M-410iB450 Maintenance Manual (B-81925EN 04)
M-410iB450 Maintenance Manual (B-81925EN 04)
M-410iB450 Maintenance Manual (B-81925EN 04)
MECHANICAL UNIT
MAINTENANCE MANUAL
B-81925EN/04
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller
labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
B-81925EN/04 SAFETY PRECAUTIONS
1 SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety
precautions when operating a robot and its peripheral devices installed
in a work cell.
s-1
SAFETY PRECAUTIONS B-81925EN/04
(1) Have the robot system operators attend the training courses held
by FANUC.
FANUC provides various training courses. Contact our sales office for
details.
(2) Even when the robot is stationary, it is possible that the robot is
still ready to move state and is waiting for a signal. In this state,
the robot is regarded as still in motion. To ensure operator
safety, provide the system with an alarm to indicate visually or
aurally that the robot is in motion.
(3) Install a safety fence with a gate so that no operator can enter the
work area without passing through the gate. Equip the gate
with an interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an
emergency. For connection, see Fig.1.1 (a), (b) and (c).
s-2
B-81925EN/04 SAFETY PRECAUTIONS
Panel board
パネルボード
FENCE1 Note) Terminals FENCE1 and FENCE2 are on the PC board
FENCE1
in the operator’s panel.
FENCE2
FENCE2
Fig. 1.1 (b) Limit switch circuit diaram of the safety fence (For R-J3iB CONTROLLER)
Panel
パネルボードboard
EAS1
EAS1 Note) Terminals EAS1, EAS11 and EAS2, 21 are on the PC
board in the operator’s panel.
EAS11
EAS11 Refer to the R-30iA CONTROLLER MAINTENANCE
EAS2
EAS2 MANUAL.
EAS21
EAS21
Fig. 1.1 (c) Limit switch circuit diaram of the safety fence (For R-30iA CONTROLLER)
s-3
SAFETY PRECAUTIONS B-81925EN/04
(1) If it is not necessary for the robot to operate, turn off the power
of the robot controller or press the EMERGENCY STOP button,
and then proceed with necessary work
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker
other than the operator from entering the work area unexpectedly
and also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's
reach.
The robot controller is designed to be connected to an external
EMERGENCY STOP button. With this connection, the controller stops the
robot operation when the external EMERGENCY STOP button is pressed.
See the diagram below for connection.
External EMERGENCY
STOP button
Panel PC board
Fig. 1.1.1 (a) Connection Diagram for External Emergency Stop Switch
(For R-J3iB CONTROLLER)
External EMERGENCY
STOP button
外部非常停止スイッチ
Panel board
パネルボード
EES1
EES11
EES2
EES21
Note) Connect between EES1 and EES11 and between EES2 and
EES21.
(注) EES1-EES11間、 EES2-EES21間に接続します。
Terminals EES1, EES11, EES2 and EES21 are on the Panel
EES1,EES11、EES2,EES21はパネルボード上にあり
board.
ます。
Refer to R-30iA CONTROLLER MAINTENANCE MANUAL.
詳細はR-J3iC制御部保守説明書をご参照下さい。
Fig. 1.1.1 (b) Connection Diagram for External Emergency Stop Switch
(For R-30iA CONTROLLER)
s-4
B-81925EN/04 SAFETY PRECAUTIONS
NOTE
The deadman's switch is provided so that the robot
operation can be stopped simply by releasing finger
from the teach pendant in case of emergency.
s-5
SAFETY PRECAUTIONS B-81925EN/04
(4) The teach pendant operator should pay careful attention so that
no other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable
switch and the deadman's switch also have the
following function.By pressing the deadman's switch
while the enable switch is on, the emergency stop
factor (normally the safety gate) connected to the
controller is invalidated. In this case, it is possible
for an operator to enter the fence during teach
operation without pressing the EMERGENCY STOP
button. In other words, the system understands
that the combined operations of pressing the teach
pendant enable switch and pressing the deadman's
switch indicates the start of teaching.
The teach pendant operator should be well aware
that the safety gate is not functional under this
condition and bear full responsibility to ensure that
no one enters the fence during teaching.
(5) When entering the robot work area, the teach pendant operator
should enable the teach pendant whenever he or she enters the
robot work area. In particular, while the teach pendant enable
switch is off, make certain that no start command is sent to the
robot from any operator's panel other than the teach pendant.
NOTE
When starting the system using the teach pendant
in the RIA specification, the three modes switch
should be T1/T2.
(6) To start the system using the operator's box, make certain that
nobody is in the robot work area and that there are no abnormal
conditions in the robot work area.
s-6
B-81925EN/04 SAFETY PRECAUTIONS
(a) Run the program for at least one operation cycle in the
single step mode at low speed.
(b) Run the program for at least one operation cycle in the
continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check
that the system operates automatically without trouble.
(e) After checking the completeness of the program through the
test run above, execute it in the automatic operation mode.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
s-7
SAFETY PRECAUTIONS B-81925EN/04
(1) Except when specifically necessary, turn off the power of the
controller while carrying out maintenance. Lock the power
switch, if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its
peripheral devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance
when the power is turned on, the worker should indicate that the
machine is being serviced and make certain that no one starts the
robot unexpectedly.
(5) Do not operate the robot in the automatic mode while anybody is
in the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay
careful attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator's panel and observe the work being
performed. If any danger arises, the worker should be ready to
press the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and also
turn off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
s-8
B-81925EN/04 SAFETY PRECAUTIONS
s-9
SAFETY PRECAUTIONS B-81925EN/04
s - 10
B-81925EN/04 SAFETY PRECAUTIONS
(2) Please make sure that adequate numbers of brake release units are
available and readily accessible for robot system before
installation.
(3) Regarding how to use brake release unit, please refer to Robot
controller maintenance manual.
NOTE
Robot systems installed without adequate number of
brake release units or similar means are not in
compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the
CE marking.
CAUTION
Robot arm would fall down by releasing its brake
because of gravity. Especially because spring
balancer is used for J2-axis, it is hard to predict
J2-arm movement by the condition of Robot attitude
and end effecter.Therefore it is strongly
recommended to take adequate measures such as
hanging Robot arm by a crane before releasing a
brake.
s - 11
SAFETY PRECAUTIONS B-81925EN/04
Sling
M12 eyebolt
M12 eyebolt
? ? Sling (2 pcs)
Unpredictable
Sling
M12 eyebolt
Fall down
s - 12
B-81925EN/04 SAFETY PRECAUTIONS
(1) Never enter the robot work area while the robot is operating.
Turn off the power before entering the robot work area for
inspection and maintenance.
