YASKAWA

MOTOPOS-S400 POSITIONER
INSTRUCTIONS
YR-MPS400-A00
YR-MPS400-B00 (WITH ROTARY JOINT)
YR-MPS400-B01 (SPECIAL SPEC WITH ROTARY JOINT)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

MOTOPOS INSTRUCTIONS
MOTOMAN SETUP MANUAL
MOTOMAN-MANIPULATOR INSTRUCTIONS
YASNAC XRC INSTRUCTIONS
YASNAC XRC OPERATORS MANUAL
YASNAC XRC OPERATORS MANUAL For BEGINNERS
MOTOPOS INSTRUCTIONS
The YASNAC XRC operators manuals above correspond to specific usage.
Be sure to use the appropriate manual.

Do not submit this electronic data to the customer.

THIS MATERIAL IS FOR STUDY PURPOSE ONLY.

YOU MUST READ THE MANUAL WHICH ENCLOSED
WITH A ROBOT.

YASKAWA MANUAL NO. HS9481813 1

 MANDATORY
This instruction manual is intended to explain operating instructions
and maintenance procedures primarily for the MOTOPOS.

General items related to safety are listed in the Safety Manual Section
1: Safety. To ensure correct and safe operation, carefully read the Setup
Manual before reading this manual.

CAUTION
Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.

The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.

YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.

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

resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.

YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-
ucts warranty.

ii
NOTES FOR SAFE OPERATION
Read this manual carefully before installation, operation, maintenance, or inspection of the
YASNAC XRC.
In this manual, the Notes for Safe Operation are classified as WARNING, CAUTION,
MANDATORY, or PROHIBITED.

Indicates a potentially hazardous situation which, if not avoided,

WARNING could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided,

CAUTION could result in minor or moderate injury to personnel and dam-
age to equipment. It may also be used to alert against unsafe
practices.

Always be sure to follow explicitly the items listed under this

MANDATORY heading.

PROHIBITED Must never be performed.

Even items described as CAUTION may result in a serious accident in some situations. At
any rate, be sure to follow these important items.

NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as CAUTION and WARNING.

iii
 WARNING
Before operating the MOTOPOS, check that servo power is turned OFF
when the emergency stop buttons on the playback panel or program-
ming pendant are pressed.
When the servo power is turned OFF, the SERVO ON READY lamp on the
playback panel and the SERVO ON LED on the programming pendant are
turned OFF.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the
MOTOPOS during an emergency. The MOTOPOS should not be used if the emergency
stop buttons do not function.

Emergency Stop Button

Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the MOTOPOS. Then turn the
servo power ON.

Injury may result from unintentional or unexpected MOTOPOS motion.

TURN

Release of Emergency Stop

Always set the Teach Lock before entering the MOTOPOS work envelope
to teach a job.

Operator injury can occur if the Teach Lock is not set and the MOTOPOS is started from
the playback panel.

Observe the following precautions when performing teaching operations

within the working envelope of the MOTOPOS :
- View the MOTOPOS from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended MOTOPOS operation may result in injury.

Confirm that no persons are present in the MOTOPOSs work envelope

and that you are in a safe location before:
- Turning ON the YASNAC XRC power
- Moving the MOTOPOS with the programming pendant
- Running check operations
- Performing automatic operations

Injury may result if anyone enters the working envelope of the MOTOPOS during opera-
tion. Always press an emergency stop button immediately if there are problems.The
emergency stop button is located on the right side of both the YASNAC XRC playback
panel and programming pendant.

iv
 WARNING
Install the safety guards.

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

Install the MOTOPOS in a location where the fully extended arm and tool
will not reach the wall, safety guards, or XRC.

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

Do not start the MOTOPOS or even turn ON the power before it is firmly
anchored.

The MOTOPOS may overturn and cause injury or damage.

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.

Before maintenance or inspection, be sure to turn the main power sup-

ply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in electric shock or injury.

v
 CAUTION
Perform the following inspection procedures prior to conducting MOTO-
POS teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in MOTOPOS movement.
-Check for damage to insulation and sheathing of external wires.

Always return the programming pendant to the hook on the XRC cabinet
after use.

The programming pendant can be damaged if it is left in the MOTOPOSs work area, on
the floor, or near fixtures.

Read and understand the Explanation of the Alarm Display in the Setup
Manual before operating the MOTOPOS.

Confirm that the MOTOPOS and the XRC have the same order number.
Special care must be taken when more than one MOTOPOS is to be
installed.

If the numbers do not match, MOTOPOS may not perform as expected and cause injury
or damage.

Sling applications and crane or forklift operations must be performed by

authorized personnel only.

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

Avoid excessive vibration or shock during transporting.

The system consists of precision components, so failure to observe this caution may
adversely affect performance.

Do not install or operate a MOTOPOS that is damaged or lacking parts.

Failure to observe this caution may cause injury or damage.

Before turning ON the power, check to be sure that the shipping bolts
and jigs have been removed.

Failure to observe this caution may result in damage to the driving parts.

Wiring must be performed by authorized or certified personnel.

Failure to observe this caution may result in fire or electric shock.

Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

vi
 CAUTION
For disassembly or repair, contact your Yaskawa representative.

Do not remove the motor, and do not release the brake.

Failure to observe this caution may result in injury from unexpected turning of the table.

