Motoman ES200D-A00 Manual

MOTOMAN-ES200D
INSTRUCTIONS
TYPE: YR-ES0200D-A00 (STANDARD SPECIFICATION)
TYPE: YR-ES0200D-A01 (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-ES200D INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number: 155977-1CD

Revision: 7
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ES200D
Copyright © 2016, 2012, 2011 Yaskawa America, Inc.
Terms of Use and Copyright Notice

All rights reserved. This manual is freely available as a service to Yaskawa
customers to assist in the operation of Motoman robots, related equipment
and software This manual is copyrighted property of Yaskawa and may
not be sold or redistributed in any way. You are welcome to copy this
document to your computer or mobile device for easy access but you may
not copy the PDF files to another website, blog, cloud storage site or any
other means of storing or distributing online content.
Printed in the United States of America
First Printing, 2016
Yaskawa America, Inc.

Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200
www.motoman.com
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ES200D
MANDATORY
• This instruction manual is intended to explain mainly on the
mechanical part of the MOTOMAN-ES200D for the application to
the actual operation and for proper maintenance and inspection. It
describes on safety and handling, details on specifications,
necessary items on maintenance and inspection, to explain
operating instructions and maintenance procedures. Be sure to
read and understand this instruction manual thoroughly before
installing and operating the manipulator.
• General items related to safety are listed in Chapter 1: Safety of the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
If such modification is made, the manual number will also be
revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
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ES200D
We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved Yaskawa training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.
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ES200D Notes for Safe Operation
Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-ES200D.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Indicates a potentially hazardous

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

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

MANDATORY items listed under this heading.
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
To ensure safe and efficient operation at all times, be sure to

NOTE follow all instructions, even if not designated as "CAUTION"
and "WARNING".
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ES200D Notes for Safe Operation
WARNING
• Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Figure 1: Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN
• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the power for the DX100.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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ES200D Definition of Terms Used In this Manual
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
Definition of Terms Used In this Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the Manipulator cable
controller
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ES200D Explanation of Warning Labels
Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Figure 3: Warning Label Locations
WARNING Label B
Nameplate WARNING Label A WARNING Label B
WARNING Label A
Nameplate: WARNING Label A:
WARNING
Moving parts
may cause
injury
WARNING Label B:
WARNING
Do not enter
robot
work area.
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ES200D Customer Support Information
Customer Support Information

If you need assistance with any aspect of your ES200D system, please
contact Motoman Customer Support at the following 24-hour telephone
number:
(937) 847-3200
For routine technical inquiries, you can also contact Motoman Customer
Support at the following e-mail address:
techsupport@motoman.com
When using e-mail to contact Motoman Customer Support, please provide

a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please use e-mail for routine inquiries only. If you have an

NOTE urgent or emergency need for service, replacement parts,
or information, you must contact Motoman Customer
Support at the telephone number shown above.
Please have the following information ready before you call Customer
Support:
• System ES200D
• Primary Application ___________________________
• Controller DX100
• Software Version Access this information on the

Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX100 controller

data plate
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ES200D Table of Contents
Table of Contents
1 Product Confirmation ...................................................................................................................... 1-1
1.1 Contents Confirmation ....................................................................................................... 1-1
1.2 Order Number Confirmation .............................................................................................. 1-2
2 Transport......................................................................................................................................... 2-1
2.1 Transport Method .............................................................................................................. 2-1
2.1.1 Using a Crane ...................................................................................................... 2-2
2.2 Shipping Bolts and Brackets.............................................................................................. 2-3
3 Installation....................................................................................................................................... 3-1
3.1 Safeguarding Installation ................................................................................................... 3-2
3.2 Mounting Procedures for Manipulator Base ...................................................................... 3-2
3.2.1 Mounting Example................................................................................................ 3-3
3.3 Location ............................................................................................................................. 3-3
4 Wiring.............................................................................................................................................. 4-1
4.1 Grounding .......................................................................................................................... 4-1
4.2 Cable Connection .............................................................................................................. 4-2
4.2.1 Connection to the Manipulator.............................................................................. 4-2
4.2.2 Connection to the DX100 ..................................................................................... 4-2
5 Basic Specifications ........................................................................................................................ 5-1
5.1 Basic Specifications........................................................................................................... 5-1
5.2 Part Names and Working Axes.......................................................................................... 5-2
5.3 Manipulator Base Dimensions ........................................................................................... 5-2
5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-3
5.5 Alterable Operating Range ................................................................................................ 5-4
5.5.1 Components for Altering Operating Range .......................................................... 5-5
5.5.2 Notes on the Mechanical Stopper Installation ...................................................... 5-6
5.5.3 Adjustment to the Pulse Limitation of S-Axis........................................................ 5-7
6 Allowable Load for Wrist Axis and Wrist Flange ............................................................................. 6-1
6.1 Allowable Wrist Load ......................................................................................................... 6-1
6.2 Wrist Flange....................................................................................................................... 6-3
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7 System Application.......................................................................................................................... 7-1
7.1 Peripheral Equipment Mounts............................................................................................ 7-1
7.2 Internal User I/O Wiring Harness and Air Line................................................................... 7-2
8 Electrical Equipment Specification .................................................................................................. 8-1
8.1 Position of Limit Switch ...................................................................................................... 8-1
8.1.1 Specification of Limit Switch ................................................................................. 8-1
8.1.2 Position of Limit Switch......................................................................................... 8-1
8.1.3 Setting of Operation Range .................................................................................. 8-2

8.1.3.1 S-Axis Operation Range.......................................................................... 8-2
8.1.3.2 L-Axis Operation Range .......................................................................... 8-2
8.1.3.3 Setting Range of LU-Axes Interference Angle......................................... 8-3
8.2 Internal Connections .......................................................................................................... 8-4
9 Maintenance and Inspection ........................................................................................................... 9-1
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

9.3.1.1 Grease Replenishment............................................................................ 9-9
9.3.1.2 Grease Exchange.................................................................................... 9-9
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer............................ 9-10

9.3.2.1 Grease Exchange.................................................................................. 9-10
9.3.2.2 Grease Exchange.................................................................................. 9-11
9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer ........................... 9-12

9.3.3.1 Grease Replenishment.......................................................................... 9-12
9.3.3.2 Grease Exchange.................................................................................. 9-13
9.3.4 Grease Replenishment/Exchange for U-Arm ..................................................... 9-14

9.3.4.1 Grease Replenishment for R-, B-, T-Axes Gears in the Casing ............ 9-15
9.3.4.2 Grease Replenishment for R-Axis Speed Reducer ............................... 9-15
9.3.4.3 Grease Replenishment for B-Axis Speed Reducer ............................... 9-16
9.3.4.4 Grease Replenishment for T-Axis Speed Reducer ............................... 9-16
9.3.4.5 Grease Exchange for R-, B-, T-Axes Gears in the Casing .................... 9-17
9.3.4.6 Grease Exchange for R-Axis Speed Reducer ....................................... 9-18
9.3.4.7 Grease Exchange for B-Axis Speed Reducer ....................................... 9-18
9.3.4.8 Grease Exchange for T-Axis Speed Reducer ....................................... 9-19
9.3.5 Grease Replenishment for Balancer Connection Part........................................ 9-20
9.3.6 Notes for Maintenance........................................................................................ 9-21

9.3.6.1 Battery Pack Connection ....................................................................... 9-21
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10 Recommended Spare Parts........................................................................................................ 10-1
11 Parts List ..................................................................................................................................... 11-1
11.1 S-Axis Unit ..................................................................................................................... 11-1
11.2 L-Axis Unit ..................................................................................................................... 11-3
11.3 URBT-Axes Unit ............................................................................................................ 11-5
11.4 U-Arm Unit ..................................................................................................................... 11-8
11.5 Wrist Unit ..................................................................................................................... 11-10
11.6 Balancer Unit ............................................................................................................... 11-13
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ES200D 1 Product Confirmation
1.1 Contents Confirmation
1 Product Confirmation
CAUTION
• Confirm that the manipulator and the DX100 have the same order
number. Special care must be taken when more than one
manipulator is to be installed.
If the numbers do not match, manipulators may not perform as
expected and cause injury or damage.
1.1 Contents Confirmation

Confirm the contents of the delivery when the product arrives.
Standard delivery includes the following four items (information for the
content of optional goods are given separately):
• Manipulator
• DX100
• Programming pendant
• Manipulator cables (3 cables between the DX100 and the
Manipulator)
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ES200D 1 Product Confirmation
1.2 Order Number Confirmation
1.2 Order Number Confirmation

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

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

AC220V 60Hz AVERAGE kVA
INTERRUPT CURRENT kA
SERIAL No.
DATE
S
MADE IN JAPAN NJ2960-1
T O P
ON
D
PE
IP
TR
OFF
T
SE
RE
WARNING
Do not open the door
THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1529
PROGRAMMING PENDANT
X81
(a) DX100 (Front View) (b) Manipulator (Side View)
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ES200D 2 Transport
2.1 Transport Method
2 Transport
CAUTION
• Sling applications and crane or forklift operations must be
performed by authorized personnel only.
Failure to observe this caution may result in injury or damage.
• Avoid excessive vibration or shock during transport.
The system consists of precision components. Failure to observe this
caution may adversely affect performances.
• The weight of the manipulator is approximately 1130 kg

including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the weight.
• Shipping bolts and brackets are designed to support the
manipulator weight. Do not use them for anything other
NOTE than transporting the manipulator.
• Mount the shipping bolts and brackets for transporting the
manipulator.
• Avoid putting external force on the arm or motor unit when
transporting by a crane, forklift, or other equipment.
Failure to observe this instruction may result in injury.
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ES200D 2 Transport
2.1.1 Using a Crane

As a rule, the manipulator should be lifted by a crane with four 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. 2-1 “Transporting Position”.
Fig. 2-1: Transporting Position
Details of shipping bolt
Rubber plate
Electrical tape
painted in yellow
B
Shipping bolt
(1 piece)
Hook
Factory setting for angle and pulse of each axis A Shipping bracket
(4 pieces)
Axis S L U R B T
Angle 0 -60 -63.9 0 -86.1 0
Pulse 0 -176014 -156393 0 -195054 0
When equipped with external cablings,

those settings are subject to change depending on the specifications.
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ES200D 2 Transport
2.2 Shipping Bolts and Brackets
2.2 Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at position A
and with the hexagon socket head cap screws at point B. (Fig. 2-1
“Transporting Position” on page 2-2).
Fig. 2-2: Shipping Bolts and Brackets
A Shipping bracket B Shipping bolt

Hook
Rubber plate
Electrical tape painted

in yellow
• The A-shipping brackets are painted in yellow.