(2) If it is necessary to enter the robot work area with the power
turned on, first press the EMERGENCY STOP button on the
operator's box.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system. When replacing the
parts in the pneumatic system, be sure to reduce the pressure in
the piping to zero by turning the pressure control on the air
regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn
off the circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified
ratings. They may cause a fire or result in damage to the
components in the controller.
(6) Before restarting the robot, be sure to check that no one is in the
robot work area and that the robot and its peripheral devices are
all in the normal operating state.
s - 13
SAFETY PRECAUTIONS B-81925EN/04
Description
When greasing and degreasing, observe the instructions indicated on
this label.
CAUTION
See sub-section 2.2.3 Replacing Grease for
explanations about specified greases, the amount of
grease to be supplied, and the locations of grease
and degrease outlets for individual models.
s - 14
B-81925EN/04 SAFETY PRECAUTIONS
Description
Do not disassemble the balance unit. It is very dangerous because a
spring is loaded in it.
Description
Do not step on or climb the robot or controller as it may adversely
affect the robot or controller and you may get hurt if you lose your
footing as well.
s - 15
SAFETY PRECAUTIONS B-81925EN/04
Description
Be cautious about a section where this label is affixed, as the section
generates heat. If you have to inevitably touch such a section when it
is hot, use a protective provision such as heat-resistant gloves.
s - 16
B-81925EN/04 SAFETY PRECAUTIONS
Description
When replacing the balancer, observe the instructions indicated on this
label.
• When replacing the balancer, keep the J2 axis at 0°.
• Use a balancer having a weight of 250 kg.
s - 17
SAFETY PRECAUTIONS B-81925EN/04
アイボルトを横引
しないこと
Do not pull eyebolt
sideways
+180DEG 0DEG
-180DEG
Motion area of
the writs tip
rotation center
A
C
A B C MAX. PAYLOAD
(mm) (mm) (mm) (kg)
M-410iB/160 3143 2880 78 160
M-410iB/300 3143 2880 78 300
M-410iB/450 3130 2696 238 450
M-410iB/700 3143 2870 88 700
s - 18
B-81925EN/04 PREFACE
PREFACE
This manual explains the maintenance and connection procedures for
the mechanical
units of the following robots:
CAUTION
Note that the models for the R-J3iB controller and
those for the R-30iA controller partly differ in the
specifications of mechanical unit cables.
p-1
PREFACE B-81925EN/04
Table 1
No. CONTENTS LETTERS
c –– FANUC Robot M-410iB/450
A05B-1039-B221
d TYPE
A05B-1039-B231
e NO. PRINT SERIAL NO.
PRINT PRODUCTION YEAR AND
f DATE
MONTH
TOTAL WEIGHT WITH
g 2430kg
CONTROLLER
TOTAL WEIGHT
h 2310kg
WITHOUT CONTROLLER
p-2
B-81925EN/04 PREFACE
Specifications
ITEM Specifications
Type Articulated type
Controlled axes 4 axes (J1, J2, J3, J4)
Installation Floor mount
Motion range J1-axis 360° (6.28rad)
J2-axis 145° (2.53rad)
J3-axis 135° (2.36rad)
J4-axis 540° (9.42rad)
Max. motion speed J1-axis 1.22rad/s (70° /s)
J2-axis 1.22rad/s (70° /s)
J3-axis 1.22rad/s (70° /s)
J4-axis 3.14rad/s (180° /s)
Max. load capacity at wrist 450 kg
Allowable load inertia at wrist 196 kgm2 (2000kgfcms2) (NOTE1) (∗1)
294 kgm2 (3000kgfcms2) (NOTE1) (∗2)
Maximum throughput 730 cycles / hour (400 kg)
700 cycles / hour (450 kg)
(NOTE1)
Drive method Electric servo drive by AC servo motor
Repeatability ±0.5 mm
Weight Integrated type controller : 2,430 kg (with control unit)
Remote type controller : 2,310 kg (without control unit)
: 120 kg (controller)
Acoustic noise level less than 70dB
NOTE
This value is equivalent continuous A-weighted sound pressure level
which applied with ISO11201 (EN31201). This value is measured
with the following conditions.
- Maximum load and speed
- Operating mode is AUTO
Installation requirement Ambient temperature : 0~45°C
Ambient humidity
Normally : 75%RH or less (NOTE 3)
Short time (within one month) : Max. 95%RH
Height :
Up to 1,000 meters above the sea level requires, no particular
provision for attitude.
Vibration : 0.5G (4.9m/s2) or less
NOTE
1 The allowable value in the standard inertia mode is indicated on the (∗1) and that in
the high inertia mode is indicated on the (∗2). For details, see Section 2.3 in the
connection manual.
2 When the horizontal range of motion is 2,000 mm and the vertical range of motion
is 400 mm.
3 No dew, nor frost allowed.
p-3
PREFACE B-81925EN/04
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
p-4
B-81925EN/04 TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
MAINTENANCE
1 CONFIGURATION .................................................................................. 3
1.1 J1-AXIS DRIVE MECHANISM....................................................................... 4
1.2 J2-AXIS DRIVE MECHANISM....................................................................... 4
1.3 J3-AXIS DRIVE MECHANISM....................................................................... 5
1.4 J4-AXIS DRIVE MECHANISM....................................................................... 5
1.5 MAJOR COMPONENT SPECIFICATIONS ................................................... 6
2 PREVENTIVE MAINTENANCE............................................................... 7
2.1 DAILY CHECKS ............................................................................................ 8
2.2 PERIODIC CHECKS ..................................................................................... 9
2.2.1 Checking for Cable Damage and Twisting ..............................................................9
2.2.2 Checking for Loose Bolts.......................................................................................11
2.2.3 Cleaning .................................................................................................................11
2.2.4 Replacing Grease....................................................................................................12
2.2.5 Procedure for Releasing Residual Pressure within the Grease Bath ......................16
2.2.6 Greasing .................................................................................................................17
2.2.7 Replacing Battery ...................................................................................................18
2.2.8 Replacing the Cables of the Mechanical Unit ........................................................19
2.2.9 Others .....................................................................................................................19
2.3 MAINTENANCE TOOLS ............................................................................. 20
3 TROUBLESHOOTING .......................................................................... 21
3.1 OVERVIEW ................................................................................................. 21
3.2 FAILURES, CAUSES AND MEASURES ..................................................... 22
3.3 BACKLASH MEASUREMENT..................................................................... 30
c-1
TABLE OF CONTENTS B-81925EN/04
4 ADJUSTMENTS.................................................................................... 32
4.1 ADJUSTING LIMIT SWITCHES AND DOGS (OPTION) ............................. 33
4.2 ZERO POINT POSITION AND MOTION LIMIT OF J2-AXIS TO
J4-AXIS ....................................................................................................... 35
4.3 J1-AXIS STROKE MODIFICATION (OPTION)............................................ 37
4.4 SOFTWARE SETTING................................................................................ 40
4.5 MASTERING ............................................................................................... 41
4.5.1 General ...................................................................................................................41
4.5.2 Mastering Method ..................................................................................................42
4.5.3 Resetting Alarms and Preparing for Mastering ......................................................43
4.5.4 Mastering to a Fixture (Master Position Master) ..................................................44
4.5.5 Mastering................................................................................................................48
4.5.6 Zero Degree Mastering...........................................................................................50
4.5.7 Quick Mastering .....................................................................................................52
4.5.8 Single Axis Mastering ............................................................................................54
4.5.9 Mastering Data Entry .............................................................................................57
6 WIRING ................................................................................................. 84
c-2
B-81925EN/04 TABLE OF CONTENTS
CONNECTION
APPENDIX
c-3
MAINTENANCE
B-81925EN/04 MAINTENANCE 1. CONFIGURATION
1 CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1 (a) and
(b).
