1CD R5 PDF

MOTOMAN-HP20D/HP20F
INSTRUCTIONS
TYPE: YR-HP0020D-A00 (STANDARD SPECIFICATION FOR DX100)
TYPE: YR-HP0020D-A01 (SLU-AXES WITH LIMIT SWITCHES FOR DX100)
YR-HP0020F-A00 (STANDARD SPECIFICATION FOR FS100)
YR-HP0020F-A01 (SLU-AXES WITH LIMIT SWITCHES FOR FS100)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HP20D/HP20F INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATORS MANUAL
DX100 MAINTENANCE MANUAL
FS100 INSTRUCTIONS
FS100 OPERATORS MANUAL
FS100 MAINTENANCE MANUAL
The HP20D/HP20F operators manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number: 156192-1CD

Revision: 5
MANUAL NO.
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HP20D/HP20F
MANDATORY
This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-HP20D/HP20F for the
application to the actual operation and for proper maintenance and
inspection. It describes on safety and handling, details on
specifications, necessary items on maintenance and inspection, to
explain operating instructions and maintenance procedures. Be
sure to read and understand this instruction manual thoroughly
before installing and operating the manipulator.
General items related to safety are listed in Chapter 1: Safety of the
DX100/FS100 Instructions. To ensure correct and safe operation,
carefully read the DX100/FS100 Instructions before reading this
manual.
CAUTION
Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
If such modification is made, the manual number will also be
revised.
If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
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HP20D/HP20F
Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-HP20D/HP20F.
In this manual, the Notes for Safe Operation are classified as
WARNING, CAUTION, MANDATORY, or PROHIBITED.
Indicates a potentially hazardous

WARNING situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous

CAUTION situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the

MANDATORY items listed under this heading.
Must never be performed.

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

some situations.
At any rate, be sure to follow these important items.
To ensure safe and efficient operation at all times, be sure to

NOTE follow all instructions, even if not designated as CAUTION
and WARNING.
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HP20D/HP20F
<DX100>
WARNING
Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Figure 1: Emergency Stop Button
Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN
Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
View the manipulator from the front whenever possible.
Always follow the predetermined operating procedure.
Keep in mind the emergency response measures against the
manipulators unexpected motion toward you.
Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
Turning ON the power for the DX100.
Moving the manipulator with the programming pendant.
Running the system in the check mode.
Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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HP20D/HP20F
<FS100>
WARNING
Before operating the manipulator, check that servo power is turned
OFF when the emergency stop button on the programming pendant
is pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency.
Figure 3: Emergency Stop Button
In the case of not using the programming pendant, be sure to

supply the emergency stop button on the equipment. Then before
operating the manipulator, check to be sure that the servo power is
turned OFF by pressing the emergency stop button.
Connect the external emergency stop button to the 5-6 pin and 16-
17 pin of the robot system signal connector (CN2).
Upon shipment of the FS100, this signal is connected by a jumper
cable in the dummy connector. To use the signal, make sure to
supply a new connector, and then input it.
If the signal is input with the jumper cable connected, it does not
function, which may result in personal injury or equipment damage.
Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 4: Release of Emergency Stop
Turn
Observe the following precautions when performing teaching

operations within the manipulators operating range:
Always follow the predetermined operating procedure.
Keep in mind the emergency response measures against the
manipulators unexpected motion toward you.
Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
Confirm that no person is present in the manipulators operating
range and that you are in a safe location before:
Turning ON the FS100 power.
Moving the manipulator with the programming pendant.
Running the system in the check mode.
Performing automatic operations.
Injury may result if anyone enters the manipulators operating range
during operation. Always press the emergency stop button
immediately if there is a problem.
The emergency stop button is located on the right of the programming
pendant.
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CAUTION
Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately,
and be sure that all other necessary processing has been
performed.
Check for problems in manipulator movement.
Check for damage to insulation and sheathing of external wires.
For the DX100, always return the programming pendant to the hook
on the cabinet of the DX100 after use.
For the FS100, always return the programming pendant to a safe
place after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
Read and understand the Explanation of Warning Labels in the
DX100/FS100 Instructions before operating the manipulator:
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HP20D/HP20F
Definition of Terms Used Often in This Manual (DX100)

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller
Definition of Terms Used Often in This Manual (FS100)

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the FS100 controller,
manipulator cables, the FS100 programming pendant (optional), and the
FS100 programming pendant dummy connector (optional).
In this manual, the equipment is designated as follows:
Equipment Manual Designation
FS100 controller FS100
FS100 programming pendant Programming pendant
Cable between the manipulator Manipulator Cable
and the controller
FS100 programming pendant Programming pendant
dummy connector dummy connector
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Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Figure 5: Warning Labels Locations
WARNING Label B
WARNING Label A
WARNING Label B
Nameplate
Nameplate: WARNING Label A:
WARNING
Moving parts
may cause
injury
WARNING Label B:
WARNING
Do not enter
robot
work area.
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HP20D/HP20F
Table of Contents
1 Product Confirmation ...................................................................................................................... 1-1
1.1 Contents Confirmation ....................................................................................................... 1-1
1.2 Order Number Confirmation .............................................................................................. 1-2
2 Transport......................................................................................................................................... 2-1
2.1 Transport Method .............................................................................................................. 2-1
2.1.1 Using a Crane ...................................................................................................... 2-2
2.1.2 Using a Forklift...................................................................................................... 2-3
2.2 Cushioning Material for Transport ..................................................................................... 2-4
3 Installation....................................................................................................................................... 3-1
3.1 Safeguarding Installation ................................................................................................... 3-2
3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2
3.2.1 Mounting Example................................................................................................ 3-3
3.3 Ways of Mounting .............................................................................................................. 3-4
3.3.1 S-Axis Operating Range....................................................................................... 3-4
3.3.2 Fixing Manipulator Base ....................................................................................... 3-4
3.3.3 Precautions to Prevent Manipulator from Falling.................................................. 3-4
3.3.4 IP (International Protection) for Main Part of Manipulator .................................... 3-5
3.4 Location ............................................................................................................................. 3-5
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-1
4.2 Cable Connection .............................................................................................................. 4-2
4.2.1 Connection to Manipulator.................................................................................... 4-2
4.2.2 Connection to DX100/FS100................................................................................ 4-2
5 Basic Specifications ........................................................................................................................ 5-1
5.1 Basic Specifications........................................................................................................... 5-1
5.2 Part Names and Working Axes.......................................................................................... 5-2
5.3 Manipulator Base Dimensions ........................................................................................... 5-3
5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-4
5.5 Alterable Operating Range ................................................................................................ 5-5
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-3
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Table of Contents
7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.1.1 Allowable Load ..................................................................................................... 7-1
7.1.2 Installation Position............................................................................................... 7-1
7.2 Internal User I/O Wiring Harness and Air Line................................................................... 7-2
8 Electrical Equipment Specification .................................................................................................. 8-1
8.1 Position of Limit Switch ...................................................................................................... 8-1
8.2 Internal Connections .......................................................................................................... 8-2
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-2
9.2 Notes on Maintenance Procedures.................................................................................... 9-6
9.2.1 Battery Pack Replacement ................................................................................... 9-6
9.3 Notes on Grease Replenishment and Exchange Procedures ........................................... 9-8
9.3.1 Grease Replenishment and Exchange for S-Axis Speed Reducer ...................... 9-9
9.3.1.1 Grease Replenishment
(Refer to Fig.9-4 S-Axis Speed Reducer Diagram.) ................................ 9-9
9.3.1.2 Grease Exchange
(Refer to Fig. 9-4 S-Axis Speed Reducer Diagram on page 9-9.) ......... 9-10
9.3.2 Grease Replenishment and Exchange for L-Axis Speed Reducer..................... 9-11
(Refer to Fig.9-5 L-Axis Speed Reducer Diagram.)............................... 9-11
(Refer to Fig. 9-5 L-Axis Speed Reducer Diagram on page 9-11.) ....... 9-12
9.3.3 Grease Replenishment and Exchange for U-Axis Speed Reducer .................... 9-13
9.3.3.1 Grease Replenishment
(Refer to Fig.9-6 U-Axis Speed Reducer Diagram.) .............................. 9-13
(Refer to Fig. 9-6 U-Axis Speed Reducer Diagram on page 9-13.) ....... 9-14
9.3.4 Grease Replenishment for R-Axis Speed Reducer ............................................ 9-15
9.3.5 Grease Replenishment for B- and T-Axis Speed Reducers ............................... 9-16
9.3.6 Grease Replenishment for T-Axis Gear.............................................................. 9-17
9.3.7 Grease Replenishment for R-Axis Cross Roller Bearing .................................... 9-18
9.3.8 Notes for Maintenance........................................................................................ 9-19

9.3.8.1 Wrist Unit ............................................................................................... 9-19
9.3.8.2 Battery Pack Connection ....................................................................... 9-20
10 Recommended Spare Parts........................................................................................................ 10-1
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Table of Contents
11 Parts List .................................................................................................................................... 11-1
11.1 S-Axis Unit ..................................................................................................................... 11-1
11.2 L-Axis Unit ..................................................................................................................... 11-3
11.3 U-Axis Unit..................................................................................................................... 11-5
11.4 Wrist Unit ..................................................................................................................... 11-10
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HP20D/HP20F 1 Product Confirmation
1.1 Contents Confirmation
1 Product Confirmation
CAUTION
Confirm that the manipulator and the DX100/FS100 have the same
order number. Special care must be taken when more than one
manipulator is to be installed.
If the numbers do not match, manipulators may not perform as
expected and cause injury or damage.
1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following five (six or seven) items
(Information for the content of optional goods is given separately.):
For DX100:
Manipulator
DX100 (including spare parts)
Programming pendant
Manipulator cable (between the DX100 and the manipulator, 4 cables)
Set of instruction manuals
For FS100:
Manipulator
FS100 (including spare parts) 2 units (for R1 and R2)
Manipulator cable (between the FS100 and the manipulator, 4 cables)
Set of instruction manuals
Programming pendant (optional)
Programming pendant dummy connector (optional)
1-1
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HP20D/HP20F 1 Product Confirmation
1.2 Order Number Confirmation
1.2 Order Number Confirmation

Check that the order number of the manipulator corresponds to the
DX100/FS100. The order number is located on a label as shown below.
Fig. 1-1: Location of Order Number Labels
Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER Check that the manipulator

SHOULD HAVE SAME ORDER NUMBER.
and the DX100/FS100 have
the same order number.
ORDER NO.
DX100
TYPE ERDR-
ER
GE N
EM
POWER SUPPLY
Y
3PHASE AC200V 50/60Hz PEAK kVA

AC220V 60Hz AVERAGE kVA
INTERRUPT CURRENT kA
SERIAL No.
DATE
S
MADE IN JAPAN NJ2960-1
T O P
ON
D
PE
IP
TR
OFF
T
SE
RE
US
F
E
CN
ORDER NO.
NJ1529
FBB
CN210 CN211
(c) FS100 (Front View)
PROGRAMMING PENDANT
(a) DX100 (Front View) (b) Manipulator (Top View)
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HP20D/HP20F 2 Transport
2.1 Transport Method
2 Transport
CAUTION
Sling applications and crane or forklift operations must be
performed by authorized personnel only.
Failure to observe this caution may result in injury or damage.
Avoid 3G or more vibration or shock during transport.
The system consists of precision components. Failure to observe this
caution may adversely affect performance.
In case a message PULSE LIMIT appeared on the programming

pendant window after the manipulator is installed and the power supply is
turned ON, execute the following procedures for restoration.
1. From the alarm message, confirm that which axis has exceeded its
motion range.
2. Select VALID to {SOFT LIMIT RELEASE} on LIMIT RELEASE
window. (Refer to 8.10 Soft LImit Release Function in DX100
INSTRUCTIONS (162536-1CD) and 8.10 Soft LImit Release
Function in FS100 INSTRUCTIONS (159644-1CD) .
3. Move the axis mentioned in step one to return it into its motion range.
4. Select INVALID to {SOFT LIMIT RELEASE} on LIMIT RELEASE
window.
In case a message OUT OF RANGE(ABSO DATA) appeared, take
measures by following the instructions mentioned in 6.4 Setting the
Second Home Position (Check Point) in DX100 MAINTENANCE
MANUAL (155492-1CD) and 7.4 Setting the Second Home Position
(Check Point) in FS100 MAINTENANCE MANUAL (159645-1CD).
Check that the eyebolts are securely fastened.

