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MECHANICAL UNIT
OPERATOR'S MANUAL
B-83494EN/04
•
Original Instructions
Thank you for purchasing FANUC Robot.
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand
the content.
• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
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-83494EN/04
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
This chapter describes the precautions which must be observed to ensure the safe use of the robot.
Before attempting to use the robot, be sure to read this chapter thoroughly.
Before using the functions related to robot operation, read the relevant operator's manual to become
familiar with those functions.
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.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
WORKING PERSON
The personnel can be classified as follows.
Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel
Programmer or teaching operator:
• Operates the robot
• Teaches robot inside the safety fence
Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)
-
-
An operator cannot work inside the safety fence.
A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc.
To work inside the fence, the person must be trained on proper robot operation.
During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following
safety precautions.
-
Use adequate clothing or uniforms during system operation
Wear safety shoes
Use helmet
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SAFETY PRECAUTIONS
2
B-83494EN/04
DEFINITION OF WARNING, CAUTION AND
NOTE
To ensure the safety of working persons and prevent damage to the machine, this manual indicates each
precaution on safety with "Warning" or "Caution" according to its severity. Supplementary information is
indicated by "Note". Read the contents of each "Warning", "Caution" and "Note" before attempting to use
the robots.
WARNING
Applied when a danger of death or serious injury is assumed to occur if the
approved procedure is not observed.
CAUTION
Applied when a danger of minor or moderate injury or equipment damage is
assumed to occur if the approved procedure is not observed.
NOTE
Applied when supplementary information other than WARNING and
CAUTION is indicated.
•
3
Read this manual carefully, and store it in a safe place.
WORKING PERSON SAFETY
Working person safety is the primary safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure
working person safety.
(1) Have the robot system working persons 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 in a ready to move state, and is
waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working
person 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 working person can enter the work area without passing
through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that
the robot is stopped as the safety gate is opened.
The controller is designed to receive this interlocking signal of the door switch. When the gate
is opened and this signal received, the controller stops the robot (Please refer to "STOP
TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see
Fig.3 (a) and Fig.3 (b).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
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B-83494EN/04
SAFETY PRECAUTIONS
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools
such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm
that stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the
power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on
when it is locked with a padlock.
(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot
(10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation
with gloved fingers could cause an operation error.
(11) Programs, system variables, and other information can be saved on memory card or USB memories.
Be sure to save the data periodically in case the data is lost in an accident.
(12) The robot should be transported and installed by accurately following the procedures recommended
by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe
injury to workers.
(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.
Then, the speed should be gradually increased to check the operation of the robot.
(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the
same time, a check must be made to ensure that there is no risk of hazardous situations. If detected,
such a situation should be eliminated before the operation.
(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and
peripheral equipment can be adversely affected, or workers can be severely injured.
- Avoid using the robot in a flammable environment.
- Avoid using the robot in an explosive environment.
- Avoid using the robot in an environment full of radiation.
- Avoid using the robot under water or at high humidity.
- Avoid using the robot to carry a person or animal.
- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)
(16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external
emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong
connection.
(17) When preparing trestle, please consider security for installation and maintenance work in high place
according to Fig.3 (c). Please consider footstep and safety belt mounting position.
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SAFETY PRECAUTIONS
B-83494EN/04
RP1
Pulsecoder
RI/RO,XHBK,XROT
RM1
Motor power/brake
EARTH
Safety fence
Interlocking device and safety plug that are activated if the
gate is opened.
Fig. 3 (a)
Safety fence and safety gate
Dual chain
デュアルチェーン仕様の場合
Emergency stop board
or Panel board
EAS1
EAS11
EAS2
EAS21
Single chain
シングルチェーン仕様の場合
(Note)
In case of R-30iB, R-30iB Mate
Terminals EAS1,EAS11,EAS2,EAS21 are provided on the
emergency stop board.
Refer to the ELECTRICAL CONNCETIONS Chapter
of CONNECTION of
R-30iB controller maintenance manual (B-83195EN) or
R-30iB Mate controller maintenance manual (B-83525EN)
or R-30iB Mate controller (Open Air) maintenance manual
(B-83525EN) for details.
Panel board
FENCE1
FENCE2
Fig. 3 (b) Limit switch circuit diagram of the safety fence
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SAFETY PRECAUTIONS
B-83494EN/04
Hook for safety belt
Fence
Steps
Trestle
Footstep
for maintenance
Fig.3 (c) Footstep for maintenance
3.1
OPERATOR SAFETY
The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.
(1) If you do not have to operate the robot, 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 of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering
the work area unexpectedly and 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 (Please refer to "STOP TYPE
OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external
EMERGENCY STOP button is pressed. See the diagram below for connection.
Dual
chain
デュアルチェーン仕様の場合
External stop button
外部非常停止ボタン
Emergency stop board
or Panel board
EES1
EES11
EES2
EES21
Single chain
シングルチェーン仕様の場合
External
stop button
外部非常停止ボタン
(Note)
Connect EES1 and EES11, EES2 and EES21
In case R-30iB, R-30iB Mate
EES1,EES11,EES2,EES21 are on the emergency stop board
Refer to the ELECTRICAL CONNCETIONS Chapter of
CONNECTION of
R-30iB controller maintenance manual (B-83195EN) or
R-30iB Mate controller maintenance manual (B-83525EN)
or R-30iB Mate controller (Open Air) maintenance manual
(B-83525EN) for details.
Panel board
EMGIN1
EMGIN2
Fig.3.1 Connection diagram for external emergency stop button
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SAFETY PRECAUTIONS
3.2
B-83494EN/04
SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the work area of the robot.
the safety of the teach pendant operator especially.
The operator must ensure
(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal
operating condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and
other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN
switch on the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
(5) Programming should be done outside the area of the safety fence as far as possible. If programming
needs to be done in the area of the safety fence, the programmer should take the following
precautions:
– Before entering the area of the safety fence, ensure that there is no risk of dangerous situations
in the area.
– Be prepared to press the emergency stop button whenever necessary.
– Robot motions should be made at low speeds.