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1. CONFIGURATION MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 1. CONFIGURATION
NOTE
A non-excited brake is incorporated in the motors
for all axes (J1, J2, J3, and J4 axes) and actuates
at power off or in an emergency.
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1. CONFIGURATION MAINTENANCE B-81925EN/04
(1) Motor
Axis Specifications Remarks
J1, J2, J3 A06B-0268-B605#S000 (Model αM30/4000i)
Model αiS 30/4000i
J4 A06B-0235-B605#S000 (Model αM8/4000i)
Model αiS 8/4000
(2) Reducer
Axis Specifications Remarks
J1-axis reducer A97L-0218-0265#450C-37 RV-450C-37
J2-axis reducer A97L-0218-0266#450E-257 RV-450E-257
J3-axis reducer A97L-0218-0266#450E-257 RV-450E-257
J4-axis reducer A97L-0118-0949#70C-36 RV-70C-36
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B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
2 PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained for a long time
by performing the periodic maintenance procedures presented in this
chapter.
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2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
Clean each part, and visually check component parts for damage
before daily system operation. Check the following items as the
occasion demands.
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B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
Movable parts of J1,the upper side and lower side of link for wrist
posture maintenance of rear side of J2 arm, movable part in uniting
part of J2 to J3 and J3 to J4 and fixed department cable who interferes
easily in peripherals
Check items
For cables with a cable cover, open the cover before making the
check.
Check the cables for a sheath break and wear.
If wires of the cable appear, replace it.
カバーを外す
Remove the cover
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2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
Check items
- Circular connector: Check the connector for looseness by turning
it manually.
- Square connector: Check the connector for disengagement of its
lever.
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B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
As part of the first quarterly inspection and the first and subsequent
yearly inspections, check whether the major bolts indicated in Fig.
2.2.2 are loose. If any loose bolts are found, retighten them.
See the operation time of Appendix C.
2.2.3 Cleaning
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2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
Figs. 2.2.4 (b) through (d) show the grease inlets and outlets of each
reducer.
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B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
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2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
CAUTION
If greasing is performed incorrectly, the internal
pressure of the grease bath may suddenly increase,
possibly causing damage to the seal, which would in
turn lead to grease leakage and abnormal operation.
When performing greasing, therefore, observe the
following cautions.
1 Before starting to grease, open the grease outlet
(remove the plug or bolt from the grease outlet).
2 Supply grease slowly without applying excessive
force, using a manual pump.
3 Whenever possible, avoid using a compressed-air
pump, powered by the factory air supply. Even
when using a compressed-air pump unavoidably,
set the gun tip pressure (see Table 2.2.4) to 0.1
5MPa or less during application of grease.
4 Use grease only of the specified type. Grease of
a type other than that specified may damage the
reducer or lead to other problems.
5 After applying grease, release the residual
pressure within the grease bath as described in the
procedure in Section 2.2.5.
6 Wipe off any grease from the floor and robot
completely, so no one will slip on it.
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B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
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2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
Operating axis
J1-axis J2-axis J3-axis J4-axis
Grease
replacement part
Axis angle of
J1-axis reducer 80° or more Arbitrary
OVR 50%
Axis angle of
J2-axis reducer Arbitrary 90° or more Arbitrary
OVR 50%
Axis angle of
J3-axis reducer Arbitrary 60° or more Arbitrary
OVR 100%
Axis angle of
J4-axis gear box Arbitrary 60° or more
OVR 100%
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B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
2.2.6 Greasing
Supply grease to the parts periodically (after the prescribed number of
operating hours or every specified interval, whichever comes earlier).
If the robot is installed in a severe environment, apply grease
whenever necessary. If water splashes on the robot, apply grease
immediately. Table 2.2.6 (a) and Fig. 2.2.6 show greasing points.
Table 2.2.6 (b) shows substitue greases. When performing greasing,
observe the cautions listed in Section 2.2.3.
NOTE
When the robot is used under high-duty
conditions that, for example, require a cooling unit
(fan), perform greasing at half of the standard
interval.
NOTE
Old grease is expelled from the bearing rotating
part after new grease is supplied. Wipe off old
grease immediately after supplying grease, and
then again after 50 to 100 hours of operation.
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2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
CAUTION
Batteries must be replaced only while the power
is on. Replacing the batteries while the power is
off will cause the current position data to be lost.
When this occurs, mastering will have to be
performed. (See Sections 4.5.)
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B-81925EN/04 MAINTENANCE 2. PREVENTIVE MAINTENANCE
2.2.9 Others
Clean the mechanical unit and controller vents whenever cleaning
those are necessary.
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2. PREVENTIVE MAINTENANCE MAINTENANCE B-81925EN/04
The following tools and instruments are required for the maintenance
procedures contained in this manual.
1) Measuring instruments
Instruments Accuracy/Tolerance Applications
Dial gauge accuracy 1/100mm Measurement of
positioning and backlash
Side calipers 150mm
Push/pull tension gauge 98N (10kgf) Measurement of
backlash
2) Tools
Cross-point (+) screwdrivers : Large, medium, and small sizes
Conventional (-) screwdrivers : Large, medium, and small sizes
Box screwdrivers : M3-M6
Hexagonal wrench key sets : M3-M20
(metric)
Adjustable wrenches : Medium and small sizes
Pliers
Cutting pliers
Cutting nippers
Double and wrench
Pliers for C-retaining ring
Torque wrench : With hexagon socket head cap screw
for M8 to M16
Grease gun
Eyebolt : M12, M20, M24
Rope
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B-81925EN/04 MAINTENANCE 3. TROUBLESHOOTING
3 TROUBLESHOOTING
3.1 OVERVIEW
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3. TROUBLESHOOTING MAINTENANCE B-81925EN/04
Table 3.2(a) lists the major failures that may occur in the mechanical
unit and their probable causes. If you cannot pinpoint a failure cause
or which measures to apply, contact FANUC.