The weight of the manipulator is approximately 280 kg
including the cushioning material for transport. Use a wire
rope strong enough to withstand the weight.
Attached eyebolts are designed to support the manipulator
NOTE mass. Do not use them for anything other than
transporting the manipulator.
Mount the cushioning material for transport to the
manipulator.
Avoid putting external force on the arm or motor unit when
transporting by a crane, forklift, or other equipment.
Failure to observe this instruction may result in injury.
2-1
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2.1.1 Using a Crane

As a rule, the manipulator should be lifted by a crane with two wire ropes
when removing it from the package and moving it. Be sure that the
manipulator is fixed with the cushioning material for transport, and lift it in
the posture as shown in Fig.2-1 Transporting Position.
Fig. 2-1: Transporting Position
Eyebolt M12 (2 eyebolts)

(Delivered with the manipulator)
Factory setting for angle and pulse of each axis

Axis S L U R B T
Angle
Pulse 0 -196244 -111514 81920 0 0
Eyebolt M12 (2 eyebolts)

View E
(Delivered with the manipulator)
B
E
A
F
View F
2-2
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2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet with
shipping bolts as shown in Fig.2-2 Using a Forklift. Insert claws under the
pallet and lift it. The pallet must be strong enough to support the
manipulator. Transport the manipulator slowly with due caution in order to
avoid overturning or slippage.
Fig. 2-2: Using a Forklift
Bolt M16
(4 places)
Pallet
Forklift claw entries
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2.2 Cushioning Material for Transport
2.2 Cushioning Material for Transport

The manipulator is provided with the cushioning materials for transport at
sections A and B. (See Fig.2-3 Cushioning Materials for Transport.)
Fig. 2-3: Cushioning Materials for Transport
Eyebolts M12 (2 eyebolts)

(delivered with the manipulator)
B
A
Enlarged View: Section A Enlarged View: Section B
A rubber cushion is respectively wedged at the sections A and B.
Before turning ON the power, check to be sure that the

cushioning materials for transport are removed.
NOTE In the event that the manipulator must be moved again, to
avoid its main body from being damaged, the cushioning
materials such as rubber plate, etc. must be used.
2-4
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HP20D/HP20F 3 Installation
3 Installation
WARNING
Install the safeguarding.
Failure to observe this warning may result in injury or damage.
Install the manipulator in a location where the tool or the workpiece
held by its fully extended arm will not reach the wall, safeguarding,
or controller.
Failure to observe this warning may result in injury or damage.
Do not start the manipulator or even turn ON the power before it is
firmly anchored.
The manipulator may overturn and cause injury or damage.
When mounting the manipulator on the wall, the base section must
have sufficient strength and rigidity to support the weight of the
manipulator. Also, it is necessary to consider countermeasures to
prevent the manipulator from falling.
Failure to observe these warnings may result in injury or damage.
CAUTION
Do not install or operate the manipulator that is damaged or lacks
parts.
Failure to observe this caution may cause injury or damage.
Before turning ON the power, check to be sure that the cushioning
materials for transport explained in Fig. 2-3 Cushioning Materials for
Transport on page 2-4 are removed.
Failure to observe this caution may result in damage to the driving
parts.
3-1
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3.1 Safeguarding Installation
3.1 Safeguarding Installation

To insure safety, be sure to install safeguarding. It prevents unforeseen
accidents with personnel and damage to equipment. Refer to the quoted
clause for your information and guidance.
Responsibility for Safeguarding (ISO10218)

The user of a manipulator or robot system shall ensure that safeguards
are provided and used in accordance with Sections 6, 7, and 8 of this
standard. The means and degree of safeguarding, including any
redundancies, shall correspond directly to the type and level of hazard
presented by the robot system consistent with the robot application.
Safeguarding may include but not be limited to safeguarding devices,
barriers, interlock barriers, perimeter guarding, awareness barriers, and
awareness signals.
3.2 Mounting Procedures for Manipulator Base

The manipulator should be firmly mounted on a baseplate or foundation
strong enough to support the manipulator and withstand repulsion forces
during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand
maximum repulsion forces of the manipulator referring to Table 3-1
Maximum Repulsion Forces of Manipulator at Emergency Stop and Table
3-2 Endurance Torque in Operation.
A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness
of installation surface may deform the manipulator shape and affect its
functional abilities. Mount the manipulator base as instructed in
chapter 3.2.1 Mounting Example at page 3-3.
Table 3-1: Maximum Repulsion Forces of Manipulator at Emergency Stop

Maximum torque in horizontal rotation 8000 Nm
(S-axis moving direction) (815 kgfm)
Maximum torque in vertical rotation 5000 Nm
(L-,U-axes moving direction) (510 kgfm)
Table 3-2: Endurance Torque in Operation

Endurance torque in horizontal operation 1700 Nm
(S-axis moving direction) (171 kgfm)
Endurance torque in vertical operation 3775 Nm
(L-,U-axes moving direction) (385 kgfm)
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3.2 Mounting Procedures for Manipulator Base
3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The
baseplate should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. It is recommend to prepare a
baseplate of 32 mm or more thickness, and anchor bolts of M16 or larger
size.
Next, fix the manipulator base to the baseplate. The manipulator base is
tapped for four mounting holes; securely fix the manipulator base to the
baseplate with four hexagon head bolts M16 (60 mm long is
recommended). Tighten the hexagon head bolts and anchor bolts firmly
so that they will not work loose during the operation.
Refer to Fig.3-1 Mounting Manipulator on Baseplate.
Fig. 3-1: Mounting Manipulator on Baseplate
Bolt M16 (4 bolts)

Spring washer
Washer
Manipulator base
25 Baseplate
40 mm
or more
Manipulator base
Anchor bolt (M16 or larger)

Baseplate
375
335
18 dia. holes 313 2000.1
(4 holes)
60
2000.1
250
335
375
60
1700.1
Baseplate
2600.1
+0.018
12 0 dia. holes (2 holes)
Manipulator Base
3-3
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3.3 Ways of Mounting
3.3 Ways of Mounting

The MOTOMAN-HP20D/HP20F is available in three ways of mounting:
floor-mounted way (standard), wall-mounted way, and ceiling-mounted
way. For wall-mounted and ceiling-mounted ways, the three points listed
below are different from the floor-mounted way.
S-Axis Operating Range
Fixing the Manipulator Base
Precautions to Prevent the Manipulator from Falling
IP (International Protection) for Main Part of the Manipulator
3.3.1 S-Axis Operating Range

For wall-mounted type, the S-axis operating range is 30.
(The range is adjusted prior to the shipment)
3.3.2 Fixing Manipulator Base

For wall- and ceiling-mounted types, be sure to use four hexagon socket
head cap screws M16 (tensile strength: 1200 N/mm2 or more) when fixing
the manipulator base. Use a torque of 206 Nm when tightening the
screws.
3.3.3 Precautions to Prevent Manipulator from Falling

For the wall- or ceiling-mounted types, take appropriate measures to avoid
the falling of the manipulator in case of emergency. Refer to Fig.3-2
Precaution Against Falling for details.
Fig. 3-2: Precaution Against Falling
Support for fall prevention
Manipulator base Hexagon socket head cap

screw M16 (4 places)
(Tensile strength: 1200 N/mm2 or more)
3-4
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3.4 Location
3.3.4 IP (International Protection) for Main Part of Manipulator

For wall-mounted or ceiling mounted ways, environmental resistance for
main part of the manipulator does not conform to IP54; environmental
resistance for IP65 is optionally available. However, the wrist part
conforms to IP67.
In case of using the wall-mounted or the ceiling-mounted

way, inform Yaskawa of the matter when placing an order.
Be sure to contact Yaskawa representative (listed on the
back cover of this instruction manual) to execute a wall or
NOTE ceiling installation on site.
Also, thoroughly read the instructions described in 8.4
ARM Control in both DX100 INSTRUCTIONS (162536-
1CD) and FS100 INSTRUCTIONS (159644-1CD) before
installing and using the manipulator.
3.4 Location
When the manipulator is installed, it is necessary to satisfy the following
environmental conditions:
Ambient temperature: 0 to + 45C
Humidity: 20 to 80%RH (non-condensing)
Free from dust, soot, oil, or water
Free from corrosive gas or liquid, or explosive gas or liquid.
Free from excessive vibration (Vibration acceleration: 4.9 m/s2
[0.5G] or less)
Free from large electrical noise (plasma)
Flatness for installation: 0.5 mm or less
3-5
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HP20D/HP20F 4 Wiring
4.1 Grounding
4 Wiring
WARNING
Ground resistance must be 100 or less.
Failure to observe this warning may result in fire or electric shock.
Before wiring, make sure to turn the primary power supply off, and
put up a warning sign. (e.g. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
4.1 Grounding
Follow electrical installation standards and wiring regulations for
grounding. A ground wire of 5.5 mm2 or more is recommended.
Refer to Fig. 4-1 Grounding Method on page 4-2 to connect the ground
line directly to the manipulator.
Never use this wire sharing with other ground lines or

grounding electrodes for other electric power, motor
power, welding devices, etc.
NOTE
Where metal ducts, metallic conduits, or distributing racks
are used for cable laying, ground in accordance with
electrical installation standards.
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4.2 Cable Connection
Fig. 4-1: Grounding Method
A
5.5 mm2 or more
Section A-A
Bolt M8 (For grounding)
Delivered with the manipulator

Two manipulator cables are delivered with the manipulator; an encoder
cable (1BC) and a power cable (2BC). (Refer to fig. 4-2(a) Manipulator
Cables (DX100) on page 4-3 and fig. 4-2(b) Manipulator Cables (FS100)
on page 4-3.)
Connect these cables to the manipulator base connectors and to the
DX100/FS100. Refer to fig. 4-3(a) Manipulator Cable Connectors
(Manipulator Side) on page 4-4, fig. 4-3(b) Manipulator Cable Connection
(DX100 Side) on page 4-4 and fig. 4-3(c) Manipulator Cable Connection
(FS100 Side) on page 4-4.
4.2.1 Connection to Manipulator