– Before starting programming, check the entire system status to ensure that no remote
instruction to the peripheral equipment or motion would be dangerous to the working person.
Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent
other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened
with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The
programmer should understand that the safety gate is disabled and is responsible for keeping other people from
entering the inside of the safety fence.
Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting
status.
(a)
Disable: The DEADMAN switch is disabled.
(b)
Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
(Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed
to its intermediate point. When the operator releases the DEADMAN switch or presses the switch
strongly, the robot stops immediately.
The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator
should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.
Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000
times per year.
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SAFETY PRECAUTIONS
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The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the
validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator
panel, the teach pendant enable switch and the remote condition on the software.
Mode
Teach pendant
enable switch
Software
remote
condition
Local
Remote
Local
Off
Remote
Local
On
T1, T2
Remote
mode
Local
Off
Remote
T1,T2 mode: DEADMAN switch is effective.
AUTO
mode
On
Teach pendant
Operator panel
Peripheral device
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
(6) To start the system using the operator’s panel, make certain that nobody is the robot work area and
that there are no abnormal conditions in the robot work area.
(7) When a program is completed, be sure to carry out a test operation according to the procedure
below.
(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 operation 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.
3.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer personnel, pay utmost attention to the following.
(1) During operation, never enter the robot work area.
(2) A hazardous situation may arise when the robot or the system, are kept with their power-on during
maintenance operations. Therefore, for any maintenance operation, the robot and the system should
be put into the power-off state. If necessary, a lock should be in place in order to prevent any other
person from turning on the robot and/or the system. In case maintenance needs to be executed in the
power-on state, the emergency stop button must be pressed.
(3) If it becomes necessary to enter the robot operation range while the power is on, press the
emergency stop button on the operator panel, or the teach pendant before entering the range. The
maintenance personnel must indicate that maintenance work is in progress and be careful not to
allow other people to operate the robot carelessly.
(4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire
system in order to make sure no dangerous situations exist. In case the worker needs to enter the
safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status
must be carefully monitored.
(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off
and the pressure in the piping should be reduced to zero.
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SAFETY PRECAUTIONS
B-83494EN/04
(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition.
(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working
nearby, make certain that their escape path is not obstructed.
(9) 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.
(10) If necessary, have a worker who is familiar with the robot system stand beside the operator 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.
(11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an
accident may occur, causing damage to the robot and injury to the worker.
(12) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.
(13) When handling each unit or printed circuit board in the controller during inspection, turn off the
circuit breaker to protect against electric shock.
If there are two cabinets, turn off the both circuit breaker.
(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction
or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.
Such a fuse may cause a fire.
(15) When restarting the robot system after completing maintenance work, make sure in advance that
there is no person in the work area and that the robot and the peripheral devices are not abnormal.
(16) When a motor or brake is removed, the robot arm should be supported with a crane or other
equipment beforehand so that the arm would not fall during the removal.
(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent
dangerous falls.
(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated
state, the worker should wear heat-resistant gloves or use other protective tools.
－ Servo motor
－ Inside the controller
－ Reducer
－ Gearbox
－ Wrist unit
(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause
any danger.
(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to
protect maintenance workers from excessive load. Otherwise, the maintenance workers would be
severely injured.
(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot
would be adversely affected. In addition, a misstep can cause injury to the worker.
(22) When performing maintenance work in high place, secure a footstep and wear safety belt.
(23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the
floor around the robot and within the safety fence.
(24) When a part is replaced, all bolts and other related components should put back into their original
places. A careful check must be given to ensure that no components are missing or left not mounted.
(25) In case robot motion is required during maintenance, the following precautions should be taken :
- Foresee an escape route. And during the maintenance motion itself, monitor continuously the
whole system so that your escape route will not become blocked by the robot, or by peripheral
equipment.
- Always pay attention to potentially dangerous situations, and be prepared to press the emergency
stop button whenever necessary.
(26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller
maintenance manual.) A failure to do the periodical inspection can adversely affect the performance
or service life of the robot and may cause an accident
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SAFETY PRECAUTIONS
(27) After a part is replaced, a test operation should be given for the robot according to a predetermined
method. (See TESTING section of “Controller operator’s manual”.) During the test execution, the
maintenance staff should work outside the safety fence.
4
4.1
SAFETY OF THE TOOLS AND
PERIPHERAL DEVICES
PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the
program to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect
the states of all devices in the system and can be stopped according to the states.
4.2
PRECAUTIONS FOR MECHANISM
(1) Keep the components of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Only use approved cuttings fluids and cleaning fluids.
(3) Use a limit switch or mechanical stopper to limit the robot motion to prevent the robot from
collisions against peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. Failure to follow these
precautions may cause mechanical problems.
Use mechanical unit cable that meet user interface requirement.
Don not route additional cables or hoses inside the mechanical unit.
Do not obstruct the movement of the mechanical unit cables when additional cables are touted
external to the mechanical unit.
For models that have exposed cables, do not modify the cable bundle construction (such as by
adding on protective covers, tying on additional cables) that could change the behavior of the
cable motion.
When installing user peripheral equipment on the robot mechanical unit, please pay attention
that equipment does not interfere with the robot itself.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please
avoid the system construction that power-off stop would be operated routinely. (Refer to bad case
example.) Please execute power-off stop after reducing the speed of the robot and stopping it by
hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type.)
(Bad case example)
Whenever poor product is generated, a line stops by emergency stop and power-off of the robot
is executed.
When alteration was necessary, safety switch is operated by opening safety fence and
power-off stop is executed for the robot during operation.
An operator pushes the emergency stop button frequently, and a line stops.
An area sensor or a mat switch connected to safety signal operate routinely and power-off stop
is executed for the robot.
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SAFETY PRECAUTIONS
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(6) Robot stops urgently when collision detection alarm (SRVO-050) etc. occurs. The frequent urgent
stop by alarm causes the trouble of the robot, too. So remove the causes of the alarm.
5
SAFETY OF THE ROBOT MECHANISM
5.1
PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can
manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the
jog mode.
