklift
1 Shipping brackets
2 Pallet
3 8 screws M20
4 Openings for the fork prongs

3 - 16
Transportation

3.2 Shipping brackets and bolts

NOTICE
Before turning ON the power, check to be sure that the shipping bolts and brackets are
removed.
After removing the transport securing devices and the shipping bolts, keep them at a safe
place. The transport securing devices and shipping bolts will be required again if the system
is transported again.

• The transportation brackets and the transportation pad in the figure are painted yellow.

2
3

1 Hook 3 Side view

2 Front view

3 - 17
Transportation

3.3 Damping material during transportation

NOTICE
Before turning ON the power, check to be sure that the rubber buffer are removed.
After removing the rubber pads, keep them at a safe place. The rubber pads will be required
again if the system is transported again.

The robot is furnished with damping material for transportation (see section A and B in the ).

2
A
3
4
B

Fig. 3-1: Damping material during transportation

1 Housing 3 L-arm
2 U-arm 4 Mechsnical operation limit

3 - 18
Installation

4 Installation
CAUTION!
Personal injury and damage to property
The following precautions must be taken.
 Check that the robot controller is complete and not damaged.
 Do not put into operation a robot controller that is damaged or incomplete.
 Check that all transport safety devices and transport screws have been removed.

4.1 Protection measures

DANGER!
Personal injury and material damage
The robot system must not be operated without protective devices. Starting up without
appropriate protective measures can lead to death of people, serious bodily harm or
material damage.
Implement the following protection measures
 Separating protection devices
 Non-contact protection devices
 Enclosures
 Marked areas
 Signs
 Emergency Stop button
 Display elements

NOTICE
Operator's responsibility
The operator of a robot or a robot system must ensure that all specifications and
requirements of the standards DIN EN ISO 10218-1 and DIN EN ISO 10218-2 are met.
In the first instance, the following must be observed:
 Preparing a risk assessment
 The installation of protective devices
 Regular training of the employees
 Regular inspection of all protective devices
 Checking for compliance with intended use

4 - 19
Installation

4.2 Ambient conditions and installation location

When installing a robot, it is necessary to satisfy the undermentioned environmental
conditions:
• Ambient temperature: From 0°C to +45°C.
• Air humidity: 20% to 80% relative humidity (non-condensing).
• Free of corrosive gases, liquids, or explosive gases. No water, oil or dust and free from
excessive electrical noise (plasma).
• Free from excessive vibration (Vibration acceleration: 4.9 m/s² [0.5 G] or less).
• Maximum unevenness of the support surface of the robot base: 0.5 mm.

4 - 20
Installation

4.3 Installation example

1. At the first set out, anchor the base plate firmly onto the floor.
2. The robot base is tapped for 8 mounting holes. Fix the robot base with the screws M20
(strength class 12.9) Minimum length: 80 mm.
3. Next, fix the robot base to the base plate. Tighten the hexagon head bolts and anchor
bolts securely so that they will not work loose during operation (see figure „Mounting of
the robot on the base plate“).

1
2
3

40
6
5

500

11 10 420

185±0.1
8
230±0.1 230±0.1
320
500

420
185±0.1

9 295±0.1 10

745

Fig. 4-1: Mounting the robot on the base plate

1 Screws 7 Anchor bolt (M20 or greater)

2 Spring washer 8 2 holes Ø 20 H7
3 Washer 9 8 holes Ø 20
4 Robot base 10 Mating surfaces
5 Base plate 11 adhesive
6 at least 40 mm

NOTICE
 YASKAWA Europe recommends to use the robot only with a base plate.
 Please contact the manufacturer of the mounting material you use

4 - 21
Installation

Direction of move- Horizontal Vertical

ment
Force FH Moment MH Force FV Torque MV
Emergency stop 24000 N 37630 Nm 15680 N 49000 Nm
(Stop category 0)
Acceleration/Decelera- 6370 N 9400 Nm 4900 N 22050 Nm
tion
(Stop category 1)

Tab. 4-1: Forces and torques

MV

FV

MH
FH

Fig. 4-2: Robot Force and Torque

4 - 22
Wiring

5 Wiring
DANGER!
Danger to life due to electric shock, risk of fire due to short circuit.
Wiring must be performed by authorized or certified personnel.
Follow the instructions given below before wiring.
 Make sure that the earthing resistance does not exceed 0.1 Ω.
 Turn OFF the main power supply.
 Put up the warning sign prescribed, e.g. "Do not turn the power on!".
 Install a switch-on guard as prescribed.

5.1 Grounding
Follow the applicable electrical installation standards and wiring regulations for earthing.
The cable cross-section must be 6 mm² or more.
With regard to the direct connection of the earthing cable, see figure “Earthing connection”

NOTICE
Note on the earthing connection
Never use the earthing cable together with an earthing cable of, for example:
 A different electrical consumer
 A different motor-driven consumer
 Welding devices, etc.

If the earthing cable is laid in a metal duct, metal conduit or some other metal system, this
must be earthed in accordance with the applicable electrical installation standards.

5 - 23
Wiring

5.2 Cable connections

YASAKAW DX200
Part No.
Power Supply Peak kVA
AC 400/415/440 Average kVA
Serial No.
Date/Signature
Type ERDR-
Robot Type
Robot Order No.
Robot Serial No.

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen

DX200

Fig. 5-1: Connecting the robot system

Two cables are delivered with the robot (refer to ).

• Encoder cable (1BC)

• Power cable (2BC)
Before connecting the robot cable, check the marking on the robot cable and the
connections on the connector plate of the robot (see the following diagram "Robot cable").
Connect the cables to the connections on the robot base and on the robot controller (see
the following chapter on "robot connection" and "robot controller connection").

2 1

1BC
X11

1BC

X11 1BC

1BC
3

2 1
2BC
X21

2BC

X21 2BC

2BC
4

Fig. 5-2: Robot cable

1 Robot control side 3 Encoder cable (1BC)

2 Robot side 4 Power cable (2BC)

5 - 24
Wiring

5.2.1 Connecting the robot

1. Check the encoder cable (1BC) and the power cable (2BC).
2. Connect the encoder cable (1BC) to the connector plate of the robot.
3. Connect the power cable(2BC) to the connector plate of the robot.
Make sure that you hear each locking clip snap into place (clicking sound).

3BC
3BC

1BC 2BC

1BC
2BC

Fig. 5-3: Connector plate of the robot

5 - 25
Wiring

5.2.2 Connection of the robot controller

Attach the robot cables in the following order.

1. Connect the encoder cable (1BC) X11 at 1BC connection to the robot controller.
2. Connect the power cable (2BC) X21 at 2BC connection to the robot controller.
Make sure that you hear the locking clips snap into place (clicking sound).

X 11

X -1 X 21

X -2

Fig. 5-4: Connection of the robot controller

5 - 26
Wiring

5.2.3 Connecting the programming pendant

Connect the programming pendant cable to the connection (X81) (see diagram
"Connecting the programming pendant")

X81
Motoman DX100
Part No.
WARNING
Power Supply
AC 400/415/440 V
Peak
Average
kVA
kVA
High Voltage
Serial No.
Date/Signature
Do not open the door
Type
Robot Type
ERDR-
with power ON.
Robot Order No.
Robot Serial No.

YASKAWA Electric corporation

2-1 Kurosaki Shiroishi Yahatanishi-Ku Kitakyushu-City Fukuoka 806-0004 Japan

Kammerfeldstr. 1, D-85391 Allershausen

NJ3053-1

CHECK ALL THE DOOR LOCKS

PROPERLY.
NJ3005-1

PROGRAMMING PENDANT
X81

Fig. 5-5: Connection programming pendant

1 Alignment marks

5 - 27
Technical data

6 Technical data
Type: A00
Types of Mounting: Floor mounting
Degree of freedom: 6
Payload: 180 kg
1
Repeatability: ±0.2 mm
Power consumption: 5.0 kVA
Weight: 970 kg
Working area of main axes:
S-axis (turning) -180° ~ +180°
L-axis (lower arm)2 -60° ~ +76°
U-axis (upper arm)² -147° ~ +90°
Working area wrist axes:
R-axis (wrist roll)² -360° ~ +360°
B-axis (wrist yaw/pitch) -130° ~ +130°
T-axis (wrist twist) -360° ~ +360°
Protection class (IP):
Main axes 54
Wrist axes 67
Maximum speed:
S-axis 2.18 rad/s, 125°/s
L-axis 2.01 rad/s, 115°/s
U-axis 2.18 rad/s, 125°/s
R-axis 3.18 rad/s, 182°/s
B-axis 3.05 rad/s, 175°/s
T-axis 4.63 rad/s, 265°/s
Allowed moment (Nm):3
R-axis 1000 Nm
B-axis 1000 Nm
T-axis 618 Nm
Permissible moment of inertia (kgm²):
R-axis 90 kgm² kg
B-axis 90 kgm²
T-axis 46,3 kgm²
Sound pressure level (dB):4 76 dB
1. Tested according to ISO 9283

2. The range of motion of L, U and R axes is limited depending on their position.

3. See the following diagram "Moment of arm rating in section 7" for further information on the permissible moment
of inertia.

4. Sound pressure level measured according to ISO 11201 (EN31201). It is measured at maximum load and
speed of the robot. The measurement is performed at height of 1.2 m and 1.5 m above the floor and at distance
of 400 mm to the working area.

6 - 28
Technical data

6.1 Parts and work axis label

U+ R+ B+ T+

R- T-
U- B-

L- L+

S+

S-

Fig. 6-1: Part names and working axes

6.2 Robot base dimension

Fig. 6-2: Robot base dimensions

1 2 holes Ø 20 H7 3 Mating surfaces

2 8 mounting holes Ø 22 All dimensions in mm

6 - 29
Technical data

6.3 Dimensions and defined working area

Fig. 6-3: Dimensions and defined work area

1 P point 2 Working area, defined with point P

All dimensions in mm

6 - 30
Technical data

6.4 Adjustable working area

The work area of the s-axis may be changed depending on the type of application.
If any modification is necessary, please contact the local YASKAWA branch office.

Item Specifications
S-axis working range ± 180° (standard)
± 150°
± 120°
± 90°
± 60°
± 30°

The mechanical stop can only be adjusted in 60° steps

6 - 31
Technical data

6.4.1 Components for Changing the Working Area

To change the working area of S-axis, the following components are required (see the
following figure).

2
3

A A

Fig. 6-4: Components of the S-axis limit

1 4 M16 x 35 screws (strength category 3 Section A-A

12.9) and 4 M16 washers
2 Limitation 4 Pin

6 - 32
Technical data

6.4.2 Adjusting the S-Axis Pulse Limit

If you want to change the movement range of S-axis, follow the instructions in the System
Setup Manual, section: "Changing the Parameter Setting".
– Pulse limit [positive direction (+) of S-axis]: SICxG400.
– Pulse limit [negative direction (+) of S-axis]: SICxG408.

Degree  ± 15° ± 30° ± 45° ± 60° ± 75° ± 90°

Number of ±0 ±28672 ±57344 ±86016 ±114688 ±143360 ±172032
pulses

Degree  ± 120° ± 135° ± 150° ± 165° ± 180 (standard)

Number of ±20070 ±22937 ±258048 ±286720 ±315392 ±344064
pulses 4 6

NOTICE
To change the movement range of the machine, set both the pulse limit and the angle of the
mechanical S-axis limit.