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B-81925EN/04 MAINTENANCE 3. TROUBLESHOOTING
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3. TROUBLESHOOTING MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 3. TROUBLESHOOTING
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3. TROUBLESHOOTING MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 3. TROUBLESHOOTING
- 27 -
3. TROUBLESHOOTING MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 3. TROUBLESHOOTING
NOTE
The value is the drop value from the end effector
mounting face.
Refer to following page for the measuring method and the measuring
posture.
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3. TROUBLESHOOTING MAINTENANCE B-81925EN/04
Measurement method
1. Maintain the robot in a specified posture. (See Fig. 3.3 (b))
2. Apply positive and negative loads to each axis as shown in Fig.
3.3(a).
3. Remove the loads and measure the displacement.
Apply positive and negative loads to each axis three times and
then remove the loads. Calculate the average of the
displacements in the second and third measurements as the
backlash.
L1
(B2=L1+L2)
L2
L3 (B3=L3+L4)
L4
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B-81925EN/04 MAINTENANCE 3. TROUBLESHOOTING
test work
test work
Trestle
3130
Loading position
Trestle test work
When measuring backlash,press Center of mounting
gauge to test work vertically. face of wrist
Loading position
When measuring backlash,press
gauge to test work vertically.
Loading position
test work 280
Loading position
Trestle
175
- 31 -
4. ADJUSTMENTS MAINTENANCE B-81925EN/04
4 ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory
before shipment. Therefore it is usually unnecessary for the customer
to make adjustments at the time of delivery. However, after for a long
period of use or after parts are replaced, adjustments may be required.
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
Fig. 4.2 (a) to (c) show zero point position and motion area and
mechanical stopper of each axis.
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
- 37 -
4. ADJUSTMENTS MAINTENANCE B-81925EN/04
(a) Changing the mechanical stopper and the dog (option) position.
Change the mechanical position and the dog position as shown in
Fig. 4.3 (b).
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
WARNING
After changing system variables, be sure to run the
robot at a low speed and make sure that the robot
stops at the ends of the stroke.
WARNING
1 If a collision should occur, the J1 axis stopper
becomes deformed to absorb energy, so that the
robot can stop safely. If the stopper is deformed
by mistake, replace it.
2 Do not add threaded holes to the frame, or do not
use a self-made stopper to control the J1 stroke at
any angle other than the one specified; otherwise,
robot operation may be dangerous.
- 39 -
4. ADJUSTMENTS MAINTENANCE B-81925EN/04
Axis limit software settings are upper and lower motion degree
limitations. The limits can be set for all robot axes and will stop robot
motion if the robot is calibrated.
1/16
AXIS GROUP LOWER UPPER
1 1 -150.00 150.00 dg
2 1 -60.00 75.00 dg
3 1 -110.00 50.00 dg
4 1 -240.00 240.00 dg
5 1 0.00 0.00 mm
6 1 0.00 0 00 mm
7 0 0.00 0.00 mm
8 0 0.00 0.00 mm
9 0 0.00 0.00 mm
[ TYPE ]
NOTE
0 indicates the robot does not have these axes.
CAUTION
Do not depend on J1 axis limit software settings to
control the motion range of your robot. Use the axis
limit switches or hardstops also; otherwise injury to
personnel or damage to equipment could occur.
CAUTION
You must turn off the controller and then turn it
back on to use the new information; otherwise
injury to personnel or damage to equipment could
occur.
8 Turn off the controller and then turn it back on again in the cold
start mode so the new information can be used.
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
4.5 MASTERING
4.5.1 General
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis.
Mastering is factory-performed. It is unnecessary to perform
mastering in daily operations. However, mastering becomes necessary
after:
• Motor replacement.
• Pulse coder replacement.
• Reducer replacement.
• Cable replacement.
• Batteries for pulse count backup in the mechanical unit have gone
dead.
CAUTION
Robot data (including mastering data) and pulse
coder data are backed up by their respective
backup batteries. Data will be lost if the batteries go
dead. Replace the batteries in the control and
mechanical units periodically. An alarm will be
issued to warn the user of a low battery voltage.
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
CAUTION
If mastering is performed incorrectly, the robot may
behave unexpectedly. This is very dangerous. So,
the positioning screen is designed to appear only
when the $MASTER_ENB system variable is 1 or 2.
After performing positioning, press F5 [DONE] on
the positioning screen. The $MASTER_ENB
system variable is reset to 0 automatically, thus
hiding the positioning screen.
CAUTION
Before performing mastering, it is recommended
that the current mastering data be backed up.
- 42 -
B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse mismatch”
Procedure
1 Display the positioning menu by following steps 1 to 6.
1 Press the screen selection key.
2 Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variable] from the
menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and
press [ENTER].
5 Press F1 [TYPE], and select[Mater/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal]
menu.
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
4.5.5 Mastering
1) Press MENUS.
2) Press NEXT and select SYSTEM.
3) Press F1, [TYPE].
4) Select Master/Cal.
5) Release brake control, and jog the robot into a posture for
mastering. See the Fig. 4.5.5 for the mastering posture.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM_GROUP.SV_OFF_ENB[*]: FALSE (for
all axes)
After changing the system variables, switch the
control unit power off and on again.
CAUTION
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the
mechanical stopper being bumped.
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
M-410iB/450 Mastering
- 49 -
4. ADJUSTMENTS MAINTENANCE B-81925EN/04
5 Release brake control, and jog the robot into a posture for
mastering.
NOTE
Brake control can be released by setting the
system variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV OFF ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the
control unit power off and on again.
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
J3-axis
VIEW B
J4-axis
J2-axis
J1-axis, J2-axis 0° position mark
J1-axis
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
CAUTION
1 Simplified mastering can be used, if the pulse count
value is lost, for example, because a low voltage
has been detected on the backup battery for the
pulse counter.
2 Simplified mastering cannot be used, after the pulse
coder is replaced or after the mastering data is lost
from the robot control unit.
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
4 Move the cursor to the SEL column for the unmastered axis and
press the numeric key "1." Setting of SEL is available for one
or more axes.
5 Turn off brake control as required, then jog the robot to the
mastering position.
6 Enter axis data for the mastering position.
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 4. ADJUSTMENTS
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4. ADJUSTMENTS MAINTENANCE B-81925EN/04
4 Select $DMR_GRP.
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
5 REPLACING PARTS
Procedure of replacement for main parts is described.
Replace the main parts according to the procedure.