Before connecting cables to the manipulator, verify the numbers on both
manipulator cables and the connectors on the connector base of the
manipulator. When connecting, adjust the cable connector positions to
the main key positions of the manipulator, and insert cables in the order of
2BC, then 1BC. After inserting the cables, depress the lever until it clicks.
4.2.2 Connection to DX100/FS100

Before connecting cables to the DX100/FS100, verify the numbers on
both manipulator cables and the connectors on the DX100/FS100. When
connecting, connect the cables in the order of X21, then X11.
For the DX100, after inserting the connectors, depress each lever until it
clicks. For the FS100, insert each connector until it clicks.
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Fig. 4-2(a): Manipulator Cables (DX100)
DX100 side Manipulator side
1BC
X11
X11 1BC
1BC
Encoder cable
DX100 side Manipulator side
2BC
X21
2BC
X21
2BC
Power cable
Fig. 4-2(b): Manipulator Cables (FS100)
FS100 side Manipulator side
1BC
X11
1BC
X11
1BC
molex
Encoder cable
FS100 side Manipulator side

2BC
X21
2BC
X21
2BC
Power cable
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Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)
2BC
1BC
3BC
Connector Details
(Manipulator Side)
Fig. 4-3(b): Manipulator Cable Connection (DX100 Side)
X11
X21
Fig. 4-3(c): Manipulator Cable Connection (FS100 Side)
X21 X11
Back View
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HP20D/HP20F 5 Basic Specifications
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table 5-1: Basic Specifications1)
Item Model MOTOMAN-HP20D/HP20F
Structure Vertically articulated
Degree of Freedom 6
Payload 20 kg
2) 0.06 mm
Repeatability
Range of Motion S-Axis (turning) -180 - +180
L-Axis (lower arm) -110 - +155
U-Axis (upper arm) -165 - +255
R-Axis (wrist roll) -200 - +200
B-Axis (wrist pitch/yaw) -50 - +230
T-Axis (wrist twist) -360 - +360
Maximum Speed S-Axis 3.44 rad/s, 197/s
L-Axis 3.05 rad/s, 175/s
U-Axis 3.58 rad/s, 205/s
R-Axis 6.98 rad/s, 400/s
B-Axis 6.98 rad/s, 400/s
T-Axis 10.47 rad/s, 600/s
3)
Allowable Moment R-Axis 39.2 Nm (4 kgfm)
B-Axis 39.2 Nm (4 kgfm)
T-Axis 19.6 Nm (2 kgfm)
2/4)
Allowable Inertia (GD R-Axis 1.05 kgm2
B-Axis 1.05 kgm2
T-Axis 0.75 kgm2 5)
Approx. Mass 257 kg
4)
Ambient Conditions Temperature 0C to 45C
Humidity 20 to 80% RH (non-condensing)
Vibration Acceleration 4.9 m/s2 or less (0.5G)
Others Free from corrosive gas or liquid, or explosive gas or liquid
Free from exposure to water, oil, or dust
Free from excessive electrical noise (plasma)
Power Requirements 2.0 kVA
1 SI units are used in this table. However, gravitational unit is used in (
).
2 Conformed to ISO9283
3 Refer to table chapter 6.1 Allowable Wrist Load on page 6-1 for details on the permissible moment
of inertia.
4 Conformed to IP54 for the main part of the manipulator (only floor-mounted type). Conformed to
IP67 for the wrist part (IP65 for the main part is optional.)
5 The allowable inertia of T-axis varies depending on the added value of the moment. Refer to
chapter 6.1 Allowable Wrist Load on page 6-1 for the details.
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5.2 Part Names and Working Axes
5.2 Part Names and Working Axes

Fig. 5-1: Part Names and Working Axes
U-arm
U+
R+ B+
T+
Wrist flange
U- T-
R- B-
L- L+
L-arm
S-head
Manipulator base
S+
S-
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5.3 Manipulator Base Dimensions
5.3 Manipulator Base Dimensions

Fig. 5-2: Manipulator Base Dimensions
2000.1
Fitting surface 60
2000.1
60
25
A
Fitting surface
375
335
18 dia. holes (4 holes) 313
(for manipulator fixing)
335
375
395.5
250
1700.1
195.5
12 +0.018
0 dia. holes 2600.1
View A (2 holes)
Units: mm
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5.4 Dimensions and P-Point Maximum Envelope
5.4 Dimensions and P-Point Maximum Envelope

Fig. 5-3: Dimensions and P-Point Maximum Envelope
180
7
71
R1
150
1
42
R
4
R31
180
View A
A
1323
1717
1417
459
635
514
349
807
413
288
2072
Lamp (optional) P-point
150 795 138.5

87.5
80
105
140

81
L-axis 1003
421
1485
760
768 264 157

0
11
155
505
505
334

255
238
0
0
31
P-point maximum
envelope
165
559 524
917
991
260
807
471
0
Note:
This figure shows the standard specification
manipulator in the home position.
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5.5 Alterable Operating Range
5.5 Alterable Operating Range

The operating range of the S-axis can be altered in accordance with the
operating conditions as shown in Table 5-2 S-Axis Operating Range.
If alteration is necessary, contact your Yaskawa representative in
advance.
Table 5-2: S-Axis Operating Range

Item Specifications
S-Axis Operating -180 - +180 (standard)
Range -150 - +150
-120 - +120
-90 - +90
-60 - +60
-30 - +30
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HP20D/HP20F 6 Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist Flange

The allowable wrist load is 20 kg maximum. If force is applied to the wrist
instead of the load, force on R-, B-, and T-axes should be within the value
shown in Table 6-1 Allowable Wrist Load. Contact your Yaskawa
representative for further information or assistance.
Table 6-1: Allowable Wrist Load

Axis Moment Nm (kgfm)1) GD2/4 Total Moment of Inertia kgm2
R-Axis 39.2 (4) 1.05
B-Axis 39.2 (4) 1.05
1 ( ): Gravitational unit
The allowable moments of inertia for R-axis and B-axis are calculated
when the moment is at the maximum. The allowable moment of inertia for
T-axis varies depending on the moment, as shown in Fig.6-1 T-axis
Allowable Moment of Inertia (Value from Rotation Center of T-axis Flange
Surface). Use the manipulator to meet those conditions.
For example, with MOTOMAN-HP20D/HP20F, the allowable moment of
inertia for the T-axis is 0.25 kgm2 when the moment is 19.6 Nm, and
0.75 kgm2 when 0 Nm.
When the volume load is small, refer to the moment arm rating shown in
Fig. 6-2 Moment Arm Rating on page 6-2.
Fig. 6-1: T-axis Allowable Moment of Inertia (Value from Rotation Center of T-axis Flange Surface)
20
19.6
15
Moment (Nm)
10
0
0.25 0.75
0 0.3 0.6 0.9
Total Inertia GD2 /4 Kgm 2
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Fig. 6-2: Moment Arm Rating
Load gravity position

LB
105
LT
R-, T-axis
rotation center
B-axis rotation center

300
T L (mm) 200
W=6Kg
W=10Kg
W=16Kg
100
W=20Kg
0 100 200 300 400

LB (mm)
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6.2 Wrist Flange
6.2 Wrist Flange

The wrist flange dimensions are shown in Fig.6-3 Wrist Flange.
In order to see the alignment marks, it is recommended that the
attachment be mounted inside the fitting. Fitting depth of inside and
outside fittings must be 5 mm or less.
Fig. 6-3: Wrist Flange
Alignment mark
0.5 6
45
Tapped holes M6
(depth: 10)
(pitch: 1.0) (4 holes)
50 -0.039 dia.
dia.
+0.021
0
6
0
P.C
25
.D4
0
Units: mm
6 +0.012
0 dia. hole
(depth: 6)
View A
Wash off anti-corrosive paint (yellow) on the wrist flange

surface with thinner or light oil before mounting the tools.
NOTE Mount the attachment with the mounting bolts (length: 10
mm or less).
Failure to observe this instruction may affect the
manipulator performance.
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HP20D/HP20F 7 System Application
7.1 Peripheral Equipment Mounts
7 System Application
7.1 Peripheral Equipment Mounts

The peripheral equipment mounts are provided on the U-axis (upper arm)
and S-axis (rotary head) as shown in Fig. 7-4 Installing Peripheral
Equipment on page 7-1 for easier installation of the userss system
applications. The following conditions shall be observed to attach or
install peripheral equipment.
7.1.1 Allowable Load

The maximum allowable load on the U-axis is 31 kg, including the wrist
load.
For instance, when the mass installed on the wrist point is 20 kg, the mass
which can be installed on the upper arm is 11 kg.
7.1.2 Installation Position

There is a limitation on the installation position.
Fig. 7-5 Allowable Load on U-axis on page 7-1 shows the distance
between the center of U-axis rotation and the load gravity.
Fig. 7-4: Installing Peripheral Equipment
A
Units: mm
W2 Z-coordinate
Limited dimension direction
of Z-coordinate: W1
220
400 at a maximum 70
X-coordinate
direction
Center of U-axis rotation
70
Rotating base
View A
Fig. 7-5: Allowable Load on U-axis

(kg)
30
W1=6kg
W1=10kg
20
W1=16kg
Weight W2
W1=20kg*1 *1 In this case, unbalanced
10 moment is not permitted.
0
-200 -100 0 100 200 300 400 500 (mm)
Distance between Center of U-axis
Rotation and Load Gravity (X direction)
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7.2 Internal User I/O Wiring Harness and Air Line

Internal user I/O wiring harness (14 wires: 0.2 mm2 x 8 wires and 1.25
mm2 x 6 wires), and an air line are incorporated in the manipulator for the
drive of peripheral devices mounted on the upper arm as shown in Fig.7-6
Connectors for Internal User I/O Wiring Harness and Air Line.
The connector pins 1 to 16 are assigned as shown in Fig. 7-7 Details of
the Connector Pin Numbers on page 7-3 on the following page. Wiring
must be performed by users.
The allowable current for internal user 3 A or less for each wire
I/O wiring harness (The total current value for pins 1 to 16
must be 40 A or less.)
The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0 mm)
Fig. 7-6: Connectors for Internal User I/O Wiring Harness and Air Line
Exhaust port (air flow): A

Tapped hole PT3/8 with
pipe plug Connector for internal user I/O
wiring harness: JL05-2A20-29SC
(socket connector with a cap)
Air inlet: Tapped hole
Prepare pin connector
PT3/8 with pipe plug
JL05-6A20-29P.
2BC
1BC
3BC
Connector for internal

user I/O wiring harness:
JL05-2A20-29PC
(pin connector with a cap)
Prepare socket connector View A
JL05-6A20-29S.
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Fig. 7-7: Details of the Connector Pin Numbers
Connector for Internal User I/O Wiring Harness

on the Connector Base
1
2
3
4
5 1
6 2 3
5 6
7 (Open) 4
Pins used 8 (Open) 7 8 10
9 9
10 11 12
13 14
11 (1.25 mm2)
12 (1.25 mm2) 16
13 (1.25 mm2) 15
14 2
15 (1.25 mm )
16 (1.25 mm2)
Internal user I/O wiring harness: 0.2 mm2, 8 wires