Fig. 6-5: Adjustable angle for the S-axis limit

1 The angle for S-axis limit in positive di- 3 Yellow: Adjustable angle
rection White: Non-adjustable angle
2 The angle for S-axis limit in negative
direction

2 3

1 Screw 3 The model shown at an angle of 165°

2 The model shown at an angle of 180°

6 - 33
Technical data

1 1

2 3

1 Screw 3 The model shown at an angle of 135°

2 The model shown at an angle of 150°

1 1

2 3

1 Screw 3 The model shown at an angle of 105°

2 The model shown at an angle of 120°

1
1

2 3

1 Screw 3 The model shown at an angle of 75°

2 The model shown at an angle of 90°

6 - 34
Technical data

1 1

2 3

1 Screw 3 The model shown at an angle of 45°

2 The model shown at an angle of 60°

1
1

2 3

1 Screw 3 The model shown at an angle of 15°

2 The model shown at an angle of 30°

1 Screw 2 The model shown at an angle of 0°

6 - 35
Technical data

6.5 Stopping Angle and Time at the Emergency Stop

The definition of the coastdown times is important for determining the safety distance for
protective devices. The overrun time is the time that elapses from the point of time when
the stop signal is triggered until the robot comes to a complete stop. The overrun distance
is the angle that the robot travels from the point of time when the stop signal is triggered
until the robot comes to a complete stop.
The following diagrams show only the values for the S, L, and U axes since these axes have
the largest deflection. For a safety stop with stop category 0, the mean values determined
through testing and simulation are specified.
The actual overrun distances and overrun times may differ due to internal and external
influence on the braking torque. According to the mode, robot application, and number of
triggered safety stops with stop category 0, a different brake wear may occur. We
recommend that the coastdown path be checked once a year.

100%

66%
33%

Fig. 6-6: Main axes at 100%, 66%, and 33% deflection

In the S, L, and U axes are shown at 33%, 66%, and 100% deflection according to DIN EN
ISO 10218-1.
In these three positions, the coastdown paths and coastdown times were determined during
a safety stop with stop category 0 and stop category 1. In the following diagrams, they are
specified at payloads of 33%, 66%, and 100%.
The pertinent legend can be found in the following table:

Definitions Description
Load 100% pink
Load 66% green
Load 33% gray
Load 100% blue
Overrun distance degrees° [deg]
Overrun time second [sec]
Robot speed degrees°/second [deg/s]

6 - 36
Technical data

6.5.1 Stop category 0

6.5.1.1 Stop position S-axis

• 100% deflection

㻠㻜 㻝㻘㻜

㻟㻡 㻜㻘㻥
㻜㻘㻤
㻟㻜
㻜㻘㻣
㻞㻡
[deg]
㻜㻘㻢

[sec]
㻞㻜 㻜㻘㻡

㻝㻡 㻜㻘㻠
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡 㻜㻘㻝
㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]

• 66% deflection

㻠㻜 㻝㻘㻜

㻟㻡 㻜㻘㻥
㻜㻘㻤
㻟㻜
㻜㻘㻣
㻞㻡 㻜㻘㻢
[deg]

[sec]
㻞㻜 㻜㻘㻡

㻝㻡 㻜㻘㻠
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡 㻜㻘㻝
㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]

• 33% deflection

㻠㻜 㻜㻘㻡

㻟㻡
㻜㻘㻠
㻟㻜

㻞㻡
[deg]

㻜㻘㻟
[sec]

㻞㻜

㻝㻡 㻜㻘㻞

㻝㻜
㻜㻘㻝
㻡

㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]

6 - 37
Technical data

6.5.1.2 Stop position L-axis

• 100% deflection

[deg]

[sec]
[deg/s] [deg/s]

• 66% deflection

㻠㻜 㻝㻘㻜

㻟㻡 㻜㻘㻥
㻜㻘㻤
㻟㻜
㻜㻘㻣
㻞㻡
[deg]

[sec]
㻜㻘㻢
㻞㻜 㻜㻘㻡

㻝㻡 㻜㻘㻠
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡 㻜㻘㻝
㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]
• 33% deflection

㻠㻜 㻜㻘㻡

㻟㻡
㻜㻘㻠
㻟㻜

㻞㻡
[deg]

㻜㻘㻟
[sec]

㻞㻜

㻝㻡 㻜㻘㻞

㻝㻜
㻜㻘㻝
㻡

㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]

6 - 38
Technical data

6.5.1.3 Stop position U-axis

• 100% deflection

㻠㻜 㻝㻘㻜
㻟㻡 㻜㻘㻥
㻜㻘㻤
㻟㻜
㻜㻘㻣
㻞㻡

[deg]

[sec]
㻜㻘㻢
㻞㻜 㻜㻘㻡
㻝㻡 㻜㻘㻠
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡
㻜㻘㻝
㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]

• 66% deflection

㻠㻜 㻝㻘㻜

㻟㻡 㻜㻘㻥
㻜㻘㻤
㻟㻜
㻜㻘㻣
㻞㻡
[deg]

㻜㻘㻢

[sec]
㻞㻜 㻜㻘㻡

㻝㻡 㻜㻘㻠
㻜㻘㻟
㻝㻜
㻜㻘㻞
㻡 㻜㻘㻝
㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]

• 33% deflection

㻠㻜 㻜㻘㻡

㻟㻡
㻜㻘㻠
㻟㻜

㻞㻡
[deg]

㻜㻘㻟
[sec]

㻞㻜

㻝㻡 㻜㻘㻞

㻝㻜
㻜㻘㻝
㻡

㻜 㻜㻘㻜
㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜 㻜 㻞㻜 㻠㻜 㻢㻜 㻤㻜 㻝㻜㻜 㻝㻞㻜
[deg/s] [deg/s]

6 - 39
Technical data

6.5.2 Stop category 1

The stopping angle and time at the emergency stop in category 1 are not subjected to the
robot position and the load.
Stop of category1 doesn't depend on the robot position and the load.

6.5.2.1 Stop position S-axis

• 100% deflection

[sec]
[deg]

[deg/s] [deg/s]

• 66% deflection
[sec]
[deg]

[deg/s] [deg/s]

• 33% deflection
[sec]
[deg]

[deg/s] [deg/s]

6 - 40
Technical data

6.5.2.2 Stop position L-axis

• 100% deflection

[sec]
[deg]

[deg/s] [deg/s]

• 66% deflection

[sec]
[deg]

[deg/s] [deg/s]

• 33% deflection

40 1.0

0.9
35
0.8
30
0.7
25 0.6

20 0.5
[sec]
[deg]

0.4
15
0.3
10
0.2

5 0.1

0.0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
[deg/s] [deg/s]

6 - 41
Technical data

6.5.2.3 Stop position U-axis

• 100% deflection

[sec]
[deg]

[deg/s] [deg/s]

• 66% deflection

[sec]
[deg]

[deg/s] [deg/s]

• 33% deflection
[sec]
[deg]

[deg/s] [deg/s]

6 - 42
Allowable load for wrist axis and wrist flange

7 Allowable load for wrist axis and wrist flange

7.1 Wrist flange

The dimensions of the wrist flange are shown in the following figure "Wrist flange". To
ensure that the home position marks can be seen at all times, the tool may only be flange-
mounted with the inner diameter. Fitting depth of inside fittings must be 8 mm.

NOTICE
Before mounting a tool, remove anticorrosive coating on the flange. Thinner or light fuel oil
are the most suitable for this purpose.

10

Fig. 7-1: Wrist flange

1 2 Holes Ø 9H7 x 8 5 Pitch circle Ø 92

2 2 Holes Ø 10H7 x8 6 Ø 63H7
3 Pitch circle Ø 125 7 Ø 160h7
4 6 M10 x 14 threaded holes 8 Alignment marks
All dimensions in mm

7 - 43
Allowable load for wrist axis and wrist flange

7.2 Allowable Wrist Load

The allowable wrist loads amounts to a maximum of 180 kg. Should however force instead
of load be exercised on the wrist axis, the power has to be at the axes within the moments
(see the following figure and table).
For further information or help, please contact your YASKAWA branch office.

Axis Allowable torque (Nm) Allowable moment of inertia (kgm²)

R-axis 1000 Nm 90 kgm² kg
B-axis 1000 Nm 90 kgm²
T-axis 618 Nm 46,3 kgm²

Tab. 7-1: Allowable torque and allowable moment of inertia

Keep the centroidal distance of the load/mass within the specifications; refer to the following
figure, "Hand loads."

Fig. 7-2: Hand loads

1 P point 3 B-axis centre of rotation

2 R-axis/T-axis centre of rotation All dimensions in mm
The peripheral devices are mounted on the upper arm of the U axis and the rotating head
of the S axis (see the following figure) to facilitate the installation of the system applications
of the user. The following conditions should be observed to attach or install peripheral
equipment.

7 - 44
Allowable load for wrist axis and wrist flange

  1
 A3

 2
1
A3


A1





  A3



3




 
A1

 




4
5


B
B



   
6


A1



 


 
   B



 
5


A2







   
   

Fig. 7-3: Installing peripheral equipment mounts

1 4 threaded holes M8 x 14 4 4 threaded holes M12 x 24

2 2 threaded holes M5 x 9 5 4 threaded holes M20 x 39
3 2 threaded holes M6 x 11 6 4 threaded holes M6 x 11

A1, A2 and Wiring and valve 30 kg maximum.

A3 load Not more than 49 Nm for increasing the torque of
the upper arm
B Other max. 250 kg

7 - 45
Allowable load for wrist axis and wrist flange

The permissible moment of inertia is calculated when the permissible torque reaches the
maximum value. The permissible moment of inertia for the T-axis varies and depends on
the permissible torque.
Contact your YASKAWA branch office in a timely manner if you have questions regarding
the calculation of the load or centroidal distance.
Example:
In the case of the YASKAWA HP20D robot, for example, the permissible moment of inertial
for the T-axis amounts to 0.25 kgm² at a permissible torque of 19.6 Nm and to 0.75 kgm² at
a permissible torque of 0.1 Nm.

7 - 46
Internal cables and compressed air lines

8 Internal cables and compressed air lines

Internal cables (23 wires 11 x 0.75 mm² and 12 x 0.5 mm²) and cables for the external
axes(4 wires x 2.00 mm², 2 wires x 0.75 mm² and 5 wires x 0.20 mm²) and air hoses are
used in order to use peripheral devices (e.g. gripper). They are mounted on the upper arm
as shown in the following diagram "Connector for internal cables and compressed air lines".
The pins 1 to 23 (1 to 16) are assigned as shown in the following figure. Wiring must be
performed by the user.
The following requirements must be met:
• The current-carrying capacity per single conductor (cross-section 2.00 mm², 0.75 mm²,
0.50 mm² and 0.20 mm²) must not exceed 16.1 A or less at 2.00 mm², 5.0 A at 0.75
mm², 3.5 A at 0.50 mm² and 2.3 A at 0.2 mm² .
• The air pressure for the air hose must not exceed 600 kPA (the inner diameter of the air
hose is Ø 8 mm).

1 Exhaust port (air flow)

with locking cap (PT3/8)
2 Connector for the exter-
nal axis (power cable ).
3 Connector for the exter-
nal axis (encoder cable ).
4 Connector for the internal
wiring harness on casing
cover.
5 Connector for the internal
wiring harness on casing
cover.
6 Air inlet with locking cap
(PT3/8)

8 - 47
Internal cables and compressed air lines

2 4 5

6
2

4 7

8
9
4

1 6

10

Fig. 8-1: Detailed drawing of connector

 = used
 = not used

1 Connector plug for the internal cable 6 shielded line

feedthrough
2 6 pins x 0.50 mm² 7 Connecting plug for the encoder cable
for the external axes
3 11 pins x 0.75 mm² 8 4 pins x 2.00 mm²
4 Pins used 9 2 pins x 0.75 mm²
5 6 pins x 0.20 mm² 10 Connecting plug for the mains cable
for the external axes
The pins used on the connectors (23 wires 11 x 0.75 mm² and 12 x 0.5 mm²) and cables for
the external axes(4 wires x 2.00 mm², 2 wires x 0.75 mm² and 5 wires x 0.20 mm²) are
connected to the stand and arm with individual wires.
The internal connections of the robot are shown in the following diagrams "Connection
diagram A" and "Connection diagram B".

