Instructionmanual MT1-3000S2D MT1-5000S2D · ©2014YaskawaNordicAB·Reg.No.ME00091EN-01 Originalinstructions Instructionmanual MT1-3000S2D MT1-5000S2D 185315-1CD 0

© 2014 Yaskawa Nordic AB · Reg.No. ME00091EN-01Original instructions

Instruction manualMT1-3000S2DMT1-5000S2D

185315-1CD0

Page 2 Reg.No. ME00091EN-01

■ Reference list

YASKAWA Nordic AB engineers

■ Revision

Second release of this manual

MT1-3000/5000S2D

Reg.No. ME00091EN-01 Page 3

MT1-3000/5000S2DContents

1 General............................................................................................................................ 51.1 About this manual ..................................................................................................... 51.1.1 Copyright ................................................................................................................. 51.2 Intended use .............................................................................................................. 51.3 Identification.............................................................................................................. 51.3.1 Product confirmation................................................................................................ 51.3.2 Order confirmation................................................................................................... 71.4 Contacts..................................................................................................................... 71.4.1 Manufacturer............................................................................................................ 71.4.2 Distributors............................................................................................................... 7

2 Safety............................................................................................................................... 82.1 General safety............................................................................................................ 82.1.1 Standard compliance............................................................................................... 82.1.2 Requirement on operating personnel ...................................................................... 82.1.3 Personal Protective Equipment .............................................................................. 92.2 Installationsafety ...................................................................................................... 92.2.1 Installation of the safeguarding................................................................................ 92.3 Wiring safety............................................................................................................ 102.3.1 Protective earth...................................................................................................... 102.3.2 Equipotential bonding............................................................................................ 102.4 Release of person trapped in or by the machine ..................................................112.5 Decommissioning, storage, and disposal .............................................................11

3 Handling and installation.......................................................................................123.1 Lifting instruction.................................................................................................... 123.1.1 Using a crane......................................................................................................... 133.1.2 Using a forklift ....................................................................................................... 133.2 Dimensions.............................................................................................................. 133.3 Fixture design.......................................................................................................... 143.3.1 Fixture disc ............................................................................................................ 143.4 Mounting .................................................................................................................. 143.4.1 Rough setting......................................................................................................... 153.4.2 Connecting ............................................................................................................ 163.4.3 Mounting of optional equipment............................................................................. 163.5 Wiring ....................................................................................................................... 173.5.1 Connection to YASKAWA robot controller ............................................................. 173.6 Safety components................................................................................................. 193.7 Before first start....................................................................................................... 203.7.1 Parameter setting .................................................................................................. 203.7.2 Initial test................................................................................................................ 20


MT1-3000/5000S2DContents

4 Basic specifications.................................................................................................214.1 Ambient conditions................................................................................................. 214.2 External supply........................................................................................................ 214.2.1 Voltage................................................................................................................... 214.2.2 Pneumatic (Option)................................................................................................ 214.3 Functional specifications....................................................................................... 224.3.1 Parameter setting .................................................................................................. 224.3.2 Position.................................................................................................................. 224.3.3 Stopping time......................................................................................................... 224.3.4 Position.................................................................................................................. 224.3.5 Colour .................................................................................................................... 224.3.6 Welding.................................................................................................................. 234.4 Maximum load and capacity................................................................................... 234.4.1 Calculation of offset ............................................................................................... 244.4.2 Maximum x-offset rotating axis MT1-3000S2D ..................................................... 244.4.3 Maximum x-offset rotating axis MT1-5000S2D ..................................................... 244.4.4 Max payload area .................................................................................................. 24

5 Maintenance................................................................................................................255.1 General..................................................................................................................... 255.2 Lubrication and maintenance ................................................................................ 255.2.1 Lubrication and maintenance schedule................................................................. 255.2.2 Lubrication and maintenance positions ................................................................. 275.2.3 Remove covers...................................................................................................... 285.3 Servo units............................................................................................................... 305.3.1 General.................................................................................................................. 305.3.2 Reduction gear ...................................................................................................... 305.3.3 AC Servo ............................................................................................................... 30

6 Spare parts and optional equipment.................................................................326.1 General..................................................................................................................... 326.1.1 Specifications for recommended lubricants........................................................... 326.2 Spare parts list......................................................................................................... 336.2.1 MT1-3000/5000S2Dcomplete............................................................................... 336.2.2 X-unit ..................................................................................................................... 346.2.3 Arm 124743–100................................................................................................... 366.2.4 Arm 124743–101................................................................................................... 386.2.5 Servo unit............................................................................................................... 406.2.6 Current transfer unit............................................................................................... 416.3 Available optional eqiupment................................................................................. 426.3.1 Option Tailstock SPB-7000 ................................................................................... 426.3.2 Option Controlled air kit ......................................................................................... 43

7 Annex Safety Data Sheet........................................................................................447.1 Annex GRAFLOSCONC-SG 0 ULTRA................................................................... 44

MT1-3000/5000S2DAbout this manual

1 General

1.1 About this manual

This manual is valid for positioners YASKAWA MT1-3000S2D and MT1-5000S2D. It is relevant forpersonnel who at some stage are affected by the machinery or its functions and it shall be keptnearby the machinery.

The manual contains:

• Technical data

• Machine safety

• Installation

• Maintenance

• Spare parts

Read

For operating instructions, see Instructions for use.

1.1.1 Copyright

This manual may be copied for internal use without our written permission but not imparted to a thirdparty.

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies inparticular to trademarks, model denominations, documents, and drawings.

1.2 Intended use

This machine is designed to be equipped with fixtures and to be incorporated into machinerycontrolled by a YASKAWA robot controller system. The machine is intended to serve welding robotsby shifting workpieces.

1.3 Identification

1.3.1 Product confirmation

Informationon Identification label

Machinery type: MT1-3000S2DMT1-5000S2D

Part No.: See machinery signSerial No.: See machinery signYear of manufacturing: See machinery sign


MT1-3000/5000S2DIdentification

Standard delivery content

• Horizontal positioner, type MT1-3000/5000S2D.