Definition of Terms Used Often in This Manual

The MOTOPOS positioner is the positioner product for the YASKAWA industrial robot.
The MOTOPOS usually consists of the positioner unit, the controller, the playback panel, the
programming pendant, and power cables.
In this manual, the equipment is designated as follows:

Equipment Manual Designation

YASNAC XRC Controller XRC

YASNAC XRC Playback Panel Playback Panel

YASNAC XRC Programming Pendant Programming Pendant

vii
AN EXPLANATION OF WARNING LABELS
The following warning labels are attached to the MOTOPOS.
Always follow the warnings on the labels.
Also, an indentification label with important information is placed on the body of the MOTO-
POS. Prior to operating the MOTOPOS, confirm the contents.

MOTOPOS
TYPE

PAYLOAD MASS
kg kg
ORDER NO. DATE

SERIAL NO.

YASKAWA ELECTRIC CORPORATION JAPAN

WARNING WARNING

ORDER NO.

Do not enter Moving parts may

robot work area cause injury

WARNING WARNING MOTOPOS

TYPE

PAYLOAD MASS
kg kg
ORDER NO. DATE

SERIAL NO.

YASKAWA ELECTRIC CORPORATION JAPAN

Do not enter Moving parts may

robot work area cause injury

viii
1 Receiving
1.1 Checking Package Contents . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Checking the Order Number . . . . . . . . . . . . . . . . . . . . . . . .1-2

2 Transporting
2.1 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1.1 Using the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

3 Installation
3.1 Safety Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2 Mounting Procedures for MOTOPOS Baseplate . . . .3-2
3.2.1 When the MOTOPOS and Robot are Installed on a Common Base
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.2.2 When the MOTOPOS is Mounted Directly on the Floor . . . . . .3-4
3.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

4 Wiring
4.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.1 Connection to the MOTOPOS . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2.2 Connection to the XRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

5 Basic Specifications
5.1 Basic Specifications List . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . .5-2
5.3 Baseplate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.4 Dimensions and Working Envelope . . . . . . . . . . . . . . . . .5-3

6 Load Specifications and Jig Mounting Section

6.1 Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 Details of Jig Mounting Face . . . . . . . . . . . . . . . . . . . . . . . .6-2

ix
7 System Application
7.1 Internal Wire and Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Minus Cable for Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

8 MOTOPOS Construction
8.1 Position of Limit Switch for Overrun . . . . . . . . . . . . . . . . 8-1
8.2 Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 Maintenance and Inspection

9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Notes on Maintenance Procedures . . . . . . . . . . . . . . . . . 9-5
9.2.1 Battery Unit Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.2 Grease Replenishment/Replacement for Speed Reducer . . . . 9-6
Grease Replenishment (Refer to Fig. 19 Speed Reducer Diagram.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Grease Replacement (Refer to Fig. 19 Speed Reducer Diagram.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

10 Recommended Spare Parts

x
 1.1 Checking Package Contents

1 Receiving

CAUTION
Confirm that the MOTOPOS and the XRC have the same order number.
Special care must be taken when more than one MOTOPOS is to be
installed.

If the numbers do not match, MOTOPOS may not perform as expected and cause injury
or damage.

1.1 Checking Package Contents

When the package arrives, check the contents for the following standard items (Any addi-
tional options ordered should be checked as well.):

Manipulator
XRC
Programming pendant
Power cable between the XRC and the manipulator (2 or 3)
MOTOPOS
Power cable between the MOTOPOS and the XRC (2)

1-1
1.2 Checking the Order Number

1.2 Checking the Order Number

Check that the order number of the MOTOPOS corresponds to the XRC. The order number is
located on a label as shown below.

Label(Enlarged view)

THE MOTOPOS AND THE CONTROLLER

SHOULD HAVE SAME ORDER NUMBER. Check that the MOTOPOS
and the XRC have the
ORDER. No. same order number.

YASNAC XRC UP6

X+ X
X- S+
R-
R+
X
S-

Y- Y+
L+
y
B- y
L- B+

Z-
U-
Z+
U+
z
T-
z
T+
MOTOPOS
7 8 9 TYPE

4 5 6 PAYLOAD MASS
kg kg
ORDER NO. DATE
1 2 3
SERIAL NO.
0 . -
YASKAWA ELECTRIC CORPORATION JAPAN

ORDER NO.

ORDER NO.
NJ1530

TYPE ERCR-
POWER SUPPLY
200/220V 50/60Hz 3PHASE KVA

SERIAL NO.
DATE P/N

MADE IN JAPAN NJ2063-1

(a) XRC (Front View) (b) MOTOPOS (Side View)

Fig. 1 Location of Order Number Labels

1-2
 2.1 Transporting Method

2 Transporting

CAUTION
Sling applications and crane or forklift operations must be performed by
authorized personnel only.

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

Avoid excessive vibration or shock during transporting.

The system consists of precision components, so failure to observe this caution may
adversely affect performance.

2.1 Transporting Method

2.1.1 Using the Crane

As a rule, when removing the MOTOPOS from the package and moving it, a crane should be
used. The MOTOPOS should be lifted using wire rope threaded through attached eyebolts.

Fig. 2 Transporting Position

2-1
2.1 Transporting Method

Check that the eyebolts are securely fastened.

NOTE The weight of the MOTOPOS is approximately 150kg including the shipping bolts and
jigs. Use a wire rope strong enough to withstand the weight.
Attached eyebolts are designed to support the MOTOPOS weight. Do not use them for
anything other than transporting the MOTOPOS.
Avoid exerting force on the arm or motor unit when transporting, use caution when using
transporting equipment other than a crane or forklift, as injury may occur.

