SSA 2000 Manipulator Manual: Motoman NX100 Controller

Motoman NX100 Controller
SSA 2000
Manipulator Manual
Part Number: 153599-1CD

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
COMPLETE OUR ONLINE SURVEY
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http://www.motoman.com/forms/techpubs.asp
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.
SSA 2000
153599-1
Chapter 1
Introduction
1.1 About This Document

This manual provides information for the SSA 2000 manipulator and contains the following sections:
CHAPTER 1 - INTRODUCTION
Provides general information about the structure of this manual, a list of reference documents, and
customer service information.
CHAPTER 2 - SAFETY
This section provides information regarding the safe use and operation of Motoman products.
CHAPTER 3 - SSA 2000 INSTRUCTIONS
Provides detailed information for the SSA 2000 manipulator.
1.2 Reference to Other Documentation

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
1.3 Customer Service Information

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:
• Robot Type (SSA 2000)
• Application Type (welding, handling, etc.)
• Robot Serial Number (located on back side of robot arm)
• Robot Sales Order Number (located on back of controller)
Final page 1
Manipulator Manual
Chapter 1 Introduction
Notes
page 2 Final
SSA 2000
153599-1
Chapter 2
Safety
2.1 Introduction
It is the purchaser’s responsibility to ensure that all local, county, state,

and national codes, regulations, rules, or laws relating to safety and safe
operating conditions for each installation are met and followed.
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 R15.06-1999. 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
INTERNET: www.roboticsonline.com
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.
Final page 3
Manipulator Manual
Chapter 2 Safety
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, Operation, and Maintenance Safety (Section 2.6)
2.2 Standard Conventions
This manual includes the following alerts – in descending order of severity – that are essential to the
safety of personnel and equipment. As you read this manual, pay close attention to these alerts to
insure safety when installing, operating, programming, and maintaining this equipment.
DANGER!
Information appearing in a DANGER concerns the protection of personnel from the immediate
and imminent hazards that, if not avoided, will result in immediate, serious personal injury or
loss of life in addition to equipment damage.
WARNING!
Information appearing in a WARNING concerns the protection of personnel and equipment from
potential hazards that can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing in a CAUTION concerns the protection of personnel and equipment,
software, and data from hazards that can result in minor personal injury or equipment damage.
Note: Information appearing in a Note provides additional information which is helpful in understanding the item being
explained.
page 4 Final
SSA 2000
153599-1
2.3 General Safeguarding Tips
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 R15.06-1999, section 4.2.5, Sources of Energy, 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).
2.4 Mechanical Safety Devices
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 R15.06-1999 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 equipment is provided as standard:
• Safety fences and barriers
• Light curtains and/or safety mats
• Door interlocks
• Emergency stop palm buttons located on operator station, robot controller, and
programming pendant
Check all safety equipment frequently for proper operation. Repair or replace any non-functioning
safety equipment immediately.
Final page 5
Manipulator Manual
Chapter 2 Safety
2.5 Installation Safety
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 R15.06-1999 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.
2.6 Programming, Operation, and Maintenance Safety
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. Improper
operation can result in personal injury and/or damage to the equipment. Only trained personnel
familiar with the operation, manuals, electrical design, and equipment interconnections of this robot
should be permitted to program, operate, and maintain the system. All personnel involved with the
operation of the equipment must understand potential dangers of operation.
• 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 all safety equipment for proper operation.
Repair or replace any non-functioning safety equipment immediately.
• Do not enter the robot cell while it is in automatic operation. Be sure that only the person
holding the programming pendant enters the workcell.
• Check the E-STOP button on the programming pendant for proper operation before
programming. The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Back up all programs and jobs onto suitable media before 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.
page 6 Final
SSA 2000
153599-1
• Any modifications to PART 1, System Section, of the robot controller concurrent I/O
program can cause severe personal injury or death, as well as damage to the robot! Do not
make any modifications to PART 1, System Section. 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.
• The robot controller allows modifications of PART 2, User Section, of the concurrent I/O
program and modifications to controller parameters for maximum robot performance. Great
care must be taken when making these modifications. 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 and other parts of the system. Double-check all
modifications under every mode of robot operation to ensure that you have not created
hazards or dangerous situations.
• Check and test any new or modified program at low speed for at least one full cycle.
• This equipment has multiple sources of electrical supply. Electrical interconnections are
made between the controller and other equipment. Disconnect and lockout/tagout all
electrical circuits before making any modifications or connections.
• Do not perform any maintenance procedures before reading and understanding the proper
procedures in the appropriate manual.
• Use proper replacement parts.
• 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).
Final page 7
Manipulator Manual
Chapter 2 Safety
Notes
page 8 Final
YASKAWA
MOTOMAN-SSA2000
INSTRUCTIONS
TYPE: YR-SSA3-A00 (STANDARD SPECIFICATION)
TYPE: YR-SSA3-A01 (SLU-AXES WITH LIMIT SWITCHES)
TYPE: YR-SSA3-A10 (CEILING-MOUNTED SPECIFICATION)
TYPE: YR-SSA3-A11 (CEILING-MOUNTED, SLU-AXES WITH LIMIT SWITCHES)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-SSA2000 INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
YASKAWA MANUAL NO.
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MANDATORY
• This instruction manual is intended to explain mainly on the mechanical
part of the MOTOMAN-SSA2000 for the application to the actual opera-
tion and for proper maintenance and inspection. It describes on safety
and handling, details on specifications, necessary items on mainte-
nance and inspection, to explain operating instructions and mainte-
nance procedures. Be sure to read and understand this instruction
manual thoroughly before installing and operating the manipulator.
• General items related to safety are listed in 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
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the
MOTOMAN-SSA2000.
In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”,
“MANDATORY”, or “PROHIBITED”.
WARNING Indicates a potentially hazardous situation which, if not avoided,

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

CAUTION could result in minor or moderate injury to personnel and dam-
age 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”.
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WARNING
• Before operating the manipulator, check that servo power is turned OFF
pressing the emergency stop buttons on the front door of the NX100 and
the programming pendant.
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 person is present in the P-point maximum envelope of

the manipulator and that you are in a safe location before:
- Turning on the power for the NX100.
- 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 front door of the NX100 and the
programming pendant.
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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 cabinet of

the NX100 after use.
The programming pendant can be damaged if it is left in the manipulator’s work area, on
the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the 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
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Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the body of the manipula-
tor. Prior to operating the manipulator, confirm the contents.
WARNING Label A
WARNING Label B
Nameplate
Nameplate: WARNING Label A:

MOTOMAN WARNING
TYPE
PAYLOAD MASS Moving parts

kg kg
ORDER NO. DATE may cause
SERIAL NO. injury
YASKAWA ELECTRIC CORPORATION JAPAN
WARNING Label B:
WARNING
Do not enter
robot
work area.
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1 Product Confirmation
1.1 Contents Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Order Number Confirmation . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 Transport
2.1 Transport Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Using a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.1.2 Using a Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2 Shipping Bolts and Brackets . . . . . . . . . . . . . . . . . . . . . . . 2-3
3 Installation
3.1 Safeguarding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Mounting Procedures for Manipulator Base . . . . . . . . 3-2
3.2.1 Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3 Types of Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . .3-5
3.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 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 . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 Dimensions and P-Point Maximum Envelope . . . . . . 5- 3
5.5 Alterable Operating Range . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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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- 3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-6
9.2.1 Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.3 Notes on Grease Replenishment/Exchange
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.3.1 Grease Replenishment/Exchange for S-Axis Speed
Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
T Grease Replenishment (Refer to " Fig. 24 S-Axis
Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
T Grease Exchange (Refer to " Fig. 24 S-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.3.2 Grease Replenishment/Exchange for L-Axis Speed
Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
T Grease Exchange (Refer to " Fig. 25 L-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
T Grease Exchange (Refer to " Fig. 25 L-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.3.3 Grease Replenishment/Exchange for U-Axis Speed
Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
T Grease Replenishment (Refer to " Fig. 26 U-Axis
Speed Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . 9-12
T Grease Exchange (Refer to " Fig. 26 U-Axis Speed
Reducer Diagram ".) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.3.4 Grease Replenishment for R-Axis Speed Reducer . . . . . . . . 9-14
9.3.5 Grease Replenishment for B-Axis Speed Reducer . . . . . . . . 9-15
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9.3.6 Grease Replenishment for T-Axis Gear . . . . . . . . . . . . . . . . .9-16

9.3.7 Notes for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
Battery Pack Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18
10 Recommended Spare Parts
11 Parts List
11.1 S-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 L-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.3 U-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.4 R-Axis Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 Wrist Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
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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 porduct arrives.

