Kmm 중상도 로봇 (Mpx3500)

MOTOMAN-MPX3500
INSTRUCTIONS
TYPE
YR-MPX3500-*0* (R-TYPE)
YR-MPX3500-*1* (L-TYPE)
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MPX3500 INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 INSTRUCTIONS (MPX INSTRUCTIONS SUPPLEMENT)
DX200 OPERATORS MANUAL FOR PAINTING
DX200 MAINTENACE MANUAL (Volume 1)(Volume 2)
The DX200 operators manual above corresponds to specific usage. Be sure to use the appropriate manual.
The DX200 maintenance manual above consists of Volume 1 and Volume 2.
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MANDATORY
This instruction manual is intended to explain mainly on the

mechanical part of the MOTOMAN-MPX3500 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 the Chapter 1: Safety of

the DX200 instructions. To ensure correct and safe operation,
carefully read the DX200 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
products warranty.
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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the MOTOMAN-MPX3500 .
In this manual, the Notes for Safe Operation are classified as DANGER,
WARNING, CAUTION, MANDATORY, or PROHIBITED.
Indicates an imminent hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
DANGER
Indicates a potentially hazardous

result in death or serious injury to
personnel.
WARNING
Indicates a potentially hazardous

result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
CAUTION
MANDATORY
PROHIBITED
Always be sure to follow explicitly the

items listed under this heading.
Must never be performed.
Even items described as CAUTION may result in a serious accident in

some situations.
At any rate, be sure to follow these important items.
NOTE
To ensure safe and efficient operation at all times, be sure

to follow all instructions, even if not designated as DANGER, WARNING and CAUTION .
DANGER
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 these safety precautions may result in death or

serious injury from unexpected turning of the manipulator's arm.
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WARNING
Before operating the manipulator, check that servo power is turned

OFF pressing the emergency stop buttons on the front door of the
DX200 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.
Fig. : 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.

Fig. : Release of Emergency Stop
TURN
Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
View the manipulator from the front whenever possible.
Always follow the predetermined operating procedure.
Keep in mind the emergency response measures against the
manipulators 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 DX200.
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
DX200 and the programming pendant.
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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 DX200 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

DX200 Instructions before operating the manipulator:
Definition of Terms Used Often 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
DX200 controller
DX200
DX200 programming pendant
Programming pendant
Cable between the manipulator and the

controller
Manipulator cable
Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or bland names for each company or
corporation. The indications of (R) and TM are omitted.
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Explanation of Warning Labels

The following warning labels are attached to the manipulator.
Always follow the warnings on the labels.
Also, an identification label with important information is placed on
the body of the manipulator. Prior to operating the manipulator,
confirm the contents.
Warning Label B
WARNING
WARNING
WARNING
Warning Label A
MPX3500-*0*
Nameplate
WARNING
Moving parts
may cause
injury
Nameplate
Moving parts
may cause
injury
Do not enter
robot
work area.
Warning Label A
Do not enter
robot
work area.
Warning Label B
Nameplate
MPX3500-*1*
Warning Label A
WARNING
Moving parts
may cause
injury
Warning Label B
WARNING
Do not enter
robot
work area.
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Contents
1 Safety Precautions.......................................................................................................................... 1-1
2 Features.......................................................................................................................................... 2-1
2.1 Explosion-Protected Structure ........................................................................................... 2-1
2.2 Teaching ............................................................................................................................ 2-1
3 Installation....................................................................................................................................... 3-1
3.1 Requirements .................................................................................................................... 3-1
3.2 Installation Site .................................................................................................................. 3-2
4 Transport and Installation ............................................................................................................... 4-1
4.1 Preparation ........................................................................................................................ 4-1
4.2 Receiving ........................................................................................................................... 4-2
4.3 Transport ........................................................................................................................... 4-3
4.3.1 Transporting Method ............................................................................................ 4-3
4.3.1.1 Using a Crane ......................................................................................... 4-4
4.3.1.2 Using a Forklift ........................................................................................ 4-5
4.3.2 Shipping Bolts and Brackets................................................................................. 4-6
4.4 Installation ......................................................................................................................... 4-6
4.4.1 Installation of Safeguarding .................................................................................. 4-7
4.4.2 Mounting Procedures for Manipulator Base ......................................................... 4-7
4.4.3 Mounting the Manipulator on the Baseplate ......................................................... 4-7
4.4.4 Location .............................................................................................................. 4-10
4.4.5 Controller and Programming Pendant ................................................................ 4-10
4.4.6 Safety Devices ................................................................................................... 4-10
5 System Configuration...................................................................................................................... 5-1
5.1 Manipulator ........................................................................................................................ 5-1
5.2 Robot Controller................................................................................................................. 5-6
5.3 Pressure Switch Unit ......................................................................................................... 5-6
5.4 Tubes................................................................................................................................. 5-7
5.5 O-Ring and X-Ring in the Wrist ......................................................................................... 5-7
6 Connection...................................................................................................................................... 6-1
6.1 Wiring................................................................................................................................. 6-1
6.1.1 Grounding............................................................................................................. 6-1
6.2 Cable Connection .............................................................................................................. 6-3
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6.3 Internal Connections .......................................................................................................... 6-7

7 Basic Specifications ........................................................................................................................ 7-1
7.1 Basic Specifications ........................................................................................................... 7-1
7.2 Part Names and Working Axes.......................................................................................... 7-2
7.3 Wrist Flange....................................................................................................................... 7-3
7.4 System Application ............................................................................................................ 7-4
8 Frequent Inspections....................................................................................................................... 8-1
8.1 Frequent Inspections ......................................................................................................... 8-1
8.2 Daily Inspections................................................................................................................ 8-3
8.2.1 Manipulator ........................................................................................................... 8-3
8.2.1.1 Visual Inspection ..................................................................................... 8-3
8.2.1.2 Manipulator Motions and Noise/Vibration during Operation .................... 8-3
8.2.1.3 Tubes and Air Leakage ........................................................................... 8-3
8.2.1.4 Dried Paint, Dust, and Dirt....................................................................... 8-3
8.2.2 Pressure Switch Unit ............................................................................................ 8-4
8.2.2.1 Pressure .................................................................................................. 8-4
8.2.3 Safety Devices...................................................................................................... 8-4
8.2.3.1 Emergency Stop Button and Safety Plug ................................................ 8-4
8.2.3.2 Photoelectric Intrusion Detecting Switch ................................................. 8-4
8.2.3.3 Limit Switch ............................................................................................. 8-4
8.2.4 Options ................................................................................................................. 8-5
8.2.4.1 Gun Tilt Switching.................................................................................... 8-5
8.2.4.2 Shear Pin................................................................................................. 8-5
9 Maintenance and Inspection ........................................................................................................... 9-1
9.1 Inspection Schedule........................................................................................................... 9-1
9.2 Maintenance for Manipulator ............................................................................................. 9-6
9.2.1 Grease Replenishment/Replacement................................................................... 9-6
9.2.1.1 Wrist Gears.............................................................................................. 9-6
9.2.1.2 S-, L-, and U-Axis Speed Reducers ........................................................ 9-7
9.2.1.3 R-, B-, and T-Axis Speed Reducers ...................................................... 9-11
9.2.2 Inspection of Wrist Gear and Bearing................................................................. 9-13
9.2.3 Inspection of Air Sealing for Internal Air Pressure .............................................. 9-13
9.2.3.1 Gasket on the Motor Case..................................................................... 9-13
9.2.4 Battery Replacement .......................................................................................... 9-17
9.3 Inspection of the Pressure Switch Unit ............................................................................ 9-20
9.3.1 Solenoid Valve.................................................................................................... 9-20
9.3.2 Pressure Reducing Valve ................................................................................... 9-20
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9.4 Inspection of Explosion-Proof Devices ............................................................................ 9-20
9.4.1 Pressure Switch Unit .......................................................................................... 9-20
9.4.2 Master Valve ...................................................................................................... 9-20
9.4.3 Pressurized Anti-Explosion Barrier..................................................................... 9-20
9.5 Notes for Maintenance..................................................................................................... 9-21
9.5.1 Encoder Connector with Warning Label ............................................................. 9-21
9.5.1.1 S-, L-, and U-Axis Motors ...................................................................... 9-21
9.5.1.2 R-, B-, and T-Axis Motors (Option: Pomp 1,2-Axis Motor) ................... 9-21
9.5.2 Filter in Motor...................................................................................................... 9-21
10 Recommended Spare Parts........................................................................................................ 10-1
11 Parts List ..................................................................................................................................... 11-1
11.1 S-, L-Axis Unit................................................................................................................ 11-1
11.2 U-Axis Unit..................................................................................................................... 11-6
11.3 U-Arm Unit ................................................................................................................... 11-10
11.4 Wrist Unit ..................................................................................................................... 11-13
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Safety Precautions
Safety Precautions
Respect the law, local regulations, and safety codes for connecting
the painting robot.
Specify the working regulations and the person in charge for the following operations:
Turning the power to the robot ON/OFF, and RUN/STOP operations
To avoid any faulty operation, take measures such as putting up a
notice to remind operators of procedures and precautions
explained in the instruction manual.
Warning sign or signal to inform operator of the robot operation
status
Starting an operation while someone is in the manipulators working envelope or while someone is doing maintenance checks or
repairs may cause a serious accident. When on standby, the
manipulator can be moved by an external signal.
To avoid these accidents caused by a lack of information, put up
a board or indicator lamp to show the robot operation status.
Action to be taken in case of a failure or an accident
Appoint a person to be contacted and the action to be taken in
case of a failure or an accident.
Safety standards and the supervisor for safe operation
Appoint a supervisor for the safe operation of the manipulator and
establish the working regulations.
Appoint a person to be in charge of teaching, maintenance and
inspections and provide training or lectures on safety and the
actions to be taken in case of an emergency.
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Safety Precautions
CAUTION
Take the following measures when teaching, correcting, inspecting,

or adjusting the manipulator when the motor power supply is ON:
a)
Appoint a personnel to stay beside the emergency stop

button of the DX200. And perform the operations holding
the programming pendant with the emergency stop button.
b)
Before the operation, verify the correct robot motion and

that the emergency stop works.
Observe the following precautions during an automatic operation:

a)
Do not enter inside the safeguarding during operation.
b)
Confirm the following before starting the operation:
No person is inside the manipulator working envelope.

No obstacles such as unnecessary workpieces and tools
are inside the manipulator working envelope.
The manipulator is in its standby position.
c)
When any abnormality occurs, immediately press the

emergency stop button to stop the manipulator.
d)
Before entering inside the manipulator working envelope,

be sure to stop the manipulator and turn OFF the main
power supply to the DX200.
Brake release (Option)
A braking system is provided on each axis of the manipulator to hold

the arm in its position when a failure or fault occurs. When the brake is
activated, the manipulator cannot be moved manually even if the power
is OFF. To change the posture of the manipulator after a failure or fault,
the brake can be released by the operation from the controller.
When the brake is released with the manipulators power OFF, each
axis falls down because of the arm weight. While two or more people
are holding the arm in position before releasing the brake, change the
posture of the manipulator within the minimum motion range.
Use the brake release function only when absolutely necessary.
1-2
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Safety Precautions
PROHIBITED
Any modification of the MOTOMAN-MPX3500, and the following is

strictly prohibited:
1. Explosion-proof devices and system installation

2. Safeguarding and the safety devices mounted on these safeguards
3. Emergency stop button, and other safety devices
4. Robot control system such as the DX200 robot controller, the
manipulator drive section and the power transmission section
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2.1
Features
Explosion-Protected Structure
Features
The MOTOMAN-MPX3500 is designed for easy-handling and to consider
safety first in operation.
2.1
Explosion-Protected Structure
The MOTOMAN-MPX3500 with their explosion-protected construction
(Exibpx IIBT4Gb) meets the requirements for Explosion-protected ratings:
The pressurized explosion-proof enclosure prevents explosive
gas from entering the manipulator 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 from igniting by electric spark and heat.
DANGER
Select a location for the MOTOMAN-MPX3500, a Division 1 area or
Division 2 area. Do not select a location which can be classified as a
Division 0 area or a more hazardous location.
2.2
Teaching
The target positions, the motion speed, and the ON/OFF timing of the
spray can be taught with the programming pendant while moving the
manipulator, which shortens the time required for teaching. And, the data
can be corrected at any time.
Because 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. And the
management function, which manages the parameter settings, enables
you to monitor the actual status during teaching. The on-screen guidance
and the interactive system on the pull-down menus lead the operator
through the operation procedures.
1. Large-capacity backup as a standard
A large-capacity drive for CF cards is provided as a standard feature of
backup unit and enables data to be transmitted easily.
CAUTION
Be sure to save the backup data for the controller, such as the data for
jobs and constants, on a CF card. If not, the necessary data for the
manipulator may be lost if an internal memory fault occurs in the
controller.
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2.2
Features
Teaching
2. High reliability
The built-in microcomputer continuously checks the I/O data and the
manipulator motion to ensure high-reliability.
Can detect power supply faults and software faults with its self-diagnosis functions.
3. When an error such as an operation error or a controller fault occurs,
the alarm code and message are displayed, and 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.
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3.1
Installation
Requirements
Installation
3.1
Requirements
Prepare the power supply, the air supply, and the grounding according to
the following specifications.
Table 3-1: Specifications

No. Item
Specifications
Remarks
Power supply
3-phase 200/220 VAC

(Voltage: 10%)
50/60 Hz (2 Hz)
3.5 kVA (at peak)
Air supply
Required pressure: 0.35 MPa to 0.65 MPa

