ROBOTICS

PMU0037-Cxx
ATEX II 2G

Operating and Maintenance

Instructions
Created on: 2016-06
Revision: 01
Document number: E1108000014GB01 Author: WOE

Changes made in revision:

Rev. 01: Revised version of original HW1483183.4 in YEU-R style

© Copyright 2016
This documentation – also in part – may be reproduced or made available to third parties only with the
express approval of YASKAWA Europe "Robotics Division GmbH".
We have checked the content of this publication for compliance with the hardware described.
Nevertheless, discrepancies cannot be ruled out. Therefore, we cannot guarantee full compliance.
However, the information given in this publication is checked regularly and any necessary corrections
will be made in subsequent editions.
Subject to technical modifications.
 Table of contents

Table of contents

1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
1.1 Notes for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
1.3 Frequently used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
1.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
1.5 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
1.6 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
1.6.1 YASKAWA additional manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
1.7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7.1 Safety in the work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7.2 Requirement for operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7.3 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.4 Customer service, repairs and modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.5 Regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7.6 Operation in hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7.7 Special conditions for safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.8 Explanation of explosion protection marking . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7.9 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.8 Registered Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.9 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.10 Authorized representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Explosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1.1 ATEX marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1.2 Explosion-proof protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 TEACH-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 Model specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Ambient conditions and installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Requirements for gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4.1 Mounting procedures for external axis motor unit. . . . . . . . . . . . . . . . . . . . . . . . 35
5.4.2 Robot controller and programming pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5 Installing safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3
Table of contents

6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2 Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.2.1 Connection of the robot controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2.2 Intrinsically safe cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7 Internal Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8 System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1 Pressure switch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

9 Enclosure protection sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

11 Frequent inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

12 Maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4
 General

1 General

1.1 Notes for safe operation

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

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

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

NOTICE
Indicates important background information and application advice.

1 -5
General

1.2 Target group

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

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

NOTICE
Trained personnel according to explosion protection
Assembly, installation, startup operation and maintenance may only conduct by trained
personnel according to explosion protection!
 Please note in addition for assembly and operation the corresponding national safety
regulations and the relative country regulations concerning the Ex-application.

1 -6
 General

1.3 Frequently used terms

The YASKAWA external axis motor is a product of YASKAWA Electric Corporation, and is
provided by default with the robot control, the programming pendant and robot cable.
The terms are designated as follows in this manual:

Term Description
Control Robot control
Industrial robot Robot
Programming pendant / teach box Programming pendant
Supplying cable between robot and robot Cable
control
Robot, robot control and cable Robot system
Yaskawa Electric Corporation YEC
YASKAWA Robotics Division YEU-R
Moving, calibrating and setting up of the ro- Teachen
bot
Movement sequences of the robot JOBs
Technical customer service TCS

1.4 Intended use

The motor is exclusively intended for painting applications or powder coating.
Use is only permitted under the specified environmental conditions (see chapter 1.7.3
"Installation location" at page 14).

1 -7
General

1.5 Improper use

Any use that deviates from the intended use shall be regarded as improper use such as:
• Transport of people and animals
• Use as ascending aid
• Use outside the permissible operating limits
• Use in environments with risk of explosion (except for ATEX-approved motors)
• Use with overload
• Use without relevant safeguards

NOTICE
Modifications to the motor, for example drilling holes, can damage parts. This will be
regarded as improper use and will lead to loss of warranty and liability claims and loss of
the declaration of incorporation.

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

1 -8
 General

1.6 About this manual

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

1.6.1 YASKAWA additional manuals

Refer to the manual „General Purpose“ (document number E1102000148XX01 or higher)

for the operation methods to ensure correct and safe operation.

1 -9
General

1.7 Safety

REMOTE TEACH
START HOLD
1
PLAY

JOB EDIT DISPLAY UTILITY

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

Main Menu Short Cut Turn on servo power

LAYOUT TOOL SEL GO BACK

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

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

INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

ROBOT INFORM 4 5 6 BWD FWD

LIST

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

MOTION 0 . -
AUX MODIFY ENTER
TYPE

Fig. 1-1: Programming pendant

1 Emergency Stop button

WARNING!
Death or injury because of danger of crushing
If the emergency stop button does not function properly, the motor cannot be stopped in the
event of an emergency.
 The robot should not be used if the emergency stop button does not function.
 Before operating the motor check the function of the emergency stop button. The
SERVO power has to immediately go off once the emergency stop button on the
programming pendant has been pressed (seeFig. 1-3: "Emergency Stop button").
 When the SERVO power is turned OFF, the SERVO ON LED on the programming
pendant goes off (see Fig. 1-2: "LED SERVO ON").

SERVO ON
Fig. 1-2: LED SERVO ON

Fig. 1-3: Emergency Stop button

1 - 10
 General

WARNING!
Death or injury because of danger of crushing
Before you release the emergency stop button (see Fig. 1-4: "Release of emergency stop
button by turning") note the following:
 Make sure that there is no one within the maximum working range of the motor.
 Clear the cell of all items which could collide with the motor.
 Now you can switch ON the SERVO power by pressing the enable switch on the
programming pendant.

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

WARNING!
Death or injury because of danger of crushing
if anyone enters the working area of the robot during operation or any problems occur,
always press the emergency stop button immediately. The emergency stop button is
located on the programming pendant (see Fig. 1-1: "Programming pendant").
Observe the following precautions when performing teaching operations within the motors
working range:
 View the motor from the front whenever possible.
 Always follow the prescribed operating procedure (see the instructions on robot control
as well as the operating instructions on "Handling" or "Universal Application").
 An area must be left clear so that the operator can retreat to it in case of emergency.

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

1 - 11
General

1.7.1 Safety in the work area

Only use the motor in proper technical condition and in accordance with its intended use in
a safety-conscious manner while observing the operating instructions.

DANGER!
Risk of explosion caused by pressurized enclosure!
 Do not remove the covers when the motor is energized.
 Remove all dust from the enclosure before connecting or restoring the electrical supply.
 Do not open the enclosure in a hazardous area.

WARNING!
To prevent dangers for the operating personnel and third parties, all the instructions of the
manufacturers must be observed.
In particular, this applies to the following instructions:
 When operating the brake release device, always keep sufficient distance to the motor.
 Before the brake is released, the axes must be properly supported or secured in some
other way.
 When releasing the brake, make sure there are no persons in the immediate vicinity of
the motor because after the brake is released, the axes may be dangerously lowered
or turned.
 A large area around the motor must be cordoned off.
 The robot must always be placed in a safe position.
 Make sure there is no risk of collision.

WARNING!
Risk of injury from movements of the motor
To ensure safety, enforce the following precautions:
 Install a safeguarding.
 Post a warning sign stating "Off-limits During Operation" at the entrance of the
enclosure.
 The gate of the barrier must be equipped with a safety interlock.
 Make sure the interlock operates correctly before operation.

CAUTION!
Risk of injury from collisions of objects or equipment
Do not store items and equipment near the motor and robot control.
 Keep the tools at appropriate locations outside the barrier.
 Keep the equipment at appropriate locations outside the barrier.
 Tools and loose equipment must not be deposited on the floor around the motor, robot
controller and other components.

1 - 12
 General

1.7.2 Requirement for operating personnel

The operator is responsible for the safety of the operating staff. He shall ensure that:
• the operating instructions and its associated documents have been read by the
operating staff (the manufacturer recommends having this confirmed in writing by the
operating staff).
• unauthorized persons cannot have access to the system.
• the protective equipment for the operating staff is available and used by them.
• all available, necessary and prescribed safety devices are installed and effective.
• the system is installed, operated, serviced and maintained only by qualified, trained
operating staff.
• nobody is in the working area of the motor or does maintenance work while the motor
is started. When on standby, the external axis motor can also be moved by an external
signal. To avoid major accidents, the operation status must be clearly evident for the
operating staff.
The operating staff must meet the following requirements:
• the operating staff must not be under the influence of alcohol, drugs or similar
substances,
• the operating staff must not have a restricted field of vision or be restricted in any other
way that could lead to risks,
• and must be in a suitable state of health to operate the robot system.