Standard delivery includes the following four items (information for the content of optional
goods is given separately):
• Manipulator
• NX100
• Programming pendant
• Manipulator cables (2 cables between the NX100 and the Manipulator)
1-1
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1.2 Order Number Confirmation
1.2 Order Number Confirmation
Check that the order number of the manipulator corresponds to the NX100. The order
number 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 GE N
ER
EM
SERIAL No.
Y
DATE
MADE IN JAPAN NJ2484-1
THE MANIPULATOR AND THE CONTROLLER S

SHOULD HAVE SAME ORDER NUMBER. T O P
ORDER NO.
NJ1529
WARNING
Do not open the door
REMOTE TEACH
PLAY
ON
D
PE
IP
TR OFF
T
SE
RE
MULTI
COORD. SERVO
DISPLAY
SWITCH
POWER
SELECT
MAIN SHORTCUT ASSIST
MENU MENU
X- X+ x x
S- S+ R- R+
Y- Y+ y y
L- L+ B- B+
- + z z
R- R+ T- T+
SHIFT INTER 7 8 WELD

9 SHIFT
LOCK FEED TEST RUN
WEAVING
START START
ROBOT
SWITCH AUXILIARY
4 WEAVING
5
WELD
6 BACK NEXT
COMPLETE COMPLETE RETRUCT
EX-AXIS 1 2 3CURRENT DELETE INSERT

SWITCH AUXILIARY TIMER VOLTAGE
CABCEK 0 . -CURRENT ENTER

INTER. REF.
POINT VOLTAGE MODIFY
(a) NX100 (Front View) (b) Manipulator (Top View)
Fig. 1 Location of Order Number Labels
1-2
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2.1 Transport Method
2 Transport
CAUTION
• Sling applications and crane or forklift operations must be performed by
authorized personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock during transport.
The system consists of precision components; failure to observe this caution may
adversely affect performance.
• The weight of the manipulator is approximately 135 kg including the shipping bolts and
NOTE brackets. Use a wire rope strong enough to withstand the weight.
• Make sure to mount the shipping bolts and brackets when transporting the manipulator.
• With any transportation equipment, make sure to avoid external force on the arm or
motor unit when transporting the manipulator.
2-1
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2.1.1 Using a Crane

As a rule, the manipulator should be lifted by a crane with wire ropes when removing it from
the package and moving it. Be sure that the manipulator is fixed with the shipping bolts and
brackets before transport, and lift it in the posture as shown in " Fig. 2 Transporting Position ".
Hexagon socket
head cap screw M10
(2 screws)
Shipping bracket
Fig. 2 Transporting Position
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2.2 Shipping Bolts and Brackets
2.1.2 Using a Forklift

When using a forklift, the manipulator should be fixed on a pallet with shipping bolts as shown
in " Fig. 3 Using a Forklift ". Insert claws under the pallet and lift it. The pallet must be strong
enough to support the manipulator. Transport the manipulator slowly with due caution in order
to avoid overturning or slippage.
Bolt M16 (4 places)
Pallet
Forklift claw entries
Fig. 3 Using a Forklift
2.2 Shipping Bolts and Brackets
The manipulator is provided with two shipping bolts and a shipping bracket. (See " Fig. 2
Transporting Position ".)
Shipping bracket
Front View Side View

Hexagon socket
head cap screw M10
(2 screws)
Fig. 4 Shipping Bolts and Brackets
• The shipping bolts and bracket are painted yellow.

• The shipping bracket is to be fixed with the hexagon socket head cap screws M10 (2
screws).
Before turning ON the power, check to be sure that the shipping bolts and brackets are
NOTE removed. The shipping bolts and brackets then must be stored for future use, in the event
that the manipulator must be moved again.
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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 fully extended arm and
tool will not reach the wall, safeguarding, or controller.
Failure to observe this warning may result in injury or damage.
• Do not start the manipulator or even turn ON the power before it is

firmly anchored.
The manipulator may overturn and cause injury or damage.
• When mounting the manipulator on wall, the base section must have suf-
ficient strength and rigidity to support the weight of the manipulator.
Also, it is necessary to consider countermeasures to prevent the manip-
ulator from falling.
Failure to observe these warnings may result in injury or damage.
CAUTION
• Do not install or operate the manipulator that is damaged or lacks parts.
Failure to observe this caution may cause injury or damage.
• Before turning ON the power, check to be sure that the shipping bolts
and brackets explained in " Fig. 4 Shipping Bolts and Brackets " (page
2-3) are removed.
Failure to observe this caution may result in damage to the driving parts.
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3.1 Safeguarding Installation
3.1 Safeguarding Installation
To insure safety, be sure to install safeguarding. It prevents unforeseen accidents with

personnel and damage to equipment. Refer to the quoted clause for your information and
guidance:
Responsibility for Safeguarding (ISO10218)

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

support the manipulator and withstand repulsion forces during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand maximum repulsion
forces of the manipulator referring to " Table 1 Maximum Repulsion Forces of the Manipulator
at Emergency Stop " and " Table 2 Endurance Torque in Operation ".
A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness of installation surface
may deform the manipulator shape and affect its functional abilities. Mount the manipulator
base as instructed in " 3.2.1 Mounting Example ".
Table 1 Maximum Repulsion Forces of the Manipulator at Emergency Stop
Maximum torque in horizontal rotation 2000 NNm

(S-axis moving direction) (204 kgfNm)
Maximum torque in vertical rotation 3500 NNm

(LU-axes moving direction) (357 kgfNm)
Table 2 Endurance Torque in Operation
Endurance torque in horizontal 450 NNm

operation (46 kgfNm)
(S-axis moving direction)
Endurance torque in vertical 1300 NNm

operation (132 kgfNm)
(LU-axes moving direction)
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3.2 Mounting Procedures for Manipulator Base
3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The baseplate should be rug-
ged and durable to prevent shifting of the manipulator or the mounting fixture. It is recom-
mend to prepare a baseplate of 40 mm or more thick, and anchor bolts of M16 or larger size.
The manipulator base is tapped for four mounting holes; securely fix the manipulator base to
the baseplate with four hexagon head bolts M16 (50 mm long is recommended). Next, fix the
manipulator base to the baseplate. Tighten the hexagon head bolts and anchor bolts firmly so
that they will not work loose during the operation.
Refer to " Fig. 5 Mounting the Manipulator on Baseplate " for the installation method.
Hexagon head bolt M16 (4 bolts)
Spring washer
Washer Manipulator base
Baseplate
20
40 or
more
Manipulator base
Anchor bolt (M16 or larger)
Baseplate
300 +0.018
16 dia. 0
260 (2 holes)
240 132±0.1
A
18 dia. (4 holes)
153±0.1
102±0.1
60
260
300
216
60
130±0.1
132±0.1
Baseplate
+0.018
12 dia. 0 102±0.1
153±0.1
100±0.1
View A Units: mm
Fig. 5 Mounting the Manipulator on Baseplate
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3.3 Types of Mounting
3.3 Types of Mounting
The MOTOMAN-SSA2000 is available in three types: floor-mounted type (standard), wall-

mounted type, and ceiling-mounted type. For wall-mounted and ceiling-mounted types, the
three points listed below are different from the floor-mounted type.
The manipulator of ceiling-mounted types are: YR-SSA3-A10 and YR-SSA3-A11.
• S-Axis Operating Range
• Fixing the Manipulator Base
• Precautions to Prevent the Manipulator from Falling
3.3.1 S-Axis Operating Range

For wall-mounted type, the S-axis operating range is ±30°. (Set before the shipment.)
3.3.2 Fixing the Manipulator Base

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

In case of installation of wall-mounted and ceiling-mounted types, to ensure safety, be sure to
take preventive measures to the manipulator base section against falling. Refer to " Fig. 6
Precaution Against Falling " for details.
Support for fall prevention
Manipulator base
Hexagon socket head cap screw M16
(4 places)
(Tensile strength: 1200 N/mm2 or more)
Fig. 6 Precaution Against Falling
In case of using the wall-mounted or ceiling-mounted type, inform Yaskawa of the matter
NOTE when placing an order. Be sure to contact your Yaskawa representative (listed on the back
cover of this instruction manual) to perform a wall/ceiling installation on site.
3.4 Location
When the manipulator is installed, it is necessary to satisfy the following environmental

conditions:
• Ambient temperature: 0° to +45°C

• Humidity: 20 to 80%RH (at constant temperature)
• Free from dust, soot, or water
• Free from corrosive gases or liquids, or explosive gases
• Free from excessive vibration (Vibration acceleration: 4.9 m/s2 or less [0.5 G] or less)
• Free from large electrical noise (plasma)
• Flatness for installation: 0.5 mm or less
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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.
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4.1 Grounding
4.1 Grounding
Follow local regulations for grounding line size. A line of 5.5 mm2 or more is recommended.
Refer to " Fig. 7 Grounding Method " to connect the ground line directly to the manipulator.
• Never use this line sharing with other ground lines or grounding electrodes for other elec-
NOTE tric 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’
A
5.5 mm2 or more
Section A-A’
Bolt M8 (For grounding)
Delivered with the manipulator
Fig. 7 Grounding Method
4.2 Cable Connection
Two manipulator cables are delivered with the manipulator; an encoder cable (1BC) and a
power cable (2BC). (Refer to " Fig. 8 Manipulator Cables ".)
Connect the manipulator cables to the connectors on the manipulator connector base and
connectors on the NX100. Refer to " Fig. 9 (a) Manipulator Cable Connectors (Manipulator
Side) ", " Fig. 9 (b) Manipulator Cable Connection to the NX100 ".
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4.2.1 Connection to the Manipulator