• Cable set between positioner and robot controller.

• Technical documentation.

• Assembly kit for robot controller.

NoteThe positioner, if provided with a bracket, can be equipped in different distances betweenfixture discs.

Main parts

B

A

Fig. 1 Positioner MT1-3000S2DA. X-unit

B. Arm

Optional equipment

• Tailstock SPB-7000

• Controlled air kit

Read

For optional equipment see chapter 6.3 Available optional eqiupment.


MT1-3000/5000S2DContacts

1.3.2 Order confirmation

Confirm that identification numbers of the positioner are identical to the numbers of the shippinginformation.

Warning

If numbers do not match, the positioner may not perform as expected and cause injuryor damages.

1.4 Contacts

1.4.1 Manufacturer

Address: YASKAWA Nordic ABP.O Box 504Verkstadsgatan 2SE-385 25 Torsås

Telephone: +46 480 417 800Telefax: +46 486 414 10

1.4.2 Distributors

See addresses at the last page of this manual.


MT1-3000/5000S2DGeneral safety

2 Safety

2.1 General safety

This equipment is constructed, produced and tested according to the laws of the MemberStates relating to Machinery directive (2006/42/EC) and the demands of the EMC directive(2004/108/EC) as well as the LVD (2006/95/EC).

YASKAWA Nordic AB’s responsibility does not cover errors or safety risks that may occur inequipment connected to and/or installed in the machine, nor errors or safety risks that mayoccur in the machine caused by equipment connected to and/or installed in the machine.

The machine must not be put into service until the complete production unit corresponds tothe laws of the Member States relating to machinery (2006/42/EC).

2.1.1 Standard compliance

This machine is developed in compliance with the following, to Machinery directive harmonized,standards.

• EN ISO 10218-1:2011 Robots and robotic devices - Safety requirements for industrial robots - Part1 Robots

• EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: Generalrequirements

• EN 60439-1 Low Voltage switchgear and control gear assemblies - Part 1: Type-tested andpartially type-tested asssemblies

• EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity forindustrial environments

• EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emissionstandard for industrial environments

2.1.2 Requirement on operating personnel

The machine must only be operated by specially trained persons.

General

The operating personnel must not be under influence of alcohol, drugs, or similar substances. Theoperating personnel must not have a resetricted filed of vision or be restricted in an other way thatcould lead to risks. The operating personnel must be in a sutable state of health to operate thesystem/component (in particular, attention must be paid to medical aids, such as cardiac pacemakers,etc..

Qualified personnel

Persons involved in commissioning, operation, maintenance, and repair of the system/componentmust be familiar with the system/component and trained accordingly. They must have read andunderstood the operating manuals. Furthermore, they must be instructed and must be able to avoidpossible residual risks to themselves and to third persons while working on the system/component orto reduce such risks as far as possible. To maintain the qualification, the safety instruction must berepeated at least every year.


MT1-3000/5000S2DInstallation safety

2.1.3 Personal Protective Equipment

Warning

Use Personal Protective Equipment (PPE), such as safety-shoes, helmet, goggles,hearing protectors, and gloves, appropriate to the type of operation being carried out.Otherwise severe injuries can easily occur!

Warning

Use hearing protectors to reduce the noise exposure level when the machine isrunning.

2.2 Installation safety

Warning

• Install the safeguarding

Failure to observe this warningmay result in injury or damage.

• Do not start the machine or turn ON the power before it is firmly anchored.

The machine may overturn and cause injury or damage.

• Do not install or operate a machine which is damaged or lacks parts.

Failure to observe this cautionmay cause injury or damage.

Important

Install the machine in a location so that the installation into which it is incorporated comply tothe regulations of the Machinery directive 2006/42/EC.

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

Read

When installing, it is necessary to observe the requirements of environmental conditions. Seechapters 3.4Mounting and 4 Basic specifications.

2.2.1 Installationof the safeguarding

To ensure safety, install the safeguarding. It prevents unforeseen accidents to personnel and damageto equipment. The following is quoted for your information and guidance.


MT1-3000/5000S2DWiring safety

Responsibility for safeguarding (EN ISO 10218-2:2011)

The user of a machine or complete system shall ensure that safeguarding is provided and used inaccordance with sections 5, 6, and 7 of EN ISO 10218-2:2011 Robots and robotic devices - Safetyrequirements for industrial robots — Part 2: Robot systems and integration. The means and degreeof safeguarding, including any redundancies, shall correspond directly to the type and level of hazardpresented by the machine system consistent with the application. Safeguarding may include, but notbe limited to safeguarding devices, barriers, interlock barriers, perimeter guarding, awarenessbarriers, and awareness signals.

2.3 Wiring safety

Warning

Before wiring, turn OFF the primary power supply, and put up a warning sign. (e.g. DONOT TURN THE POWER ON.) Failure to observe this warning may result in fire orelectric shock.

Warning

Wiring must be performed by authorized or certified personnel. Failure to observe thiscautionmay result in fire or electric shock.

Important

Keep equipotential bonding and protective earth separated. Equipotential bonding andprotective earth are two separate circuits.

2.3.1 Protective earth

Warning

Protective earth shall be performed following the directive LVD 2006/95/EC and itsharmonised standards.

Failure to do so may result in severe incidents.

2.3.2 Equipotential bonding

The recommended wire shall correspond to a low resistance according to LVD 2006/95/EC and itsharmonised standards. For equipotential bonding, connect the wire directly to the frame of themachine.


MT1-3000/5000S2DRelease of person trapped in or by the machine

NoteNever share this line with other ground lines or grounding electrodes for other electric power,motor power, welding devices, etc..

2.4 Release of person trapped in or by the machine

Read

For instructions on “release of person trapped in or by the machine”: see the instructions foruse concerning the complete integration.