: 1.25 mm2, 6 wires
Connector for Internal User I/O Wiring Harness

on the U-arm
1
2
3
4
5 1
6 2 3
7 (+24V: for shock sensor) 4 5 6
Pins used 8 (For DX100: shock sensor signal input 7 8
9 For FS100: Not used) 9 10
10 11 12
11 (1.25 mm ) 2 13 14
12 (1.25 mm2)
13 15 16
14 (1.25 mm2)
15 (1.25 mm2)
16 (1.25 mm2)
Internal user I/O wiring harness: 0.2 mm2, 8 wires
: 1.25 mm2, 6 wires
For the standard specification, the pins No.7 and No.8 of

3BC connector on the U-arm are respectively connected
with the shock sensor power supply and shock sensor
signal input port of the DX100/FS100 controller.
NOTE The pins No.7 and No.8 of respective 3BC connectors on

the connector base side and the U-arm side are not
connected with each other.
For wiring, refer to fig. 8-3(a) Internal Connection Diagram
(DX100) on page 8-3 and fig. 8-3(c) Internal Connection
Diagram (FS100) on page 8-5.
The same numbered pins (1 to 16) of the two connectors are connected
with a single lead wire of 0.2 mm2 or 1.25 mm2.
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HP20D/HP20F 8 Electrical Equipment Specification
8.1 Position of Limit Switch
8 Electrical Equipment Specification
8.1 Position of Limit Switch

The limit switches are optional. See Fig.8-1 Location of Limit Switches.
The manipulators with S- and L-axis overrun limit switches, and LU-axis
interference limit switch are the types YR-HP0020D-A01 and YR-
HP0020F-A01.
Fig. 8-1: Location of Limit Switches
LU-axes interference
limit switch (optional)
L-axis interference
S-axis overrun
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HP20D/HP20F 8 Electrical Equipment Specification
8.2 Internal Connections
8.2 Internal Connections

Highly reliable connectors are equipped on each connection part of the
manipulator to enable easy removal and installation for maintenance and
inspection. For the number and location of connectors, see Fig.8-2
Locations and Numbers of Connectors.
Diagrams for Internal connections of the manipulator are shown in fig. 8-
3(a) Internal Connection Diagram (DX100) on page 8-3, fig. 8-3(b) Internal
Connection Diagram (DX100) on page 8-4, fig. 8-3(c) Internal Connection
Diagram (FS100) on page 8-5, and fig. 8-3(d) Internal Connection
Diagram (FS100) on page 8-6.
Fig. 8-2: Locations and Numbers of Connectors
3BC (For internal user

I/O wiring harness)
3BC (For internal user

I/O wiring harness)
Table 8-1: List of Connector Types

Name Type of Connector
Connector for the internal user I/O JL05-2A20-29PC
wiring harness on the connector base (JL05-6A20-29S: Optional)
Connector for the internal user I/O JL05-2A20-29SC
wiring harness on the U-arm (JL05-6A20-29P: Optional)
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HP20D/HP20F 8.2 Internal Connections
Fig. 8-3(a): Internal Connection Diagram (DX100)

POWER CABLE INTERNAL CABLE IN S-AXIS INTERNAL CABLE IN L-AXIS INTERNAL CABLE IN BT-AXIS
<NOTES>
- For the limit switch specification, the connection of the section A is changed as follows:
0BT 1 0BAT11 17 0BAT1
P BAT
0BT
2
3
BAT11
0BAT12
18
19
BAT1
0BAT2
- For the IP65 specification, the connection of the section A and B are changed as follows:
P BAT 4 BAT12 20 BAT2
21 0BAT3
22 BAT3 S-AXIS OVERRUN L.S
LA1 LA1
23 LB1
24 LB1 LB1 LA2 LA2
0BT 5 0BAT21 25 0BAT4 L-AXIS OVERRUN L.S
P BAT
0BT
6
7
BAT21
0BAT22
26
27
BAT4
P LA3
LB2
A
P BAT 8 BAT22 28 LB3 LB3 L AND U-AXIS INTERFERENCE L.S
29 S-AXIS OVERRUN L.S
30 LC1 LC1
1 31 LD1
2 32 LD1 LD1 LC2 LC2
3 1 PG0V1 LD2 L-AXIS OVERRUN L.S
4
5
2
3
PG5V1
PG0V2
P LC3
LD3 LD3 L AND U-AXIS INTERFERENCE L.S
6 4 PG5V2
7
8
5
6
PG0V3
PG5V3 SLU-axes with Overrun Limit Switch Specification
7 PG0V4
8 PG5V4
1BC(10X4)
DX100 9
10
PG0V5
PG5V5 LB1 LB1 LB1 LB1 LA1 LA1 LA2
A
LA2
CN1-5 CN1-5 +24V 1 11 PG0V6 L-AXIS OVERRUN L.S
S-AXIS OVERRUN L.S LB2
CN1-4 P CN1-4 0V 3 12
13
PG5V6
LA1 LA1 P P LA3
CN1-10 CN1-10 +24V 2 14 LB1 LB3 LB3 L AND U-AXIS INTERFERENCE L.S
CN1-9 P CN1-9 0V 4 15
16 No.20CN
CN1-1 CN1-1 SPG+1 20CN-1 DATA+1
LD1 LD1 LD1 LD1 LC1 LC1 LC2 LC2
CN1-2 P CN1-2 SPG-1 P -2 DATA-1
-6 BAT S-AXIS OVERRUN L.S LD2 L-AXIS OVERRUN L.S
P -5 OBT PG S-AXIS LC1 LC1 P P LC3
-4 +5V
P -9 0V
LD1 LD3 LD3 L AND U-AXIS INTERFERENCE L.S
CN1-3 CN1-3 FG1 -10 FG1
OBT
SLU-axes with Overrun Limit Switch Specification (IP65 specification)
BAT
No.21CN
-6 BAT
P -5
-4
OBT
+5V
PG L-AXIS - For the standard specification, the pins No.7 and No.8 of 3BC connector on the U-arm are
CN1-8 CN1-8 FG2
P -9
-10
0V
FG2 respectively connected with the shock sensor power supply and the shock sensor signal input
OBT
BAT port of the DX100 controller.
No.5CN No.22CN
CN2-1 CN2-1 SPG+3 5CN-1 DATA+3 22CN-1 DATA+3
CN2-2 P CN2-2 SPG-3 P -2 DATA-3 P -2 DATA-3
P
-3
-4
BAT
OBT P
-6
-5
BAT
OBT PG Pin No. DX100 Connection Port
6CN-1 +5V -4 +5V U-AXIS
CN2-3 CN2-3 FG3
P -2
-3
0V
FG3
P -9
-10
0V
FG3
7 Shock sensor power supply; +24V (1A)
No.6CN OBT
BAT 8 Shock sensor signal input
No.23CN
1BC(10X4) P P
-3
-4
BAT
OBT PG R-AXIS
24CN-1 +5V
P -2 0V
CN2-8 CN2-8 FG4 -3 FG4
OBT
BAT
No.7CN No.14CN
CN3-1 CN3-1 SPG+5 7CN-1 DATA+5 14CN-1 DATA+5
-2 BAT -3 BAT
P -8 OBT P -4 OBT PG B-AXIS
-3 +5V 15CN-1 +5V
P -9 0V P -2 0V
CN3-3 CN3-3 -3 FG5
FG5
OBT
BAT
No.16CN
CN3-6 CN3-6 SPG+6 -4 DATA+6 16CN-1 DATA+6
-3 BAT
P -4 OBT PG T-AXIS
-5 +5V 17CN-1 +5V
P -11 0V P -2 0V
CN3-8 CN3-8 -6 FG6 -3 FG6
FG6
OBT
BAT
CN4-1 CN4-1 +24V LA1 LB1

CN4-6 P CN4-6 LB1 P LB3 LA2 - When connecting the pin No.7 and No.8 of the connector base respectively with the pin No.7 and No.8
CN4-2 CN4-2 A
of 3BC connectors on the U-arm, the connection of crimped contact-pins (SS1, SS2) should be changed
SS2
CN4-7 P CN4-7 AL1 LC1 LD1
P LD3 LC2
CN4-3 CN4-3 BC2 as shown in the section C below.

CN4-8 P CN4-8
(Contact your Yaskawa representative when modifying the wiring before use.)
AL2
CN4-10 CN4-10 0V
P FOR LAMP(OPTION)
CN2-4 CN2-4 SPG+7
CN2-5 P CN2-5 SPG-7
POWER CABLE INTERNAL CABLE
CN2-9 CN2-9 CONNECTOR BASE U-ARM
CN2-10 P CN2-10 +24V
LB1 LB1 LB1 LB1
CN3-4 CN3-4
LA1 LA1 P
P LB3 LA2
DX100 1BC(10X4)
0V
CN3-5 P CN3-5 +5V
LD1 LD1 LD1 LD1
LC1 LC1 P
CN3-9
CN3-10 P
CN3-9
CN3-10
0V
+5V
P LD3 LC2 Casing
CN4-1 CN4-1 24V(1A) SS1
Section A for IP65 Specification CN4-2 CN4-2 SS2 SS2
Crimped
E
C
E E
CN4-4 CN4-4 +24V
CN4-5 P CN4-5 LD1 E E E
CN4-9 CN4-9 Contact-Pin
FG7
E Base
E
E
Base 3BC(20-29) 3BC(20-29)
Casing E E E E
E E UNUSED
3BC-1 1 1 1 1 1 1 3BC-1
3BC(20-29) -2 2 2 2 P 2 2 P 2 -2
3BC(20-29) -3 3 3 3 3 3 3 -3
E E E -4 4 4 4 P 4 4 P 4 -4
-5 5 5 5 5 -5
-6 6 6 6 P 6 -6
3BC-1 1 1 1 1 1 3BC-1 -7 7 7 SS1 SS1 SS1 7 -7
-2 2 2 2 P 2 2 P 2 -2 -8 8 8 SS2 P SS2 SS2 P 8 -8
-3 3 3 3 3 3 3 -3 -9 9 9 -9
-4 4 4 4 P 4 4 P 4 -4 -10 10 P 10 -10
-11 11 11 -11
-5 5 5 5 5 -5 -12 12 12 -12
-6 6 6 6 P 6 -6 -13 13 13 -13
-7 7 7 SS1 SS1 SS1 SS1 7 -7 -14 14 14 -14
-8 8 8 SS2 SS2 P SS2 SS2 P 8 -8 FOR SPARE CABLE -15 15 15 -15
-16 16 16 -16
-9 9 9 -9
-10 10 P 10 -10
-11 11 11 -11
-12 12 12 -12
-13 13 13 -13
-14 14 14 -14
-15 15 15 -15
-16 16 16 -16
C B
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Fig. 8-3(b): Internal Connection Diagram (DX100)
2BC(6X6) FOR SPARE CABLE

Casing
E 3BC(20-29)
E
E E
No.3CN
CN1-1 CN1-1 ME1 No.8CN
3CN-3 MU1
8CN-1 1 1 1 1 3BC-1
CN1-2 CN1-2 ME2 -2 MV1 P 2 2 P 2 -2
SM S-AXIS 2 2
CN1-3 CN1-3 ME2 -1 MW1
3 3
3 3 3 -3
CN1-4 CN1-4 MU1 -PE ME1 P 4 4 P 4 -4
4 4
CN1-5 CN1-5 MV1 -4 BA1
5 5
5 -5
CN1-6 CN1-6 MW1 -5 BB1 YB P 6 -6
6 6
7 7
SS1 SS1 7 -7
No.4CN 8 8
P SS2 SS2 P 8 -8
CN2-1 CN2-1 MU2 4CN-1-A MU2
9 9
9 -9
CN2-2 CN2-2 MV2 -B MV2 P 10 -10
SM L-AXIS 10 10
-11
CN2-3 CN2-3 MW2 -C MW2
9CN-1 1
11
CN2-4 CN2-4 MU2 -D ME2
2 2
12 -12
CN2-5 CN2-5 MV2 -1 BA2
3 3
13 -13
CN2-6 CN2-6 MW2 -2 BB2 YB 4 4
14 -14
5 5
15 -15
6 6
16 -16
No.9CN
Section B for IP65 Specification