Before connecting two cables to the manipulator, verify the numbers on both manipulator
cables and the connectors on the connector base of the manipulator. When connecting,
adjust the cable connector positions to the main key positions of the manipulator, and insert
cables in the order of 2BC, then 1BC, and set each lever low until it clicks.
4.2.2 Connection to the NX100

Before connecting two cables to the NX100, verify the numbers on both manipulator cables
and the connectors on the NX100. When connecting, insert the cables in the order of X21,
then X11, and set each lever low until it clicks.
The NX100 Side The Manipulator Side

X11
1BC
X11 1BC
1BC
Encoder Cable
The NX100 Side The Manipulator Side

2BC
X21
2BC
X21
2BC
Power Cable
Fig. 8 Manipulator Cables
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2BC
1BC
3BC
Connector Details
(Manipulator Side)
Fig. 9 (a) Manipulator Cable Connectors (Manipulator Side)
X11
X21
Fig. 9 (b) Manipulator Cable Connection to the NX100
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5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table 3 Basic Specifications*1
Item Model MOTOMAN-SSA2000
Application Arc Welding
Structure Vertically Articulated
Degree of Freedom 6
Payload 3 kg
Repetitive Positioning Accuracy *2 ±0.08 mm
S-Axis (turning) ±170°

L-Axis (lower arm) +155°, -90°
Range U-Axis (upper arm) +190°, -175°
of
Motion R-Axis (wrist roll) ±150°
B-Axis (wrist pitch/yaw) +180°, -45°
T-Axis (wrist twist) ±200°
S-Axis 3.67 rad/s, 210°/s
L-Axis 3.32 rad/s, 190°/s
Maximum U-Axis 3.67 rad/s, 210°/s

Speed R-Axis 6.98 rad/s, 400°/s
B-Axis 6.98 rad/s, 400°/s
T-Axis 10.47 rad/s, 600°/s
R-Axis 8.8 N•m (0.9 kgf•m)
Allowable
B-Axis 8.8 N•m (0.9 kgf•m)
Moment*3
T-Axis 2.9 N•m (0.3 kgf•m)
R-Axis 0.27 kg•m 2

Allowable
Inertia B-Axis 0.27 kg•m 2
(GD2/4)
T-Axis 0.03 kg•m 2
Mass 130 kg
Temperature 0°C to 45°C
Humidity 20 to 80% RH (non-condensing)
Ambient Vibration Acceleration 4.9 m/s2 or less (0.5 G)

Conditions • Free from corrosive gasses or liquids, or
explosive gasses
Others
• Free from exposure to water, oil, or dust
• Free from excessive electrical noise (plasma)
Power Requirements 1.5 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 permissible moment of inertia.
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5.2 Part Names and Working Axes
5.2 Part Names and Working Axes
U-arm Wrist
U+
R+ B+
B-
R-
U-
T- T+
L-arm
Wrist flange
L- L+
S-head
S+
S- Manipulator base
Fig. 10 Part Names and Working Axes
5.3 Manipulator Base Dimensions
300
260
240 132±0.1
+0.018
16 dia. 0 (2 holes)
18 dia. 60
153±0.1
102±0.1
(4 holes)
300
260
216
60
132±0.1
20
130±0.1
+0.018
12 dia. 0
102±0.1
100±0.1 153±0.1
A
View A Units: mm
Fig. 11 Manipulator Base Dimensions
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5.4 Dimensions and P-Point Maximum Envelope
170
153
01 R139
0
R4
210 170
R28
5
170
View A
1690
110
P-point maximum
150 640 30 envelope
P-point
200
200
83
A
726
570
90
155
0
10
2427
258
450
322
175
737
1390
229
430
1090
1016
Units: mm
Fig. 12 (a) Dimensions and P-Point Maximum Envelope
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1090
1016
1390
430
229
0
737 P-point maximum
175 envelope
322
450
258
0
10
2427
15
90
5
726
570
170 210
83
122
200
84
200
110
P-point
78
100 dia.
153 1690
30 640 150
The area where the manipulator operates

with its wrist (B-axis) pointed downward
R2
85
170
0
R139
01
R4
170
Units: mm
Fig. 12 (b) Dimensions and P-Point Maximum Envelope
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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 Operating Range ". If alteration is necessary, contact your
Yaskawa representative in advance.
Table 4 S-Axis Operating Range
Item Specifications
±170°(standard)
±150°
±135°
±120°
S-Axis ±105°
Operating ± 90°
Range ± 75°
± 60°
± 45°
± 30°
± 15°
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6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist

Flange
6.1 Allowable Wrist Load
The allowable wrist load is 3 kg maximum. If force is applied to the wrist instead of the load,
force on R-, B-, and T-axes should be within the value shown in " Table 5 Moment and Total
Moment of Inertia ". Contact your Yaskawa representative for further information or
assistance.
Table 5 Moment and Total Moment of Inertia
GD2/4 Total Moment of Inertia

Axis Moment NNm (kgfNm)*1
kgNm2
R-Axis 8.8 (0.9) 0.27

B-Axis 8.8 (0.9) 0.27
T-Axis 2.9 (0.3) 0.03
*1 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in " Fig. 13 Moment
Arm Rating ".
The allowable total moment of inertia is calculated when the moment is at the maximum.
Contact your Yaskawa representative beforehand when only moment of inertia, or load
moment is small and moment of inertia is large. Also, when the load mass is combined with
an outside force, contact your Yaskawa representative beforehand.
LB
Load gravity position
200
200
LT (mm)
LT
R-, T-axis 100

rotation center
B-axis rotaion center W=3 Kg
0 100 200 300 400

LB (mm)
Fig. 13 Moment Arm Rating
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6.2 Wrist Flange
6.2 Wrist Flange
The wrist flange dimensions are shown in " Fig. 14 Wrist Flange ". It is recommended that the
attachment be mounted inside the fitting in order to identify the alignment marks. Fitting depth
shall be 6 mm or less. As shown in the figure below, the attachment shall be mounted on the
range of 90 diameter or less with up to 5 mm height from the flange face.
Tapped holes M4 (6 holes)

Attachments shall be mounted (Depth: 10) (Pitch: 0.7)
within this range.
30°
5
+0.025
(The range of 42 dia. 0 )
56
.D.
P.C
+0.025
0
90 dia.
6
42 dia.
+0.012
6 dia. 0
(Depth: 6)
Units: mm
Fig. 14 Wrist Flange
NOTE Wash off anti-corrosive paint (solid color) on the wrist flange surface with thinner or light oil
before mounting the tools.
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7.1 Peripheral Equipment Mounts
7 System Application
The peripheral equipment mounts are provided on the U-axis (upper arm) and S-axis (rotary
head) as shown in " Fig. 15 Installing Peripheral Equipment " for easier installation of the
users’s system applications. The following conditions shall be observed to attach or install
peripheral equipments.
7.1.1 Allowable Load

• The maximum allowable load on the U-axis is 12 kg, including the wrist load.
For instance, when the mass installed on the wrist point is 3 kg, the mass which can be
installed on the upper arm is 9 kg.
• The maximum allowable load on the S-axis is 20 kg. Install the peripheral equipment
on the S-axis so that the moment of inertia (GD2/4) from the S-axis rotation center is
1.25 kgNm2 or less.
7.1.2 Installation Position

There is a limitation on where to install the peripheral equipment as shown in " Fig. 15
Installing Peripheral Equipment " on the following page.
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View A Tapped hole M6 (2 holes)

(Depth: 12) (Pitch: 1.0)
Tapped hole M8 (3 holes)

36
95 50
35
75 70
25
70
A
Mount the peripheral
equipment within this
range. 300 60
300
Upper arm Mount the peripheral

equipment so that
the center of gravity of
15
the peripheral equipment
on the U-arm should be
within this range.
Rotary head
90 105
Tapped hole M10 (4 holes)

155

50
Units: mm
Fig. 15 Installing Peripheral Equipment
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7.2 Internal User I/O Wiring Harness and Air Line
Internal user I/O wiring harness (14 wires: 0.2 mm2 x 8 wires and 1.25 mm2 x 6 wires), and an
air line are incorporated in the manipulator for the drive of peripheral devices mounted on the
upper arm as shown in " Fig. 16 Connectors for Internal User I/O Wiring Harness and Air Line ".
The connector pins 1 to 16 are assigned as shown in " Fig. 17 Details of the Connector Pin
Numbers " on the following page. Wiring must be performed by users.
• The allowable current for internal user 3 A or less for each wire
I/O wiring harness (The total current value for pins 1 to 16 must
be 40 A or less.)
• The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 6.5 mm)
Connector for the internal user I/O wiring harness:

JL05-2A20-29SC (socket connector with a cap)
Prepare pin connector: JL05-6A20-29P
Exhaust port: PT3/8

with a pipe plug
Air Inlet: PT3/8

with a pipe plug
2BC
1BC
Connector for the internal user I/O wiring harness:
JL05-2A20-29PC
3BC
Prepare connector JL05-6A20-29S
View A
Fig. 16 Connectors for Internal User I/O Wiring Harness and Air Line
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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 2
14 2
15 (1.25 mm ) 15 16 15 (1.25 mm ) 15 16
16 (1.25 mm2) 16 (1.25 mm2)
Internal user I/O wiring harness: 0.2 mm2, 8 wires Internal user I/O wiring harness: 0.2 mm2, 8 wires
: 1.25 mm2, 6 wires : 1.25 mm2, 6 wires
Fig. 17 Details of the Connector Pin Numbers
• For the standard specification, the pins No.7 and No.8 of 3BC connector on the U-arm
NOTE are respectively connected with the shock sensor power supply and shock sensor signal
input port of the NX100 controller.
• The pins No.7 and No.8 of respective 3BC connectors on the connector base side and
the U-arm side are not connected with each other.
• For wiring, refer to (a) and (b) of " Fig. 20 Internal Connection Diagram ".
The same pin number (1-16) of two connectors is connected in the wire lead of single
0.2 mm2, or 1.25 mm2.
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8.1 Position of Limit Switch
8 Electrical Equipment Specification
8.1 Position of Limit Switch
The limit switches are optional. See " Fig. 18 Location of Limit Switches " for the locations of
limit switches. The manipulator with S- and L-axis overrun limit switches, and LU-axis
interference limit switch is the type YR-SSA3-A01 (standard specification) or YR-SSA3-A11
(ceiling-mounted specifcation).
LU-axis interference
limit switch (optional)
L-axis overrun
S-axis overrun
Fig. 18 Location of Limit Switches
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8.2 Internal Connections
Highly reliable connectors are equipped on each connection part of the manipulator to enable
easy removal and installation for maintenance and inspection. For the number and location of
connectors, see " Fig. 19 Locations and Numbers of Connectors ".
Diagrams for Internal connections of the manipulator are shown in “ Fig. 20 (a) Internal
Connection Diagram ” and “ Fig.20 (b) Internal Connection Diagram ”.
3BC (for internal user I/O wiring harness)

on the U-arm
3BC (for internal user I/O wiring harness)

on the connector base
Fig. 19 Locations and Numbers of Connectors
Table 6 List of Connector Types
Name Type of Connector
Connector for the internal user I/O JL05-2A20-29PC

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

wiring harness on the U-arm (JL05-6A20-29P: Optional)
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Power Cable Internal Cable in S-axis Internal Cable in L-axis Internal Cable in BT-axes
0BT 1 0BAT11 17 0BAT1

K R P BAT
0BT
2
3
BAT11
0BAT12
18
19
BAT1
0BAT2
<Notes>
K R P BAT 4 BAT12 20 BAT2
21 0BAT3 - For the limit switch specification, the connection of the section A is changed as follows:
22 BAT3
23
24
0BT 5 0BAT21 25 0BAT4 S-axis Overrun Limit Switch
K R P BAT 6 BAT21 26 BAT4 LA1 LA1
0BT 7 0BAT22 27 LB1
K R P BAT 8 BAT22 28 LB1 LA2 LA2 LA2
29 LB2 L-axis Overrun Limit Switch A
1
30
31
P LA3
LB3 LB3 L U-axis Interference
2 32 Limit Switch
3 1 PG0V1
4 2 PG5V1
5 3 PG0V2 SLU-axes with Overrun Limit Switch Specification
6 4 PG5V2
7 5 PG0V3
8 6 PG5V3
7 PG0V4
8 PG5V4
1BC(10X4) 9 PG0V5 - For standard specification, the pins No.7 and No.8 of 3BC connector
NX100 CN1-5 CN1-5 +24V 1
10
11
PG5V5
PG0V6 on the U-arm are respectively connected with the shock sensor power supply
CN1-4 P CN1-4 0V 3 12 PG5V6
13 and shock sensor signal input port of the NX100 controller.
CN1-10 CN1-10 +24V 2 14
CN1-9 P CN1-9 0V 4 15
CN1-1 CN1-1 SPG+1

16 No.20CN
20CN-1 DATA+1
Pin No. Connected Port in NX100
CN1-2 P CN1-2 SPG-1 P -2
-6
DATA-1
BAT
7 Shock sensor power supply; +24V (1A)
P -5 OBT PG S-axis 8 Shock sensor signal input port
-4 +5V
P -9 0V
CN1-3 CN1-3 FG1 -7 FG1
OBT
BAT - In case of connecting the pins No.7 and No.8 of respecteve 3BC connectors on the U-arm
No.21CN
CN1-6 CN1-6 SPG+2 21CN-1 DATA+2 and connector base, the connection in the section B should be changed as shown in
CN1-7 P CN1-7 SPG-2 P -2 DATA-2
-6 BAT
L-axis
section C below.
P -5 OBT PG
P
-4
-9
+5V
0V
(Contact your Yaskawa representative in case of modifying the wiring before use.)
CN1-8 CN1-8 FG2 -7 FG2
OBT
BAT
No.22CN
CN2-1 CN2-1 SPG+3 22CN-1 DATA+3
-6 BAT
P -5 OBT PG U-axis
-4 +5V
P -9 0V
CN2-3 CN2-3 FG3 -7 FG3
OBT
BAT
No.23CN
CN2-6 CN2-6 SPG+4 23CN-1 DATA+4
-3 BAT
P -4
24CN-1
OBT
+5V
PG R-axis
1BC(10X4) P -2 0V
CN2-8 CN2-8 -3 FG4
OBT
P BAT
No.7CN No.14CN
CN3-1 CN3-1 SPG+5 -1 DATA+5 14CN-1 DATA+5
CN3-2 P CN3-2 SPG-5 P -7 DATA-5 P -2 DATA-5
-2 BAT -3 BAT
-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
CN3-7 P CN3-7 SPG-6 P -10 DATA-6 P -2 DATA-6
-3 BAT
-5 +5V
-4
17CN-1
OBT
+5V
PG T-axis
P -11 0V P -2 0V
CN3-8 CN3-8 -6 FG6 -3 FG6
FG6
OBT
BAT
CN4-1 CN4-1 +24V LA1 LA2

C
CN4-6 P CN4-6 LB1 P LB3 LA2
CN4-2
CN4-7 P
CN4-2
CN4-7
SS2
A Power Cable Internal Cable
Connector Base U-arm
CN4-3 CN4-3 BC2
CN4-8 P CN4-8 NX100 1BC(4X10)
CN2-4 CN2-4
P For Lamp (Optional)
0V CN4-1 CN4-1 +24V(1A) SS1
CN2-5 P CN2-5 +5V
CN4-2 CN4-2 SS2 SS2 Crimped
E E
E
Contact-Pin Casing
CN2-9 CN2-9
CN2-10 P CN2-10
0V Base 3BC(20-29)
+5V 3BC(20-29)
E E E E E
Unused
3BC-1 1 1 1 1 1 1 3BC-1
-2 2 2 2 P 2 2 P 2 -2
CN3-4 CN3-4 -3 3 3 3 3 3 3 -3
0V -4 4 4 4 4 4 4 -4
CN3-5 P CN3-5 +5V
P P
-5 5 5 5 5 -5
-6 6 6 6 P 6 -6
-7 7 7 SS1 SS1 SS1 7 -7
CN3-9 CN3-9 -8 8 8 SS2 P SS2 SS2 P 8 -8
0V -9 9 9 -9
CN3-10 P CN3-10
+5V -10 10 P 10 -10
-11 11 11 -11
-12 12 12 -12
-13 13 13 -13
-14 14 14 -14
CN4-4 CN4-4 SPG+7 -15 15 15 -15
CN4-5 P CN4-5 SPG-7 -16 16 16 -16
CN4-9 CN4-9 FG7
E Wiring of 3BC Cable after Changing Connection of Section B