NOTE
When applying LOCTITE to the important bolt
tightening points, make sure that it is applied to the
entire longitudinal portion in the engaging section of
the female threads. If it is applied to the male
threads, the bolts may be loosened because
sufficient effects cannot be obtained. Remove the
dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no solvent
in the taps.
NOTE
Be careful when removing and installing the
following heavy parts.
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
Fig. 5.2 (a) Replacing the J1-axis motor (M1) (Integrated control unit)
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
Fig. 5.2 (b) Replacing the J1-axis motor (M1) (Integrated control unit)
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
Fig. 5.2 (c) Replacing the J1-axis motor (M1) (Remote control unit)
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
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5. REPLACING PARTS MAINTENANCE B-81925EN/04
This section describes the procedure for replacing the wrist unit. To
order a replacement wrist unit, use the ordering information
A05B-1039-K501. To replace only the J4-axis reducer, see (2) in
Section 5.4.
1 Turn the power off.
2 Remove the hand, workpiece, and other loads from the wrist.
3 Remove the cover from the J3-axis arm (3pcs M6×10) (see Fig.
5.5).
4 Disconnect a connector from the J4-axis motor.
5 Remove the wrist connector box from the wrist unit (see Section
7).
6 Remove the J3-axis link from the wrist unit by following the
steps below.
• Remove the rubber cap from both ends of the J3-axis link.
• Remove the bolts (four M6×12 bolts) from both ends of the
J3-axis link.
• Remove the bolts (eight M8×20 bolts) from the J3 base-side
shaft of the J3-axis link.
• Remove the wrist unit from the J3-axis link.
7 Remove the bolts (eight M8×25 bolts) from the J3-axis link shaft,
and dismount it from the wrist unit.
8 Remove the bolts (four M10×30 bolts) from the wrist subshaft,
and dismount it.
9 Remove the cross-roller internal ring mounting bolts (twelve
M10 ×75 bolts), and dismount the wrist unit from the J3 arm.
10 Remove the cross-roller external ring mounting bolts (eight
M10×45 bolts), and dismount the cross roller from the wrist unit.
11 Remove the J4-axis motor mounting bolts (four M8×20 bolts),
and dismount the motor (see Section 5.4).
12 Mount a new replacement wrist unit as follows :
• Apply grease (SHELL SEKIYU Alvania GREASE S2) to the
oil seal attached to the replacement wrist unit.
• Replace each removed washer with a new one.
• Apply sealant (Loctite Gasket Eliminator No. 518) to the
surface on which the wrist flange is to be mounted to the
reducer. A light, uniform coating of the sealant should be
applied to the area shown in Fig. 5.4 (c).
13 Apply grease (see Section 2).
14 Carry out an adjustment (see Sections 4.5).
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
- 81 -
5. REPLACING PARTS MAINTENANCE B-81925EN/04
1) Remove the limit switch from the metal plate of mounting limit
switch.
2) Disconnect the cable from the limit switch.
3) Replace the limit switch with a new one.
4) Reassemble the unit by reversing the above procedure.
• Those bolts for which no tightening torque is specified must
be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
5) Adjust the limit switch. (See item 4.1)
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B-81925EN/04 MAINTENANCE 5. REPLACING PARTS
- 83 -
6. WIRING MAINTENANCE B-81925EN/04
6 WIRING
Fig. 6 (a), (b) show the wiring diagram in the mechanical unit.
Fig. 6 (a) Wiring diagram in the mechanical unit (Integrated control unit)
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B-81925EN/04 MAINTENANCE 6. WIRING
Fig. 6 (b) Wiring diagram in the mechanical unit (Control unit remote type)
- 85 -
7. REPLACING CABLES MAINTENANCE B-81925EN/04
7 REPLACING CABLES
Replace the cables periodically (every 15,360 operating hours or every
four years, whichever comes earlier). When a cable is broken or
damaged, replace it according to this chapter.
Do not disconnect the cable except the time to replace the pulse coder
cable.
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
When replacing cables, clamp the cable at the position specified in Fig.
7.1 (a) and (b) using a nylon band. Otherwise, cables are loosened or
forcedly pulled to cause their disconnection.
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
CRF7 CNJ1
Robot M-410iB/450
CNJ2
Motor power
J1M
CNJ5 J2M
J3M
J4M
Pulse coder
RDI/RDO
CNG HBK,ROT
BRAKE
CNJ3
CNJ4
CRR64
R-J3iB(Servo amplifier)
CNJ1A
CRF7
CNJ1B
CRR64 CNJ2A
CNJ2B
CNJ4
CNJ3A
CNGC CNJ3B
CNGB
Pulse coder
CNGA (Pulse coder,RDI/RDO,
HBK,ROT)
BRAKE
Motor power
(J4M)
Motor power
(J3M)
Motor power
(J2M)
Motor power
(J1M)
- 99 -
7. REPLACING CABLES MAINTENANCE B-81925EN/04
CNJ6
CNJ3 Robot M-410iB/450
CNJ5 CNJ2
(R-30iA Controller)
CNJ4
CNG Motor power
CNJ1 J1M
J2M
J3M
J4M
pulse coder
RDI/RDO
RI/RO
HBK,ROT
HBK,ROT
BRAKE
CRF8
CRR88
Robot M-410iB/450
・Detail of the cable connection for servo amplifier (R-30iA Controller)
R-30iA (Servo amplifier)
CNJ1A
CRF8
CNJ1B
CRR88 CNJ2A
CNJ2B
CNJ4
CNJ3A
CNGC CNJ3B
CNGB
Pulse coder
CNGA (Pulse coder,RI/RO,
HBK,ROT)
BRAKE
Motor power
(J4M)
Motor power
(J3M)
Motor power
(J2M)
Motor power
(J1M)
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
30
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7. REPLACING CABLES MAINTENANCE B-81925EN/04
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B-81925EN/04 MAINTENANCE 7. REPLACING CABLES
- 105 -
7. REPLACING CABLES MAINTENANCE B-81925EN/04
- 106 -
CONNECTION
B-81925EN/04 CONNECTION 1. ROBOT EXTERNAL DIMENSION
- 109 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
- 110 -
B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
Fig. 2.1 (a) shows the relationships between the horizontal offset of
the center of gravity of the wrist load and the permissible load inertia.
See Fig. 2.1 (b) to check whether the center of gravity of the load is
inside or outside of the wrist.
Fig. 2.1 (c) shows the relationships between the vertical offset of the
center of gravity of the wrist load and permissible load weight. See
Fig. 2.1 (d) for explanations about the vertical offset of the center of
gravity of the wrist load.
The wrist load must fall within the corresponding ranges in Figs. 2.1
(a) and 2.1 (c) and the allowable wrist moment and allowable wrist
inertia conditions must be satisfied.