• The B-shipping bolt: hexagon socket head cap screw is taped in
yellow.
Position Bolt Type Pcs
A Hexagon socket head cap screw M20 X 70 mm 12
B Hexagon socket head cap screw M16 X 20 mm 1
Before turning ON the power, check to be sure that the

NOTE shipping bolts and brackets are 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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ES200D 3 Installation
3 Installation
WARNING
• Install the safeguarding.
Failure to observe this warning may result in injury or damage.
• Install the manipulator in a location where the tool or the workpiece
held by its fully extended arm will not reach the wall, safeguarding,
or controller.
Failure to observe this warning may result in injury or damage.
• Do not start the manipulator or even turn ON the power before it is
firmly anchored.
The manipulator may overturn and cause injury or damage.
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. 2-2 “Shipping Bolts and
Brackets” on 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 3-1
"Maximum Repulsion Forces of the Manipulator at Emergency Stop" and
Table 3-2 "Endurance Torque in Operation".
A baseplate flatness must be kept at 0.5 mm or less: insufficient flatness
of installation surface may deform the manipulator shape and affect its
functional abilities. Mount the manipulator base as instructed in section
3.2.1 “Mounting Example”.
Table 3-1: Maximum Repulsion Forces of the Manipulator at Emergency

Stop
Maximum torque in horizontal rotation 32000 N•m
(S-axis moving direction) (3265 kgf•m)
Maximum torque in vertical rotation 78500 N•m
(L-, U-axes moving direction) (8000 kgf•m)
Table 3-2: Endurance Torque in Operation

Endurance torque in horizontal operation 9400 N•m
(S-axis moving direction) (960 kgf•m)
Endurance torque in vertical operation 27150 N•m
(L-, U-axes moving direction) (2771 kgf•m)
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3.3 Location
3.2.1 Mounting Example

For the first process, anchor the baseplate firmly to the ground. The
baseplate should be rugged and durable to prevent shifting of the
manipulator or the mounting fixture. It is recommend to prepare a
baseplate of 50 mm or more thick, and anchor bolts of M20 or larger size.
The manipulator base is tapped for eight mounting holes; securely fix the
manipulator base to the baseplate with eight hexagon head bolts M20
(80 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. 3-1 “Mounting the Manipulator on Baseplate” on page 3-3.
Fig. 3-1: Mounting the Manipulator on Baseplate
Hexagon socket head cap screw

M20 (8 screws)
Spring washer
Washer
Manipulator base
40
Baseplate
Flatness: 0.5mm or less
Units: mm
3.3 Location
When installing a manipulator, it is necessary to satisfy the following
environmental conditions:
• Ambient temperature: 0° to + 45°C
• Humidity: 20 to 80%RH (no-condensing)
• Free from dust, soot, oil, or water
• Free from corrosive gas or liquid, or explosive gas or liquid.
• Free from excessive vibration
(Vibration acceleration: 4.9 m/s2 [0.5 G] or less)
• Free from large electrical noise (plasma)
• Flatness for installation: 0.5 mm or less
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ES200D 4 Wiring
4.1 Grounding
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.
• Do not cover the cable or allow it to tangle. Keep the cable as
straight as possible.
Failure to observe this caution may result in preventing heat of the
cable from being discharged.
4.1 Grounding
Follow electrical installation standards and wiring regulations for
grounding. A ground wire of 5.5 mm2 or more is recommended.
Refer to Fig. 4-1 “Grounding Method” on page 4-2 to connect the ground
line directly to the manipulator.
• Never use this line sharing with other ground lines or

grounding electrodes for other electric power, motor
power, welding devices, etc.
NOTE
• Where metal ducts, metallic conduits, or distributing racks
are used for cable laying, ground in accordance with
electrical installation standards.
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ES200D 4 Wiring
4.2 Cable Connection
Fig. 4-1: Grounding Method
A Bolt M8 (for grounding)

Delivered with manipulator
5.5mm2 or more View A

Three manipulator cables are delivered with the manipulator; an encoder
cable for detection (1BC) and two power cables (2BC and 3BC). (Refer to
Fig. 4-2 “Manipulator Cables” on page 4-3.)
• with electrical installation standards.
Connect these cables to the manipulator base connectors and to the
DX100. Refer to Fig. 4-3(a) "Manipulator Cable Connectors (Manipulator
Side)" on page 4-4 and Fig. 4-3(b) "Manipulator Cable Connection (DX100
Side)" on page 4-4 “.
4.2.1 Connection to the Manipulator

Before connecting three 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, 1 BC, then 3BC. After inserting the cables, depress the lever until it
clicks.
4.2.2 Connection to the DX100

Before connecting cables to the DX100, verify the numbers on both
manipulator cables and the connectors on the DX100. When connecting,
insert the cables in the order of X21, X22, then X11, and depress each
lever low until it clicks.
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ES200D 4 Wiring
Fig. 4-2: Manipulator Cables
The DX100 Side The Manipulator Side
1BC
X11
X11 1BC
1BC
Encoder Cable
X21 2BC
2BC
2BC
X21
Power Cable
X22 3BC
3BC
3BC
X22
Power Cable
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ES200D 4 Wiring
Fig. 4-3(a): Manipulator Cable Connectors (Manipulator Side)
1BC
AIR S1
2BC
molex
molex
3BC
1BC 2BC 3BC
Key positions
Connector Details
(Manipulator Side)
Fig. 4-3(b): Manipulator Cable Connection (DX100 Side)
X11
X21
X22
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ES200D 5 Basic Specifications
5.1 Basic Specifications
5 Basic Specifications
5.1 Basic Specifications

Table 5-1: Basic Specifications1)
Item Model MOTOMAN-ES200D
Application Spot Welding
Structure Vertically Articulated
Degree of Freedom 6
Payload 200 kg
2) ±0.2 mm
Repeatability
Range of Motion S-Axis (turning) -180° - +180°
L-Axis (lower arm) -60° - +76°
U-Axis (upper arm) -142.5° - +230°
R-Axis (wrist roll) -360° - +360°
B-Axis (wrist pitch/yaw) -125° - +125°
T-Axis (wrist twist) -360° - +360°
Maximum Speed S-Axis 1.67 rad/s, 95°/s
L-Axis 1.58 rad/s, 90°/s
U-Axis 1.67 rad/s, 95°/s
R-Axis 2.11 rad/s, 120°/s
B-Axis 2.11 rad/s, 120°/s
T-Axis 3.32 rad/s, 190°/s
Allowable Moment3) R-Axis 1344 N•m (137 kgf•m)
B-Axis 1344 N•m (137 kgf•m)
T-Axis 715 N•m (73 kgf•m)
2/4)
Allowable Inertia (GD R-Axis 143 kg•m2
B-Axis 143 kg•m2
T-Axis 80 kg•m2
Approx. Mass 1130 kg
Ambient Conditions Temperature 0° C to 45° C
Humidity 20 to 80% RH (non-condensing)
Vibration Acceleration 4.9 m/s2 or less (0.5 G)
Others Free from corrosive gasses or liquids, or
explosive gasses
Free from exposure to water, oil, or dust
Free from excessive electrical noise
(plasma)
Power Requirements 5.0 kVA
1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Conformed to ISO9283
3 Refer to chapter 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

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

Fig. 5-2: Manipulator Base Dimensions
893
640
+0.021
Fitting surface 290 0.1 290 0.1 20 0 dia. (2 holes)
(Pin hole for manipulator
540 positioning)
350 0.1
290 0.1
735
640
540
Fitting surface
40
290 0.1
A 290 0.1 290 0.1 +0.018

16 0 dia. (2 holes)
353 0.1 (Pin hole for manipulator
Units: mm 22 dia. (8 holes)
positioning)
(For fixing the manipulator)
View A
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5.4 Dimensions and P-Point Maximum Envelope
5.4 Dimensions and P-Point Maximum Envelope

Fig. 5-3: Dimensions and P-Point Maximum Envelope
R7
89
180
8
R60
491
180
R26
51
View A
4612
1961 2651
3050
P-point maximum
envelope
285 1225 250 491 294

153
250
P-point
25 18
42
50
1225
1150
76
2203
60 1089
.5
142
687 650
499
348
650
126
0 0
16
322
775
789
766
532
582
945
1307
1401
0
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5.5 Alterable Operating Range