5.2
PRECAUTIONS IN PROGRAMMING
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the
motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has
terminated.
5.3
PRECAUTIONS FOR MECHANISMS
(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,
and dust.
5.4
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER
IN EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or pinched by the robot), turn off the
robot controller immediately, change robot posture by directly pressing robot arm and release the
worker.
6
SAFETY OF THE END EFFECTOR
6.1
PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time
delay after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of
the end effector.
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7
STOP TYPE OF ROBOT
The following three robot stop types exist:
Power-Off Stop (Category 0 following IEC 60204-1)
Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
An alarm is generated and servo power is turned off.
The robot operation is stopped immediately. Execution of the program is paused.
Frequent Power-Off stop of the robot during operation can cause mechanical problems of the robot.
Avoid system designs that require routine or frequent Power-Off stop conditions.
Controlled stop (Category 1 following IEC 60204-1)
The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
An alarm is generated and servo power is turned off.
Hold (Category 2 following IEC 60204-1)
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.
When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off
stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop
pattern is different according to the controller type or option configuration.
There are the following 3 Stop patterns.
Stop
pattern
A
B
C
P-Stop:
C-Stop:
Mode
AUTO
T1
T2
AUTO
T1
T2
AUTO
T1
T2
Emergency
stop
button
External
Emergency
stop
FENCE open
SVOFF input
Servo
disconnect
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
C-Stop
P-Stop
C-Stop
-
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
Power-Off stop
Controlled stop
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Disable
The following table indicates the Stop pattern according to the controller type or option configuration.
R-30iB/ R-30iB Mate
Option
Standard
Controlled stop by E-Stop
A (*)
C (*)
(A05B-2600-J570)
(*) R-30iB / R-30iB Mate does not have servo disconnect. / R-30iB Mate does not have SVOFF
input.
The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please
refer to "Software version" in operator's manual of controller for the detail of software version screen.
"Controlled stop by E-Stop" option
When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following
alarms becomes
Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is
the normal operation of the system.
Alarm
SRVO-001 Operator panel E-stop
SRVO-002 Teach pendant E-stop
SRVO-007 External emergency stops
SRVO-408 DCS SSO Ext Emergency Stop
SRVO-409 DCS SSO Servo Disconnect
Condition
Operator panel emergency stop is pressed.
Teach pendant emergency stop is pressed.
External emergency stop input (EES1-EES11, EES2-EES21) is
open.
In DCS Safe I/O connect function, SSO[3] is OFF.
In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows:
In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
In Controlled stop, physical impact is less than Power-Off stop. This function is effective for
systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be
minimized.
The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the
operator's manual of a particular robot model for the data of stopping distance and stopping time.
When this option is loaded, this function cannot be disabled.
The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.
s-12
SAFETY PRECAUTIONS
B-83494EN/04
8
WARNING & CAUTION LABEL
(1) Transportation label
Fig. 8 (a)
Transportation label
Description
When transporting the robot, observe the instructions indicated on this label.
1)
2)
3)
Use a crane having a load capacity of 500 kg or greater.
Use at least four slings each having a withstand load of 980 N (100 kgf) or greater.
Use at least four shackles each having a withstand load of 784 N (80 kgf) or greater.
(2) Greasing label (if greasing kit A05B-1142-K021,A05B-1142-K023 is specified)
在将润滑脂装入注射器之前,
请揉搓软管使里面的润滑脂变软。
每向前推动柱塞2.5mm,
就会有1cc的润滑脂被推出来。
轴
每向前推动柱塞2.5mm,
就会有1ml的润滑脂被推出来。
量
轴
量
供脂时
(Except 7C,7L)
Fig. 8 (b)
供脂时
(7C,7LC)
Greasing label
Description
When using a grease kit, observe the instructions indicated on this label.
s-13
SAFETY PRECAUTIONS
1)
2)
(3)
B-83494EN/04
Before filling the cylinder with grease from tube, squeeze the tube to make the grease in it soft.
Pushing in the plunger by 2.5 mm causes a grease of 1 ml to be pushed out.
Motion range and payload label
The following label is added if the CE specification is requested.
(Except 7H)
Fig 8 (c)
(7H)
Motion range and payload label
s-14
PREFACE
B-83494EN/04
PREFACE
This manual explains operation procedures for the mechanical units of the following robots:
Model name
Mechanical unit
specification No.
Maximum load
Remarks
FANUC Robot LR Mate 200iD
A05B-1142-B201
FANUC Robot LR Mate 200iD/7H
A05B-1142-B211
5-axes type
FANUC Robot LR Mate 200iD/7C
A05B-1142-B221
Clean type
FANUC Robot LR Mate 200iD/7WP
A05B-1142-B231
FANUC Robot ARC Mate 50iD
A05B-1142-B251
FANUC Robot LR Mate 200iD/7L
A05B-1142-B301
Long arm type
FANUC Robot LR Mate 200iD/7LC
A05B-1142-B321
Long arm, clean type
FANUC Robot ARC Mate 50iD/7L
A05B-1142-B351
Long arm type
7kg
For washing
NOTE
The following abbreviations are used herein.
STANDARD
: LR Mate 200iD, ARC Mate 50iD
7H
: LR Mate 200iD/7H
7C
: LR Mate 200iD/7C
7WP
: LR Mate 200iD/7WP
7L
: LR Mate 200iD/7L, ARC Mate 50iD/7L
7LC
: LR Mate 200iD/7LC
The label stating the mechanical unit specification number is affixed in the position shown below. Before
reading this manual, determine the specification number of the mechanical unit.
p-1
PREFACE
B-83494EN/04
(1)
TYPE
NO.
DATE
(2)
(3)
(4)
WEIGHT
(5) kg
Position of label indicating mechanical unit specification number
TABLE 1）
(1)
CONTENTS
LETTERS
Model name
FANUC Robot
LR Mate 200iD
FANUC Robot
LR Mate 200iD/7H
FANUC Robot
LR Mate 200iD/7C
FANUC Robot
LR Mate 200iD/7WP
FANUC Robot
ARC Mate 50iD
FANUC Robot
LR Mate 200iD/7L
FANUC Robot
LR Mate 200iD/7LC
FANUC Robot
ARC Mate 50iD/7L
(2)
TYPE
(3)
No.