2.5 Decommissioning, storage, and disposal

Destruction must comply with all applicable local and national standards at the time of destruction.The unit must be decommissioned, stored and disposed of in accordance with the applicable nationallaws, regulations and standards.


MT1-3000/5000S2DLifting instruction

3 Handling and installation

3.1 Lifting instruction

Read

Read and understand the contents of chapter 2 Safety before handling the machine.

Warning

Crane operation, forklift truck operation etc. should be only performed by licensedpersonnel. When handling the positioner, extra care must be taken regarding thefollowing:

• Do no place any part of your body under a suspendedmachine.

• Do not move the machine over another person's body.

Careless handlingmay result in severe personnel injury.

B

C

D E F

A

Fig. 2 Lifting instruction

A. Lifting straps

B. Eye bolt

C. Lifting hole

D. Forks

E. Support

F. Pallet


MT1-3000/5000S2DDimensions

3.1.1 Using a crane

Warning

The straps shall be certificated for at least 5000 kg each.

Important

For eyebolts, use bolts of approved safety class.

To lift the machine, use the intended straps placed through eyebolts and the lifting holes. Lift themachine as shown in Fig. 2 Lifting instruction. When using straps a locking bolt must be applied.

3.1.2 Using a forklift

To lift the machine, use a fork lift with its forks in their outer position. Put the machine on a pallet,place support under the arm and lift the machine as shown in Fig. 2 Lifting instruction. Transport themachine slowly with due caution in order to avoid overturning or slippage.

3.2 Dimensions

L1

L2

- +

-+

L3L4

2175

H118

3012

50

Ø80

0

240030

60

A

B

H2

H3

D

±225

Fig. 3 Main drawings, dimensions in mm

A. Tilt axis B. Rotating axis


MT1-3000/5000S2DFixture design

Model Weight[kg]

Range D[mm]

H1[mm]

H2[mm]

H3[mm]

L1[mm]

L2[mm]

L3[mm]

L4[mm]

124620-100 7061 3306 1327 789 1041 1552 1800 3768 4168

124620-101 7109 3306 1330 789 1041 1556 1800 3773 4173124621-100 7051 2980 1367 1033 797 1507 1485 3417 3817

124621-101 7092 2980 1370 1033 797 1513 1495 3427 3827

3.3 Fixture design

3.3.1 Fixture disc

60º (6x)

Ø600

Ø800

Ø50 H7

M16 (6x)

Fig. 4 Fixture disc 231207B

3.4 Mounting

Read


Read

The forces in table of chapter 4 Basic specifications has to be considered when constructingand mounting the positioner onto foundation.

The positioner shall be firmly mounted on a base or a foundation firm enough to support thepositioner and withstand maximum repulsion forces during acceleration and deceleration.

While constructing a solid foundation and further when applying anchoring bolts or corresponding,follow the European Commission directive 89/106/EEC (Construction Products) by its harmonizedstandards and if necessary the specific Construction Product’s ETA (European Technical Approval)(e.g. regarding appropriate concrete thickness/quality and the depth of anchoring bolt attachments).


MT1-3000/5000S2DMounting

3.4.1 Rough setting

1. Make sure the surface of the base or foundation is level and even. If necessary, grind the swelland flatten the surface.

NoteIt is important to place foot washers under the adjustment screws. See Fig. 5 Footwasher.

A E

B

C

D25 mm F

Fig. 5 Foot washer

A. Adjustment screw

B. Baseplate of positioner

C. Foot washer

D. Base or foundation

E. Anchor bolt

F. Recommended distance app. 25 mm

2. Place the machine in its final position.

A

B

C

Fig. 6 Adjust surface with high precision spirit-level

A. Surface to level

B. Adjustment screw

C. Holes for anchor bolts

3. Fix the base plate to the floor with anchor bolts.


MT1-3000/5000S2DMounting

4. Place a high precision spirit-level on the surface A. See Fig. 6 Adjust surface with high precisionspirit-level.

5. Adjust the surface A to a level of <0.2/1000 mm by means of adjustment screws.

Fig. 7 Tighten all bolts

6. Fix the stand to the floor by tightening the anchoring bolts.

3.4.2 Connecting

7. Connect electric wiring, see 3.5Wiring

8. Connect pneumatic connections, if needed.

3.4.3 Mounting of optional equipment

NoteAll mounting screws, especially for the fixture brackets and the fixture itself, shall be of atleast strength class 12:9 and minimum thread length 1.5xD, where D = thread diameter.

Dimension (12:9 strength) Tightening torque (Nm)M10 79M12 136M14 217M16 333M18 463M20 649


MT1-3000/5000S2DWiring

3.5 Wiring

Read


3.5.1 Connection to YASKAWA robot controller

Warning

• Install all electrical cables to the positioner, control system, welding equipment etc.so that there is no possibility to stumble over or step on the cables.

• Do not put any object directly on the cables.

• Do not place the cables along power cables, or underneath the welding power

The positioner is controlled from the robot controller and the operator's panel. Place the controllerand panel so that the operator has full view over the machine.

Installation and connection to the robot controller comprises hardware as well as software installation.This work steps shall be carried out by YASKAWA Nordic AB service personnel. When the positioneris delivered together with a robot, the installation is already carried out at YASKAWA Nordic ABfactory. When delivered together with other equipment: see separate diagram for electricalconnection, included in the in the order specific documentation:

Connections

A

X1B X2 X3 X4

Fig. 8 Connections to controllerA. Connection for weld -

B. Connection for equipotential bonding


MT1-3000/5000S2DWiring

Connector Drawing no Position in Fig. 8 Connections tocontroller

Internal wiring I/O 348358–10 X3Internal wiring servo motor/signal 347924–12 X1/X2External servo signal 347262–xx X1

External servo motor 347763–xx X2

Options X4

“-xx” stands for a certain cable length. Available lengths are shown in table Cable lengths.