8 - 48
 Note: The connecting terminal A and B for the indication of the end switch has been changed as follows:

0BT 1 0BAT11 17 0BAT1 LA1 LA1

P BAT 2 BAT11 18 BAT1 LB1 LB1 Overrun limit switch S axis Connected to A1
0BT 3 0BAT12 19 0BAT2
P BAT 4 BAT12 20 BAT2
21 0BAT3 LC1 LC1
22 BAT3 LD1 LD1 Overrun limit switch S axis Connected to B1
23
24 S-Axis limit switch specification
0BT 5 0BAT21 25 0BAT4
P BAT 6 BAT21 26 BAT4 LA1 LA1
0BT 7 0BAT22 27 0BAT5 LB1 LB1 A1
P BAT 8 BAT22 28 BAT5 Overrun limit switch S axis Connected to
29 0BAT6 LB1 LA2
30 BAT6 LB2 LB2 Overrun limit switch L axis Connected to A2
1 31 0BAT7
2 32 BAT7 LB2 LA3
3 1 PG0V1 LB1 LB3 L and U-axes interference L.S. Connected to A3
4 2 PG5V1
5 3 PG0V2
6 4 PG5V2 LC1 LC1
7 5 PG0V3
LD1 LD1 Overrun limit switch S axis Connected to B1
8 6 PG5V3
7 PG0V4 LD1 LC2
8 PG5V4
1BC(10×4) 9 PG0V5 LD2 LD2 Overrun limit switch L axis Connected to B2
DX200 No.24CN X 10 PG5V5 LD2 LC3
CN1-5 +24V CN1-5 +24V -1 +24V 1 11 PG0V6
0V 0V LD1 LD3 L and U-axes interference L.S. Connected to B3
CN1-4 P CN1-4 -3 0V 3 12 PG5V6
13 PG0V7
CN1-10 +24V CN1-10 +24V -2 +24V 2 14 PG5V7 SLU axes with limit switch specifications
0V P CN1-9 0V -4 0V 4 15
CN1-9
16 No.1CN
CN1-1 SPG+1 CN1-1 SPG+1 1CN-1 DATA+1
SPG-1 P CN1-2 SPG-1 No.18CN S P -2 DATA-1
CN1-2
-1 BAT1 -6 BAT
-2 0BAT1 P -5 OBT PG S-AXIS
-3 PG5V1 -4 +5V
-4 PG0V1 P -9 0V
Internal cables and compressed air lines

CN1-3 FG1 CN1-3 FG1 -10 FG1

OBT
BAT
No.2CN
CN1-6 SPG+2 CN1-6 SPG+2 2CN-1 DATA+2
SPG-2 P CN1-7 SPG-2 No.19CN L P -2 DATA-2
CN1-7
-1 BAT2 -6 BAT
-2 0BAT2 P -5 OBT PG L-AXIS
-3 PG5V2 -4 +5V
-4 PG0V2 P -9 0V
CN1-8 FG2 CN1-8 FG2 -10 FG2
OBT
BAT
No.3CN
CN2-1 SPG+3 CN2-1 SPG+3 3CN-1 DATA+3
SPG-3 P CN2-2 SPG-3 No.20CN U P -2 DATA-3
CN2-2
-1 BAT3 -6 BAT
-2 0BAT3 P -5 OBT PG U-AXIS
-3 PG5V3 -4 +5V
-4 PG0V3 P -9 0V
CN2-3 FG3 CN2-3 FG3 -10 FG3
OBT
BAT
No.4CN
CN2-6 SPG+4 CN2-6 SPG+4 4CN-1 DATA+4
SPG-4 P CN2-7 SPG-4 No.21CN R P -2 DATA-4
CN2-7
-1 BAT4 -6 BAT
-2 0BAT4 P -5 OBT PG R-AXIS
-3 PG5V4 -4 +5V
-4 PG0V4 P -9 0V
CN2-8 FG4 CN2-8 FG4 -10 FG4
OBT
BAT
No.5CN
CN3-1 SPG+5 CN3-1 SPG+5 5CN-1 DATA+5
SPG-5 P CN3-2 SPG-5 No.22CN B P -2 DATA-5
CN3-2
-1 BAT5 -6 BAT
-2 0BAT5 P -5 OBT PG B-AXIS
-3 PG5V5 -4 +5V
-4 PG0V5 P -9 0V
CN3-3 FG5 CN3-3 FG5 -10 FG5
OBT
BAT
No.6CN
CN3-6 SPG+6 CN3-6 SPG+6 6CN-1 DATA+6
SPG-6 P CN3-7 SPG-6 No.23CN T P -2 DATA-6
CN3-7
-1 BAT6 -6 BAT
-2 0BAT6 P -5 OBT PG T-AXIS
-3 PG5V6 -4 +5V
-4 PG0V6 P -9 0V
FG6 CN3-8 FG6 -10 FG6
CN3-8
OBT
BAT
No.7CN
SPG+GUN CN4-4 SPG+GUN 7CN-1 DATA+GUN
CN4-4 SPG-GUN SPG-GUN No.24CN 7
P CN4-5 P -2 DATA-GUN
CN4-5 -1 BAT7 -11
FG-GUN CN4-9 FG-GUN BAT
CN4-9 -2 0BAT7 P -12 0BT Gun
-3 -10 0V
PG5V7
0V CN3-4 0V -4 P -9 +5V
CN3-4 5V P 5V PG0V7
CN3-5 CN3-5 -15 FG-GUN
0V CN3-9 0V
CN3-9 5V P CN3-10 5V
CN3-10

Fig. 8-2: Connection diagram for internal connections (a)

+24V CN2-4 +24V
CN2-4 LD1 P CN2-5 LD1
CN2-5 FG7 CN2-9
CN2-9 +24V CN2-10 +24V SS1
CN2-10 BC1
BC2 For Lamp (o ptional)
CN4-1 +24V CN4-1 +24V
LB1 P CN4-6 LB1
CN4-6

LB1 LA2 A2
LA1 LB1 LB2 LB2
CN4-2 SS2 CN4-2 SS2 SS2
CN4-7
AL1 P CN4-7 A1 LD1 LC2
LD2 LD2 B2
LC1 LD1 LB2 LA3
CN4-3 BC2 CN4-3 BC2 LB1 LB3
A3
AL2 P CN4-8
CN4-8
LD2 LC3 B3
B1 LD1 LD3
0V CN4-10 0V
CN4-10
E

8
E

Base Robot Housing

- 49
8
- 50
2BC 2BC(8PX3+12PX3)

E E

E-8 MU1 E-8 MU1

E-7 MU1 E-7 MU1
MV1 E-2 MV1 No.9CN
E-2 MV1 MV1 9CN-A MU1
E-1 E-1
MW1 E-6 MW1 -B MV1
E-6 -C MW1 SM S-axis
E-5 MW1 E-5 MW1
-D ME1
ME1 E-4 ME1
E-4 ME1 ME1
E-3 E-3 -1 BA1
B-5 BA1 B-5 BA1 -2 BB1 YB
B-10 BB1 B-10 BB1

F-8 MU2 F-8 MU2

F-7 MU2 F-7 MU2
MV2 F-2 MV2 No.10CN
F-2 MV2 F-1 MV2 10CN-A MU2
F-1 -B MV2
F-6 MW2 F-6 MW2
MW2 F-5 MW2 -C MW2 SM L-axis
F-5 -D ME2
F-4 ME2 F-4 ME2
ME2 F-3 ME2
Internal cables and compressed air lines

F-3 -1 BA2
B-4 BA2 B-4 BA2 -2 BB2 YB

D-8 MU3 D-8 MU3

D-7 MU3 D-7 MU3
MV3 D-4 MV3 No.11CN
D-4 MV3 D-3 MV3 11CN-A MU3
D-3 -B MV3
D-6 MW3 D-6 MW3
MW3 D-5 MW3 -C MW3 SM U-axis
D-5 -D ME3
D-2 ME3 D-2 ME3
D-1 ME3 D-1 ME3 -1 BA3
B-3 BA3 B-3 BA3 -2 BB3 YB

No.12CN
A-6 MU4 A-6 MU4 12CN-A MU4
MV4 A-3 MV4 -B MV4
A-3 -C MW4 SM R-axis
A-1 MW4 A-1 MW4 -D ME4
A-5 ME4 A-5 ME4
BA4 B-2 BA4 -1 BA4
B-2 -2 BB4 YB
B-9 BB4 B-9 BB4

No.13CN
C-11 MU5 C-11 MU5 13CN-A MU5
MV5 C-9 MV5 -B MV5
C-9 -C MW5 SM B-axis
C-7 MW5 C-7 MW5 -D ME5
C-8 ME5 C-8 ME5
B-12 BA5 B-12 BA5 -1 BA5
-2 BB5 YB

No.14CN
MU6 C-6 MU6 14CN-A MU6
C-6 -B MV6
MV6 C-4 MV6
C-4 -C MW6 SM T-axis
C-2 MW6 C-2 MW6 -D ME6
ME6 C-5 ME6
C-5
BA6 B-11 BA6 -1 BA6
B-11 -2 BB6 YB

Fig. 8-3: Connection diagram for internal connections (b)

No15CN(18-1)
E

A-11 MU7 A-11 MU7 1

MU7
A-9 MV7 A-9 MV7 2
MV7
A-2 MW7 A-2 MW7 3 Servo gun
MW7
ME7 A-4 ME7 4
A-4 ME7
BA7 B-8 BA7 5
B-8 BA7
BB7 B-7 BB7 6
B-7 BB7

PE
Maintenance and inspection

9 Maintenance and inspection

DANGER!
Danger to life due to electric shock
Maintenance and inspections must be performed by specified personnel.
The instructions given below must be followed before taking maintenance and inspection
measures:
 Turn OFF the main power supply.
 Put up the required warning sign, e.g "Do not turn the power on!".
 Install a switch-on guard as prescribed.

If you have any questions regarding disassembly or repair, please contact the local
YASKAWA branch office.

NOTICE
Home position data is lost
Before removing the connector of the encoder cable to perform maintenance or inspection,
 Connect the spare battery unit.

9 - 51
Maintenance and inspection

9.1 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 are classified into several time levels as shown by the following table "Inspection
intervals".
In the table of "Inspection intervals", the inspections are divided according to three levels of
requirement:
• Works, carried out by trained staff.
• Work carried out by staff trained by YASKAWA.
• Works, carried out by YASKAWA staff.
Inspections are only carried out by trained staff.

NOTICE
 The inspection intervals depend on the SERVO power time (see point 1 in ).
 The table "Inspection intervals" applies to normal cases.
 Deviations are to be determined by the TCS service department of YEU-R.

START HOLD
REMOTE TEACH
PLAY

JOB EDIT DISPLAY UTILITY

JOB CONTENT
-TEST01 S:0000
CONTROL GROUP:R1 TOOL:
0000 NOP
0001 SET B000 1
0002 SET B001 0
0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
MOVJ VJ=0.78

Main Menu Short Cut Turn on servo power

LAYOUT TOOL SEL GO BACK

DIRECT
COORD OPEN
Multi PAGE AREA
ENTRY
SERVO
SELECT
MAIN SIMPLE ON CANCEL
MENU MENU READY ASSIST

SERVO ON
X- X+ X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
Z- Z+ MANUAL SPEED
Z- Z+
U- U+ T- T+
SLOW
E- E+ 8- 8+

INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

ROBOT INFORM 4 5 6 BWD FWD

LIST

EX.AXIS
WELD 1 2 3 DELETE INSERT
ON/OFF

MOTION 0 . -
AUX MODIFY ENTER
TYPE

DATA EDIT DISPLAY UTILITY

SYS MONITORING TIME

CONTROL POWER TIME (1998/07/06 10:00 )

2385:42'02
1 SERVO POWER TIME (1998/07/06 10:30 )
36000:00'00
PLAYBACK TIME (1998/10/22 11:12 )
2210:00'20
MOVING TIME (1998/10/22 15:30 )
1875:15'30
OPERATING TIME (1998/10/22 16:12 )
0:0'0

Main Menu ShortCut

Fig. 9-1: SERVO power time

The numbers in the above figure are equal to the numbers in the table of "Inspection
intervals".