Capacity:
For pressurized type of explosion
protected construction
50 NI/min usually
1000 Nl/min at purging
Dryness: Freezing at -18 C
Use dry air for the

pressurized explosion-proof
construction.
Grounding resistance: 100 ohm or less
For the robot controller
Pressurized
explosion-proof
construction
Grounding
CAUTION
Use dry air for the pressurized explosion-proof enclosure. Moisture in
the air supply may damage the electronic parts.
3-1
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3.2
3.2
Installation
Installation Site
Installation Site
This section describes the conditions of the installation site for the robot
system. 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 controller and
control panels in a location free from water drops, dust, and dirt.
Table 3-2: Installation Site

System Components
Manipulator (explosion-proof)
Hazardous
Location
Non-hazardous
location
(Inside Painting
Booth)
(Outside Painting
Booth)
0 to 40 C
80%RH
0 to 45 C
90%RH
0 to 40C
85%RH
0 to 40 C
85%RH
0 to 40 C
85%RH
0 to 50 C
90%RH
0 to 50 C
90%RH
0 to 50 C
90%RH
0 to 50 C
85%RH
0 to 45 C
90%RH
Controller
(not explosion-proof)
Pressure Switch unit

(explosion-proof)
Programming pendant
Programming pendant (explosionproof) (Option)
Conveyer speed detector

Conveyer speed detector

(explosion-proof)
Conveyer switch
(explosion-proof)
Workpiece supplier
(explosion-proof)
Ambient
Temperature
Maximum
Ambient
Humidity
Control panel for workpiece

supplier
Safety devices
Box for emergency stop
switches
Safety plugs
Limit switches
Flashing light
Indicator lamps
Photoelectric switches
Selected according to the requirements of the customer. Refer to the

appropriate instruction manual provided separately.
: Not acceptable
: Acceptable
-: Should be always mounted within the painting booth.
WARNING
Devices that are not explosion-proof must not be installed in hazardous
locations. Failure to observe this warning may result in a fire.
3-2
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4.1
Transport and Installation

Preparation

Carry out the operation safely observing the following precautions.
I)
Signs indicating prohibitions such as, The lighting of fires is

prohibited
II)
Clean working place that is clearly defined and free of obstacles
III) Appointment of personnel in charge

IV) Company working regulations for safe operation
4.1
Preparation
Before installing the MOTOMAN, do the following:
I)
Confirm the installation layout and the dimensions of each

device to ensure the transportation route and the installation
space.
II)
Check if the transportation route can support the weight of

each device. If necessary, reinforce the route.
III) To lift the manipulator, use the appropriate machinery such as a

forklift.
4-1
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4.2
4.2

Receiving
Receiving
When the package arrives, check the contents. Are the items and
quantities in accordance with your order sheet? Was any damage incurred
during shipment?
CAUTION
Confirm that the manipulator and the DX200 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.
Fig. 4-1: Location of Order Number Labels
Label (Enlarged View)

THE MANIPULATOR AND THE CONTROLLER
SHOULD HAVE SAME ORDER NUMBER.
ORDER. No.
5'401
Check that the manipulator

and the DX200 have the
same order number.
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4.3
4.3

Transport
Transport
CAUTION
Sling and crane or forklift operations must be performed by

authorized personnel only.
Failure to observe this caution may result in injury or damage.
4.3.1
Avoid excessive vibration or shock during transport.
The system consists of precision components. Failure to observe

this caution may adversely affect performance.
Transporting Method
The mass of the manipulator is approximately 730 kg

including the shipping bolts and brackets. Use a wire rope
strong enough to withstand the mass.
NOTE
The attached eyebolts are designed to support the manipulator mass. Never use them for anything other than
transporting the manipulator.
Mount the shipping bolts and brackets before transporting
the manipulator.
With any transportation equipment, make sure to avoid
external force on the arm or motor unit when transporting
the manipulator.
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4.3
4.3.1.1

Transport
Using a Crane
As a rule, when uncrating the manipulator and moving it, a crane

should be used. Lift the manipulator with a wire rope using the
attached eyebolts. Make sure to fix the manipulator with shipping
bolts and brackets before transport, and lift it in the posture as
shown in fig. 4-2 Transport Using a Crane .
Fig. 4-2: Transport Using a Crane
Shipping bolt and bracket
(Fixed to the manipulator
before shipment.)
Eyebolts M24
(Fixed to the manipulator
before shipment.)
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4.3
4.3.1.2

Transport
Using a Forklift
When using a forklift, the manipulator should be fixed on a pallet

with shipping bolts and bracket as shown in fig. 4-3 Transport
Using a Forklift . Insert claws under the pallet and lift it. The pallet
must be strong enough to support the manipulator.
Transport the manipulator slowly with due caution in order to avoid
overturn or slippage.
Fig. 4-3: Transport Using a Forklift
Hexagon socket head cap screw M12

(length: 55 mm, 8 screws)
Forklift fork entries
17.5 dia. (8 holes)
4-5
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4.4
4.3.2

Installation
Shipping Bolts and Brackets

The manipulator is provided with shipping bolts and brackets at positions
as shown in fig. 4-2 Transport Using a Crane , to protect its driving units
from various external force during transport.
The shipping brackets are painted yellow.
NOTE
4.4
Before turning ON the power, check to be sure that the shipping bolts and brackets have been removed. The shipping
bolts and brackets then must be stored for future use, in the
event that the manipulator must be moved again for relocation.
Installation
WARNING
Install the safeguarding.
Failure to observe this warning may result in injury or damage.
Install the manipulator in a location where the manipulators tool or

the workpiece held by the manipulator will not reach the wall,
safeguarding, or DX200 when the arm is fully extended.
Failure to observe this warning may result in injury or damage.
Do not start the manipulator or even turn ON the power before it is

firmly anchored.
The manipulator may overturn and cause injury or damage.
CAUTION
Do not install or operate a manipulator that is damaged or lacks

parts.
Failure to observe this caution may cause injury or damage.
Do not install the paint gun and the gun brackets until the
manipulator is firmly anchored.
Any contact to the unstable manipulator may cause injury or damage.
Before turning ON the power, check to be sure that the shipping

bolts and brackets explained in "fig. 4-2 Transport Using a Crane
are removed.
Failure to observe this caution may result in damage to the driving

parts.
4-6
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4.4
4.4.1

Installation
Installation of Safeguarding
To insure safety, be sure to install the safeguarding. They prevent
unforeseen accidents with personnel and damage to equipment. The
following is quoted for your information and guidance.
Responsibility for Safeguarding (ISO 10218)
The user of a manipulator or robot system shall ensure that safeguarding
is 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.
4.4.2
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 force of the manipulator. (Refer to table 4-1
Maximum Repulsion Force of the Manipulator at Emergency Stop .)
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.
For installation, refer to chapter 4.4.3
Baseplate .
Mounting the Manipulator on the
Table 4-1: Maximum Repulsion Force of the Manipulator at Emergency

Stop
4.4.3
Maximum torque in horizontal rotation
31400 Nm
(3200 kgfm)
Maximum torque in vertical rotation
46100 Nm
(4700 kgfm)
Mounting the Manipulator on the Baseplate

The baseplate should be rugged and durable to withstand maximum
repulsion force of the manipulator and to ensure that the manipulator and
fixture are in the correct relative position. The thickness of the baseplate is
40 mm or more and an M20 size or larger anchor bolt is recommended.
Fix the manipulator base to the baseplate with the hexagon socket head
cap screws M20 (8 screws, length of 80 mm or more is recommended)
using mounting holes on the manipulator base.
Tighten the hexagon socket head cap screws and anchor bolts securely
so that they will not work loose during operation.
4-7
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4.4

Installation
Fig. 4-4(a): Mounting the Manipulator on the Baseplate (MPX3500-*0*)

Hexagon socket head cap screw M16 (8 screws)
(Tightening strength:1200N/mm or more)
2
Spring washer
Washer
Manipulator base
Center
17.5dia.(8holes)
250 0.1
325 0.1
116 0.1
25
566
15 0.1
12H7dia.(2holes)
130
130
Enlarged View of B
130
28
250 0.1
32mm or more
24mm or more
(Screw tightening depth)
(Tightening torque:206N m (21kgfm)
277 0.1
277 0.1
Section A-A
Unit:mm
Manipulator base
Flatness
0.5mm or less
Anchor bolt
M20 or larger
VIGOGREASE
RE0
OUT
Baseplate

SHOULD HAVE SAME NUMBER.
ORDER
NO.
NJ1530
MOTOMAN
MODEL
MOTOMANTYPE
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
YASKAWA ELECTRIC CORPORATION
2-1 Kurosakishiroishi, Yahatanishi-ku,
Kitakyushu 806-0004 Japan
MADE IN JAPAN
NJ3247
4-8
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4.4

Installation
Fig. 4-4(b): Mounting the Manipulator on the Baseplate (MPX3500-*1*)
Hexagon socket head cap screw M16 (8 screws)

(Tightening strength:1200N/mm or more)
2
(Tightening torque:206N m (21kgfm)

24mm or more
(Screw tightening depth)
Spring washer
Washer
Center
Manipulator base
17.5dia. (8holes)
250 0.1
325 0.1
566
15 0.1
277
116 0.1
25
130
130
130
12H7dia. (2holes)
0.1
277
Section A-A
0.1
Unit:mm
Manipulator base
Flatness
0.5mm or less
VIGOGREASE
RE0
OUT
Baseplate
ORDER
NO.
S
L
U
R
B
T
7
8
ATAD.SBA
.ON.RES
NJ1530
MOTOMAN
TYPE
MOTOMANMODEL
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
NJ3247
MADE IN JAPAN
Anchor bolt
M20 or larger

Enlarged View of B
32mm or more
28
250 0.1
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4.4
4.4.4

Installation
Location
When installing the manipulator, satisfy the following environmental
conditions.
Ambient temperature: 0 to 40C
Humidity: 20 to 80%RH at constant temperature
Free from exposure to water, oil, or dust
Free from excessive vibration (Vibration acceleration: 4.9 m/s2 [0.5
G] or less)
Free from large electrical noise (plasma)
Flatness for installation is 0.5 mm or less
4.4.5
Controller and Programming Pendant

The controller and the programming pendant are not explosion-proof
(the explosion- proof programming pendant is available as an
option). Never install the controller and the programming pendant
that are not explosion-proof in a hazardous location.
Keep a minimum space of 60 cm around the controller for maintenance. When the sufficient space is not available, provide equipment for maintenance such as a drawing-out system.
An exhaust fan is provided on the back of the controller. Keep
enough space behind the controller so that air can be exhausted
properly.
Do not install the controller and programming pendant close to any
noise source such as the power supply for other devices.
Install the 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.
4.4.6
Safety Devices
The standard safety devices are listed below. Refer to the instructions for
connecting safety devices required for your system application.
Install each device considering each function.
Emergency stop switches
Safety plugs
Limit switches
Flashing lights
Indicator lamps
Photoelectric intrusion detecting switches
4-10
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5.1
System Configuration
Manipulator
fig. 5-1(a) System Configuration (MPX3500-*0*) and fig. 5-1(b)
System Configuration (MPX3500-*1*) show the system configuration of
the MOTOMAN-MPX3500.
5.1
Manipulator
The explosion-proof manipulator can be installed in hazardous locations
such as in the painting booth. For painting, a spray gun is mounted on the
end of the wrist with special fixtures.
fig. 5-2(a) Dimensions and P-point Maximum Envelope (MPX3500-*0*) "
and fig. 5-2(b) Dimensions and P-point Maximum Envelope (MPX3500*1*) show the dimensions and the range of motion of the MPX3500. The
manipulator is driven by the servo motors in vertically articulated operation
mode with 6 degrees of freedom on the manipulator base. The motion of
the manipulator is made by six axes:
The three main axes are used for positioning the spray gun: the S-axis
which turns the arm, the L-axis which moves the arm left and right, and the
U-axis which moves the arm up and down.
The three wrist axes are used for changing the direction of the spray gun:
the R-, B-, and T-axes.
The range of motion shown in fig. 5-2(a)and fig. 5-2(b) is that of the wrist
axis center P-point that is made by the combination of the motions of the
three main axes.
DANGER
When taking safety precautions, consider the range of motion of the
manipulator shown in fig. 5-2(a)and fig. 5-2(b).
5-1
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5.1
Manipulator
Fig. 5-1(a): System Configuration (MPX3500-*0*)
Non-Hazardous Location
Hazardous Location
7
Program
selector
(optional)
Conveyor switch
(optional)
4
Air supply
(0.35MPa-0.65MPa)
Intrincical cable
1
Manipulator
9
Solenoid valve
(optional)
3
Paint unit
8
Master valve
Pressure switch unit
Programming Pendant
(not explosion proof)
VIGOGREASE
RE0
OUT
(PP)
Power supply
3-phase AC200/220V
50/60Hz
NJ1530

ORDER
NO.
NJ1530
MOTOMAN
MODEL
MOTOMANTYPE
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
MADE IN JAPAN
NJ3247
Robot
controller
(DX200)
Grounding resistance
100 or less
Programming Pendant
Explosion proof
(optional)
Dedicated cables (1 cable)

*Cable for painting machine)
(optional)
(PP)
5-2
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5.1
Manipulator
Fig. 5-1(b): System Configuration (MPX3500-*1*)

Non-Hazardous Location
Hazardous Location
7
Program
selector
(optional)
Conveyor switch
(optional)
Air tube(6tubes)
Air supply
(0.35MPa-0.65MPa)
9
Solenoid valve
(optional)
Air supply
3
Paint
unit
(0.35MPa-0.65MPa)
Programming Pendant
(not explosion proof)
1
Manipulator
2
(PP)
Robot
controller
(DX200)
8
Master valve
Pressure switch unit
Power supply
VIGOGREASE
RE0
OUT
3-phase AC200/220V
50/60Hz