See Fig. 2.1 (e) for explanations about how to calculate the load inertial.
Fig. 2.1 (a) Line chart of the permissible load for the wrist section
(horizontal offset) (M-410iB/450)
- 111 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
Fig. 2.1 (c) Line chart of the permissible load for the wrist section
(vertical offset) (M-410iB/450)
- 112 -
B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
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2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
Fig. 2.2 shows the end effector mounting surface at the end of the
wrist.
the
- 114 -
B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
MOTION PERFORMANCE
Group1
No. PAYLOAD [kg] Comment
1 450.00 [ ]
2 450.00 [ ]
3 450.00 [ ]
4 450.00 [ ]
5 450.00 [ ]
6 450.00 [ ]
7 450.00 [ ]
8 450.00 [ ]
9 450.00 [ ]
10 450.00 [ ]
Active PAYLOAD number = 0
[ TYPE ] GROUP DETAIL ARMLOAD SETIND >
INDENT >
Group 1
Schedule No[ 1]:[Comment ]
1. PAYLOAD [kg] 450.00
2. PAYLOAD CENTER X [cm] 0.00
3. PAYLOAD CENTER Y [cm] 0.00
4. PAYLOAD CENTER Z [cm] 0.00
5. PAYLOAD INERTIA X [kgfcms^2] 0.00
6. PAYLOAD INERTIA Y [kgfcms^2] 0.00
7. PAYLOAD INERTIA Z [kgfcms^2] 0.00
- 115 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
手首フランジ
Center of robot flange
xg(cm)
Center of gravity
zg(cm)
2
Iy(kg・cm)
Center of重心
gravity
質量m(kg)
Masss
2
Ix(kg・cm)
yg(cm)
X
Center重心
of gravity
6 Set the payload, gravity center position, and inertia around the
gravity center on the MOTION PAYLOAD SET screen. The X,
Y, and Z directions displayed on this screen correspond to the
respective standard tool coordinates (with no tool coordinate
system set up). When values are entered, the following
message appears: "Path and Cycletime will change. Set it?"
Respond to the message with F4 ([YES]) or F5 ([NO]).
7 Clicking F3 ([NUMBER]) will bring you to the MOTION
PAYLOAD SET screen for another condition number. For a
multigroup system, clicking F2 ([GROUP]) will bring you to the
MOTION PAYLOAD SET screen for another group.
8 Click the previous page key to return to the MOTION
PERFORMANCE screen. Click F5 ([SETIND]), and enter the
desired payload setting condition number.
- 116 -
B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
CAUTION
If a workpiece with an inertia exceeding the
allowable inertia in the standard inertia mode is
used in the mode, parts of the mechanical unit may
degrade earlier.
Setting method
Specify and execute the program of Table 2.3.2 directly on the
program selection screen or create another program and call the
program within it.
Set input parameter i for setting program to the group number of the
robot. When input parameter i is omitted, the parameter settings for
all M-410iB/450’s in the controller are changed for the high inertia
mode.
- 117 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
Exception processing
In the following cases, exception processing is applied, parameters are
not changed, and a message describing the exception processing
appears on the user screen.
(1) When the group set in input parameter i for setting program is
not present
(2) When the group set in input parameter i for setting program is
not M-410iB/450.
- 118 -
B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
Fig. 2.4 shows the positions of holes for mounting the equipment.
Those bolts, for which no tightening torque is specified, tighten as the
table of Appendix D.
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2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
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B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
- 121 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
Fig. 2.6 (a) and (b) show the position of the end effector interface.
End
effector interface (EE) is prepared as basic function. The user cable
(signal lines option) is prepared as an option.
Fig. 2.6 (a) Interface for end effector (Integrated control unit)
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B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
Fig. 2.6 (b) Interface for the end effector (Remote control unit)
- 123 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
WARNING
The RDO signal for the R-J3iB controller and the
RO signal for the R-30iA controller are
incompatible with each other because different
output formats are used. For details, refer to the
maintenance manuals for the controllers.
Comformable connector
End effector interface (RDI/RDO) (Wrist side) A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
A63L-0001-0234#R2524F(Fujikura.Ltd)
1 2 3 4
RDO1 RDO2 RDO3 RDO4
5
RDO5
6
RDO6
7
XHBK
8
0V
9
RDI1 End
10 11 12 13 14 15 effector
RDI2 RDI3 RDI4 RDI8 XPPABN RDI5
16 17 18 19 20
RDI6 +24V +24V +24V +24V
21 22 23 24
RDO7 RDO8 RDI7
Please prepare by user.
XHBK : Hand broken
Controller XPPABN : Pneumatic pressure abnormal
Fig. 2.6 (c) Pin layout for the end effector interface (EE) (for R-J3iB controller)
Comformable connector
End effector interface (RI/RO) (Wrist side)
A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
A63L-0001-0234#R2524F(Fujikura.Ltd)
1 2 3 4
RO1 RO2 RO3 RO4
5
RO5
6
RO6
7
XHBK
8
0V
9
RI1 End
10 11 12 13 14 15 effector
RI2 RI3 RI4 RI8 XPPABN RI5
16 17 18 19 20
RI6 +24V +24V +24V +24V
21 22 23 24
RO7 RO8 0V RI7
Please prepare by user.
XHBK : Hand broken
Controller XPPABN : Pneumatic pressure abnormal
Fig 2.6 (d) Pin layout for the end effector interface (EE) (R-30iA controller)
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B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
Conformable
適合コネクタconnector
A63L-0001-0234#S2524MX(Fujikura
A63L-0001-0234#S2524MX((株)フジクラ)Ltd.)
User cable interface(AS2) (Wrist
ユーザケーブルインタフェース side)
(AS2) (手首側) (Fujikura Ltd.: JMSP2524MX)
(フジクラ仕様;JMSP2524MX)
A63L-0001-0234#R2524FX(Fujikura
A63L-0001-0234#R2524FX((株)フジクラ) Ltd.)
1 2 3 4
S1 S2 S3 S4 End
エンド
5 6 7 8 9
S5 S6 S7 S8 S9 effector
エフェクタ
10 11 12 13 14 15
S10 S11 S12 S13 S14 S15
16 17 18 19 20
S16 S17 S18 S19 S20
21 22 23 24
}
S21 S22 S23 S24
A63L-0001-0234#W2524M((株)フジクラ)
1 2 3 4
External
外部信号 9
S4
8
S3
7
S2
6
S1
5
signal 10
S9
11
S8
12
S7
13
S6
14
S5
15
S10 S11 S12 S13 S14 S15
20 19 18 17 16
S20 S19 S18 S17 S16 2
24 23 22 21
S24 S22 S22 S21
Conformable
適合コネクタconnector
A63L-0001-0234#S2524F(Fujikura
A63L-0001-0234#S2524F((株)フジクラ)Ltd.)