(4)
(5)
DATE
WEIGHT kg
(Without
controller)
A05B-1142-B201
25
A05B-1142-B211
24
A05B-1142-B221
25
A05B-1142-B231
A05B-1142-B251
SERIAL
NO. IS
PRINTED
PRODUCTION
YEAR AND
MONTH ARE
PRINTED
25
25
A05B-1142-B301
27
A05B-1142-B321
27
A05B-1142-B351
27
p-2
PREFACE
B-83494EN/04
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN
All persons who use the FANUC Robot and
system designer must read and understand
thoroughly this handbook
R-30iB Mate OPERATOR’S MANUAL
controller
Basic Operation
B-83284EN
Alarm Code List
B-83284EN-1
Optional Function
B-83284EN-2
MAINTENANCE MANUAL
Standard : B-83525EN
Open Air : B-83555EN
Intended readers :
Operator, system designer
Topics :
Safety items for robot system design, operation, maintenance
Intended readers :
Operator, programmer, maintenance engineer, system designer
Topics :
Robot functions, operations, programming, setup, interfaces, alarms
Use :
Robot operation, teaching, system design
Intended readers :
Maintenance engineer, system designer
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start-up, connection, maintenance
p-3
TABLE OF CONTENTS
B-83494EN/04
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
1
STRANSPORTATION AND INSTALLATION ......................................... 1
1.1
1.2
1.3
1.4
2
CONNECTION WITH THE CONTROLLER .......................................... 11
2.1
3
TRANSPORTATION...................................................................................... 1
INSTALLATION ............................................................................................. 5
MAINTENANCE AREA .................................................................................. 9
INSTALLATION SPECIFICATIONS ............................................................ 10
CONNECTION WITH THE CONTROLLER ................................................. 11
BASIC SPECIFICATIONS..................................................................... 13
3.1
ROBOT CONFIGURATION ......................................................................... 13
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.3
3.4
3.5
3.6
4
AIR SUPPLY (OPTION) .............................................................................. 39
INSTALLING THE AIR PURGE KIT ............................................................ 42
INTERFACE FOR OPTION CABLE (OPTION) ........................................... 45
AXIS LIMIT SETUP ............................................................................... 48
6.1
7
MECHANICAL COUPLING OF END EFFECTOR TO WRIST .................... 33
EQUIPMENT MOUNTING FACE ................................................................ 33
LOAD SETTING .......................................................................................... 35
HIGH INERTIA MODE (LR Mate 200iD/7H)................................................ 37
PIPING AND WIRING TO THE END EFFECTOR................................. 38
5.1
5.2
5.3
6
MECHANICAL UNIT OPERATION AREA AND INTERFERENCE AREA ... 18
ZERO POINT POSITION AND MOTION LIMIT........................................... 21
WRIST LOAD CONDITIONS ....................................................................... 27
LOAD CONDITION ON EQUIPMENT MOUNTING FACE .......................... 31
OPERATING AREA FOR INCLINATION INSTALLATION .......................... 31
MECHANICAL COUPLING TO THE ROBOT....................................... 33
4.1
4.2
4.3
4.4
5
Note of Severe Dust /Liquid Specification.............................................................17
Cautions in Selecting the 7WP ...............................................................................17
Cautions for 7C,7LC (Clean class 10)....................................................................18
IP69K (option)........................................................................................................18
SOFTWARE SETTING................................................................................ 48
CHECKS AND MAINTENANCE ........................................................... 50
7.1
PERIODIC MAINTENANCE ........................................................................ 50
7.1.1
7.1.2
7.2
Daily Checks ..........................................................................................................50
Periodic Check and Maintenance ...........................................................................51
CHECK POINTS.......................................................................................... 53
7.2.1
7.2.2
7.2.3
7.2.4
Confirmation of Oil Seepage..................................................................................53
Confirmation of the Air Control Set and Air Purge kit ..........................................54
Check the Connectors.............................................................................................55
Check of Mechanical Stopper ................................................................................55
c-1
TABLE OF CONTENTS
7.3
MAINTENANCE........................................................................................... 56
7.3.1
7.3.2
7.4
8
Replacing the Batteries
(1-Year Periodic Inspection If Built-in Batteries Are Specified)
(1.5-Year Periodic Inspection If External Batteries Are Specified) .......................56
Replenish the Grease of the Drive Mechanism
(4 years (15360 hours) checks) ..............................................................................59
STORAGE ................................................................................................... 60
MASTERING ......................................................................................... 61
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9
B-83494EN/04
GENERAL ................................................................................................... 61
RESETTING ALARMS AND PREPARING FOR MASTERING ................... 63
ZERO POSITION MASTERING .................................................................. 64
QUICK MASTERING ................................................................................... 66
QUICK MASTERING FOR SINGLE AXIS ................................................... 68
SINGLE AXIS MASTERING ........................................................................ 70
MASTERING DATA ENTRY........................................................................ 72
CHECKING THE MASTERING ................................................................... 74
TROUBLESHOOTING .......................................................................... 75
9.1
9.2
OVERVIEW ................................................................................................. 75
FAILURES, CAUSES AND MEASURES ..................................................... 75
APPENDIX
A
PERIODIC MAINTENANCE TABLE ..................................................... 83
B
MOUNTING BOLT TORQUE LIST ....................................................... 90
C
OPTIONAL CONNECTOR WIRING PROCEDURE .............................. 91
D
INSULATION ABOUT ARC WELDING ROBOT................................... 92
D.1
D.2
ABSTRACT.................................................................................................. 92
INSULATION AT THE WRIST ..................................................................... 92
c- 2
1.STRANSPORTATION AND INSTALLATION
B-83494EN/04
1
STRANSPORTATION AND INSTALLATION
1.1
TRANSPORTATION
The robot can be transported by a crane. When transporting the robot, be sure to change the posture of the
robot to that shown below and lift by using the eyebolts and the transport equipment at their points.