ORDER
NO.
NJ1530
MOTOMAN
TYPE
MOTOMANMODEL
PAYLOAD
ORDER NO.
kg
MASS
kg
DATE
SERIAL NO.
MADE IN JAPAN
Programming Pendant
Explosion proof
(optional)
(PP)
Grounding resistance
100 or less
Dedicated cables (1 cable)

*Cable for painting machine)
(optional)
5-3
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5.1
Manipulator
Fig. 5-2(a): Dimensions and P-point Maximum Envelope (MPX3500-*0*)

150
R270
35
25
150
L-axis range of motion: -65 to +115
2700
P-point maximum
envelope
180
1400
450
1950
1142
90
1300
11
5
65
10
65
0
14
98.7
P-point
550
37
33
59.5
800
65
1358
S-axis range of motion:35 to +150
Limited range of motion within ( )
566
130 130 130
2447
517
222
836
2700
862
2395
17.5 dia. (8 holes)
3120.1
250
250
277 0.1
116 0.1
3120.1
277 0.1
25
365 0.1
2 12H7 dia. (2 holes)
Manipulator Base Dimensions
Units: mm
5-4
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5.1
Manipulator
Fig. 5-2(b): Dimensions and P-point Maximum Envelope (MPX3500-*1*)
L-axis range of motion: -65 to +115
P-point maximum
envelope
P-point
S-axis range of motion:35 to +150

Limited range of motion within ( )
17.5 dia. (8 holes)
2 12H7 dia. (2 holes)
Manipulator Base Dimensions
Units: mm
5-5
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5.2
5.2
Robot Controller
Robot Controller
The robot controller has a built-in microcomputer that controls all motion of
the robot by saving motion signals when teaching and sending these
signals to the manipulator. The power unit that supplies power to the
manipulator is also built into the robot controller.
DANGER
The power supply of the robot controller is 200/220 VAC. Be sure

to turn OFF the primary power supply of the controller before
starting maintenance.
Failure to observe this warning may result in electric shock.
5.3
Pressure Switch Unit

The pressure switch unit supplies protective air or gas to the manipulator
to prevent explosive gas from entering the manipulator. Usually, the unit is
attached to the side of the robot controller.
The circuit diagram and dimensions are shown in fig. 5-3 Pressure
Switch Unit Air Circuit and fig. 5-4 Pressure Switch Unit External View
. Set the air pressure so that the pressure shown on the pressure gauge
of each pressure reducing valve will be within the pressure ranges shown
in fig. 5-4.
Between the manipulator and the pressure switch unit, the distance of up
20 m is allowed.
It is very dangerous to disassemble/remove the pressure switch unit or to
operate a robot in the explosive environment after removing the pressure
switch unit.
CAUTION
The pressure switch unit is used to provide a pressurized explosionproof barrier for the manipulator. Because the barrier is only ensured
when the air supply is within the recommended pressure range, a lower
air pressure will reduce the barriers efficiency, and a higher air
pressure will damage the pneumatic unit. Be sure to keep the air
pressure within the specified range.
5-6
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5.4
Tubes
Intrnsically safety Terminal Box
Fig. 5-3: Pressure Switch Unit Air Circuit
Manipulator
Solenoid Valve
to control pressure
SV1
Operating pressure
reducing Valve
Industorial compressed air
Master Valve
(0.01 to 0.02MPa)
AV1
Purging pressure
reducing Valve (0.28 to 0.3MPa)
Solenoid Valve for

switching operating/purging pressure
To manipulator (16 dia. tube)

M3X6
4(A)
2(B)
Fig. 5-4: Pressure Switch Unit External View
M3X6
Pressure reducing valve for purging air:

0.28 - 0.30 [MPa]
Industorial compressed air
0.35 - 0.65 [MPa]
Pressure reducing valve for the operation pressure

0.01 - 0.02 [MPa]
From manipulator (16 dia. tube)
5.4
Tubes
For the tube, please use nylon (16 dia.) tube.
Daily inspection is requested for the tubes used for supplying paints,
thinner, and air (excluding the tube for supplying protective gas into the
manipulator). Replace them periodically.
5.5
O-Ring and X-Ring in the Wrist

Periodically replace the O-ring and X-ring in the wrist. Contact your
Yaskawa representative to replace the ring.
5-7
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6
6.1
Connection
Wiring
Connection
6.1
Wiring
WARNING
Ground resistance must be 100 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 with heat insulating material, and avoid
multiple cabling.
Failure to observe this caution may result in burn caused by cable heat
emission failure.
6.1.1
Grounding
Follow the local regulations for ground line size. A line of 5.5 mm2 or more
with round crimping terminal is highly recommended.
Refer to fig. 6-1 Grounding Method .
NOTE
Do not use this line sharing with other ground lines or

grounding electrodes for other electric power, motor
power, welding devices, etc.
Where metal ducts, metallic conduits, or distributing racks
are used for cable laying, ground in accordance with Electric Equipment Technical Standards.
The grounding methods differ depending on the system application. Refer

to the connection instructions that are provided separately.
6-1
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6.1
Connection
Wiring
Fig. 6-1: Grounding Method
VIGOGREASE
RE0
OUT
J1
806-
5.5mm or more
N
VIGOGREASE
RE0
OUT

ORDER
NO.
NJ1530
Screw M8(for grounding)

(Delivered with the Manipulator)
MOTOMAN
MODEL
MOTOMANTYPE
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
MADE IN JAPAN
NJ3247
View from A
MPX3500-*0*
Screw M8 (for grounding)

(Delivered with the Manipulator)
N
J1
806 -
5.5mm or more
B
ESAERGOGIV
0ER
TUO
VIGOGREASE
RE0
OUT
VIGOGREASE
RE0
IN

ORDER
NO.
NJ1530
MASS
PAYLOAD
kg
ORDER NO.
View from B
MOTOMAN
MODEL
MOTOMANTYPE
kg
DATE
SERIAL NO.
MADE IN JAPAN
NJ3247
MPX3500-*1*
6-2
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6.2
6.2
Connection
Cable Connection
Cable Connection
Refer to the DX200 Instruction Manual for the connection of the power
cable and the intrinsically safe cable to the DX200. The air hose 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) or to be put either in the ditch on the floor and be
covered with the metal plate or through the metal pipe.
Fig. 6-2(a): Manipulator Internal Cable Connection (MPX3500-*0*)
Grounding line connecting tap

Use following parts for grounding the power cable:
-Cross-recessed head machine screws M5
-Plain washers
-Spring lock washers
-Hexagon socket head cap screw M6

(trivalent chromium , length: 20 mm, 8 screws)
-Conical spring washer 2H-6
(trivalent chromium , 8 washers)
-Tightening torque 10 N?m (1.0 kgf?m)
Cover
Gasket
Reference sticker
View A
2BC-F
2BC-E
2BC-D
2BC-C
2BC-B
2BC-A
1BC-CN1
1BC-CN2
1BC-CN3
1BC-CN4
1BC-CN5
1BC-CN6
3BC-CN1
3BC-CN2
3BC-CN3
3BC-CN4
3BC-CN5
3BC-CN6
4BC-CN1
4BC-CN2
4BC-CN3
Channel Position
6-3
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6.2
Connection
Cable Connection
Fig. 6-2(b): Manipulator Internal Cable Connection (MPX3500-*1*)

-Tightening torque 10 N m (1.0 kgf m)
Cover
Grounding line connecting tap

Use following parts for grounding the power cable:
-Cross-recessed head machine screws M5
-Plain washers
-Spring lock washers
Gasket
Reference sticker
View B
B
2BC-F
2BC-E
2BC-D
2BC-C
2BC-B
2BC-A
1BC-CN1
1BC-CN2
1BC-CN3
1BC-CN4
1BC-CN5
1BC-CN6
3BC-CN1
3BC-CN2
3BC-CN3
3BC-CN4
3BC-CN5
3BC-CN6
4BC-CN1
4BC-CN2
4BC-CN3
Channel Position
6-4
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6.2
Connection
Cable Connection
Fig. 6-3: Power Supply Cable Connection to the DX200

Gasket
DX200
Cover
X11
1BC-1,2,3,4,5,6
Manipulator
1BC-1
1BC-2
X11
1BC-3
1BC-4
Encorder Cable
Cable gland
1BC-5
1BC-6
Connect to the grounding tap

2BC-F
X21
2BC-A,B,C,D,E,F X21
2BC-E
2BC-D
2BC-C
Power Cable
Cable gland
2BC-B
2BC-A

XS1
3BC-1
XS1
3BC-1,2
Electro-pheumatic Valve cable

(Option)
Cable gland
3BC-2
XS2
XS2
3BC-3,5
3BC-3
CC-Link,Device-Net,Ethernet Cable
(Option)
Cable gland
J31
EX-X12
4BC-1,2
3BC-5
4BC-1
4BC-2
Encorder Cable
(Option) Cable gland
J32
EX-X22
4BC-3,4

4BC-3
4BC-4
Power Cable
(Option) Cable gland
X21
X11
For the cable gland, it is required to use the specified one for the
explosion-proof certification.
It is highly recommend to use the cable gland prepared by Yaskawa which
is the exclusively one.
Also, please do not reassemble or remodel the cable gland.
Contact your Yaskawa representatives when there is an abnormality to it.
6-5
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6.2
Connection
Cable Connection
Fig. 6-4: Air Hose Connection

Union
Elbow
Union
Elbow
Insert
MPX3500-*0*
Elbow
Union
Union
Elbow
Insert
MPX3500-*1*
6-6
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6.3
Connection
Internal Connections
Fig. 6-5: Pressure Switch Unit Connection to Intrinsically Safe Terminal

Block and Barrier
1Intrinsically safe cable
Cable type: UL2586-SB ,
1.25 mm2, 2-core
3) Controller side: Crimped terminals

For connecting the intrinsically safe cable
to the relay bariier in the DX200
Cable connection
- For terminal block P1 to N3
Manipulator side
Intrinsically safe
terminal block
P1
Cotroller (DX200)
N1
N1
P2
P2
N2
N2
P3
P3
N3
N3
4.4 max
5.3 min
6 max
P1
3.2 dia. min
For connecting the intrinsically safe cable

to the insulation bariier in the DX200
- For terminal block 1 to 3
2.3
2) Manipulator side :Crimped terminals