(フジクラ仕様;JMSP2524F)
(Fujikura Ltd.: JMSP2524F)
Fig. 2.6 (e) Pin layout for the user cable (signal line) interface (option)
- 125 -
2. MOUNTING A DEVICE TO THE ROBOT CONNECTION B-81925EN/04
Fig. 2.7 (a) shows the position of the servo hand cable interface
option.
Fig. 2.7 (a) Interface for the servo hand cable interface (option)
- 126 -
B-81925EN/04 CONNECTION 2. MOUNTING A DEVICE TO THE ROBOT
NOTE
A connector prepared by the customer for the
servo cable interface must be a straight type; an
elbow type cannot pass through the hole in the J4
axis.
Fig. 2.7 (b) Pin layout for the servo hand cable interface (option)
- 127 -
3. TRANSPORTATION AND INSTALLATION CONNECTION B-81925EN/04
- 128 -
B-81925EN/04 CONNECTION 3. TRANSPORTATION AND INSTALLATION
3.1 TRANSPORTATION
- 129 -
3. TRANSPORTATION AND INSTALLATION CONNECTION B-81925EN/04
CAUTION
When a peripherals are installed on a robot, the
center of gravity of the robot changes and the robot
might become unstable while being transported.
Robot becomes unstable when it is transported
with the end effector applied to wrist ,and it is
dangerous.
Please be sure to remove end effector when robot
is transported.
Use the forklift pockets only to transport the robot
with a forklift. Do not use the forklift pockets for any
other transportation method. Do not use the forklift
pockets to secure the robot.
Before moving the robot by using forklift pockets,
check and tighten any loose bolts on the forklift
pockets.
Do not pull eyebolts sideways.
Prevent the forks of the forklift from having impact
on a transport equipment.
Do not thread a chain or the like through a
transport equipment.
- 130 -
B-81925EN/04 CONNECTION 3. TRANSPORTATION AND INSTALLATION
3.2 INSTALLATION
(1) Installing the robot using the standard pedestal
Described below is how to install the robot using the standard pedestal,
which is factory-assembled with the robot.
Fig. 3.2 (a) shows the robot base dimensions. Fig. 3.2 (b) shows an
actual example of robot installation. Secure the floor plate (iron
plate) to the floor using 16 M20 chemical anchors (strength class 4.8).
• Those bolts for which no tightening torque is specified must
be tightened according to the APPENDIX D BOLT
TIGHTENING TORQUE TABLE.
Table 3.2 (a) and Fig. 3.2 (c) indicate the force and moment applied to
the robot base plate. When installing the robot, be sure that the setup
is strong enough to withstand the indicated force and moment.
Table 3.2(b) indicates the coasting time and distance consumed from
the pressing of the emergency stop button until the robot stops
NOTE
1 If the robot base is secured directly to the floor with
chemical anchors, the anchors may fail due to
fluctuating load during robot operation.
2 Do not provide leveling (with a wedge, for example)
between the robot base and floor plate.
Otherwise, any robot vibration may be accentuated
due to the robot not being in close contact with the
floor plate.
1080
- 131 -
3. TRANSPORTATION AND INSTALLATION CONNECTION B-81925EN/04
NOTE
1 The customer should prepare the following parts:
• Eight robot securing bolts: M20×40 (strength
class 12.9)
• 16 chemical anchors: M20 (strength class 4.8)
• One floor plate: 32t in thickness
2 The customer is responsible for preparation prior to
installation (mounting of anchors, for example)
- 132 -
B-81925EN/04 CONNECTION 3. TRANSPORTATION AND INSTALLATION
Table 3.2 (b) Stopping time and distance when emergency stop
Fig. 3.2 (c) Force and moment acting to the robot base
- 133 -
3. TRANSPORTATION AND INSTALLATION CONNECTION B-81925EN/04
Fig. 3.2 (d) shows how to remove the standard pedestal from the robot.
First put the robot in the attitude of J1-axis = 0°, J2-axis = -45°,
J3-axis = 25°, and J4-axis = 0°, then prepare to sling up the robot
portion above the J1-axis base with rope. Remove the J1-axis
mounting bolts (sixteen M16×65 bolts), and separate the J1-axis base
from the pedestal.
Fig. 3.2 (e) shows the installation interface for the robot. Design a
pedestal while taking care of the following points:
• Provide space required when replacing the J1-axis motor.
• Provide space required when mounting and dismounting the
mastering fixture.
• Provide space for periodic maintenance (such as battery
exchange and degreasing)
• Avoid interference of the robot with the cables and connector
box.
• Make sure that the setup is strong enough to withstand the force
and moment listed in Table 3.2 (b).
To fasten the J1-axis base to the pedestal, use sixteen bolts having a
size of M16 (in strength class 12.9) and a length of at least 65 mm.
- 134 -
B-81925EN/04 CONNECTION 3. TRANSPORTATION AND INSTALLATION
Fig. 3.2 (d) How to remove the pedestal (robot with a separate control unit)
- 135 -
3. TRANSPORTATION AND INSTALLATION CONNECTION B-81925EN/04
322 176
Mastering fixture 88
Battery box
60
Robot front
242
357
371
(500)
172
80
209 250 Required space to 185
replace the J1-axis motor 370
Robot connection cable
B
65 290 290 65 16-Φ18 Through View A
Tap for earth 65 160 160 65 spot hole Φ26 Depth 20(Back side)
J1-axis base mounting through hole
65
880
65
340
210 210
340
Mastering fixture
65
65
880
Grease outlet
View B
Fig. 3.2 (e) Installation interface for the robot (with a separate control unit) with the standard pedestal removed
- 136 -
B-81925EN/04 CONNECTION 3. TRANSPORTATION AND INSTALLATION
- 137 -
3. TRANSPORTATION AND INSTALLATION CONNECTION B-81925EN/04
NOTE
Contact the service representative, if the robot is
to be used in an environment or a place subjected
to severe vibrations, heavy dust, cutting oil splash
and or other foreign substances.
- 138 -
APPENDIX
B-81925EN/04 APPENDIX A. SPARE PARTS LIST
- 141 -
A. SPARE PARTS LIST APPENDIX B-81925EN/04
- 142 -
B-81925EN/04 APPENDIX A. SPARE PARTS LIST
NOTE
A motor whose specification number is terminated
with #S000 has the built-in auxiliary seal.
When ordering a motor, specify a motor whose
specification number is terminated with #S000.
- 143 -
A. SPARE PARTS LIST APPENDIX B-81925EN/04
NOTE
A motor whose specification number is
terminated with #S000 has the built-in auxiliary
seal.