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

Item Specifications
S-Axis Operating Range -180° - +180° (standard)
*(-165° - +165°)
-150° - +150°
-135° - +135°
-120° - +120°
-105° - +105°
-90° - +90°
-75° - +75°
-60° - +60°
-45° - +45°
-30° - +30°
*(-15° - +15°)
* The interval between stoppers must be 60° or more.
NOTE When altering the operating range to ±15° or ±165°, please

contact your Yaskawa representative.
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5.5.1 Components for Altering Operating Range

Arrange the components listed in Fig. 5-4 “The Components of the S-Axis
Stopper”, when modifying the angle of S-axis.
(1) Pin (drawing No. HW0402104-1, 1 pin)
(2) Stopper (drawing No. HW0302424-2, 1 stopper)
(3) Hexagon socket head cap screw M20
(length: 45 mm) (3 screws) (tightening torque: 402 N•m)
(4) Flat washer M20 (3 flat washers)
Fig. 5-4: The Components of the S-Axis Stopper
Hexagon socket head cap screws M20 (3 screws)

(length: 45) (tightening torque: 12.9)
Flat washer M20
Stopper
HW0302424-2
Section A-A
Pin
HW0402104-1
A A
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5.5.2 Notes on the Mechanical Stopper Installation

• For S-Axis mechanical stopper, install the stopper (drawing No.
HW0302424-2) with the pin which is used bottom up (drawing No.
HW0402104-1) as in Fig. 5-4 “The Components of the S-Axis Stopper”
on page 5-5.
• DO NOT forget to apply the locktite 242 to the thread part of pin before
inserting it into the stopper.
• Mount the stopper to the S-head with three hexagon head screws M20
(length: 45 mm) and tighten the screws to the tightening torque of
402 N•m (tensile strength: 1200 N/mm2 or more). The stopper is to be
installed as shown in the Fig. 5-4 “The Components of the S-Axis
Stopper” on page 5-5 when the operating range is ±180°.
• The stopper can be installed by every 15 degree pitch, however, to
avoid the mechanical troubles caused by interference between
stoppers (e.g. ±15°, ±165°), install the S-axis mechanical stopper
referring to Table 5-3 "The settable angle for S-Axis Stopper" on page
5-8.
• Confirm to stabilize both sides of the protrusion with the hexagon
socket head cap screws as in Fig. 5-5 “Properly-Mounted Image” on
account of the limitation of strength to the unit.
• Refer to the figures: Fig. 5-6(a) to Fig. 5-6(g) as adjusting the setting
angle of the S-Axis mechanical stopper. When mounting the S-Axis
mechanical stopper by inverse angle to the examples in the figures:
Fig. 5-6(a) to Fig. 5-6(g), settle the machinery symmetrical to those
models.
• As in the figures: Fig. 5-6(a) to Fig. 5-6(g), the component is reversible
that both sides of the machinery can be attached to the stopper,
except for the angles of ±30, ±60, ±120, ±150 degrees. Flip side and
retry installing the S-Axis mechanical stopper if finding any difficulty to
set the machinery to the stopper based on Fig. 5-4 “The Components
of the S-Axis Stopper” on page 5-5.
Fig. 5-5: Properly-Mounted Image
Hexagon socket Hexagon socket

head cap scerws head cap scerws
Improperly-mounted Properly-mounted
1. Apply the specified components when mounting the

NOTE S-Axis mechanical stopper.
2. TURN OFF the electric power supply before mounting.
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5.5.3 Adjustment to the Pulse Limitation of S-Axis

Apply the Instruction for “DX100 Instructions section 8.17 Changing the
Parameter Setting” (162536-1CD) as part of reference materials for
adjusting the programming pendant when modifying the range of motion
of S-Axis.
The limitation to the pulse (Pulse Soft Limit + 1st Axis) : SICxG400
The limitation to the pulse (Pulse Soft Limit - 1st Axis) : SICxG408
Degree ±0° ∗(±15°) ±30° ±45° ±60° ±75° ±90°
Number
±0 ±35840 ±71680 ±107520 ±143360 ±179200 ±215040
of Pulse
Degree ±105° ±120° ±135° ±150° ∗(±165°) ±180° (Standard)
Number
±250880 ±286720 ±322560 ±358400 ±394240 ±430080
of Pulse
* Refer to section 5.5 “Alterable Operating Range” on page 5-4.
Adjust both of the pulse limitation and the angle of S-Axis

NOTE mechanical stopper as modifying the range of motion for
machinery.
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The Angle of S-Axis Stopper for + Direction

180 165 150 135 120 105 90 75 60 45 30 15 0 -15 -30 -45 -60 -75 -90 -105 -120 -135 -150 -165 -180
-180
-165
-150
-135
-120
-105
5-8
5 Basic Specifications
-90
-75
-60
-45
-30
-15
0
15
30
45
60
Table 5-3: The settable angle for S-Axis Stopper
75
90
105
The Angle of S-Axis Stopper for - Direction

120
135
150
165
180
Settable angle "Table 5-3 The Settable Angle for S-Axis Stopper" indicates the angle range
Non settable angle which allows S-axis to be set for + direction and - direction angles.
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Fig. 5-6(a): The Properly-Mounted Models for S-Axis Stopper
Hexagon head screws
The stopper is reversible.

Either side of the stopper can be used.
Installation at + 180°
Hexagon head screws

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Fig. 5-6(b): The Properly-Mounted Models for S-Axis Stopper
The stopper is irreversible.

Only this side of the stopper can be used at this angle.
Hexagon head screws

Hexagon head screws
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Fig. 5-6(c): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws
Hexagon head screws The stopper is reversible.

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Fig. 5-6(d): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws

Hexagon head screws
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Fig. 5-6(e): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws

Hexagon head screws
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Fig. 5-6(f): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws

Hexagon head screws
Fig. 5-6(g): The Properly-Mounted Models for S-Axis Stopper

Hexagon head screws
Installation at 0°
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ES200D 6 Allowable Load for Wrist Axis and Wrist Flange
6.1 Allowable Wrist Load
6 Allowable Load for Wrist Axis and Wrist Flange

The allowable wrist load including the weight of the mount/gripper
is:
• YR-ES0200D-A00, -A01: 200 kg maximum
If force is applied to the wrist instead of the load, force on R-, B-, and
T-axes should be within the value shown in Table 6-1 "Allowable Wrist
Load". Contact your Yaskawa representative for further information or
assistance.
Table 6-1: Allowable Wrist Load
Axis Moment N•m (kgf•m)1) GD2/4 Total Moment of Inertia kg•m2
R-Axis 1344 (137) 143
B-Axis 1344 (137) 143
T-Axis 715 (73) 80
1 ( ): Gravitational unit
When the volume load is small, refer to the moment arm rating shown in
Fig. 6-1 “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.
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Fig. 6-1: Moment Arm Rating

LT(mm)
1200 60kg
1000 80kg
800 100kg
600 130kg
165kg
400
P-point
200kg
200 T-, R-axis
center of rotation
400 600 800 1000 1200 1400 LB(mm)
200
400
600
800
1000
1200
LT(mm)
B-axis center of rotation
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6.2 Wrist Flange
6.2 Wrist Flange

The wrist flange dimensions are shown in Fig. 6-2 “Wrist Flange”. In order
to see the alignment mark, it is recommended that the attachment be
mounted inside the fitting. Fitting depth of inside and outside must be
8 mm or less.
Fig. 6-2: Wrist Flange
P. Tapped hole M10

8 C
.D (6 holes) (depth: 12 mm)
.9
2
5
.D.12
P.C
dia.
dia.
8
-0.025
0
+0.030
0
180
63
Tapped hole M10

(6 holes) (depth: 12 mm)
+0.015
9 0 dia.
10
+0.015
dia. (2 holes) (depth: 8 mm)
0
(2 holes) (depth: 8 mm)
Alignment mark
Units: mm
NOTE Wash off anti-corrosive paint (yellow) on the wrist flange

surface with thinner or light oil before mounting the tools.
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ES200D 7 System Application
7.1 Peripheral Equipment Mounts
7 System Application
7.1 Peripheral Equipment Mounts

The peripheral equipment mounts are provided on the U-axis (upper arm)
and S-axis (rotary head) as shown in Fig. 7-1 “Installing Peripheral
Equipment” for easier installation of the users’ system applications.
The following conditions shall be observed to attach or install peripheral
equipment. (Refer to Table 7-1 "Conditions for Installation".)
Fig. 7-1: Installing Peripheral Equipment
133
120
255 40 A1
120
Tapped hole M8
133
(4 holes) (depth: 15mm)

73
40 255
120
410
A2
255 40 Tapped hole M8
40 255
120
75 137.5
5
B Tapped hole M12

85
117 73
30
B 75 137.5 117 73
Tapped hole M12
50
30

5
85
50
Table 7-1: Conditions for Installation

Application Note
A1, A2 Cable Processing 30 kg max.
and Valve Load 49 N•m (5 kgf•m) max. for moment increase
amount of upper arm
B Others 250 kg max.
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7.2 Internal User I/O Wiring Harness and Air Line