1 - 13
General

1.7.3 Installation location

DANGER!
Danger of explosion and damage to the system!
Due to an installation site that does not correspond to the standard.
 Do not select an installation site, which is more dangerous than a site with the
classification Zone 1.
 For further information about this topic, refer to chapter 1.7.8.2 "Equipment categories"
on page 18.

DANGER!
Danger of explosion and damage to the system!
Due to jigs, which are installed in hazardous areas without explosion prevention and
protection.
 Only install jigs, which are certified as explosion-proof.

For further information on the requirements and the ambient conditions of the installation
site, refer to chapter 5.2 "Ambient conditions and installation location" on page 32.

CAUTION!
Damage of the robot controller and control panels!
Trough water, dust and dirt inside the robot controller.
 Install the robot controller and control panels in a location free from water, dust, and dirt.

1.7.4 Customer service, repairs and modifications

Only have repairs to the motor carried out by the YASKAWA Europe GmbH Customer
Service responsible.
Use only genuine parts from YASKAWA Europe GmbH for maintenance work.
YASKAWA is not responsible for incidents arising from unauthorized modification of its
products. Unauthorized modification voids your product's warranty!

Any modification of the motor, and of the following system components is strictly prohibited:
• to explosion-proof devices and system installation
• to safeguards and the safety devices mounted on these safeguards
• to emergency stop button and other safety devices
• to the robot controller, the motor handling drive section and the power transmission
section

1 - 14
 General

1.7.5 Regulations

The motor meets the following requirements:

• Directive 2014/34/EU for equipment and protective systems for intended use in
hazardous areas
• IEC60079-0 for electrical apparatus for explosive gas atmospheres - Part 0: General
requirements
• IEC 60079-2 for electrical apparatus for explosive gas atmospheres - Part 2:
Pressurized enclosures "p"
• IEC60079-11 for electrical apparatus for explosive gas atmospheres - Part 11: Intrinsic
safety " i "
• DIN EN 1127-1 Explosive atmospheres - Explosion prevention and protection Part 1:
Basic concepts and methodology
• DIN EN 13463-1 Non-electrical equipment for use in potentially explosive atmospheres
Part 1: Basic method and requirements
• DIN EN 13463-5 Non-electrical equipment intended for use in potentially explosive
atmospheres Part 5: Protection by constructional safety
• Machinery Directive 2006/42/EC
• Low Voltage Directive 2006/95/EC
• EMC Directive 2004/108/ EC
When classifying a motor environment as a hazardous area (zone), observe the
„Guidelines for the Avoidance of Dangers due to Explosive Atmospheres with Collection of
Examples - Explosion Protection Guidelines - (EX-Directives)“.
In special cases, or if you are not sure about the specification of areas with the risk of
explosion, contact the competent authorities and have them decide.

1 - 15
General

1.7.6 Operation in hazardous area

In hazardous areas, only operate the motor of the corresponding equipment category and
temperature class.
The motor has the following explosion protection marking:

Explosion protection marking for gas hazards

Marking Description
Symbol for explosion-proof devices

II Equipment group
2G Equipment category for gas
ib px Type of protection
IIB Gas group
T4 Temperature class
Gb Equipment protection level for gases

Tab. 1-1: Explosion protection marking for gas hazards

1 - 16
 General

1.7.7 Special conditions for safe use

All equipment fitted to the enclosure shall be suitably ATEX certified and shall be installed
in accordance with EN 60079-14.

DANGER!
Risk of explosion and damage to the system!
1. Avoid the build up of dust on the enclosures.
2. Perform the following routine tests after the installation.
a) Verify the operation of the safety devices (functional test). Confirm that on loss of
purge and pressure the enclosure is electrically isolated.
b) Record all tests.
The manufacturer shall be consulted before performing any of the permitted modifications
or additions described below!
• Modifications of the battery:
The battery in the external motor unit shall not be replaced whilst an explosive
atmosphere may be present.
• Modifications of the internal cables:
The customer is permitted to modify the cables contained within the PMU and add to
them. Some cables carry intrinsically safe signals and EN 60079-14 shall be considered
when modifying these.
• Modifications of the safe area cables:
The customer is permitted to modify the safe area cables supplied with the equipment.
Some cables carry intrinsically safe signals and EN 60079-14 shall be considered when
modifying these.
• Modifications of the motor:
The customer is permitted to add equipment to the safe area paint unit and modify the
cables where necessary. The paint unit contains intrinsically safe barriers, any
modifications shall be done in accordance with EN 60079-14 and the creepage and
clearances of EN 60079-11 shall be observed where necessary.

1 - 17
General

1.7.8 Explanation of explosion protection marking

1.7.8.1 Equipment groups

Equipment group I Equipment group II

This equipment group applies to products
for use in underground plants of mines and
their above-ground systems which can be
endangered by methane and/or flammable
dusts.
This equipment group applies to products
for use in the remaining areas which can
be endangered by an explosive atmo-
sphere.

1.7.8.2 Equipment categories

The equipment category describes the frequency and duration of the occurrence of
explosive atmospheres in an area.
 Equipment categories for gas

Equipment cat- Description (in accordance with EN Design safety

egory 1127-1)
1G Areas in which it is to be expected that a Very high
mixture of air and flammable substances in
the form of gas, vapor or mist will occur
constantly, over longer periods or frequent-
ly (Area: zone 0, equipment protection lev-
el Ga in accordance with IEC 60079-0).
2G Areas in which it is to be expected that a High
mixture of air and flammable substances in
the form of gas, vapor or mist will occur oc-
casionally (Area: zone 1, equipment pro-
tection level Gb in accordance with IEC
60079-0).
3G Areas in which it is not to be expected that Normal
a mixture of air and flammable substances
in the form of gas, vapor or mist will occur.
However, if it does occur, then only seldom
and only briefly (Area: zone 2, equipment
protection level Gc in accordance with IEC
60079-0).

Tab. 1-2: Equipment categories for gas

1 - 18
 General

 Equipment categories for dusts or flyings and fibres

Equipment cat- Description (in accordance with EN Design safety

egory 1127-1)
1D Areas in which it is to be expected that a Very high
cloud of combustible dust in the air will oc-
cur constantly, over longer periods or fre-
quently (Area zone 20, equipment
protection level Da in accordance with IEC
60079-0).
2D Areas in which it is to be expected that a High
cloud of combustible dust in the air will oc-
cur occasionally (Area zone 21, equipment
protection level Db in accordance with IEC
60079-0).
3D Areas in which it is not to be expected that Normal
a cloud of combustible dust in the air will
occur. However, if it does occur, then only
seldom and only briefly (Area zone 22,
equipment protection level Dc in accor-
dance with IEC 60079-0).

Tab. 1-3: Equipment categories for dusts or flyings and fibres

1.7.8.3 Types of protection

The types of protection are subdivided into several sub-classes. Refer to the corresponding
standards in the following table for detailed information.

Type Description
d Gas - Flameproof enclosures in accordance with IEC 60079-1
p Gas - Pressurized enclosures in accordance with IEC 60079-2
q Gas - Protection by powder filling in accordance with IEC 60079-5
o Gas - Protection by oil immersion in accordance with IEC 60079-6
e Gas - Increased safety in accordance with IEC 60079-7
i Gas - Intrinsic safety in accordance with IEC 60079-11 and IEC 60079-27
n Gas - Type of protection in accordance with IEC 60079-15 and IEC 60079-27
m Gas - Encapsulation in accordance with IEC 60079-18
s Special protection in accordance with IEC 60079-33

Tab. 1-4: Types of protection

1 - 19
General

1.7.8.4 Explosion groups

Gas explosion groups

Flammable gases and vapors are classified according to gas explosion groups (IIA, IIB, IIC
and I) and temperature classes.
Tab. 1-5: "Gas explosion groups" shows the classification of the most common flammable
gases and vapors.