9 - 52
 Maintenance and inspection
1 Trained staff
2 YASKAWA trained staff
3 YASKAWA personnel
9
- 53
9 - 54

Maintenance and inspection

Inspection intervals

Item number1 Schedule (h) Method Operation To be per-

formed by:

Daily
1000
6000
12000
24000
36000
1 2 3

1 Alignment marks  Visual inspection Check alignment mark correspondence and   

damage at the zero position.

2 External cables  Visual inspection Check cables for damage.   

3 Working area and robot  Visual inspection If the working area is dirty, it must be cleaned.   
Check the robot for damage and external cracks.
4 Motors for L and U-axes  Visual inspection Check for grease discharge.2.   

5 Fastening bolts of the base  Using a correspond- tighten loose screws (replace if necessary).   
plate ing tool,

6 Fixing screws of the cover  Using a correspond- tighten loose screws (replace if necessary).   
ing tool,

7 S-, L-, and U-axes motor con-  Manually Check for loose plug connections (tighten if nec-   
nection essary).

8 Power input module  Manually Check for loose connections.   

9 Balancer unit  Grease gun The grease has to be refilled every 6000 hours  
(see chapter 9.4.3 "Grease replenishment for
balancer link part" on page 65).

 Special tools for Check the gas pressure every 6000 hours. If the  
maintenance gas pressure is not correct, fill the Gas Balancer
(see chapter 9.5 "Gas maintenance procedure in
the gas balancer" on page 66).
 Inspection intervals

Maintenance and inspection

Item number1 Schedule (h) Method Operation To be per-
formed by:

Daily
1000
6000
12000
24000
36000
1 2 3
10 Cable harness in robot  Visual inspection Check the bushing between the connector on  
with multimeter the stand and the intermediate connectors by
manually moving the wires. Check the protective
coil.3).

 Exchange4 

11 Battery unit in robot  If a battery alarm appears or after the robot has  
been operated for 36000 hours, the battery must
be exchanged.

12 S, L, U, R, B and T-axes gear   Grease gun Check for malfunctions (replace if necessary).  
The grease5 must be refilled every 6000 hours
and exchanged every 12000 hours (see Chapter
9.4.1 "Grease filling the main axes" and 9.4.2
"Grease filling the wrist axes").
9
- 55
 Inspection intervals
9 - 56

Maintenance and inspection

Item number1 Schedule (h) Method Operation To be per-
formed by:

Daily
1000
6000
12000
24000
36000
1 2 3
13 Overhaul  
1. The item numbers correspond with the following figure, "Inspection intervals."

2. The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. The damage can be damaged as a result. In case of questions, please contact your YASKAWA
branch office.

3. When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of the plug connections of the respective motor. Then remove the connectors of the encoders of the
respective motor; if this is not observed, the zero positions are lost.

4. The internal wiring harness in the robot (for the S, L, U, R, B and T axes) must be replaced at the 24,000 hours inspection.

5. The lubricants used can be found in the following table, "Inspection points and lubricants used."

Tab. 9-1: Inspection intervals

Maintenance and inspection

Fig. 9-2: Inspection intervals

9 - 57
Maintenance and inspection

9.2 Note on battery unit

9.2.1 Battery pack replacement

1 3

Fig. 9-3: Battery unit location

1 Fastening bolts of cover plate 3 Battery unit

2 Power input module 4 Circuit board
The battery units are installed as shown in picture "The location of the battery unit".
If battery alarm occuring in the robot controller, battery pack has to be changed in the
following form.
1. Turn the robot controller to the main power supply (see ).

WARNING
High Voltage
Do not open the door
with power ON.

Fig. 9-4: Main power switch in "switch-off" position

1 Main power switch in "switch-off" position

2. Remove the fixing screws from the cover plate.
3. Carefully pull out the battery pack from the base.

NOTICE
The absolute encoder data will be lost
Removing the battery pack, make sure you not to remove the plug from circuit board.

9 - 58
Maintenance and inspection

4. Connect the new battery pack to the unoccupied connector on the board.

6 1

Fig. 9-5: Battery pack connections

1 Old battery pack before replacement 4 Plug

2 New battery pack 5 Circuit board
3 See exchange, step 6 6 See exchange, step 7
5. Remove the old battery pack from the battery holder.
6. Mount the new battery pack to the battery holder.

NOTICE
The absolute encoder data will be lost
Never remove old battery pack before having installed new battery pack.

7. Please remove old battery pack plug from circuit board.

NOTICE
Make sure that no wires are pinched when you install the battery pack and the cover plate
again.

8. Please apply Teroson Plast sealing compound (material no. 143813) to thread part of
screws.
Exchanging the battery unit iscompleted after reinstalling the cover plate on the plug plate.

9 - 59
Maintenance and inspection

9.2.2 Battery pack connector (including warning note)

3
2

OBT b a OBT*
BAT a b BAT

5 4

Fig. 9-6: Battery unit connector diagram for S-, L- and U-axes

1 Motor 4 Battery unit

2 Motor power connector 5 Plug for backup
3 Encoder connector
Before removing the encoder connector (with CAUTION label), connect the battery to the
motor as shown in the following figure.

1
9

8 7
b OBT4
OBT a a BAT4
BAT b
removing connector.
to save the data before
Connect battery to encoder

CAUTION

5 3

6
OBT a b OBT4
4 BAT b a BAT4

Fig. 9-7: Battery unit connector diagram for R-, B- and T-axes

1 Encoder 6 Warning label

2 Motor cable 7 Power connector
3 Battery unit 8 Wiring harness of the robot
4 a: Plug - socket 9 Motor
b: Plug - pin
5 Encoder connector

9 - 60
Maintenance and inspection

9.3 Note on maintenance

NOTICE
The absolute encoder data will be lost.
Removing the encoder connector without connecting the battery pack results in the
disappearance of the encoder absolute data.
 When performing maintenance such as replacement of a wire harness in the robot, the
encoder connector may be necessary to be removed. In this case, be sure to connect
the battery pack to the battery backup connector before removing the encoder
connector. The battery connectors are dealt with in the chapter 9.2.1 "Battery pack
replacement"on page 58.

9 - 61
Maintenance and inspection

9.4 Refill/Replace grease.

Make sure to follow the instructions. If the following instructions are not followed, it might
cause damage to motor or gear.

CAUTION!
Burns from heated grease
The grease may be under pressure and may spray out of the threaded hole when opening
the threaded hole.
 Wear safety goggles

NOTICE
 Make sure that the plug has been removed from the grease outlet. If the plug is not
removed, grease will enter the motor or the oil seal of the gear will be damaged. This
might cause damage to the motor or gear.
 Lubrication or grease replacement is only allowed at operating temperature.
 Lack the labels "IN and" OUT "is generally lubricated from the bottom up.
 Do not install a joint, hose, etc. to the grease outlet. If this instruction is not followed, the
motor will be damaged.
 Avoid air getting into the gear.
 Insert grease with a grease gun.
 If an automatic lubricating pump is used, the grease supply pressure must be 0.3 kPa.
 Set the grease injection rate to a value not higher than 7 g/s.
 The limit values may not be exceeded also if a conventional grease gun is used.
 In ceiling-mounted robots the grease outlet and the grease inlet are located the other
way around (related to the figures in the operating and maintenance instructions).
 Install a receptacle at the grease outlet.
 Exchanged grease must be disposed of in an environmentally sound manner.

Lubricants used

Lubricant types Material no. Axis

Molywhite RE No. 00 176891 Gear for all axes and R-, B- and T-pin-
ion.

Shell Gadus S2 V220 2 146745 Balancer unit

The safety data sheets for the lubricants can be requested from YEU-R.

9 - 62
Maintenance and inspection

Tightening torque of sealing plug

Designation Tightening torque (Nm)
PT 3/8 23
PT 1/4 12
PT 1/8 5
PT 1/16 4

1. Remove plug from grease exhaust port (OUT) and grease inlet (IN) port.

Example:

2. Mount the lubricating nipple to the grease inlet opening.

3. Press the grease into the grease inlet opening using a grease gun.
4. To squeeze out the excess fat, all taxes must be brought to operating temperature.
• In a operating JOB or a special moving JOBs (about 20 minutes at 100% speed).
5. Wipe away excess grease with a cloth.
6. Remove the lubricating nipple from the grease inlet opening and mount the plug again.
Before mounting the plug, apply to thread part.

Amount of grease
Axis types Refill grease Replace grease
S-axis 1000 cm³ / approx. 870 g 5000 cm³ / approx. 4350 g1
L-axis 500 cm³ / approx. 435 g 2500 cm³ / approx. 2175 g
U-axis 500 cm³ / approx. 435 g 2500 cm³ / approx. 2175 g
R-axis 330 cm³ / approx. 287 g 2200 cm³ / approx. 1914 g
R-, B- and T-pinion 400 cm³ / approx. 348 g 2600 cm³ / approx. 2262 g
B- and T-axes B-axis 260 cm³ / approx. 226 B-axis 1300 cm³ / approx. 1130
g g
Gas balancer type 1 / 8 cm³ / approx. 7 g -
type 2
1. The grease exchange is complete when new grease appears from the exhaust port. (The new grease can be
distinguished from the old grease by color.)

9 - 63
Maintenance and inspection

9.4.1 Grease filling the main axes

Figures the main axes

S-axis gear

PT3/8

PT1/4

L-axis gear

PT3/8

PT1/8

U-axis gear

PT3/8

PT1/8

1 Grease outlet opening

2 Grease inlet opening

9 - 64
Maintenance and inspection

9.4.2 Grease filling the wrist axes

Figures the wrist axes

R-axis gear

PT1/8

PT1/8

B and T-axis gear

PT1/8

PT1/8

R-, B- and T-axes pinion

PT3/8

PT1/8

1 Grease outlet opening

2 Grease inlet opening

9.4.3 Grease replenishment for balancer link part

Figure the axes

1 Grease outlet type 1

9 - 65
Maintenance and inspection

Figure the axes

2 Grease inlet type 1
3 Grease outlet type 2
4 Grease inlet type 2

9.5 Gas maintenance procedure in the gas balancer

9.5.1 Notes on gas maintenance procedure in the gas balancer

Please read these precautions thoroughly before you perform the gas inspection, or
discharge of the gas, i.e. filling.

WARNING!
Risk of accident and injury when extending or shortening the compensating cylinder.
Risk of suffocation with insufficient ventilation
Before you carry out the gas inspection or discharge of the gas, i.e. filling, check that the
brake of the L-axis motor is working properly and that the L-axis is securely locked.
 The compensating cylinder is nitrogen filled.
 Feed no other gas than nitrogen into the balancer unit.
 When working with nitrogen, the possibility of suffocation exists. Therefore, adequate
ventilation is required during work.
 Before you carry out the gas pressure inspection of the balancer unit or discharge of
the gas, i.e. filling, check that the brake of the L-axis motor is working properly and that
the L-axis is securely locked so that it cannot move. Non-observance can lead to very
dangerous situations by loosening the brake of the L-axis motor. Because the L-axis
causes the rotating of the arm without retaining force.
 When dealing with nitrogen, sufficient caution, as well as compliance with the applicable
laws and regulations of local authorities are required.
 For gas filling devices, contact your YASKAWA service representative.

NOTICE
To maintain the sealing performance, small quantity of oil used may leak from the bottom
part of the gas balancer.

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Maintenance and inspection

9.5.2 Gas pressure inspection

NOTICE
Personal injury or damage to property
The operation of the robot with an incorrect gas pressure in the compensating cylinder can
lead to failure or breakage.
 Run the gas pressure test every 6000 hours.

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Maintenance and inspection

9.5.2.1 Necessary devices

Make sure you have following devices for checking gas pressure.

Description Order no.

