HP20

Motoman NX100 Controller
HP20
Manipulator Manual
Part Number: 149615-1CD

Revision: 1
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
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Motoman is committed to total customer satisfaction! Please give us your feedback on the technical manuals you
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The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2007 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
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The Motoman HP20 and NX100 controller represent state-of-the-art technology in robotics
today. The Motoman HP20 is a high speed robot with a 20 kg payload. It has six individual
axes: Sweep, Lower arm, Upper arm, Rotate, Bend, and Twist. The NX100 controller
coodinates the operation of the HP20 robot with external equipment such as power supply
and positioning tables. The NX100 processes input and output signals, maintains variable
data, and performs numeric processing to convert to and from different coordinate systems.
Furthermore, it provides main logic functions, servo control, program and constant data
memory, and power distribution. Please read this manual thoroughly to familiarize yourself
with the many aspects of the HP20 robot and NX100 controller.:
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This manual provides system information for the HP20 robot and NX100 controller and
contains the following sections:
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Provides general information about the structure of this manual, a list of reference documents,
and customer service information.
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This section provides information regarding the safe use and operation of Motoman products.
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Provides detailed information about the HP20, including installation, wiring, specifications,
and maintenance..
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For additional information refer to the following:
• NX100 Controller Manual (P/N 149201-1)
• Concurrent I/O Manual (P/N 149230-1)
• Operator’s Manual for your application
• Vendor manuals for system components not manufactured by Motoman
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If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200.
Please have the following information ready before you call:
• Product Type (HP20)
• Robot Serial Number (located on back side of robot arm)
• Robot Sales Order Number (located on back of controller)
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We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for
Industrial Robots and Robot Systems. This information can be obtained from the Robotic
Industries Association by requesting ANSI/RIA R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for providing
personnel who are adequately trained to operate, program, and maintain the robot cell. The
robot must not be operated by personnel who have not been trained!
We recommend that all personnel who intend to operate, program, repair, or use the robot
system be trained in an approved Motoman training course and become familiar with the
proper operation of the system.
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This safety section addresses the following:

• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)
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This manual includes information essential to the safety of personnel and equipment. As you
read through this manual, be alert to the four signal words:
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NOTE:
Pay particular attention to the information provided under these headings which are defined
below (in descending order of severity).
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Note: Information appearing in a Note caption provides additional information which is helpful in
understanding the item being explained.
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All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the operation of
this equipment. All personnel involved with the operation of the equipment must
understand potential dangers of operation. General safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to the equipment.
Only trained personnel familiar with the operation of this robot, the operator's
manuals, the system equipment, and options and accessories should be permitted to
operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers must
have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made within
the standard voltage and current ratings of the robot I/O (Inputs and Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in
use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use lockout/tagout
procedures during equipment maintenance. Refer also to Section 1910.147 (29CFR,
Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).
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The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the
user's responsibility. The conditions under which the equipment will be operated safely
should be reviewed by the user. The user must be aware of the various national codes,
ANSI/RIA R15.06 safety standards, and other local codes that may pertain to the installation
and use of industrial equipment. Additional safety measures for personnel and equipment
may be required depending on system installation, operation, and/or location. The following
safety measures are available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.
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Safe installation is essential for protection of people and equipment. The following
suggestions are intended to supplement, but not replace, existing federal, local, and state laws
and regulations. Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local codes, and
ANSI/RIA R15.06 safety standards are permitted to install the equipment.
• Identify the work envelope of each robot with floor markings, signs, and barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry into
the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot and
other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and maintenance
procedures.
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understand potential dangers of operation. Programming tips are as follows:
Any modifications to PART 1 of the NX100 controller PLC can cause severe personal injury or
death, as well as damage to the robot! Do not make any modifications to PART 1. Making any
changes without the written permission of Motoman will VOID YOUR WARRANTY!
Some operations require standard passwords and some require special passwords. Special
passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use these
special passwords.
Back up all programs and jobs onto a floppy disk whenever program changes are made. To
avoid loss of information, programs, or jobs, a backup must always be made before any
service procedures are done and before any changes are made to options, accessories, or
equipment.
The concurrent I/O (Input and Output) function allows the customer to modify the internal
ladder inputs and outputs for maximum robot performance. Great care must be taken when
making these modifications. Double-check all modifications under every mode of robot
operation to ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
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Only trained personnel familiar with the operation, manuals, electrical design, and
equipment interconnections of this robot should be permitted to operate the system.
• Inspect the robot and work envelope to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-STOP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at low speed for at least one full cycle.
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understand potential dangers of operation. Operation tips are as follows:
• Be sure that only trained personnel familiar with the operation of this robot, the
operator's manuals, the system equipment, and options and accessories are
permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any
• Inspect the robot and work envelope to ensure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
have the teach pendant when they enter the cell.
use.
• This equipment has multiple sources of electrical supply. Electrical interconnections
are made between the controller, external servo box, and other equipment.
Disconnect and lockout/tagout all electrical circuits before making any modifications
or connections.
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• All modifications made to the controller will change the way the robot operates and
can cause severe personal injury or death, as well as damage the robot. This includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.
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understand potential dangers of operation. Maintenance tips are as follows:
• Do not perform any maintenance procedures before reading and understanding the
proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any
• Back up all your programs and jobs onto a floppy disk whenever program changes
are made. A backup must always be made before any servicing or changes are made
to options, accessories, or equipment to avoid loss of information, programs, or jobs.
have the teach pendant when they enter the cell.
use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical interconnections
are made between the controller, external servo box, and other equipment.
Disconnect and lockout/tagout all electrical circuits before making any modifications
or connections.
• All modifications made to the controller will change the way the robot operates and
can cause severe personal injury or death, as well as damage the robot. This includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made within
the standard voltage and current ratings of the robot I/O (Inputs and Outputs).
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YASKAWA
MOTOMAN-HP20
INSTRUCTIONS
TYPE: YR-HP20-A00 (STANDARD SPECIFICATIONS)
YR-HP20-A01 (WITH SLU-AXES LIMIT SWITCHES)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-HP20 INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
YASKAWA MANUAL NO. RE-MTO-A247

MANDATORY
• This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOMAN-HP20.
• General items related to safety are listed in the Section 1: Safety of the
NX100 Instructions. To ensure correct and safe operation, carefully
read the NX100 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 rep-

resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-
uct’s warranty.
ii
Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or inspection of the
NX100.
In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,”
“MANDATORY,” or “PROHIBITED.”
Indicates a potentially hazardous situation which, if not

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

CAUTION avoided, could result in minor or moderate injury to personnel
and damage to equipment. It may also be used to alert
against unsafe practices.
Always be sure to follow explicitly the items listed under this

MANDATORY heading.
PROHIBITED Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations.
At any rate, be sure to follow these important items.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING.”
iii
WARNING
• Before operating the manipulator, check that servo power is turned OFF
when the emergency stop buttons on the front door of the NX100 and
programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the program-
ming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.
Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.

TURN
Release of Emergency Stop
• Observe the following precautions when performing teaching operations

within the P-point maximum envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the P-point maximum envelope of

the manipulator and that you are in a safe location before:
- Turning ON the NX100 power.
- Moving the manipulator with the programming pendant.
- Running the system in the check mode.
- Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the manipulator dur-
ing operation. Always press an emergency stop button immediately if there is a problem.
The emergency stop buttons are located on the right of the front door of the NX100 and
the programming pendant.
iv
CAUTION
• Perform the following inspection procedures prior to conducting manip-
ulator teaching. If problems are found, repair them immediately,
and be sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the NX100 cabi-
net after use.
The programming pendant can be damaged if it is left in the P-point maximum envelope
of manipulator, on the floor, or near fixtures.
• Read and understand the Explanation of the Warning Labels in the

NX100 Instructions before operating the manipulator.
Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming pendant, and supply
cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
NX100 Controller NX100
NX100 Programming Pendant Programming Pendant
Cable between the Manipulator and the Controller Manipulator Cable
v
Explanation of Warning Labels
The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the manipula-
tor. Prior to operating the manipulator, confirm the contents.
Warning label B
Warning label A Warning label B
WARNING
Moving parts
may cause
injury WARNING
Do not enter
robot
work area.
Nameplate
Nameplate Warning Label A:
MOTOMAN WARNING
TYPE
Moving parts
PAYLOAD MASS
kg kg may cause
ORDER NO. DATE
injury
SERIAL NO.
YASKAWA ELECTRIC CORPORAION JAPAN
Warning Label B:
WARNING
Do not enter
robot
work area.
vi
1 Product Confirmation
1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . .1-2
2 Transporting
2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.2 Using a Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2 Shipping Bolts and Brackets . . . . . . . . . . . . . . . . . . . . . . . .2-4
3 Installation
3.1 Installation of Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . .3-2
3.2.1 Installation Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.1 S-axis Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.2 Fixing the Manipulator Base . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.3 Precautions to Prevent the Manipulator from Falling. . . . . . . . .3-4
3.3.4 IP (International Protection) for Main Part of the Manipulator . .3-5
3.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
4 Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2 Manipulator Cable Connection . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.1 Connection to the Manipulator. . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2.2 Connection to the NX100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
5 Basic Specifications
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
vii
6 Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Wrist Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7 System Application
7.1 Peripheral Equipment Mounts . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 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 Position of Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9 Maintenance and Inspection