2-2
3 Installation

WARNING
Install the safety guards.

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

Install the MOTOPOS in a location where the fully extended arm and tool
will not reach the wall, safety guards, or XRC.

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

Do not start the MOTOPOS or even turn ON the power before it is firmly
anchored.

The MOTOPOS may overturn and cause injury or damage.

CAUTION
Do not install or operate a MOTOPOS that is damaged or lacking parts.

Failure to observe this caution may cause injury or damage.

3-1
3.1 Safety Guard Installation

3.1 Safety Guard Installation

To insure safety, be sure to install safety guards. They prevent unforeseen accidents with per-
sonnel and damage to equipment. The following is quoted for your information and guidance.
(ISO 10218)

Responsibility for Safeguarding

The user of a MOTOPOS or robot system shall ensure that safeguards are provided and used
in accordance with Sections 6, 7, and 8 of this standard. The means and degree of safeguard-
ing, including any redundancies, shall correspond directly to the type and level of hazard pre-
sented by the robot system consistent with the robot application. Safeguarding may include
but not be limited to safeguarding devices, barriers, interlock barriers, perimeter guarding,
awareness barriers, and awareness signals.

3.2 Mounting Procedures for MOTOPOS Baseplate

The MOTOPOS should be firmly mounted on a baseplate or foundation strong enough to sup-
port the MOTOPOS and withstand repulsion forces during acceleration and deceleration.
Construct a solid foundation with the appropriate thickness to withstand maximum repulsion
forces of the MOTOPOS.
During installation, if out of the plane is not right, the MOTOPOS shape may change and its
functional ability may be compromised. Out of the plane for installation must be kept at 0.5mm
or less. Mount the baseplate in either of the following ways: 3.2.1 or 3.2.2.

Table. 1 Maximum repulsion forces of the MOTOPOS

Maximum torque when rotary axis 2450N m

used

Moment by overhang payload 1960N m

3-2
 3.2 Mounting Procedures for MOTOPOS Baseplate

3.2.1 When the MOTOPOS and Robot are Installed on a

Common Base
The common base should be rugged and durable to prevent shifting of the MOTOPOS or the
robot.Use the common base of such thickness or the mounting anchor bolts of such size rec-
ommended for the robot to be combined.
Mount the MOTOPOS base securely with four M16 hexagon socket head cap bolts (55 mm
long recommended). Tighten the bolts and anchor bolts so that they will not work loose during
operation.

Spring Washer 4 M16 Bolts

MOTOPOS Base
Washer

25
Common Base
Out of plane : 0.5mm or less

Fig. 3 Mounting the MOTOPOS Baseplate on the Common Base

3-3
3.2 Mounting Procedures for MOTOPOS Baseplate

3.2.2 When the MOTOPOS is Mounted Directly on the Floor

The floor should be strong enough to support the MOTOPOS. Construct a solid foundation
with the appropriate thickness to withstand maximum repulsion forces of the MOTOPOS as
shown in " Table. 1 Maximum repulsion forces of the MOTOPOS ". As a rough standard,
when there is a concrete thickness (floor) of 200mm or more, base plate (MOTOPOS 28mm
or more) can be fixed directly to the floor with M20 anchor bolts. Before mounting the MOTO-
POS, however, check that the floor is level and that all cracks, etc. are repaired. Any thickness
less than 200mm is insufficient for mounting, even if the floor is concrete.

Base Plate

350

500

600
MOTOPOS base

270

550
4- 24 drilled holes
650
4- M16 tapped holes

Hexagon socket head bolts

M1655 (4 places)
Washer for M16,S-washer for M16

M20 anchor bolts (4 places)

Concrete floor
28mm or more
25
200mm or more

Bolts and base plate should be equipped by user.

Fig. 4 Affixing the MOTOPOS on the Floor

3-4
 3.3 Location

3.3 Location

When the MOTOPOS is installed, it is necessary to satisfy the undermentioned environmental

conditions:

0 to 45C (Ambient temperature)

20 to 80%RH (non-condensing)
Free from dust, soot, or water
Free from corrosive gases or liquid, or explosive gases
Free from excessive vibration ( 4.9 m/s2 [0.5 G] or less)
Free from large electrical noise (plasma)
Out of the plane for installation is 0.5mm or less.

3-5
 4.1 Grounding

4 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.

4.1 Grounding

Follow local regulations and electrical installation standards for grounding. The recom-
mended grounding wire size is 5.5 mm2 or more.

Do not use this line in common with other ground lines or grounding electrodes for other
NOTE 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.

4-1
4.2 Cable Connection

5.5mm or more
MOTOPOS
TYPE

PAYLOAD MASS
kg kg
ORDER NO. DATE

SERIAL NO.

A
YASKAWA ELECTRIC CORPORATION JAPAN

ORDER NO.

M8 bolt (For grounding)

(Provided at factory)

View A

Fig. 5 Grounding Method

4.2 Cable Connection

There are two cables for the power supply; a power cable (1BC) and a signal cable for detec-
tion (2BC). Connect these cables to the MOTOPOS base connectors and the XRC, respec-
tively. (See Fig. 6 Connection between the MOTOPOS and Power Cable.)