No.26CN
CN3-1 CN3-1 MU3 26CN-3 MU3
CN3-2 CN3-2 MV3 -2 MV3
U-AXIS
CN3-3 CN3-3 MW3 -1 MW3
SM
CN3-4 CN3-4 MU4 -PE ME3
CN3-5 CN3-5 MV4 -4 BA3
CN3-6 CN3-6 MW4 -5 BB3 YB
2BC(6X6)
No.25CN
CN4-1 CN4-1 MU5 25CN-1 MU4
CN4-2 CN4-2 MV5 -2 MV4
SM R-AXIS
CN4-3 CN4-3 MW5 -3 MW4
CN4-4 CN4-4 MU6 -4 ME4
CN4-5 CN4-5 MV6 -1 BA4
CN4-6 CN4-6 MW6 -2 BB4 YB
No.35CN No.18CN
No.10CN
CN5-1 CN5-1 ME3 10CN-1 MU5 18CN-1 MU5
CN5-2 CN5-2 ME4 -2 MV5 -2 MV5
SM
CN5-3 CN5-3 ME5 -3 MW5 -3 MW5 B-AXIS
CN5-4 CN5-4 ME6 -4 ME5 -4 ME5
CN5-5 CN5-5 BA1 -1 BA5
CN5-6 CN5-6 BB1 -2 BB5 YB
No.36CN
No.19CN
CN6-1 CN6-1 BA2 -5 MU6 19CN-1 MU6
CN6-2 CN6-2 BA3 -6 MV6 -2 MV6
SM
CN6-3 CN6-3 BA4 -7 MW6 -3 MW6 T-AXIS
CN6-4 CN6-4 BB4 -8 ME6 -4 ME6
CN6-5 CN6-5 BA5 -1 BA6
CN6-6 CN6-6 BA6 No.12CN -2 BB6 YB
12CN-1 BA5 No.37CN
-2 BB5
-3 BA6
-4 BB6
PE
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Fig. 8-3(c): Internal Connection Diagram (FS100)
<NOTES>
- For the limit switch specification, the connection of the section A is changed as follows:
S-AXIS OVERRUN L.S
LA1 LA1
LB1
LB1 LB1 LA2 LA2
LB2 L-AXIS OVERRUN L.S
0BT 1 0BAT11 17 0BAT1 P LA3
K R P BAT 2 BAT11 18 BAT1 LB3 LB3 L AND U-AXIS INTERFERENCE L.S
0BT 3 0BAT12 19 0BAT2 S-AXIS OVERRUN L.S
K R P BAT 4 BAT12 20 BAT2 LC1 LC1
21 0BAT3 LD1
22 BAT3 LD1 LD1 LC2 LC2
23 LD2 L-AXIS OVERRUN L.S
0BT 5 0BAT21
24
25 0BAT4
P LC3
LD3 LD3 L AND U-AXIS INTERFERENCE L.S
K R P BAT 6 BAT21 26 BAT4
0BT 7 0BAT22 27
K R P BAT 8 BAT22 28 Section A SLU-axes with Overrun Limit Switch Specification
29
30
1 31
2 32 LB1 LB1 LB1 LB1 LA1 LA1 LA2 LA2
3 1 PG0V1 S-AXIS OVERRUN L.S LB2 L-AXIS OVERRUN L.S
4
5
2
3
PG5V1
PG0V2 LA1 LA1 P P LA3
6 4 PG5V2 LB1 LB3 LB3 L AND U-AXIS INTERFERENCE L.S
7 5 PG0V3
8 6 PG5V3
7 PG0V4 LD1 LD1 LD1 LD1 LC1 LC1 LC2
LC2
8 PG5V4 S-AXIS OVERRUN L.S LD2 L-AXIS OVERRUN L.S
1BC(10X4) 9 PG0V5
FS100 10 PG5V5 LC1 LC1 P P LC3
B2 CN1-5 +24V 1 11 PG0V6 LD1 LD3 LD3 L AND U-AXIS INTERFERENCE L.S
B1 P CN1-4 0V 3 12 PG5V6
B4 CN1-10 +24V 2
13
14
Section A SLU-axes with Overrun Limit Switch Specification (IP65 specification)
B3 P CN1-9 0V 4 15
16 No.20CN
A1 CN1-1 SPG+1 20CN-1 DATA+1
A2 P CN1-2 SPG-1 P -2 DATA-1
-6 BAT
P -5 OBT PG S-AXIS
-4 +5V
P -9 0V
A3 CN1-3 FG1 -10 FG1
OBT
BAT
No.21CN
A4 CN1-6 SPG+2 21CN-1 DATA+2
A5 P CN1-7 SPG-2 P -2 DATA-2
-6 BAT
P -5 OBT PG L-AXIS
-4 +5V
P -9 0V
A6 CN1-8 FG2 -10 FG2
OBT
BAT
No.5CN No.22CN
C1 CN2-1 SPG+3 5CN-1 DATA+3 22CN-1 DATA+3
C2 P CN2-2 SPG-3 P -2 DATA-3 P -2 DATA-3
-3 BAT -6 BAT
P -4 OBT P -5 OBT PG
6CN-1 +5V -4 +5V U-AXIS
P -2 0V P -9 0V
C3 CN2-3 FG3 -3 FG3 -10 FG3
No.6CN OBT
BAT
No.23CN
C4 CN2-6 SPG+4 23CN-1 DATA+4
C5 P CN2-7 SPG-4 P -2 DATA-4
1BC P P
R
K
-3
-4
BAT
OBT PG R-AXIS
24CN-1 +5V
P -2 0V
C6 CN2-8 FG4 -3 FG4
OBT
BAT
No.7CN No.14CN
E1 CN3-1 SPG+5 7CN-1 DATA+5 14CN-1 DATA+5
E2 P CN3-2 SPG-5 P -7 DATA-5 P -2 DATA-5
R -2 BAT -3 BAT
P K -8 OBT P -4 OBT PG B-AXIS
-3 +5V 15CN-1 +5V
P -9 0V P -2 0V
E3 CN3-3 -3 FG5
FG5
OBT
BAT
No.16CN
E4 CN3-6 SPG+6 -4 DATA+6 16CN-1 DATA+6
E5 P CN3-7 SPG-6 P -10 DATA-6 P -2 DATA-6
-3 BAT
P -4 OBT PG T-AXIS
-5 +5V 17CN-1 +5V
P -11 0V P -2 0V
E6 CN3-8 -6 FG6 -3 FG6
FG6
OBT
BAT
D3 CN4-1 +24V LA1 LB1

D4 P CN4-6 OT_1+ P LB3 LA2
B5 CN4-2 NC A
D1 P CN4-7 NC LC1 LD1
P LD3 LC2
F6 CN4-3 LAMP-
D2 P CN4-8 NC
F2 CN4-10 0V
U
P V FOR LAMP(OPTION)
D5 CN2-4 NC
D6 P CN2-5 NC
B6 CN2-9 NC
F1 CN2-10 OT_1-
LB1 LB1 LB1 LB1
LA1 LA1 P
G1 CN3-4 P LB3 LA2
NC
G2 P CN3-5 NC
LD1 LD1 LD1 LD1
G3 CN3-9 LC1 LC1 P
NC P LD3 LC2
F3 P CN3-10
NC
G4 CN4-4 OT_2+
Section A for IP65 specification
G5 P CN4-5 OT_2-
G6 CN4-9 NC
E
E
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Fig. 8-3(d): Internal Connection Diagram (FS100)
E E
E
Base
Casing
E E FOR SPARE CABLE
3BC(20-29) 3BC(20-29)
E E E
3BC-1 1 1 1 1 K 1 3BC-1
-2 2 2 2 P 2 2 R P 2 -2
-3 3 3 3 3 3 K 3 -3
-4 4 4 4 P 4 4 R P 4 -4
-5 5 5 5 5 -5
-6 6 6 6 P 6 -6
-7 7 7 SS1 SS1 SS1 SS1 K 7 -7
-8 8 8 SS2 SS2 P SS2 SS2 R P 8 -8
-9 9 9 -9
-10 10 P 10 -10
-11 11 11 -11
-12 12 12 -12
-13 13 13 -13
-14 14 14 -14
-15 15 15 -15
-16 16 16 -16
C Item-A B
2BC(6X6) FOR SPARE CABLE
E
Casing 3BC(20-29)
E
E E
No.3CN
ME1 No.8CN
A5 CN1-1 3CN-3 MU1
8CN-1 1
K 1 1 K 1 3BC-1
H6 CN1-2 ME2 -2 MV1
SM S-AXIS 2 2
R P 2 2 R P 2 -2
G6 CN1-3 ME2 -1 MW1
3 3
K 3 3 K 3 -3
A2 CN1-4 MU1 -PE ME1
4 4
R P 4 4 R P 4 -4
A3 CN1-5 MV1 -4 BA1
5 5
K 5 -5
A4 CN1-6 MW1 -5 BB1 YB R P 6 -6
6 6
7 7
K SS1 SS1 K 7 -7
No.4CN 8 8
R P SS2 SS2 R P 8 -8
B6 CN2-1 MU2 4CN-1 -A MU2
9 9
K 9 -9
D6 CN2-2 MV2 -B MV2 R P 10 -10
SM L-AXIS 10 10
-11
F6 CN2-3 MW2 -C MW2
9CN-1 1
11
A6 CN2-4 MU2 -D ME2
2 2
12 -12
C6 CN2-5 MV2 -1 BA2
3 3
13 -13
E6 CN2-6 MW2 -2 BB2 YB 4 4
14 -14
5 5
15 -15
6 6
16 -16
No.9CN
Section B for IP65 Specification