9.1 Inspection Schedule
(Manipulator in the Home Position: Refer to “Fig.21.”) . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-5
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.2 Grease Replenishment/Exchange for S-axis Speed Reducer . 9-7
Grease Replenishment (Refer to "Fig. 24 S-axis
Speed Reducer Diagram".). . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Grease Exchange
(Refer to "Fig. 24 S-axis Speed Reducer Diagram".) . . . . . 9-8
9.2.3 Grease Replenishment/Exchange for L-axis Speed Reducer . 9-9
Grease Replenishment
(Refer to "Fig. 25 L-axis Speed Reducer Diagram".). . . . . . 9-9
Grease Exchange
(Refer to "Fig. 25 L-axis Speed Reducer Diagram".). . . . . 9-10
9.2.4 Grease Replenishment/Exchange for U-axis Speed Reducer 9-11
(Refer to "Fig. 26 U-axis Speed Reducer Diagram".) . . . . 9-11
Grease Exchange
(Refer to "Fig. 26 U-axis Speed Reducer Diagram".) . . . . 9-12
9.2.5 Grease Replenishment for R-axis Speed Reducer. . . . . . . . . 9-13
9.2.6 Grease Replenishment for B-, T-axes Speed
Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.2.7 Grease Replenishment for T-axis Gear . . . . . . . . . . . . . . . . . 9-15
9.2.8 Grease Replenishment for R-axis Cross Roller Bearing. . . . . 9-16
9.2.9 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
viii
Wrist Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17
9.2.10 Encoder Connector (with CAUTION Label) . . . . . . . . . . . . .9-17
Battery Pack Connection (for S-, L-, U-axes Motors) . . . . .9-17
Battery Pack Connection (for R-, B-, T-axes Motors) . . . . .9-19
10 Recommended Spare Parts
11 Parts List
11.1 S-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
11.2 L-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.3 U-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5
11.4 R-axis Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7
11.5 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9
ix
1.1 Contents Confirmation
1 Product Confirmation
CAUTION
• Confirm that the manipulator and the NX100 have the same order num-
ber. Special care must be taken when more than one manipulator is to
be installed.
If the numbers do not match, manipulators may not perform as expected and cause injury
or damage.
1.1 Contents Confirmation
Confirm the contents of the delivery when the product arrives.

Standard delivery includes the following four items (information for the content of optional
goods is given separately):
• Manipulator
• NX100
• Programming pendant
• Manipulator cable
1-1
1.2 Order Number Confirmation
1.2 Order Number Confirmation
Check that the order number of the manipulator corresponds to the NX100. The order num-
ber is located on a label as shown below.
Label (Enlarged View)
THE MANIPULATOR AND THE CONTROLLER Check that the manipulator
SHOULD HAVE SAME ORDER NUMBER.
and the NX100 have the
same order number.
ORDER NO.
NX100
TYPE ERCR-
******
POWER SUPPLY
200V 50Hz
220V 50/60Hz 3PHASE kVA
SERIAL No.
DATE
MADE IN JAPAN NJ2484-1
THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1529
WARNING
Do not open the door
ON
ED
IPP
TR
OFF
ET
RES
(b) Manipulator (Top View)
(a) NX100 (Front View)
Fig. 1 Location of Order Number Labels
1-2
2.1 Transporting Method
2 Transporting
CAUTION
• Sling and crane or forklift operations must be performed by authorized
personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock during transportation.
The system consists of precision components, so failure to observe this caution may
adversely affect performance.
2.1.1 Using a Crane

As a rule, when removing the manipulator from the package and moving it, a crane should be
used. The manipulator should be lifted using wire rope threaded through attached eyebolts.
Be sure the manipulator is fixed with shipping bolts and brackets before transportation, and lift
it in the posture as shown in "Fig. 2 Transporting Position".
• Check that the eyebolts are securely fastened.

NOTE • The mass of the manipulator is approximately 280 kg including the shipping bolts and
brackets. Use a wire rope strong enough to withstand the mass.
• Attached eyebolts are designed to support the manipulator mass. Do not use them for
anything other than transporting the manipulator.
• Be sure to mount the shipping bolts and brackets before transporting the manipulator.
(Refer to "Fig. 2 Transporting Position.")
• Avoid external force on the arm or motor unit when transporting the manipulator. Use
caution when using transporting equipment other than a crane or forklift to avoid injury.
2-1
Eyebolt M12 (2 eyebolts)
(Delivered with the manipulator)
A
B
Eyebolt M12 (2 eyebolts) View E
(Delivered with the manipulator)
C
F
View F
Fig. 2 Transporting Position
2-2
2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet with shipping bolts and
brackets as shown in "Fig. 3 Using the Forklift." Insert claws under the pallet and lift it. The
pallet must be strong enough to support the manipulator. Transportation of the manipulator
must be performed slowly in order to avoid overturning or slippage.
Bolts M16 (4 bolts)
Pallet
Forklift claw entry
Fig. 3 Using the Forklift
2-3
2.2 Shipping Bolts and Brackets
2.2 Shipping Bolts and Brackets
The manipulator is provided with shipping bolts and brackets at sections A and B. ("Fig. 2
Transporting Position")
Eyebolts M12 (2 eyebolts) B
(delivered with the manipulator)
A C D
Enlarged View: Section A Enlarged View: Section C Enlarged View: Sections B and D
Parts Drawing for Section A Parts Drawing for Section B
• The brackets in the sections A and B are painted yellow.

• The section A is fixed with a hexagon socket head cap screw M8, and the section B is
fixed with two hexagon socket head cap screws M6.
• A rubber cushion is respectively wedged at the sections C and D.
Before turning ON the power, check to be sure that the shipping bolts, brackets, and rubber
NOTE cushions have been removed. The shipping bolts, brackets, and rubber cushions then
must be stored for future use, in the event that the manipulator must be moved again.
2-4
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 manipulator’s tool or the

workpiece held by the manipulator will not reach the wall, safeguarding,
or NX100 when the arm is fully extended.
Failure to observe this warning may result in injury or damage.
• Do not start the manipulator or even turn ON the power before it is

firmly anchored.
The manipulator may overturn and cause injury or damage.
• When mounting the manipulator on the ceiling or wall, the base section
must have sufficient strength and rigidity to support the mass of the
manipulator. Also, it is necessary to consider countermeasures to pre-
vent the manipulator from falling.
Failure to observe these warning 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 shipping bolts
and brackets explained in " 2.2 Shipping Bolts and Brackets " are
removed.
Failure to observe this caution may result in damage to the driving parts.
3-1
3.1 Installation of Safeguarding
3.1 Installation of Safeguarding
To insure safety, be sure to install the safeguarding. It prevents unforeseen accidents with per-
sonnel and damage to equipment. The following is quoted for your information and guidance.
Responsibility for Safeguarding (ISO10218)

The user of a manipulator or robot system shall ensure that the safeguarding is provided and
used in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safe-
guarding, including any redundancies, shall correspond directly to the type and level of hazard
presented by the robot system consistent with the robot application. Safeguarding may
include but not be limited to safeguarding devices, barriers, interlock barriers, perimeter
guarding, awareness barriers, and awareness signals.
3.2 Mounting Procedures for Manipulator Base
The manipulator should be firmly mounted on a base or foundation strong enough to support
the manipulator and withstand repulsion forces during acceleration and deceleration.
Refer to "Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop" and
" Table. 2 Endurance Torque in Operation " to construct a solid foundation with the appropri-
ate thickness to withstand maximum repulsion forces of the manipulator.
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 described in " 3.2.1 Installation Example ".
Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop
Horizontal rotating maximum torque 8000 Nm

(S-axis moving direction) (815 kgfm)
Vertical rotating maximum torque 5000 Nm

(LU-axes moving direction) (510 kgfm)
Table. 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

(LU-axes moving direction) (385 kgfm)
3-2
3.2 Mounting Procedures for Manipulator Base
3.2.1 Installation Example

For the first process, anchor the baseplate firmly on the floor. The baseplate should have
enough rigidity, which is 32 mm or more in thickness. The size of the anchor bolt recom-
mended for the baseplate fixation is M16 or larger.
Next, fix the manipulator base to the baseplate. There are 4 mounting holes on the manipula-
tor base: securely fix the manipulator to the baseplate using 4 hexagon head screws M16 (60
mm long is recommended). Tighten the hexagon head screws and anchor bolts firmly so that
they will not be loosened during the operation. See "Fig. 4 Manipulator Installation Example"
for the method.
Bolt M16 (4 bolts)
Spring washer
Washer
Manipulator base
25 Baseplate
40 mm
or more
Manipulator base
Anchor bolt (M16 or larger)
Baseplate
375
18 dia. holes 335
(4 holes) 313 200 ±0.1
Baseplate 60
200 ±0.1
250
335
375
60
170 ±0.1
+0.018
12 dia. holes (2 holes)
0 260 ±0.1
Manipulator Base
Fig. 4 Manipulator Installation Example
3-3
3.3 Installation Method
3.3 Installation Method
The manipulator can be mounted in three different ways: floor-mounted (standard), wall-
mounted, and ceiling-mounted types are available. For wall- and ceiling-mounted types, the
three points listed below are different from the floor-mounted types.
• 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 the wall-mounted type, the S-Axis operating range must be ±30°. (Adjusted prior to the
shipment.)
3.3.2 Fixing the Manipulator Base