Digital pressure gauge: FRDSG-1 170839
Tapered roller bearing 168211
Rapid action coupling: T2-770-G1/8
Valve 168213
Valve tool 168214
Thermometer (to measure the surface/level of the compensating cylinder)

Nitrogen - pressure gas cylinders

Gas filling device: Have a suitable facility at hand for the compressed gas cylin-
ders used in your region. For questions, please contact your Yaskawa represen-
tative.

9.5.2.2 Adequate gas pressure

Adequate nitrogen gas pressure in the compensating cylinder will vary depending to
temperature.
Refer to the following table.

Compensating cylinder Adequate gas pressure

surface temperature (MPa)
-10° 10.5
-5° 10.8
0° 11.1
5° 11.4
10° 11.6
15° 11.9
20° 12.2
25° 12.4
30° 12.7
35° 13.0
40° 13.2
45° 13.5
50° 13.8
55° 14.1
60° 14.4

Tab. 9-2: Adequate gas pressure according to the surface temperature of compensating cylinder

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Maintenance and inspection

9.5.2.3 Inspection procedures

WARNING!
 Before you carry out the gas pressure inspection of the compensating cylinder or
discharge of the gas, i.e. filling, check if the brake of the L-axis motor is working properly
and if the L-axis is securely locked for that it cannot move.
 Non-observance can lead to very dangerous situations by loosening the brake of the L-
axis motor. Without retaining force due to the extension or shortening, the L-axis causes
the compensating cylinder to rotate the L-arm.

1. Move the robot to home position and turn off the power of the robot control.
2. Remove the cover and insert the quick connector to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve, and gate valve of the gas filling device are firmly closed.
4. Check the compensating cylinder surface temperature.
5. Slowly open the needle valve of the gas filling device, and then check that the pressure
indicated on the digital pressure gauge is satisfying the value shown in table 9.5.2.2
"Adequate gas pressure" on page. 68
Depending on the value, procedures after this are subject to change.
Case 1:
If the value is exceeding the adequate value.
 Discharge the gas till the value satisfies the adequate value (refer to chapter 9.5.3
"Gas discharging procedure" on page 70).
Case 2:
If the value is lower than the adequate value by 0.5 MPa or more.
 Discharge the gas till the value satisfies the adequate value (refer to chapter 9.5.4
"Gas injecting procedure" on page 71).
Not according to case 1 and 2  Proceed to step 6.
6. Close the needle valve of the gas filling device and then remove the gas filling device
from the quick connector.
7. Disconnect the rapid-action coupling and mount the cover (tightening torque 5 Nm).
8. Turn on the power to the robot control.

Pressure testing of gas in the compensating cylinder

1 Gas inlet/outlet
2 2 screws M4 x 6
3 Cover
1
4 When you dismount/remove
2
the compensating cylinder
from the robot. 3
5
5 Screw M6 4

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Maintenance and inspection

9.5.3 Gas discharging procedure

NOTICE
In the following cases, drain all gas from the compensating cylinder.
 When you dismount/remove the compensating cylinder from the robot.
 It is considered as dangerous goods, should you transport the robot by plane and the
compensating cylinder is filled with gas.
 When discharging the gas, the blowdown valve must not be fully opened. Take time and
discharge gas little by little. If the blowdown valve is fully opened with high internal
pressure, the non-return valve in the gas balancer can be damaged.

 If you drain all gas

1. Bring the robot to the home position and turn off the power of the robot controller.
2. Remove the cover and insert the rapid-action coupling to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve, and gate valve of the gas filling device are firmly closed.
4. Slowly open the needle valve.
5. Discharge gas a small amount at a time by slowly releasing the blowdown valve.
6. Close the needle valve and blowdown valve and then remove the gas filling device from
the quick connector.
7. Remove the quick connector and mount the cover, then tighten the screw with flange
by using a tightening torque shown in table 9.5.2.2 "Adequate gas pressure".
8. Turn on the power to the robot controller.
 When you let off gas to the pressure setting
1. Bring the robot to the home position and turn off the power of the robot controller.
2. Remove the cover and insert the quick connector to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve and gate valve of the gas filling device are firmly closed.
4. Check the temperature of the gas balancer surface.
5. Slowly open the needle valve.
6. Drain gas by opening the valve of the digital pressure gauge, until pressure will reach
the value according to the table 9.5.2.2 "Adequate gas pressure".

NOTICE
When you let off the gas or fill up, wait some minutes to allow for the stabilization of the gas
pressure and then measure the gas pressure.

7. Close the needle valve and blowdown valve and then remove the gas filling device from
the quick connector.
8. Remove the quick connector, then tighten the screw with flange by using the tightening
torque shown in the table 9.4 "Refill/Replace grease.".
9. Mount the cover and tighten the screws by using the tightening torque shown in the
table 9.4 .
10. Turn on the power to the robot controller.

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Maintenance and inspection

9.5.4 Gas injecting procedure

 Gas injecting procedure

WARNING!
Danger of injury in case of unforeseeable robot motion
Releasing the brake of the L -axis motor will lead to loss of the retaining force. As a result
the compensating cylinder will extend or shorten and will lead to the rotation of the L-arm.
 Before you drain or fill the gas from the compensating cylinder, check the brake function
of the L -axis motor.
 The robot should be secured for the L- axis should not move unpredictably.
 Keep safe distance in the direction of movement of the robot axes.
 Keep the appropriate pressure value show in table Tab. 9-2: "Adequate gas pressure
according to the surface temperature of compensating cylinder".

1. Move the robot to the home position and turn off the power of the robot controller.
2. Remove the cover and insert the quick connector to the gas inlet.
3. Connect the gas filling device to the quick connector after confirming that the blowdown
valve, needle valve and gate valve of the gas filling device are firmly closed.
4. Check the temperature of the gas balancer surface.
5. Connect the nitrogen gas cylinder to the gas filling device.
6. Release the valve of the nitrogen gas cylinder and then set the gas pressure slightly
higher than the adequate pressure shown in table Tab. 9-2: .
7. Slowly open the needle valve of the gas filling device.
8. Release the gate valve of the gas filling device to inject gas until the gas pressure
indicated by the digital pressure gauge is slightly higher than the adequate pressure
shown in table Tab. 9-2: .
9. Close the gate valve of the gas filling device, wait for the gas pressure in the gas
balancer to stabilize and then confirm that the gas pressure is the adequate pressure
shown in table Tab. 9-2: .
If the pressure is higher than the adequate pressure, discharge the gas gradually and
stabilize the gas pressure, then confirm that the gas pressure finally reached the
adequate value.

NOTICE
After draining/filling with gas, wait a few minutes to allow for the stabilization of the gas
pressure and then measure the gas pressure.

10. Close needle valve of the gas filling device and the valve of the nitrogen gas cylinder.
11. Disconnect the gas filling device from the quick connector.
12. Remove the quick connector and mount the cover, then tighten the screw M6 with
flange by using a tightening torque shown in table 9.4 "Refill/Replace grease.".
13. Mount the cover and tighten the screws by using the tightening torque shown in table
9.4 .
14. Release the blowdown valve of the gas filling device and regulator and then discharge
the gas in the hose.
15. Disconnect the gas filling device from the nitrogen gas cylinder.
16. Turn on the power to the robot controller.

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Maintenance and inspection

9.6 Home position calibration

Follow the safety instructions described see in chapter ExternalLink: Sicherheit.

NOTICE
 Teaching or playback are not possible before the completion of the home position
calibration.
 Teach and save a second testing position immediately after installing the robot system.
This second testing position can be determined, e.g., by using tips (screw-in tip on the
torch, fixed counterpart on the cell wall) and stored in the robot controller.
 After a collision or in the event of track deviations it is recommended not to re-teach
individual JOBs, but to approach and reset the basic position and/or the second home
position.
 After each collision or emergency stop situation the robot must be moved to its basic
position in setup mode and its home position must be checked.
 In a system with two or more Robots, the home position of all the Robots must be
calibrated before starting teaching or playback.
 For more information, see also system setup in the manual or contact your YASKAWA
branch.

When setting the home position, the position of the absolute encoder must match it.
Although this operation is performed prior to shipment at the factory, the following cases
require this operation to be performed again.
• Change in the combination of the robot and robot controller.
• Replacement of the motor or absolute encoder.
• Clearing stored memory (by replacement of the main CPU board, weak battery pack,
etc.).
• Home position deviation caused by hitting the robot.
Home position calibration
To calibrate the home position mark on each axis, use the axis keys, so that the robot can
take their position as home position.
There are two operations for home position calibration:
• All the axes can be moved at the same time.
– If the combination of robot and main board (CPU) has been changed, reset the
home position. The home position set by moving all axes simultaneously.
• Axes can be moved individually.
– If you have replaced the motor or the absolute encoder, reset the home position for
the individual axes.
If the absolute data of its posture for the home position is already known, set them again
after completing home position registration.

NOTICE
The window for calibrating the home position is only displayed if SAFTEY mode is selected
as the MANAGEMENT mode.

9.6.1 Registering all axes at the time

1. Select {ROBOT} from the main menu.

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Maintenance and inspection

2. Select {HOME POSITION}.

The <HOME POSITIONING> window appears.

3. Select {DISPLAY} under the menu, or select “PAGE” to display the selection window for
the control group, or press [PAGE].
The pull-down menu appears.

4. Select the desired control group.

5. Select {EDIT} in the main menu.
The pull-down menu appears.

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Maintenance and inspection

6. Select {SELECT ALL AXES}.

A confirmation dialog box is displayed.

7. Select {YES}.
Displayed position data of all axes are registered as home position.
When {NO} is selected, the registration will be canceled.

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Maintenance and inspection

9.6.2 Registering individual axes

1. Select {ROBOT} on the main menu.

The sub-menu choices appear.
2. Select {HOME POSITION}.
3. Select the module to be calibrated (e.g. R1:ROBOT).
Perform steps 3 and 4 which have been described in “Registering All Axes at One Time”
to select the desired control group.
4. Select the axis to be registered.

A confirmation dialog box appears.

5. Select {YES}.
Displayed position data of the axis are registered as home position.
When {NO} is selected, the registration will be canceled.

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Maintenance and inspection

9.6.3 Changing the absolute data

To change the absolute data of the axis when home position calibration is completed,
perform the following:
1. Select {ROBOT} from the main menu.
2. Select {HOME POSITION}.
3. Select the desired control group.
Perform steps 3 and 4 which have been described in chapter “Registering All Axes at
One Time” to select the desired control group.
4. Select the absolute data to be registered.
The number can now be entered.

5. Enter the absolute data using the numeric keys.

6. Select {ENTER}.
Absolute data are modified.

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Maintenance and inspection

9.6.4 Clearing absolute data

1. Select {ROBOT} from the main menu.

2. Select {HOME POSITION}.
Perform steps 2, 3, and 4 which have been described in “Registering All Axes at One
Time” to display the HOME POSITIONING window and select the desired control
group.
3. Select {DATA} under the menu.
The pull-down menu appears.

4. Select {CLEAR ALL DATA}.

The confirmation dialog box appears.

5. Select {YES}.
The all absolute data are cleared.
When {NO} is selected, the registration will be canceled.

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Maintenance and inspection

9.7 Setting the second home position (check point)

9.7.1 Purpose of position check operation

If the absolute number of rotation detected at power supply ON does not match the data
stored in the absolute encoder the last time the power supply was turned off, alarm 4107
“OUT OF RANGE (ABSO DATA)” is issued when the controller power is turned ON.
There are two possible causes of this alarm:
• An error was found in the encoder communication related components.
• No error was found in the encoder communication related components, but the robot
was moved after the power supply was turned OFF.
If there is an error in the encoder communication related components, the robot may stall
when playback is started. If the absolute data allowable range error alarm has occurred,
playback and test runs will not function and the position must be checked.