No.26CN
H5 CN3-1 MU3 26CN-3 MU3
H4 CN3-2 MV3 -2 MV3
H3 CN3-3 MW3 -1 MW3
SM U-AXIS
H1 CN3-4 MU4 -PE ME3
G1 CN3-5 MV4 -4 BA3
F1 CN3-6 MW4 -5 BB3 YB
2BC
No.25CN
D1 CN4-1 MU5 25CN-1 MU4
C1 CN4-2 MV5 -2 MV4
SM R-AXIS
B1 CN4-3 MW5 -3 MW4
C2 CN4-4 MU6 -4 ME4
C3 CN4-5 MV6 -1 BA4
C4 CN4-6 MW6 -2 BB4 YB
No.35CN No.18CN
No.10CN
H2 CN5-1 ME3 10CN-1 MU5 18CN-1 MU5
E1 CN5-2 ME4 -2 MV5 -2 MV5
SM B-AXIS
A1 CN5-3 ME5 -3 MW5 -3 MW5
C5 CN5-4 ME6 -4 ME5 -4 ME5
D5 CN5-5 BA1 -1 BA5
D4 CN5-6 BB1 -2 BB5 YB
No.36CN
No.19CN
D3 CN6-1 BA2 -5 MU6 19CN-1 MU6
E5 CN6-2 BA3 -6 MV6 -2 MV6
SM T-AXIS
E3 CN6-3 BA4 -7 MW6 -3 MW6
E2 CN6-4 BB4 -8 ME6 -4 ME6
F5 CN6-5 BA5 -1 BA6
F3 CN6-6 BA6 No.12CN -2 BB6 YB
12CN-1 BA5 No.37CN
-2 BB5
-3 BA6
-4 BB6
PE
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HP20D/HP20F 9 Maintenance and Inspection
9 Maintenance and Inspection
WARNING
Before maintenance or inspection, be sure to turn the main power
supply OFF, and put up a warning sign. (e.g. DO NOT TURN THE
POWER ON.)
Failure to observe this warning may result in electric shock or injury.
CAUTION
Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
For disassembly or repair, contact your Yaskawa representative.
The battery pack must be connected before removing detection
connector when maintenance and inspection.
Failure to observe this caution may result in the loss of home position
data.
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9.1 Inspection Schedule
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 intervals are classified into six
levels as shown in Table 9-1 Inspection Items on page 9-3.
In Table 9-1 Inspection Items on page 9-3, the inspection items are
categorized by three types of operations: operations which can be
performed by personnel authorized by the user, operations to be
performed by trained personnel, and operations to be performed by
service company personnel. Only specified personnel shall perform the
inspection work.
The inspection interval depends on the total servo

operation time.
The following inspection schedule is based on the case
where the manipulator is used for arc welding application.
If the manipulator is used for other application or if it is
used under special conditions, a case-by-case
examination is required.
NOTE The inspection may be conducted at shorter intervals if the
manipulator is used very frequently for the application
such as handling; in this case, contact your Yaskawa
representative.
In Table 9-2 Inspection Parts and Grease Used on page 9-
6, the speed reducers which use VIGO grease RE No.0
may make noises at the initial operation or at the first
operation after a long interval. These noises are
eliminated after the running-in period of one or two days.
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HP20D/HP20F
Table 9-1: Inspection Items (Sheet 1 of 2)
Items1) Schedule Method Operation Inspection
Charge
12000 H Cycle
1000 H Cycle
6000 H Cycle
Personnel
Company
Specified
Licensee
24000 H
36000 H
Service
Daily
1 Alignment mark Visual Check alignment mark accordance and damage at the home position.
9.1
9
2 External lead Visual Check for damage and deterioration of leads.
3 Working area and Visual Clean the work area if dust or spatter is present.
Inspection Schedule
Maintenance and Inspection
manipulator Check for damage and outside cracks.
4 Motors for S-, L-, U-axes Visual Check for grease leakage.2)
5 Baseplate mounting bolts Spanner,
wrench
Tighten loose bolts. Replace if necessary.
9-3
6 Cover mounting screws Screwdriver,

wrench
Tighten loose bolts. Replace if necessary.
7 Connector base Manual Check for loose connectors.
8 Timing belts for B- and
T-axes
Manual Check for belt tension and wear.
9 Wire harness in manipulator
(SLEU-axis wires)
Visual,
multimeter
Check for conduction between the main connector of base and intermediate
connector with manually shaking the wires.

(RBT-axis wires) Check for wear of protective spring.3)
Replace.4)
HW0484979
10 Wire harness in manipulator

(BT-axis wires)
Visual,
multimeter
Check for conduction between terminals and wear of protective spring.3)
Replace4)
11 Battery pack in manipulator Replace the battery pack when the battery alarm occurs or the manipulator
drove for 36000 H.

12 S-axis speed reducer Grease gun Check for malfunction. (Replace if necessary.) Supply grease5) (6000 H
cycle). See chapter 9.3.1 at page 9-9 .

Replace grease5). (12000 H cycle) See chapter 9.3.1 at page 9-9 .
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Table 9-1: Inspection Items (Sheet 2 of 2)
HP20D/HP20F
Items1) Schedule Method Operation Inspection
Charge
12000 H Cycle
1000 H Cycle
6000 H Cycle
Personnel
Company
Specified
Licensee
24000 H
36000 H
Service
Daily
13 Speed reducers for L- and
U-axes
Grease gun Check for malfunction. (Replace if necessary.)
Supply grease5) (6000 H cycle). See chapter 9.3.2 at page 9-11 and

9.1
9
chapter 9.3.3 at page 9-13 .
Replace grease5) (12000 H cycle). See chapter 9.3.2 at page 9-11 and
Inspection Schedule
14 R-, B- and T-axes speed
reducer
Grease gun Check for malfunction. (Replace if necessary.)
Supply grease5) (6000 H cycle). See chapter 9.3.4 at page 9-15 and

15 T-axis gear Grease gun Check for malfunction. (Replace if necessary.)
Supply grease5) (6000 H cycle). See chapter 9.3.6 at page 9-17

9-4
16 R-axis cross roller bearing Grease gun Check for malfunction. (Replace if necessary.)
Supply grease5) (6000 H cycle). See chapter 9.3.7 at page 9-18

17 Overhaul
1 Inspection No. correspond to the numbers in Fig. 9-1 Inspection Items on page 9-5.
2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa
representative.
3 When checking for conduction with multimeter, connect the battery to BAT and OBT of connectors on the motor side for each axis, and then remove connectors on
detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer to chapter 9.3.8 Notes for Maintenance at page 9-19)
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4 Wire harness in manipulator to be replaced at 24000 H inspection.

5 For the grease, refer to Table 9-2 Inspection Parts and Grease Used on page 9-6.
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Fig. 9-1: Inspection Items
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S-AXIS
4 2
5
T-AXIS
HP20D/HP20F
1 8
S-AXIS
9
9.1
8
B-AXIS
10 1 14 BT-AXES
U-AXIS
1 R-AXIS
13
9-5
16
Inspection Schedule
15
4
U-AXIS
9 1 L-AXIS
13
11
12 4 7
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9.2 Notes on Maintenance Procedures
Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts
12, 13 VIGO Grease RE No. 0 Speed reducers for S-, L- and U-axes
14, 15 Harmonic Grease SK-1A Speed reducers for R-, B- and T-axes
T-axis gear
16 Alvania EP Grease 2 R-axis cross roller bearing
The numbers in the above table correspond to the numbers in Table 9-1
Inspection Items on page 9-3.
9.2.1 Battery Pack Replacement

The battery packs are installed in the position shown in Fig.9-2 Battery
Location. If the battery alarm occurs in the DX100/FS100, replace the
battery in accordance with the following procedure:
Fig. 9-2: Battery Location
Battery pack
Connector base
Support
Connector base
Connector base fixing screw
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Fig. 9-3: Battery Connection
Battery pack
See step 5 below before replacement
Connector
Board
(type: SGDR-EFBA02A) See step 4 below
New battery pack

(HW0470360-A)
1. Turn OFF the DX100/FS100 main power supply.

2. Remove the plate fixing screws and the plate on the connector base,
then pull the battery pack out to replace it with the new one.
3. Remove the battery pack from the battery holder.
4. Connect the new battery pack to the unoccupied connector on the
board.
5. Remove the old battery pack from the board.
NOTE Remove the old battery pack after connecting the new one
so that the encoder absolute data does not disappear.
6. Mount the new battery pack to the holder.

7. Reinstall the plate.
NOTE Do not allow plate to pinch the cables when reinstalling the
plate.
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9.3 Notes on Grease Replenishment and Exchange Procedures

Make sure to follow the instructions listed below at grease replenishment
and exchange. Failure to observe the following notes may result in
damage to motor and speed reducer.
If grease is added without removing the plug or screw from

the grease exhaust port, the grease will leak inside a
motor or an oil seal of a speed reducer will come off, which
may result in damage to the motor. Make sure to remove
the plug or screw.
Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in
NOTE damage to the motor due to coming off of an oil seal.
Make sure to use a grease pump to inject grease. Set air
supply pressure to the grease pump at 0.3 MPa or less,
and the grease injection rate at 8 g/s or less.
Make sure to fill the hose on the grease inlet with grease
beforehand to prevent air from leaking into the speed
reducer.
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9.3.1 Grease Replenishment and Exchange for S-Axis Speed Reducer

Fig. 9-4: S-Axis Speed Reducer Diagram
Grease exhaust port

Hexagon socket head plug PT1/8
S-axis speed reducer

Grease inlet
Hexagon socket head plug PT1/8
NOTE For the ceiling-mounted manipulator, the grease exhaust

port and the grease inlet are inverted.
9.3.1.1 Grease Replenishment (Refer to Fig.9-4 S-Axis Speed Reducer Diagram.)

Replenish the grease according to the following procedure:
1. Remove the hexagon socket head plugs PT1/8 from the grease inlet
and grease exhaust port.
If grease is injected with the plug on, the grease will leak
NOTE inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
2. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
3. Inject the grease through the grease inlet using a grease gun
Grease type: VIGO Grease RE No. 0
Amount of grease: 30 cc (60 cc for 1st supply)
Air supply pressure of grease pump: 0.3 MPa or less
Grease injection rate: 8 g/s or less
4. Move the S-axis for a few minutes to discharge excess grease.
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5. Remove the grease zerk from the grease inlet, and reinstall the plug.
Before installing the plug, apply ThreeBond 1206C (see Table 10-1
Spare Parts for YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 on
page 10-1) on the thread part of the plug, then tighten the plug with a
tightening torque of 5 Nm (0.51 kgfm).
6. Wipe the discharged grease with a cloth, and reinstall the plug. Before
installing the plug, apply ThreeBond 1206C on the thread part of the
plug, then tighten the plug with a tightening torque of 5 Nm (0.51
kgfm).
9.3.1.2 Grease Exchange (Refer to Fig. 9-4 S-Axis Speed Reducer Diagram on page 9-9.)
1. Remove the hexagon socket head plugs PT1/8 from the grease inlet
and grease exhaust port.
2. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is
3. Inject the grease through the grease inlet using a grease gun.
Amount of grease: approx. 1800 cc
4. The grease exchange is completed when new grease appears in the
grease exhaust port. (The new grease can be distinguished from the
old grease by color.)
5. Move the S-axis for a few minutes to discharge excess grease.
Before installing the plug, apply ThreeBond 1206C on the thread part
of the plug, then tighten the plug with a tightening torque of 5 Nm
(0.51 kgfm).
kgfm).
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9.3.2 Grease Replenishment and Exchange for L-Axis Speed Reducer

Fig. 9-5: L-Axis Speed Reducer Diagram
Grease exhaust port

Hexagon socket head plug PT 1/8
L-arm
L-axis speed reducer
Grease inlet
Hexagon socket head cap screw M6

9.3.2.1 Grease Exchange (Refer to Fig.9-5 L-Axis Speed Reducer Diagram.)

1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT1/8 from the grease
exhaust port.
3. Remove the hexagon socket head cap screw M6 from the grease inlet.
4. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is
5. Inject grease through the grease inlet using a grease gun.
6. Move the L-axis for a few minutes to discharge excess grease.
7. Remove the grease zerk from the grease inlet, and reinstall the screw.
Before installing the screw, apply ThreeBond 1206C on the thread part
of the screw, then tighten the screw with a tightening torque of 5 Nm
(0.51 kgfm).
kgfm).
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9.3.2.2 Grease Exchange (Refer to Fig. 9-5 L-Axis Speed Reducer Diagram on page 9-11.)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT1/8 from the grease
exhaust port.
If grease is injected with the screw on, the grease will leak
remove the screw before the grease injection.
6. The grease exchange is completed when new grease appears in the
7. Move the L-axis for a few minutes to discharge excess grease.
(1.0 kgfm).
plug, then tighten the plug with a tightening torque of 4.9 Nm (0.5
kgfm).
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9.3.3 Grease Replenishment and Exchange for U-Axis Speed Reducer