For the wall- or ceiling-mounted types, be sure to use 4 hexagon socket head cap screws M16
(tensile strength: 1200 N/mm2 or more) to fix the manipulator base. Use a torque of 206 Nxm
in tightening the screws.
3.3.3 Precautions to Prevent the 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. 5 When Using Ceiling and Wall-mounted
Types" for details.
Preventive support from falling
Manipulator base
Hexagon socket head cap screws M16 (4 screws)
(Tensile strength: 1200N/mm2)
Fig. 5 When Using Ceiling and Wall-mounted Types
3-4
3.4 Location
3.3.4 IP (International Protection) for Main Part of the

Manipulator
For wall-mounted or ceiling mounted types, environmental resistance for main part of the
manipulator does not conform to IP54; environmental resistance for IP65 is optionally avail-
able. However, the wrist part conforms to IP67.
In case of using the wall-/ceiling-mounted type, inform Yaskawa of the matter when placing
NOTE an order. Be sure to contact Yaskawa representative (listed on the back cover of this
instruction manual) to execute a wall/ceiling installation on site.
3.4 Location
When the manipulator is installed, it is necessary to satisfy the undermentioned environmental

conditions:
• 0° to +45°C (ambient temperature)

• 20 to 80%RH (no moisture, at constant temperature)
• Free from dust, soot, or water
• Free from corrosive gases or liquid, or explosive gases
• Free from excessive impact or vibration (vibration acceleration: 4.9 m/s2 [0.5 G] or less)
• Free from large electrical noise (plasma)
• The flatness for installation is 0.5 mm or less.
3-5
4 Wiring
WARNING
• Ground resistance must be 100 Ω or less.
Failure to observe this warning may result in fire or electric shock.
• Before wiring, make sure to turn the primary power supply OFF, and put
up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in fire or electric shock.
CAUTION
• Wiring must be performed by authorized or certified personnel.
Failure to observe this caution may result in fire or electric shock.
4-1
4.1 Grounding
4.1 Grounding
Follow the local regulations and electrical installation standards for grounding. The recom-
mended grounding wire size is 5.5 mm2 at minimum.
For grounding, connect the ground wire directly to the manipulator as shown in "Fig. 6
Grounding Method".
• Do not use this line in common with other ground lines or grounding electrodes for other
NOTE electric power, motor power, welding devices, etc.
• Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
ground in accordance with Electric Equipment Technical Standards.
A
5.5 mm2 or more
Bolt M8 (for grounding)
Section A-A
(delivered with the manipulator)
Fig. 6 Grounding Method
4.2 Manipulator Cable Connection
There are two manipulator cables; an encoder cable for detection (1BC) and power cable
(2BC). (Refer to "Fig. 7 Manipulator Cables (1BC and 2BC).") Connect these cables respec-
tively to the connectors at the manipulator base and the NX100. Refer to " Fig. 8 (a) Manipu-
lator Cable Connection to the Manipulator ", and " Fig. 8 (b) Manipulator Cable Connection to
the NX100 ".
4-2
4.2.1 Connection to the Manipulator

Before connecting the manipulator cables to the manipulator, verify the numbers: 1BC and
2BC on both the cables and the connectors of the manipulator. Connect 2BC first, and then
connect 1BC. After inserting the cables, lower each lever until it clicks.
4.2.2 Connection to the NX100

Before connecting the manipulator cables to the NX100, verify the numbers: 1BC and 2BC on
both the cables and the NX100 connectors. Connect 2BC first, and then connect 1BC. After
inserting the cables, lower each lever until it clicks.
NX100 side Manipulator side
1BC
X11
X11 1BC
1BC
Encoder cable
NX100 side Manipulator side
2BC
X21
2BC
X21 2BC
Power cable
Fig. 7 Manipulator Cables (1BC and 2BC)
4-3
2BC
1BC
3BC
Connector details
(Manipulator side)
Fig. 8 (a) Manipulator Cable Connection to the Manipulator
X11
X21
Fig. 8 (b) Manipulator Cable Connection to the NX100
4-4
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table. 3 Basic Specifications*1
Item Model MOTOMAN-HP20
Configuration Vertically Articulated

Degree of Freedom 6
Payload 20 kg
Repeatability*2 ±0.06 mm
S-axis (turning) ±180°
L-axis (lower arm) +155°, -110°
Range of U-axis (upper arm) +255°, -165°

Motion R-axis (wrist roll) ±200°
B-axis (wrist pitch/yaw) +230°, -50°
T-axis (wrist twist) ±360°
S-axis 2.96 rad/s, 170°/s
L-axis 2.96 rad/s, 170°/s
Maximum U-axis 3.05 rad/s, 175°/s

Speed R-axis 6.20 rad/s, 355°/s
B-axis 6.02 rad/s, 345°/s
T-axis 9.16 rad/s, 525°/s
R-axis 39.2 Nm (0.9 kgfm)
Allowable
B-axis 39.2 Nm (0.9 kgfm)
Moment*3
T-axis 19.6 Nm (0.25 kgfm)
Allowable
R-axis 0.9 kgm2
Inertia B-axis 0.9 kgm2
2/4)*3
(GD
T-axis 0.25 kgm2
Mass 280 kg
Temperature 0 to 45°C
Humidity 20 to 80% RH (at constant temperature)
Ambient
Vibration Acceleration 4.9 m/s2 (0.5G) or less
Conditions*4 • Free from corrosive gasses or liquids, or explo-

sive gasses
Others
• Clean and dry
• Free from excessive electrical noise (plasma)
Power Requirements 2.8 kVA
*1 SI units are used in this table. However, gravitational unit is used in ( ).

*2 Conformed to ISO9283
*3 Refer to " 6.1 Allowable Wrist Load " for details on the allowable moment and inertia.
*4 Conformed to IP54 for the main part of the manipulator (floor-mounted type only). Conformed to IP67 for the
wrist part (IP65 for the main part is optional.)
5-1
5.2 Part Names and Working Axes
5.2 Part Names and Working Axes
U+ R+ B+ T+
Wrist flange
U- R- B- T-
U-arm
Wrist
L-arm
L- L+
Rotary head
S+
S- Manipulator base
Fig. 9 Part Names and Working Axes
5-2
5.3 Manipulator Base Dimensions
5.3 Manipulator Base Dimensions
200±0.1
Fitting surface 60
200 ±0.1
60
25
A
Fitting surface
375
335
18 dia. holes (4 holes) 313
(for manipulator fixing)
335
375
395.5
250
170 ±0.1
195.5
+0.018
12 dia. holes
0 260 ±0.1
(2 holes)
View
Units: mm
Fig. 10 Manipulator Base Dimensions
5-3
5.4 Dimensions and P-Point Maximum Envelope
5.4 Dimensions and P-Point Maximum Envelope
A
1323
1717
1417
356
807
459
635
514
421
288
0
2072
125
C
150 795 105
80
87.5
180°
7
71
140
° R1
455
80
P-point
1003 264 191
150
1485
760
776
0°
11
155°
505
505
505
328
1
42
5°
R
25
4
238
R31
135
180°
0
0
P-point maximum envelope
165° View A
524
559
917
991
260
807
471
Units: mm
Fig. 11 Dimensions and P-point Maximum Envelope
5-4
5.5 Alterable Operating Range
5.5 Alterable Operating Range
The operating range of the S-axis can be altered according to the operating conditions as
shown in "Table. 4 S-axis Working Range." If alteration is necessary, contact your Yaskawa
representative in advance.
Table. 4 S-axis Working Range
Item Specifications
±180° (standard)
±150°
S-axis
±120°
Operating
±90°
Range
±60°
±30°
5-5
6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist

Flange
6.1 Allowable Wrist Load
The allowable wrist load is 20 kg. 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. 5 Allowable Moment and Iner-
tia." Contact your Yaskawa representative for further information or assistance.
Table. 5 Allowable Moment and Inertia
Axis Moment N•m (kgf•m)*1 Inertia kg•m2
R-axis 39.2 (4) 0.9