WARNING
1 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.
2 Before moving the robot by using crane, check and tighten any loose bolts on
the forklift pockets.
3 Do not pull eyebolts sideways.
Transportation using a crane (Fig. 1.1 (a) - (f))
Fasten the transport equipments to the robot base and lift the robot with the four slings.
CAUTION
Note that slings with insufficient length may break the J2 base or J2 arm cover.
Craneクレーン
Craneクレーン許容荷重：500kg以上
capacity : 500kg or more
Sling スリング
スリング許容荷重：100kg以上
Sling capacity
: 100kg or more
Transport
輸送部材
equipment
703
シャックル
Shackle
Transport
Transport posture
Horizontal wrist
posture輸送姿勢 (7H 輸送姿勢
(標準,7WP)
specification)
(7H
手首水平が0°)
(Standard,
7WP) zero
J1： 0°
J2：-30°
J3：-40°
J4： 0°
J5：-45°
J6： 0°
235
207
191
J1： 0°
J2：-30°
J3：-40°
J4：-45°
J5： 0°
Transport posture
輸送姿勢
(7H Downward
wrist
(7H 手首下向きが0°)
zero specification)
J1： 0°
J2：-30°
J3：-40°
J4： 5°
J5： 0°
Note) 注）
1.
Mechanical unit mass: 25kg (Standard, 7WP)
1. 機構部質量：25kg (標準,7WP)
24kg (7H)
24kg (7H)
2.
Shackle
complied
JIS B 2801.
2. シャックル
JISwith
B 2801に準ずるものを使用
3.
Quantity
Shackle:4
3. 使用数
シャックル：4Sling:4
スリング：4
Fig. 1.1 (a) Transportation using a crane (back side connector plate)
(Standard, 7H,7WP)
-1-
1.STRANSPORTATION AND INSTALLATION
B-83494EN/04
クレーン
Crane
クレーン許容荷重：500kg以上
Crane
capacity : 500kg or more
スリング
Sling
スリング許容荷重：100kg以上
Sling
capacity : 100kg or more
Transport
輸送部材
equipment
786
Shackle
シャックル
Transport
輸送姿勢
posture
(標準,7WP)
(Standard,
7WP)
J1： 0°
J2：-30°
J3：-40°
J4： 0°
J5：-45°
J6： 0°
Stand
スタンド
Transport posture
(7H Horizontal wrist
輸送姿勢
zero
specification)
(7H
手首水平が0°)
J1： 0°
J2：-30°
J3：-40°
J4：-45°
J5： 0°
Transport posture
輸送姿勢
(7H Downward wrist
(7H 手首下向きが0°)
zero specification)
190
130
235
207
130
191
J1： 0°
J2：-30°
J3：-40°
J4： 5°
J5： 0°
Note)
注）
1.
Mechanical unit mass: 25kg (Standard, 7WP)
1. 機構部質量：25kg (標準,7WP)
24kg (7H)
24kg (7H)
2.
Shackle complied
with JIS B 2801.
2. シャックル JIS B 2801に準ずるものを使用
3. 3. 使用数
Quantityシャックル：4
Shackle:4 スリング：4
Sling:4
Fig. 1.1 (b) Transportation using a crane (bottom connector plate)
(Standard, 7H,7WP)
-2-
1.STRANSPORTATION AND INSTALLATION
B-83494EN/04
クレーン
Crane
クレーン許容荷重：500kg以上
Crane
capacity : 500kg or more
Slingスリング
Sling
capacity : 100kg or more
スリング許容荷重：100kg以上
798
Transport
輸送部材
equipment
Shackle
シャックル
Transport
posture
輸送姿勢
235
217
J1： 0°
J2：-30°
J3：-40°
J4： 0°
J5：-50°
J6： 0°
246
Note)
注）
1.
Mechanical unit mass: 27kg
機構部質量：27kg
2. 1. Shackle
complied with JIS B 2801.
2. シャックル JIS B 2801に準ずるものを使用
3. 3. Quantity
Shackle:4スリング：4
Sling:4
使用数 シャックル：4
Fig. 1.1 (c) Transportation using a crane (back side connector plate) (7L)
クレーン
Crane
クレーン許容荷重：500kg以上
Crane capacity : 500kg or more
Sling
スリング
Sling
capacity : 100kg or more
スリング許容荷重：100kg以上
798
Transport
輸送部材
equipment
シャックル
Shackle
Transport
posture
輸送姿勢
J1： 0°
J2：-30°
J3：-40°
J4： 0°
J5：-50°
J6： 0°
190
235
130
217
130
246
Note)
注）
1.
Mechanical unit mass: 27kg
1. 機構部質量：27kg
2.
Shackle
with JIS B 2801.
2. シャックル
JIScomplied
B 2801に準ずるものを使用
3. 使用数
シャックル：4
スリング：4Sling:4
3.
Quantity
Shackle:4
Fig. 1.1 (d) Transportation using a crane (bottom connector plate) (7L)
-3-
1.STRANSPORTATION AND INSTALLATION
B-83494EN/04
クレーン
Crane
クレーン許容荷重：500kg以上
Crane
capacity : 500kg or more
Sling
スリング
Sling
capacity : 100kg or more
スリング許容荷重：100kg以上
Transport
posture
輸送姿勢
J1： 0°
J2：-30°
J3：-40°
J4： 0°
J5：-45°
J6： 0°
プラスチック袋
Plastic
bag
A290-7134-X918 (1)
A290-7134-X918 (1)
727
Plastic bag
プラスチック袋
A290-7134-X918
A290-7134-X918(1)(1)
テープにて固定すること。
Fix with tape
Tape
テープ
（クリーンルーム用）
(for clean room)
Eyebolt (M10)
アイボルト
(M10)
380
570
注）
Tape
(for clean room)
テープ（クリーンルーム用）
Note)
1. 機構部質量：25kg
1.
Mechanical unit mass: 25 kg
2. アイボルト JIS B 1168に準ずるものを使用
2.
Eyebolt
complied スリング：4
with JIS B 2801.
3. 使用数
アイボルト：4
3.