- 144 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
B CIRCUIT DIAGRAM
- 145 -
B. CIRCUIT DIAGRAM APPENDIX B-81925EN/04
Fig. B (a) Internal circuit diagram (R-J3iB Integrated control unit for CE)
- 146 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
- 147 -
B. CIRCUIT DIAGRAM APPENDIX B-81925EN/04
Fig. B (b) Internal circuit diagram (R-J3iB Integrated control unit for CE with servo hand option)
- 148 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
- 149 -
B. CIRCUIT DIAGRAM APPENDIX B-81925EN/04
Fig. B (c) Internal circuit diagram (R-J3iB Remote control unit for CE)
- 150 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
- 151 -
B. CIRCUIT DIAGRAM APPENDIX B-81925EN/04
Fig. B (d) Internal circuit diagram (R-J3iB Remote control unit for CE with servo hand option)
- 152 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
- 153 -
B. CIRCUIT DIAGRAM APPENDIX B-81925EN/04
- 154 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
Fig. B (e) Internal circuit diagram (R-30iA Integrated control unit for CE)
(Including the case where the servo hand option is selected)
- 155 -
B. CIRCUIT DIAGRAM APPENDIX B-81925EN/04
Fig. B (f) Internal circuit diagram (R-30iA Integrated control unit for CE)
(Including the case where the servo hand option is selected)
- 156 -
B-81925EN/04 APPENDIX B. CIRCUIT DIAGRAM
- 157 -
C. PERIODIC MAINTENANCE APPENDIX B-81925EN/04
C PERIODIC MAINTENANCE
1.8 10800 ml
0.9 2300 ml
2300 ml
1600 ml
10 ml
40 ml
20 ml
- 158 -
B-81925EN/04 APPENDIX C. PERIODIC MAINTENANCE
- 159 -
D. BOLT TIGHTENING TORQUE TABLE APPENDIX B-81925EN/04
NOTE
When applying Loctite to the important bolt
tightening points, make sure that it is applied to the
entire longitudinal portion in the engaging section of
the female threads. If it is applied to the male
threads, the bolts may be loosened because
sufficient effects cannot be obtained. Remove the
dust within the bolts and taps and wipe oil off the
engaging section. Make sure that there is no
solvent in the taps.
- 160 -
B-81925EN/04 APPENDIX D. BOLT TIGHTENING TORQUE TABLE
- 161 -
B-81925EN/04 INDEX
INDEX
<A> <J>
ADJUSTING LIMIT SWITCHES AND DOGS J1-AXIS DRIVE MECHANISM ...................................... 4
(OPTION) ....................................................................... 33 J1-AXIS STROKE MODIFICATION
ADJUSTMENTS ............................................................ 32 (OPTION) ....................................................................... 37
AIR SUPPLY ................................................................ 120 J2-AXIS DRIVE MECHANISM ...................................... 4
J3-AXIS DRIVE MECHANISM ...................................... 5
<B>
J4-AXIS DRIVE MECHANISM ...................................... 5
BACKLASH MEASUREMENT .................................... 30
<L>
BOLT TIGHTENING TORQUE TABLE .................... 160
LOAD CONDITION AT WRIST................................. 111
<C>
LOAD SETTING.......................................................... 115
CABLE FORMING ........................................................ 87
<M>
Checking for Cable Damage and Twisting .......................9
Checking for Loose Bolts................................................ 11 MAINTENANCE AREA ............................................. 137
CIRCUIT DIAGRAM................................................... 145 MAINTENANCE TOOLS ............................................. 20
Cleaning .......................................................................... 11 MAJOR COMPONENT SPECIFICATIONS................... 6
CONFIGURATION ..........................................................3 Mastering ........................................................................ 48
COUPLING OF THE END EFFECTOR TO MASTERING ................................................................. 41
THE WRIST ................................................................. 114 Mastering Data Entry...................................................... 57
Mastering Method........................................................... 42
<D>
Mastering to a Fixture (Master Position Master) ............ 44
DAILY CHECKS..............................................................8 Motion Performance Screens ........................................ 115
MOUNTING A DEVICE TO THE ROBOT ................ 110
<E>
EQUIPMENT MOUNTING SURFACE ...................... 119
<O>
Others.............................................................................. 19
<F>
OVERVIEW ................................................................... 21
FAILURES, CAUSES AND MEASURES..................... 22
<P>
<G>
PART REPLACEMENT AND
General............................................................................ 41 CORRESPONDING ADJUSTMENT ............................ 60
Greasing .......................................................................... 17 PERIODIC CHECKS ....................................................... 9
PERIODIC MAINTENANCE ...................................... 158
<I>
PREFACE...................................................................... p-1
INSTALLATION.......................................................... 131 PREVENTIVE MAINTENANCE.................................... 7
INSTALLATION CONDITION................................... 138 Procedure for Releasing Residual Pressure
INTERFACE FOR END EFFECTOR .......................... 122 within the Grease Bath.................................................... 16
i-1
INDEX B-81925EN/04
<Q> <T>
Quick Mastering.............................................................. 52 TRANSPORTATION................................................... 129
TRANSPORTATION AND INSTALLATION............ 128
<R>
TROUBLESHOOTING.................................................. 21
REPLACING A CABLE ................................................ 96
<W>
Replacing Battery............................................................ 18
REPLACING CABLES .................................................. 86 WIRING ......................................................................... 84
Replacing Grease ............................................................ 12
<Z>
REPLACING J1-AXIS MOTOR (M1) AND
REDUCER ...................................................................... 61 Zero Degree Mastering ................................................... 50
REPLACING J2/J3-AXIS MOTOR (M2/M3) ZERO POINT POSITION AND MOTION
AND REDUCER ............................................................ 68 LIMIT OF J2-AXIS TO J4-AXIS................................... 35
REPLACING J4-AXIS MOTOR (M4) AND
REDUCER ...................................................................... 77
REPLACING PARTS ..................................................... 59
Replacing the Cables of the Mechanical Unit ................. 19
REPLACING THE J1-AXIS PENDULUM
STOPPER........................................................................ 83
REPLACING THE OPTIONAL J1-AXIS
LIMIT SWITCH (OPTION) .......................................... 82
REPLACING THE WRIST UNIT .................................. 80
Resetting Alarms and Preparing for Mastering ............... 43
ROBOT EXTERNAL DIMENSION ............................ 109
<S>
SAFETY PRECAUTIONS ............................................ s-1
SERVO HAND CABLE INTERFACE
(OPTION) ..................................................................... 126
Single Axis Mastering..................................................... 54
SOFTWARE SETTING.................................................. 40
SPARE PARTS LIST.................................................... 141
Switching between Modes ............................................ 117
i-2
Revision Record
01 Jan., 2003