B-axis 39.2 (4) 0.9
T-axis 19.6 (2) 0.25
*1 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in "Fig. 12 Moment
Arm Rating."
The allowable inertia is calculated when the moment is at the maximum. Contact your
Yaskawa representative when only load inertia, or load moment is small and inertia is large.
Also, when the load is combined as a force but a mass, contact your Yaskawa representative.
Load gravity
LB
position 300
105
200
L T mm
W=6Kg
LT
W=10Kg
W=16Kg
T-axis, R-axis 100
W=20Kg
rotation center line
B-axis rotation center line
0 100 200 300 400
L B mm
Fig. 12 Moment Arm Rating
6-1
6.2 Wrist Flange
6.2 Wrist Flange
The wrist flange dimensions are shown in " Fig. 13 Wrist Flange ". In order to see the align-
ment 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.
Alignment mark
0.5 6
45°
Tapped holes M6
(depth: 10)
(pitch: 1.0) (4 holes)
50 dia.
25 dia.
+0.021
-0.039
0
6
0
P.C
.D4
0
+0.012
6 dia. hole
0
(depth: 6)
View A
Units: mm
Fig. 13 Wrist Flange
• Wash off anti-corrosive paint (yellow color) on the wrist flange surface with thinner or light
NOTE oil before mounting the tools.
• Mount the attachment with the mounting bolts (length: 10 mm or less).
Failure to observe this instruction may affect the manipulator performance.
6-2
7.1 Peripheral Equipment Mounts
7 System Application
7.1 Peripheral Equipment Mounts
The peripheral equipment mounts are fixed on the upper arm for easier installation of
the user’s system application as shown in " Fig. 14 Installing Peripheral Equipment Mounts ".
When peripheral equipment is attached to the U-axis, the following conditions should be
observed.
7.1.1 Allowable Load
The allowable load on the U-axis is a maximum of 31 kg, including the wrist load.
For instance, when the mass installed in 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. 15 Allowable Load on U-axis " shows the distance between the center of U-axis rotation
and the load gravity.
W2 Z-coordinate
Limited dimension direction
W1
of Z-coordinate:
220
400 at a maximum 70
X-coordinate
direction
Center of U-axis rotation
70
View A
Units: mm
Fig. 14 Installing Peripheral Equipment Mounts
7-1
7.2 Internal User I/O Wiring Harness and Air Line
(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 ( direction)
Fig. 15 Allowable Load on U-axis
14 wires (0.2 mm2 x 8 wires and 1.25 mm2 x 6 wires) and an air line are used in the manipula-
tor for the drives of the peripheral devices mounted on the upper arm as shown in " Fig. 16
Internal User I/O Wiring Harness and Air Line ". The connector pins (1 to 16) are assigned as
shown in "Fig. 17 Detailed Drawing of Connector Pin Numbers." Wiring must be performed
by users, following the conditions below:
• The allowable current for cables: 3 A or less for each cable (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 inside diameter: 6.5 mm)
7-2
Connectors on Connector Base
Air inlet: Tapped hole
PT3/8 with pipe plug
View A
Connector for internal
Connectors on U-arm
user I/O wiring harness:
JL05-2A20-29PC
(pin connector with a cap)
Prepare socket connector
JL05-6A20-29S.
Connector for internal user I/O
wiring harness: JL05-2A20-29SC
(socket connector with a cap)
Exhaust port (air flow):
Prepare pin connector
Tapped hole PT3/8 with
pipe plug JL05-6A20-29P.
Fig. 16 Internal User I/O Wiring Harness and Air Line
Connector for Internal User I/O Wiring Harness Connector for Internal User I/O Wiring Harness
on the Connector Base on the U-arm
1 1
2 2
3 3
4 4
5 5
6 6
7 (Open) 1 7 (+24V: for shock sensor) 1
Pins used 8 (Open) 2 3 Pins used 8 (Shock sensor signal input) 2 3
9 5 9 4 5
4 6 6
10 7 8 10 7 8
11 (1.25 mm2) 9 10 11 (1.25 mm2) 9 10
12 (1.25 mm2) 11 12 12 (1.25 mm2) 11 12
13 (1.25 mm2) 13 14 13 (1.25 mm2) 13 14
14 14 2
15 (1.25 mm )
2
15 (1.25 mm ) 15 16 15 16
16 (1.25 mm2) 16 (1.25 mm2)
Internal user I/O wiring harness : 0.2 mm2, 8 lead wires Internal user I/O wiring harness : 0.2 mm2, 8 lead wires
: 1.25 mm2, 6 lead wires : 1.25 mm2, 6 lead wires
Fig. 17 Detailed Drawing of Connector Pin Numbers
• The 7th pin and 8th pin of 3BC connector on the U-arm are respectively connected with
NOTE the shock sensor power supply and shock sensor signal input port of the NX100 controller.
• The 7th pins and 8th pins of respective 3BC connectors are not connected with each other.
• For the wiring, refer to "Fig. 20 (a) Internal Connection Diagram" on page 8-3.
The same pin number (1-16) of two connectors is connected by the lead wire of single
0.2 mm2 or 1.25 mm2.
7-3
8.1 Position of Limit Switch
8 Electrical Equipment Specification
8.1 Position of Limit Switch
Limit switches are optional. Refer to " Fig. 18 Location of Limit Switch " for location. A manip-
ulator type with the S- or L-axis overrun limit switch or the LU-axes interference limit switch is
YR-HP20-A01.
LU-axes interference limit switch (optional)
L-axis interference limit switch (optional)
S-axis overrun limit

switch (optional)
Fig. 18 Location of Limit Switch
8-1
8.2 Internal Connections
High reliability connectors which can be easily put on and removed are used with each
connector part. For the numbers, types, and locations of connectors, refer to "Fig. 19 Loca-
tion and Numbers of Connectors." Diagrams for internal connections of the manipulator are
shown in " Fig. 20 (a) Internal Connection Diagram " and in " Fig. 20 (b) Internal Connection
Diagram ".
3BC (For internal user

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

I/O wiring harness)
Fig. 19 Location and Numbers of Connectors
Table. 6 List of Connector Types
Name Type of Connector
Connector for internal user I/O JL05-2A20-29PC

wiring harness on connector base (JL05-6A20-29S: Optional)
Connector for internal user I/O JL05-2A20-29SC

wiring harness on U-arm (JL05-6A20-29P: Optional)
8-2
POWER CABLE INTERNAL CABLE IN S-AXIS INTERNAL CABLE IN L-AXIS INTERNAL CABLE IN BT-AXES
<NOTES>
0BT 1 0BAT11 17 0BAT1
- For the limit switch specification, the connection ofthe section A is changed as follows:
P BAT 2 BAT11 18 BAT1
0BT 3 0BAT12 19 0BAT2
P BAT 4 BAT12 20 BAT2
21 0BAT3
22 BAT3
23 S-AXIS OVERRUN LIMIT SWITCH
24 LA1 LA1
0BT 5 0BAT21 25 0BAT4 LB1
LB1 LA2 LA2 LA2
P BAT 6 BAT21 26 BAT4 L-AXIS OVERRUN LIMIT SWITCH
A
LB2
0BT 7 0BAT22 27
P BAT 8 BAT22 28 P LA3
29 LB3 LB3
30 L AND U-AXES INTERFERENCE
1 31 LIMIT SWITCH
2 32
3 1 PG0V1
4 2 PG5V1 SLU-AXES OVERRUN LIMIT SWITCH SPECIFICATION
5 3 PG0V2
6 4 PG5V2
7 5 PG0V3
8 6 PG5V3
7 PG0V4
NX100 1BC(4X10)
8
9
PG5V4
PG0V5 - The pins No.7 and No.8 of 3BC connector on the U-arm are respectively connected with
10 PG5V5
CN1-5
CN1-4 P
CN1-5
CN1-4
+24V
0V
1
3
11
12
PG0V6
PG5V6
the shock sensor power supply and shock sensor signal input port of the NX100 controller.
13
CN1-10 CN1-10 +24V 2 14
CN1-9 P CN1-9 0V 4 15
16 No.20CN Pin No. Connected Port in NX100
CN1-1 CN1-1 SPG+1 20CN-1 DATA+1
CN1-2 P CN1-2 SPG-1 P -2
-6
DATA-1
BAT
7 Shock sensor power supply; +24V (1A)
P -5
-4
OBT
+5V
PG S-AXIS 8 Shock sensor signal input
P -9 0V
CN1-3 CN1-3 FG1 -7 FG1
OBT
BAT
CN1-6
CN1-7 P
CN1-6
CN1-7
SPG+2
SPG-2 P
No.21CN
21CN-1
-2
DATA+2
DATA-2
- In case of connecting the pin No.7 and No.8 of respective 3BC connectors on the U-arm
P
-6
-5
BAT
OBT PG L-AXIS and connector base, the connection in the section B should be changed as shown in the
-4 +5V
CN1-8 CN1-8 FG2

P -9
-7
0V
FG2
section C below.
OBT
BAT (Contact your Yaskawa representative in case of modifying the wiring before use.)
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
-3 BAT -6 BAT
P -4
6CN-1
OBT
+5V
P -5
-4
OBT
+5V
PG U-AXIS
P -2 0V P -9 0V
CN2-3 CN2-3 FG3 -3 FG3 -7 FG3
No.6CN OBT
BAT
No.23CN
CN2-6 CN2-6 SPG+4 23CN-1 DATA+4
CN2-7 P CN2-7 SPG-4 P -2 DATA-4
1BC(10X4) -3 BAT
P P -4
24CN-1
OBT
+5V
PG R-AXIS
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
-3
OBT
+5V
P -4
15CN-1
OBT
+5V
PG B-AXIS
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
-5 +5V
P -4
17CN-1
OBT
+5V
PG T-AXIS
P -11 0V P -2 0V
CN3-8 CN3-8
FG6 -6 FG6 -3 FG6
OBT
BAT
CN4-1 CN4-1 +24V LA1 LA2

CN4-6 P CN4-6 LB1 P LB3 LA2
CN4-2
CN4-7 P
CN4-2
CN4-7
SS2
A C
CN4-3 CN4-3 BC2
CN4-8 P CN4-8 AL2
U POWER CABLE INTERNAL CABLE