E
Fig. 20 (a) Internal Connection Diagram
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E E E
Base Casing
E E E B
3BC(20-29) 3BC(20-29)
E E
3BC-1 1 1 1 1 1 1 2BC-1
-2 2 2 2 P 2 2 P 2 -2
-3 3 3 3 3 3 3 -3
-4 4 4 4 P 4 4 P 4 -4
-5 5 5 5 5 -5
-6 6 6 6 P 6 -6
-7 7 7 SS1 SS1 SS1 SS1 7 -7
-8 8 8 SS2 SS2 P SS2 SS2 P 8 -8 For Spare Cable
-9 9 9 -9
-10 10 P 10 -10 Shock Sensor
-11 11 11 -11 (Optional)
-12 12 12 -12
-13 13 13 -13
-14 14 14 -14
-15 15 15 -15
-16 16 16 -16
2BC(6X6)
E
E
No.3CN
CN1-1 CN1-1 BA1 3CN-1 MU1
CN1-2 CN1-2 BA2 -2 MV1
CN1-3 CN1-3 -3 MW1
SM S-axis
BB1
CN1-4 CN1-4 ME1 -4 ME1
CN1-5 CN1-5 ME2 -5 BA1
CN1-6 CN1-6 -6 BB1 YB
No.4CN
CN2-1 CN2-1 MU1 4CN-1 MU2
CN2-2 CN2-2 MV1 -2 MV2
CN2-3 CN2-3 -3 MW2
SM L-axis
MW1
CN2-4 CN2-4 MU2 -4 ME2
CN2-5 CN2-5 MV2 -5 BA2
CN2-6 CN2-6 MW2 -6 BB2 YB
No.26CN
CN3-1 CN3-1 26CN-1 MU3
CN3-2 CN3-2 -2 MV3
CN3-3 CN3-3 -3 MW3
SM U-axis
CN3-4 CN3-4 MU3 -4 ME3
CN3-5 CN3-5 MV3 -5 BA3
2BC(6X6)
No.25CN
CN4-1 CN4-1 MU4 25CN-1 MU4
CN4-2 CN4-2 MV4 -2 MV4
CN4-3 CN4-3 -3 MW4
SM R-axis
MW4
CN4-4 CN4-4 MU5 -4 ME4
CN4-5 CN4-5 MV5 -1 BA4
No.35CN No.18CN
No.11CN
CN5-1 CN5-1 MU6 11CN-1 MU5 18CN-1 MU5
CN5-2 CN5-2 MV6 -2 MV5 -2 MV5
CN5-3 CN5-3 -3 MW5 -3 MW5
SM B-axis
MW6
CN5-4 CN5-4 ME3 -4 ME5 -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 -5 MU6 19CN-1 MU6
CN6-2 CN6-2 BA3 -6 MV6 -2 MV6
-7 SM T-axis
CN6-3 CN6-3 BB4 MW6 -3 MW6
CN6-4 CN6-4 BA4 -8 ME6 -4 ME6
CN6-5 CN6-5 BA5 -1 BA6
CN6-6 CN6-6 BA6 12CN-1 BA5 -2 BB6 YB
-2 BB5 No.37CN
-3 BA6
-4 BB6
No.12CN
PE
Fig. 20 (b) Internal Connection Diagram
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9.1 Inspection Schedule
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
intervals are classified into six levels as shown in " Table 7 Inspection Items ". Conduct
periodical inspections according to the inspection schedule in Table 7.
In Table 7, the inspection items are categorized by three types of operations: operations which
can be performed by personnel authorized by the user, operations to be performed by trained
personnel, and operations to be performed by service company personnel. Only specified
personnel shall perform the inspection work.
• The inspection interval depends on the total servo operation time.

NOTE • The following inspection schedule is based on the case where the manipulator is used for
arc welding application. If the manipulator is used for other application or if it is used
under special conditions, a case-by-case examination is required.
The inspection may be conducted at shorter intervals if the manipulator is used very fre-
quently for the application such as handling; in this case, contact your Yaskawa represen-
tative.
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Table 7 Inspection Items
Schedule Inspection Charge
Items*4 1000 6000 12000 Method Operation

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

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

Working area if dust or spatter is
e and { Visual present. Check for { { {
manipulator damage and outside
cracks.
Motors for S-, Check for grease

f L-, U-axes
{ Visual
leakage.*5
{ { {
Baseplate Spanner Tighten loose bolts.

g mounting bolts
{ Wrench Replace if necessary. { { {
Cover mount- Screw- Tighten loose bolts.

h ing screws
{ driver, Replace if necessary. { { {
Wrench
Connector Check for loose con-

i base
{ Manual nectors. { { {
Timing belts Check for belt

j for B- and T- { Manual tension and wear. { {
axes
Check for conduc-

tion between the
main connector of
Wire harness in Visual, base and intermedi-
{ Multimeter ate connector with
{ {
manipulator
k (SLU-axis wires)
manually shaking the
wires. Check for wear
(RBT-axis wires) of protective spring*1
{ Replace*2 {
Check for conduc-

Visual, tion between termi-
Wire harness { Multimeter nals and wear of
{ {
l in manipulator protective spring.*1
(BT-axis wires)
{ Replace*2 {
Replace the battery

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

tion. (Replace if nec-
essary.) Supply
grease*3 (6000H
cycle). See Par.
" 9.3.1 Grease
Replenishment/
S-axis speed Grease Exchange for S-Axis
reducer
{ { Gun Speed Reducer ". { {
Replace grease*3.
(12000H cycle)
See Par. " 9.3.1
Grease Replenish-
ment/Exchange for
S-Axis Speed
Reducer ".
Check for malfunc-

essary.) Supply
grease*3 (6000H
cycle).
See Par." 9.3.2
Grease Replenish-
ment/Exchange for L-
Axis Speed Reducer
", " 9.3.3 Grease
Speed reduc- Replenishment/
Grease
ers for L- and { { Gun
Exchange for U-Axis { {
U-axes Speed Reducer ".
Replace grease*3
(12000H cycle).
See Par. " 9.3.2
Grease Replenish-
ment/Exchange for L-
Axis Speed Reducer
", " 9.3.3 Grease
Replenishment/
Exchange for U-Axis
Speed Reducer ".
Check for malfunc-

essary.) Supply
R-axis speed Grease grease*3 (6000H
reducer
{ Gun cycle). { {
See Par. " 9.3.4
Grease Replenish-
ment for R-Axis
Speed Reducer ".
Check for malfunc-

essary.) Supply
B-axis speed Grease grease*3 (6000H
reducer
{ Gun cycle). { {
See Par. " 9.3.5
Grease Replenish-
ment for B-Axis
Speed Reducer ".
Check for malfunc-

essary.) Supply
Grease grease*3 (6000H
T-axis gear { Gun cycle). See Par.
{ {
" 9.3.6 Grease
Replenishment for T-
Axis Gear "
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Licensee
Company
H H
Cycle Cycle Cycle
Overhaul { {
*1 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the
motor side for each axis, and then remove connectors on detector side for each axis from the motor. Other-
wise, the home position may be lost. (Refer to " 9.3.7 Notes for Maintenance ")
*2 Wire harness in manipulator to be replaced at 24000H inspection.
*3 For the grease, refer to " Table 7 Inspection Parts and Grease Used ".
*4 Inspection No. correspond to the numbers in “Fig. 21 Inspection Parts and Inspection Numbers”.
*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.
Fig. 21 Inspection Parts and Inspection Numbers
Table 7 Inspection Parts and Grease Used
No. Grease Used Inspected Parts
Speed reducers for S-, L-, and U-

, VIGO Grease RE No. 0
axes
Harmonic Grease 4B No. 2 R-axis speed reducer
Harmonic Grease SK-1A B-axis speed reducer
Alvania EP Grease 2 T-axis gear
The numbers in the above table correspond to the numbers in " Table 7 Inspection Items ".
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5 14
4 8
Note:
This figure shows the standard specification
manipulator in the home position.
8
15
13
9-5
16
4
13
11 9 4
12
Fig. 21 Inspection Parts and Inspection Numbers

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9.2 Notes on Maintenance Procedures
9.2.1 Battery Pack Replacement

The battery packs are installed in the position shown in " Fig. 22 Battery Location ". If the bat-
tery alarm occurs in the NX100, replace the battery according to the following procedure:
2BC
Battery pack 1BC
Plate 3BC
Connector base
Plate fixing
screw Support Holder
Fig. 22 Battery Location
Battery pack
See step 5 below. before replacement
Connector
Board
See step 4 below.

New battery pack
Fig. 23 Battery Connection
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1. Turn OFF the NX100 main power supply.

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

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

Procedures
Make sure to follow the instructions listed below at grease replenishment/exchange. Failure
to observe the following notes may result in damage to motor and speed reducer.
• If grease is added without removing the plug/screw from the grease exhaust port, the
NOTE grease will go inside a motor or an oil seal of a speed reducer will come off, which may
result in damage to the motor. Make sure to remove the plug.
• Do not install a joint, a hose, etc. to the grease exhaust port. Failure to observe this
instruction may result in damage to the motor due to coming off of an oil seal.
• Make sure to use a grease pump to inject grease. Set air supply pressure to the grease
pump at 0.3 MPa or less, and the grease injection rate at 8 g/s or less.
• Make sure to fill the hose on the grease inlet with grease beforehand to prevent air from
leaking into the speed reducer.
9.3.1 Grease Replenishment/Exchange for S-Axis Speed

Reducer
Grease exhaust port

Hexagon socket head plug PT1/8
(Applicable serial number:
before RH9520-4023)
2BC
1BC
3BC
Grease exhaust port
(Applicable serial number:
RH9520-4024 and over)
Grease inlet
S-axis speed reducer
Fig. 24 S-Axis Speed Reducer Diagram
NOTE For the ceiling-mounted manipulator, the grease exhaust port and the grease inlet are
inverted.
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T Grease Replenishment (Refer to " Fig. 24 S-Axis Speed Reducer Diagram ".)
Replenish the grease according to the following procedure:
1. Remove the hexagon socket head plugs PT1/8 from the grease inlet and grease
exhaust port.
• If grease is injected with the plug on, the grease will go inside the motor and may cause a
NOTE damage. Make sure to remove the plug before the grease injection.
2. Install a grease zerk PT1/8 to the grease inlet. (The grease zerk is delivered with the
manipulator.)
3. Inject the grease into the grease inlet using a grease gun.
Grease type: VIGO Grease RE No. 0

Amount of grease: 70 cc
(140 cc for 1st supply)
Air supply pressure of grease pump: 0.3 MPa or less
Grease injection rate: 8 g/s or less
4. Move the S-axis for a few minutes to discharge excess grease.