For connecting the intrinsically safe
cable to the intrinsically safe terminal
block
- For terminal block P1 to 2
4 max
1.25AF2.3B(JST Made)
(Recommended terminal)
7.8 max
3.5 min
0.8
10
3.7 dia. min
6.3
Internal Connections
The fig. 6-1(a) Internal Connection Diagram and fig. 6-1(b) Internal
Connection Diagram show the internal connections.
6-7
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6.3 Internal Connections
Fig. 6-1(a): Internal Connection Diagram
0BT-SL
DX200
BAT-SL
BATTERY
BAT-SL
0BT-SL
CN1-1
CN1-2
1BC(12X6)
CN1-1
CN1-2
DATA+1
DATA-1
P
P
CN1-3
CN1-4
CN1-5
P
P
CN2-1
CN2-2
CN1-3
CN1-4
CN1-5
CN2-1
CN2-2
+5V-1
0V-1
FG1
DATA+2
DATA-2
P
P
CN2-3
CN2-4
CN2-5
P
P
CN3-1
CN3-2
CN2-3
CN2-4
CN2-5
CN3-1
CN3-2
+5V-2
0V-2
FG2
DATA+3
DATA-3
No.1CN
CN -1
-2
-6
-5
-4
-9
-10
DATA+1
DATA-1
BAT
OBT
+5V
0V
FG1
No.2CN
CN- B
A
OBT
BAT
No.3CN
CN -1
-2
-6
-5
-4
-9
-10
DATA+2
DATA-2
BAT
OBT
+5V
0V
FG2
No.4CN
CN- B
A
OBT
BAT
No.5N
CN-1
-2
-3
-4
P
P
CN3-3
CN3-4
CN3-5
P
P
CN4-1
CN4-2
CN3-3
CN3-4
CN3-5
+5V-3
0V-3
FG3
CN4-1
CN4-2
DATA+4
DATA-4
CN4-3
CN4-4
CN4-5
+5V-4
0V-4
FG4
CN5-1
CN5-2
DATA+5
DATA-5
CN5-3
CN5-4
CN5-5
+5V-5
0V-5
FG5
CN6-1
CN6-2
DATA+6
DATA-6
CN6-3
CN6-4
CN6-5
+5V-6
0V-6
FG6
CN-1
-2
-3
No.52CN
No.6CN
CN-1
-2
-3
-4
P
P
CN4-3
CN4-4
CN4-5
P
P
CN5-1
CN5-2
CN-1
-2
-3
No.53CN
No.7CN
CN-1
-2
-3
-4
P
P
CN5-3
CN5-4
CN5-5
P
P
CN6-1
CN6-2
CN-1
-2
-3
No.54CN
No.8CN
CN-3
-4
PG
S-AXIS
PG
L-AXIS
DATA+3
DATA-3
BAT
OBT
P
P
P
+5V
0V
FG3
P
P
0BT-UR
BATTERY
P
P
+5V
0V
FG4
0BT-BT
BATTERY
0BT-BT
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
P
P
P
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
P
P
P
CN6-1
CN6-2
CN6-3
CN6-4
P
P
3BC-1
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
S1
C1
S2
C2
S3
C3
3BC-2
CN2-1
CN2-2
CN2-3
CN2-4
CN2-5
CN2-6
V1
V2
V3
M1
M2
M3
3BC-6
CN6-1
CN6-2
CN6-3
CN6-4
BAT-UR
E
BASE
E E E E
BAT-BT
No.27CN
CN-1
-2
-3
-4
DATA+4
DATA-4
BAT
OBT
PG
U-AXIS
No.29CN
CN-1
-2
-3
-4
P
P
+5V
0V
FG5
DATA+6
DATA-6
+5V
0V
FG6
DATA+5
DATA-5
BAT
OBT
CN-1
-2
-3
No.30CN
PG
B-AXIS
PG
T-AXIS
+5V
0V
FG5
OBT
BAT
No.31CN
CN-1
-2
-3
-4
R-AXIS
OBT
BAT
No.28CN
DATA+5
DATA-5
BAT
OBT
PG
+5V
0V
FG4
CN-1
-2
-3
DATA+6
DATA-6
BAT
OBT
+5V
0V
FG6
CN-1
-2
-3
No.32CN
BAT-UR
0BT-UR
CN-1
-2
-3
No.55CN
DATA+3
DATA-3
BAT
OBT
+5V
0V
FG3
OBT
BAT
DATA+4
DATA-4
BAT
OBT
P
CN6-3
CN6-4
CN6-5
No.26CN
CN1-1
-2
-6
-5
-4
-9
-10
OBT
BAT
BAT-BT
E E E E E E
E E E E
MANIPULATOR
P
P
P
P
P
P
CN-1
-2
-3
-4
-5
-6
-7
No.58CN
S1
C1
S2
C2
S3
C3
E
CN-1
-2
-3
-4
-5
-6
No.59CN
V1
V2
V3
M1
M2
M3
P
P
P
P
P
P
No.63CN
B1+
B1B2+
B2-
P
P
CN-1
-2
-3
-4
-5
No.39CN
No.56CN
CN-1
-2
-3
-4
-5
-6
-7
S1
C1
S2
C2
S3
C3
E
No.57CN
CN-1
-2
-3
-4
-5
-6
V1
V2
V3
M1
M2
M3
S1
C1
S2
C2
S3
C3
P
P
P
Electro
pneumatic
V1
V2
V3
M1
M2
M3
P
P
P
Spare cable
No.62CN
B1+
B1B2+
B2-
CN-1
-2
-3
-4
P
P
-5
B1+
B1B2+
B2-
B1+
B1B2+
B2-
P
P
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN4-7
CN4-8
CN4-9
P
P
P
P
3BC-4
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
CN4-7
CN4-8
CN4-9
ET1
ET2
ET3
ET4
ET5
ET6
ET7
ET8
E
P
P
P
P
3BC-3
P
CN3-1
CN3-2
CN3-3
CN3-4
DA
DB
DG
SLD
No.19CN
CN-1
-2
-3
-4
CHANH
CHANL
V+
VSLD
No.21CN
CN-1
-2
-3
-4
-5
3BC-5
P
P
CN5-1
CN5-2
CN5-3
CN5-4
CN5-5
No.20CN
CN-1
-2
-3
-4
-5
-6
-7
-8
-9
P
P
ET1
ET2
ET3
ET4
ET5
ET6
ET7
ET8
E
P
P
P
P
No.41CN
CN-1
-2
-3
-4
-5
-6
-7
-8
-9
ET1
ET2
ET3
ET4
ET5
ET6
ET7
ET8
E
DA
DB
DG
SLD
No.40CN
CN-1
-2
-3
-4
DA
DB
DG
SLD
CHANH
CHANL
V+
VSLD
No.42CN
CN-1
-2
-3
-4
-5
CHANH
CHANL
V+
VSLD
P
P
P
P
P
P
ET1
ET2
ET3
ET4
ET5
ET6
ET7
ET8
DA
DB
DG
V+
VSLD
P
P
CHANH
CHANL
V+
VSLD
Solenoid valve
Ethernet
Solenoid valve
CC-Link
Solenoid valve
Device Net
6-8
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HW1482773
6 Connection
6.3 Internal Connections
Fig. 6-1(b): Internal Connection Diagram
4BC-1
DATA+7
DATA-7
+5V-7
+5V-7
0V-7
0V-7
FG7
DATA+8
DATA-8
+5V-8
+5V-8
0V-8
0V-8
FG8
CN1-1
CN1-2
DATA+7
DATA-7
CN1-3
CN1-4
CN1-5
+5V-7
0V-7
FG7
4BC-2
CN2-1
CN2-2
DATA+8
DATA-8
CN2-3
CN2-4
CN2-5
+5V-8
0V-8
FG8
P
P
4BC-3
MU7
MV7
MW7
ME7
BA7
BB7
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
OBT-FGP1/2
BATTERY BAT-FGP1/2
OBT-FGP1/2
BAT-FGP1/2
No.22CN
CN-1
-2
-3
-4
CN-1
-2
-3
No.60CN
No.23CN
CN-3
-4
CN-1
-2
-3
No.61CN
DATA+7
DATA-7
BAT
OBT
P
P
+5V
0V
FG7
DATA+8
DATA-8
+5V
0V
FG8
No.43CN
CN-1
-2
-3
-4
CN-1
-2
-3
No.44CN
No.45CN
CN-1
-2
-3
-4
CN-1
-2
-3
No.46CN
MU7
MV7
MW7
ME7
BA7
BB7
No.24CN
CN-1
-2
-3
-4
-5
-6
MU8
MV8
MW8
ME8
BA8
BB8
No.25CN
CN-1
-2
-3
-4
-5
-6
No.47CN
47CN-1
-2
-3
-4
MU7
MV7
MW7
ME7
BA7
BB7
-1
-2
DATA+7
DATA-7
BAT
OBT
PG
FGP1-AXIS
PG
FGP2-AXIS
+5V
0V
FG7
OBT
BAT
DATA+8
DATA-8
BAT
OBT
+5V
0V
FG8
OBT
BAT
MU7
MV7
MW7
ME7
BA7
BB7
SM
YB
FGP1-AXIS
No.48CN
4BC-4
MU8
MV8
MW8
ME8
BA8
BB8
CN4-1
CN4-2
CN4-3
CN4-4
CN4-5
CN4-6
No.49CN
49CN-1
-2
-3
-4
MU8
MV8
MW8
ME8
BA8
BB8
-1
-2
MU8
MV8
MW8
ME8
BA8
BB8
SM
YB
FGP2-AXIS
No.50CN
2BC(8PX3+12PX3)
E
E-8
E-7
E-2
E-1
E-6
E-5
E-4
E-3
B-5
B-10
E-8
E-7
E-2
E-1
E-6
E-5
E-4
E-3
B-5
B-10
MU1
MU1
MV1
MV1
MW1
MW1
ME1
ME1
BA1
BB1
F-8
F-7
F-2
F-1
F-6
F-5
F-4
F-3
B-4
F-8
F-7
F-2
F-1
F-6
F-5
F-4
F-3
B-4
MU2
MU2
MV2
MV2
MW2
MW2
ME2
ME2
BA2
D-8
D-7
D-4
D-3
D-6
D-5
D-2
D-1
B-3
D-8
MU3
D-4
MV3
D-6
MW3
D-2
ME3
B-3
BA3
-5
-6
A-6
A-3
A-1
A-5
B-2
B-9
MU4
MV4
MW4
ME4
BA4
BB4
No.15CN
CN-1
-2
-3
-4
-5
-6
MU4
MV4
MW4
ME4
BA4
BB4
C-11
C-9
C-7
C-8
B-12
MU5
MV5
MW5
ME5
BA5
No.16CN
CN-1
-2
-3
-4
-5
-6
MU5
MV5
MW5
ME5
BA5
BB5
No.9CN
CN-A
-B
-C
-D
-1
-2
MU1
MV1
MW1
ME1
BA1
BB1
SM
S-AXIS
YB
No.10CN
No.11CN
CN-A
-B
-C
-D
-1
-2
MU2
MV2
MW2
ME2
BA2
BB2
SM
L-AXIS
YB
No.12CN
No.13CN
CN-1
-2
-3
-4
MU3
MV3
MW3
ME3
BA3
BB3
No.14CN
CN-A
-B
-C
-D
-1
-2
MU3
MV3
MW3
ME3
BA3
BB3
SM
U-AXIS
YB
No.51CN
A-6
A-3
A-1
A-5
B-2
B-9
C-11
C-9
C-7
C-8
B-12
No.33CN
CN-1
-2
-3
-4
-1
-2
MU4
MV4
MW4
ME4
BA4
BB4
SM
R-AXIS
YB
No.34CN
No.35CN
CN-1
-2
-3
-4
-1
-2
MU5
MV5
MW5
ME5
BA5
BB5
SM
YB
B-AXIS
No.36CN
C-6
C-4
C-2
C-5
B-11
C-6
C-4
C-2
C-5
B-11
MU6
MV6
MW6
ME6
BA6
No.17CN
CN-1
-2
-3
-4
-5
-6
MU6
MV6
MW6
ME6
BA6
BB6
No.37CN
CN-1
-2
-3
-4
-1
-2
MU6
MV6
MW6
ME6
BA6
BB6
SM
YB
T-AXIS
No.38CN
PE
6-9
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7
7.1
Basic Specifications
7.1
Table 7-1: Basic Specifications1)

Item
Type
YR-MPX3500-*0*
YR-MPX3500-*1*
Configuration
Vertically articulated
Degree of Freedom
Payload
15 kg
0.15 mm
2)
Repeatability
S-axis (turning)
Range of Motion
Maximum Speed
Allowable
Moment
+125 - - 25
L-axis (lower arm)
+140 - - 65
U-axis (upper arm)
+90 - - 65
R-axis (wrist roll)
720
B-axis (wrist pitch/yaw)
720
T-axis (wrist twist)
720
S-axis
1.7 rad/s, 100 /s
L-axis
1.7 rad/s, 100 /s
U-axis
1.9 rad/s, 110 /s
R-axis
7.8 rad/s, 450 /s
B-axis
7.8 rad/s, 450 /s
T-axis
9.6 rad/s, 550 /s
R-axis
45.8 Nm (4.67 kgfm)
B-axis
33.8 Nm (3.45 kgfm)
T-axis
10.8 Nm (1.1 kgfm)
Approx. Mass
Ambient Conditions
+25 - - 125
590 kg
Temperature
0 to + 40 C
Humidity
20 to 80 %RH (non-condensing)
Vibration Acceleration
Less than 4.91 m/s2 (0.5 G)
Others
Free from excessive electrical noise (plasma).

3.5 kVA3)
Power Capacity
1 SI units are used in this table. However, gravitational unit is used in ( ).
2 Conformed to ISO9283.
3 Differs depending on the motion pattern.
7-1
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7
7.2
7.2
Part Names and Working Axes
Part Names and Working Axes
T-
B-
Lower arm
(L-arm)
Wrist flange
S+
L-
L+
Upper arm
(U-arm)
Rotary head
(S-head)
T+
R+
R-
Wrist
B+
U+
U-
Fig. 7-1: Part Names and Working Axes
VIGOGREASE
RE0
OUT
S-
Base
ORDER
NO.
NJ1530
MOTOMAN
MODEL
MOTOMANTYPE
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
MADE IN JAPAN
NJ3247
B+
Wrist flange
U-
Lower arm
(L-arm)
R-
B-
L-
S+
Upper arm
(U-arm)
L+
T-
T+
Wrist
U+
R+
MPX3500-*0*
Rotary head
(S-head)
VIGOGREASE
RE0
OUT
S-
Base
VIGOGREASE
RE0
IN

ORDER
NO.
NJ1530
MOTOMAN
MODEL
MOTOMANTYPE
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
MADE IN JAPAN
NJ3247
MPX3500-*1
7-2
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7
7.3
7.3
Wrist Flange
Wrist Flange
The wrist flange dimensions are shown in fig. 7-2 Wrist Flange . Fitting
depth of inside and outside fittings must be 21 mm or less.
Fig. 7-2: Wrist Flange
+0.012
5.2 dia. 0
(Depth:10, 2 holes)
Tapped six holes M6

(Depth:12, Pitch:1.0)
02
.1
D
C.
ia.
140dia.
70d
116 dia. -0.035
P.
51 0.02
51 0.02
21.5 0.1
7-3
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7
7.4
7.4
System Application
System Application
The device required for the system application can be mounted on the
horizontal arm.
Observe the following restrictions.
Maximum allowable load: 5 kg
Mounting position: Refer to fig. 7-3 Device Mounting Position .
Fig. 7-3: Device Mounting Position
700 mm or less
Moment applied on U-axis:
19N m(2.0kgf m)
Allowable load:25kg or less
VIGOGREASE
RE0
OUT

ORDER
NO.
NJ1530
700 mm or less
MOTOMAN
MODEL
MOTOMANTYPE
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
MADE IN JAPAN
NJ3247
Moment applied on U-axis:

19N m(2.0kgf m)
MPX3500-*0*
Allowable load:25kg or less
VIGOGREASE
RE0
OUT
VIGOGREASE
RE0
IN

ORDER
NO.
NJ1530
MOTOMAN
MODEL
MOTOMANTYPE
MASS
PAYLOAD
kg
ORDER NO.
kg
DATE
SERIAL NO.
MADE IN JAPAN
NJ3247
MPX3500-*1*
7-4
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8
8.1
Frequent Inspections
8.1
The painting robot is a precision device using advanced technology. It is
important to frequently inspect the robot and remove any dried paint.
Conduct the daily and weekly inspections listed in table 8-1 Frequent
Inspections to ensure the long life of the robot and its performance.
For more information about the inspection items, refer to chapter 8.2
Daily Inspections .
Table 8-1: Frequent Inspections

Item
No.
Items to be
Inspected
Inspection
Daily
Manipulator
Exterior
No deformations or
cracks to the
pressurized explosionproof enclosure.
Covers are
appropriately mounted.
No other exterior
abnormality.
Smooth tuning,
horizontal, and vertical
motions of each arm.
The robots home
position does not
change.
No abnormal noise and

vibration during robot
operation.
Off or no severe wear

and tear on paint and
air supply tubes.
No excessive air
leakage from the fitting
of the motor case.
Motion
Noise and vibration

during operation
Tubes
Air leakage
Weekly Remarks
DANGER
If any deformations or
cracks are found,
immediately stop the
operation and contact
your Yaskawa
representatives.
WARNING
Do not enter the robot

working envelope.
WARNING
Do not enter the robot

working envelope.
CAUTION
Use a pair of protective

glasses to protect your
eyes against paint or
thinner that is being
removed.
CAUTION
Make sure that the air

tube is firmly inserted in
the joint. Accidental
disconnection of the air
tube may cause injury.
6
Dried paint
Remove the dried paint

on the robot.
Replace the sheet.