Fig. 9-6: U-Axis Speed Reducer Diagram
U-arm
Grease exhaust port

U-axis Hexagon socket head cap
speed reducer screw M6
Grease inlet
Hexagon socket head plug PT 1/8

9.3.3.1 Grease Replenishment (Refer to Fig.9-6 U-Axis Speed Reducer Diagram.)

1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head cap screw M6 from grease exhaust
port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
6. Move the U-axis for a few minutes to discharge excess grease.
(0.51 kgfm).
8. Wipe the discharged grease with a cloth, and reinstall the screw.
(0.51 kgfm).
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9.3.3.2 Grease Exchange (Refer to Fig. 9-6 U-Axis Speed Reducer Diagram on page 9-13.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head cap screw M6 from the grease
exhaust port.
inside the motor and may cause a damage. Make sure to
NOTE
Do not install a joint, a hose, etc. to the grease exhaust
port. Failure to observe this instruction may result in
damage to the motor due to coming off of an oil seal.
5. The grease exchange is complete when new grease appears in the
6. Move the U-axis for a few minutes to discharge excess grease.
(0.51 kgfm).
8. Wipe the discharged grease with a cloth, and reinstall the screw to the
grease exhaust port. Before installing the screw, apply ThreeBond
1206C on the thread part of the screw, then tighten the screw with a
tightening torque of 5 Nm (0.51 kgfm).
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9.3.4 Grease Replenishment for R-Axis Speed Reducer

Fig. 9-7: R-Axis Speed Reducer Diagram
Grease inlet
Grease zerk A-MT6X1
Exhaust port
1. Remove the hexagon socket head cap screw M6 from the exhaust
port.
2. Inject grease through the grease inlet using a grease gun. (Refer to
Fig.9-7 R-Axis Speed Reducer Diagram.)
Grease type: Harmonic grease SK-1A
Amount of grease: 8 cc (16 cc for the first supply)
The exhaust port is used for air exhaust, and the grease is
NOTE not exhausted from the exhaust port. Do not inject exces-
sive grease through the grease inlet.
3. Reinstall the screw on the exhaust port. Before installing the screw,
apply ThreeBond 1206C on the thread part of the screw, then tighten
the screw with a tightening torque of 5 Nm (0.51 kgfm).
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9.3.5 Grease Replenishment for B- and T-Axis Speed Reducers

Fig. 9-8: B- and T-Axis Speed Reducers Diagram
Exhaust port (for B-axis)

(Plug LP-M5)
T-axis speed reducer
Exhaust port (for T-axis)

B-axis speed reducer (Hexagon socket set screw M6)
Gease inlet (for T-axis)

(Hexagon socket head cap screw M6)
Gease inlet (for B-axis)
(Hexagon socket head cap screw M6)
1. Remove the plug LP-M5 and the hexagon socket head cap screw M6
from the exhaust ports.
NOTE Remove the cover for the B-axis speed reducer.
2. Remove the hexagon socket head cap screws M6 from the grease
inlets.
Fig.9-8 B- and T-Axis Speed Reducers Diagram.)
Amount of grease: For B-axis: 10 cc
(20 cc for the first supply)
For T-axis: 5 cc
(10 cc for the first supply)
5. Reinstall the plug/screw to the exhaust ports. Before installing the

plug/screw, apply ThreeBond 1206C on the thread part of the plug/
screw, then tighten the plug/screw with a tightening torque of 5 Nm
(0.51 kgfm).
6. Remove the grease zerk from the grease inlets, and reinstall the
screws. Before installing the screws, apply ThreeBond 1206C on the
thread part of the screws, then tighten the screws with a tightening
torque of 5 Nm (0.51 kgfm).
NOTE Mount the cover for the B-axis speed reducer. (Refer to
chapter 9.3.8 Notes for Maintenance at page 9-19.)
9-16
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9.3.6 Grease Replenishment for T-Axis Gear

Fig. 9-9: T-Axis Gear Diagram
Exhaust port
Plug LP-M5
Grease inlet
1. Remove the plug LP-M5 from the exhaust port.

4. Inject grease through the gear grease inlet using a grease gun. (Refer
to Fig.9-9 T-Axis Gear Diagram.)
5. Reinstall the plug to the exhaust port. Before installing the plug, apply
ThreeBond 1206C on the thread part of the plug, then tighten the
screw with a tightening torque of 5 Nm (0.51 kgfm).
6. Remove the grease zerk from the gear grease inlet, and reinstall the
screw. Before installing the screw, apply ThreeBond 1206C on the
thread part of the screw, then tighten the screw with a tightening
torque of 5 Nm (0.51 kgfm).
9-17
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9.3.7 Grease Replenishment for R-Axis Cross Roller Bearing

Fig. 9-10: R-Axis Cross Roller Bearing Diagram
Exhaust port
Plug LP-M5
R-axis cross roller bearing
Grease inlet
(Length: 6mm)
1. Remove the plug LP-M5 from the exhaust port.

Fig.9-10 R-Axis Cross Roller Bearing Diagram.)
Grease type: Alvania EP grease 2
5. Reinstall the plug to the exhaust port. Before installing the plug, apply
ThreeBond 1206C on the thread part of the plug, then tighten the
screw with a tightening torque of 5 Nm (0.51 kgfm).
(0.51 kgfm).
9-18
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9.3.8 Notes for Maintenance
9.3.8.1 Wrist Unit

The motor and encoder units are provided with the wrist unit. To prevent
fumes from penetrating into the wrist unit, the matched parts are sealed
with sealing bond. If the wrist cover is disassembled, make sure to reseal
with sealing bond (ThreeBond 1206C, refer to Table 10-1 Spare Parts for
YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 on page 10-1.)
Fig. 9-11: Sealing Part of Wrist Unit
Cover Cover matching surface
Cover matching surface

Cover
9-19
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9.3.8.2 Battery Pack Connection
When performing maintenance such as replacement of a

wire harness in the manipulator, the encoder connector
(with CAUTION label) will be removed. In this case, be sure
to connect the battery pack to the battery backup connector
before removing the encoder connector.
NOTE Removing the encoder connector without connecting the

battery pack leads to disappearance of the encoder abso-
lute data.
For the battery pack connection, refer to fig. 9-12(a)
Encoder Connector Diagram (for S-, L-, and U-Axes) on
page 9-21 and fig. 9-12(b) Encoder Connector Diagram (for
R-, B-, and T-Axes) on page 9-22.
Battery Pack Connection (for S-, L-, and U-Axis Motors)

The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motors (marked as BAT and OBT). Connect the
battery pack according to the following procedure.
1. Remove the cap attached to the battery backup connector of the

motors.
2. Connect the battery packs (HW9470932-A) with the battery backup
connectors located at the end point of the cables for the encoder.
(Under this condition, remove the encoder connector and carry out the
maintenance checks).
3. After the maintenance check, verify that all the connectors are
connected and remove the battery pack. Install the caps attached to
the battery backup connector of the motor.
NOTE Do not remove the battery pack in the connector base.
9-20
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Fig. 9-12(a): Encoder Connector Diagram (for S-, L-, and U-Axes)
Encoder connector
Motor
CAUTION
Motor power connector
Connect battery to encoder
to save the data before
removing conector.
CAUTION label
0BT b a 0BT*
BAT a b BAT*
Battery pack (HW9470932-A)

Connector for the battery backup
a: Crimped contact-pin (pin)
CAUTION label (Enlarged view)
b: Crimped contact-pin (socket)
CAUTION
removing conector.
Battery Pack Connection (for R-, B-, and T-Axis Motors)

The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motors (marked as BAT and OBT). Connect the
battery pack according to the following procedure.
1. Connect the battery packs (HW9470932-A) with the battery backup

connectors located at the end point of the cables for the encoder.
(Under this condition, remove the encoder connector and carry out the
maintenance checks).
2. After the maintenance check, verify that all the connectors are
connected and remove the battery pack. Install the caps attached to
the battery backup connector of the motor.
NOTE Do not remove the battery pack in the connector base.
9-21
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Fig. 9-12(b): Encoder Connector Diagram (for R-, B-, and T-Axes)
Encoder
Motor
Motor cable, etc.
Wire harness
in manipulator Power connector
Connection
b 0BT
0BT a a BAT
BAT b
removing conector.
CAUTION
Encoder connector Battery pack
(HW9470932-A)
CAUTION label
0BT a b 0BT
BAT b a BAT
CAUTION label (Enlarged view)

a: Crimped contact-pin (pin)
b: Crimped contact-pin (socket)
CAUTION
removing conector.
9-22
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HP20D/HP20F 10 Recommended Spare Parts
10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table
in stock as spare parts for the MOTOMAN-HP20D/HP20F. Product
performance cannot be guaranteed when using spare parts from any
company other than Yaskawa. The spare parts are ranked as follows:
Rank A: Expendable and frequently replaced parts
Rank B: Parts for which replacement may be necessary as a result of
frequent operation
Rank C: Drive unit
NOTE For replacing parts in Rank B or Rank C, contact your

Yaskawa representative.
Table 10-1: Spare Parts for YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 (Sheet 1 of 2)
Rank Parts Name Type Manufacturer Qty. Qty. Remarks
No. per
Unit
A 1 Grease VIGO Grease RE Yaskawa 16 kg -
No. 0
A 2 Grease Harmonic Grease Harmonic Drive Systems 2.5 kg -
SK-1A Inc.
A 3 Grease Alvania EP Grease 2 Showa Shell Sekiyu K.K. 16 kg -
A 4 Liquid Seal ThreeBond 1206C ThreeBond Co., Ltd. - -
A 5 Battery Pack HW0470360-A Yaskawa 1 1 for
connector
base
A 6 Battery Pack HW9470932-A Yaskawa 1 1 for wire
harness in
manipulator
replacing
B 7 B-Axis Timing Belt 80S4.5M653 Mitsuboshi Belting Limited 1 1
B 8 T-Axis Timing Belt 80S4.5M518 Mitsuboshi Belting Limited 1 1
B 9 S-Axis Speed HW0387753-B Yaskawa 1 1
Reducer
B 10 S-Axis Input Gear HW0313491-1 Yaskawa 1 1
B 11 L-Axis Speed HW0387753-C Yaskawa 1 1
Reducer
B 12 L-Axis Input Gear HW0313492-1 Yaskawa 1 1
B 13 U-Axis Speed HW9280880-G Yaskawa 1 1
Reducer
B 14 R-Axis Speed HW0381463-A Yaskawa 1 1
Reducer
B 15 B-Axis Speed HW9381633-A Yaskawa 1 1
Reducer
B 16 T-Axis Speed HW0382140-A Yaskawa 1 1
Reducer
B 17 Internal Wire HW0174855-A Yaskawa 1 1
Harness
10-1
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HP20D/HP20F 10 Recommended Spare Parts
Table 10-1: Spare Parts for YR-HP0020D-A00, -A01, YR-HP0020F-A00, -A01 (Sheet 2 of 2)
Rank Parts Name Type Manufacturer Qty. Qty. Remarks
No. per
Unit
B 18 Internal Cable for HW0270954-A Yaskawa 1 1
B- and T-Axes
C 19 S-Axis AC HW0388665-A Yaskawa 1 1
Servomotor SGMRV-09ANA-
YR1*
C 20 L-Axis AC HW0388667-A Yaskawa 1 1
YR2*
C 21 U-Axis AC HW0388663-A Yaskawa 1 1
YR1*
C 22 AC Servo Motor HW0389298-A Yaskawa 1 3
for R-, B- and T- SGMPH-02ANA-
Axes YR1*
C 23 Board SGDR-EFBA02A Yaskawa 1 1
10-2
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HP20D/HP20F 11 Parts List
11.1 S-Axis Unit
11 Parts List
11.1 S-Axis Unit
1008
1001
1011
1012 1010
1034
1013
1036
1035 1031
1020 1032
1014
1022 1024
1023
1021 1030
1026
1009
1024
1023
1027
1030 1033
1002
1016
1004
1015 1003
1017
1006
1018
1025 1005
1014
1020
1007
1028
1029
11-1
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11.1 S-Axis Unit
Table 11-1: S-axis Unit