4.2.1 Connection to the MOTOPOS

Before connecting the cables to the MOTOPOS, verify the numbers on both cables and the
MOTOPOS base connectors. When connecting, adjust the cable connector positions to the
main key positions of the MOTOPOS, insert cables, and then tighten the nut until hearing a
click.

4.2.2 Connection to the XRC

Remove the cover on the XRC side. Pass the power cable (1BC) and the signal cable (2BC)
through the opening for the cables, and then fasten bolts on the opening.
Connect the power cable (1BC) to the boards. Be sure to verify the numbers on both the
cable and board connectors before connecting, and to fasten the bolts on connectors to pre-
vent cables from loosening.
Connect the signal cable (2BC) to the SERVOPACK and the board. Be sure to verify the num-
bers on both the cable and the SERVOPACK board connectors before connecting.

4-2
 4.2 Cable Connection

Connection to the XRC Connection to the MOTOPOS

EX1SV-CN1

1BC

1BC
EXBRAKE1

Power cable

2BC
EX-PG1

2BC
signal cable

OT7
ROT7

Fig. 6 (a) Connection between the MOTOPOS and the Power Cable

4-3
4.2 Cable Connection

Key position

1BC 2BC
MOTOPOS
TYPE

PAYLORD MASS

ORDER NO. DATE

SERIAL NO.

1BC 2BC

Connector for motor signal

Connector for motor power cable
(MS3102A-20-15P) (MS3102A-20-29P)

Details in Power Cable Connection

MOTOPOS-S400-A00

Key position

Connector for internal wires

(MS3102A-18-1P)

1BC 2BC 3BC

MOTOPOS
TYPE

PAYLORD MASS

ORDER NO. DATE

SERIAL NO.

1BC 2BC 3BC

Connector for motor power cable Connector for motor signal

(MS3102A-20-15P) (MS3102A-20-29P)

Details in Power Cable Connection

MOTOPOS-S400-B00, -B01

Fig. 6 (b) Connection between the MOTOPOS and the Power Cable

4-4
 4.2 Cable Connection

Tighten the screws with a

small-size screw driver (+)
Ground plate
Signal/Power cable
Terminal No.E
Signal cable
JZNC-XRK01
XCP01 CPS-150F
CN30

CN07

XCP01
CPS-150F
CN29
CN28

CN05

CN06

CN04/CARD

CN06/SV
CN26
CN27
CN24 CN25

CN04

CN12
CN13

CN03/RS232C
CN23
CN22

CN02/PP
CN03
CN21

CN02

CN01/IO
CN10
CN11
CN20

CN01

GRIP

DF9203102-B0
CN12
CNPB04 CNPB05 CNPB06

8830-032-170SD 8830-032-170SD 8830-032-170SD

C249
JUSP-ACP05JAA
DUSB-ARB8X-T11

102
CN10

507H015

CONV
331MPH

2CN
UNIT TYPE

N P
CNPG456
10220-6202JL

+5V PWM
CN20

10250-52A2JL

JUSP-
4

RCP01AAA
CN10
178323-2

PWM
1
CN50

B3

A3

Connector No.
CNPG123

PWM
B1

A1
FRC5-C14S52T-OL(D20)

1CN
B3

A3
10250-52A2JL

-OL(D20)

A1
B1
CN30

FRC5-C14S52T-OL(D20)

CNE 3-175475-6

EX-PG1
2
CN2

U V W
1
CN40

13

CNPB01 CNPB02 CNPB03

10
CN9
7

8830-032-170SD 8830-032-170SD 8830-032-170SD

4
1

JUSP-ACPCA05JAA
REV.B
S L U R B T

GRIP

Power cable
Power cable

Connector No.
Signal cable
EXBRAKE1

Connector No.
EX1SV-CN1
Terminal No.
OT7, ROT7

Fig. 6 (c) Connection between the XRC and the Power Cable

4-5
 5.1 Basic Specifications List

5 Basic Specifications

5.1 Basic Specifications List

Table. 2 Basic Specifications*1

YR-MPS400-B00
Item Model YR-MPS400-A00
YR-MPS400-B01

Degree of Freedom 1

Allowable Loading Weight 400kg

Repetitive Positioning Accuracy*2 0.1mm (R250mm)

Motion Range 370 370 (endless*3)

Maximum Speed 100/s (16.7r/min)

Allowable Moment*4 509.6Nm (52kgfm)

430mm from table surface

Allowable Overhang Amount (when allowable loading weight is 400kg)

Allowable Inertia (GD2/4) 35kgm2

Equipment Signal *5
0.5 mm2 6
Specificatio
ns Air *5 3/8 1

Standard Painting Color Light gray

Mass 150kg

Temperature 0 to 45C
Humidity 20 to 80% RH (non-condensing)

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

Conditions Free from corrosive gasses or liquids, or
explosive gasses
Others
Clean and dry
Free from excessive electrical noise (plasma)
Power Capacity 2kVA

*1 SI units are used in this table. However, gravitational unit is used in ().
*2 Conformed to ISO9283.
*3 The rotary axis endless function is optional.
*4 Refer to 6.1 "Allowable Load" for details on the permissible moment of inertia.
*5 Use hollow shaft hole (55).