6 cables for valves (0.75 mm2), 18 internal user I/O wires (0.5 mm2 x
6 wires, 0.3 mm2 x 12 wires), the cables for the external axis (1.25 mm2 x
7 cables, 0.75 mm2 x 2 cables, 0.2 mm2 x 4 cables), and an air line are
used in the manipulator for the drives of the peripheral devices mounted
on the upper arm as shown in Fig. 7-2 “Connectors for Internal User I/O
Wiring Harness and Air Line” on page 7-3.
The connector pins, and the terminals are assigned as shown in Fig. 7-2
“Connectors for Internal User I/O Wiring Harness and Air Line” on page 7-
3 and Fig. 7-3 “Details of the Connector Pin Numbers” on page 7-4.
Wiring must be performed by user.
The allowable current for internal user 8.0 A or less / wire. (1.25 mm2)
I/O wiring harness 5.0 A or less / wire. (0.75 mm2)
3.5 A or less / wire. (0.5 mm2)
The maximum pressure for the air line 490 kPa (5 kgf/cm2) or less
(The air line inside diameter: 8.0 mm )
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Fig. 7-2: Connectors for Internal User I/O Wiring Harness and Air Line
Exhaust port (air flow)

Tapped holes PT3/8
with pipe plug Connector for the external axis (Encoder cable):
JL05-2A20-29SC
(socket connector with cap).
Prepare pin connector: JL05-6A20-29P.
Connector for internal user

Connector for the external axis I/O wiring harness (Casing):
(Power cable): JL05-2A22-14SC
JL05-2A18-1SC (socket connector with cap).
(socket connector with cap). Prepare pin connector: JL05-6A22-14P.
Prepare pin connector: JL05-6A18-1P.
Key position
Key position

I/O wiring harness (Base):
JL05-2A28-21PC (pin connector with cap).
1BC
Prepare socket connector: JL05-6A28-21S.
AIR S1
3BC
Air inlet (air flow)

Tapped holes PT3/8 with pipe plug
2BC
View A
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Fig. 7-3: Details of the Connector Pin Numbers
1
P
2
3 0.5mm2
P
4
5 (6 pins)
P
6
1
7 P 2
8 3
9 P 0.5mm2
4 (6 pins)
10 5
11 P 6
12 7
0.3mm2
13 8
(12 pins)
14 9
Pins used 15 Pins used 10
16 11
17 12 0.3mm2
18 13 (12 pins)
14
19 15
20 16
21 0.75mm2
(6 pins) 17
22 18
23
24
1 2 3
4 5 6 7
1 2 3 4 8 9 10 11 12
5 6 7 8 9 13 14 15 16
10 11 12 13 14 15 17 18
16 17 18 19 20 21 22
23 24 25 26 27 28 Pin details for internal user I/O wiring harness
(Casing side)
29 30 31 32 33
34 35 36
1
2 1.25mm2
3 (4 pins)
Pin details for internal user I/O wiring harness Pins used 4
(Base side) 5 0.75mm2
6 (2 pins)
7
1.25mm2
8
(3 pins)
9
1
P
2 0.2mm2
Pins used P
9 (4 pins)
1 2
10
15 Shielded wire 3 4 5
6 7 8
9
2 1 3
4 5 6
9
7 8
10 Pin details for external axis power cable
13 11 12 14
15 16
Pin details for external axis encoder cable
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ES200D 8 Electrical Equipment Specification
8.1 Position of Limit Switch
8 Electrical Equipment Specification
8.1.1 Specification of Limit Switch

1. The interference limit switch at S-, L- and U-axes electrically limit the
operating range of respective axes by adjusting the position of the dog
using the limit switch.
The positions of the mechanical limits (mechanical stoppers) at S-, L-
and U-axes are changeable.
When the limit switch is activated, the power supply to the manipulator
is interrupted, then the manipulator makes an emergency stop as a
result. Refer to section 8.9 “Overrun/Tool Shock Sensor Releasing” in
the “DX100 INSTRUCTIONS” for releasing the status of this overrun.
2. The range of S-, L- and U-axes limit switches are set to the maximum
operating range before shipping.
In case of re-adjusting the operating range of each subject

NOTE axis, it is also required to change the dog location and limit
values in software. Contact your Yaskawa representative if
re-adjustment is required.
8.1.2 Position of Limit Switch

The limit switches are optional. For the S, L, and U-Axes with limit
switches specifications, L.S. are located on S-Axis, L-Axis, and U-Axis
respectively.
For the location, refer to Fig. 8-1 “Location of Limit Switches”. The
inspection and adjustment of the limit switches should be made after
removing the cover.
Fig. 8-1: Location of Limit Switches
L- and U-axes interference

limit switch
L-axis overrun
limit switch
S-axis overrun
limit switch
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8.1.3 Setting of Operation Range
8.1.3.1 S-Axis Operation Range

By the S-axis limit switch, S-axis operation range can be set to those
ranges mentioned inTable 5-2 "S-Axis Operating Range" on page 5-4 .
8.1.3.2 L-Axis Operation Range

By the L-axis limit switch, the L-axis operation range can be set to any
angles within -61° to +77° as mentioned in the figure below.
Fig. 8-2: L-Axis Overrun Limit Switch Setting Range
Negative side Positive side
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8.1.3.3 Setting Range of LU-Axes Interference Angle

L- and U-axes interference limit switches are designed to check the
interference angle of L- and U-axes.
As shown in Fig. 8-3 “LU-Axes Interference Angle”, the operation range of
U-axis can be set to any angles within +8° to +288° as the interference
angle with L-axis.
Fig. 8-3: LU-Axes Interference Angle
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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. 8-4
“Locations and Numbers of Connectors”.
Diagrams for Internal connections of the manipulator are shown in
Fig. 8-5(a) "Internal Connection Diagram" on page 8-5 and Fig. 8-5(b)
"Internal Connection Diagram" on page 8-6.
Fig. 8-4: Locations and Numbers of Connectors
Connector for external axis

(Encoder cable)
I/O wiring harness (Casing)
Connector for external axis

(Power cable)
Connector for
1BC
2BC 3BC Internal user I/O
wiring harness
(Base)
Table 8-1: List of Connector Types

Name Type of Connector
Connector Base Connector for internal JL05-2A28-21PC
user I/O wiring harness (JL05-6A28-21S: Optional)
U-arm Connector for internal JL05-2A22-14SC
user I/O wiring harness (JL05-6A22-14P: Optional)
Connector for external axis JL05-2A20-29SC
(Encoder cable) (JL05-6A20-29P: Optional)
Connector for external axis JL05-2A18-1SC
(Power cable) (JL05-6A18-1P: Optional)
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Fig. 8-5(a): Internal Connection Diagram
Notes
0BT 1 0BAT11 17 0BAT1 1. For the limit switch specification, the connection of the section
P BAT 2 BAT11 18 BAT1
0BT 3 0BAT12 19 0BAT2 A and B parts are changed as follows:
P BAT 4 BAT12 20 BAT2
21 0BAT3
22 BAT3 LA1 LA1
23
24 LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1
0BT 5 0BAT21 25 0BAT4
P BAT 6 BAT21 26 BAT4 LB1 LA2
0BT
P BAT
7
8
0BAT22
BAT22
27
28
0BAT5
BAT5
LB2 LB2 L-AXIS OVERRUN L.S. Connected to A2
29 0BAT6 LA3
30 BAT6 LB2
1
2
31
32
LB1 LB3 L AND U-AXIS INTERFERENCE L.S. Connected to A3
3 1 PG0V1
4 2 PG5V1
5 3 PG0V2 LC1 LC1
6 4 PG5V2 LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1
7 5 PG0V3
8 6 PG5V3 LC2
7 PG0V4
LD1
8 PG5V4 LD2 LD2 L-AXIS OVERRUN L.S. Connected to B2
9 PG0V5
DX100 1BC(10P 4)
No.22CN X 10 PG5V5 LD2 LC3
+24V CN1-5 +24V -1 +24V 1 11 PG0V6
CN1-5
0V CN1-4 0V -3 0V 3 12 PG5V6 LD1 LD3 L AND U-AXIS INTERFERENCE L.S. Connected to B3
CN1-4
13
CN1-10
CN1-9
+24V
0V
CN1-10
CN1-9
+24V
0V
-2
-4
+24V
0V
2
4
14
15 SLU-axes with Limit Switch Specification
16 No.1CN
CN1-1 SPG+1 CN1-1 SPG+1 1CN-1 DATA+1
SPG-1 CN1-2 SPG-1 No.16CN S P -2 DATA-1
CN1-2
-1 BAT1 -6 BAT
-2 0BAT1 P -5 OBT PG S-AXIS
-3 PG5V1 -4 +5V
-4 PG0V1 P -9 0V
CN1-3 FG1 CN1-3 FG1 -10 FG1
OBT
BAT
No.2CN
SPG-2 CN1-7 SPG-2 No.17CN L P -2 DATA-2
CN1-7
-1 BAT2 -6 BAT
-2 0BAT2 P -5 OBT PG L-AXIS
-3 PG5V2 -4 +5V
-4 PG0V2 P -9 0V
CN1-8 FG2 CN1-8 FG2 -10 FG2
OBT
BAT
No.3CN
SPG-3 CN2-2 SPG-3 No.18CN U P -2 DATA-3
CN2-2
-1 BAT3 -6 BAT
-2 0BAT3 P -5 OBT PG U-AXIS
-3 PG5V3 -4 +5V
-4 PG0V3 P -9 0V
CN2-3 FG3 CN2-3 FG3 -10 FG3
OBT
BAT
No.4CN
SPG-4 CN2-7 SPG-4 No.19CN R P -2 DATA-4
CN2-7
-1 BAT4 -6 BAT
-2 0BAT4 P -5 OBT PG R-AXIS
-3 PG5V4 -4 +5V
-4 PG0V4 P -9 0V
CN2-8 FG4 CN2-8 FG4 -10 FG4
OBT
BAT
No.5CN
SPG-5 CN3-2 SPG-5 No.20CN B P -2 DATA-5
CN3-2
-1 BAT5 -6 BAT
-2 0BAT5 P -5 OBT PG B-AXIS
-3 PG5V5 -4 +5V
-4 PG0V5 P -9 0V
CN3-3 FG5 CN3-3 FG5 -10 FG5
OBT
BAT
No.6CN
SPG-6 CN3-7 SPG-6 No.21CN T P -2 DATA-6
CN3-7
-1 BAT6 -6 BAT
-2 0BAT6 P -5 OBT PG T-AXIS
B1 -3 PG5V6 -4 +5V
-4 PG0V6 P -9 0V
CN3-8 FG6 CN3-8 FG6 -10 FG6
SS1 LC1 LD1 OBT
BAT
CN4-1 +24V
LB1
CN4-1
CN4-6
+24V
LB1
LA1 LB1 A1
CN4-6
LB1
LB2
LA2
LB2 A2
LD1
CN4-2
LD2
LC2
LD2 B2
CN4-2 SS2 SS2 SS2
LB2
CN4-7 AL1 CN4-7
LB1
LA3
LB3 A3
LD2
LD1
LC3
LD3 B3
BC1
CN4-3 BC2 CN4-3 BC2 BC2 FOR LAMP (OPTION)
CN4-8 AL2 CN4-8
CN4-10 0V CN4-10 0V No.7CN(20-29)