5. Wipe the discharged grease with a cloth. Remove the grease zerk from the grease
inlet, and reinstall the plugs to the grease inlet and grease exhaust port. Before install-
ing the plugs, apply Three Bond 1206C on the thread part of each plug, then tighten
the plug with a tightening torque of 4.9 NNm (0.5 kgfNm).
T Grease Exchange (Refer to " Fig. 24 S-Axis Speed Reducer Diagram ".)
1. Remove the hexagon socket head plugs PT1/8 from the grease inlet and grease
exhaust port.
manipulator.)
3. Inject the grease into the grease inlet using a grease gun.

4. The grease exchange is completed when new grease appears in the grease exhaust
port. (The new grease can be distinguished from the old grease by color.)
5. Move the S-axis for a few minutes to discharge excess grease.
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6. Wipe the discharged grease with a cloth. Remove the grease zerk from the grease
inlet, and reinstall the plugs to the grease inlet and grease exhaust port. Before install-
ing the plugs, apply Three Bond 1206C on the thread part of each plug, then tighten
the plug with a tightening torque of 4.9 NNm (0.5 kgfNm).
9.3.2 Grease Replenishment/Exchange for L-Axis Speed

Reducer
L-arm Grease exhaust port
Hexagon socket head plug PT 1/8
L-axis
speed reducer
Grease Inlet
Fig. 25 L-Axis Speed Reducer Diagram
inverted.
T Grease Exchange (Refer to " Fig. 25 L-Axis Speed Reducer Diagram ".)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.
3. Remove the hexagon socket head cap screw M6 from the grease inlet.
4. Install a grease zerk A-MT6X1 to the grease inlet. (The grease zerk is delivered with
the manipulator.)
5. Inject grease into the grease inlet using a grease gun.

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6. Move the L-axis for a few minutes to discharge excess grease.

7. Remove the grease zerk from the grease inlet, and reinstall the screw. Before install-
ing the screw, apply Three Bond 1206C on the thread part of the screw. Then tighten
the screw with a tightening torque of 10 NNm (1.0 kgfNm).
8. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the
plug, apply Three Bond 1206C on the thread part of the plug. Then tighten the plug
with a tightening torque of 4.9 NNm (0.5 kgfNm).
T Grease Exchange (Refer to " Fig. 25 L-Axis Speed Reducer Diagram ".)
1. Make the L-arm vertical to the ground.
2. Remove the hexagon socket head plug PT1/8 from the grease exhaust port.
the manipulator.)

Amount of grease: approx. 360 cc
6. The grease exchange is completed when new grease appears in the grease exhaust
7. Move the L-axis for a few minutes to discharge excess grease.
ing the screw, apply Three Bond 1206C on the thread part of the screw. Then tighten
9. Wipe the discharged grease with a cloth, and reinstall the plug. Before installing the
plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug with
a tightening torque of 4.9 NNm (0.5 kgfNm).
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9.3.3 Grease Replenishment/Exchange for U-Axis Speed

Reducer
U-axis
U-arm speed reducer
Grease exhaust port

Grease inlet
Hexagon socket head plug PT 1/8
Order No.:
product ordered before S7Y237-1 or earlier
Grease inlet
Back View Hexagon socket head plug PT 1/8 Front View
Order No.:
product ordered in S7Y237-1 or later
Fig. 26 U-Axis Speed Reducer Diagram
inverted.
Grease Replenishment (Refer to " Fig. 26 U-Axis Speed Reducer Diagram ".)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head cap screw M6 from grease exhaust port.
3. Remove the hexagon socket head plug PT1/8 from the grease inlet.
• If grease is injected with the screw on, the grease will go inside the motor and may cause
NOTE a damage. Make sure to remove the screw before the grease injection.
manipulator.)

6. Move the U-axis for a few minutes to discharge excess grease.

7. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing
the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug
with a tightening torque of 4.9 Nxm (0.5 kgfxm).
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8. Wipe the discharged grease with a cloth, and reinstall the screw. Before installing the
screw, apply Three Bond 1206C on the thread part of the screw, then tighten the screw
with a tightening torque of 10 NNm (1.0 kgfNm).
T Grease Exchange (Refer to " Fig. 26 U-Axis Speed Reducer Diagram ".)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head cap screw M6 from the grease exhaust port.
3. Remove the hexagon socket head cap plug PT1/8 from the grease inlet.
• If grease is injected with the screw on, the grease will go inside the motor and may cause
NOTE a damage. Make sure to remove the screw before the grease injection.
manipulator.)

Amount of grease: approx. 200 cc
6. The grease exchange is complete when new grease appears in the grease exhaust
7. Move the U-axis for a few minutes to discharge excess grease.
8. Remove the grease zerk from the grease inlet, and reinstall the plug. Before installing
the plug, apply Three Bond 1206C on the thread part of the plug, then tighten the plug
with a tightening torque of 4.9 NNm (0.5 kgfNm).
9. Wipe the discharged grease with a cloth, and reinstall the screw to the grease exhaust
port. Before installing the plug, apply Three Bond 1206C on the thread part of the
screw, then tighten the screw with a tightening torque of 10 NNm (1.0 kgfNm).
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9.3.4 Grease Replenishment for R-Axis Speed Reducer
R-axis speed reducer
Exhaust port
Grease inlet
Fig. 27 R-Axis Speed Reducer Diagram
NOTE For the ceiling-mounted manipulator, the exhaust port and the grease inlet are inverted.
1. Remove the hexagon socket head cap screw M6 from the exhaust port.
the manipulator.)
4. Inject grease into the grease inlet using a grease gun. (Refer to " Fig. 27 R-Axis
Speed Reducer Diagram ".)
Grease type: Harmonic grease 4B No.2

(24cc for the first supply)
NOTE The exhaust port is used for air exhaust, and the grease is not exhausted from the exhaust
port. Do not inject excessive grease into the grease inlet.
ing the screw, apply Three Bond 1206C on the thread part of the screw, then tighten
the screw with a tightening torque of 6 Nxm (0.6 kgfxm).
6. Reinstall the screw to the exhaust port. Before installing the screw, apply Three Bond
1206C on the thread part of the screw, then tighten the screw with a tightening torque
of 6 Nxm (0.6 kgfxm).
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9.3.5 Grease Replenishment for B-Axis Speed Reducer
B-axis speed Grease inlet

Cover Exhaust port reducer (Screw M6)
(Plug LPM5)
Fig. 28 B-Axis Speed Reducers Diagram
1. Remove the plug LPM5 from the exhaust port.

2. Remove the screw from the grease inlet.
the manipulator.)
4. Remove the cover, then inject grease into the grease inlet using a grease gun. (Refer
to " Fig. 28 B-Axis Speed Reducers Diagram ")
Grease type: Harmonic grease SK-1A

(14 cc for the 1st supply)
6. Reinstall the plug to the exhaust port, then reinstall the cover.
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9.3.6 Grease Replenishment for T-Axis Gear
Grease inlet 1
Hexagon socket head cap screw M6 Grease inlet 2
Exhaust port
Hexagon socket set screw M6
Fig. 29 T-Axis Gear Diagram
1. Remove the hexagon socket set screw from the exhaust port.
2. Remove the hexagon socket head cap screw M6 from the grease inlet 1.
3. Install a grease zerk A-MT6X1 to the grease inlet 1. (The grease zerk is delivered with
the manipulator.)
4. Inject grease into the grease inlet 1 using a grease gun.
Grease type: Alvania EP Grease 2

5. Remove the grease zerk from the grease inlet 1, and reinstall the screw. Before install-
6. Remove the hexagon socket head cap screw M6 from the grease inlet 2.
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7. Install a grease zerk A-MT6X1 to the grease inlet 2. (The grease zerk is delivered with
the manipulator.)
8. Inject grease into the grease inlet 2 using a grease gun.
Grease type: Alvania EP Grease 2

9. Remove the grease zerk from the grease inlet 2, and reinstall the screw. Before install-
10. Reinstall the set screw to the exhaust port. Before installing the set screw, apply Three
Bond 1206C on the thread part of the screw, then tighten the screw with a tightening
torque of 2.9 NNm (0.29 kgfNm).
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9.3.7 Notes for Maintenance

T Wrist Unit
The motor and encoder units are provided with the wrist unit. To prevent fumes from
penetrating into the wrist unit, the matched parts are sealed with sealing bond. If the wrist
cover is disassembled, make sure to reseal with sealing bond (Three Bond 1206C, refer to
" Table 9 Spare Parts for the YR-SSA3-A00, -A01, -A10, -A11 ").
Cover
Cover jointing face
Cover jointing face
Cover
Fig. 30 Sealing Part of Wrist Unit
T Battery Pack Connection