No. DWG No. Name Pcs.
1001 SGMRV-09ANA-YR1* Motor 1
1002 HW0100545-2 S head 1
1003 M16X20 Socket screw 1
1004 2H-16 Spring washer 1
1005 HW0387753-B Speed reducer 1
1006 M10X40 GT-SA bolt 16
1007 HW0100544-2 Base 1
1009 HW0305306-2 M base 1
1010 M5X10 APS bolt 1
1011 PT1/8 Plug 1
1012 UKM6-01 Union 1
1013 HW0305809-1 Cover 1
1014 NB-0640-0.3 Tube 2
1015 HW0304221-1 Cover 1
1017 MSB8-15 Shoulder 1
1018 HW0400645-1 Lever 1
1020 TSH6-01M Union 2
1021 CD-31 Saddle 1
1023 TA1-S10 Clamp 2
1024 M5X10 Screw with spring 2
washer
1025 EZ5036A0 Cap 1
1027 HW0305812-1 Holder 1
1028 HW9406775-1 Cover 1
1030 M12 Eye bolt 2
1034 HW0313491-1 Gear 1
11-2
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11.2 L-Axis Unit
11.2 L-Axis Unit
2024
2025 2001
2023
2017 2005
2004
2003
2011 2008
2012 2019 2018 2006 2002 2007
2010
2009
2028
2026 2032
2027
2014
2013
2022
2021
2014 2020
2013
2016
2015
2029 1002
2031
2030
2033
2034
2035
2036
2031
11-3
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11.2 L-Axis Unit
Table 11-2: L-Axis Unit

2001 SGMRV-13ANA-YR2* Motor 1
2004 HW0313492-1 Gear 1
2005 HW0304229-1 M base 1
2006 Y426012.5 Oil seal 1
2007 HW0401506-1 Plate 1
2008 HW0304226-1 Support 1
2011 HW0304227-1 Cover 1
2017 HW0100546-2 L arm 1
2018 HW0387753-C Speed reducer 1
2022 HW0404196-4 Washer 1
*DACROTIZED coating*
washer
2029 HW0305813-1 Holder 1
2030 HW0305698-1 Cover 1
2032 PT1/8 Plug 1
2033 CD-31 Saddle 1
washer
1002 HW0100545-2 S head 1
11-4
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11.3 U-Axis Unit
11.3 U-Axis Unit

3003
3004
3002 3003
3004
3001
3005
3020
3002
3019
3019
3012
3016
3018
3006 3017
2017 3016
3009
3008 3018
3017
3011
3010
3007
3013
3015 3014
11-5
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11.3 U-Axis Unit
Table 11-3: U-Axis Unit

3001 SGMRV-05A3A-YR1* Motor 1
3002 HW0313489-1 Cover 1
3004 M4 Washer 7
3005 HW0102378-1 Casing 1
3006 HW9280880-G Speed reducer 1
3011 GT-SH-14 GT-SH washer 6
3014 H-10 Spring washer 1
3016 HW0404196-2 Washer 2
3019 PT1/8 Plug 2
3020 EZ2940A0 Cap 1
2017 HW0100546-2 L arm 1
11-6
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11.3 U-Axis Unit
R-Axis Unit
4033 4012
4031 4032
4029
4074 4071
4036
4010 4072
4066
4008 4030 4029
4042 3005
4058 4005
4057
4035
4009
4056 4043
4006
4007 4044
4011
4003
4028
4027 4073
4026
4076
4075 4022
4034
4037 4023 4060
4039 4055
4025
3014 4040 4051
4062
3012 4046
4045 4020
4013
4024
4019
4021
4015
4017 4067
4065
4014
4016 4002
4004 4001
4070
4069
4068
5046
4018
11-7
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11.3 U-Axis Unit
Table 11-4: R-Axis Unit (Sheet 1 of 2)

4002 2H-6 Spring Washer 8
4005 HW0305305-1 M cover 1
4008 HW0404196-5 Washer 1
4012 A-MT6X1 G Nipple 1
4013 HW0381872-A Cross roller bearing 1
4015 HW0403879-1 Saddle 1
4016 TC941045*A727* Oil seal 1
4017 HW0403857-1 Shaft 1
4018 HW0405201-2 Block 1
4019 HW0304318-1 Housing 1
4020 HW0304085-1 Shaft 1
4021 HW0304914-1 Support 1
4022 HW0403879-1 Saddle 1
4025 HW0200530-1 S cover 1
4026 HW0404919-1 Support 1
4029 HW0381463-A Speed reducer 1
4030 HW0404403-1 Shaft 1
4031 AE1314A0 Oil seal 1
4032 HW0304932-1 M base 1
4033 HW0404402-1 Shaft 1
4035 HW0404900-1 N base 1
washer
4039 TA1-S8 Clamp 4
washer
4044 LP-M5 Plug 1
11-8
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11.3 U-Axis Unit
Table 11-4: R-Axis Unit (Sheet 2 of 2)

4055 HW0404918-1 Support 1
4056 SGMPH-02A2A-YR1* Motor 1
4057 EZ5036A0 Cap 1
4060 HW0304930-1 Support 1
4062 6811LLU Bearing 1
4066 KQE12-03 Union 1
4070 MS4-10 Pin 2
4072 PT 3/8 Plug 1
4075 TA1-S8 Clamp 3
washer
3005 HW0102378-1 Casing 1
3014 HW0404179-1 Support 2
5046 HW0100623-1 U arm 1
11-9
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11.4 Wrist Unit
11.4 Wrist Unit

3005
5045
5046 5005
5001 5002
5003
5006
5007
5011
5008
5008
5007
5045 5026
5044 5006 5037 5064
5003
5035
5043 5071
5005
5048 5038
5014
5039 5019
5049
5040 5034
5013
5012
5036
5041 5018
5016 5062 5063
5017
5047
5031
5042 5023
5071
5032 5029
5020
5053 5022
5028
5050
5027 5033
5021
5024
5025
5026 5065
5030
5066
5052
5060
11-10
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11.4 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)

5001 HW9406556-1 Support 1
5005 HW9200798-1 Cover 2
5006 SGMPH-02A2A-YR12 Motor 2
5008 HW9482727-A Pulley 2
5011 80S4.5M518 Belt 1
5012 HW9381658-A Gear 1
5014 HW9405452-1 B cover 1
5016 HW9482725-A Pulley 1
5019 HW9482218-A Bearing 1
5020 HW9405199-1 B nut 1
5021 SP-0120** Shim 1
5022 HW9481180-A Bearing 1
5025 HW0304232-1 Shaft 1
5026 TC60747 Oil seal 2
5027 HW9481187-A Bearing 1
5028 HW0304233-1 Shaft 1
5029 S75 O ring 1
5030 HW0304087-1 Housing 1
5032 HW0304086-1 Housing 1
5033 HW9381659-A Gear 1
5034 HW9482726-A Pulley 1
5036 6002ZZ Bearing 1
5039 HW9482668-A Oil seal 1
5041 HW9405792-1 Housing 1
5042 HW0200451-1 Wrist base 1
5044 80S4.5M653 Belt 1
5046 HW0100623-1 U arm 1
11-11
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11.4 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)

5057 M6 L Washer 1
5062 LP-M5 Plug 1
5063 HW9405791-3 Housing 1
5064 6811LLU Bearing 1
5065 HW0404606-1 Cover 1
5066 HW040605-1 Plug 1
3005 HW0102378-1 Casing 1
11-12
HW0484979 80/81
MOTOMAN-HP20D/HP20F
INSTRUCTIONS
Specifications are subject to change without notice

for ongoing product modifications and improvements.
MANUAL NO.
HW0484979 5 81/81

1CD R5 PDF

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MOTOMAN-HP20D/HP20F

Part Number: 156192-1CD

Notes for Safe Operation

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

Must never be performed.

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

To ensure safe and efficient operation at all times, be sure to

Observe the following precautions when performing teaching

In the case of not using the programming pendant, be sure to

Observe the following precautions when performing teaching

Definition of Terms Used Often in This Manual (DX100)

Definition of Terms Used Often in This Manual (FS100)

Explanation of Warning Labels

Nameplate: WARNING Label A:

1 Product Confirmation ...................................................................................................................... 1-1

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

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

2.1 Transport Method .............................................................................................................. 2-1

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

2.1.2 Using a Forklift...................................................................................................... 2-3

2.2 Cushioning Material for Transport ..................................................................................... 2-4

3.1 Safeguarding Installation ................................................................................................... 3-2

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

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

3.3 Ways of Mounting .............................................................................................................. 3-4

3.3.1 S-Axis Operating Range....................................................................................... 3-4

3.3.2 Fixing Manipulator Base ....................................................................................... 3-4

3.3.3 Precautions to Prevent Manipulator from Falling.................................................. 3-4

3.3.4 IP (International Protection) for Main Part of Manipulator .................................... 3-5

3.4 Location ............................................................................................................................. 3-5

4.1 Grounding .......................................................................................................................... 4-1

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

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

4.2.2 Connection to DX100/FS100................................................................................ 4-2

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

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

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

5.3 Manipulator Base Dimensions ........................................................................................... 5-3

5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-4

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

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

6.2 Wrist Flange....................................................................................................................... 6-3

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

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

7.1.1 Allowable Load ..................................................................................................... 7-1

7.1.2 Installation Position............................................................................................... 7-1

8 Electrical Equipment Specification .................................................................................................. 8-1

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

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

9 Maintenance and Inspection ........................................................................................................... 9-1

9.1 Inspection Schedule........................................................................................................... 9-2

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

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

9.3 Notes on Grease Replenishment and Exchange Procedures ........................................... 9-8

9.3.4 Grease Replenishment for R-Axis Speed Reducer ............................................ 9-15

9.3.6 Grease Replenishment for T-Axis Gear.............................................................. 9-17

9.3.8 Notes for Maintenance........................................................................................ 9-19

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

11 Parts List .................................................................................................................................... 11-1

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