CN2-4 CN2-4
P V FOR LAMP (OPTIONAL)
0V
CN2-5 P CN2-5 +5V CONNECTOR BASE U-ARM
CN2-9
CN2-10 P
CN2-9
CN2-10
0V NX100 1BC(4X10)
+5V
CN3-4 CN3-4 0V
CN3-5 P CN3-5
CN4-1
+5V CN4-1 +24V(1A) SS1
CN4-2 CN4-2 SS2 SS2 CRIMPED
CN3-9 CN3-9
0V
CN3-10 P CN3-10 E E CONTACT-PIN
+5V
E
Casing
Base 3BC(20-29)
3BC(20-29)
CN4-4 CN4-4
E E
CN4-5 CN4-5
SPG+7
E E E
UNUSED
P
SPG-7
CN4-9 CN4-9 FG7 E E 3BC-1 1 1 1 1 1 1 3BC-1
E
E E
Base Casing B -2
-3
-4
2
3
2
3
2
3
P 2
3
2
3
P 2
3
-2
-3
-4
E E E 4 4 4 P 4 4 P 4
-5 5 5 5 5 -5
-6 6 6 6 P 6 -6
3BC(20-29) 3BC(20-29) -7 7 7 SS1 SS1 SS1 7 -7
E E -8 8 8 SS2 P SS2 SS2 P 8 -8
-9 9 9 -9
3BC-1 1 1 1 1 1 1 3BC-1 -10 10 P 10 -10
-2 2 2 2 P 2 2 P 2 -2 -11 11 11 -11
-3 3 3 3 3 3 3 -3 -12 12 12 -12
-4 4 4 4 P 4 4 P 4 -4 -13 13 13 -13
-5 5 5 5 5 -5 -14 14 14 -14
-15 15 15 -15
-6 6 6 6 P 6 -6 -16 16 16 -16
-7 7 7 SS1 SS1 SS1 SS1 7 -7
-8 8 8 SS2 SS2 P SS2 SS2 P 8 -8
-9 9 9 -9
-10 10 P 10 -10 SHOCK SENSOR
-11 11 11 -11 (OPTIONAL) FOR SPARE WIRING OF 3BC CABLE AFTER CHANGING CONNECTIONS OF B
-12 12 12 -12
-13 13 13 -13 CABLE
-14 14 14 -14
-15 15 15 -15
-16 16 16 -16
CONNECTOR BASE U-ARM
Fig. 20 (a) Internal Connection Diagram
8-3
2BC(6X6)
E
E
No.3CN
CN1-1 CN1-1 BA1 3CN-1 MU1
CN1-2 CN1-2 BA2 -2 MV1
SM S-AXIS
CN1-3 CN1-3 BB1 -3 MW1
CN1-4 CN1-4 ME1 -4 ME1
CN1-5 CN1-5 ME2 -5 BA1
CN1-6 CN1-6 ME2 -6 BB1 YB
No.4CN
CN2-1 CN2-1 MU1 4CN -A MU2
CN2-2 CN2-2 MV1 -B MV2
SM L-AXIS
CN2-3 CN2-3 MW1 -C MW2
CN2-4 CN2-4 MU2 -D ME2
CN2-5 CN2-5 MV2 -E BA2
CN2-6 CN2-6 MW2 -F BB2 YB
No.26CN
CN3-1 CN3-1 MU2 26CN-1 MU3
CN3-2 CN3-2 MV2 -2 MV3
SM U-AXIS
CN3-3 CN3-3 MW2 -3 MW3
CN3-4 CN3-4 MU3 -4 ME3
CN3-5 CN3-5 MV3 -5 BA3
CN3-6 CN3-6 MW3 -6 BB3 YB
2BC(6X6)
No.10CN No.25CN
CN4-1 CN4-1 MU4 10CN-1 MU5 25CN-1 MU4
CN4-2 CN4-2 MV4 -2 MV5 -2 MV4
SM R-AXIS
CN4-3 CN4-3 MW4 -3 MW5 -3 MW4
CN4-4 CN4-4 MU5 -4 ME5 -4 ME4
CN4-5 CN4-5 MV5 -5 MU6 -1 BA4
CN4-6 CN4-6 MW5 -6 MV6 -2 BB4 YB
-7 MW6
-8 No.35CN No.18CN
ME6
CN5-1 CN5-1 MU6 18CN-1 MU5
CN5-2 CN5-2 MV6 -2 MV5
SM
CN5-3 CN5-3 MW6 -3 MW5 B-AXIS
CN5-4 CN5-4 ME3 -4 ME5
CN5-5 CN5-5 ME4 -1 BA5
CN5-6 CN5-6 ME5 -2 BB5 YB
No.36CN
No.19CN
CN6-1 CN6-1 ME6 19CN-1 MU6
CN6-2 CN6-2 BA3 -2 MV6
SM T-AXIS
CN6-3 CN6-3 BB4 -3 MW6
CN6-4 CN6-4 BA4 No.12CN -4 ME6
CN6-5 CN6-5 BA5 12CN-1 BA5 -1 BA6
CN6-6 CN6-6 BA6 -2 BB5 -2 BB6 YB
-3 BA6 No.37CN
-4 BB6
PE
Fig. 20 (b) Internal Connection Diagram
8-4
9 Maintenance and Inspection
WARNING
• Before maintenance or inspection, be sure to turn the main power sup-
ply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)
Failure to observe this warning may result in electric shock or injury.
CAUTION
• Maintenance and inspection must be performed by specified personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your Yaskawa representative.
• The battery pack must be connected before removing detection connec-

tor when maintenance and inspection.
Failure to observe this caution may result in the loss of home position data.
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 inter-
vals are classified into six levels. Conduct periodical inspections according to the inspection
schedule in "Table 7 Inspection Items".
In "Table 7 Inspection Items", the inspection items are categorized by three types of opera-
tions: operations which can be performed by personnel authorized of the user, operations
which can be performed by personnel being trained, and operations which can be performed
by service company personnel. Only specified personnel are to do the inspection work.
• The inspection interval must be based on the servo power supply ON time.
NOTE • These inspections were developed for applications where the manipulator is used for arc
welding work. For any different or special applications, the inspection process should be
developed on an case-by-case basis.
For axes which are used very frequently (in handling applications, etc.), it is recom-
mended that inspections be conducted at shorter Intervals. Contact your Yaskawa repre-
sentative.
9-1
Table. 7 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Person
Licensee
Company
H H
Cycle Cycle Cycle
Check alignment
mark accordance
c Alignment mark { Visual
and damage at the
{ { {
home position.
Check for damage

d External lead { Visual and deterioration of { { {
leads.
Working area Clean the working

and whole exte- area if dust or spatter
e rior of manipula-
{ Visual is present. { { {
Check for damage
tor and exterior cracks.
SLU-axes Check for grease

f motors
{ Visual
leakage.*5
{ { {
Manipulator Tighten loose bolts.

g base { Wrench Replace if necessary. { { {
mounting bolts
Phillips Tighten loose bolts.

Cover mounting screw- Replace if necessary.
h screws
{ driver,
{ { {
wrench
Check for loose con-

i Connector base { Manual
nectors.
{ { {
BT-axes Check for belt

j timing belts
{ Manual tension and wear. { {
Check for conduc-

tion between the
main connector of
connector base and
Wire harness in Visual,
{ intermediate connec-
multimeter tor with manually
{ {
manipulator
k (for SLU-axes) shaking the wire.
Check for wear of
(for RBT-axes)
protective spring.*1
{ Replace.*2 {
Check for connec-

Visual,
Wire harness in { multimeter
tion between termi- { {
nals.*1
l manipulator
(for BT-axes)
{ Replace.*2 {
Replace the battery

Battery pack in pack when the bat-
11
manipulator
{ tery alarm occurs or { {
the manipulator
drove for 36000H.
Check for malfunc-

tion. (Replace if nec-
essary.) Supply
S-axis speed Grease grease *3 (6000H
12
reducer
{ { Gun cycle). See Par.9.2.2.
{ {
*3
Exchange grease
(12000H cycle).
See Par. 9.2.2
9-2
Table. 7 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

24000 36000 Specified Service
Daily H H H Licensee
H H Person Company
Cycle Cycle Cycle
Check for malfunc-

essary.) Supply
grease (6000H
LU-axes speed cycle)*3

Grease
13
reducers
{ { Gun
See Par. 9.2.3 and { {
9.2.4
Exchange grease
(12000H cycle). *3
See Par. 9.2.3 and
9.2.4
Check for malfunc-

essary.) Supply
RBT-axes speed Grease
14
reducers
{ { Gun
grease (6000H { {
cycle).*3
See Par. 9.2.5 and
9.2.6.
Check for malfunc-

Grease essary.) Supply
15 T-axis gear { Gun grease*3 (12000H
{ {
cycle).
See Par. 9.2.7.
Check for malfunc-

R-axis cross Grease essary.) Supply
16
roller bearing
{ Gun grease*3 (12000H
{ {
cycle).
See Par. 9.2.8.
17 Overhaul { {
*1 When checking for conduction with multimeter, connect the battery pack to “BAT” and “OBT” of connectors
on the motor side for each axis, and then remove connectors on detector side for each axis from the motor.
Otherwise, the home position may be lost. (Refer to " 9.2.9 Notes for Maintenance.")
*2 Internal cables to be replaced at 24000H inspection.
*3 For the grease, refer to "Table 8 Inspection Parts and Grease Used."
*4 Inspection No. correspond to the numbers in "Fig. 21 Inspection Parts and Inspection Numbers (Manipulator
in Home Position)."
*5 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.
Table. 8 Inspection Parts and Grease Used
No. Grease Used Inspected Parts
Molywhite RE No. 00 S-, L-, and U-axes speed reducers

12 , 13
Harmonic Grease SK-1A R-, B- and T-axes speed reducers,

14 , 15
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 7 Inspection Items."
9-3
2
4
5 S-axis
1 8 T-axis
S-axis Note: The manipulator is in the home position.
8 B-axis
14 BT-axes 1 14
10 1 U-axis
13 R-axis
15 16
1 U-axis 4
L-axis
9
11
13
12 7
11
Fig. 21 Inspection Parts and Inspection Numbers (Manipurator in Home Position)
9-4
9.2 Notes on Maintenance Procedures
9.2.1 Battery Pack Replacement
The battery packs are attached in the two positions indicated in "Fig. 22 Battery Pack Loca-
tion". If the battery alarm occurs in the NX100, replace the battery pack in accordance with
the following procedure:
Battery pack
Connector base
Support
Connector base
Connector base fixing screw
Fig. 22 Battery Pack Location
9-5
Battery pack before replacement

See the step 5.
Connector
Circuit board
See the step 4.
New battery pack
Fig. 23 Battery Pack Connection
1. Turn the NX100 main power supply OFF.