When performing maintenance such as replacement of a wire harness in the manipulator,
NOTE the encoder connector (with CAUTION label) will be removed. In this case, be sure to con-
nect the battery pack to the battery backup connector before removing the encoder con-
nector.
Removing the encoder connector without connecting the battery pack leads to disappear-
ance of the encoder absolute data.
For the battery pack connection, refer to " Fig. 31 (a) Encoder Connector Diagram (for S-,
L-, and U-Axes) " and " Fig. 31 (b) Encoder Connector Diagram (for R-, B-, and T-Axes) ".
Before removing the encoder connector (with CAUTION label), connect the battery pack refer-
ring to the following figures.
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Motor
Motor power connector

Encoder connector
0BT b a 0BT*
BAT a b BAT*
Battery pack HW9470932-A

Connector for battery back-up
Fig. 31 (a) Encoder Connector Diagram (for S-, L-, and U-Axes)
Encoder
Motor
Motor cable, etc.
Wire harness
in manipulator Power connector
Connection
OBT4
OBT BAT4
BAT
removing connector.
to save the data before
Connect battery to encoder
CAUTION
Encoder connector Battery pack
CAUTION label
Connection Diagram
0BT a b 0BT4
BAT b a BAT4
CAUTION Label (Enlarged View)
a: Crimped contact-pin (Socket)

CAUTION b: Crimped contact-pin (Pin)
Connect battery to encoder

to save the data before
removing connector.
Fig. 31 (b) Encoder Connector Diagram (for R-, B-, and T-Axes)
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10 Recommended Spare Parts
It is recommended to keep the parts and components in the following table in stock as spare
parts for the MOTOMAN-SSA2000. Product performance cannot be guaranteed when using
spare parts from any company other than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts.

• Rank B: Parts for which replacement may be necessary as a result of frequent operation.
• Rank C: Drive unit.
NOTE For replacing parts in Rank B or Rank C, contact your Yaskawa representative.
Table. 9 Spare Parts for the YR-SSA3-A00, -A01, -A10, -A11
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
Grease VIGO Grease RE Yaskawa Electric

A 1 16 kg -
No. 0 Corporation
Grease Harmonic Grease Harmonic Drive

A 2 2.5 kg -
4B No.2 Systems Co., Ltd.
Grease Harmonic Grease Harmonic Drive

A 3 2.5 kg -
SK-1A Systems Co., Ltd.
Grease Alvania EP Grease 2 Showa Shell

A 4 16 kg -
Sekiyu K.K.
Liquid Seal Three Bond 1206C Three Bond Co.,

A 5 - -
Ltd.
Battery Pack HW0470360-A Yaskawa Electric

A 6 1 1
Corporation
Battery Pack HW9470932-A Yaskawa Electric

A 7 1 -
Corporation
B-Axis Timing Belt 60S4.5M711 Mitsuboshi Belt-

B 8 1 1
ing Limited
T-Axis Timing Belt 60S4.5M932 Mitsuboshi Belt-

B 9 1 1
ing Limited
S-Axis HW0386621-B Yaskawa Electric

B 10 1 1
Speed Reducer Corporation
S-Axis HW0310786-1 Yaskawa Electric

B 11 1 1
Input Gear Corporation
L-Axis HW9280732-B Yaskawa Electric

B 12 1 1
10-1
HW0483930 58/60
HW0483930
Table. 9 Spare Parts for the YR-SSA3-A00, -A01, -A10, -A11
Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit
L-Axis HW0303276-1 Yaskawa Electric

B 13 1 1
U-Axis HW9280738-B Yaskawa Electric

B 14 1 1
U-Axis HW0303277-1 Yaskawa Electric

B 15 1 1
R-Axis HW0381645-A Yaskawa Electric

B 16 1 1
B-Axis HW0381646-A Yaskawa Electric

B 17 1 1
R-Axis Gear HW0303288-A Yaskawa Electric

B 18 1 1
Corporation
R-Axis Gear Unit HW0370905-A Yaskawa Electric

B 19 1 1
Corporation
T-Axis Gear (Out- HW0372792-A Yaskawa Electric

B 20 1 1
put Side) Corporation
T-Axis Gear (Input HW0310757-A Yaskawa Electric

B 21 1 1
Side) Corporation
Internal HW0171190-A Yaskawa Electric

B 22 1 1
Wire Harness Corporation
Internal Cable HW0270867-A Yaskawa Electric

B 23 1 1
for B- and T-Axes Corporation
AC Servomotor HW0382153-A Yaskawa Electric

C 24 1 2
for S- and U-Axes SGMRS-06A2B-YR1* Corporation
L-Axis HW0382155-A Yaskawa Electric

C 25 1 1
AC Servomotor SGMRS-12A2B-YR1* Corporation
R-Axis HW0382151-A Yaskawa Electric

C 26 1 1
AC Servomotor SGMPH-01A2A-YR1* Corporation
AC Servo Motor HW0382150-A Yaskawa Electric

C 27 1 2
for B- and T-Axes SGMAS-01A2A-YR1* Corporation
10-2
HW0483930 59/60
HW04803930
11.1 S-Axis Unit
11 Parts List
11.1 S-Axis Unit
1002
1001 1008 1025
1007
1024
1006
1003 1026
1004
1005
1032
1033 1009
1031 1032
1029 1033
1028 1029
1027
1030 1015
1016
1011 1017
1013 1010
1014
1018 1012
1023 1019
1022
1020
1021
11-1
HW0483930 59A/60
HW0483930
11.1 S-Axis Unit
No. DWG No. Name Pcs

1001 SGMRS-06A2B-YR1* Motor 1
1002 M8X30 GT-SA Bolt 3
1003 HW0310786-1 Gear 1
1004 2H-4 Spring washer 1
1005 M4X85 Socket screw 1
1006 HW0310754-1 M-Base 1
1009 HW0101815-1 S-head 1
1010 HW0386621-B Speed reducer 1
1012 HW0101813-1 Base 1
1013 HW0200492-1 Cover 1
1015 HW9405278-1 Dog 1
1019 EZ5036A0 Cap 1
(YR-SSA3-A00)
HW9481319-A Cap 1
(YR-SSA3-A01)
1020 TSH6-01M Air joint 1
1021 NB-0640B Tube 1
1022 HW030350-A Limit switch 1
(YR-SSA3-A01)
(YR-SSA3-A01)
1024 POC6-01 Union 1
1025 NB-0640B Tube 1
1026 PT1/8 Pulg 1
1027 HW0404549-1 Support 1
1028 HW0403842-1 Support 1
1030 CD-19 Saddle 1
1031 CD-31 Saddle 1
11-2
HW0483930 59B/60
HW04803930
11.2 L-Axis Unit
11.2 L-Axis Unit
2002
2001
2003
2005
2004
2008
2021
2006
2013
2007
2012
2015
2014
2011
2019 2010
2018 2009
2017
1009
2016 2020
2021
11-3
HW0483930 59C/60
HW0483930
11.2 L-Axis Unit

2003 HW0303276-1 Gear 1
2008 HW0100503-1 L-arm 1
2010 M14 GT-SH washer 6
2012 HW0304457-1 Cover 1
2013 M6X8 APS Bolt 4
2016 HW0304456-1 Cover 1
2019 M6 Washer 4
2020 PMF6-01 Union 2
2021 PT1/8 Plug 2
1009 HW0101815-1 S-head 1
11-4
HW0483930 59D/60
HW04803930
11.3 U-Axis Unit
11.3 U-Axis Unit
3020
3022 3031
3021 3032
3026
3011
3028
3030
3027 3012
3002 3029
3030 3009
3034
3033
3013
3003 3010
3025
3005
3004
3001 3024
3023 3016
3015
3006
3014
2008
3016
3015
3014 3018
3019
3017
3008 3019
3007
11-5
HW0483930 59E/60
HW0483930
11.3 U-Axis Unit

3003 HW0303277-1 Gear 1
3009 HW0100616-1 Casing 1
3010 HW0200494-1 Cover 1
3012 HW0404554-1 N-base 1
3016 HW0404196-2 Washer 2
3020 HW0304454-1 Cover 1
3022 M4 Washer 7
3023 PT1/8 Plug 1
3024 HW0304458-1 Support 1
3026 HW0404719-1 Plate 1
3028 PZ1212 Saddle 1
3031 PT3/8 Plug 1
(DUCRODAIZD Coting)
3032 KQE10-03 Air joint 1
3033 M3X16 Round head 2
screw
3034 M3 Nut 2
2008 HW0100503-1 L-arm 1
11-6
HW0483930 59F/60
HW04803930
11.4 R-Axis Unit
11.4 R-Axis Unit
4045
4046
5013 4043
4044 4042
4041
4040
4038
4049
4050
4047
4035 4037
4048
4036
4030
4033 4039
4032
4031
4051
4029
4034 4028
4024
4025
4023
4022 4052
4021 3004
4018 4020
4027
4019
4026
4016
4015
4017 4010
4007
4009 4013
4008 4014
4006 4011
4004 4005
4003
4012
4010
4002
4001
11-7
HW0483930 59G/60
HW0483930
11.4 R-Axis Unit