SPG+7 CN4-4 SPG+7 1
CN4-4 SPG-7 CN4-5 SPG-7 P 2
SPG+7
CN4-5 FG7 CN4-9 FG7 10
SPG-7
CN4-9 0V
CN2-4
+24 CN2-4 +24 P 9 5V
LD1 CN2-5 LD1 15
CN2-5 FG7
CN2-9 CN2-9
CN2-10 CN2-10
CN3-4
0V CN3-4 0V
5V CN3-5 5V
CN3-5 0V CN3-9 0V
CN3-9 5V CN3-10 5V
CN3-10
E
EE E E EEEE
Base MANIPULATOR Casing

S1(28-21)
E E E E E E E
19 SP19
20 SP20
21 SP21
No.8CN(22-14)
22 SP22
23 SP23
24 SP24
1 1 SP1
2
P 2 SP2
3 SP3
3 P 4
4 5 SP4
5 P 6 SP5
6 SP6
7 SP7
7 P 8
8 9 SP8
9 P 10 SP9
10 11 SP10
11 P 12 SP11
12 13 SP12
13 P 14 SP13
14 15 SP14
15 P 16 SP15
16 17 SP16
17 P 18 SP17
18 SP18
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Fig. 8-5(b): Internal Connection Diagram
2BC(8PX5+12PX1)
E E
LA1 LA1
LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1
CN1-1 MU1 CN1-1 MU1
CN1-2 MU1 CN1-2 MU1 LA2
CN1-3 MU1 CN1-3 MU1
LB1
LB2 LB2 L-AXIS OVERRUN L.S. Connected to A2
CN1-5 MV1 CN1-5 MV1
CN1-6 MV1 CN1-6 MV1 LC1 LC1
CN1-7 MV1 CN1-7 MV1 No.9CN
9CN-A MU1 LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1
CN2-1 MW1 CN2-1 MW1 -B MV1
CN2-2 MW1 CN2-2 MW1 -C MW1 SM S-AXIS LD1 LC2
CN2-3 MW1 CN2-3 MW1 -D ME1
LD2 LD2 L-AXIS OVERRUN L.S. Connected to B2
CN1-4 ME1 CN1-4 ME1
CN1-8
CN2-4
ME1
ME1
CN1-8
CN2-4
ME1
ME1 SL-axes with Limit Switch Specification
CN6-1 BA1 CN6-1 BA1 -1 BA1
CN6-2 BB1 CN6-2 BB1 -2 BB1 YB
LC1 LC1
LD1 LD1 S-AXIS OVERRUN L.S. Connected to B1
CN2-5 MU2 CN2-5 MU2
CN2-6 MU2 CN2-6 MU2 LA1 LA1
CN2-7 MU2 CN2-7 MU2
LB1 LB1 S-AXIS OVERRUN L.S. Connected to A1
CN3-1 MV2 CN3-1 MV2
CN3-2
CN3-3
MV2
MV2
CN3-2
CN3-3
MV2
MV2 No.10CN S-axis with Limit Switch Specification
10CN-A MU2
CN3-6 MW2 CN3-6 MW2 -C
-D
MW2
ME2
SM L-AXIS
CN3-7 MW2 CN3-7 MW2
CN2-8 ME2 CN2-8 ME2

CN3-4 ME2 CN3-4 ME2
CN3-8 ME2 CN3-8 ME2
CN6-3 BA2 CN6-3 BA2 -1 BA2

CN4-1 MU3 CN4-1 MU3

CN4-2 MU3 CN4-2 MU3
CN4-3 MU3 CN4-3 MU3
CN4-5 MV3 CN4-5 MV3

CN4-6 MV3 CN4-6 MV3
11CN-A MU3
CN5-2 MW3 CN5-2 MW3 -C MW3 SM U-AXIS
CN5-3 MW3 CN5-3 MW3 -D ME3
CN4-4 ME3 CN4-4 ME3

CN4-8 ME3 CN4-8 ME3
CN5-4 ME3 CN5-4 ME3
CN6-5 BA3 CN6-5 BA3 -1 BA3

CN6-7 BA4 CN6-7 BA4

CN6-8 BB4 CN6-8 BB4
CN6-9 BA5 CN6-9 BA5

CN6-10 BB5 CN6-10 BB5
CN6-11 BA6 CN6-11 BA6

CN6-12 BB6 CN6-12 BB6
3BC(6PX6)
E E
CN1-1 MU4 CN1-1 MU4

CN1-2 MU4 CN1-2 MU4
CN1-5 MV4 CN1-5 MV4 12CN-A MU4
CN2-2 MW4 CN2-2 MW4 -C MW4 SM R-AXIS
CN1-3 ME4 CN1-3 ME4 -D ME4
CN1-6 ME4 CN1-6 ME4
-1 BA4
-2 BB4 YB
CN2-4 MU5 CN2-4 MU5

CN2-5 MU5 CN2-5 MU5
CN3-2
CN3-3
MW5
ME5
CN3-2
CN3-3
MW5
ME5
-C
-D
MW5
ME5
SM B-AXIS
CN3-6 ME5 CN3-6 ME5
-1 BA5
-2 BB5 YB
CN3-4 MU6 CN3-4 MU6

CN3-5 MU6 CN3-5 MU6
CN4-3 MW6 CN4-3 MW6 -C MW6 SM T-AXIS
CN4-5 ME6 CN4-5 ME6 -D ME6
CN4-6 ME6 CN4-6 ME6
-1 BA6
-2 BB6 YB
No.15CN
E
CN5-1 MU7 CN5-1 MU7 1
CN5-4 MU7 CN5-4 MU7 7
CN6-1 MV7 CN6-1 MV7 2
CN6-4 MV7 CN6-4 MV7 8
CN6-5 MW7 CN6-5 MW7 3
CN6-6 MW7 CN6-6 MW7 9
CN5-2 ME7 CN5-2 ME7 4
CN5-5 ME7 CN5-5 ME7
CN5-3 BA7 CN5-3 BA7 5

CN5-6 BB7 CN5-6 BB7 6
PE
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ES200D 9 Maintenance and Inspection
9.1 Inspection Schedule
9 Maintenance and Inspection
WARNING
• Before maintenance or inspection, be sure to turn the main power
supply 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.
• Do not remove the motor, and do not release the brake.
Failure to observe this caution may result in injury from unexpected
turning of the manipulator’s arm.
• The battery pack must be connected before removing detection
connector when maintenance and inspection.
Failure to observe this caution may result in the loss of home position
data.

Proper inspections are essential not only to assure that the mechanism
will be able to function for a long period, but also to prevent malfunctions
and assure safe operation. Inspection intervals are classified into six
levels as shown in Table 9-1 "Inspection Items" on page 9-2.
In Table 9-1, 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.
• For any different or special applications, the inspection
NOTE process should be developed on an case-by-case basis.
• For axes which are used very frequently (in handling
applications, etc.), it is recommended that inspections be
conducted at shorter intervals. Contact your Yaskawa
representative.
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Table 9-1: Inspection Items (Sheet 1 of 2)
ES200D
Items1) Schedule Method Operation Inspection
Charge
12000HCycle
1000HCycle
6000HCycle
Personnel
Company
Specified
Licensee
Service
24000H
36000H
Daily
1 Alignment mark
• Visual Check alignment mark accordance and damage at the home position.
• • •
2 External lead
• Visual Check for damage and deterioration of leads.
• • •
3 Working area and manipulator
• Visual Clean the work area if dust or spatter is present. Check for damage
• • •

and outside cracks.
4 Motors for L- and U-axes
• Visual Check for grease leakage.2)
• • •
5 Baseplate mounting bolts
• Spanner
Wrench
Tighten loose bolts. Replace if necessary.
• • •
6 Cover mounting screws
• Screwdriver,
Wrench
Tighten loose bolts. Replace if necessary.
• • •
7 S-,L-,U-axes motor connector
• Manual Check for loose connectors and tighten if necessary.
• • •
9-2
8 Connector base
• Manual Check for loose connectors.
• • •
9 Balancer
• Grease Gun Supply grease. See section 9.3.5 on page 9-20.
• •
10 Wire harness in manipulator
(SLU-axis wires)
• Visual,
Multimeter
Check for conduction between the main connector of base and
intermediate connector with manually shaking the wires. Check for
• •
(RBT-axis wires) wear of protective spring.3)
• Replace4)
•
11 Battery pack in manipulator
• Replace the battery pack when the battery alarm occurs or the
manipulator drove for 36000H.
• •
12 S-axis speed reducer,
S-axis gear
• • Grease Gun Check for malfunction. (Replace if necessary.)
Supply grease5) (6000H cycle). See section 9.3.1 on page 9-8.
• •
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13 L-axis speed reducer,
• •
14 U-axis speed reducer,
• •
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Table 9-1: Inspection Items (Sheet 2 of 2)
155977-1CD
ES200D
Items1) Schedule Method Operation Inspection
Charge
12000HCycle
1000HCycle
6000HCycle
Personnel
Company
Specified
Licensee
Service
24000H
36000H
Daily
15 R-axis speed reducer
Supply grease5) (6000H cycle). See section 1 on page 9-15.
• •