2. Remove the mounting screws for the battery pack on the support.
3. Remove the battery pack from the holder.
4. Connect the new battery pack to an unconnected connector.
5. Remove the old battery pack from the circuit board.
NOTE Connect the new battery pack before removing the old one so that the encoder absolute
data does not disappear.
6. Mount the new battery pack to the battery holder.

7. Reinstall the plate.
NOTE Do not pinch the cable when the plate is installed.
9-6
9.2.2 Grease Replenishment/Exchange for S-axis Speed

Reducer
Grease exhaust port

(Hexagon socket head plug PT1/8)
Grease exhaust port

(Hexagon socket
head plug PT1/8)
Grease inlet S-axis speed reducer

Fig. 24 S-axis Speed Reducer Diagram
NOTE For ceiling mounted manipulators, the exhaust port and the grease inlet are inverted.
Grease Replenishment (Refer to "Fig. 24 S-axis Speed Reducer

Diagram".)
Replenish the grease in accordance with the following procedure:
1. Remove plugs from exhaust port and grease inlet.
NOTE If grease is injected with the plug on, the grease will go inside the motor and may damage
it. Never fail to remove the plug before the grease injection.
9-7
2. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk PT1/8 is delivered
with the manipulator.)
3. Inject the grease into the grease inlet using a grease gun.
Grease type: Molywhite RE No.00

Amount of grease: 30 cc
(60 cc for the 1st supply)
4. Move the S-axis for a few minutes to discharge the excess grease.
5. Remove the grease zerk and reinstall the plug on the grease inlet. Tighten the plug
with a tightening torque of 5 N·m (0.51 kgf·m). Apply Three Bond 1206C (listed on
table9) on the thread part of the plug.
6. Wipe the grease exhaust port with a cloth and reinstall the plug. Tighten the plug with
a tightening torque of 5 N·m (0.51 kgf·m). Apply Three Bond 1206C on the thread part
of the plug.
Grease Exchange
(Refer to "Fig. 24 S-axis Speed Reducer Diagram".)
Exchange the grease in accordance with the following procedure:
1. Remove plugs from exhaust port and grease inlet.
2. Install the grease zerk PT1/8 to the grease inlet. (The grease zerk PT1/8 is delivered
with the manipulator.)

Amount of grease: Approx. 1440 cc
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.
4. Move the S-axis for a few minutes to discharge the excess grease.
5. Remove the grease zerk and reinstall the plug on the grease inlet. Tighten the plug
with a tightening torque of 5 N·m (0.51 kgf·m). Apply Three Bond 1206C on the thread
part of the plug.
of the plug.
9-8
9.2.3 Grease Replenishment/Exchange for L-axis Speed

Reducer
L-arm
Grease exhaust port
L-axis speed reducer
Grease inlet
(Hexagon socket head
cap screw M6)
Fig. 25 L-axis Speed Reducer Diagram
NOTE The exhaust port and the grease inlet are inverted in case of ceiling installation.
(Refer to "Fig. 25 L-axis Speed Reducer Diagram".)
1. Posture the L-axis vertical to the ground.

2. Remove the plug and the screw from grease exhaust port and grease inlet respec-
tively.
3. Install the grease zerk A-MT6X1 on the grease inlet. (The grease zerk A-MT6X1 is
delivered with the manipulator.)

5. Move the L-axis for a few minutes to discharge the excess grease.
6. Remove the grease zerk and reinstall the hexagon socket head cap screw M6 on the
grease inlet. Tighten the screw with a tightening torque of 5 N·m (0.51 kgf·m). Apply
Three Bond 1206C on the thread part of the screw.
9-9
of the plug.
Grease Exchange
(Refer to "Fig. 25 L-axis Speed Reducer Diagram".)
Exchange the grease according to the following procedure:
1. Posture the L-arm vertical to the ground.

2. Remove the plug and the screw from grease exhaust port and grease inlet respec-
tively.

Amount of grease: approx. 560 cc
5. Move the L-axis for a few minutes to discharge the excess grease.
6. Remove the grease zerk on the grease inlet and reinstall the hexagon socket head cap
screw M6. Tighten the screw with a tightening torque of 5 N·m (0.51 kgf·m). Apply
Three Bond 1206C on the thread part of the screw.
7. Wipe the grease exhaust port with a cloth and reinstall the hexagon socket head plug.
Tighten the plug with a tightening torque of 5 N·m (0.51 kgf·m). Apply Three Bond
1206C on the thread part of the plug.
9-10
9.2.4 Grease Replenishment/Exchange for U-axis Speed

Reducer
U-arm
Grease exhaust port

U-axis cap screw M6)
speed
reducer
Grease inlet
plug PT1/8)
Fig. 26 U-axis Speed Reducer Diagram
NOTE The exhaust port and the grease inlet are inverted in case of ceiling installation.
(Refer to "Fig. 26 U-axis Speed Reducer Diagram".)
1. Posture the U-arm as shown in "Fig. 26 U-axis Speed Reducer Diagram".

2. Remove the screw and the plug from grease exhaust port and grease inlet respec-
tively.
NOTE If grease is injected with the screw on, the grease will go inside the motor and may damage
it. Never fail to remove the screw before the grease injection.

5. Move the U-axis for a few minutes to discharge the excess grease.
6. Remove the grease zerk and reinstall the hexagon socket head plug on the grease
inlet. Tighten the plug with a tightening torque of 5 N·m (0.51 kgf·m). Apply Three
Bond 1206C on the thread part of the plug.
7. Wipe the grease exhaust port with a cloth and reinstall the hexagon socket head cap
screw. Tighten the screw with a tightening torque of 5 N·m (0.51 kgf·m). Apply Three
Bond 1206C on the thread part of the screw.
9-11
Grease Exchange
(Refer to "Fig. 26 U-axis Speed Reducer Diagram".)
Exchange the grease according to the following procedure:
1. Posture the U-arm as shown in "Fig. 26 U-axis Speed Reducer Diagram".

2. Remove the hexagon socket head cap screw on the grease exhaust port.
NOTE If grease is injected with the screw on, the grease will go inside the motor and may damage
it. Never fail to remove the screw before the grease injection.
3. Remove the hexagon socket head plug PT1/8 on the grease inlet and install the grease
zerk A-MT6X1.

Amount of grease: approx. 320 cc
5. Move the U-axis for a few minutes to discharge the excess grease.
6. Remove the grease zerk and reinstall the hexagon socket head plug on the grease
inlet. Tighten the plug with a tightening torque of 5 N·m (0.51 kgf·m). Apply Three
Bond 1206C on the thread part of the plug.
7. Wipe the grease exhaust port with a cloth and reinstall the hexagon socket head cap
Bond 1206C on the thread part of the screw.
9-12
9.2.5 Grease Replenishment for R-axis Speed Reducer
Grease inlet
(Grease zerk A-MT6X1)
Exhaust port
(Hexagon socket head cap screw M6)
Fig. 27 R-axis Speed Reducer Diagram
1. Remove the hexagon socket head cap screw M6 on the exhaust port.
Grease type: Harmonic grease SK-1A

Amount of grease: 8cc
(16cc for the 1st supply)
NOTE The exhaust port is used for air flow. Do not inject excessive grease into the grease inlet.
3. Reinstall the hexagon socket head cap screw on the exhaust port. Tighten the screw
with a tightening torque of 5 N·m (0.51 kgf·m). Apply Three Bond 1206C on the thread
part of the screw.
9-13
9.2.6 Grease Replenishment for B-, T-axes Speed

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

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

cap screw M6)
Gease inlet (for B-axis)
Fig. 28 B-, T-axes Speed Reducers Diagram
1. Remove the plug on the exhaust port for B-axis or the hexagon socket set screw on the
exhaust port for T-axis.
NOTE Remove the cover for the B-axis speed reducer.
2. Remove the hexagon socket head cap screw on the grease inlet and install the grease
zerk A-MT6X1.

Amount of grease:
For B-axis: 10 cc (20 cc for the 1st supply)
For T-axis: 5 cc (10 cc for the 1st supply)
4. Reinstall the plug on the exhaust port for B-axis or the hexagon socket set screw on
the exhaust port for T-axis. Apply Three Bond 1206C on the thread parts.
5. Remove the grease zerk on the grease inlet and reinstall the hexagon socket head cap
Bond 1206C on the thread part.
NOTE Mount the cover for the B-axis speed reducer. (Refer to " 9.2.9 Notes for Maintenance.")
9-14
9.2.7 Grease Replenishment for T-axis Gear
Exhaust port
(Plug LP-M5)
Gear grease inlet

Fig. 29 T-axis Gear Diagram
1. Remove the plug on the exhaust port.