4001 SGMPH-01A2A-YR1* Motor 1
4002 M5x12 GT-SA Bolt 2
4005 HW0404304-1 Gasket 1
4006 AE0478G Oil seal 1
4007 HW0410364-1 M-base 1
4008 M5X35 Bolt 3
4011 HW0381645-A Speed reducer 1
4017 STW-30 Retaining rings 1
C-type
4018 HW0304452-1 Housing 1
4020 6906DDU Bearing 1
4021 RTW47 Retaining rings 1
4022 HW0303725-1 Gear 1
4023 HW0303724-1 Gear 1
4025 HW0403979-1 Collar 2
4026 HW0403980-1 Pin 4
4027 SWB8-20 Spring 2
4028 6905 Bearing 1
4029 STW-25 Retaining rings 1
C-type
4030 EZ5036A0 Cap 1
4031 BE4615E Oil seal 1
4032 HW0303288-1 Gear 1
4033 HW0303343-1 Shaft 1
4035 CRBH11016AUE01 Cross roller 1
bearing
4037 BE3908E Oil seal 1
4038 HW0304453-1 Flange 1
4040 HW0303345-1 Shaft 1
4042 HW0304451-1 Shaft 1
4051 PT1/8 Plug 1
4052 KQL10-00 Union 1
3004 HW0100616-1 Casing 1
5013 HW0100617-1 U-arm 1
11-8
HW0483930 59H/60
HW04803930
11.5 Wrist Unit
11.5 Wrist Unit
5069
5070
5068
5067
5066 5079
5064 5076
5065
5064 5075
5090 5074
5091 5073 5077
5061 5089 5088
5072
5087 5071 5085
5062 5092 5083
5060
5046 5086
5047 5081
5063 5055 5095
5056
5057 5080
5058 5084
5093 5082
5060
5060 5048
5049 5094 5060
5059 5050 5045 5044
5051 5043
5042
5052
5053 5029
5054
5041
5039 5037
5035 5017
5038
5034
5033 5031
5040 5032
5030
5036
5015 5005
5006 5096
5004
5097
5016 5018
5014 5002
5013
5020 5021
5022
5012
5019 5024
5025
5011 5097 5006
5010 5023 5026
5005
5008 5027
5001 5009
5003 5002
5004
5007 5028
5029
11-9
HW0483930 59I/60
HW0483930
11.5 Wrist Unit

5060 MS4-10 Pin 4
No. DWG No. Name Pcs 5061 HW0410930-1 Cover 1
5001 HW0100617-1 U-arm 1 5062 M4X16 GT-SA Bolt 4
5002 SGMAS-01A2A-YR1* Motor 2 5063 M6X6 Socket screw 1
5003 M4X10 GT-SA Bolt 2 5064 WR12 Circlip 2
5004 HW0404547-1 M-base 2 5065 NA4901 Needle bearing 1
5005 M4X16 GT-SA Bolt 4 5066 IRTW24 Retaining rings 1
C-type
5067 HW0310757-1 Gear 1
5007 HW0481429-A Pulley 1
5068 HW8411125-3 Washer 1
5071 TC65786 Oil seal 1
5072 AR78 Circlip 1
5012 HW0404354-1 Spacer 1
5073 HW0310763-1 Shaft 1
5013 HW0404353-1 Fly wheel 1
5014 HW0480866-B Pulley 1
5075 6812DBLU Bearing 1
5076 HW0401552-1 B-cover 1
5077 CBS4X12 Bolt 6
5017 HW0381646-A Speed reducer 1
5079 HW0310762-1 Housing 1
5019 RTW28 Retaining rings 1
C-type 5080 HW0372792-A Gear Unit 1
5020 6902ZZ Bearing 1 5081 M4X12 GT-SA Bolt 6
5021 HW0403705-1 Housing 1 5082 HW0310761-1 Frange 1
5022 M4X12 GT-SA Bolt 4 5083 M5X16 GT-SA Bolt 4
5023 M4X16 GT-SA Bolt 4 5084 TC70826 Oil seal 1
5024 HW0481692-A Pulley 1 5085 HW0310758-1 Frange 1
5025 M5X16 Socket screw 1 5086 M4X12 GT-SA Bolt 5
5026 2H-5 Spring washer 1 5087 HW0404366-1 Gasket 1
5027 60S4.5M711 Belt 1 5088 HW0404365-1 Cover 1
5028 HW0100622-1 Cover 1 5089 M5X10 APS Bolt 2
5029 M4X10 GT-SA Bolt 20 5090 HW0303390-1 Cover 1
5030 HW0401553-1 B-cover 1 5091 M4X10 APS Bolt 2
5031 CBS4X12 Bolt 4 5092 M6X6 H-set screw 1
5032 HW0301300-2 Gear 1 5093 M6X6 Socket screw 1
5033 HW9405890-3 Shim * 5094 LP-M5 Plug 1
5034 HW9482218-A Bearing 1 5095 HW0404371-1 Bolt 1
5035 HW0301310-2 Shaft 1 5096 HW0403207-1 Cover 1
5036 M4X12 GT-SA Bolt 4 5097 M4X10 GT-SA Bolt 4
5037 HW0480867-B Pulley 1
5040 60S4.5M932 Belt 1
5041 HW0100621-1 Cover 1
5043 688A Bearing 1
5044 HW0404303-2 Collar 1
5045 6812LLU Bearing 1
5046 6811LLU Bearing 1
5047 HW0100618-1 Wrist 1
5048 WR15 Circlip 1
5049 NA4902 Needle bearing 1
5050 WR28 Circlip 1
5051 HW0311214-1 Shaft 1
5052 HW0311225-1 Gear 1
5055 WB22-20 Spring 1
5056 HW0410762-1 Shaft 1
5057 6804DDU Bearing 1
5058 WR20 Circlip 1
5059 HW0410761-1 Spacer 1
11-10
HW0483930 59J/60
MOTOMAN-SSA2000
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
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 10, Box 4004, SE-390 04 Kalmar, Sweden
Phone +46-480-417800 Fax +46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA ELECTRIC KOREA CORPORATION
1F, Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone +82-53-382-7844 Fax +82-53-382-7845
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
Unit 47-1 and 2. Jalan PJU 5/9, Dataran Sunway, Kota Damansara, 47810, Petailng Jaya Selangor, Malaysia
Phone +60-3614-08919 Fax +60-3614-08929
YASKAWA ELECTRIC (THAILAND) CO., LTD.
252/246, 4th Floor. Muang Thai-Phatra office Tower II Rechadapisek Road, Huaykwang Bangkok 10320, Thailand
Phone +66-2-693-2200 Fax +66-2-693-4200
SHOUGANG MOTOMAN ROBOT CO., LTD.
No.7,Yongchang-North Road, Beijing Economic and Technological and Development Area, Beijing 100076, China
Phone +86-10-6788-0541 Fax +86-10-6788-0542
MOTOMAN MOTHERSON ROBOTICS LTD.
910, DLF Galleria, DLF City Phase IV, Gurgaon - 122002 Haryama, india
Phone +91-124-414-8514 Fax +91-124-414-8016
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice

for ongoing product modifications and improvements. C Printed in Japan November 2007 07-04
MANUAL NO.
HW0483930 2 60/60

SSA 2000 Manipulator Manual: Motoman NX100 Controller

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SSA 2000 Manipulator Manual: Motoman NX100 Controller

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Motoman NX100 Controller

Part Number: 153599-1CD

1.1 About This Document

1.2 Reference to Other Documentation

1.3 Customer Service Information

It is the purchaser’s responsibility to ensure that all local, county, state,

This safety section addresses the following:

2.2 Standard Conventions

2.3 General Safeguarding Tips

2.4 Mechanical Safety Devices

2.5 Installation Safety

2.6 Programming, Operation, and Maintenance Safety

YASKAWA MANUAL NO.

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

• 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

Notes for Safe Operation

WARNING Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

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 person is present in the P-point maximum envelope of

-Check for problems in manipulator movement.

• Always return the programming pendant to the hook on the cabinet of

• Read and understand the Explanation of Warning Labels in the NX100

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

Explanation of Warning Labels

Nameplate: WARNING Label A:

PAYLOAD MASS Moving parts

6 Allowable Load for Wrist Axis and Wrist Flange

8 Electrical Equipment Specification

9 Maintenance and Inspection

9.3.6 Grease Replenishment for T-Axis Gear . . . . . . . . . . . . . . . . .9-16

10 Recommended Spare Parts

1.1 Contents Confirmation

1.1 Contents Confirmation

Confirm the contents of the delivery when the porduct arrives.

1.2 Order Number Confirmation

Label (Enlarged View)

THE MANIPULATOR AND THE CONTROLLER Check that the manipulator

MADE IN JAPAN NJ2484-1

THE MANIPULATOR AND THE CONTROLLER S

SHIFT INTER 7 8 WELD

EX-AXIS 1 2 3CURRENT DELETE INSERT

CABCEK 0 . -CURRENT ENTER

(a) NX100 (Front View) (b) Manipulator (Top View)

Fig. 1 Location of Order Number Labels

2.1 Transport Method

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

• Avoid excessive vibration or shock during transport.

2.1 Transport Method

2.1.1 Using a Crane

Fig. 2 Transporting Position