5-1
5.2 Part Names and Working Axes

5.2 Part Names and Working Axes

Cover
Speed reducer
Frame

Table

Cover

Motor

Base connector
Ground unit

Base section

Fig. 7 Part Names and Working Axes

5.3 Baseplate Dimensions

4- 18 hole
MOTOPOS base
25

266

400
350

85 150
0.1
203
25

25 270 25

320 Mounting face

A
View A

Fig. 8 Baseplate Dimensions (mm)

5-2
 5.4 Dimensions and Working Envelope

5.4 Dimensions and Working Envelope

203 0.1
200

403
200
59 320

379

365
(S400-B01:230)
210

- 370
420 (S400-B01:
550 (S400-B01:570)

+ 370

WARNING WARNING
340

Do not enter Moving parts may

robot work area cause injury

350 270

Fig. 9 Dimesions and Working Envelope

5-3
 6.1 Allowable Load

6 Load Specifications and Jig Mounting

Section

6.1 Allowable Load

The allowable load is up to 400 kg. This section describes the allowable values and various
limitations. The moment and moment inertia are limited as shown in " Table. 3 Moment and
Total Inertia ".

Table. 3 Moment and Total Inertia

Axis Name Moment Nm (kgfm) *1 GD2/4 Total Inertia kgm2

Rotary Axis 509.6 (52) 35

*1 ( ): Gravitational unit

When the volume load is small, refer to the moment rating shown in " Fig. 10 Moment Rating ".
The allowable total inertia is calculated when the moment is at the maximum. Contact your
Yaskawa reprsentative when only inertia moment, or load moment is small and inertia
moment is large. Also, when the load is combined as a force but a mass, contact your
Yaskawa representative. For allowable overhang payload, refer to Fig. 10 Moment Rating.
If overhang payload exceeds maximum value or jig length is long even if it is within allowable
value, use the method of holding both ends using tailstock.

L1 (mm)

200 kg
260

300 kg
173

130 400 kg

0 L2 (mm)
430 550 700

130

173

260
L1 (mm) Jig mounting face Rotation center line

Fig. 10 Moment Rating

6-1
6.2 Details of Jig Mounting Face

6.2 Details of Jig Mounting Face

The jig mounting dimensions are shown in " Fig. 11 (a) Details of Jig Mounting Face (YR-
MPS400-A00,-B00) " ." Fig. 11 (b) Details of Jig Mounting Face (YR-MPS400-B01) ". It is
recommended that the table and the jig be mounted using an inside dowel and dowel pin, or
two dowel pins.

37

250 0.02 23

+0.018
2- 12 0 Depth20

+0.035
420

100 0
7

280
PCD

6-M12 tapped hole

(6 places)

Fig. 11 (a) Details of Jig Mounting Face (YR-MPS400-A00,-B00)

Drilled hole 18 dia.(8 places) 8

Counterbore 26 dia.
(depth:17.5) 25

72
10
5
60

80
40

0.5

0
D 40
PC
-0.034
0

Reamed hole 10 dia. 0

+0.015 0.1
60 0
(2 places) 0.1 15
Tapped hole M10 60
(10 places)
0
15

Units:mm

Fig. 11 (b) Details of Jig Mounting Face (YR-MPS400-B01)

NOTE Wash OFF anti-corrosive paint (solid color) on the jig mounting surface with thinner or light
oil before mounting the tools.

6-2
 7.1 Internal Wire and Air duct

7 System Application

7.1 Internal Wire and Air duct

For type MPS400-B00,-B01, wires and an air hose are incorporated into the MOTOPOS for
user application as shown in " Fig. 12 Internal Wires and Air Duct (for type MPS400-B00,-
B01) ".

YR-MPS400-B00: Cables (0.5 mm2 6)

-B01 Air hose (inner diameter 8mm 1)

Connector pins are assigned as shown in Fig. 12. Wiring must be performed by user.
The allowable current for wires: 3A or less for each wire
The maximum pressure for the air hose: 490 kPa (5 kgf/cm2) or less
For type MPS400-A00, signal cable for jig and air hose are not provided. Use hollow shaft
hole (55).

For cables
Insertion-type pin terminal

Air outret

One-touch tube
TU1208B

Connector for cable

(MS3102A-18-1P)

Air inlet
PT3/8 tapped hole

View A

Fig. 12 Internal Wires and Air Duct (for type MPS400-B00,-B01)

7-1
7.1 Internal Wire and Air duct

Table. 4 List of Connector Types

Applicable
Positioner Name Connector Type
Pin No.

Base Connector for MS3102A-18-1P 1 to 6

Internal Wire (MS3106B-18-1S: Optional)
YR-MPS400-B00,
-B01 Table Connector for Insertion-type pin terminal PC2005-W 1 to 6
Internal Wire (Insertion-type
pin terminal PC2005-M: Optional)

The internal wires and the air hose at the table side are of construction where they are drawn
out from the center part.
Provide a hole for drawing on the jig base plate.
Be sure to mount a cover on the hole, so that spatters may not enter inside of the MOTOPOS.
" Fig. 13 Internal Wire and Air Hose Drawing Section "shows an example of mounting.

Jig base plate

Internal wire: cable fitting

Air hose: Union type connector

(Provided by user)

Internal wire and air hose at the jig side

(Provided by user)

Cover

Table (MOTOPOS)

Fig. 13 Internal Wire and Air Hose Drawing Section

NOTE Be sure to provide a cover for the internal wire and air hose drawing section at the table
side. Otherwise, spatters may enter the inside of the MOTOPOS, resulting in a failure.