Tempera- IIA IIB IIC I

ture class
T1 Acetone, Ethane, Ethyl Natural gas Hydrogen Methane
acetate, Ammonia, Ethyl
chloride, Benzole, Acetic
acid, Carbon monoxide,
Methanol, Methyl chlo-
ride, Naphthalene, Phe-
nol, Propane, Toluene
T2 i-Amyl acetate, n-Butane, Ethylene, Ethyl al- Acetylene -
n-Butyl alcohol, Cyclo- cohol
hexanon, 1.2-Dichlo-
roethane, Acetic acid-
anhydride
T3 Gasoline, Diesel fuel, Jet Hydrogen sulfide - -
fuel, Heating oil, n-Hex-
ane
T4 Acetaldehyde Ethyl ether - -
T5 - - - -
T6 - - Carbon di- -
sulfide

Tab. 1-5: Gas explosion groups

Dust explosion groups

Explosive dust atmospheres are classified according to the dust explosion groups (IIIA, IIIB
and IIIC).

Group Description according to IEC 60079-0:2012

IIIA Combustible flyings
IIIB Non-conductive dust
IIIC Conductive dust

Tab. 1-6: Dust explosion groups

1 - 20
 General

1.7.8.5 Temperature classes

Maximum surface temperature

The maximum surface temperature is the highest temperature reached by a motors surface
under the most unfavorable conditions.

Ignition temperature
The maximum surface temperature of the motor must always be lower than the lowest flash
point of the gas or vapor-air mixture in which it is used.

Temperature class
The maximum surface temperature results from the motors design and is specified as the
temperature class.

Temperature class Maximum surface temperature [°C]

T1 450
T2 300
T3 200
T4 135
T5 100
T6 85

1.7.9 Environmental protection

Store all replacement parts in a protected manner and dispose of them properly in
accordance with the applicable environmental protection regulations.
Observe the respective international regulations. This especially applies to parts
contaminated with toxic substances.

1.8 Registered Trademarks

In this manual, names of companies, corporations, or products are trademarks, registered
trademarks, or brand names for each company or corporation. The indications of  and TM
are omitted.

1 - 21
General

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

1.10 Authorized representative

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

1 - 22
 Features

2 Features

2.1 Explosion protection

2.1.1 ATEX marking

ATEX Protection level:

PMU Power on Power off

ATEX CAT2 II 2G Ex ib px IIB T4 Gb II 2G Ex ib IIB T4 Gb

Paint module:

II (2)G [Ex ib] IIB Gb

2.1.2 Explosion-proof protection

The motor with its explosion-proof construction meets the requirements for explosion-
protected ratings:
• The pressurized explosion-proof enclosure prevents explosive gas or dust from
entering the motor by supplying a protective gas, such as clean air or an inert gas, to
keep the internal air pressure constant.
• The explosion-proof/intrinsically safe enclosure prevents explosive gas or dust
from igniting by electric spark and heat.

2 - 23
Features

2.2 TEACH-IN

NOTICE
Risk of data loss due to an internal memory fault in the robot controller.
 Save the backup data for the robot controller, such as the data for JOBs and constants,
on a CompactFlash card or an USB stick.

Following features can be taught using the programming pendant while moving the PMU:
• Target position
• Motion speed
• ON/OFF timing of the spray
This shortens the time required for teaching. The data can be corrected at any time.
Since the teaching function and the correction function are integrated, the operations such
as forward/reverse run, position modification, addition/deletion of points can be performed
during teaching. The management function, which manages the parameter settings,
enables the operator to monitor the actual status during teaching. The on-screen guidance
and the interactive system on the pull-down menus guide the operator through the
operation procedures.
• Large-capacity backup as a standard feature. The large-capacity drive for
CompactFlash cards is provided as a standard feature of the backup unit and enables
data to be transmitted easily.
• High reliability. The built-in microcomputer continuously checks the I/O data and the
robot motion. This ensures a high reliability. Furthermore, the built-in microcomputer
can detect power supply faults and software faults with its self-diagnosis functions.
• Easy fault remedy. When an error such as an operation error or a controller fault
occurs, the alarm code and message are displayed. The date and time of the error
occurrence with its explanation are stored in the alarm history to help you take a quick
corrective action.

2 - 24
 Supply

3 Supply

3.1 Checking the scope of delivery

When the package arrives, check the contents. Check the items and quantities in
accordance with the order sheet or any damages incurred during shipment, etc.

JZRCR-YCS21-P00
II(2)G [EXib] IIBGb
Serial No:
*******
Year of Manufacture:
20**
Rated Single phase: AC200V 50/60Hz
AC220V 60Hz
Rated intrinsically safe circuit:
DC13.2V 14.2 mA
Pressure/Flow Switch Circuit DC17.22V 220mA
Solenoid Value Circuit DC3.6V 81mA
Battery Back Up Circuit
(Thionyl Chloride Lithium Battery (ER17500VLY))
Rated non intrinsically safe circuit
Allowable voltage: AC250V 50/60Hz, DC250V

Installation location: Non Hazardous area

Ambient temperature: 0° to +45° C
WARNINGS:
1. Do not make any changes of the equipments and wiring in the painting
unit including intrinsically safe apparatus.
2. Battery backup circuit is consisted of batteryy position detector
and encoder separation board. The circuit is intrinsically safe circuit
when the power supply is shutdown or air purging.
3. The controller combired wich pairting unit shall be grounded at 100 ohms or less.
4. The painting unit including relay barrier, isolatded barrir and encoder
separation board shall be installed in a non-hazardous area.

:$51,1*
+LJK9ROWDJH
'RQRWRSHQWKHGRRU
ZULWKSRZHU21

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

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen
DX200

When the package arrives, check the content.

WARNING!
Risk of injury and damage to the system by damaged motor or missing parts!
 Make sure that the parts are not damaged during transport.
 Make sure that the parts and quantities are in accordance with your order sheet and
complete.
 Check the motor for damage.

WARNING!
Risk of injury and damage to the system!
For safe operation the motor and the robot controller have to match.
 Confirm that the motor and the robot controller have the same order number.
 Take special care when more than one motor is to be installed.

3 - 25
Supply

3.2 Type plate

Check whether the serial numbers of the programming pendant, the robot controller and the
robot match the details on your delivery note. You can find the serial number at the type
plate.
The type plate and the ATEX type plate are located on the PMU as pictured in the following
figure.

NOTICE
When the serial number does not match with the delivery note, contact your YASKAWA
subsidiary.

Following warning labels are attached to the external axis motor unit.
Always follow the warnings on the labels.
Also, an identification labels with important information are placed on the body of the
external axis motor unit. Prior to operating the external axis motor unit, confirm the
contents.

ATEX Type plate

Name plate indication on explosion proof 1 Quality number
2 Certificate number
YASKAWA Europe GmbH
Yaskawastr. 1, D-85391 3 Refer to tables below "Model
Allershausen Germany
specification"
PMU0037-Cxx CML 15ATEX1064X
II2G External axis motor unit ExibpxIIBT4Gb/ExibIIBT4GB
II(2) G Controller [Exib]IIBGb
Serial No: *****
Year of Manufacture: 20**
Maximum Voltage: 3Px200V 50/60Hz(+10%,-15%)
3Px200V 60Hz(+10%,-15%)
Maximum Current: 4.3 A
Maximum Capacity: 3.7 A
Maximum Power: 1.5 KVA

Ambient Temperature:
External axis motor unit: 0°C to + 40°C
Painting unit: 0°C to + 45°C
Intrinsically Saftey Circuitry
Pressure Switch/Flow Switch Circuity: DC13.2V 14.2mA
Solenoid Value Ciricuity: DC17.22V 220mA
Battery Back Up Circuitry: DC3.6V 81mA
{Thionly Chloride Lithium Batteries (ER1750VLY)}