CAUTION
When removing the

paint with a tool, be
careful not to damage
the robot.
8-1
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8
8.1
Table 8-1: Frequent Inspections

Item
No.
Items to be
Inspected
Inspection
Daily
Pressure
Switch Unit
Pressure set value
The pressure of the

pressure reducing valve
is within the specified
range
Safety
Devices
Operation of
emergency stop
button and safety
plug.
Dried paint
1. The manipulator
stops immediately
when the
emergency stop
button is pressed.
2. The manipulator
stops immediately
when the safety
plug is pulled out.
3. Remove the
dried paint on
the emergency
stop button and the
safety plug.
1. The manipulator
stops when the
photoelectric
switch is turned
OFF.
2. Remove the dried

paint on the light
beam detector.
Operation of limit
switch.
Dried paint
1. Normal operation
of the limit switch
Operation of the gun

tilt switching
The gun tilt changes

correctly when air is
supplied.
Operation of the
shear pin system
1. The manipulator
stops immediately
when the shear pin
is sheared.
2. The test valve is

closed and the tube
is not broken.
Options
Operation of the
photoelectric
intrusion detecting
switch
Dried paint
2. Remove the
dried paint on
the limit switch.
Weekly Remarks
CAUTION
Inspect the robot while it

is in its standby position
and not in motion.
8-2
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8
8.2
8.2
Daily Inspections
Daily Inspections
Inspect the robot daily to ensure its high performance and early detection
of any abnormalities.
8.2.1
8.2.1.1
Manipulator
Visual Inspection
Before turning ON the power to the manipulator, check if any abnormality
can be found on the manipulator. Remove the jacket if it is attached.
8.2.1.2
Manipulator Motions and Noise/Vibration during Operation

Check if the manipulator home posture does not change when turning ON
the power supply using the eye mark.
Also, check for abnormal noise and vibration during operation.
DANGER
Never enter inside the safeguarding and the manipulator working
envelope after turning ON the power supply.
8.2.1.3
Tubes and Air Leakage

Check for excessive air leakage from the tubes (for air exhaust), the
couplings, and the joint fittings of the motor on each axis when the air is
supplied in the manipulator to form the anti-explosion barrier.
The actual amount of air leakage is not important if a fault in the internal
air pressure does not occur. However, if internal air pressure faults occur
frequently, check if the pressure of the air source and the pressure setting
of the pressure reducing valve are correct and if excessive air is leaking.
8.2.1.4
Dried Paint, Dust, and Dirt

Remove any dried paint on the manipulator and other devices.
Replace the vinyl sheet if any.
Replace the jacket if it is dirty.
WARNING
When using a tool to remove the dried paint, be careful not to damage
the manipulator.
8-3
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8
8.2
Daily Inspections
CAUTION
Paint stuck on the manipulator rotating parts prevents them
from turning normally and smoothly. Periodically remove the
paint on the manipulator.
A cloth that is soaked in paint thinner can be used for
cleaning the inside of the wrist, because an anti-thinner
enclosure is provided. But, be careful not to remove the
original coat of paint on the manipulator.
8.2.2
8.2.2.1

Pressure
Before moving the manipulator, check if the gauges of the pressure
reducing valves on the pressure switch unit show the pressure to be within
the specified range. (Refer to fig. 5-4 Pressure Switch Unit External
View .)
Pressure reducing valve for the operating pressure
: 0.01 to 0.02 [MPa]
Pressure reducing valvefor purging air
: 0.28 to 0.30 [MPa
8.2.3
8.2.3.1
Safety Devices
Emergency Stop Button and Safety Plug
Before operating the manipulator, check the following to make sure that
the emergency stop button and the safety plug operate correctly:
The manipulator stops immediately when the emergency stop button is
pressed.
The manipulator stops immediately when the safety plug is pulled out.
Inspect the manipulator while it is in the standby posture and not in motion
with the power supply turned ON. Repeated sudden stops while the
manipulator is in motion will damage the braking system.
Remove any dried paint on the emergency stop button and the safety
plug.
8.2.3.2
Photoelectric Intrusion Detecting Switch

Make sure that the photoelectric intrusion detecting switch operates
correctly.
Remove any dried paint on the light beam receiving section on the switch.
When the air is purging, check the air for purging.
8.2.3.3
Limit Switch
Make sure that the limit switches for positioning workpieces, starting the
robot, and return the robot to home operate correctly.
Remove any dried paint that may obstruct the robot motion.
8-4
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8
8.2
8.2.4
8.2.4.1
Daily Inspections
Options
Gun Tilt Switching
Check if the gun changes its tilt smoothly when compressed air is
supplied.
If excessive shock is applied on both ends, reduce the pressure supplied
to the actuator.
8.2.4.2
Shear Pin
Disconnect the air supply tube, and check if the shear pin breaks
immediately to shut off the
power supply to the manipulator.
Also, make sure that the air tube is not bent or crushed.
8-5
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9
9.1
Maintenance and Inspection

Inspection Schedule
DANGER
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 these safety precautions may result in death or

serious injury from unexpected turning of the manipulator's arm.
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
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.
9.1
Inspection Schedule
Conduct daily and periodic inspections to ensure the long life of the robot
and its performance.
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 given in the levels shown in table 9-1 Inspection
Schedule .
In table 9-1, the inspection items are classified into three types of
operation: operations which can be performed by personnel authorized of
the user, operations which can be performed by personnel being trained,
and operations which can be performed by service company personnel.
Only specified personnel are to do inspection work.
NOTE
The inspection interval must be based on the servo power

supply ON time.
9-1
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Table 9-1: Inspection Schedule
Filter in the motor part
9-2
Cover mounting screws
Motor connectors
Air seals for internal

pressure
S- and L-axis
internal cables
10 O-ring and X-ring

in wrist
Visual
Check for filter clogging.
Wrench
Tighten loose bolts. Replace if necessary.
Manual
Check for loose connectors.
Visual
Check for wear or tear. Replace if necessary.

See chapter 9.2.3 .
Specified
Tighten loose bolts. Replace if necessary.
Replace the cables.4)

Visual
Check the conduction between terminals.
Multi-meter Check for wear on the protective spring.
Replace the cables.4)
Replace the battery unit when the battery alarm occurs or the manipulator drove for
36000H.
See chapter 9.2.4 .
Manual
Visual
Check for O-ring and X-ring. (3000 H cycle).

Replace O-ring and X-ring. (6000 H cycle).

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Battery in manipulator
Spanner
Wrench
Visual
Check for conduction between the main connector of the base and the intermediate
Multi-meter connector with manually shaking the wire.
Check for wear on the protective spring.3)
Check for grease leakage.2)
36000H
24000H
12000HCycle
U-arm
internal cables
Visual
Service Company
Base mounting bolts
Inspection
Charge
personnel
Licensee
Operation

Inspection Schedule
S-, L-, and U-axis

motors
Method
9
9.1
6000HCycle
Schedule
1000HCycle
Item1)
Service Company
Inspection
Charge
personnel
Licensee
Operation
Specified
Method
36000H
24000H
12000HCycle
6000HCycle
Schedule
1000HCycle
Item1)
Grease
gun
Check for malfunction. (Replace if necessary.)

Replenish grease5) (6000H cycle). (See chapter 9.2.1 .)
Replace grease5) (12000H cycle). (See chapter 9.2.1 .)
12 R-, B-, and T-axis

speed reducers
Grease
gun

Replenish grease5) (6000H cycle).(See chapter 9.2.1 .)
Grease
gun

Replenish grease*5) (6000H cycle).(See chapter 9.2.1 .)
9-3
14 Explosion-proof devices
15 Pressure switch unit

16 Overhaul
Confirm that the pressure switch, the master valve, and the explosion-proof system
operate correctly.
(Replace if necessary.)See chapter 9.4.
Confirm that the solenoid valve and the pressure reducing valve operate correctly.
Contact your Yaskawa representatives.
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1 Inspection No. correspond to the numbers in fig. 9-1(a) Inspection Parts and Inspection Numbers (MPX3500-*0*) and fig. 9-1(b) Inspection Parts and Inspection
Numbers (MPX3500-*1*) .
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 detector side for each axis from the motor. Otherwise, the home position data may be lost. (Refer to chapter 9.5.1 Encoder Connector with Warning Label .)
4 Internal cables to be replaced at 24000H inspection
5 For the grease, refer to table 9-2 Inspection Parts and Grease Used .

Inspection Schedule
9
9.1
11 S-, L-, and U-axis

speed reducers
13 Wrist gear
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Table 9-1: Inspection Schedule
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Inspection Schedule
9
9.1
Fig. 9-1(a): Inspection Parts and Inspection Numbers (MPX3500-*0*)
MODEL
MOTOMANTYPE
SERIAL NO.
ORDER NO.
PAYLOAD
kg
DATE
MASS
MOTOMAN

MADE IN JAPAN
kg
NJ3247
5 3
5 3
5 3
5 3
15
14
RE0
OUT
1 4
10
5 3
VIGOGREASE
ORDER
NO.

NJ1530
5 3
5 3
1 4
11
10
1 4
7
6
10
5 3
5 3
5 3
15
4
13
5 3
9 12
IN
RE0
VIGOGREASE
9-4
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9
9.1

Inspection Schedule
Fig. 9-1(b): Inspection Parts and Inspection Numbers (MPX3500-*1*)
10 1 4
1 4
10
3 5
3 5
3 5
3 5
1 4
3 5
NO.

MADE IN JAPAN
NJ3247
NJ1530
DATE
ORDER NO.
MODEL
MOTOMANTYPE
SERIAL NO.
IN
RE0
VIGOGREASE
PAYLOAD
kg
MASS
MOTOMAN
kg

ORDER
RE0
OUT
VIGOGREASE
15
2
11
10
3 5
13
9 12
15
3 5
3 5
14 3 5
IN
RE0
VIGOGREASE
3 5
Table 9-2: Inspection Parts and Grease Used

No.
10
12
11
Grease Used
Inspected Parts
VIGO grease RE No. 0
S-, L-, U-, R-, B-, and T-axis

speed reducers
Alvania EP grease 2
Wrist gear
9-5
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9
9.2
9.2
9.2.1

Maintenance for Manipulator
Grease Replenishment/Replacement
table 9-1(a) Inspection Parts and Inspection Numbers (MPX3500-*0*)
and table 9-1(b) Inspection Parts and Inspection Numbers (MPX3500*1*) show the location of the components of the manipulator.
Replenish or replace the grease for the following sections:
I)
Wrist gears
II)
S-, L-, and U-axis speed reducers
III) R-, B-, and T-axis speed reducers

IV) U-arm end shaft gear
9.2.1.1
Wrist Gears
Remove the plugs and apply Alvania EP grease 2 on the gear teeth of
gears R1, B1, B2, T1, T2, and T3 by using a grease gun. Apply seal tape
on the thread part of each plug, then reinstall the plugs. (Each plug must
be tightened with the specified tightening torque.)
Fig. 9-2: Wrist Gears
-Tightening torque 2.4 Nm (0.24 kgfm)
Plug
-Hexagon socket head plug PT1/2
-Tightening torque 39 Nm (4 kgfm)
Cover
R- axis gear
T- axis gear
B- axis gear
Grease inlet
B-axis gear
T-axis gear
T-axis gear
Grease inlet
Plug
-Hexagon socket head plug PT1/2
-Tightening torque 39 Nm (4 kgfm)
Grease gun
9-6
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9
9.2
9.2.1.2

S-, L-, and U-Axis Speed Reducers
Grease Replenishment
1. Remove the plug on the So (Lo, Uo) exhaust port.
NOTE
If grease is injected with the plug (So, Lo, Uo) on, the
grease will go inside the motor and may cause a damage.
Make sure to remove the plug (So, Lo, Uo) before the
grease injection.
2. Remove the plug 1/8 on the Si (Li, Ui) grease inlet and install the
grease zerk A-PT1/8. Inject grease by using a grease gun.
Grease type:
Amount of grease:
S-axis: 2000 cc (1740 g)
(4000 cc (3480 g) for the 1st supply)
L-axis: 2000 cc (1740 g)
U-axis: 800cc (720 g)
Air supply pressure of grease pump:
0.3 MPa or less
Grease injection rate:
8 g/s or less
3. Move S-axis (L-axis, U-axis) for a few minutes to discharge excessive

grease.
4. Remove the grease zerk on the Si (Li, Ui) grease inlet. Wipe the So
(Lo, Uo) exhaust port and the Si (Li, Ui) grease inlet. Apply seal tape
on the thread part of each plug, and reinstall the plugs on the So (Lo,
Uo) exhaust port and the Si (Li, Ui) grease inlet.
9-7
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9
9.2