1 If the "OUT OF RANGE (ABSO DA-

1
TA)" alarm occurs:
2 Reset alarm
2
3 Turn ON SERVO power
4 Procedure after alarm occurs 3
5 Position confirmation operation 4
6 Compare second home position
(check point)* with current position 5
pulses.
7 Alarm occurs again
NOK
8 Correct defective axis 6
• Replace encoder communication re- 7
OK
lated components
• Home position calibration 8
9
9 * Position checking point
10 Playback possible 10
1. Position check
After the “OUT OF RANGE (ABSO DATA)” alarm occurs, move to the second home
position using the axis keys and perform the position confirmation. For performing the
position confirmation, refer to chapter “Procedure after the Alarm”. Playback and test
runs will not function unless “CONFIRM POSITION” is performed.
2. Pulse difference check
The pulse number at the second home position is compared with that at the current
position. If the difference is within the allowable range, playback is enabled. If not, the
alarm occurs again.
• The allowable range pulse is the number of pulses per rotation of the motor (PPR data).
• The initial value of the second home position is the home position (where all axes are
at pulse 0). The second home position can be changed. For details, refer to chapter
“Procedure for the Second Home Position Setting (Check Point)”.
3. Alarm Occurrence

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Maintenance and inspection

If the alarm occurs again, there may be an error in the encoder communication related
components. Check the components. After adjusting the erroneous axis, calibrate the home
position of the axis and then check the position again.

NOTICE
Home position calibration of all the axes at the same time enables playback operations
without having to check the position.
Sometimes in a system with a robot that has no brake, it is possible to enable playback
without position checking after the alarm occurs. However, as a rule, always perform
“CONFIRM POSITION”.
Under the above special conditions, the robot moves as follows:
 After starting, the robot moves at low speed (1/10 of the maximum speed) to the step
indicated by the cursor.
 If it is stopped and restarted during this motion, the low speed setting is retained until
the step at cursor is reached. Regardless of cycle setting, the robot stops after the
cursor step is reached
 Starting the robot again then moves it at the programmed speed and cycle of the JOB.

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Maintenance and inspection

9.7.2 Procedure for the second home position setting

Apart from the “home position” of the robot, the second home position can be set up as a
check point for absolute data. Use the following steps to set the specified point.

NOTICE
If 2 or more Robots or stations are controlled by one controller, the second home position
must be set for each robot or station.

1. Select {ROBOT} under the main menu.

2. Select {SECOND HOME POS}.
The {SECOND HOME POS} window appears.
The Message „Available to move to and modify specified point“ shown.

3. Press the page key [PAGE] or select “PAGE” to display the selection window for the
control group.
The group axes by which the second home position is set is selected when there are
two or more group axes.

4. Press the axis keys.

- Move the robot to the new second home position.
5. Press {MODIFY} then {ENTER}.
- The second home position is changed.

9.7.3 Procedure after alarm

Follow the safety instructions described in chapter 1.7 "Safety".

WARNING!
Death or injury because of danger of crushing
When performing the position check operation, pay careful attention to ensure the safety of
the surrounding operation environment.

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Maintenance and inspection

If the „OUT OF RANGE (ABSO DATA)“ alarm occurs,

• Reset the alarm.
• the SERVO power ON.
Then confirm the second home position. After the confirmation, if the PG system is found
to be the cause of the alarm, perform the necessary operation, such as replacing the PG
system, etc.
The robot current position data when turning main power supply ON and OFF can be
confirmed in {POWER ON/OFF POS} window.

NOTICE
For details on the “POWER ON/OFF POS“ window, refer to „Position Data When
Power is Turned ON/OFF“ in Maintenance manual.

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Maintenance and inspection

9.8 Zeroing Function (Optional)

The zero setting function (optional function) enables the automatic recovery of the robot’s
initial data in case they get lost. This function is possible only on robots which are delivered
with this option.
The robot control memorizes the initial position of the robot on the basis of the pulse value
of each encoder axis. Since the initial position is factory-set and registered, the setting to
zero must not be carried out in normal operation.
However, the setting to zero must be carried out if the initial position must be restored. The
initial position data will get lost when you effect the following operations or if the following
events occur.
• Replacement of motors
• Replacement of Encoders
• Discharging the battery of the robot
The home position data is stored by the backup battery. In the case of a discharged battery,
the data specific to the initial position will get lost if you switch off the power supply of the
robot control, even in the case of a reset. Make sure to change the battery on a regular
basis. You will find more information specific to changing the battery in the user manual of
the robot.

The initial position cannot be accurately set via the reset function if you modify the
combination robot and robot control.

9.8.1 Connection diagram

4 5

Zeroing Devices
8

1
7

1 Sensor 5 Data communication card (CF)

2 Amplifier YasXzero 6 Robot controller
3 Connection cable 7 Robot
4 Connection cable (RS232 8 Zeroing device YasXzero

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Maintenance and inspection

9.8.2 Overview and operation Reset to zero device YasXzero

Data exchange in case of resetting to zero occurs between sensor and programming
pendant via the amplifier.
Scope of supply
The following elements are included in the box:
• Amplifier YasXzero
• Mains unit for power supply and for charging the battery.
• Sensor with connection cable to the amplifier.
• Extension cable RS232
• Connection cable RS232 with CF data transmission card for programming pendant.
Display and operating elements front panel

R G T M F G
PW CH BA CO OK IN RN

SENSOR POWER

Socket sensor: Plug in the sensor cable.

LED PWR (Power): Lights up when the power cable is inserted or when the de-
vice is on.
LED CHG (Charge): Lights up when the power cable is inserted and when the
battery is being charged.
LED BAT (Battery): Lights up when the battery must be charged. The devices’
runtime with battery is approximately 2 – 3 hours.
LED COM (Communication): Flickers when data between YasXzero and the program-
ming pendant are being transmitted.
LED OK: Flashes at one-second intervals when the reset process is
taking place properly.
Lights up continuously in case of a hardware failure. Try to
restart the device. In case of further error signals please
contact your local YASKAWA branch office.
LED INF (Information): Without function
LED RNG (Range): Lights up continuously when the sensor is in a ± 0,2 mm
range.
Flashes if the ± 5mm measuring range is exceeded.
POWER Key: To switch-on the device.

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Maintenance and inspection

Operating elements Rear side

RoHS
RS232
6V DC
CONFIG

Material No. 157471

Socket 6VDC: Plug in the power supply.

CONFIG Key: Without function (only for manufacturer’s device configura-
tion).
Socket RS232: Plug in the cable specific to the programming pendant.
Description sensor
The sensor comprises the following parts
• Screw-fitted sensor tips
• Adapter for screwing to the robot
• LVDT sensor module
Application instruction
Avoid the following when using and storing the device:
• Direct sunlight.
• High humidity. Humidity must not condense.
• Extreme ambient temperatures.
• Large amounts of dust or other extremely dirty conditions.
• Strong movements or vibrations.
• Strong magnetic fields.
For cleaning use a clean and dry cloth. Never use liquids or aggressive cleaning agents.
The device must not be used in a potentially explosive environment.
The device can cause interferences to the reception of radio receivers, televisions or similar
devices. Ensure a sufficient distance to the devices.

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Maintenance and inspection

9.8.3 Resetting

The zero setting function can be effected only if the safety mode is set as extended mode.
To this effect, refer to the operating manual of the robot control system.

9.8.3.1 Preparatory measures

1. Remove the tools fastened to the robot.
If the zero setting is effected on a robot with tools, the weight of the tool can affect the
positioning accuracy.
2. Drive all the axes of the robot to home position, as otherwise errors might occur if axes
are coupled.
3. Insert the CF data transmission card of the reset to zero device in the opening of the
programming pendant.

Fig. 9-8: Inserting the data transmission card

4. Connect the CF data transmission card and the amplifier to the RS232 connecting cable
(extension cable and connecting cable to the CF card).
5. Connect the connecting wire to the YasXzero amplifier (socket “Sensor”). Do not
connect the sensor yet.

NOTICE
To install the reset to zero device and the reset sensor, please refer to chapter “Overview
of the YasXzero reset to zero device” included in this manual.

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Maintenance and inspection

9.8.3.2 Resetting an axis

WARNING!
Danger caused by unintentional start of the robot.
An unexpected start of the robot while people are standing in its movement area can cause
life threatening injuries.
 Ensure before entering the danger zone that the programming pendant is active and
that the robot cannot be controlled from other positions (e.g. central control desk).
 All the following robot movements must be effected exclusively by trained specialized
personnel and with the programming pendant.

NOTICE
Resetting will be described in the following using an S axis as example. This procedure
applies to all other axes.
The illustrations serve as example as the installation situation varies depending on robot
and robot axis. To this effect refer to the drawings in the annex.

1. Drive the axis in position so that the marking on the screw-in point of the reset sensor
coincides with the corresponding alignment marking.

The markings differ depending on the type of robot and the axis. Also refer to the
enclosed drawing that illustrates the resetting points.
2. Remove the locking device and the cover on the screw-in point for the sensor.
3. Ensure that the fastening bore is free from dirt, rust or any other impurities.
When the reset sensor becomes visible through the fastening bore, you should be able
to see a counter bore for resetting. If not, then probably the axis is not accurately
positioned between the alignment markings. Re-position the axis.
4. Screw-in the reset sensor manually.
Do not use a screwing tool to avoid damaging the sensor. Clean the sensor before
screwing with a soft cloth.
5. Connect the connecting cable to the sensor.
6. Switch on the YasXzero amplifier.
7. Switch the mode switch on the programming pendant to TEACH.
8. Select <MAIN MENU> → <ROBOT> → <ZEROING>..

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Maintenance and inspection

9. Select the axis on the screen (e.g. S-axis).

10. Leave the movement area of the robot and ensure that nobody is standing in this area.
11. Switch on the SERVO power. Press <SERVO ON READY> and the on-off switch on
the programming pendant.
12. Press <Zeroing> on the screen.
A window with a warning message opens:

If you have followed all the previously described steps, then you fulfilled all the points
stated on the list and you can proceed with the following step.
13. Press <OK>.
The robot starts automatically and carries out the reset movements. The movements
are very slow and very small, therefore they are hard to recognize. Observe the screen
of the programming pendant.

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Maintenance and inspection

14. The message confirming the resetting of the axis (S-axis in the example) appears on
the screen of the programming pendant. The calculated absolute data are then
displayed.

XXXXXXXX

15. Switch off the SERVO power.

16. Switch off the YasXzero amplifier.
17. Disconnect the connecting cable from the sensor.
18. Remove the sensor from the robot.
19. Mount the locking device of the sensor opening and the cover on the robot.
20. Check the position of the robot. Press <MAIN MENU> → <SECOND HOME
POSITION> → <ROBOT>.
The window SECOND HOME POSITION opens.
21. Leave the movement area of the robot and ensure that nobody is standing in this area.
22. Switch on the SERVO power. To this effect, press <SERVO ON READY> and the on-
off switch on the programming pendant.
23. Press <FWD> to move the TCP in the second home position.
24. Check if the second home position deviates from your required position.
25. Press <MAIN MENU> → <CONFIRM POSITION> → <DATA>.
A message "Home position checked" appears.
26. Check the home position with a Teach operation before starting automatic operation in
playback. To this effect, check the following points:
-Are there deviations from the second home position of the robot?
-Are there position deviations at one or several points?
-Are there irregularities during the test drive?

NOTICE
The home position must be checked before starting automatic operation.
If during the reset a wrong home position is entered, this can cause the robot to malfunction
during operation.

9.8.4 Positions for the reset sensor

In the following drawings, the positions at which the reset sensors are mounted will be
illustrated on the corresponding robots. The letters correspond to designations of the axis.

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Maintenance and inspection

T (b)

R (b)

T (a)

R (a)
B

Fig. 9-9: Installation positions

9.8.5 Error and solutions during resetting

If an error occurs during resetting, please refer to the following table that illustrates the most
common errors and their possible solutions.