Non Intrinsically Saftey Circuitry

Allowrable Voltage: AC250V 50/60Hz,DC250V
Minimum Dilution Flow Rate: 400 l/Min
Purging Pressure Reducing Valve: 0.28 to 0.30 MPa
Minimum Purge Flow Time: 1 Min
Maximum Leakage: 50N I/min
Minimum Over Pressure(Input): 5 kPa
Maximum Over Pressure(Input): 50 kPa
Operating Pressure Reducing Valve: 0.01 to 0.02 MPa
Protective Gas Temperature: 0°C to +40°C
Internal Volume 18.7 l
Pressurrization System
Minimum Line Pressure: 0.35 MPa
Maximum Line Pressure: 0.65 MPa
Warnings:
1. Do not make any changes of the equipments and wiring in the external axis moto unit,
relay barrier, isolated barrier and encoder separation board (inside the painting unit)
including intrinsically safe apparatus and combination equipment of internal
pressure explosion--proof structure.
2. Battery backup circuit is consisted of battery, position detector
and encoder separation board. The circuit is intrinsically safe circuit
when the power supply of the controller is shut down or air purging.
3. The painting unit combined shall be grounded at 0,1 ohms or less.
4. Relay barrier, isolated barrier and encoder
separation board (Inside the painting unit) shall be installed in a non-hazardous area.
5. Pressurized enclosure, do not open when energised.
Enclsure contains lithium battery.
6. Do not open when on explosure atmosphere is present.
7. This is inner pressurized enclosure.
8. Refer to instructions in the manual before opening. DWG.No.
9. Remove all dust from this enclosure before connecting
or restoring the electrical supply.
NJ

4
1. Do not make any changes of the equipments and wiring in the external axis motor unit,
relay barrier, isolated barrier and encoder separation board (inside the painting unit)
including intrinsically safe apparatus and combination equipment of internal pressure
explosion--proof structure.
2. Battery backup circuit is consisted of battery, position detector and encoder separation
board. The circuit is intrinsically safe circuit when the power supply of the controller is
shut down or air purging.

3 - 26
 Supply

3. The painting unit combined shall be grounded at 0,1 ohms or less.

4. Relay barrier, isolated barrier and encoder separation board (Inside the painting unit)
shall be installed in a non-hazardous area.
5. Pressurized enclosure, do not open when energized. enclosure contains lithium battery.
6. Do not open when on explosive atmosphere is present.This is inner pressurized
enclosure.
7. This is inner pressurized enclosure.
8. Refer to instructions in the manual before opening.
9. Remove all dust from this enclosure before connecting or restoring the electrical supply

3.3 Model specification

Model Motor shaft speci- Exchange of incident part which isn’t

fication related to explosion proof structure
YRT-PMU0037-A00 Standard (No incidental)
YRT-PMU0037-A01 Incidental specifications A
YRT-PMU0037-A02 Incidental specifications B
YRT-PMU0037-A03 Incidental specifications C
YRT-PMU0037-A04 Incidental specifications D
Flange shaft type
YRT-PMU0037-A05 Incidental specifications E
YRT-PMU0037-A06 Incidental specifications F
YRT-PMU0037-A07 Incidental specifications G
YRT-PMU0037-A08 Incidental specifications H
YRT-PMU0037-A09 Incidental specifications I
YRT-PMU0037-A10 Standard (No incidental)
YRT-PMU0037-A11 Incidental specifications A
YRT-PMU0037-A12 Incidental specifications B
YRT-PMU0037-A13 Incidental specifications C
YRT-PMU0037-A14 Incidental specifications D
Shaft gear type
YRT-PMU0037-A15 Incidental specifications E
YRT-PMU0037-A16 Incidental specifications F
YRT-PMU0037-A17 Incidental specifications G
YRT-PMU0037-A18 Incidental specifications H
YRT-PMU0037-A19 Incidental specifications I

Tab. 3-1: TIIS explosion-proof specification

3 - 27
Supply

Model Motor shaft speci- Exchange of incident part which isn’t re-
fication lated to explosion proof structure
YRT-PMU0037-B00 Standard (No incidental)
YRT-PMU0037-B01 Incidental specifications A
YRT-PMU0037-B02 Incidental specifications B
YRT-PMU0037-B03 Incidental specifications C
YRT-PMU0037-B04 Incidental specifications D
Flange shaft type
YRT-PMU0037-B05 Incidental specifications E
YRT-PMU0037-B06 Incidental specifications F
YRT-PMU0037-B07 Incidental specifications G
YRT-PMU0037-B08 Incidental specifications H
YRT-PMU0037-B09 Incidental specifications I
YRT-PMU0037-B10 Standard (No incidental)
YRT-PMU0037-B11 Incidental specifications A
YRT-PMU0037-B12 Incidental specifications B
YRT-PMU0037-B13 Incidental specifications C
YRT-PMU0037-B14 Incidental specifications D
Shaft gear type
YRT-PMU0037-B15 Incidental specifications E
YRT-PMU0037-B16 Incidental specifications F
YRT-PMU0037-B17 Incidental specifications G
YRT-PMU0037-B18 Incidental specifications H
YRT-PMU0037-B19 Incidental specifications I

Tab. 3-2: Explosion-proof specification of north America

3 - 28
 Supply

Model Motor shaft speci- Exchange of incident part which isn’t

fication related to explosion proof structure
YRT-PMU0037-C00 Standard (No incidental)
YRT-PMU0037-C01 Incidental specifications A
YRT-PMU0037-C02 Incidental specifications B
YRT-PMU0037-C03 Incidental specifications C
YRT-PMU0037-C04 Incidental specifications D
Flange shaft type
YRT-PMU0037-C05 Incidental specifications E
YRT-PMU0037-C06 Incidental specifications F
YRT-PMU0037-C07 Incidental specifications G
YRT-PMU0037-C08 Incidental specifications H
YRT-PMU0037-C09 Incidental specifications I
YRT-PMU0037-C10 Standard (No incidental)
YRT-PMU0037-C11 Incidental specifications A
YRT-PMU0037-C12 Incidental specifications B
YRT-PMU0037-C13 Incidental specifications C
YRT-PMU0037-C14 Incidental specifications D
Shaft gear type
YRT-PMU0037-C15 Incidental specifications E
YRT-PMU0037-C16 Incidental specifications F
YRT-PMU0037-C17 Incidental specifications G
YRT-PMU0037-C18 Incidental specifications H
YRT-PMU0037-C19 Incidental specifications I

Tab. 3-3: ATEX explosion-proof specification

3 - 29
Supply

1 Battery warning label

2 Name plate
3 Name plate indication an explosion proof

WARNING
When replacing battery instuction
manual details are to be followed.
Battery only to be replaced when
the area is known to be safe.

MODEL
TYPE

MASS
kg
SERIAL NO. ORDER NO.

PNEUMATIC PRESSURE MAX.

kPa
POWER SUPPLY AC 400V
3-phase 50/60Hz
Average kVA
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku
Kitakyushu 806-0004, Japan
MADE IN JAPAN
Authorized Representative:
YASKAWA Europe GmbH
Yaskawastr. 1
D-85391 Allershausen Germany NJ3836
DWG.No.
3Px200V 50/60Hz(+10%,-15%)

1. Do not make any changes of the equipments and wiring in the external axis moto unit,

separation board (Inside the painting unit) shall be installed in a non-hazardous area.
ExibpxIIBT4Gb/ExibIIBT4GB

3Px200V 60Hz(+10%,-15%)
CML 15ATEX1064X

relay barrier, isolated barrier and encoder separation board (inside the painting unit)
AC250V 50/60Hz,DC250V

including intrinsically safe apparatus and combination equipment of internal

14.2mA
220mA
81mA

NJ
0.28 to 0.30 MPa

0.01 to 0.02 MPa

and encoder separation board. The circuit is intrinsically safe circuit

when the power supply of the controller is shut down or air purging.
3. The painting unit combined shall be grounded at 0,1 ohms or less.
[Exib]IIBGb

0°C to + 40°C
0°C to + 45°C

0°C to +40°C

2. Battery backup circuit is consisted of battery, position detector

DC17.22V

50N I/min

0.35 MPa
0.65 MPa
400 l/Min
DC13.2V

DC3.6V

50 kPa
5 kPa

6. Do not open when on explosure atmosphere is present.

1 Min

18.7 l

9. Remove all dust from this enclosure before connecting

5. Pressurized enclosure, do not open when energised.
*****
20**

8. Refer to instructions in the manual before opening.

YASKAWA Europe GmbH

{Thionly Chloride Lithium Batteries (ER1750VLY)}

Yaskawastr. 1, D-85391
Allershausen Germany

PMU0037-Cxx
II2G External axis motor unit

4. Relay barrier, isolated barrier and encoder

1.5 KVA

Pressure Switch/Flow Switch Circuity:

4.3 A
3.7 A

Operating Pressure Reducing Valve:

Non Intrinsically Saftey Circuitry

pressure explosion--proof structure.