2. Remove the hexagon socket head cap screw on the grease inlet and install the grease
zerk A-MT6X1.
3. Inject the grease into the gear grease inlet using a grease gun.

(10cc for the 1st supply)
NOTE The exhaust port is used for air flow. Do not inject excessive grease into the gear grease
inlet.
4. Reinstall the plug on the exhaust port. Apply Three Bond 1206C on the thread part of
the plug.
5. Remove the grease zerk on the gear grease inlet and reinstall the hexagon socket
head cap screw. Tighten the screw with a tightening torque of 5 N·m (0.51 kgf·m).
Apply Three Bond 1206C on the thread part of the screw.
9-15
9.2.8 Grease Replenishment for R-axis Cross Roller Bear-

ing
Exhaust port
(Plug LP-M5)
R-axis cross roller bearing
Grease inlet
(Hexagon socket head cap
screw M6) (Length: 6mm)
Fig. 30 R-axis Cross Roller Bearing Diagram
1. Remove the plug on the exhaust port.

2. Remove the hexagon socket head cap screw from the grease inlet and install the
grease zerk A-MT6X1.
3. Inject grease into the grease inlet using a grease gun.
Grease type: Alvania EP grease 2

4. Reinstall the plug on the exhaust port. Apply Three Bond 1206C on the thread part of
the plug.
5. Remove the grease zerk on the gear grease inlet and reinstall the hexagon socket
head cap screw. Tighten the screw with a tightening torque of 5 N·m (0.51 kgf·m).
Apply Three Bond 1206C on the thread part of the screw.
9-16
9.2.9 Notes for Maintenance

Wrist Axes
The motor and encoder units are provided with the wrist unit. To prevent fumes from penetrat-
ing into the wrist unit, the matched parts are sealed with sealing bond. Therefore, if the wrist
cover is disassembled, reseal with sealing bond (Three Bond 1206C). Refer to "Table 9
Spare Parts for the MOTOMAN-HP20".
Cover Cover jointing face
Cover Cover jointing face
Fig. 31 Sealing Part of Wrist Unit
9.2.10 Encoder Connector (with CAUTION Label)
• When performing maintenance such as replacement of a wire harness in the manipulator,

NOTE the encoder connector (with CAUTION label) may be necessary to be removed. In this
case, be sure to connect the battery pack to the battery backup connector before remov-
ing the encoder connector. Removing the encoder connector without connecting the bat-
tery backup leads to disappearance of the encoder absolute data.
For the battery pack connection, refer to "Fig. 32 (a) Encoder Connector for S-, L-, U-
axes" and "Fig. 32 (b) Encoder Connector for R-, B-, T-axes."
Battery Pack Connection (for S-, L-, U-axes 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.
9-17
NOTE Do not remove the battery pack in the connector base.
Encoder connector
Motor
CAUTION
Connect battery to encoder
Motor power connector
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.
Fig. 32 (a) Encoder Connector for S-, L-, U-axes
9-18
Battery Pack Connection (for R-, B-, T-axes 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.
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.
Fig. 32 (b) Encoder Connector for R-, B-, T-axes
9-19
10 Recommended Spare Parts
It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOMAN-HP20. The spare parts list for the MOTOMAN-HP20 is shown below.
Check the serial number and contact your Yaskawa representative for preparing lead wires for
internal wiring, etc.
Product performance can not be guaranteed when using spare parts from any company other
than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation
• Rank C: Drive unit
NOTE To replace parts in Rank B or Rank C, be sure to contact your Yaskawa representative.
Table. 9 Spare Parts for the MOTOMAN-HP20
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
Molywhite Yaskawa Electric

A 1 Grease 16kg -
RE No. 00 Corporation
Harmonic Grease Harmonic Drive

A 2 Grease 2.5kg -
SK-1A System Co., Ltd.
Alvania EP Showa Oil Co.,

A 3 Grease 16kg -
Grease 2 Ltd.
Three Bond Co.,

A 4 Liquid Gasket Three Bond 1206C - -
Ltd.
Yaskawa Electric
A 5 Battery Pack HW0470360-A 1 1
Corporation
Yaskawa Electric
A 6 Battery Pack HW9470932-A 1 1
Corporation
Mitsuboshi Belt-
B 7 B-axis Timing Belt 80S4.5M653 1 1
ing Limited
Mitsuboshi Belt-
B 8 T-axis Timing Belt 80S4.5M518 1 1
ing Limited
S-axis Yaskawa Electric

B 9 HW9381641-B 1 1
Speed Reducer Corporation
S-axis Yaskawa Electric

B 10 HW0304301-1 1 1
Input Gear Corporation
L-axis Yaskawa Electric

B 11 HW9381641-A 1 1
10-1
Table. 9 Spare Parts for the MOTOMAN-HP20
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
L-axis Yaskawa Electric

B 12 HW0304302-1 1 1
Input Gear Corporation
U-axis Yaskawa Electric

B 13 HW9280880-A 1 1
R-axis Yaskawa Electric

B 14 HW0381463-A 1 1
B-axis Yaskawa Electric

B 15 HW9381633-A 1 1
T-axis Yaskawa Electric

B 16 HW0382140-A 1 1
Wire Harness in Yaskawa Electric

B 17 HW0171559-A 1 1
Manipulator Corporation
Wire Harness in
Yaskawa Electric
B 18 Manipulator for B- HW0270954-A 1 1
Corporation
and T-axes
HW0382155-A
AC Servomotor for SGMRS-12A2B- Yaskawa Electric
C 19 1 1
S-axis Corporation
YR1∗
HW0382156-A
AC Servomotor for SGMRS-13A2A- Yaskawa Electric
C 20 1 1
L-axis Corporation
YR1∗
HW0382154-A
AC Servomotor for SGMRS-06A2B- Yaskawa Electric
C 21 1 1
U-axis Corporation
YR2∗
HW0382152-A
AC Servomotor for SGMPH-02A2A- Yaskawa Electric
C 22 1 3
R-, B-, T-axes Corporation
YR1∗
10-2
11.1 S-axis Driving Unit
11 Parts List
1014
1013
1040
1041
1016
1031
1017
1033
1041
1032
1005 1042
1003 1004 1027
1008 1006 1028
1002
1007
1010 1015
1009
6001 (Zeroing Option)

1029
1011

1023
1019
1018
1039
1025
1038
1020
1021 1024
1001
1012
1022 1026
1037
1034
1035
1036
11-1
No. DWG No. Name Pcs

1001 EZ5036A0 Cap 1
1002 CD-31 Saddle 1
1003 M6X10 Socket screw 2
1004 TA1-S10 Clamp 1
1005 M5X10 Screw with 1
spring washer
1006 TSH6-01M Union 1
1007 HW0305812-1 Holder 1
2H-6 Spring washer 2
spring washer
1011 M12 Eyebolt 2
1012 PT3/8 Plug 1
1013 SGMRS-12A2B-YR1* Motor 1
1015 HW0304228-1 M base 1
1016 M5X10 APS Bolt 4
1017 HW0305809-1 Cover 1
1019 2H-16 Spring Washer 1
1020 MSB8-15 Shoulder 1
1021 HW0400645-1 Lever 1
1023 HW0100545-1 S head 1
1024 HW9381641-B Reduction gear 1
1026 HW0100544-1 Base 1
1027 M8X60 Socket Screw 3
1031 HW0304301-1 Gear 1
1034 TSH6-01M Union 1
1035 HW9406775-1 Cover 1
1037 NB-0640B-0.27 Tube 1
1038 HW0304221-1 Cover 1
1040 PT1/8 Plug 1
1041 UKM6-01 Union 1
1042 NB-0640B-0.2 Tube 1
6001 HW0405202-1(Zeroing Plug 1
Option)
6002 HW0405203-1(Zeroing Gasket 1
Option)
6005 M4X8 Screw 2
6006 HW0404492-1 (Zeroing Cover 1
Option)
Option)
11-2
11.2 L-axis Driving Unit
2019

2020
2022
2035 2021
2016 2014
2013
2015
2030
2018
2017
2002
2036 2003
2004
2037
6012 (Zeroing Option) 2007
2012
2010
2001 2006
2009
2008
2011
2025
2024
2023
1023
2025 2032
2024 2031
2026
2023
2027 2028
2029
2028
2033 2029
2034
11-3

2001 PT1/8 Plug 1
2002 PT1/8 Plug 2
2006 HW0304229-1 M base 1
2007 SGMRS-13A2A-YR1* Motor 1
2010 HW0304302-1 Gear 1
2011 Y426012.5 Oil seal 1
2012 HW0401506-1 Plate 1
2013 HW0304226-1 Support 1
2015 HW0304227-1 Cover 1
2019 HW0100546-1 L arm 1
2020 HW9381641-A Reduction gear 1
2025 HW0404196-4 Washer 2
2026 FCD-31 Saddle 1
spring washer
2031 HW0305813-1 Holder 1
2033 HW0305698-1 Cover 1
spring washer
1023 HW0100545-1 S head 1
Option)
Option)
6010 M5X10 Screw 2
Option)
Option)
11-4
11.3 U-axis Driving Unit
3003
3034
3002
3016
3004
3001
3004
3018 3005
3020
3019
3018
3020 6018 (Zeroing Option)
6017
3008
3006
3011 3007
3010
3022
3033
3015