16 B- and T-axes speed reducer,
B- and T-axes gear
Supply grease5) (6000H cycle). See section 6 on page 9-16.
• •
17 Overhaul
• •
1 Inspection No. correspond to the numbers in Fig. 9-1 “Inspection Items” on page 9-4.
2 The occurrence of a grease leakage indicates the possibility that grease has seeped into the motor. This can cause a motor breakdown. Contact your Yaskawa
representative.
3 When checking for conduction with multimeter, connect the battery to “BAT” and “OBT” of connectors on the motor side for each axis, and then remove connectors on
9-3
detector side for each axis from the motor. Otherwise, the home position may be lost. (Refer to section 9.3.6 “Notes for Maintenance” on page 9-21)
4 Wire harness in manipulator to be replaced at 24000H inspection.
5 For the grease, refer to Table 9-2 "Inspection Parts and Grease Used" on page 9-5.
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Fig. 9-1: Inspection Items
ES200D
5
R-AXIS B-AXIS
T-AXIS
1 1
S-AXIS 1 1
16
15

2 14
10 6
9-4
7 U-AXIS
Check that no grease is 4 1
leaked into the tube (2 tubes).
6
L-AXIS
13
1
4
7 9
7
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6 2
12
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Table 9-2: Inspection Parts and Grease Used

No. Grease Used Inspected Parts
12, 13, Molywhite RE No. 00 Speed Reducers for all Axes
14, 15, 16 R-, B-, and T-Axes gears
9 Alvania EP Grease 2 L-Axis Balancer
The numbers in the above table correspond to the numbers in Table 9-1
"Inspection Items" on page 9-2
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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. 9-2(a) “Battery
Location (Back View)” and Fig. 9-2(b) “Battery Location (Top View)”.
If a battery alarm occurs in the DX100, replace the battery in accordance
with the following procedure:
Fig. 9-2(a): Battery Location (Back View)
Plate
Plate fixing screw M4
1BC
AIR S1
2BC
3BC
Base
Connector base
Fig. 9-2(b): Battery Location (Top View)
Battery pack
Board
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Fig. 9-3: Battery Connection

Battery pack
See replacing step 5. before replacement
Connector
Board
See replacing step 4.
(Type: SGDR-EFBA02A)
New battery pack
1. Turn OFF the DX100 main power supply.

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

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

Fig. 9-4: S-Axis Speed Reducer Diagram
1BC
A
AIR S1
2BC
3BC
Grease inlet S-axis speed reducer

Hexagon socket head plug A-PT1/4
Grease exhaust port
Hexagon socket head plug PT3/8
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9.3.1.1 Grease Replenishment

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram” on page 9-8.)
Replenish the grease according to the following procedure:
1. Remove the hexagon socket head plug PT3/8 from the grease
exhaust port.
If grease is injected with the plug on, the grease will leak
NOTE inside the motor and may cause a damage. Make sure to
remove the plug before the grease injection.
2. Install a grease zerk A-PT1/4 to the grease inlet. (The grease zerk is
delivered with the manipulator.)
3. Inject the grease through the grease inlet using a grease gun
– Grease type: Molywhite RE No. 00
– Amount of grease: 1200 cc
(2400 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, 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 5 N•m
(0.51 kgf•m).
9.3.1.2 Grease Exchange

(Refer to Fig. 9-4 “S-Axis Speed Reducer Diagram” on page 9-8.)
1. Remove the hexagon socket head plugs PT3/8 from the exhaust port.
3. Inject the grease through the grease inlet using a grease gun.
– Amount of grease: approx. 7000 cc
4. The grease exchange is completed when new grease appears in the
grease exhaust port. (The new grease can be distinguished from the
old grease by color.)
5. Move the S-axis for a few minutes to discharge excess grease.
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(0.51 kgf•m).
NOTE If the plug is installed when the grease is being exhausted,

the grease will go inside the motor and may damage it.
9.3.2 Grease Replenishment/Exchange for L-Axis Speed Reducer

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

(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram”.)
1. Make the L-arm vertical to the ground.
exhaust port.
4. Inject grease through the grease inlet using a grease gun.
5. Move the L-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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(Refer to Fig. 9-5 “L-Axis Speed Reducer Diagram” on page 9-10.)
1. Make the L-arm vertical to the ground.
exhaust port.
6. Move the L-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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9.3.3 Grease Replenishment/Exchange for U-Axis Speed Reducer

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

Grease inlet
Grease zerk A-PT1/8
9.3.3.1 Grease Replenishment

(Refer to Fig. 9-6 “U-Axis Speed Reducer Diagram”.)
1. Make the U-arm horizontal to the ground.
2. Remove the hexagon socket head plug PT1/8 from grease exhaust
port.
5. Move the U-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
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(Refer to Fig. 9-6 “U-Axis Speed Reducer Diagram” on page 9-12.)
1. Make the U-arm horizontal to the ground.
exhaust port.
5. The grease exchange is complete when new grease appears in the
6. Move the U-axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
NOTE If the plug is installed when the grease is being exhausted,

the grease will go inside the motor and may damage it.
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9.3.4 Grease Replenishment/Exchange for U-Arm

Fig. 9-7: U-Arm Diagram
Grease inlet (R-,B-, and T-gears in the casing)

Grease zerk A-PT1/8
T-axis speed reducer
Grease exhaust port

(T-axis speed reducer)
Hexagon socket head
plug PT1/16
Grease Inlet
R-axis speed reducer (B-, and T-axes speed reducer)
B-axis speed reducer
Grease exhaust port

(R-, and B-axes speed reducer)
Grease inlet (R-axis speed reducer)

Grease exhaust port

(R-,B-,and T-gears in the casing)
View A
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9.3.4.1 Grease Replenishment for R-, B-, T-Axes Gears in the Casing
(Refer to Fig. 9-7 “U-Arm Diagram”.)
exhaust port.
4. Move the R-, B-, T-Axes for a few minutes to discharge excess grease.
(0.51 kgf•m).
6. 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 5 N•m
(0.51 kgf•m).
9.3.4.2 Grease Replenishment for R-Axis Speed Reducer

(Refer to Fig. 9-7 “U-Arm Diagram” on page 9-14.)
exhaust port.
4. Move the R-Axis for a few minutes to discharge excess grease.
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plug, then tighten the plug with a tightening torque of 5 N•m (0.51
kgf•m).
(0.51 kgf•m).
9.3.4.3 Grease Replenishment for B-Axis Speed Reducer

exhaust port.
4. Move the B-Axis for a few minutes to discharge excess grease.
plug, then tighten the plug with a tightening torque of 5 N•m (0.51
kgf•m).
(0.51 kgf•m).
9.3.4.4 Grease Replenishment for T-Axis Speed Reducer

exhaust port.
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4. Move the T-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
9.3.4.5 Grease Exchange for R-, B-, T-Axes Gears in the Casing
exhaust port.
5. Move the R-, B-, T-Axes for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
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9.3.4.6 Grease Exchange for R-Axis Speed Reducer

exhaust port.
5. Move the R-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
9.3.4.7 Grease Exchange for B-Axis Speed Reducer

exhaust port.
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5. Move the B-Axis for a few minutes to discharge excess grease.

(0.51 kgf•m).
(0.51 kgf•m).
9.3.4.8 Grease Exchange for T-Axis Speed Reducer

exhaust port.
5. Move the T-Axis for a few minutes to discharge excess grease.
(0.51 kgf•m).
(0.51 kgf•m).
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9.3.5 Grease Replenishment for Balancer Connection Part

Fig. 9-8: Balancer Connection Part
Connection 2 Grease inlet

Grease zerk A-PT1/8
Exhaust port 2
Exhaust port 1
Connection 2 Needle bearing
Connection 1 Tapered roller bearing

(2 bearings)
Connection 1 Grease inlet

Grease zerk A-PT1/8 (2 grease zerks)
1. Remove the hexagon socket head plugs of connection and .

(Refer to Fig. 9-8 “Balancer Connection Part”.)
– Grease type: Alvania EP grease 2
2. Inject grease through grease inlets of connection and using a
grease gun.
The exhaust port is used only for air flow.