7. This is inner pressurized enclosure.

Purging Pressure Reducing Valve:

Enclsure contains lithium battery.

Maximum Over Pressure(Input):
Minimum Over Pressure(Input):

or restoring the electrical supply.

Intrinsically Saftey Circuitry
II(2) G Controller

Minimum Dilution Flow Rate:

Protective Gas Temperature:

Minimum Purge Flow Time:
Battery Back Up Circuitry:

Pressurrization System
Year of Manufacture:

Maximum Line Pressure:

Ambient Temperature:

Minimum Line Pressure:

Solenoid Value Ciricuity:
External axis motor unit:
Maximum Voltage:

Maximum Capacity:

Maximum Leakage:
Allowrable Voltage:
Maximum Current:

Maximum Power:

Internal Volume
Painting unit:
Serial No:

Warnings:

YASKAWA Europe GmbH

Yaskawastr. 1, D-85391
Allershausen Germany

PMU0037-Cxx CML 15ATEX1064X

Battery warning label II2G External axis motor unit
II(2) G Controller
ExibpxIIBT4Gb/ExibIIBT4GB
[Exib]IIBGb
Serial No: *****
Year of Manufacture: 20**
WARNING Maximum Voltage: 3Px200V 50/60Hz(+10%,-15%)
3Px200V 60Hz(+10%,-15%)
When replacing battery instuction Maximum Current: 4.3 A
manual details are to be followed. Maximum Capacity: 3.7 A
Battery only to be replaced when Maximum Power: 1.5 KVA
the area is known to be safe.
Ambient Temperature:
External axis motor unit: 0°C to + 40°C
Painting unit: 0°C to + 45°C

Pressure switch unit warning label Intrinsically Saftey Circuitry

Pressure Switch/Flow Switch Circuity: DC13.2V 14.2mA

(Attached to the pressure switch unit) Solenoid Value Ciricuity: DC17.22V 220mA
Battery Back Up Circuitry: DC3.6V 81mA
{Thionly Chloride Lithium Batteries (ER1750VLY)}

Non Intrinsically Saftey Circuitry

Allowrable Voltage: AC250V 50/60Hz,DC250V
WARNING Minimum Dilution Flow Rate: 400 l/Min
Purging Pressure Reducing Valve: 0.28 to 0.30 MPa
Explosion proof safety device. Minimum Purge Flow Time: 1 Min
Maximum Leakage: 50N I/min
Do not change any parameters.
Minimum Over Pressure(Input): 5 kPa
Maximum Over Pressure(Input): 50 kPa
Operating Pressure Reducing Valve: 0.01 to 0.02 MPa

Name plate Protective Gas Temperature:

Internal Volume
0°C to +40°C
18.7 l
Pressurrization System
Minimum Line Pressure: 0.35 MPa
Maximum Line Pressure: 0.65 MPa
MODEL
TYPE DATE Warnings:
1. Do not make any changes of the equipments and wiring in the external axis moto unit,
MASS relay barrier, isolated barrier and encoder separation board (inside the painting unit)
kg
including intrinsically safe apparatus and combination equipment of internal
SERIAL NO. ORDER NO.
pressure explosion--proof structure.
2. Battery backup circuit is consisted of battery, position detector
PNEUMATIC PRESSURE MAX. and encoder separation board. The circuit is intrinsically safe circuit
kPa
when the power supply of the controller is shut down or air purging.
POWER SUPPLY AC 400V
3-phase 50/60Hz 3. The painting unit combined shall be grounded at 0,1 ohms or less.
4. Relay barrier, isolated barrier and encoder
Average kVA separation board (Inside the painting unit) shall be installed in a non-hazardous area.
YASKAWA ELECTRIC CORPORATION 5. Pressurized enclosure, do not open when energised.
2-1 Kurosakishiroishi, Yahatanishi-ku Enclsure contains lithium battery.
Kitakyushu 806-0004, Japan 6. Do not open when on explosure atmosphere is present.
MADE IN JAPAN 7. This is inner pressurized enclosure.
Authorized Representative: DWG.No.
8. Refer to instructions in the manual before opening.
YASKAWA Europe GmbH
9. Remove all dust from this enclosure before connecting
Yaskawastr. 1 or restoring the electrical supply.
NJ3836 NJ
D-85391 Allershausen Germany

Tab. 3-4: Warning labels

3 - 30
 Transportation

4 Transportation

4.1 Requirements

CAUTION!
Personal injury or damage to property
Carry out the operation safely observing the following precautions.
 Signs indicating prohibitions such as, “The lighting of fires is prohibited”.
 Clean working place that is clearly defined and free of obstacles.
 Appointment of personnel in charge.
 Company working regulations for safe operation.

Before you transport and install the motor, conduct the following instructions:
1. Confirm the installation layout and the dimensions of each device to ensure the
transportation route and the installation space.
2. Check if the transportation route can support the weight of each device. If necessary,
reinforce the route.
3. To lift the motor, use the appropriate machinery such as a forklift.

WARNING!
Risk of injury and motor damage by wrong transport!
The PMU weighs approximately 42 kg including shipping bolts and brackets.
 Pay attention to the maximum load capacity of the lifting devices.
 Carefully check the lengths and the tensions of the belts and chains to maintain the
balance of the PMU while lifting.
 Make sure that the PMU will be lifted only by qualified and authorized personnel.

4 - 31
Assembly and installation

5 Assembly and installation

5.1 Requirements
 Prepare the power supply and the grounding according to the following specifications:

Item Specification Remark

Power supply Three phase 200 VAC (-15 %
to +10 %) 50/60 Hz
220 VAC (-15 % to +10 %) 60
Hz
50/60 Hz (2 Hz)
1.5 kVA (at peak)
Air supply Required pressure: between Use dry air for the pres-
Pressurized explosion- 0.35 MPa to 0.65 MPa surized explosion-proof
proof enclosure Capacity for pressurized ex- enclosure.
plosion-proof enclosure: 50
NL/min during operation
400 NL/min when purging
Dryness: Freezing at -18° C
Grounding Grounding resistance: 0.1  or For the robot controller
less0.1  or less
Cable cross-section: 6 mm²

Tab. 5-1: Specifications

CAUTION!
Moisture in the air supply may damage the electronic parts.
 Use dry air for the pressurized explosion-proof enclosure.

5.2 Ambient conditions and installation location

When installing a PMU, it is necessary to satisfy the following environmental conditions:
• Ambient temperature: 0° to 40°C.
• Air humidity: 20% to 80% relative humidity at constant temperature.
• Free from exposure to water, oil, or dust.
• Free from corrosive gas or liquid, or explosive gas or liquid.
• Free from excessive vibration (Vibration acceleration: 4.9 m/s² [0.5 G] or less).
• Free from large electrical noise (plasma).
• Maximum unevenness of the support surface of the robot base: 0.5 mm.
This section describes the conditions of the installation site for the external axis motor unit.
Only devices that are approved as explosion-proof can be installed in hazardous locations.
Refer to the local regulations and safety codes for the definition of a hazardous location.
Install the robot controller and control panels in a location free from water drops, dust, and
dirt.

5 - 32
 Assembly and installation

Requirements for the location

System component Hazardous lo- Non-hazard- Ambient Maximum

cation (inside ous location temperature ambient hu-
painting (outside paint- midity
booth) ing booth)
External axis motor 0° to 40°C 80% RH
 
unit (explosion-proof)
Controller (not explo- 0° to 45°C 90% RH
x 
sion-proof)
Pressure Switch unit 0° to 40°C 85% RH
 
(explosion-proof)
Programming pen- 0° to 40°C 85% RH
dant (not explosion- x 
proof)
Programming pen- 0° to 40°C 85% RH
dant (optional: explo-  
sion-proof)
Conveyor speed de- 0° to 50°C 90% RH
tector (optional: ex-  
plosion-proof)
Conveyor switch (ex- 0° to 50°C 90% RH
 
plosion-proof)
 Acceptable
x Not acceptable
 Should be always mounted within the painting booth.