Grease Replacement
1. Remove the plug on the So (Lo) grease exhaust port.
NOTE
If grease is injected with the plug (So, Lo, Uo) on, the
grease will go inside the motor and may cause a damage.
Make sure to remove the plug (So, Lo, Uo) before the
grease injection.
2. Remove the plug 1/8 on the Si (Li, Ui) grease inlet and install the
grease zerk A-PT1/8. Inject grease by using a grease gun.
Grease type:
Amount of grease:
S-axis: 2000 cc (4872 g)
L-axis: 5600 cc (4872 g)
U-axis: 2300 cc (2112 g)
0.3 MPa or less
8 g/s or less
3. The grease replacement is completed when new grease appears in

the So (Lo, Uo) exhaust port. The new grease can be distinguished
from the old grease by color.
4. Move S-axis (L-axis, U-axis) for a few minutes to discharge excessive
grease.
5. Remove the grease zerk on the Si (Li, Ui) grease inlet. Wipe the So
(Lo, Uo) exhaust port and the Si (Li, Ui) grease inlet. Apply seal tape
on the thread part of each plug, and reinstall the plugs on the So (Lo,
Uo) exhaust port and the Si (Li, Ui) grease inlet. Reinstall the cover on
each axis motor side.
NOTE
If the plug (So, Lo, Uo) is installed while the grease is being
exhausted, the grease will go inside the motor and may
cause a damage. Ensure that the grease has been completely exhausted before installing the plug (So, Lo, Uo).
9-8
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9
9.2

Fig. 9-3: S-Axis Speed Reducer

Grease exhaust port (S-axis head)
(Hexagon socket head plug PT3/8)
Grease inlet (S-axis base)

MPX3500-*0*
Grease inlet (S-axis base)


MPX3500-*1*
Fig. 9-4: L-Axis Speed Reducer

Grease inlet (L-arm)

MPX3500-*0*
MPX3500-*1*
9-9
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9.2

Fig. 9-5: U-Axis Speed Reducer

Grease exhaust port (Casing)
Grease inlet (L-arm)

MPX3500-*0*
MPX3500-*1*
9-10
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9
9.2
9.2.1.3

R-, B-, and T-Axis Speed Reducers
Grease Replenishment
1. Remove the plug on the Ro (Bo, To, P1o, P2o) exhaust port.
NOTE
If grease is injected with the plug (Ro, Bo, To, P1o, P2o) on,
the grease will go inside the motor and may cause a damage. Make sure to remove the plug (Ro, Bo, To, P1o, P2o)
before the grease injection.
Note that grease replacement is not necessary for R-, B-,
and T-axes.
2. Remove the plug on the Ri (Bi, Ti) grease inlet, and install the grease
zerk PT1/8. Inject grease by using a grease gun.
Grease type:
Amount of grease:
R-axis: 25 cc (22 g)
B-axis: 25 cc (22 g)
T-axis: 20 cc (17 g)
0.3 MPa or less
8 g/s or less
3. Move R-axis (B-axis, T-axis) for a few minutes to discharge excessive

grease.
4. Remove the grease zerk on the Ri (Bi, Ti) grease inlet. Wipe the Ro
(Bo, To) exhaust port and the Ri (Bi, Ti) grease inlet. Apply seal tape
on the thread part of each plug, and reinstall the plugs on the Ro (Bo,
To) exhaust port and the Ri (Bi, Ti) grease inlet.
5. Install the cover and tighten each screw with the specified tightening
torque.
9-11
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9.2

Fig. 9-6: R-, B-, and T-axes Speed Reducer
Grease inlet (P2)

Hexagon socket head plug PT1/8)
Grease inlet (P1)
Grease inlet (T-axis)
Grease exhaust port (P2)

Grease exhaust port (T-axis)
Grease inlet (B-axis)

Grease exhaust port (B-axis)

Grease inlet (R-axis)

Grease exhaust port (R-axis)


Grease exhaust port (T-axis)
Grease inlet (P2)

Grease inlet (P1)
Grease inlet (T-axis)
Grease exhaust port (B-axis)

Grease inlet (B-axis)

Grease exhaust port (R-axis)

Grease inlet (R-axis)

MPX3500-*0*
MPX3500-*1*
9-12
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9
9.2
9.2.2

Inspection of Wrist Gear and Bearing

Check if three wrist axes move smoothly.
If any of the axes does not move smoothly, the wrist should be removed
and disassembled for investigation of the cause such as detective
bearing, gear or sealing. Contact your Yaskawa representative.
CAUTION
To remove the wrist from the U-arm, firmly hold the wrist and remove
the fixing bolt. If not, the wrist may fall down when the fixing bolt is
removed.
9.2.3
9.2.3.1
Inspection of Air Sealing for Internal Air Pressure

Gasket on the Motor Case
a)
S-, L-axes
Remove the mounting bolts on the motor case and check the gasket
where the case is mounted.
Excessive oil contained in the air used to keep the internal pressure can
damage the gasket, which result in air leakage. Replace the gasket if air
leakage is found.
Fig. 9-7: S- and L-Axis Motor Gasket
Motor cover

(trivalent chromium ,length: 25 mm, 21 screws)
(trivalent chromium , 21 washer)
Tightening torque 10 Nm (1.0 kgfm)
Motor cover
Gasket
Gasket
/2:
/2:
9-13
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9
9.2

Fig. 9-8: L-Arm Motor Gasket

(trivalent chromium, length: 25 mm, 12 screws)
(trivalent chromium, 12 wahers)
Tightening torque 10 N?m (1.0 kgf?m)
Gasket
Gasket
Cover
Cover

(trivalent chromium,
length: 25 mm, 18 screws)
Gasket
Cover

Cover
Gasket
MPX3500-*1*
MPX3500-*0*
9-14
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9
9.2

Fig. 9-9: U-Axis and U-Arm Motor Gasket

(trivalent chromium, 16 washers)
Motor cover
Motor cover
Gasket
Gasket
MPX3500-A0*
MPX3500-A1*
9-15
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9
9.2

b)
Base
Remove the cover on the backside of the base, and check for wear and
tear on the rubber gaskets.
Fig. 9-10: Rubber Gaskets on the Base
Cover
Gasket
Gasket
Cover

Tightening torque 10 N m (1.0 kgf m)

Tightening torque 10 N m (1.0 kgf m)
9-16
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9
9.2
9.2.4

Battery Replacement
Two batteries are installed in the locations shown in fig. 9-11 Battery
Location .
Battery : HW1470715-*
If a battery alarm occurs in the DX200, replace the battery in the following
procedure.
Fig. 9-11: Battery Location
Battery

(length: 16 mm, 2 screws)
Cover
Gasket
Cover

9-17
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9
9.2

Fig. 9-12: Battery Connection

Battery for S-, L-axes
bofore replacement
See step 6 below

See step 7 below
BAT1
OBT1
b BAT1
a OBT1
BAT1
OBT1
See step 4 below

See step 6 below
See step 7 below
BAT4
OBT4
BAT4
OBT4
BAT
OBT
Battery for U-, R- axes

bofore replacement
New battery board
See step 5 below

b BAT3
a OBT3
See step 4 below
See step 6 below

See step 7 below
BAT4
OBT4
BAT4
OBT4
BAT
OBT
Battery for B-, T-axes

bofore replacement
b BAT5
a OBT5
BAT
OBT
See step 4 below

See step 6 below
See step 7 below
BAT4
OBT4
BAT4
OBT4
Battery for Pomp1,2 (option)

bofore replacement
See step 5 below
New battery board
b BAT7
a OBT7
See step 4 below
BAT
OBT
a: Crimped contact-pin (pin)

b: Crimped contact-pin (socket)
9-18
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9
9.2

1. Turn OFF the power to the DX200.

2. Detach and pull out the connector base from the base.
3. Remove the battery mounting screws.
4. Remove the electrical tape protecting connection part of the battery in
the manipulator.
5. Connect two new batteries.
6. Remove the old batteries.
NOTE
Be sure to connect the new batteries before disconnecting

the old one so that the data does not disappear.
7. Protect the connection part of the battery in the manipulator with

electrical tape.
8. Insert the battery screws in the mounting holes on the connector base,
and fix the connector base on the base.
9-19
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9
9.3
9.3

Inspection of the Pressure Switch Unit
Inspection of the Pressure Switch Unit

Before inspection, please turn OFF the power supply to the DX200 and
check that no explosive atmosphere exist around it.
9.3.1
Solenoid Valve
Check if the air purge starts right after turning ON the power to the DX200
and if it ends approximately four minutes later.
9.3.2
Pressure Reducing Valve

Measure the air pressure for the pressure switch unit with a pressure
gauge. Remove the test plug or the relief valve on the pressure switch
unit and connect the gauge. The air pressure must always be from 0.01
MPa to 0.02 MPa under normal conditions and from 0.28 MPa to 0.30
MPa when purging.
9.4
9.4.1
Inspection of Explosion-Proof Devices

Remove the front cover of the pressure switch unit box and check the
conduction of the pressure switches (monitor the low pressure side).
Connectors P1 and N1 of the pressure switch unit must be [ON] when the
air is being supplied and [OFF] when the air is not being supplied.
(Connect P1 to +, and N1 to - before checking the conduction.)
CAUTION
Be sure to turn OFF the power to the DX200 before inspecting the
pressure switch.
Do not touch the pressure setting dial on the pressure switch during an
inspection. Changing the setting prevents the correct pressure from
being detected.
9.4.2
Master Valve
While the air is being supplied from the pressure switch unit, check if the
air purge starts right after the power to the DX200 is turned ON. Also,
check if the air goes out of the two air outlets for the master valve during
the air purge.
9.4.3
Pressurized Anti-Explosion Barrier

While the air is being supplied from the pressure switch unit, check if the
air purge starts right after the power to the DX200 is turned ON and if it
ends approximately four minutes later.
Also, check the following:
a)
The alarm AIR PRESSURE ERROR occurs immediately

after the air supply from the pressure switch unit is stopped
and the power supply to the DX200 is turned ON.
b)
The alarm AIR PRESSURE ERROR occurs when the air

supply from the pressure switch unit is stopped during air
purging.
9-20
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9.5
9.5
9.5.1

Notes for Maintenance
Encoder Connector with Warning Label

Remove the old battery after connecting the new one so that the encoder
absolute data does not disappear.
9.5.1.1
S-, L-, and U-Axis Motors

The connectors for the battery are prepared on each of the S-, L-, and Uaxis motors. Refer to fig. 9-13(a) Backup Battery Connection for S-, L-,
and U-Axis Motors and connect the battery according to the following
procedure.
1. Remove the mounting bolts, then remove the cap on the slot of the
motors encoder.
2. Connect the battery (JARCR-XIS01) to the connectors for battery
backup (crimped contact-pin terminals) on the inside of the cap.
3. Confirm all connectors connection after the maintenance check ends,
and remove the battery.
9.5.1.2
R-, B-, and T-Axis Motors (Option: Pomp 1,2-Axis Motor)

The connectors for the battery backup (crimped contact-pin terminals) are
prepared on the cables from the encoder connector of each of the R-, B-,
and T-axis motors (BAT and OBT are marked).
Refer to fig. 9-13(b) Backup Battery Connection for R-, B-, and T-Axis
Motors , and connect the battery according to the following procedure.
1. Connect the battery to the connectors for the battery backup of the
motor encoder connector.
2. Confirm all connectors connection after the maintenance check ends,
and remove the battery.
NOTE
9.5.2
Do not remove the battery pack in the connector base.
Filter in Motor
In case the filter in the motor cloggs, the air inside the manipulator
cannot be ventilaed smoothly.
1. Please check that the filter at the side of the motor so that it is not
clogged. (refer to fig. 9-13(a) Backup Battery Connection for S-, L-,
and U-Axis Motors and fig. 9-13(b) Backup Battery Connection for
R-, B-, and T-Axis Motors for the location of the filter.)
9-21
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9
9.5

Fig. 9-13(a): Backup Battery Connection for S-, L-, and U-Axis Motors
S-, L-, and U-Axis Motors

Filter
Power connector
Encoder connector
Encoder
Motor
Connector for the battery backup

Internal
cables
Cover mounting screw
CAUTION
Connect battery to encoder

to save the data before
removing connector.