Error message Possible error Possible solution

The bore is not deep enough of Sensor captures wrong bore • Check if dust or spilled liquids
too big. depth. penetrated in the bore.
Inspect the hole. Error • Check the exterior of the sensor
code:55550004 for damages or cracks as well
as the end of the sensor for de-
formations.
• Carry out a new reset.
Switch to TEACH mode. The mode switch on the pro- Switch the mode switch onto
Again, execute zeroing. gramming pendant is in the TEACH and carry out the reset.
“Play Mode” position when
starting the reset.
"Keep servo on state in teach The SERVO power is not Turn ON the SERVO power by
mode between under zeroing turned ON at the start of the ze- pressing the enable switch of the
execution." roing operation. programming pendant.
Again, execute zeroing.
Loop error Error in the zeroing processing. Possible cause: False parameter
[The maximum measurement settings for zeroing speed, dis-
point were exceeded.] tance, radius, false starting point
of the zeroing operation. Contact
Error code:55550005 the local YASKAWA branch of-
fice.

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Maintenance and inspection

Error message Possible error Possible solution

Loop error Communication errors Possible cause: Incorrect soft-
[Error by pulse capturing.] ware version. Please contact
your local YASKAWA branch of-
Error code:55550006 fice.
Loop error
[Error in the process that starts
robot movements.]
Error code:55550008
Loop error
[Error in the process that stops
robot movements.]
Error code:55550009
Loop error Communication errors Contact the local YASKAWA
[Error when capturing sensor branch office.
values.]
Error code:55550010
error
[Sensor Amp (Read():D1)]
Error code:55550044
Information* Check the SERVO Communication errors • Check if the alarm lamp is lit and
power of the sensor.* Check the if the cable etc. is correctly con-
connection of the cable RS- nected.
232C.* Check the battery. • Switch off the amplifier then
switch it on again.
• Carry out the reset again.
Alarm: Sensor amp (battery) The battery of the amplifier is Replace the battery.
empty.
Alarm: Sensor amp (write error Amplifier EEPROM writing er- Contact the local YASKAWA
EEPROM) ror branch office.
Alarm: Sensor amp (AD over) AD over alarm of the amplifier Contact the local YASKAWA
branch office.
Error Error when resetting the ampli- Contact the local YASKAWA
[Sensor amp (auto zero:OK)] fier branch office.

Error code:55550046
Error [No CtrlGroup] The reset was carried out with a Carry out the reset with a control-
Error code:55550052 controller without robot control ler with robot control group.
group.
Error [no axis] The reset was carried out with Enter the robot control group with
Error code:55550056 the robot control group without movement axis.
movement axis.
Not found: The CF card for the RS-232C is Slide the CF card for the RS-
CF card RS-232C located in the storage opening 232C in the storage opening.
of the programming pendant.
Error code:55550001

9 - 90
Maintenance and inspection

Error message Possible error Possible solution

error Error during the amplifier com- Contact the local YASKAWA
[RS-232C communication] munication branch office.

Error code:55550017
error
[RS-232C communication]
Error code:55550018
error
[RS-232C communication]
Error code:55550019
error
[RS-232C communication]
Error code:55550020
Error occur The reset will end due to an er- • Confirm the error message and
Finished! (Error occur) ror. eliminate the error.
• Repeat the reset from the begin-
ning.
Operator stop The reset is ended with the Repeat the reset from the begin-
Finished! (Operator stop) Stop switch. ning.

The operator has pressed the

Stop key.
Error [Any axis don't set ABSO.] Error in the zeroing processing Contact the local YASKAWA
Error code:55550088 branch office.

Loop error Error in the zeroing processing Contact the local YASKAWA
[Exceeding the maximal move- branch office.
ment pulse.]
Error code:55550097

Tab. 9-3: Error and solutions during resetting

9 - 91
Recommended spare parts list

10 Recommended spare parts list

It is recommended to keep in stock parts and components in the following table as spare
parts. Product performance cannot be guaranteed when using spare parts from any
company other than YASKAWA.

NOTICE
Please contact your YASKAWA branch office if you need spare or replacement parts.

Part List robot

Description Part-No. Material no.

Grease Molywhite RE No. 0 176891
Grease Grease Shell Gadus S2 146745
V220 2
Sealing compound Teroson Plast 143813
Battery pack Robot 128708
Battery pack Controller 155543
Wire harness HW1171456-A 164778
Power input module HW1371448-A 164779
Wrist unit HW1171565-A 164791
Balancer unit HW1382567-A 164777
Battery board SGDR-EFBA02A 154241
S-axis:
Gear HW0388208-B 159169
Pinion HW1303369-1 164766
Motor SGMRV-37ANA-YR1* 144071
Limit switches HW1470807-A 164780
L-axis:
Gear HW1382455-C 164785
Pinion HW1303887-1 164786
Motor SGMRV-37ANA-YR1* 144071
Limit switches HW1470430-B 164783
U-axis:
Gear HW0388209-F 164788
Pinion HW1303890-1 164789
Motor SGMRV-37ANA-YR1* 144071
Limit switches HW1470430-C 164784
R-axis:
Gear HW0386260-A 139436
Motor SGMRV-13ANA-YR1* 144074
B-axis:
Gear HW9380961-G 145908
Motor SGMRV-13ANA-YR1* 144074
T-axis:

10 - 92
Recommended spare parts list

Part List robot

Description Part-No. Material no.
Gear HW0389174-C 164790
Motor SGMRV-13ANA-YR1* 144074

Part List robot controller

Description Part-No. Material no.

Power supply JZNC-YPS21-E 164754
Additional power supply JZNC-YPS02-E 147571
CPU Rack JZNC-YRK21-1E 164756
CPU Circuit Board JANCD-YCP21-E 168996
Robot I/F board JANCD-YIF01-2E 145855
Machine safety CPU board JANCD-YSF21-E 164757
Machine safety I/O logic board JANCD-YSF22B-E 169501
General I/O board (PNP Type) JANCD-YIO22-E 164762
Power ON unit (Cat.4) JZRCR-YPU52-1 164764
Axis board SRDA-EAXA21A 170650
Converter module SRDA-COA30A21B-E 164767
Capacitor module (12A Type) SRDA-CUA662AA 164781
SERVO Amplifier S SRDA-SDA71A01A-E 144169
SERVO Amplifier L SRDA-SDA71A01A-E 144169
SERVO Amplifier U SRDA-SDA71A01A-E 144169
SERVO Amplifier R SRDA-SDA35A01A-E 155478
SERVO Amplifier B SRDA-SDA35A01A-E 155478
SERVO Amplifier T SRDA-SDA35A01A-E 155478
Resistor SMVK500W6R0J 164775
Memory device (Compact Flash) SFCF0256H1BK1MT-I-MS- 172731
553-SMA

10 - 93
Parts lists

11 Parts lists

11.1 S-axis unit

1031

1012 1032

1003 1002
1018
1019
1027

1028
1001 1046
1004

1005
1013

1006

1016
1030 1024

1029 1025
1015
1045
1022
1023

1009
1020
1034 1021
1033
1011 1008
1017
1010

1047 1045 1041

1026
1043 1044
1042

1007

1038

1039

1014
1036
1035 1037
1040

Fig. 11-1: S-axis drive

11 - 94
Parts lists

No. DWG no. Designation Piece

1001 HW0388208-B Gear 1
1002 SGMRV-37ANA-YR1* Motor 1
1003 TC12015014 Oil seal 1
1004 STW-50 Circlip 1
1005 6310 Bearing 1
1006 HW1303369-1 Gear 1
1007 HW1100520-1 Housing 1
1008 HW1100521-1 Housing 1
1009 HW1303370-1 Pipe 1
1010 HW9404863-1 Stop 1
1011 HW9404486-1 Shaft 1
1012 MSTH12-30 Pin 1
1013 MSTH12-30 Pin 2
1014 KQ2L10-01S Support 1
1015 PT3/8 Sealing plug 1
1016 G415 O-ring 1
1017 G130 O-ring 1
1018 M12 x 50 Screw 16
1019 SW2H-12 Washer 16
1020 M8 x 45 Screw 1
1021 2L-8 Washer 1
1022 M6 x 16 Screw 6
1023 2L-6 Washer 6
1024 M16 x 55 Screw 12
1025 GT-SH-16 Washer 12
1026 EZ5002A0 Sealing plug 1
1027 HW1303371-1 Spacer 1
1028 HW1404226-1 Flywheel 1
1029 M8 x 70 Screw 1
1030 2L-8 Washer 1
1031 M12 x 60 Screw 4
1032 2H-12 Washer 4
1033 M6 x 12 Washer 5
1034 HW1404239-1 Cover 1
1035 HW1404229-1 Cover 1
1036 M6 x 16 Screw 2
1037 2L-6 Washer 2
1038 HW1404228-1 Cover 1
1039 M6 x 12 Screw 6
1040 M6 Washer 2
1041 HW1401636-1 Stop 1

11 - 95
Parts lists

No. DWG no. Designation Piece

1042 M16 x 35 Screw 4
1043 2H-16 Washer 4
1044 HW0402104-1 Pin 1
1045 HW1404681-1 Shaft 2
1046 M6 x 30 Screw 2
1047 HW1405024-1 Gasket 1
Tab. 11-1: Parts list S-axis drive

11 - 96
Parts lists

11.2 L-axis unit

2057
2056 2073

2053 2022

2007 2004
2016
2028 2015 2045
2011
2010 2028
2008 2028 2046
2074 2047
2073
2009 2054
2026
2026 2025 2017 2001

2026 2026 2060

2025 2025 2006
2026 2073
2025
2042 2063
2062
2064 2061
2044
2072
2071

2059
2058 2034
2028
2043 2033

2005 2023
2035 2027 2002
2036
1008
2003

2031
2032
2038

2067 2029
2030
2025
2073
2026
2066
2021
2065 2022
2026 2007
2025 2018
2028
2074 2028
2011
2010 2057
2070
2053 2056
2028
2009 2016
2069
2068 2026
2025 2008

Fig. 11-2: L-axis drive

No. DWG no. Designation Piece

2001 HW1382455-C Gear 1
2002 SGMRV-37ANA-YR1* Motor 1
2003 HW9482447-A Oil seal 1
2004 HW1100591-1 L-arm 1

11 - 97
Parts lists

No. DWG no. Designation Piece

2005 HW1304057-1 Pinion 1
2006 AS568-275 O-ring 1
2007 VB75956 Oil seal 2
2008 VB60787 Oil seal 1
2009 22212EAE4 Bearing 2
2010 G105 O-ring 2
2011 STW-60 Circlip 2
2014 HW1404638-1 Holder 2
2015 HW1305071-1 Shaft 1
2016 HW1303707-1 Fork head 2
2017 HW1304162-1 Spacer 1
2018 HW1305071-2 Shaft 1
2021 HW1405133-1 Spacer 1
2022 HW1482236-A Bearing 2
2023 M12 x 35 Screw 4
2025 M8 x 20 Screw 36
2026 2L-8 Washer 36
2027 PT3/8 Sealing plug 1
2028 PT1/8 Sealing plug 7
2029 M12 x 30 Screw 23
2030 2H-12 Washer 23
2031 M16 x 35 Screw 6
2032 2H-16 Washer 6
2033 M12 x 75 Screw 25
2034 2H-12 Washer 25
2038 HW1304368-1 Cover 1
2042 HW1303711-A Support 1
2043 HW1382567-A Balancer unit 1
2044 HW1404713-1 Cover 1
2045 HW1404712-1 Cover 1
2046 M6 x 12 Screw 4
2047 2L-6 Washer 4
2053 M6 x 10 Screw 4
2054 HW1304161-1 Spacer 1
2056 HW1303630-1 Shaft 1
2057 HW0408806-2 Washer 1
2058 HW0483320-C Screw 1
2059 HW1404554-1 Shaft 1
2060 ISTW10 Circlip 1
2061 M12 x 40 Screw 12
2062 2H-12 Washer 12