CAUTION!
Failure to observe this warning may result in a fire.
Devices that are not explosion-proof must not be installed in hazardous locations.

5.3 Requirements for gaskets

The equipment PMU0037-Cxxx makes use of (liquid-) gaskets shown below.
Their performance should be considered with respect to the chemicals that may be present
in the hazardous area.
1) Threebond 1206C
2) Dreibond 1108
3) Teroson fluid D
4) TNKL 7007-HP NBR

5 - 33
Assembly and installation

5.4 Assembly

WARNING!
Danger of injury and damage to the system!
Through an incomplete assembling the motor can fall over.
 Do not install and operate the motor before it is firmly anchored.

5 - 34
 Assembly and installation

5.4.1 Mounting procedures for external axis motor unit

Please fix the motor unit and the pressure switch unit referring to Fig. 5-1: "External axis
mounting dimensions (3.7kW)" and Fig. 5-2: "Pressure switch unit mounting dimension" for
the installation of the external axis motor unit.
30°

45°

30
60

°
H7

h7

Ø52
Ø20
C1

45°
C1

h6
C

Ø130
6

11.5
66

Fig. 5-1: External axis mounting dimensions (3.7kW)

1 8 tapped holes M8 x 20 4 8 tapped holes M5 x 12

2 P.C.D. 248 5
3 P.C.D. 42 6
4 x Ø7
35 226

255
80
88

239 354
167

Fig. 5-2: Pressure switch unit mounting dimension

5 - 35
Assembly and installation

5.4.2 Robot controller and programming pendant

• The robot controller and the programming pendant are not explosion-proof (the
explosion- proof programming pendant is available as an option). Never install the robot
controller and the programming pendant that are not explosion-proof in a hazardous
location.
• Secure a space around the robot controller for maintenance. When the sufficient space
is not available, provide equipment for maintenance such as a drawing-out system.
• Do not install the robot controller and programming pendant close to any noise source
such as the power supply for other devices.
• Install the robot controller in a location where the optimum atmosphere, temperature,
and humidity are assured and provide protection against water drops or thinner. If
necessary, install a control room to supply clean and temperature-controlled air.

5.5 Installing safeguards

To ensure safe operation, the following procedures are to be taken into account.

DANGER!
Personal injury and material damage!
The robot system may not be operated without any safeguards. A startup operation without
safeguarding measures leads to death, serious injuries or damage to property.
Install the following safeguards:
 Separating safeguards
 Non-contact safeguards
 Enclosures
 Marked areas
 Signs
 Emergency stop button
 Display elements

NOTICE
Operator's responsibility
The operator of a motor or a robot system must ensure that all specifications and
requirements of the standards DIN EN ISO 10218-1, DIN EN ISO 10218-2 and the directive
1999/92/EG, are met.
In the first instance, the following must be observed:
 Preparing a risk assessment
 The installation of safeguards
 Regular training of the employees
 Regular inspection of all safeguards
 Checking for compliance with intended use

5 - 36
 Assembly and installation

NOTICE
The motor is equipped with safeguards such as safety speed and hold-to-run buttons
(DSW) which allow for safe handling of the equipment.
 They must not be changed.

There are additional safeguards which must be installed for a safe operation of a motor.
Should you have questions in this respect or require further information, please contact
your YASKAWA Europe GmbH sales partner.

5 - 37
Wiring

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

WARNING!
Risk of fire and risk of burning at hot power cable!
 Do not cover the power cable between the motor and the robot controller.
 Separate the power cable from the other cables.

6.1 Grounding
Follow the electrical installation standards and wiring regulations for grounding. The cable
cross-section must be 6 mm² or more with round crimping terminal.

NOTICE
Note on grounding connection!
 Never use the grounding cable together with another grounding cable. For example
with a grounding cable of a different electrical consumer, a different motor-driven
consumer or welding devices.
 Where metal ducts, metallic conduits, or distributing racks are used for cable laying,
grounding should be performed in accordance with the applicable electrical installation
standards.

The grounding method differs depending on the system application. Refer to the connection
instructions that are provided separately.

Fig. 6-1: Grounding method (Outside motor unit)

6 - 38
 Wiring

Fig. 6-2: Grounding method (Inside motor unit)

Fig. 6-3: Grounding method (Pressure switch unit)

1 Screw M8 for grounding (Delivered with the motor unit)

2 6 mm² or more
3 Grounding cable connecting tap (for the grounding cable of the motor cable)
• Cross-recessed head machine screw M5
• Washer
• Spring washer

6 - 39
Wiring

6.2 Cable connections

DANGER!
Risk of explosion!
 For the cable gland, it is required to use the specified one for the explosion-proof
certification motor.
 Also, please do not detach, reassemble or remodel the cable gland since it is already
an assembled parts.
 Contact your YASKAWA representatives when any abnormalities are found.

NOTICE
Refer to the manual of the robot controller for the connection of the power cable and the
intrinsically safe cable to the robot controller. The air tube for the pressure switch, the
intrinsically safe cable, and the crimped terminals should be prepared by the customer.
Furthermore, inside the painting booth, the power supply cables are required to be
protected by the wire blade prepared by YASKAWA (length should be specified),
accommodated through the metal pipe, or put in the ditch on the floor and covered with the
metal plate.
The PMU is originally equipped with suitable cables including the according cable glands.
 Any changes regarding cables or cable glands have to be made by YASKAWA Europe
GmbH.

NOTICE
Protect the power supply cables inside the painting booth through one of the following
measures:
 by the wire blade prepared by YASKAWA (length must be specified),
 or by laying the cables in a floor joint and covering them with a metal plate,
 or by laying the cables through a metal pipe.

Refer to 6.2.1 "Connection of the robot controller"

1. Connect the power cable connector to the connector base (check the reference sticker).
2. Connect the grounding cable of the power cable to the grounding cable connecting tap.
3. Attach the gasket side of the power cable to the base after checking that no tube is
going to be bent, and then tighten it with the hexagon socket head cap screws.

6 - 40
 Wiring

6.2.1 Connection of the robot controller

EX-X11

EX-X21

Fig. 6-4: Power and signal cable connection to the robot controller

1 Robot controller side 6 Cable gland

2 Signal cable 7 Cover
3 Power cable 8 Gasket
4 Motor unit side 9 Connect to the grounding tap
5 3.7 kW motor unit

EX1-SIG
EX-X11

EX1-POW1, POW2

EX-X21

Fig. 6-5: Cable connection (When relaying cables)

1 Robot controller side 6 Cable gland

2 Signal cable 7 Cover
3 Power cable 8 Gasket
4 Cable gland Motor unit side 9 Connect to the grounding tap
5 Terminal box 3.7 kW motor unit

6 - 41
Wiring

6.2.2 Intrinsically safe cable

Intrinsically safe cable:

• Cable type (recommended): UL2586-SB,1.25 mm2
• The cable to be connected with terminal blocks P1 to N3, and 1 to 2 are different.
• The group of terminal blocks P1 to N3, and 1 to 2 are binded with shield separately.

Cable connection

Motor side Robot control-

(intrinsically ler side
safe termi-
nal block)
P1  P1
N1  N1
P2 P2*
N2 N2*
P3  P3
N3  N3

1  1
2  2

*P2 and N2 relay barrier connectors are short circuited inside the robot controller by a cable.
Do not remove the cable. However, they are not short circuited inside the motor. Also, each
P2 and N2 connector at motor and robot controller side are not connected each other.