Quantity Eyebolt:4
Sling:4
輸送部材
Transport
equipment
Fig. 1.1 (e) Transportation using a crane (7C)
クレーン
Crane
クレーン許容荷重：500kg以上
Crane
capacity : 500kg or more
スリング
Sling
スリング許容荷重：100kg以上
Sling
capacity : 100kg or more
Transport
posture
輸送姿勢
J1： 0°
J2：-30°
J3：-40°
J4： 0°
J5：-50°
J6： 0°
820
Plastic
bag
プラスチック袋
A290-7134-X918 (1)
A290-7134-X918
Plastic bag
プラスチック袋
A290-7134-X918
A290-7134-X918 (1)
テープにて固定すること。
Fix with tape
Eyebolt (M10)
アイボルト
(M10)
Tape
テープ
（クリーンルーム用）
(for
clean room)
380
注）
Note)
570
輸送部材
Transport
equipment
Tape
(for clean room)
テープ（クリーンルーム用）
1.機構部質量：27kg
Mechanical unit mass: 25 kg
1.
2.
JIScomplied
B 1168に準ずるものを使用
2.アイボルト
Eyebolt
with JIS B 2801.
3.
アイボルト：4
スリング：4Sling:4
3.使用数
Quantity
Eyebolt:4
Fig. 1.1 (f) Transportation using a crane (7LC)
-4-
1.STRANSPORTATION AND INSTALLATION
B-83494EN/04
NOTE
About the LR Mate 200iD/7C,7LC
1 Before shipment of the LR Mate 200iD/7C,7LC, it is cleaned in a clean room,
covered with an antistatic sheet, then packed as shown in Fig. 1.1 (e),(f).
2 The transport plate can be used as a roll–over prevention plate in a clean room.
If the plate is cleaned before being carried in a clean room, it can be carried in
the room together with the robot.
3 The antistatic sheet can be removed in a clean room.
4 When installing the robot, use the eyebolts to lift it as shown Fig 1.1 (e),(f).
5 Once the robot has been installed, remove the eyebolts from it.
6 After transportation, be sure to fix it as described in Section 1.2.
1.2
INSTALLATION
Fig. 1.2 (a),(b) show the robot base dimensions.
Fig.1.2 (c) shows the dimensions of the connector cover for the IP69K option.
Front
正面
J1-axis
( 7 )
J1軸旋回中心
rotation center
165
82.5
( 13 )
165
82.5
4-O11through
貫通
190
( 7 )
( 13 )
( 7 )
95
198
( 13 )
15
( 7 )
( 13 )
95
200
190
Locating
突き当て面 surface
Fig. 1.2 (a) Dimensions of the robot base (back side connector plate)
-5-
1.STRANSPORTATION AND INSTALLATION
Front
正面
B-83494EN/04
J1-axis
J1軸旋回中心
rotation
center
165
4-O11through
貫通
82.5
200
15
95
165
* 35
190
82.5
92
* R
* R
21
* R
21
* 5°
Locating
突き当て面 surface
°
* 35
* 92
95
190
*) *)
Please
be careful to the interference of the mounting holes and the bolts.
設置面の取り付け穴とボルトの干渉にご注意下さい。
Fig. 1.2 (b) Dimensions of the robot base (bottom connector plate)
190
95
95
190
95
173
157
CONNECTOR
COVER
NYLON BAND
23
144
23
154
ROBOT CONNECTION
CABLE
Fig. 1.2 (c) Dimensions of the connector cover for IP69K option
(back side connector plate)
NOTE
Bottom connector plate does not have the connector cover.
-6-
1.STRANSPORTATION AND INSTALLATION
B-83494EN/04
If robot is used except floor mount, be sure to set the mounting angle referring to the procedure below.
1
2
3
Perform a Controlled Start. Turn ON the controller with [PREV] and [NEXT] key pressed.
Then select [3 Controlled start].
Press MENU key and select “9 MAINTENANCE”.
Select the robot which you want to set mount angle and press INPUT key.
ROBOT MAINTENANCE
CTRL START MANU
Setup Robot System Variables
Group Robot Library/Option Ext Axes
1
LR Mate 200iD
0
[TYPE]ORD NO
4
5
AUTO
MANUAL
Press F4 key.
Press INPUT key until screen below is displayed.
*******Group 1 Initialization************
*************LR Mate 200iD*************
--- MOUNT ANGLE SETTING --0 [deg] : floor mount type
90 [deg] : wall mount type
180 [deg] : upside-down mount type
Set mount_angle (0-180[deg])->
Default value = 0
6
Input mount angle referring to Fig.1.2 (d). 7H Downward wrist zero specification is restricted to floor
mount and upside-down mount.
＋
Angle of
設置角度
mounting face
Fig.1.2 (d) Robot mounting angle
-7-
1.STRANSPORTATION AND INSTALLATION
7
B-83494EN/04
Press INPUT key until screen below is displayed again.
ROBOT MAINTENANCE
CTRL START MANU
Setup Robot System Variables
Group Robot Library/Option Ext Axes
1
LR Mate 200iD
0
[TYPE]ORD NO
8
AUTO
MANUAL
Press FCTN key and select ”1 START (COLD)”.
Fig. 1.2 (e), Table 1.2 (a) to Table 1.2 (d) indicate the force and moment applied to the base plate at the
time of Power-Off stop of the robot and indicate the stopping distance and time of the J1 through J3 axes
until the robot stopping by Power-Off stop or by Controlled stop after input of the stop signal.
Refer to the data when considering the strength of the installation face.