Connect to
Caution label
Battery (+)
Battery (-)
b BAT
a OBT
Battery pack
Fig. 9-13(b): Backup Battery Connection for R-, B-, and T-Axis Motors
Encoder
Filter
Motor
Motor cable, etc.
Internal
cables

Power connector
Connect to
BAT
OBT
a
b
b BAT
a OBT
CAUTION

removing connector.
Encoder connector
Battery pack
Caution label
9-22
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9.5

Fig. 9-14: Connection Diagram
OBT
OBT
BAT
BAT
Fig. 9-15: Caution Label
CAUTION
removing connector.
9-23
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10
Recommended Spare Parts
10 Recommended Spare Parts

It is recommended that the following parts and components be kept in
stock as spare parts for the MOTOMAN-MPX3500. The spare parts list
for the MOTOMAN-MPX3500 is shown below.
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 units
NOTE
To replace parts in Rank B or Rank C, contact your

Yaskawa representative.
Table 10-1: Spare Parts for the MOTOMAN-MPX3500-*0*, -*1*

Rank
Parts Name
Type
Manufacturer
Qty
No.
Qty
Remarks
per
Unit
Battery
HW1470715-S
HW1470715-T
HW1470715-U
HW1470715-V
Yaskawa
Electric
Corporation
For S-,L-axis
For U-,R-axis
For B-,T-axis
For Pomp axis 1
and 2
Sealing compound
DB-1600
Diabond
Industry Co.,
Ltd.
200 ml -
Seal tape
TB-4501
ThreeBond Co., Ltd.
Grease
Alvania EP grease 2 Showa Shell

Sekiyu K. K.
16 kg
For bearing and

gear in the wrist
Grease
VIGO grease RE
No. 0
Yaskawa
Electric
Corporation
16 kg
For S-,L-,U-,R-,Band T-axis speed

reducers
S- and L-axis
speed reducers
HW0389760-A
Yaskawa
Electric
Corporation
U-axis speed
reducer
HW0383528-A
Yaskawa
Electric
Corporation
R- and B-axis
speed reducers
HW1383139-A
Yaskawa
Electric
Corporation
T-axis speed
reducer
HW0386187-A
Yaskawa
Electric
Corporation
For gasket
10-1
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Recommended Spare Parts
Table 10-1: Spare Parts for the MOTOMAN-MPX3500-*0*, -*1*

Rank
Parts Name
Type
Manufacturer
Qty
No.
Qty
Remarks
per
Unit
10
Wrist unit
HW1171714-A
Yaskawa
Electric
Corporation
11
S- and L-axis
AC servomotors
HW0388937-A
Yaskawa
Electric
Corporation
12
U-axis AC
servomotor
HW0388933-A
Yaskawa
Electric
Corporation
13
R-, B- and T-axis

AC servomotors
HW0388651-A
Yaskawa
Electric
Corporation
14
Pressure switch
unit
HW1271102-A
Yaskawa
Electric
Corporation
15
Internal cable
HW1171758-A
Yaskawa
Electric
Corporation
In S- and L-axes
16
Internal cable
HW1171759-A
Yaskawa
Electric
Corporation
In U-axis
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Parts List
11.1 S-, L-Axis Unit
11 Parts List
11.1
S-, L-Axis Unit

Fig. 11-1(a): S-,L-Axis Unit
1019
1020 1018
1026
1025
1002
1016
1027
1017
1006
1007
1005
1024
1023
1028
1015
1021
1003
1004
1009
1010
1029
1030
1008
1022
1001
1042
1013
1014
1012
1044
1043
1011
1039
1041
1040
1035
1038
1037
1036
1032
1031
1034
1033
11-1
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Parts List
Fig. 11-1(b): S-,L-Axis Unit
1105
1104
1046
1106
1107
1108
1119
1117
1115
1054
1047
1114
1109
1048
1047
1116
1050
1053
1046
1048
1046
1049
1110
1111
1112
1049
1051
1057
1052
1056
1114
1116
1115
1055
1113
1117
1081
1083
1082
1092
1093
1091
1094
1089
1096
1095
1090
1085
1084
1079
1080
1079
1076
1077
1078
1073
1075
1074
1066
1071
1070
1103
1101 1102
1072
1088
1086
1087
1069
1068
1067
1099
1063
1062
1058
1066
1059
1100
1061
1065
1099
1060
1057
1064
1097
1090 1086
1087
1100
1089
1084
1094
1066
1093
1085 1068
1092
1091 1075 1088
1067
1077 1078
1074
1066
1076
1117
1083
1069 1116
1082
1098
1070
1071
1079
1081
1080
1079
1073
1072
1054
1118
1056
1055
1049
1053
1065
1050
1064
1052
1051
1049
1115
1061
1063
1062
1001
1060
1045
1059
1058
1045
1046
1048
1047
1048
1047
1046
1046
1048
1047
11-2
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11
Parts List
Table 11-1: S-,L-Axis Unit

No.
DWG No.
Name
Pcs
1001
HW1100664-1
Base
1002
HW1304246-1
Spacer
1003
M6x25
(DACROTIZED coating)
Socket screw
12
1004
2H-6
Spring washer
12
1005
HW1304801-1
Bracket
1006
M6x16
Socket screw
1007
2H-6
Spring washer
1008
HW1304802-1
Bracket
1009
M6x25
Socket screw
1010
2H-6
Spring washer
1011
HW1405270-1
Cover
1012
HW1405269-1
Packing
1013
M6x20
Socket screw
1014
2H-6(DACROTIZED coating)
Spring washer
1015
HW1405273-1
Stopper
1016
M12x50(DACROTIZED
coating)
Socket screw
1017
Spring washer
1018
HW1405488-1
Cover
1019
M6x12(DACROTIZED coating)
Socket screw
1020
Spring washer
1021
HW1271102-A
Switch
1022
HW1405494-1
Bracket
1023
Socket screw
1024
Spring washer
1025
Socket screw
1026
Spring washer
1027
HW1405270-2
Cover
1028
HW1405269-1
Packing
1029
Socket screw
1030
Spring washer
1031
HW1405267-1
Cover
1032
HW1405268-1
Packing
1033
Socket screw
12
1034
Spring washer
12
1035
CD-70
Saddle
1036
M6x10
Socket screw
1037
2H-6
Spring washer
1038
M6
Washer
1039
HW1304804-1
Bracket
1040
M6x25
Socket screw
11-3
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Parts List
No.
DWG No.
Name
Pcs
1041
2H-6
Spring washer
1042
HW1304317-A
Box
1043
M6x20
Socket screw
1044
2H-6
Spring washer
1045
PT3/8
Plug
1046
HW1405964-1
Plate
1047
M16x60
Socket screw
30
1048
2H-16
Spring washer
30
1049
AE4063F0
Oil seal
1050
HW1304248-1
Shaft
1051
M6x15
Socket screw
1052
2H-6
Spring washer
1053
S135
O ring
1054
HW0389760-A
Speed reducer
1055
M12x90
Socket screw
32
1056
2H-12
Spring washer
32
1057
AS568-281
O ring
1058
RTW-130
Retaining ring
1059
6821
Bearing
1060
HW1304261-1
Gear
1061
HW0414804-1
B holder
1062
M5x16
Socket screw
16
1063
2H-5
Spring washer
16
1064
6830
Bearing
1065
STW-150
Retaining ring
1066
PT3/8
Plug
1067
M8x40
Socket screw
1068
2H-8
Spring washer
1069
HW1304262-1
Gear
1070
6012
Bearing
1071
STW-60
Retaining ring
1072
S100
O ring
1073
HW1304250-1
M base
1074
M6x30
Socket screw
1075
2H-6
Spring washer
1076
M4x12
Socket screw
1077
2H-4
Spring washer
1078
HW0404196-1
Washer
1079
HW9481329-A
Oil seal
1080
HW0415325-2
Collar
1081
SGMRV-37ANA-YRA2
Motor
1082
M12x65
Socket screw
1083
2H-12
Spring washer
1084
S105
O ring
1085
HW1304251-1
Shaft
11-4
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11
Parts List
No.
DWG No.
Name
Pcs
1086
M6x20
Socket screw
12
1087
2H-6
Spring washer
12
1088
HW1304249-1
Support
1089
M6x16
Socket screw
1090
2H-6
Spring washer
1091
HW1405275-1
Plate
1092
M4x8
Socket screw
1093
2H-4
Spring washer
1094
M4
Washer
1095
HW1200330-1
Cover
1096
HW1405274-1
Packing
1097
Socket screw
21
1098
Spring washer
21
1099
M12x90
Socket screw
10
1100
2H-12
Spring washer
10
1101
M12x55
Socket screw
1102
Spring washer
1103
HW0414814-1
Stopper
1104
HW1405281-1
Support
1105
M6x20
Socket screw
1106
2H-6
Spring washer
1107
CD-70
Saddle
1108
M6x10
Socket screw
1109
2H-6
Spring washer
1110
HW1405280-1
Cover
1111
HW1405277-1
Packing
1112
Socket screw
12
1113
Spring washer
12
1114
PT3/8
Plug
1115
M16x35(DACROTIZED
coating)
Socket screw
1116
Spring washer
1117
HW0414803-1
Stopper
1118
HW1100665-1
S head
1119
HW1100666-1
L arm
11-5
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11
Parts List
11.2 U-Axis Unit
11.2
U-Axis Unit
Fig. 11-2: U-Axis Unit
2044
2043
2054
2052
2053
2055
2051
2056
2048
2057
2045
2040
2087
2041
2042
2092
2102
2103
2099
2098
2095
2095
2096
2058
2060
2059
2088
2089
2090
2091
2097
2086
2093
2073
2094 2075
2074
2071
2070
2062
2072
2061
2064
2063
2068
2069
2100
2080 2081
2101
2045
2077
2076
2046
2060
2058
2059
2048
2078
2082
2046
2076
2085
2084
2083
2067
2066
2065
2050
2049
2047
2026 2025
2023
2079
2024
2032
2033
2028
2029
2027
2030
2036
2037
2012
2104
2018
2017
2019
2020
2021
2022
2013
2015
2034
2014
2035
2038
2014
2015
2031
2013
2039
2014
2015
2016
2013
2004
2012
2008
2006
2007
2010 2011
2010 2011
2009
2001
2003
2002
1119
2005
11-6
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Parts List
11.2 U-Axis Unit
Table 11-2: U-Axis Unit (Sheet 1 of 3)

No.
2001
DWG No.
HW1405283-1
Name
Cover
Pcs
1
2002
M620(DACROTIZED coating)
Socket screw
2003
Spring washer
2004
HW1405838-1
Cover
2005
HW1405278-1
Packing
2006
Socket screw
18
2007
Spring washer
18
2008
HW1405960-1
Stopper
2009
HW1405961-1
Stopper
2010
Socket screw
2011
Spring washer
2012
PT3/8
Plug
2013
HW1405509-1
Plate
2014
M1250
Socket screw
18
2015
2H-12
Spring washer
18
2016
HW1405285-1
Support
2017
M620
Socket screw
2018
2H-6
Spring washer
2019
FCD-51
Saddle
2020
M510
Socket screw
2021
2H-5
Spring washer
2022
M5
Washer
2023
HW1405286-1
Cover
2024
HW1405279-1
Packing
2025
Socket screw
12
2026
Spring washer
12
2027
HW1304254-1
Shaft
2028
M616
Socket screw
2029
2H-6
Spring washer
2030
G85
O ring
2031
HW0383528-A
Speed reducer
2032
M10105
Socket screw
16
2033
2H-10
Spring washer
16
2034
HW1304316-1
Gear
2035
HW0414785-1
B holder
2036
M520
Socket screw
2037
2H-5
Spring washer
2038
6818
Bearing
2039
STW-90
Retaining ring
2040
HW1100667-1
Casing
2041
HW1200331-1
Cover
2042
HW1405290-1
Packing
2043
Socket screw
16
2044
Spring washer
16
2045
PT3/8
Plug
2046
MSTH6-15
Parallel pin
11-7
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Parts List
11.2 U-Axis Unit
No.
2047
DWG No.
HW1405699-1
Name
Cover
Pcs
1
2048
HW1405288-1
Packing
2049
Socket screw
2050
Spring washer
2051
HW1405289-1
Cover
2052
Socket screw
2053
Spring washer
2054
PT1/4
Plug
2055
PT1/8
Plug
2056
C4N107.5-PT1/4
Union
2057
C4N86-PT1/8
Union
2058
HW1405705-1
Spacer
2059
Socket screw
2060
Spring washer
2061
HW1304256-1
Cover
2062
HW1405287-1
Packing
2063
Socket screw
2064
Spring washer
2065
PT3/8
Plug
2066
PT1/4
Plug
2067
M-5P
Plug
48
2068
M1045
Socket screw
2069
2H-10
Spring washer
2070
RTW-100
Retaining ring
2071
6816
Bearing
2072
G105
O ring
2073
HW1304255-1
Shaft
2074
M520
Socket screw
2075
2H-5
Spring washer
2076
AE3618F3
Oil seal
2077
HW1405292-1
Collar
2078
RTW-100
Retaining ring
2079
HW1304805-1
Support
2080
M616
Socket screw
2081
2H-6
Spring washer
2082
HW0414857-1
Plate
2083
M48
Socket screw
2084
2H-4
Spring washer
2085
M4
Washer
2086
M660
Socket screw
2087
2H-6
Spring washer
2088
HW1304252-1
Gear
2089
6209
Bearing
2090
STW-45
Retaining ring
2091
G90
O ring
2092
HW1304253-1
M base
2093
M420
Socket screw
11-8
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11
Parts List
11.2 U-Axis Unit
No.
2094
DWG No.
2H-4
Name
Spring washer
Pcs
2
2095
Y426012.5
Oil seal
2096
HW0415325-1
Collar
2097
HW0409965-1
Cover
2098
M412
Socket screw
2099
2H-4
Spring washer
2100
HW0400470-2
Collar
2101
HW0388933-A
Motor
2102
M850
Socket screw
2103
2H-8
Spring washer
2104
AS568-274
O ring
11-9
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11
Parts List
11.3 U-Arm Unit
11.3
U-Arm Unit
Fig. 11-3: U-Arm Unit
3061
3059
3060
3059
3058
3057
3056
3052
3054
3052
3071
3069
3058
3057
3055
3051
3053
3051
3068
3049
3050
3068
3049
3067
3050
3045
3046
3043
3028
3029
3027
3070
3067
3045
3046
3043
3045
3046
3044
3041
3042
3040
3037
3039
3038
3039
3038
3039
3038
3035
3036
3047
3037
3037
3034
3033
3032
3030
3031
3030
3049
3050
3041
3042
3040
3041
3042
3040
3058
3057
3055
3051
3053
3051
3068
3067
3048
3047
3070
3062
3063
3061
3062
3063
3062 3061
3063
3034
3033
3032
3030
3031
3030
3027
3035
3036
3028
3029
3035
3036
3034
3033
3032
3030
3031
3030
3028
3029
3027
3026
3025
3026
3020
3019
3018
3020
3019
3018
3024
3020
3018
3023
3022
3017
3017
3019
3021
3009
3013
3010
3013
3066
3065
3009
3013
3001
3013
3011
3007
3008
3006
3012
3013
3009
3013
3005
3004
3002
3003
3064
3014
3014
3016
3015
3016
3015
11-10
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Parts List
11.3 U-Arm Unit
Table 11-3: U-arm Unit