7-2
 7.2 Minus Cable for Welding

7.2 Minus Cable for Welding

Minus cable for welding is provided inside the MOTOPOS.

Minus cable allowable current: 500 A
Since the minus cable at the table side is connected directly to the table, it is connected to the
jig base plate through the table.
Therefore, no minus cable is needed at the jig side. However, to connect the cable to any
place near the welded part, connect the minus cable to the jig base plate as shown in " Fig. 14
Minus cable Connection ".

Jig base plate

Minus cable (provided by user)

Table (MOTOPOS)
Minus cable connection tapped hole
M10 tapped hole,Depth: 15 mm

Fig. 14 Minus cable Connection

7-3
 8.1 Position of Limit Switch for Overrun

8 MOTOPOS Construction

8.1 Position of Limit Switch for Overrun

For type MPS400-A00, the overrun limit switch can be mounted. For the location, refer to "
Fig. 15 Location of Limit Switch ".

Overrun L.S.

Fig. 15 Location of Limit Switch

8.2 Internal Connections

High reliability connectors which can be easily removed are used with each connector part.

8-1
 Power cable Internal wiring

S-IRV,0.3XK-R OBT BAT

YASNAC-XRC 2BC(20-29) BATTERY NO.1CN

IPVV-SB,7-2X0.3 BAT7 S-IRV,0.3XK-R R K R BAT7
RMCV-SB-0,0.3/6P Black 7
EX-PG1 OBT7 K OBT7
Gray 8
Red A PA7 Red PA7 1
EX-PG1-48
Red/White B *PA7 Blue *PA7 2
-46
Green C PB7 White PB7 3
-44
Green/White D 4
-42 *PB7 Yellow *PB7
ABS Encoder
Brown E PC7 Brown PC7 5
-20
Brown/White F *PC7 Light blue *PC7 6
54306-5011 -18
Black H 5V7 S-IRV,0.5XK-R R Green 5V7 9
-19
Black/White G 0V7 K Orange 0V7 10
-21
Blue K 5V7 S-IRV,0.5XK- R FG7 11
-45
Blue/White L 0V7 K 12
-47
S-IRV,0.5XK J FG7 S-IRV,0.3XK S-IRV,0.3XK SHIELD

S-IRV,0.5XK-R Red M S-IRV,0.5XK OT7

A terminal OT7
1.25-4 N S-IRV,0.5XK R0T7
OVERRUNL.S.
R0T7 Black

KIVTW-6,2XG-Y P KIVTW-6,2XG-Y

E
BASE
A terminal E 1BC (20-15) E
2-4
KIVTW-6,2XG-Y 1BC-G E KIVTW-6,2XG-Y
E
No.2CN
EX1SV-CN1
KIVTW-6,2XK -A MU7 RMFEV-0,0.75/6C Red 3CN-1 MU7
2
KIVTW-6,2XK -B MV7 Green -2 MV7
316040-2 3 SM Motor
KIVTW-6,2XK -C MW7 Yellow -3 MW7
4
KIVTW-6,2XG-Y -D ME7 Brown -4 ME7
1

EXBRAKE1
KIVTW-6,2XK -E BA7 Black -5 BA7
A
917511-2
B
KIVTW-6,2XK -F BB7 White -6 BB7 YB

Fig.16 (a) Internal Connection Diagram (Type: YR-MPS400-A00)

8-2
 Power cable Internal wiring

S-IRV,0.3XK-R OBT BAT

YASNAC-XRC BATTERY NO.1CN

2BC(20-29)
BAT7 S-IRV,0.3XK-R R K R Black BAT7
IPVVSB,7-2X0.3 RMCV-SB-0,0.3/6P 7
EX-PG1 OBT7 K Gray OBT7 8
Red A PA7 Red PA7 1
EX-PG14-48
Red/White B *PA7 Blue *PA7 2
-46
Green C PB7 White PB7 3
-44
Green/White D Yellow 4
-42 *PB7 *PB7
ABS Encoder
Brown E PC7 Brown PC7 5
-20
Brown/White F *PC7 Light blue *PC7 6
-18
Black H 5V7 S-IRV,0.5XK-R R Green 5V7 9
-19
54306-5011 Black/White G 0V7 K Orange 0V7 10
-21
Blue K FG7 S-IRV,0.5XK- R FG7 11
-45
Blue/White L K 12
-47

S-IRV,0.5XK J FG7 S-IRV,0.3XK S-IRV,0.3XK SHIELD

KIVTW-6,XG-Y P KIVTW-6,2XG-Y

E
BASE
A terminal E 1BC (20-15) E E
2-4
KIVTW-6,2XG-Y 1BC-G E KIVTW-6,2XG-Y
E

EX1SV-CN1 No.2CN
KIVTW-6,2XK -A MU7 RMFEV-0,0.75/6C Red 3CN-1 MU7
2
KIVTW-6,2XK -B MV7 Green -2 MV7
316040-2
3
KIVTW-6,2XK MW7 Yellow MW7
SM Motor
4 -C -3
KIVTW-6,2XG-Y -D ME7 Brown -4 ME7
1

EXBRAKE1
KIVTW-6,2XK -E BA7 Black -5 BA7
917511-2 A
KIVTW-6,2XK -F BB7 White -6 BB7 YB
B

PLC 3BC (18-1)