Table 1.2 (a) Force and moment that acts on J1 base (Standard,7H,7WP,7C)
Force in Vertical
Horizontal
Force in
Vertical moment
direction
moment
Horizontal direction
Mv(Nm)
Fv(N)
Mh(Nm)
Fh(N)
During stillness
During acceleration or
deceleration
During Power-Off stop
115.5
313.6
0
0
605.2
595.2
289.1
860.3
768.3
1054.6
402.2
1100.1
Table 1.2 (b) Force and moment that acts on J1 base (7L,7LC)
Force in Vertical
Horizontal
Vertical moment
direction
moment
Mv(Nm)
Fv(N)
Mh(Nm)
During stillness
During acceleration or
deceleration
During Power-Off stop
Force in
Horizontal direction
Fh(N)
147.3
333.2
0
0
439.8
602.1
336.3
784.8
1657.2
1612.7
1285.6
1656.8
Table 1.2 (c) Stopping time and distance until the robot stopping by Power-Off stop after input of stop signal
J1
J2
J3
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
7L,7LC
Stopping angle [deg] (rad)
※ Max payload and max speed
308
64.5 (1.13)
356
61.9(1.08)
Standard,7H,7WP,7C
284
43.0 (0.75)
124
12.6(2.16)
332
63.7 (1.11)
324
54.4(5.65)
Table 1.2 (d) Stopping time and distance until the robot stopping by Controlled stop after input of stop signal
J1
J2
J3
Stopping time [ms]
Stopping angle [deg] (rad)
Stopping time [ms]
7L,7LC
Stopping angle [deg] (rad)
※ Max payload and max speed
516
128.4 (2.24)
524
106.9(9.14)
Standard,7H,7WP,7C
-8-
516
92.0 (1.61)
508
79.6(8.86)
540
122.7 (2.14)
540
117.9(9.42)
1.STRANSPORTATION AND INSTALLATION
B-83494EN/04
Mv
Fv
Fh
Mh
Fig. 1.2 (e) Force and moment that acts on J1 base
1.3
MAINTENANCE AREA
500
250
190
500
Fig.1.3 shows the maintenance area of the mechanical unit. Be sure to leave enough room for the robot to
be mastered.
See Chapter 8 for the mastering.
(*)
500
500
(In case of bottom
connector plate)
500
(*)
620 (Standard,7H,7C,7WP)
705 (7L,7LC)
Fig. 1.3 Maintenance area
-9-
1.STRANSPORTATION AND INSTALLATION
1.4
B-83494EN/04
INSTALLATION SPECIFICATIONS
Refer to caution below about installation specifications.
Refer to specifications of Section 3.1 and Section 3.2 too.
CAUTION
When external battery option is specified, Please fix the battery box in the part without
the vibration, and do measures of a protection against dust and liquid.
CAUTION
The wound of coating of robot connection cable and external battery cable causes the
flood. Please note handling enough when setting it up, and exchange it when damaging.
- 10 -
2.CONNECTION WITH THE CONTROLLER
B-83494EN/04
2
CONNECTION WITH THE CONTROLLER
2.1
CONNECTION WITH THE CONTROLLER
The robot is connected with the controller (NC) via the power cable and signal cable. Connect these
cables to the connectors on the back of the base.
Please be sure to connect the earth cable.
For details on air and option cables, see Chapter 5.
CAUTION
1 Before connecting the cables, be sure to turn off the controller power.
2 Don’t use 10m or longer coiled cable without untying. The long coiled cable will
heat and damage itself.
3 If external batteries are in use, do not remove it with the power supply turned off.
Replacing the batteries with the power supply turned off causes all current
position data to be lost. Therefore, mastering will be required again.
WARNING
Before turning on controller power, be sure to connect robot and controller with
the earth line. Otherwise, there is the risk of electrical shock.
Robot
Controller
cable for power and signal
earth cable
Air
Connector for
power and signal
Earth
Detail A
A
Fig. 2.1 (a) Cable connection (back side connector plate)
- 11 -
2.CONNECTION WITH THE CONTROLLER
B-83494EN/04
Robot
Controller
cable for power and brake
earth cable
Connector for
power and signal
Air
A
Earth
Detail A
Fig. 2.1 (b) Cable connection (bottom connector plate)
- 12 -
3.BASIC SPECIFICATIONS
B-83494EN/04
3
BASIC SPECIFICATIONS
3.1
ROBOT CONFIGURATION
J3 housing
J3ハウジング
J5-axis
motor
J5軸モータ
J4-axis
motor
J4軸モータ
J6-axis motor
J6軸モータ
End effector
エンドエフェクタ取付面
mounting face
手首ユニット
Wrist
unit
J3
arm
J3アーム
J2
arm
J2アーム
J3-axis
motor
J3軸モータ
J2-axis
motor
J2軸モータ
J2ベース
J2 base
J1
base
J1ベース
J1-axis
motor
J1軸モータ
Fig. 3.1 (a) Mechanical unit configuration (Except 7H)
J3ハウジング
J3
housing
J4-axis
motor
J4軸モータ
J5-axis
motor
J5軸モータ
エンドエフェクタ
End
effector
mounting
取付面face
Wrist
unit
手首ユニット
J2
arm
J2アーム
J3J3アーム
arm
J3軸モータ
J3-axis
motor
J2-axis
motor
J2軸モータ
J2ベース
J2
base
J1
J1ベース
base
J1-axis
motor
J1軸モータ
Fig. 3.1 (b) Mechanical unit configuration (7H)
- 13 -
3.BASIC SPECIFICATIONS
B-83494EN/04
X
Y
J6
+
+
J4
J3
J2
J5 +
Z
+
-
+
-
J1
+
*All axes are 0°at this posture
Fig. 3.1 (c) Each axis coordinates and mechanical interface coordinates (Except 7H)
+
X
Y
J5
+
Z
J3
J2
J4
--
+
+
-
J1
+
*All axes are 0°at this posture
Fig. 3.1 (d) Each axis coordinates and mechanical interface coordinates
(7H Horizontal wrist zero specification)
- 14 -
3.BASIC SPECIFICATIONS
B-83494EN/04
+
+
Y
J3
J2
J4
-
X
J5
+
Z
+
-
J1
+
*All axes are 0°at this posture
Fig. 3.1 (e) Each axis coordinates and mechanical interface coordinates
(7H Downward wrist zero specification)
NOTE
Zero point of mechanical interface coordinates is the end effector mounting face
center.