6 - 42
 Wiring

1 2

3.5 min 4 max 5.3 min 4.4 max

7.8 max

6 max
Ø 3.7 min Ø 3.2 min

10

2.3

0.8
Fig. 6-6: Pressure switch unit connection to intrinsically safe terminal block and barrier

1 Motor: Crimped terminals 3 For connecting the intrinsically safe

For connecting the intrinsically safe cable to the insulation barrier inside
cable to the intrinsically safe terminal the robot controller.
block. For terminal block 1 to 2
For terminal block P1 to 2
2 Robot controller: Crimped terminals
For connecting the intrinsically safe
cable to the relay barrier inside the ro-
bot controller.
For terminal block P1 to N3

6 - 43
Internal Cable Connections

7 Internal Cable Connections

EXD-XG1

EX-XG2
TA2 or TA15
TA1 or TA15
EX-X11

EX-X21

Fig. 7-1: Wiring diagram (PMU0037 3.7kW Motor unit)

7 - 44
 System configuration

8 System configuration

(PP)
DX200

(PP)

Fig. 8-1: System Configuration

1 Non-Hazardous location 9 Hazardous location

2 Program selector (optional) 10 Conveyor switch (optional)
3 Paint unit 11 Intrinsically safe cable (1 or 2 cables)
4 Programming pendant (not explosion 12 Air supply (0.35 Mpa - 0.65 Mpa)
proof)
5 Power supply 3-phase AC200/220V 13 Master value Pressure switch unit
50/60Hz
6 D-class grounding with grounding re- 14 3.7 kW motor unit
sistance of 0.1 Ω or less
7 Motor cables for 3.7 kW 15 Programming pendant (explosion-
proof: optional)
8 Ex-proof terminal box (When relaying
the cables)

8 - 45
System configuration

8.1 Pressure switch unit

WARNING!
Explosion-proof safety device
 Do not change any parameters

The pressure switch unit supplies protective air or gas to the external axis motor unit to
prevent explosive gas from entering the external axis motor unit. Usually, the unit is installed
aside from the robot controller.
The circuit diagram and dimensions are shown in and Fig. 8-2: "Purge unit air circuit"Fig.
8-3: "Pressure switch external view".
Set the air pressure so that the pressure shown on the pressure gauge of each pressure
reducing valve to be within the pressure ranges shown in Fig. 8-2: "Purge unit air circuit".
As shown in the Tab. 8-1: "Connection overview", the distance of up to 20 m is allowed
between the external axis motor unit and the pressure switch unit.
Adjust the length of the air tube (Ø16) to be as same length as the distance between them.
It is very dangerous to disassemble/remodel the pressure switch unit or to operate the
external axis motor unit in the explosive environment after removing the pressure switch
unit.
It should be kept free of obstacles around the pressure switch unit when purging.

20 kPa 400 L/min

5 kPa
1

50 kPa 8
2

5
6 7

Fig. 8-2: Purge unit air circuit

1 Intrinsically safe terminal box 5 Compressed air

2 Master valve 6 Purging pressure reducing valve
(0.28 to 0.30 MPa)
3 Solenoid valve to control pressure 7 Solenoid valve for switching operat-
ing/purging air pressure
4 Operating pressure reducing valve 8 Motor

8 - 46
 System configuration

Fig. 8-3: Pressure switch external view

1 Exhaust port 6 Operation pressure (0.01 - 0.02 MPa)

2 To motor unit (Ø16 tube) 7 Entrance of the intrinsically safe cable
for the external axis motor unit
3 Industrial compressed air (0.35 - 0.65 8 Entrance of the intrinsically safe cable
MPa) for the limit switch
4 From motor unit (Ø16 tube) 9 Entrance of the signal cable for the
limit switch
5 Purging air pressure (0.28 -0.30 MPa) 10

1 3.7 kW motor unit

2 Signal cable
3 20m or less1
4 Power cable
5 Pressure switch unit
6 Compressed air supply

JZRCR-YCS21-P00
II(2)G [EXib] IIBGb
Serial No:
*******
Year of Manufacture:
20**
Rated Single phase: AC200V 50/60Hz
AC220V 60Hz
Rated intrinsically safe circuit:
DC13.2V 14.2 mA
Pressure/Flow Switch Circuit DC17.22V 220mA
Solenoid Value Circuit DC3.6V 81mA
Battery Back Up Circuit
(Thionyl Chloride Lithium Battery (ER17500VLY))
Rated non intrinsically safe circuit
Allowable voltage: AC250V 50/60Hz, DC250V

Installation location: Non Hazardous area

Ambient temperature: 0° to +45° C
WARNINGS:
1. Do not make any changes of the equipments and wiring in the painting
unit including intrinsically safe apparatus.
2. Battery backup circuit is consisted of batteryy position detector
and encoder separation board. The circuit is intrinsically safe circuit
when the power supply is shutdown or air purging.
3. The controller combired wich pairting unit shall be grounded at 100 ohms or less.
4. The painting unit including relay barrier, isolatded barrir and encoder
separation board shall be installed in a non-hazardous area.

:$51,1*
+LJK9ROWDJH
'RQRWRSHQWKHGRRU
ZULWKSRZHU21

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

YASKAWA ELECTRIC CORPORATION

2-1 SHIROISHI KUROSAKI, YAHATANISHILU KITAKYUSYU, JAPAN

YASKAWA Europe „Robotics Division“ GmbH

Yaskawastr. 1, D-85391 Allershausen
DX200

1. The length of the air tube from the external axis motor unit at the end of air circuit to the pressure switch unit is
20m or less.

Tab. 8-1: Connection overview

8 - 47
Enclosure protection sequence

9 Enclosure protection sequence

Our enclosure protection sequence is composed of the following four modes:
1) Preparation mode
2) Purging mode
3) Operation mode
4) Shutdown mode

#
3 4

##

1
#
6 7

##

###
8 9

####

10
B

Fig. 9-1: Preparation mode

1 Preparation mode 6 Check the switch unit.

2 Preparation mode START
3 Supply the protective gas after the in-
spection.
• Loosen bolts to enclosures should
not be allowed.
• Any damages of the enclosure
should not be allowed.
4 Reconnect the tubes, tighten the bolts
for covers or change the enclosure.
5 Start supplying the protective gas into
the purge unit. The protective gas is
regulated in proper values by the re-
ducer valve to operate, then supply to
the motor.
• Device troubles such as master
valves.
• Air leakage at relief valve or connec-
tions
7 Change the purge unit.
8 Check the setting values of the purge
unit. Reducer valve for purging: 0.28
to 0.30Mpa, reducer valve for opera-
tion: 0.01 to 0.02Mpa, the primary
pressure for purge unit: 0.35 to
0.65Mpa. Check on the facility pre-
pared by user.
9 Change the setting values within the
values shown in the left.
10 Turn on the breaker of the controller
by manual. Purging mode is simulta-
neously ready to start by turning the
power on.

9 - 48

Fig. 9-2: Purging mode
1 Purging mode
2 Purging mode START
1. Switch from the operation pres-
sure to the purging
2. Open the master valve
3 Did the flow rate reach 400 l/min with
35 kPa or more of purging air pres-
sure?
4 Did 1 minutes pass since the purging
mode started
5 Start counting the purging time (four
minutes).
6 Did the flow rate reach 400 l/min with
35 kPa or more of purging air pres-
sure?
Four minutes passed since the begin-
ning of purging time start counting.
Enclosure protection sequence
7 1 minutes passed after the beginning
of purging time start counting.
8 Switch purging mode to operation
mode after executing the following
steps. 1) Switch the purging press to
the operation. 2) Close the master
valve. 3) Display “Purging Comple-
tion” on the programming pendant. 4)
Supply power will be available to mo-
tors, brakes and painting device. After
this, the mode is switched to operation
mode.
9 Abnormal pressure mode
10 Turn the breaker off by manual. Stop
supplying the protective gas into the
purge unit.
11 Execute abnormal pressure mode
(abnormal purging). The SERVO unit-
, encoder- and painting unit-power-
sources are automatically shut down
and the master valve is simultaneous-
ly and automatically opened, then the
protective gas is released. “Abnormal
Purging” is displayed on the program-
ming pendant and the alarm lamp on
the controller is lit.
9 - 49
Enclosure protection sequence

C D E

4
N
1
2 Y

6
N
7
Y

N
8

Y
END

Fig. 9-3: Operation mode

1 Operation mode 4 Is the operation pressure keeping

2 Operation mode START
3 Is the operation pressure keeping
5 kPa or more?
50 kPa or less?
Pressure greater than the set pres-
sure is released automatically from
the relief valve into the atmosphere,
which keeps the pressure in the pipe
tube at a certain value.
5 Shutdown mode
6 Execute abnormal pressure mode
(abnormal pressure (LOW)). The
SERVO unit-, encoder- and painting
unit-power sources are automatically
shut down. “Abnormal Purging
(LOW)” is displayed on the program-
ming pendant and the alarm lamp on
the controller is lit.