KIVTW-6,2XG-Y 3BC-J E KIVTW-6,2XG-Y Rotary Joint
A terminal E
2-4 KIVTW-3,0.75XK -A 1 RMCV-SB-0,0.5/3P Red 1
1 1
2
KIVTW-3,0.75XR -B 2 Blue 2 2 Internal Wire
KIVTW-3,0.75XK -C 3 Green 3
A terminal 3 3
1.25-3 KIVTW-3,0.75XR -D 4 Orange 4
Pin PC2005-W
4 4
KIVTW-3,0.75XK -E 5 Yellow 5
5 5
KIVTW-3,0.75XR -F 6 White 6
6 6
KIVTW-3,0.75XG-Y -G 7 S-IRV,0.5XK
E

Fig.16 (b) Internal Connection Diagram (Type: YR-MPS400-B00,-B01)

8-3
 9.1 Inspection Schedule

9 Maintenance and Inspection

WARNING
Before maintenance or inspection, be sure to turn the main power sup-
ply OFF, and put up a warning sign. (ex. DO NOT TURN THE POWER ON.)

Failure to observe this warning may result in electric shock or injury.

CAUTION
Maintenance and inspection must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

For disassembly or repair, contact your Yaskawa representative.

Do not remove the motor, and do not release the brake.

Failure to observe this caution may result in injury from unexpected turning of the table.

9.1 Inspection Schedule

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 inter-
vals are displayed in the levels shown in Table 5. Conduct periodical inspections according to
the inspection schedule in " Table. 5 Inspection Items ".
In " Table. 5 Inspection Items ", the inspection items are classified into three types of opera-
tion: operations which can be performed by personnel authorized by 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.

9-1
9.1 Inspection Schedule

The inspection interval must be based on the servo power supply on time.
NOTE For axes which are used very frequently other than arc welding, it is recommended that
inspections be conducted at shorter intervals. Contact your Yaskawa representative.

Table. 5 Inspection Items

Schedule Inspection Charge

Items *4 Method Operation
1000H 6000H 12000H 24000 36000 Specified Service
Daily Licensee
Cycle Cycle Cycle H H Person Company

Check tram mark

accordance and
1 Tram mark { Visual
damage at the home
{ { {
position.

Check for damage

2 External lead { Visual and deterioration of { { {
leads.

Clean the work area

Working area if dust or spatter is
3 and { Visual present. Check for { { {
MOTOPOS damage and outside
cracks.

Check for grease

4 Motor { Visual
leakage.*5
{ { {

Check for damage,

deterioration and
5 Earth brush { Air blow wear of brushes. { { {
Remove wear pow-
der or spatter.

Baseplate Tighten loose bolts.

Spanner Replace if necessary.
6 mounting { Wrench
{ { {
bolts

Cover mount- Screw- Tighten loose bolts.

7
ing screws
{ driver, Replace if necessary. { { {
Wrench

Check for loose con-

8 Connectors { Manual nectors and tighten if { { {
necessary.

Check for air leak-

9 Air hose { Auditory
age.
{ { {

Check for damages

Rotary joint on rotary locking
(only for Visual, parts, spatter
10
model:
{ auditory engagement and air
{ {
B00,-B01) leakage. (Replace if
a fault is found.)

Check for conduc-

tion between the
main connecter of
Wire harness base and end con-
11
in MOTOPOS
{ Multimeter nector with manually { {
shaking the wire.
Check for wear of
protective spring.*1

9-2
 9.1 Inspection Schedule

Table. 5 Inspection Items

Schedule Inspection Charge

Items*4 Method Operation
1000H 6000H 12000H 24000 36000 Specified Service
Daily Licensee
Cycle Cycle Cycle H H Person Company

Replace the battery

unit when the battery
Battery unit in
12
MOTOPOS
{ alarm occurs or the { {
MOTOPOS drove for
36000H .*1

Check for malfunc-

tion. (Replace if nec-
essary.) Supply
Speed Grease grease*3 (6000H
13
reducer
{ { Gun cycle). See Par. 9.2.2
{ {
Replace grease*3.
(12000H cycle).
See Par. 9.2.2

14 Overhaul { {

*1 When checking for conduction with multimeter, remove connectors on detecter side for each axis from the
motor.
*2 For the grease, refer to Table 6.
*3 Inspection No. correspond to the numbers in Fig.17.
*4 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.

9-3
9.1 Inspection Schedule

7
13

7
10
1

9
11 12

7
7
4

6
5 11
2

8 8 7

Fig. 16 Inspection Parts and Inspection Numbers

Table. 6 Inspection Parts and Grease Used

No. Grease Used Inspected Parts

13 Molywhite RE No. 00 Speed reducers

The numbers in the above table correspond to the numbers in " Table. 5 Inspection Items ".

9-4
 9.2 Notes on Maintenance Procedures

9.2 Notes on Maintenance Procedures

9.2.1 Battery Unit Replacement

The battery unit is mounted as shown in " Fig. 17 Battery Location ".
If a battery alarm occurs in the XRC, replace the battery according to the following procedure:

A Battery unit

View A
Frame

M4 Screw

Motor
Cover

Fig. 17 Battery Location

Insertion-type
pin terminal
Battry unit

OBT a b OBT
BAT b a BAT

Internal wires a: Insertion-type pin terminal (Male)

b: Insertion-type pin terminal (Female)

Fig. 18 Battery Connection

1. Turn the XRC main power supply OFF.

2. Remove the cover of the frame section.
3. Remove the battery unit mounting screw.
4. Remove the old battery unit and connect the new one.
5. Mount the battery unit with the screws and mount the cover to complete the replace-
ment.
.