Cable lengths

Cable -80 -81 -82 -83 -84 -85 -86 -87 -88 -89Length (m) 3 6 9 12 15 18 21 24 27 30


MT1-3000/5000S2DSafety components

3.6 Safety components

One limit switch is used to control the servo axis on the headstock. One switch is used to control theservo axis on the arm. These must be connected to the safety circuit. The safety circuit is notincluded. It is not allowed to remove the limit switches. For more information regarding sensors, seeifm electronic Original operating instructions Fail-safe inductive sensor GG712S.

A

B

CD

Fig. 9 Failsafe sensors

A. Bracket

B. Sensor

C. Bracket

D. Sensor

For parts number and annotation, see chapter 6.2 Spare parts list.

Fig. 10 Operation as 4-wire unit


MT1-3000/5000S2DBefore first start

3.7 Before first start

Read


Warning

Check all safety functions as emergency stop, safety switches and light beams.

Failure to do so could result in severe personal injury.

Important

Personnel shall be instructed to never stay inside the safety guard during operation.

Caution

During operation, check that nothing abnormal occurs as vibrations, unusual noise etc. If anyof these occurs, stop the machine immediately by pushing EMERGENCY STOP and contactYASKAWA Nordic AB service.

3.7.1 Parameter setting

The parameter setting for the positioner is performed by authorised personnel at factory or atinstallation.

3.7.2 Initial test

Read

For initial test and examination of the positioner and its protective measures: see theinstructions for use concerning the complete integration.


MT1-3000/5000S2DAmbient conditions

4 Basic specifications

4.1 Ambient conditions

Temperature 0 to 40ºC

Humidity 20 to 80% RH at constant temperature

Vibration acceleration 4.9 m/s2 (0.5 G) or less

Others Free from corrosive gas, liquid or explosive gasFree from exposure to water or oil.Free from abnormal exposure to dust.Free from excessive electrical noise (plasma)Location indoor

NoteAbove ambient conditions are general requirements if no specific equipment, such as eg. IP-kit or other, allows certain extreme environments or conditions.

4.2 External supply

4.2.1 Voltage

Read

See the requirements for robot-controller system in its installation/instruction manual.

4.2.2 Pneumatic (Option)

The specification on compressed air are:

Working pressure: 0.6 MPaMinimum pressure: 0.5 MPaQuality: According to ISO 8573-1, Class 5,4,3Connector: G1/2” (ISO 228-1)


MT1-3000/5000S2DFunctional specifications

4.3 Functional specifications

Model Refer to YASKAWA Nordic AB dimension drawing noMT1-3000S2D 124620-100

124620-101MT1-5000S2D 124621–100

124621–101

4.3.1 Parameter setting

Read

The parameter setting for positioner are excluded in manuals since it is changeable. Seepositioner’s part number for correct MMS document.

4.3.2 Position

Repetitive position accuracy: ± 0.1 mm

4.3.3 Stopping time

When the emergency stop is activated the machine will make an immediate stop. This time from fullvelocity to still machine is called stopping time. The stopping time is based on the parameter settingsin the MMS-document.

Measured stopping time (category 1) at 100% payload and 100% speed for the motionsModel Axis Stopping time Stopping angleMT1-3000S2DMT1-5000S2D

Tilt axis 0.428 s 3.0°Rotating axis 0.422 s 4.1º

NoteIf a tailor-made configuration of this positioner is delivered: check with your YASKAWA NordicAB representative for the correct stopping-time.

4.3.4 Position

Repetitive position accuracy: ± 0.1 mm

4.3.5 Colour

Colour TypeFrameworkGlare shield

Two-pack convertible coatingRAL5005 (Blue)RAL9005 (Black)


MT1-3000/5000S2DMaximum load and capacity

4.3.6 Welding

Welding capacity, standard Continuous duty 100% 700 ADuty factor 60% 920 A

4.4 Maximum load and capacity

To guarantee long and safe operation with high positioning accuracy of the MT1-3000/5000S2D: themachine must not be overloaded. Follow the restriction below.

Tilt axis MT1-3000S2D MT1-5000S2DDynamic torque 15058 Nm 15058 Nm

Static torque 12045 Nm 12046 NmMax capacity load 3000 kg 5000 kgMotor power 4.4 kW 4.4 kW

Gear ratio spur 131/20 131/20Gear ratio reducer 119:1 119:1

Gear ratio total 779.45 779.45Efficiency 0.8 0.8Nominal speed 0–1.92 rpm 0–1.92 rpm

Max speed 2.5 rpm 2.5 rpm

Rotating axis MT1-3000S2D MT1-5000S2DDynamic torque 10498 Nm 10498 Nm

Static torque 8398 Nm 8398 NmMax capacity load 3000 kg 5000 kg

Max capacity offset 285 mm 172 mmMotor power 4.4 kW 4.4 kW

Gear ratio spur 137/30 137/30

Gear ratio reducer 119:1 119:1

Gear ratio total 543.433 543.433Efficiency 0.8 0.8Nominal speed 2.7 rpm 0–2.7 rpm

Max speed 3.6 rpm 3.6 rpm


MT1-3000/5000S2DMaximum load and capacity

4.4.1 Calculation of offset

(Max static torque of axis in Nm)X Max offset of axis in m=

(MMax payload in kg x 9.81)

4.4.2 Maximum x-offset rotating axis MT1-3000S2D

Maximum static torque of rotating axis = 8398 Nm.

MMaximum payload 3000 kg (incl. fixtures).

XMaximum offset from rotation centre at 3000 kg = 285 mm

4.4.3 Maximum x-offset rotating axis MT1-5000S2D

Maximum static torque of rotating axis = 8398 Nm.

MMaximum payload 5000 kg (incl. fixtures).