No.
DWG No.
Name
Pcs
5001
HW0387737-B
Speed reducer
3001
HW1100668-1
U-arm
3002
M6x35
Socket screw
3003
2H-6
Spring washer
3004
XK70
X ring
3005
HW1383653-H
O ring
3006
HW1304314-1
Shaft
3007
M4x16
(TRIVALENT CHROMIUM
coating)
Socket screw
3008
2H-4
(TRIVALENT CHROMIUM
coating)
Spring washer
3009
HW0406082-1
Cover
3010
HW0414773-1
Cover
3011
HW0414774-1
Cover
3012
HW1405374-1
Cover
3013
M4x10
(STAINLESS coating)
Button bolt
24
3014
HW1405420-1
Collar
3015
M4x16
Socket screw
3016
2H-4
Spring washer
3017
HW1405419-1
Shaft
3018
STW-20
Retaining ring
3019
HW1405418-1
Collar
3020
6904ZZ
Bearing
3021
HW1405295-1
Shaft
3022
PT1/8
Plug
3023
HW1405348-1
Collar
3024
RTW-37
Retaining ring
3025
HW1304315-1
Shaft
3026
HW1304356-1
Shaft
3027
HW0415046-2
Collar
3028
M4x20
Socket screw
12
3029
2H-4
Spring washer
12
3030
6904ZZ
Bearing
3031
HW0415044-1
Washer
3032
HW1405418-1
Collar
3033
STW-20
Retaining ring
3034
HW0414771-1
B holder
3035
M4x10
Socket screw
12
3036
2H-4
Spring washer
12
3037
HW1405350-1
Shaft
3038
M6x25
Socket screw
18
3039
2H-6
Spring washer
18
11-11
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11
Parts List
11.3 U-Arm Unit
Table 11-3: U-arm Unit
No.
DWG No.
Name
Pcs
3040
HW0314883-1
Spacer
3041
M5x25
Socket screw
12
3042
2H-5
Spring washer
12
3043
HW1383139-A
Speed reducer
3044
HW0386187-A
Speed reducer
3045
M8x20
Socket screw
12
3046
2H-8
Spring washer
12
3047
HW1304355-1
M base
3048
HW1304259-1
M base
3049
M4x75
Socket screw
24
3050
2H-4
Spring washer
24
3051
Y234010.5
Oil seal
3052
Y35478
Oil seal
3053
HW0409966-4
Collar
3054
HW0409966-2
Collar
3055
RTW-40
Retaining ring
3056
RTW-47
Retaining ring
3057
M5x35
Socket screw
3058
2H-5
Spring washer
3059
HW1304354-1
Gear
3060
HW1304260-1
Gear
3061
HW0388651-A
Motor
3062
M5x20
Socket screw
12
3063
2H-5
Spring washer
12
3064
HW1405948-6-15
Pin
3065
M10x35
Socket screw
3066
2H-10
Spring washer
3067
PT1/4
Plug
3068
KFH10N-02S
Joint
3069
KFH08N-01S
Joint
3070
KFL08N-01S
Joint
3071
PT1/8
Plug
11-12
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11
Parts List
11.4 Wrist Unit
11.4
Wrist Unit
Fig. 11-4: Wrist Unit
4032
4033
4077
4029
4027
4028
4030
4076
4031
4026
4025
4075
4024
4023
4074
4022
4021
4073
4072
4020
4116
4133
4147
4146
4148
4146 4145
4125
4126
4069
4018
4124
4066
4068
4067
4017
4065
4016
4064
4015
4014
4062
4122
4120
4119
4116
4115
4114
4113
4012
4011
4145
4146
4139
4136
4135
4139
4130
4149
4146
4061
4006
4058
4059
4005
4057
4004
4003
4056
4002
4055
4001
4054
4142
4143
4141
4138
4144 4118
4142
41434117
4134
4141
4148
4146
4131
4132
4121
4118
4117
4115
4147
4146
4127
4123
4114
4146
4113
4112
4110
4007
4145
4145
4144
4114
4063
4010
4009
4008
4142
4143
4140
4137
4119
4070
4019
4013
4145
4145
4144
4071
4111
4105
4106
4060
4108
4109
4107
4102
4104
4103
4101
4053
4098
4052
4099
4100
4097
4051
4096
4050
4049
4048
4047
4048
4046
4044
4043
4094
4095
4093
4045
4042
4039
4092
4091
4089
4090
4088
4087
4041
4040
4086
4038
4037
4084
4085
4083
4036
4082
4035
4080
4081
4079
4034
4078
11-13
HW1482773
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4129
HW1482773
11
Parts List
11.4 Wrist Unit
Table 11-4: Wrist Unit

No.
DWG No.
Name
Pcs
5001
HW0387737-B
Speed reducer
4001
M48
Flat head screw
4002
HW0401761-1
Cover
4003
M412
Socket screw
12
4004
2H-4
Spring washer
12
4005
HW0302270-3
Flange
4006
GJ3618KO
Oil seal
4007
HW1405947-4-10
Pin
4008
M416
Socket screw
12
4009
2H-4
Spring washer
12
4010
HW0302272-3
Shaft
4011
AS568:251
O ring
4012
HW1383653-P
O ring
4013
HW1383654-B
X ring
4014
M416
Socket screw
4015
2H-4
Spring washer
4016
HW0302274-1
B holder
4017
S120
O ring
4018
HW0400570-*
Shim
4019
RA1008UUCC0S
Cross roller bearing
4020
HW0301437-2
Housing
4021
HW0400573-*
Shim
4022
HW0302293-2
Gear
4023
M310
Socket screw
4024
2H-3
Spring washer
4025
HW0302271-1
Shaft
4026
HW1405947-4-10
Pin
4027
M616
Socket screw
4028
2H-6
Spring washer
4029
C8
Cap
4030
M412
Socket screw
4031
2H-4
Spring washer
4032
PT1/2
Plug
4033
HW0100292-2
Case
4034
AS568:261
O ring
4035
HW1383653-AA
O ring
4036
HW1383654-E
X ring
4037
HW1383653-K
O ring
4038
XK75
X ring
4039
HW0302273-2
Gear
4040
M310
Socket screw
16
4041
2H-3
Spring washer
16
4042
HW0300487-1
B cover
11-14
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Parts List
11.4 Wrist Unit
No.
DWG No.
Name
Pcs
4043
M430
Socket screw
12
4044
2H-4
Spring washer
12
4045
HW0400570-*
Shim
4046
M410
Socket screw
4047
M420
Socket screw
4048
2H-4
Spring washer
10
4049
HW0300486-1
B cover
4050
RB13015UUCC00S
4051
HW0300493-1
Housing
4052
HW0300491-1
Housing
4053
RA1008UUCC0S
4054
HW0400571-*
Shim
4055
HW0300435-1
Gear
4056
HW0302280-3
Gear
4057
HW0302275-2
Shaft
4058
M310
Socket screw
16
4059
2H-3
Spring washer
16
4060
XK75
X ring
4061
HW1383653-K
O ring
4062
HW1100081-1
Case
4063
PT1/2
Plug
4064
HW1383653-K
O ring
4065
XK75
X ring
4066
HW0314877-2
Gear
4067
M412
Socket screw
12
4068
2H-4
Spring washer
12
4069
HW0414751-*
Shim
4070
HW0314871-2
Shaft
4071
6817VV
Bearing
4072
M412
Socket screw
12
4073
2H-4
Spring washer
12
4074
HW0314876-1
Gear
4075
HW0414752-*
Shim
4076
HW0314870-2
Shaft
4077
6824VV
Bearing
4078
HW1405947-6-15
Pin
4079
HW0313769-1
Shaft
4080
M530
Socket screw
10
4081
2H-5
Spring washer
10
4082
RU155-3203372
4083
HW1405941-1
B holder
4084
M414
Socket screw
4085
2H-4
Spring washer
4086
HW1383653-AD
O ring
4087
HW1383654-F
X ring
11-15
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HW1482773
11
Parts List
11.4 Wrist Unit
No.
DWG No.
Name
Pcs
4088
HW1304311-1
Gear
4089
M414
Socket screw
24
4090
2H-4
Spring washer
24
4091
6820VV
Bearing
4092
HW0414754-*
Shim
4093
HW1304312-1
Gear
4094
M414
Socket screw
16
4095
2H-4
Spring washer
16
4096
6817VV
Bearing
4097
HW0414755-*
Shim
4098
HW1304313-1
Gear
4099
M414
Socket screw
12
4100
2H-4
Spring washer
12
4101
AS568:264
O ring
4102
HW1200375-1
Gear case
4103
M620
Socket screw
4104
2H-6
Spring washer
4105
M530
Socket screw
4106
2H-5
Spring washer
4107
HW0414759-1
Cover
4108
M412
Socket screw
4109
2H-4
Spring washer
4110
HW1304263-1
Gear
4111
HW1304264-1
Gear
4112
HW1304265-1
Gear
4113
P21
O ring
4114
HW1405347-*
Shim
4115
AR42
Circlip
4116
GD37474
Oil seal
4117
GD32424
Oil seal
4118
IRTW-42
Retaining ring
4119
IRTW-47
Retaining ring
4120
HW1405376-1
Collar
4121
HW1405376-2
Collar
4122
NA5906
Bearing
4123
NA4905R
Bearing
4124
HW1304323-1
Holder
4125
M490
Socket screw
4126
2H-4
Spring washer
4127
HW1304322-1
Holder
4128
M4105
Socket screw
4129
2H-4
Spring washer
4130
HW1305351-1
Holder
4131
M460
Socket screw
4132
2H-4
Spring washer
11-16
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11
Parts List
11.4 Wrist Unit
No.
DWG No.
Name
Pcs
4133
HW1405415-1
Collar
4134
HW1405416-1
Collar
4135
HW1405294-1
Collar
4136
HW1405294-2
Collar
4137
6205ZZ
Bearing
4138
6005ZZ
Bearing
4139
6005VV
Bearing
4140
HW1405375-1
B holder
4141
HW1405349-1
B holder
4142
M412
Socket screw
4143
2H-4
Spring washer
4144
HW1405346-1
B nut
4145
M58
H set screw
4146
PT1/8
Plug
4147
LF-C
Joint
4148
C-PT1/8
Grease nipple
4149
4dia. length: 25 mm
Pin
11-17
HW1482773
MOTOMAN-MPX3500
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 vn. 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 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.
252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
Rachadaphisek RoadHuaykwang, Bangkok 10320, Thailand
Phone +66-2693-2200
Fax +66-2693-4200
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.
Printed in Japan January 2015 14-05
MANUAL NO.
HW1482773

Kmm 중상도 로봇 (Mpx3500)

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MOTOMAN-MPX3500

This instruction manual is intended to explain mainly on the

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

The drawings and photos in this manual are representative

YASKAWA may modify this model without notice when necessary

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

YASKAWA is not responsible for incidents arising from unauthorized

Notes for Safe Operation

Indicates a potentially hazardous

Indicates a potentially hazardous

Always be sure to follow explicitly the

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

Maintenance and inspection must be performed by specified

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 these safety precautions may result in death or

Before operating the manipulator, check that servo power is turned

Injury or damage to machinery may result if the emergency stop circuit

Injury may result from unintentional or unexpected manipulator motion.

Observe the following precautions when performing teaching

Improper or unintended manipulator operation may result in injury.

Confirm that no person is present in the P-point maximum envelope

Perform the following inspection procedures prior to conducting

Always return the programming pendant to the hook on the cabinet

The programming pendant can be damaged if it is left in the

Read and understand the Explanation of Warning Labels in the

Definition of Terms Used Often in This Manual

DX200 programming pendant

Cable between the manipulator and the

Explanation of Warning Labels

6.3 Internal Connections .......................................................................................................... 6-7

Take the following measures when teaching, correcting, inspecting,

Appoint a personnel to stay beside the emergency stop

Before the operation, verify the correct robot motion and

Observe the following precautions during an automatic operation:

Do not enter inside the safeguarding during operation.

Confirm the following before starting the operation:

No person is inside the manipulator working envelope.

When any abnormality occurs, immediately press the

Before entering inside the manipulator working envelope,

Brake release (Option)

A braking system is provided on each axis of the manipulator to hold

Any modification of the MOTOMAN-MPX3500, and the following is

1. Explosion-proof devices and system installation

Table 3-1: Specifications

3-phase 200/220 VAC

Required pressure: 0.35 MPa to 0.65 MPa

Use dry air for the

Grounding resistance: 100 ohm or less

For the robot controller

Table 3-2: Installation Site

Pressure Switch unit

Programming pendant (explosionproof) (Option)

Conveyer speed detector

Conveyer speed detector

Control panel for workpiece

Selected according to the requirements of the customer. Refer to the

Transport and Installation

Transport and Installation

Signs indicating prohibitions such as, The lighting of fires is

Fig. 4-4(a): Mounting the Manipulator on the Baseplate (MPX3500-0)

Fig. 4-4(b): Mounting the Manipulator on the Baseplate (MPX3500-1)

Fig. 5-1(a): System Configuration (MPX3500-0)

Fig. 5-1(b): System Configuration (MPX3500-1)

Fig. 5-2(a): Dimensions and P-point Maximum Envelope (MPX3500-0)

Fig. 5-2(b): Dimensions and P-point Maximum Envelope (MPX3500-1)