NOTE Do not pinch the cable when the cover is installed.

9-5
9.2 Notes on Maintenance Procedures

9.2.2 Grease Replenishment/Replacement for Speed

Reducer

Ti: Grease inlet

Speed reducer (G Nipple A-PT1/8)
To To: Grease outlet
(Hexagon socket head PT1/8 plug)

MOTOPOS

Ti
TYPE

PAYLOAD MASS
kg kg
ORDER NO. DATE

SERIAL NO.

YASKAWA ELECTRIC CORPORATION JAPAN

ORDER NO.

Fig. 19 Speed Reducer Diagram

Grease Replenishment (Refer to Fig. 19 Speed Reducer Dia-

gram.)
1. Remove the To exhaust plug.

NOTE If grease is added without removing the exhaust plug, the grease will go inside the motor
and may damage it. It is absolutely necessary to remove the plug.

2. Inject the grease into the Ti grease inlet using a grease gun.

Grease type: Molywhite RE No.00

Amount of grease: 100cc
(200cc for 1st supply)

3. Move the rotary axis for a few minutes to discharge the excess grease.
4. Wipe the To exhaust plugs with a cloth and reinstall the plugs. (Spread the Modifier sil-
icon Caulk on the screw of the plug.)

9-6
 9.2 Notes on Maintenance Procedures

Grease Replacement (Refer to Fig. 19 Speed Reducer Diagram.)

1. Remove the To exhaust plug.

NOTE If grease is added without removing the exhaust plug, the grease will go inside the motor
and may damage it. It is absolutely necessary to remove the plug.

2. Inject the grease into the Ti grease inlet using a grease gun.

Grease type: Molywhite RE No.00

Amount of grease: 1000cc

3. The grease replacement is complete when new grease appears in the To exhaust port.
The new grease can be distinguished from the old grease by color.
4. Move the rotary axis for a few minutes to discharge the excess grease.
5. Wipe the To exhaust port with a cloth and reinstall the plug.(Spread the Modifier silicon
Caulk on the screw of the plug.)

9-7
10 Recommended Spare Parts

It is recommended that the following parts and components be kept in stock as spare parts for
the MOTOPOS. The spare parts list for the MOTOPOS is shown below. Product performance
can not be guaranteed when using spare parts from any company other than Yaskawa. The
spare parts are ranked as follows:

Rank A: Expendable and frequently replaced parts

Rank B: Parts for which replacement may be necessary as a result of frequent operation
Rank C: Drive Unit

NOTE To replace parts in Rank A or Rank B, contact your Yaskawa representative.

Table 7 Spare Parts for the MOTOPOS

Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit

Grease Molywhite Yaskawa For all axes

A 1 RE No. 00 Electric 16kg - speed reducers
Corporation

Silicon Rubber Modifier Silicon Konishi Co., Ltd.

A 2 1 1
Compound Tube Caulk

Battery Unit HW8471030-A Yaskawa

A 3 Electric 1 1
Corporation

Brush Unit HS9381750-A Yaskawa

B 4 Electric 1 1
Corporation

Bearing (Center 6816 Nippon Seiko

B 5 1 1
gear section) K.K.

Bearing (Input gear 6805 Nippon Seiko

B 6 1 1
section) K.K.

Rotary Axis HS9381751-A Yaskawa

B 7 Speed Reducer Electric 1 1
Corporation

Rotary Joint (Only HS9281104-A Yaskawa

B 8 for YR-MPS400- Electric 1 1
B00,-B01) Corporation

AC Servomotor HW9380768-A Yaskawa

C 9 Electric 1 1
Corporation

Input Gear HS9405095-1 Yaskawa

C 10 Electric 1 1
Corporation

10-1
 Table 7 Spare Parts for the MOTOPOS

Qty
Parts
Rank Name Type Manufacturer Qty per Remarks
No.
Unit

Internal Wiring HS9371383-A Yaskawa For YR-MPS400-

1 1
Electric A00
C 11 Corporation
HS9371382-A For YR-MPS400-
1 1
B00,-B01

10-2
MOTOPOS-S400 POSITIONER
INSTRUCTIONS

HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
3530 Laird Road, Unit 3, Mississauga, Ontario, L5L 5Z7, Canada
Phone 1-905-569-6686 Fax 1-905-813-5911
MOTOMAN ROBOTICS EUROPE AB
Franska Vagen 1039854, Kalmar, Sweden
Phone 46-480-417800 Fax 46-480-417999
MOTOMAN ROBOTEC GmbH
Kammerfeld strasse 1, DE-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
1F Samyang Bldg. 89-1, Shinchun-dong, Donk-Ku, Daegu, Korea
Phone 82-53-745-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park, Singapore 556741, Singapore
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (MALAYSIA) SDN. BHD.
No.71, Jalan Bandar Rawang 2, 48000 Rawang, Selangor D.E., Malaysia
Phone 60-3-6092-1377 Fax 60-3-6092-6377
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16 Nanking E. Rd., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878

YASKAWA ELECTRIC CORPORATION

YASKAWA

Specifications are subject to change without notice MANUAL NO. HS9481813 1

for ongoing product modifications and improvements. C Printed in Japan January 2006 99-9