NOTE Do not inject excessive grease through the gear grease
inlet.
3. Reinstall the plugs PT1/8 of connection and . Before installing

the plug, apply Three Bond 1206C on the thread part of the plug, then
tighten the plug with a tightening torque of 5 N•m (0.51 kgf•m).
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9.3.6 Notes for Maintenance
When performing maintenance such as replacement of a

wire harness in the manipulator, the encoder connector may
be necessary to be removed. In this case, be sure to
connect the battery pack to the battery backup connector
before removing the encoder connector.
NOTE
Removing the encoder connector without connecting the
battery pack leads to disappearance of the encoder
absolute data.
For the battery pack connection, refer to Fig. 9-9 “Battery
Pack Connection” on page 9-21.
9.3.6.1 Battery Pack Connection

The connectors (crimped contact-pin) for the battery backup are installed
at the end point of the motors (BAT and OBT are marked). Connect the
battery packs according to the following procedure.
1. Removed the cap attached to the battery backup connector of the
motors.
2. Connect the battery packs (HW9470932-A) with the battery backup
connectors (BAT and OBT are marked) located at the end point of the
cables for the encoder. (Under this condition, remove the encoder
connector and carry out the maintenance checks).
3. Confirm all connectors connected after the maintenance check, and
remove the battery packs. Install the caps attached to the battery
backup connectors of the motors.
NOTE Do not remove the battery pack in the connector base.
Fig. 9-9: Battery Pack Connection

Motor
Motor power connector

Connector for the encoder
0BT b a 0BT*
BAT a b BAT*
Battery Pack: HW9470932-A
Connector for the battery backup
a:Insertion-type pin terminal (Pin)

b:Insertion-type pin terminal (Socket)
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ES200D 10 Recommended Spare Parts
10 Recommended Spare Parts

It is recommended to keep the parts and components in the following table
in stock as spare parts for the MOTOMAN-ES200D. Product performance
cannot be guaranteed when using spare parts from any company other
than Yaskawa. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts.
• Rank B: Parts for which replacement may be necessary as a result of
frequent operation.
• Rank C: Drive unit.
NOTE For replacing parts in Rank B or Rank C, contact your

Yaskawa representative.
Table 10-1: Spare Parts for the YR-ES0200D-A00, -A01 (Sheet 1 of 2)

Rank Parts Name Type Manufacturer Qty Qty Remarks
No. per
Unit
A 1 Grease Molywhite RE No. 00 Yaskawa 16 kg - for all axes
speed reducers
and wrist units
A 2 Grease Alvania EP Grease 2 Showa Oil Co.,Ltd. 16 kg - for balancer joint
part
A 3 Liquid Seal Three Bond 1206C Three Bond Co., Ltd. 1 1
A 4 Battery Pack HW0470360-A Yaskawa 1 1
A 5 Battery Pack HW9470932-A Yaskawa 1 - For wire harness
in manipulator
replacing
B 6 S-Axis Speed HW0388208-A Yaskawa 1 1
Reducer
B 7 S-Axis Input Gear HW0314016-1 Yaskawa 1 1
B 8 L-Axis Speed HW0390225-B Yaskawa 1 1
Reducer
B 9 L-Axis Input Gear HW0301778-1 Yaskawa 1 1
B 10 U-Axis Speed HW0388210-A Yaskawa 1 1
Reducer
B 11 U-Axis Input Gear HW0301780-1 Yaskawa 1 1
B 12 R-Axis Speed HW0388212-A Yaskawa 1 1
Reducer
B 13 B-Axis Speed HW9381453-B Yaskawa 1 1
Reducer
B 14 T-Axis Speed HW0380794-A Yaskawa 1 1
Reducer
B 15 Wrist Unit HW0170621-I Yaskawa 1 1
C 16 AC Servo Motor SGMRV-37ANA- Yaskawa 1 3
for S-, L-, and YR1*
U-Axes HW0388670-A
for R-Axis YR1*
HW0388666-A
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ES200D 10 Recommended Spare Parts
Table 10-1: Spare Parts for the YR-ES0200D-A00, -A01 (Sheet 2 of 2)

Rank Parts Name Type Manufacturer Qty Qty Remarks
No. per
Unit
for B-and T-Axes YR2*
HW0388667-A
C 19 Internal Wire HW0174287-A Yaskawa 1 1
Harness
C 20 Connector Base HW0374283-A Yaskawa 1 1
Set
C 21 Board SGDR-EFBA02A Yaskawa 1 1
C 22 Limit switch set HW0371747-A Yaskawa 1 1 Treatment of
for S-axis -A01 lead
terminal is done
C 23 Limit switch set HW0374590-A Yaskawa 1 1 Treatment of
for L-axis -A01 lead
terminal is done
C 24 Limit switch set HW0374590-B Yaskawa 1 1 Treatment of
for U-axis -A01 lead
terminal is done
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ES200D 11 Parts List
11.1 S-Axis Unit
11 Parts List
11.1 S-Axis Unit

Fig. 11-1: S-Axis Unit
1029
1030
1002
1029
1030
1039
1040
1004
1005
1015
1003
1025 1006
1026
1032
1001 1031
1037
1038
1016
1020
1027 1021 1008

1028
1014
1009
1033
1034 1012
1023 1035
1041 1024 1036
1017
1013 1010
1042 1022
1011
1007
1019
1018
11-1 75 of 89
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11.1 S-Axis Unit
Table 11-1: S-Axis Unit

No. DWG No. Name Pcs
1001 HW0388208-A Speed reducer 1
1002 SGMRV-37AN2A-YR1* Motor 1
1003 TC12015014 Oil seal 1
1004 STW-50 Retaining rings 1
1005 6310 Bearing 1
1006 HW0314016-1 Gear 1
1007 HW0100193-2 Base 1
1008 HW0100471-1 S head 1
1009 HW0402102-1 Stopper 1
1010 HW0302424-2 Stopper 1
1011 HW0402104-1 Pin 1
1012 HW0306181-1 Pipe 1
1013 HW0403903-1 Plate 1
1014 HW9404486-1 Shaft 1
1015 MSTH12-30 Pin 1
1016 MSTH12-40 Pin 2
1017 MSTH6-20 Pin 2
1018 KQ2L10-01S Union 1
1019 NB-1075-1 Tube 1
1020 PT3/8 Plug 1
1021 G415 O ring 1
1022 G105 O ring 1
1023 M6X16 Socket screw 1
1024 2H-6 Spring washer 1
1026 SW2H-12 Spring washer 16
1027 M8X40 Socket Screw 1
1035 M20X45(12.9) Bolt 3
1036 M20 Spring washer 3
1038 GT-SH-16 Spring washer 12
1039 HW0404753-1 Spacer 1
1040 HW0404752-1 Fly wheel 1
1041 HW0374283-A Connector base 1
1042 EZ5002A0 Cap 1
11-2 76 of 89
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11.2 L-Axis Unit
11.2 L-Axis Unit

Fig. 11-2: L-Axis Unit
2033
2034
2020-26
2012
2019
2037 2005
2019 2018
2038 2017
6004
2010 2031
2032
2009 2027
2013 2019A
2019
2002
2017 1008
2005
2012 2009
2020-26
2018 2032 2003
2031
2007
2015
2019 2049
2008
2016
2004
2034
2033
2040
2039
2006
2011
2001
2036
2035
2014
2019
2030
2029
11-3 77 of 89
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11.2 L-Axis Unit
Table 11-2: L-Axis Unit

2001 HW0390225-B Speed reducer 1
2002 SGMRV-37ANA-YR1* Motor 1
2003 Y507212.5 Oil seal 1
2004 ISTW-10 Retaining rings 1
2005 HR32916J Bearing 2
2006 HW0100647-2 L arm 1
2007 HW9482306-E Shaft 1
2008 HW0481082-A Bolt 1
2009 HW9405055-1 Shaft 2
2010 EZ0094-A0 Air breather 1
2011 G300 O ring 1
2012 S105 O ring 2
2013 62PP050BG14 Plug 6
2014 CP-30-BC-12 Cap 6
2015 HW9481343-A Gear 1
2016 HW0301778-1 Gear 1
2017 KE901107 Oil seal 2
2018 HW9405699-1 B cover 2
2019 PT1/8 (Stainless) Plug 5
2019A PT3/8 (Stainless) Plug 1
2020 HW9405195-* Shim -
2027 GT-SA-M12X35 Socket screw 4
2040 SW-2H-12 Spring washer 24
2049 HW0408806-1 Spring washer 1
1008 HW0100471-1 S head 1
6004 HW0100477-1 Case 1
11-4 78 of 89
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11.3 URBT-Axes Unit
11.3 URBT-Axes Unit

Fig. 11-3: URBT-Axes Unit
3016
R-axis 3019 3017
3004
3020 3008 3049
3055 3047
3006
3054 3053 3045
3056 3044 3037
B-axis 3007 3002 3046
3005 3048
T-axis 3056 3018
3055
3009 3003
3020 3010
3012 3053 3032
3051 3030
3052 3011 3033 3031
3011 3034
3020 3014
3055 3053 3035
3025
3015
3026 3036
3027 3010
3029 3001
3024
3022 3023
3028
3050
3038
3041
3040 4001
3039
3043
3042
3013
2006
11-5 79 of 89
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11.3 URBT-Axes Unit
Table 11-3: URBT-Axes Unit (Sheet 1 of 2)