XMaximum offset from rotation centre at 5000 kg = 172 mm

4.4.4 Max payload area

C D

E

F

A

B

Fig. 11 Max payload areaA. Tilt axis

B. Rotating axis

Model Max payload C = D E FMT1-3000S2D 3000 kg 285 mm 491 mm 326 mm

MT1-5000S2D 5000 kg 172 mm 253 mm 237 mm


MT1-3000/5000S2DGeneral

5 Maintenance

5.1 General

Maintenance of the positioner should be handled only by authorised personnel or YASKAWA NordicAB Service, who are thoroughly familiar with the design and construction of the machine. For all kindof service/maintenance, be sure to:

1. Turn off and lock the electrical supplies.

2. Turn off and lock the wiring circuit breaker.

Warning

Depending on type of installation, connections between several machines can existand consequently electrical supplies from several power sources occurs.

Turn off all live circuits before servicing.

To avoid incidents caused by inadvertent using the machine, put up an informationsign indicating that maintenance is performed.

Check after performedmaintenance that all covers are remounted and all bolts aretightened to requisite torque. Check that no tools are left in the cell.

5.2 Lubrication and maintenance

The pos No. in the table in 5.2.1 Lubrication and maintenance schedule refers to the positions in Fig.13 Lubrication and maintenance positions, X-unit and Fig. 14 Lubrication and maintenance positions,arm.

The symbol in Fig. 12 Symbol for lubrication indicates a location on the positioner to performinspection or maintenance according to Fig. 13 Lubrication and maintenance positions, X-unit andFig. 14 Lubrication and maintenance positions, arm.

Fig. 12 Symbol for lubrication


MT1-3000/5000S2DLubrication and maintenance

5.2.1 Lubrication and maintenance schedule

Interval PosNo.

Object Method/specification Lubricant/means

Every shift 1 Overall cleaning The machine does not needany special cleaning besidenormal cleaning (dust etc.).

Dry cloth andcompressed air

Daily 2 Vibrations and noise inservo unit.

Listen to make sure thateverything is normal.

Weekly 3 Check bolts for fixtureand anchor bolts in thefloor.

If necessary tighten. Wrench key

Pneumatic system air(optional equipment).Not shown in figure.

Check air supply and airquality.

500 h 4a Current transfer unit Check the current transferunits and ground discsregularly. If the surface is tooworn, bad contact and badwelding result will occur.See Check current transferunits and ground discs

4b Ground disc

5a Gear wheel Manually with a brush.If the cycle time is shorter than2 minutes, grease every15.000 indexes. Covers mustbe removed to accesslubrication point.See Lubrication X-unit andLubrication arm

20 gram KlüberGraflosconC-SG 0 Ultra5b Slewing ring gear

Cables and hoses. Notshown in figure.

Check for wear and damages.Clean if necessary.

Compressed air

Annually 6 Insulation resistance inservo-motors

Make sure that it is more than10 Mohm by measuring with a500 V megger afterdisconnected the motor fromthe controller.See Check insulationresistance in servo-units

500 V megger

Repairreplacing

Reduction gear Contact YASKAWA Nordic ABrepresentative



5.2.2 Lubrication and maintenance positions

1

2,6

3

5a

5b

Fig. 13 Lubrication and maintenance positions, X-unit

1

2,6

5a

5b

4b

4a

Fig. 14 Lubrication and maintenance positions, arm



5.2.3 Remove covers

NoteKeep screws, washers, nuts, and other parts organized to facilitate remounting. All partsmust be fastened properly before start.

A

C

B C

Fig. 15 Removing gear covers

A. Gear cover, X-unit

B. Gear cover, arm

C. Screw, part no. 6002027

LubricationX-unit

1. Loosen the 4 screws C.

2. Remove the cover A on the X-unit, see Fig. 15 Removing gear covers.

3. Lubricate according to 5.2.1 Lubrication and maintenance schedule.

4. Remount in reverse order.

Lubrication arm

1. Loosen the 4 screws C.

2. Remove the cover B on the arm, see Fig. 15 Removing gear covers.

3. Lubricate according to 5.2.1 Lubrication and maintenance schedule.




Check current transfer units and ground discs

A

B

D

C

Fig. 16 Removing cover

A. Cover, arm

B. Cover, X-unit

C. Screw, part no. 6002077

D. Flanged nut, part no. 6023002

1. Place the arm in an appropriate maintenance position.

2. Loosen the 14 screws C and remove the cover A, see Fig. 16 Removing cover.

3. Loosen the 8 flanged nuts D and remove the cover B on the x-unit, see Fig. 16 Removing cover.

4. Check the current transfer units and the ground discs for wear and damage.

5. Replace, if necessary.


Check insulation resistance in servo-units

1. Place the arm in an appropriate maintenance position.

2. Loosen the 14 screws C and remove the cover A on the arm, see Fig. 16 Removing cover.

3. Loosen the 8 flanged nuts D and remove the cover B on the x-unit, see Fig. 16 Removing cover.

4. Check the insulation resistance in servo-motor on the arm and on the x-unit.

5. If the servo motors are not in order, contact YASKAWA Nordic AB representative.



MT1-3000/5000S2DServo units

5.3 Servo units

5.3.1 General

Important

Dismounting of servo unit is not recommended.

If the gear is dismounted by personnel without adequate knowledge, the technical data cannot be guaranteed.

If certain work has to be performed on the servo units, YASKAWA Nordic AB representativeshould be contacted.

Condition at delivery

When reduction gears are delivered mounted on positioner, they are properly filled with grease atYASKAWA Nordic AB.

Considerationswhen assembling servo units

Motor shafts should be coated with MoS2-paste or spray (e.g. Molycote).

Disassembly - reassemble

In principle, disassembly of the reduction unit is not recommended. No attempt should be made tochange the mesh or clearances within the unit. If the unit is disassembled by other than YASKAWApersonnel then the operating and performance characteristic cannot be guaranteed.

5.3.2 Reduction gear

Lubrication

Gears are filled with grease when delivered from YASKAWA Nordic AB.

The gear is lifetime lubricated.

5.3.3 AC Servo

Servo motor

The AC servomotor has no wearing parts (e.g. brushes), so simple daily inspection is sufficient. Theinspection schedule for the motor is shown in section 5.2.1 Lubrication and maintenance schedule.Do not disassemble the motor. If disassembly should become necessary, contact YASKAWA NordicAB service.