Abnormal pressure mode

1. Abnormal pressure (LOW)
If the pressure in protective gas line dropped and the detectors (PS1) were opened, the
SERVO unit-, encoder- and painting unit-power sources are automatically shut down by
the hardware circuitry (power control circuitry, purging control relay and encoder
separation substrate OFF). If the abnormal pressure (LOW) occurred during purging
mode, the master valve is automatically shut off to prevent from the dangerous gas
coming from outside. “Abnormal Pressure (LOW)” is displayed on the programming
pendant and the alarm lamp on the controller is lit.
2. Abnormal purging
During the purging, if the pressure in protective gas line is dropped and the detector
(PS3) were opened, the SERVO unit-, encoder-and painting unit-power sources are
automatically shut down by the hardware circuitry (power control circuitry, purging
control relay, and encoder separation substrate OFF), and the master valve is
simultaneously and automatically opened, then the protective gas is released.
“Abnormal Purging” is displayed on the programming pendant and the alarm lamp on
the controller is lit.

9 - 50
 Technical data

10 Technical data
Style: AC SERVO motor Motor type: SGMAV-37ANA-YRA*
Item Symbol Unit Value Tolerance
Rated output PR W 3700
Rated torque TR Nm 23.5
Stall torque TR Nm 27
Rated motor speed NR min-1 1500
Rated armature current IR Arms 23.6
Rated power rate QR QR kW/s 96.8
Rated angular accelera- αR rad/s² 4123
tion
Peak torque TP Nm 67
Peak armature current IP Arms 71
Maximum motor speed Nmax min-1 4200
Rotor Moment of inertia JM kgm² × 10-4 57 ±10%
Torque constant KT Nm/Arms 1.054 ±10%
Mechanical time constant tm ms 1.2
Electrical time constant te ms 15.8
Heat resistance class F
Power source voltage Vin V 200
Electro- Moment of in- kgm² ×1 0-4 8.5
magnetic ertia
brake Static friction Nm 43.1 or less
spec. torque
Electric volt- V DC24
age
Capacity W 18.5

Motor unit specification

Motor unit mass kg 42 (Cables are not include)
The amount of seal sliding resistor increase Nm 0.8
The amount of moment of inertia increase kgm² × 10-4 6.8
Environmental condition Temperature 0° C to + 40° C
Humidity 20% to 80%RH (No condensation)
Vibration 4.91m/s² (0.5G) or less
Others Keep it free of electrical noise source

Tab. 10-1: Basic specification (3.7 kW)

10 - 51
 11 Frequent inspections
11 - 52

Frequent inspections
Item No. Items to be inspected Inspection Remarks

Weekly
Daily
External axis 1 Exterior  If any deformations or cracks are found, im-
motor unit mediately stop the operation and contact
your YASKAWA representatives.
2 Motion  Do not enter the motor working envelope.
3 Noise and vibration  Do not enter the motor working envelope.
during operation
4 Tubes   Use a pair of protective glasses to protect
your eyes against paint or thinner that is
being removed.
5 Air leakage   Make sure that the air tube is firmly inserted
in the joint. Accidental disconnection of the
air tube may cause injury.
6 Dried paint   When removing the paint with a tool, be
careful not to damage the motor.
Pressure 1 Pressure set value  The pressure switch unit is a safety device
switch unit 2 Air leakage  for explosion-proof specification.

Safety devices 1 Operation of emergency 1. The external axis stops immediately when  Inspect the external axis while it is in its
stop button and safety the emergency stop button is pressed. standby position and not in motion.
plug. Dried paint 2. The external axis stops immediately when
the safety plug is pulled out.
3. Remove the dried paint on the emergency
stop button and the safety plug.
2 Operation of the photo- 1. The external axis stops when the photoelec- 
electric intrusion detect- tric switch is turned OFF.
ing switch. Dried paint 2. Remove the dried paint on the light beam de-
tector.
 Item No. Items to be inspected Inspection Remarks

Weekly
Daily
3 Operation of limit switch. 1. Normal operation of the limit switch 
Dried paint 2. Remove the dried paint on the limit switch.

Frequent inspections
11
- 53
Maintenance and inspection

12 Maintenance and inspection

DANGER due to electric current!
Danger to life due to electric shock!
All maintenance work and inspection work must be performed by specified personnel.
Regard the following instructions before you implement the maintenance work and the
instruction measures:
 Turn off the main power supply.
 Put up the required warning sign „Do not turn the power on!“.
 Install a switch-on guard as prescribed.

On questions relating to disassembly or repair, contact your YASKAWA representative.

DANGER due to electric current!

Danger to life due to electric shock!
The power supply of the robot controller amounts to 400 V alternating current.
 Turn off the main power supply of the robot controller before starting maintenance work.

Proper inspections are essential not only to assure that the mechanism will be able to
function for a long period. But also to prevent malfunctions and assure safe operation.
Inspection are classified into several time levels as shown by the following table "Inspection
intervals".
In the table of "Inspection intervals", the inspections are divided according to three levels of
requirement:
• Works, carried out by trained staff.
• Work carried out by staff trained by YASKAWA.
• Works, carried out by YASKAWA staff.
Inspections are only carried out by trained staff.

NOTICE
 The inspection intervals depend on the SERVO power time (see point 1 in Fig. 12-1:
"SERVO power time").
 The table "Inspection intervals" applies to normal cases.
 Deviations are to be determined by the TCS service department of YEU-R.

12 - 54
 Maintenance and inspection

START HOLD
REMOTE TEACH
PLAY

JOB EDIT DISPLAY UTILITY

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

Main Menu Short Cut Turn on servo power

LAYOUT TOOL SEL GO BACK

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

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

INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

ROBOT INFORM 4 5 6 BWD FWD

LIST

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

MOTION 0 . -
AUX MODIFY ENTER
TYPE

DATA EDIT DISPLAY UTILITY

SYS MONITORING TIME

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

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

Main Menu ShortCut

Fig. 12-1: SERVO power time

12 - 55
12 - 56

Maintenance and inspection

1 Trained staff
2 YASKAWA trained staff
3 YASKAWA staff

Inspection intervals

Item number Schedule (h) Method Operation Inspection

Charge:

Daily
1000
6000
12000
24000
36000
1 2 3

5 External axis motor unit  Spanner, Tighten loose bolts. Replace if necessary.   
mounting bolts Wrench Stop the external axis for this inspection.

6 External axis motor unit  Visual Check for grease leakage1   

Same above

7 Cover mounting  Wrench Tighten loose bolts. Replace if necessary.   

screws Same above

8 Motor part  Visual Check for filter clogging.  

9 Motor connectors  Manual Check for loose connectors.  

10 Gasket for internal  Visual Replace if necessary.  

pressure

11 Cables for external axis  Visual Check for the cables exterior, cable carriers, damages, etc.  
carriers2
 Visual, Remove the lid of the cable carriers, and check for damages1  
Multimeter

 Replace the cables3 

12 Battery in motor unit  Replace the battery unit when the battery alarm occurs or the motor  
drove for 36000H.
 Inspection intervals

Item number Schedule (h) Method Operation Inspection

Charge:

Daily
1000
6000
12000
24000
36000
1 2 3
13 Pressure switch unit 

14 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. Otherwise, the home position data may be lost.

2. When External axis motor unit is installed in the motor, movable cables are protected by using the cable career. movable cables in the cable career are called "Cables for external axis carriers",
and these are parts for maintenance.

3. Cables for external axis carrier to be replaced at 24000H inspection

Maintenance and inspection

12
- 57
YASKAWA Headquarter