2019
11-5

3002 HW0404656-1 M cover 2
3004 PT1/8 Plug 2
3005 HW0100729-1 Casing 1
3011 GT-SH-14 Spring Washer 6
3016 SGMRS-06A2B-YR2* Motor 1
3018 HW0404196-2 Washer 2
3021 ARP568-258 O ring 1
3034 M4 L washer 6
2019 HW0100546-1 L arm 1
6015 HW0404491-1 (Zeroing Base 1
Option)
6016 M5X16 (Zeroing Option) Socket screw 2
6017 MS4-10 (Zeroing Option) Pin 2
Option)
Option)
Option)
Option)
6024 M5X10 Screw 2
11-6
11.4 R-axis Driving Unit
4033 4012
4032
4031
4029
4074 4036
4071
4008 4072
4030
4010 4029 4066
4042 3005
4035
4009
4058 4057 4043
4006
4005 4007
4056
4044
4003 4011
4075 4076
4027 4073
4022
4026 4060
4034
4037 4023 4055
4039
4025
4040 4051
3014 4046
4045
3012
4062
4024
4067 4020
4065 4021
4015
4013
4019
4016 4014
4004 4002
4017 4001
4070
4069
4068
4018

11-7
No. DWG No. Name Pcs No. DWG No. Name Pcs
4001 M6X65 Socket screw 8 4060 HW0304930-1 Support 1
4002 2H-6 Spring Washer 8 4062 6811LLU Bearing 1
4003 M5X20 Socket screw 4 4065 M4X20 Socket screw 2
2H-5 Spring washer 4 4066 KQE12-03 Union 1
4004 M4X12 Socket screw 4 4067 2H-4 Spring Washer 2
2H-4 Spring washer 4 4068 M4X20 Socket screw 2
4005 HW0305305-1 M cover 1 4069 2H-4 Spring Washer 2
4006 M4X20 Socket screw 12 4070 MS4-10 Pin 2
4007 2H-4 Spring Washer 12 4071 2H-4 Spring Washer 1
4008 HW0404196-5 Washer 1 4072 PT 3/8 Plug 1
2H-6 Spring washer 8 2H-4 Spring washer 2
4011 M6X6 Socket screw 1 2H-6 Spring washer 3
4012 A-MT6X1 G Nipple 1 4075 TA1-S8 Clamp 3
4013 HW0381872-A Cross roller 1 4076 M4X8 Screw with 3
bearing spring washer
4014 M6X35 Socket screw 8 3005 HW0100729-1 Casing 1
4015 HW0404503-1 Saddle 1 2H-4 Spring washer 4
4016 TC941045*A727* Oil seal 1 3014 HW0404179-1 Support 2
4017 HW0403857-1 Shaft 1 5046 HW0100623-1 Uarm 1
4018 HW0405201-2 Block 1 6025 HW0405202-1 Plug 1
HW0405201-1 Block 1 (Zeroing Option)
(For zeroing spec. only) 6026 HW0405203-1 Gasket 1
4019 HW0304318-1 Housing 1 (Zeroing Option)
4020 HW0304085-1 Shaft 1
4021 HW0304914-1 Support 1
4022 HW0404503-1 Saddle 1
4025 HW0200530-1 S cover 1
4026 HW0404919-1 Support 1
4030 HW0404403-1 Shaft 1
4031 AE1314J1 Oil seal 1
4032 HW0304932-1 M base 1
4033 HW0404402-1 Shaft 1
4035 HW0404900-1 N base 1
spring washer
4039 TA1-S8 Clamp 1
spring washer
4042 M5X8 APS bolt 1
4044 LP-M5 Plug 1
4055 HW0404918-1 Support 1
4056 SGMPH-02A2A-YR1* Motor 1
4057 EZ5036A0 Cap 1
11-8
11.5 Wrist Unit
11.5 Wrist Unit
5045
5069 5005
5068
3005
5002
5001
5046 5003
5006 5070 5011

5007
5008
5055
5057
5026
5008
5007 5006
5005 5044 5064
5070
5045 5003
5037
5043 5038 5071
5039
5048 5035
5034
5040 5013
5014
5049 5036 5019
5010 5018
5071 5041 (Zeroing Option) 5062 5063
5067 5009
5047 5042
5017 5015
(Zeroing Option)
5061 5071
5023
5032 5029 5033
5053
5020
5021
5050 5031
5022
5024
5028
5027
5025 5066
5052 5065
5026
5030
5060
11-9
11.5 Wrist Unit
No. DWG No. Name Pcs No. DWG No. Name Pcs
5001 HW9406556-1 Support 1 5052 M5X16 Socket screw 5
5002 M4X12 Socket screw 2 2H-5 Spring washer 5
5003 M5X20 Socket screw 4 5055 M6X14 Bolt 1
2H-5 Spring washer 4 HW0405202-1 Plug 1
5005 HW9200798-1 Cover 2 (Zeroing Option)
5006 SGMPH-02A2A-YR12 Motor 2 5057 M6 L Washer 1
5007 M4X16 Socket screw 2 HW0405203-1 Packin 1
(Zeroing Option)
5008 HW9482727-A Pulley 2
5009 HW0404543-1 Cover 1
(Zeroing Option) 2H-5 Spring washer 4
5010 M4X8 (Zeroing Option) Screw 2 5061 M4X12 Socket screw 8
5011 80S4.5M518 Belt 1 2H-4 Spring washer 8
5012 HW9381658-A Gear 1 5062 LP-M5 Plug 1
5013 M4X12 Socket screw 4 5063 HW9405791-3 Housing 1
2H-4 Spring washer 4 5064 6811LLU Bearing 1
5014 HW9405452-1 B cover 1 5065 HW0404606-1 Cover 1
5015 HW0404544-1 Cover 1 5066 HW040605-1 Plug 1
(Zeroing Option) 5067 M6X6 Socket screw 1
5016 HW9482725-A Pulley 1 5068 TA1-S8 Clamp 1
5017 M5X16 Socket screw 1 5069 M4X8 Screw with 1
5018 M4X16 Socket screw 4 spring washer
2H-4 Spring washer 4 5070 2H-4 Spring washer 2
5019 HW9482218-A Bearing 1 5071 2H-5 Spring washer 3
5020 HW9405199-1 B nut 1 3005 HW0100729-1 Casing 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
11-10
MOTOMAN-HP20
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686 Fax 1-905-813-5911
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800 Fax 46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone 60-3-6092-1377 Fax 60-3-6092-6377
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice MANUAL NO. RE-MTO-A247

for ongoing product modifications and improvements. C Printed in Japan April 2005 05-04

HP20

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Motoman NX100 Controller

Part Number: 149615-1CD

This safety section addresses the following:

YASKAWA MANUAL NO. RE-MTO-A247

• The drawings and photos in this manual are representative examples

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

• YASKAWA is not responsible for incidents arising from unauthorized

Indicates a potentially hazardous situation which, if not

Indicates a potentially hazardous situation which, if not

Always be sure to follow explicitly the items listed under this

PROHIBITED Must never be performed.

Emergency Stop Button

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Stop

• Observe the following precautions when performing teaching operations

Improper or unintended manipulator operation may result in injury.

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

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

Definition of Terms Used Often in This Manual

Equipment Manual Designation

NX100 Controller NX100

NX100 Programming Pendant Programming Pendant

Cable between the Manipulator and the Controller Manipulator Cable

8 Electrical Equipment Specification

9 Maintenance and Inspection

10 Recommended Spare Parts

1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.

1.2 Order Number Confirmation

Fig. 1 Location of Order Number Labels

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

• Avoid excessive vibration or shock during transportation.

2.1 Transporting Method

2.1.1 Using a Crane

• Check that the eyebolts are securely fastened.

Fig. 2 Transporting Position

2.1.2 Using a Forklift

Fig. 3 Using the Forklift

2.2 Shipping Bolts and Brackets

Enlarged View: Section A Enlarged View: Section C Enlarged View: Sections B and D

• The brackets in the sections A and B are painted yellow.

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

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

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

The manipulator may overturn and cause injury or damage.

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

Failure to observe this caution may cause injury or damage.

3.1 Installation of Safeguarding

Responsibility for Safeguarding (ISO10218)

3.2 Mounting Procedures for Manipulator Base

Table. 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop

Horizontal rotating maximum torque 8000 Nm

Vertical rotating maximum torque 5000 Nm

Table. 2 Endurance Torque in Operation

Endurance torque in horizontal operation 1700 Nm

Endurance torque in vertical operation 3775 Nm

3.2.1 Installation Example

Fig. 4 Manipulator Installation Example

3.3 Installation Method

• S-axis Operating Range

3.3.1 S-axis Operating Range

3.3.2 Fixing the Manipulator Base

3.3.3 Precautions to Prevent the Manipulator from Falling

Horizontal rotating maximum torque 8000 Nm

Vertical rotating maximum torque 5000 Nm

Endurance torque in horizontal operation 1700 Nm

Endurance torque in vertical operation 3775 Nm