Servopack

The servopack does not require any special maintenance. Remove dust and tighten screwsperiodically


MT1-3000/5000S2DServo units

Troubleshooting

Warning

Shaded text, turn power OFF before corrective action.

Trouble Cause RemedyMotor does not start Loose connection Tighten connection

Wrong wiring Correct wiring

Overload Reduce loadUnstable operation Wrong wiring Inspect and correct wiring across motor terminals L1, L2,

L3 and PEMotor overheats Excessive ambient

temperatureReduce ambient temperature below 40°C

Motor surface is dirty Clean motor surface

Overload Reduce loadUnusual noise Motor loosely mounted Tighten foundation bolts

Motor misaligned Realign

Coupling out of balance Balance coupling

Noisy bearing Check alignment, noise of bearing, lubrication andcontact YASKAWA Nordic AB service

Vibration of drivenmachine

Contact machine manufacturer, YASKAWA Nordic ABservice


MT1-3000/5000S2DGeneral

6 Spare parts and optional equipment

6.1 General

It is recommended to use original YASKAWA Nordic AB spare parts. Using inappropriate parts mayresult in severe incidents.

When ordering spare parts, always state:

• Machine type

• Machine number

• Part number

• Name of part

• Number of parts

It is always advisable to keep some of the most frequent spare parts in stock.

For MT1-3000/5000S2D the following parts are recommended:

Name Part no QuantitySensor 8540244 2Carbon brush Straight 414757 2Grease Grafloscon 9100551 1

Send your order to:

Address: YASKAWA Nordic ABP.O Box 504Verkstadsgatan 2SE-385 25 Torsås

Telephone: +46 480 417 800Telefax: +46 486 414 10

Or nearest YASKAWA Nordic AB distributor (see addresses at the last page of this manual).

6.1.1 Specifications for recommended lubricants

See 7.1 Annex GRAFLOSCON C-SG 0 ULTRA


MT1-3000/5000S2DSpare parts list

6.2 Spare parts list

6.2.1 MT1-3000/5000S2D complete

2

1

Fig. 17 MT1-3000S2D 124620-100

Pos. no. Part no. Part name Note Quantity124620-100 MT1-3000S2D complete 1

124620-101 MT1-3000S2D complete withbracket

Bracket for use with Fig.23 Tailstock.

124621–100 MT1-5000S2D complete

124621–101 MT1-5000S2D complete withbracket

Bracket for use with Fig.23 Tailstock.

1 124733-102 X-unit H=1830 12 124742-100 Arm 124620-100 1

124742-101 Arm 124620-101124743-100 Arm 124621-100124743-101 Arm 124621-101



6.2.2 X-unit

1

2

3

4

5

6

7

822

9

10

11

23

12

13

14

15

16

17

18

1920

21

Fig. 18 X-unit 124733–102

Pos. no. Part no. Part name Note Quantity124733–102 X- unit H = 1830 1

1 114538-80 Stand H = 1830 12 213176-80 Cam shaft Ø130 L 13 213637 Shaft 14 213640 Cover 15 124589-100 Servounit 4,4 kW F1C-A75G-119 16 314003 Gear wheel z=20 17 6044930 Ball race slewing m=8 z=131 1

8 313994 Pressure washer 19 213638 Spacer ring Ø429/370 t=32 1

10 314033 Connection block 3-Connections 111 315641 Cover plate 1



Pos. no. Part no. Part name Note Quantity12 413927-80 Key 28x16 L=74 1

13 413944 Bracket 114 413945 Ring 1

15 413975 Foot plate 70x70x15 14

16 414938 Cover plate 1100x727x1,5 1

17 113853 Harting junction panel

18 6050312 Handle 1405-200 219 127759-100 ground disc 22.5° 1

20 415199-101 Bracket for sensor 121 8540244 Sensor M18x1 122 6002027 Screw MC6S 823 6023002 Flanged nut M6 8



6.2.3 Arm 124743–100

1

2

3

4

455

6

78

9

10

11

12

13

14

14

15

25

16

17

17

18

19

20

24

21

22

23

Fig. 19 Arm 124743–100

Pos. no. Part no. Part name Note Quantity124743–100 Arm 1

1 114762-100 Arm 12 413924 Cover 5x250x250 1



Pos. no. Part no. Part name Note Quantity3 6038203 Plastic plugg PE Ø42x38-40S 1

4 16326-102 Bracket power conduction 240 YPB 2

5 315439-82 Conductor brush Plan 26 213636 Shaft Ø80 17 8540244 Sensor M18x1 18 128723-100 Bracket Z 275 19 127759-100 ground disc S235JRG2 1

10 313625 Cover 2x140x190 111 8220018 Cable connector KRF 70-10 112 314183 Wear cover Nylon-6/6 1

13 413922 Counterweight 1500 kg 1

14 313707 Insulating plate 2

15 213176-804 Cam shaft Ø130 L=11 116 213207B Fixture disc Ø800 117 413927-81 Key 2

18 6044915 Slewing ring m=5 z=137 1

19 213638-101 Spacer 36 mm 1

20 314005 Gear wheel Z=30 121 113404 Transmission casing 1

22 124589-100 Servounit 4.4 kW F1C-A75G-119 123 315639 Cover 124 6002027 Screw MC6S 6x8 625 6002067 Screw MC6S 20



6.2.4 Arm 124743–101

1

2

3

4

455

6

78

9

10

11

12

13

14

14

15

16

17

17

18

19

2021

22

2

24

23

Fig. 20 Arm 124743–101

Pos. no. Part no. Part name Note Quantity124743–101 Arm 1

1 114762-101 Arm 12 413924 Cover 5x250x250 2



Pos. no. Part no. Part name Note Quantity3 6038203 Plastic plugg PE Ø42x38-40S 1

4 16326-102 Bracket power conduction 240 YPB 2

5 315439-82 Conductor brush Plan 26 213636 Shaft Ø80 17 8540244 Sensor M18x1 18 128723-100 Bracket Z 275 19 127759-100 ground disc S235JRG2 1