11 - 98
Parts lists

No. DWG no. Designation Piece

2063 SLH-M6X12 Screw 4
2064 2L-6 Washer 4
2066 HW1405134-1 Cover 1
2067 M4 x 6 Screw 2
2068 2L-4 Washer 2
2069 HW1304369-A Cover 1
2070 M6 x 16 Screw 3
2071 2H-6 Washer 3
2072 M6 Washer 3
2073 M5 x 10 Screw 2
2074 2L-5 Washer 2
2075 HW1406698-1 Cover 1
2076 M6 x 16 Screw 2
2077 2L-6 Washer 2
2078 MSTH6-20 Pin 4
2079 HW1406482-1 Holder 2
1008 HW1100521-1 Housing 1
Tab. 11-2: Parts list L-axis drive

11 - 99
Parts lists

11.3 For R-, B- and T-axes drive

T-axis 3010
R-axis 3010

3027
3027
3003 3007
3011
3011 3009 3031
3009 3029
3029 3030
3001
3028 3008
3008 3005
3004
B-axis 3010 3002
3013
3014
3027
3012
3006 3015
3011
3009
3029 4016
3014
3008 4001
3026

3009

3014 3034
3033
3032

3035
3036
3037
3023
3025
3016
3024

2004
3020
3019

3022
3021

3018
3017
3032

Fig. 11-3: URBT-axis unit

No. DWG no. Designation Piece

3001 HW0402391-1 Sleeve 1
3002 HW0402406-1 Sleeve 1

11 - 100
Parts lists

No. DWG no. Designation Piece

3003 HW1303889-1 Gear 1
3004 ISTW-36 Circlip 1
3005 HW0402390-1 Sleeve 1
3006 HW1303377-1 Gear 1
3007 HW1303378-1 Gear 1
3008 M6 x 25 Screw 3
3009 2L-6 Washer 5
3010 SGMRV-13ANA-YR1* Motor 3
3011 M8 x 25 Screw 9
3012 HW1100592-1 Housing 1
3013 HW9482447-A Oil seal 1
3014 PT3/8 Sealing plug 3
3015 SGMRV-37ANA-YR1* Motor 1
3016 HW0388209-F Gear 1
3017 M12 x 55 Screw 16
3018 2H-12 Washer 16
3019 M10 x 25 Screw 18
3020 2L-10 Washer 18
3021 M16 x 35 Screw 6
3022 2H-16 Washer 6
3023 HW0481083-A Screw 1
3024 ISTW-12 Circlip 1
3025 HW1303890-1 Gear 1
3026 G270 O-ring 1
3027 Y507212.5 Oil seal 3
3028 TAFI405520 Bearing 1
3029 HW0401506-1 Washer 3
3030 IRTW-55 Circlip 1
3031 M12 x 35 Screw 4
3032 PT1/8 Sealing plug 2
3033 HW1404759-1 Cover 1
3034 M6 x 12 Screw 2
3035 HW9482306-E Shaft 1
3036 HW9481343-A Shaft 1
3037 HW0408806-1 Washer 1
2004 HW1100591-1 L-arm 1
4001 HW1100593-1 U-arm 1
4016 HW0100173-2 Housing 1
Tab. 11-3: Parts list URBT-axis unit

11 - 101
Parts lists

11.4 U arm unit

3012

4024
4021 4025
4022
4002
4019 4023

4027
4035
4027
4016

4012

4008 4030

4018
4017

4010 4006
4030 4007

4020 4014

4033 4011
4013

4032
4031

4005
4001
4003
4034 4004

4009
4029
4028

4036
4026

Fig. 11-4: U-arm unit

No. DWG no. Designation Piece

4001 HW1100593-1 U-arm 1
4002 HW0401508-1 Washer 1
4003 6810DDU Bearing 1
4004 WR50 Circlip 1
4005 AC2847F3*NOK* Oil seal 1
4006 NK25/20R Bearing 1
4007 WR20 Terminal 1
4008 LRT202526 Bearing 1
4009 HW0386260-A Gear 1
4010 HR32017XJ Bearing 1
4011 AC3842-F1-(FKM) Oil seal 1

11 - 102
Parts lists

No. DWG no. Designation Piece

4012 HW1303780-1 Shaft 1
4013 HW0302261-A Shaft 1
4014 HW0302262-B Shaft 1
4016 HW0100173-2 Housing 1
4017 HR32013XJ Bearing 1
4018 HW1303381-1 Gear 1
4019 HW0401505-1 Nut 1
4020 HW0303951-1 Gear 1
4021 M8 x 20 Screw 1
4022 2L-8 Washer 1
4023 M4 x 6 Screw 1
4024 M8 x 20 Screw 6
4025 2L-8 Washer 6
4026 PT1/8 Sealing plug 1
4027 HR32006XJ Bearing 2
4028 M8 x 95 Screw 16
4029 2L-8 Washer 16
4030 M5 x 12 Screw 6
4031 M12 x 35 Screw 18
4032 2H-12 Washer 18
4033 GS210 O-ring 1
4034 MSTM8-20 Pin 1
4035 HW0303948-1 Gear 1
4036 MSTH6-15 Pin 1
3012 HW1100592-1 Housing 1
Tab. 11-4: Parts list U-arm unit

11 - 103
Parts lists

11.5 Wrist unit

4013

4012

5014 5013
5013
5009

5012 5068
5010 5018
5015 5037 5042
5011 5088
5001 5025
5073 5026 5030
5023 5032
5024
5028
5008 5061 5033 5038
5021 5027 5032
5080 5023
5076 5029 5033
5075 5020 5031
5003 5019 5074 5023
5002 5022
5078 5036
5038
5079
5057
5077 5023
5089
5086 5085
5084 5043
5087 5086 5050
5095 5042
5017 5004
5005 5018 5034 5094
5035 5047
5090
5065 5091 5042

5016 5044
5039 5046
5093 5045
5092
5007
5006
5041
5040

5042

Fig. 11-5: Wrist unit

No. DWG no. Designation Piece

5001 HW1100595-1 Wrist unit 1
5002 M12 x 35 Screw 8
5003 2H-12 Washer 8
5004 HW1100594-1 Manual 1
5005 HW9380961-G Gear 1
5006 M8 x 15 Screw 14
5007 2L-8 Washer 14
5008 G110 O-ring 1
5009 6908DB Bearing 1
5010 HW0401511-1 Holder 1

11 - 104
Parts lists

No. DWG no. Designation Piece

5011 HW0401509-1 Housing 1
5012 HW0401510-1 Nut 1
5013 M4 x 12 Screw 8
5014 M4 x 6 Screw 1
5015 6909 Bearing 1
5016 ARP568-263 O-ring 1
5017 6009 Bearing 1
5018 STW-45 Circlip 2
5019 HW1303384-1 Gear 1
5020 HW0301223-1 Gear 1
5021 HW9481236-A Bearing 1
5022 HW1404234-1 Cover 1
5023 HR32004XJ Bearing 4
5024 6911 Bearing 1
5025 AE3290E3 Oil seal 1
5026 AR80 Circlip 1
5027 S60 O-ring 1
5028 HW9403618-1 Housing 1
5029 M6 x 15 Screw 5
5030 HW0301224-1 Gear 1
5031 HW0301225-1 Gear 1
5032 HW0401514-1 Nut 2
5033 M5 x 7 Screw 4
5034 M8 x 20 Screw 3
5035 2L-8 Washer 3
5036 HW9403617-1 Housing 1
5037 HW0200615-1 Cover 1
5038 M6 x 15 Screw 10
5039 HW0300889-1 Cover 1
5040 M6 x 25 Screw 4
5041 2L-6 Washer 4
5042 PT1/8 Sealing plug 4
5043 HW0301227-1 Gear 1
5044 HW0389174-C Gear 1
5045 M14 x 40 Screw 4
5046 GT-SH-M14 Washer 4
5047 HW1303903-1 Flange 1
5050 HW0406766-* Adjusting washer 1
5057 HW9403621-* Adjusting washer 1
5061 HW9403622-* Adjusting washer 1
5065 HW0401517 Adjusting washer 1

11 - 105
Parts lists

No. DWG no. Designation Piece

5068 HW0401516-* Adjusting washer 1
5073 PT3/8 Sealing plug 2
5074 HW9405444-1 Nut 1
5075 HW9403610-1 Cover 1
5076 *HW1404864-1*G Housing 1
5077 M4 x 6 Screw 1
5078 M8 x 20 Screw 16
5079 2HL-8 Washer 16
5080 HW9403623-* Adjusting washer 1
5084 M4 x 16 Screw 4
5085 M4 x 8 Screw 8
5086 2L-4 Washer 12
5087 HW0301231-1 Gear 1
5088 HW0301230-1 Gear 1
5089 HW0301226-1 Gear 1
5090 M8 x 40 Screw 14
5091 2L-8 Washer 14
5092 M8 x 85 Screw 6
5093 2L-8 Washer 6
5094 HW9482951-A Gasket 1
5095 HW1405841-1 Sleeve 1
4012 HW1303780-1 Shaft 1
4013 HW0302261-A Shaft 1
Tab. 11-5: Parts list wrist unit

11 - 106
Parts lists

11 - 107
YASKAWA Headquarters YASKAWA ACADEMY
YASKAWA Europe GmbH and sales office Frankfurt
Robotics Division YASKAWA Europe GmbH
Yaskawastraße 1 Robotics Division
D-85391 Allershausen Hauptstraße 185
Tel. +49 (0) 8166 / 90 - 0 D-65760 Eschborn
Fax +49 (0) 8166 / 90-103 Tel. +49 (0) 6196 / 77725 - 0
Fax +49 (0) 6196 / 77725 - 39

YASKAWA GROUP DISTRIBUTORS

A YASKAWA Austria BG ARAMET ROBOTICS Ltd.
Schwechat/Wien Yambol +359-885 317 294
+43(0)1-707-9324-15
Kammarton Bulgaria Ltd.
CZ YASKAWA Czech s.r.o. Sofia +359-02-926-6060
Rudná u Prahy
CH Messer Eutectic Castolin
+420-257-941-718
Switzerland S.A.
E YASKAWA Ibérica, S.L. Dällikon +41-44-847-17-17
Gavà/Barcelona
DK Robotcenter Danmark
+34-93-6303478
Løsning +45 7022 2477
F YASKAWA France SARL
EE RKR Seadmed OÜ
Saint-Aignan-de-Grand-Lieu
Tallinn/Estonia +372-68-35-235
+33-2-40131919
GR Gizelis Robotics
FIN YASKAWA Finland Oy
Nea Kifissia +30-2106251455
Turku +358-(0)-403000600
H Flexman Robotics Kft
GB YASKAWA UK Ltd.
Budapest +36-30-9510065
Banbury +44-1295-272755
LT Profibus UAB
I YASKAWA Italia s.r.l.
Panevezys +370-45-518575
Torino +39-011-9005833
N Skala Robotech AS
IL YASKAWA Europe Technology Ltd.
Lierstranda +47-32240600
Rosh Ha’ayin +972-3-9004114
PT ROBOPLAN Lda
NL YASKAWA Benelux B.V.
Aveiro +351-234 943 900
Son +31-40-2895500
RO Sam Robotics srl
PL YASKAWA Polska Sp. z o.o.
Timisoara +40-720-279-866
Wrocław +48-71-7928670
RO MPL Automation S.R.L.
RUS YASKAWA Nordic AB
Satu Mare +40 (0) 261 750 741
Moskva +46-480-417-800
SE YASKAWA Nordic AB
Torsås +46-480-417-800
SI YASKAWA Slovenia
Ribnica +386-1-8372-410
TR YASKAWA Turkey Elektrik
Ticaret Ltd. Sti.
İstanbul +90-216-5273450
ZA YASKAWA Southern Africa (PTY) Ltd
Johannesburg +27-11-6083182

robotics@yaskawa.eu.com
www.yaskawa.eu.com