3001 GS210 O ring 1
3002 HW0402391-1 Collar 1
3003 HW0402406-1 Collar 1
3004 HW0306788-1 Gear 1
3008 HW0402544-1 Collar 1
3009 HW0306797-1 Gear 1
3012 HW0306795-1 Gear 1
3013 PT1/8 Plug 1
3014 PT1/8 Plug 1
3015 HW0401507-1 Plate 1
3018 IRTW-55 Retaining rings 1
3020 M8X25 GT-SA bolt 12
3022 HW0100239-4 Casing 1
3025 HW9405703-1 Flange 1
3028 MSTM8-20 Pin 1
3029 HW0402885-1 Cover 1
3032 HW9482447-A Oil Seal 1
3033 HW9405481-1 Collar 1
3034 IRTW-72 Stopper 1
3035 PT1/8 Plug 1
3036 PT1/8 Plug 1
3039 HW0301779-1 Spacer 1
3044 HW0481083-A Bolt 1
11-6 80 of 89
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155977-1CD
11.3 URBT-Axes Unit
Table 11-3: URBT-Axes Unit (Sheet 2 of 2)

3045 HW0408806-1 Washer 1
3046 HW0301780-1 Gear 1
3047 HW9481343-A Shaft 1
3048 ISTW-12 Retaining ring C-type 1
3049 HW9482306-E Shaft 1
3050 G280 O ring 1
3051 TSH6-01M Union 2
3052 UB0605-0.1C Air tube 2
3053 Y507212.5 Oil seal 3
3054 TAFI405520 Needle bearing 1
3055 HW0401506-1 Plate 3
2006 HW0100647-2 L arm 1
4001 HW0100241-1 U arm 1
11-7 81 of 89
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11.4 U-Arm Unit
11.4 U-Arm Unit

Fig. 11-4: U-Arm Unit
4024
4025 4037
4038
4023
4004
4031
3022 4026
4030
4029
4030
4016
4002 4035
4036
4033
4034
4002A
4008
4028
4022
4032
4027
4018
4007
4014
4015
4001 4005
4013
4020
4006
4012
4011
4039
4009
4010
11-8 82 of 89
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11.4 U-Arm Unit
Table 11-4: U-Arm Unit

4001 HW0100241-1 U-Arm 1
4002 NK25/20R Bearing 1
4002A LRT202526 Bearing 1
4004 HW0401508-1 Plate 1
4005 6812LLU Bearing 1
4006 HW0402204-1 Collar 1
4007 STW-60 Retaining ring C-type 1
4008 WR20 Retaining ring C-type 1
4010 HW9302581-1 washer 1
4013 SC60789 Oil seal 1
4014 HR32017XJ Bearing 1
4015 AC3842-F1-FKM Oil seal 1
4016 HW0312106-1 Shaft 1
4018 HW0306113-A Shaft C 1
4022 HW0302261-A Shaft 1
4023 M4X6 H set screw 1
4026 HW0100173-2 Housing 1
4028 HW0306798-1 Gear 1
4029 HW0306796-1 Gear 1
4031 HW0401505-1 B nut 1
4032 HW0306787-1 Gear 1
4039 MSTH6-15 Parallel pin 1
3022 HW0100239-4 Casing 1
11-9 83 of 89
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11.5 Wrist Unit
11.5 Wrist Unit

Fig. 11-5: Wrist Unit
5018 5070
5052 4016
5013
5017 5078
5014 5023
5049
5019 5072
5016 5015 5040
5034 5042
5001 5087 5036
5033 5035
5071
5077 5043 5055
5027 5042
5031 5025 5024 5032 5037
5026 5043
5085 5050 5032 5041
5030 5032
5003 5086 5032
5002 5024 5048
5044 5083 5069
5045
5008 5084 5057
5073
5009
5047
5021 5038
5022 5039
5005 5023 5054
5007 5046 5066
5004 5012
5006 5067
5081 5058
5068 5064
5020 5063
5051 5065
5060
5059 5011
5053 5010
5029
5028
11-10 84 of 89
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11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 1 of 2)

5001 HW0100242-1 Wrist base 1
5004 HW0100243-1 Wrist 1
5005 HW9381453-B Speed reducer 1
5007 GT-SH M14 Spring washer 6
5012 ARP568-263 O ring 1
5013 6908DB Bearing 1
5014 HW0401511-1 B holder 1
5015 HW0306791-1 Gear 1
5016 HW0401509-1 Housing 1
5017 HW0401510-1 B nut 1
5018 M4X8 H set screw 1
5019 6909 Bearing 1
5020 G220 O ring 1
5021 HW0306792-1 Gear 1
5022 6009 Bearing 1
5023 STW-45 Retaining rings C- 2
type
5025 HW0309518-1 Gear 1
5026 HW0301223-1 Gear 1
5027 6007 Bearing 1
5030 HW0409072-1 Cover 1
5031 G140 O ring 1
5033 6911 Bearing 1
5034 AE3290E3 Oil seal 1
5035 S60 O ring 1
5036 HW9403618-1 Housing 1
5040 HW0301224-1 Gear 1
5041 HW0301225-1 Gear 1
5042 HW0401514-1 B nut 2
5043 M5X7 Magic screw 4
11-11 85 of 89
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11.5 Wrist Unit
Table 11-5: Wrist Unit (Sheet 2 of 2)

5048 HW9403617-1 Housing 1
5049 HW0200615-1 Cover 1
5051 HW9302370-1 Cover 1
5053 PT1/8 Plug 1
5054 HW0306790-1 Gear 1
5057 HW0306789-1 Gear 1
5063 HW0302422-2 Flange 1
5064 HW0301782-1 Spacer 1
5065 PT1/16 Plug 1
5066 HW0402206-* Shim -
5067 STW-30 Retaining ring C-type 1
5068 6006 Bearing 1
5071 EZ5036A0 Cap 2
5072 PT1/8 Plug 1
5073 HW9403621 Shim -
5077 HW9403622 Shim -
5078 HW0401516-* Shim -
5081 HW0402205-* Shim -
5083 HW0410868-* Shim -
5084 HW0411721-1 B nut 1
5086 HW0411718-1 Collar 1
5087 HW0404270-1 Shim 1
4016 HW0312106-1 Shaft 1
11-12 86 of 89
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11.6 Balancer Unit
11.6 Balancer Unit

Fig. 11-6: Balancer Unit
6018
6004
6011
6007 6005
6001
6002
6006
6016 6017
6015
6012
6003
6008
6003
6012 6014
6010
6013
2006
6009
2046
2041
2045
2042 2044
2043
2048
2047
11-13 87 of 89
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11.6 Balancer Unit
Table 11-6: Balancer Unit

6001 HW0481740-A Coil spring 1
6003 SOB607440 Oiless 2
6004 HW0100477-1 Case 1
6005 HW0306033-1 Flange 1
6006 HW0200420-1 Flange 1
6007 HW0401112-1 Flange 1
6008 HW0303581-1 Rod 1
6009 HW9405057-1 Clevis 1
6010 FD3187A0 Dust seal 1
6011 EZ2228B0 Cap 1
6012 IRTW-75 Stopper 2
2006 HW0100647-2 L arm 1
2041 NA6912 Needle bearing 1
2042 HW9302054-1 Shaft 1
2043 AR-85 Clip 1
2044 WR60 Sir clip 1
2045 VB75X95X6 Oil seal 1
2046 VB60X78X7 Oil seal 1
11-14 88 of 89
HW0485255
MOTOMAN-ES200D
INSTRUCTIONS
HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802
YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277
YASKAWA Europe GmbH Robotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103
YASKAWA Nordic AB
Bredbandet 1 vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone +46-480-417-800 Fax +46-480-417-999
YASKAWA Electric (China) Co., Ltd.

22/F One Corporate Avenue No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878
YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542
YASKAWA Electric Korea Co., Ltd

9F, KyoboSecuritiesBldg., 26-4, Yeouido-dong,Yeongdeungpo-gu, Seoul 150-737, Korea
Phone +82-2-784-7844 Fax +82-2-784-8495
YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513
YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003
YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199
PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741
Specifications are subject to change without notice

for ongoing product modifications and improvements.
89 of 89
MANUAL NO.
HW0485255 8

Motoman ES200D-A00 Manual

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MOTOMAN-ES200D

Part Number: 155977-1CD

Copyright © 2016, 2012, 2011 Yaskawa America, Inc.

Terms of Use and Copyright Notice

Printed in the United States of America

First Printing, 2016

Yaskawa America, Inc.

Notes for Safe Operation

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

PROHIBITED Must never be performed.

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

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

• Observe the following precautions when performing teaching

Definition of Terms Used In this Manual

Explanation of Warning Labels

Nameplate WARNING Label A WARNING Label B

Nameplate: WARNING Label A:

Customer Support Information

When using e-mail to contact Motoman Customer Support, please provide

Please use e-mail for routine inquiries only. If you have an

• Primary Application ___________________________

• Software Version Access this information on the

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX100 controller

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

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

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

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

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

2.2 Shipping Bolts and Brackets.............................................................................................. 2-3

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

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

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

3.3 Location ............................................................................................................................. 3-3

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

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

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

4.2.2 Connection to the DX100 ..................................................................................... 4-2

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

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

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

5.3 Manipulator Base Dimensions ........................................................................................... 5-2

5.4 Dimensions and P-Point Maximum Envelope.................................................................... 5-3

5.5 Alterable Operating Range ................................................................................................ 5-4

5.5.1 Components for Altering Operating Range .......................................................... 5-5

5.5.2 Notes on the Mechanical Stopper Installation ...................................................... 5-6

5.5.3 Adjustment to the Pulse Limitation of S-Axis........................................................ 5-7

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

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

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

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

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

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

8.1.1 Specification of Limit Switch ................................................................................. 8-1

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

8.1.3 Setting of Operation Range .................................................................................. 8-2

8.2 Internal Connections .......................................................................................................... 8-4

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

9.1 Inspection Schedule........................................................................................................... 9-1

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

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