10 313625 Cover 2x140x190 111 8220018 Cable connector KRF 70-10 112 314183 Wear cover Nylon-6/6 1

13 413922 Counterweight 1500 kg 1

14 313707 Insulating plate 2

15 213176-804 Cam shaft Ø130 L=11 116 213207B Fixture disc Ø800 117 413927-81 Key 2

18 6044915 Slewing ring m=5 z=137 1

19 213638-101 Spacer 36 mm 1

20 314005 Gear wheel Z=30 121 113404 Transmission casing 1

22 124589-100 Servounit 4.4 kW F1C-A75G-119 123 6002027 Screw M MC6S 6x8 624 6002067 Screw MC6S MC6S 20



6.2.5 Servo unit

1

2

3

Fig. 21 Servo unit

Pos. no. Part no. Part name Note Quantity124589–100 Servo unit 4.4 kW 1

1 9055240 Motor SGMRV-44ANA-YR21 12 6057027 Gear F1C-A75G-119-Ø28 13 214964 Adapter 1



6.2.6 Current transfer unit

2

1

3

45

6

7

Fig. 22 Current transfer unit 315439-82

Pos. no. Part no. Part name Note Quantity315439-82 Current transfer unit Std 1

1 214725 Frame 12 414734 Insulate plug 1

3 6034066 Spring 1

4 413574 Washer 15 60026008 Washer 16 6001017 Screw 17 414757 Brush Straight 1


MT1-3000/5000S2DAvailable optional eqiupment

6.3 Available optional eqiupment

6.3.1 Option Tailstock SPB-7000

A positioner with arm 124743–101 can be equipped in different distances between fixture discs.

This tailstock option can only be used together with the arm 124743–101.

H

Fig. 23 Tailstock

Pos. no. Part no. Part name Note Quantity1 113261-92 SPB-7000 SIngle H=1830 Std 1

Tailstock fixture disc

Ø292Ø400

30°

30°

Ø80 H7

Ø500

M8 (6x)

M16(8x)

Fig. 24 Fixture disc

Pos. no. Part no. Part name Note Quantity1 313153 Fixture disc 1


MT1-3000/5000S2DAvailable optional eqiupment

6.3.2 Option Controlled air kit

1

2

3

4

Fig. 25 Controlled air kit

Pos. no. Part no. Part name Note Quantity215746–100 Controlled air kit 2x Ø1 3mm 1

1 215745-101 Bracket 12 215744-100 Shaft 2x1/2" 13 215743-100 Swivel Ø100 2 channels 14 7027600 Hose coupling nipple 1/2" 4


MT1-3000/5000S2DAnnex GRAFLOSCONC-SG 0 ULTRA

7 Annex Safety Data Sheet

7.1 Annex GRAFLOSCONC-SG 0 ULTRA


Page 1/4Safety Data Sheet

according to 1907/2006/EC, Article 31Printing date 15.07.2008 Revision: 24.07.2006

DR

* 1 Identification of the substance/preparation and of the company/undertaking· Product details· Trade name: GRAFLOSCON C-SG 0 ULTRA· Article number: 039067· Application of the substance / the preparation Grease· Manufacturer/Supplier:KLÜBER LUBRICATION MÜNCHEN KGGeisenhausenerstrasse 7D-81379 MünchenTel.: 0049 (0) 897876-0Fax: 0049 (0) 897876-333

· Further information obtainable from:Material Compliance ManagementE-Mail: [email protected]

· Information in case of emergency: 0049 (0) 89 7876 700 (24 hrs)

2 Hazards identification· Hazard description: Not applicable.· Information concerning particular hazards for human and environment:The product has to be labelled due to the calculation procedure of the "General Classificationguideline for preparations of the EU" in the latest valid version.R 52/53 Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic

environment.· Classification system:The classification is according to the latest editions of the EU-lists, and extended by company andliterature data.

3 Composition/information on ingredients· Chemical characterization· Description:mineral oilaluminium soapsolid lubricant

· Dangerous components:CAS: 68390-93-2 Fatty acids, (C=16-18) and (C=18)-unsatd., Methyl esters,

sulfurizedR 53

≤ 2.5%

CAS: 68937-41-7EINECS: 273-066-3

Phenol, isopropylated, phosphateXn; R 62-63

≤ 2.5%

CAS: 115-86-6EINECS: 204-112-2

triphenyl phosphateN; R 50/53

0.25-1%

· Additional information: For the wording of the listed risk phrases refer to section 16. GB

(Contd. on page 2)



Trade name: GRAFLOSCON C-SG 0 ULTRA

(Contd. of page 1)

DR

4 First-aid measures· After inhalation: Supply fresh air; consult doctor in case of complaints.· After skin contact: Wash off with soap and plenty of water.· After eye contact:Rinse opened eye for several minutes under running water. If symptoms persist, consult a doctor.

· After swallowing: If symptoms persist consult doctor.

5 Fire-fighting measures· Suitable extinguishing agents:Water hazeFoamFire-extinguishing powderCarbon dioxide

· For safety reasons unsuitable extinguishing agents: Water with full jet· Special hazards caused by the substance, its products of combustion or resulting gases:In case of fire, the following can be released:Carbon monoxide (CO)Hydrocarbons

· Protective equipment:Do not inhale explosion gases or combustion gases.Standard procedure for chemical fires.

· Additional informationCool endangered receptacles with water spray.Dispose of fire debris and contaminated fire fighting water in accordance with official regulations.

6 Accidental release measures· Person-related safety precautions: Not required.· Measures for environmental protection: Do not allow to enter sewers/ surface or ground water.· Measures for cleaning/collecting:Pick up mechanically.Dispose of the material collected according to regulations.

7 Handling and storage· Handling:· Information for safe handling: No special measures required.· Information about fire - and explosion protection: No special measures required.· Storage:· Requirements to be met by storerooms and receptacles:Store in cool, dry conditions in well sealed receptacles.

· Information about storage in one common storage facility:Store away from foodstuffs.Store away from oxidizing agents.

· Further information about storage conditions: None.

8 Exposure controls/personal protection· Additional information about design of technical facilities: No further data; see item 7.

(Contd. on page 3) GB




(Contd. of page 2)

DR

· Ingredients with limit values that require monitoring at the workplace:The product does not contain any relevant quantities of materials with critical values that have to bemonitored at the workplace.

· Additional information: The lists valid during the making were used as basis.· Personal protective equipment:· General protective and hygienic measures:Immediately remove all soiled and contaminated clothingAvoid close or long term contact with the skin.Be sure to clean skin thoroughly after work and before breaks.

· Respiratory protection: Not required.· Protection of hands: Preventive skin protection by use of skin-protecting agents is recommended.· Eye protection: Not required.

9 Physical and chemical properties· General Information

Form: PastyColour: BlackOdour: Product specific

· Change in conditionDrip point: > 100°C (DIN ISO 2176)

· Flash point: not applicable· Danger of explosion: Product does not present an explosion hazard.· Density at 20°C: 0.96 g/cm³· Solubility in / Miscibility with

water: Insoluble.

10 Stability and reactivity· Thermal decomposition / conditions to be avoided:No decomposition if used and stored according to specifications.

· Materials to be avoided: oxidizing agents· Dangerous reactions No dangerous reactions known.· Dangerous decomposition products: none under normal use

11 Toxicological information· Additional toxicological information:Prolonged skin contact may cause skin irritation and/or dermatitis.

12 Ecological information· Ecotoxical effects:· Behaviour in sewage processing plants: The product can be mechanically separated.· General notes: Do not allow product to reach ground water, water course or sewage system.

13 Disposal considerations· Product:· Recommendation Can be incinerated in accordance with local and national regulations.

(Contd. on page 4) GB




(Contd. of page 3)

DR

· Waste disposal key:For this product no waste disposal key according the European Waste Catalogue (EWC) can bedetermined, as only the purpose of application defined by the user enables an allocation. The wastecode number has to be determined in accordance with the local waste disposer.

· Uncleaned packaging:· Recommendation:Empty contaminated packagings thoroughly. They may be recycled after thorough and propercleaning.

14 Transport information· Land transport ADR/RID (cross-border)· ADR/RID class: - · Maritime transport IMDG:· IMDG Class: - · Air transport ICAO-TI and IATA-DGR:· ICAO/IATA Class: - · Transport/Additional information:Not classified as dangerous according to the above specifications.

15 Regulatory information· Labelling according to EU guidelines:The product has been classified and marked in accordance with EU Directives / Ordinance onHazardous Materials.

· Risk phrases:52/53 Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic

environment.· Safety phrases:61 Avoid release to the environment. Refer to special instructions/safety data sheets.

16 Other informationThis information is based on our present knowledge. However, this shall not constitute a guaranteefor any specific product features and shall not establish a legally valid contractual relationship.

· Relevant R-phrases50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in the aquatic

environment.53 May cause long-term adverse effects in the aquatic environment.62 Possible risk of impaired fertility.63 Possible risk of harm to the unborn child.

· Department issuing MSDS: Material Compliance Management· Contact: +49(0)897876-1564· * Data compared to the previous version altered.

GB


YASKAWA Nordic ABPO Box 504, SE-385 25 TorsåsSWEDEN

Phone +46 (0)480 417 800www.motoman.se

last page

YASKAWA Company groupAT YASKAWA Europe GmbH

Vienna +43-1-707 9324 15

CZ YASKAWA Czech s.r.o.Rudná u Prahy +420-257 941 718

DE YASKAWA Europe GmbHAllershausen +49-8166-90-0

ES YASKAWA Iberica S.L. Gavà +34-93-6303478

FI YASKAWA Finland Oy Turku +358-403000600

FR YASKAWA France S.A. Nantes +33-2-40131919

IL YASKAWA Europe Technology LtdRosh Ha’ayin +972-3-9030412

IT YASKAWA Italia SRL Torino +39-011-9005833

NL YASKAWA Benelux B.V.Son +31 40-2895500

RU YASKAWA Nordic ABMoscow +7 495 6442409

SE YASKAWA Nordic ABTorsås +46-480-417800

SI YASKAWA Slovenia d.o.oRibnica +386-1-8372-410

SK YASKAWA Europe GmbH, o.z. Bratislava +421 2 6828 6535

TU YASKAWA Turkey Elektrik Ticaret Limited Sirketi Ümraniye-Istanbul +90 216 5273450

UK YASKAWA UK Ltd Banbury +44-1295-272755

ZA YASKAWA Southern Africa PTY LtdJohannesburg +27-11-6083182

DistributorsBG Kammarton Bulgaria Ltd

Sofia +359 (02) 926 6060

CH MESSER Eutectic Castolin Switzerland S.A.Dällikon +41-44-847 17 17

DK Robotcenter DanmarkHorsens +45 7022 2477

EE RKR Seadmed OÜTallin +372 68 35 235

GR Kouvalias RoboticsAvlona +30-22950 42902

HU Flexman Robotics KftBudapest +36 30 951 0065

LT Profibus UABPanevezys +370-45-518575

NO Skala Robotech asLierstranda +47-32240600

PL Integrator RHC Sp.z.o.oTorun +48 56 65 19 710

PT Roboplan Lda Aveiro +351 234 943 900

RO Sam Robotics srlTimisoara +40 720 279 866

RO S.C. MPL Automation S.R.L.Satu Mare +40 261 750 741

Documents

Instructionmanual MT1-3000S2D MT1-5000S2D · ©2014YaskawaNordicAB·Reg.No.ME00091EN-01 Originalinstructions Instructionmanual MT1-3000S2D MT1-5000S2D 185315-1CD 0