- 15 -
3.BASIC SPECIFICATIONS
B-83494EN/04
Table 3.1 Specifications
Item
Specifications
LR Mate 200iD
LR Mate 200iD/7L
ARC Mate 50iD
Model
LR Mate 200iD/7H
LR Mate 200iD/7C
LR Mate 200iD/7LC
LR Mate 200iD/7WP
Type
Articulated Type
Controlled axis
6-axis(J1, J2, J3, J4, J5, J6)
Reach
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
Max. load capacity
(NOTE 3)
911mm
12.57rad (17.45rad/s)
12.57rad (17.45rad/s)
Wrist
Max.7 kg
16.6Nm
J5-axis
16.6Nm
16.6Nm
4.0Nm
16.6Nm
5.5Nm(NOTE 4)
J6-axis
9.4Nm
J4-axis
0.47 kg･m
2
J5-axis
0.47 kg･m
2
J6-axis
Drive method
Repeatability
Mass (NOTE 5)
0.1 5kg･m
2
Allowable load
inertia at wrist
6-axis(J1, J2, J3, J4, J5, J6)
Floor, Upside-down, (Angle mount)
340° /360°(option) (450°/s)
340° /360°(option) (370°/s)
5.93rad/6.28rad(option) (7.85rad/s)
5.93rad/6.28rad(option) (6.45rad/s)
245° (380°/s)
245° (310°/s)
4.28rad (6.63rad/s)
4.28rad (5.41rad/s)
420° (520°/s)
430° (410°/s)
7.33rad (9.08rad/s)
7.50rad (7.15rad/s)
380° (550°/s)
250° (545°/s)
380° (550°/s)
6.63rad (9.60rad/s)
4.36rad (9.51rad/s)
6.63rad (9.60rad/s)
250° (545°/s)
720° (1500°/s)
250° (545°/s)
4.36rad (9.51rad/s)
12.57rad (26.18rad/s)
4.36rad (9.51rad/s)
720° (1000°/s)
720° (1000°/s)
J4-axis
Allowable load
moment at wrist
5-axis(J1, J2, J3, J4, J5)
717mm
Installation (NOTE 1)
Motion range
(Max. speed)
(NOTE 2)
ARC Mate 50iD/7L
Dust proof and drip proof
mechanism (NOTE 6)
Acoustic noise level
0.47 kg･m
2
0.046 kg･m
16.6Nm
9.4Nm
2
0.47 kg･m
2
2
0.15 kg･m (NOTE 4)
0.47 kg･m
2
2
0.1 5kg･m
Electric servo drive by AC servo motor
±0.02mm
±0.03mm
25kg
24kg
27kg
Conform to IP67 (Option :IP69K) (Except 7C,7LC)
Conform to IP67 , Class 10 (ISO class 4) (Option :IP69K) (7C,7LC)
*7LC does not support IP69K option
64.7dB (Note 7)
Ambient temperature:
0 - 45°C (NOTE 8)
Ambient humidity:
Normally 75%RH or less. No dew, nor frost allowed.
Height:
Up to 1000 meters above the sea level required,
Short time (within one month) Max 95%RH
Installation environment
no particular provision for posture.
2(
Vibration acceleration :
4.9m/s 0.5G) or less
Free of corrosive gases (NOTE 9)
NOTE 1)
NOTE 2)
NOTE 3)
NOTE 4)
NOTE 5)
NOTE 6)
NOTE 7)
Under the installation condition within ( ), the J1 and J2 axis motion range will be limited. See Section 3.6.
7H Downward wrist zero specification is restricted to floor mount and upside-down mount.
In case of short distance motion, the axis speed may not reach the maximum value stated.
The all up weight including the equipment and connection cables and its swing must not exceed this
value when you install the equipment. See Section 3.5.
This value is for high inertia mode. Please refer to Section 4.4 about change method.
It doesn't contain the mass of the control part.
The liquid that is the deterioration of the seal material such as Organic solvent, acid, alkali and chlorine
system, cutting liquid cannot be use.(See Section 3.2.)
This value is equivalent continuous A-weighted sound pressure level that applied with ISO11201
(EN31201). This value is measured with the following conditions.
Maximum load and speed
Operating mode is AUTO
- 16 -
3.BASIC SPECIFICATIONS
B-83494EN/04
NOTE 8)
When robot is used in low temperature environment that is near to 0ºC, or robot is not operated for a long
time in the environment that is less than 0ºC in a holiday or the night, because viscous resistance of the
drive train is so big that may cause occurrence of collision detect alarm (SRVO –050) etc. In this case, we
recommend performing the warm up operation for several minutes.
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.
NOTE 9)
3.1.1
1
2
3
4
The liquids below cannot be applied because they may cause deterioration or corrosion of the rubber
parts (such as gaskets, oil seals, and O-rings) used in the robot.
(a) Organic solvent
(b) Chlorine-based cutting fluid
(c) Amine-based cleaning fluid
(d) Liquid or solution that includes a corrosive such as an acid or alkali or causes rust
(e) Some other liquid or solution to which nitrile rubber (NBR) does not have resistance
When the robot is used in an environment where a liquid such as water is dashed over the robot,
great attention should be given to drainage under the J1 base. A failure may be caused if the J1 base
is kept immersed in water due to poor drainage.
Please exchange it absolutely for the new article when you remove the gaskets by the component
replacement and the check.
Don’t use unconfirmed liquid.
3.1.2
1
Note of Severe Dust /Liquid Specification
Cautions in Selecting the 7WP
The 7WP specifies cleaning liquids usable with the robot.
(Always keep all the liquids at or below 60°C.)
Liquid model name
Manufacturer name
CleanMate MS-1
TOHO Chemical Industry Co., LTD.
Toyosol ST-91P
Toyoda Chemical Industry Co., Ltd.
Toyosol SE-78P
Toyoda Chemical Industry Co., Ltd.
TOYOKNOCK
RE-777P
Toyoda Chemical Industry Co., Ltd.
MP-70
Henkel Japan
Pakuna FD-800
YUKEN Industry CO., LTD.
Yushiro cleaner
W51H
YUSHIRO CHEMICAL INDUSTRY CO., LTD.
Yushiro cleaner W80
YUSHIRO CHEMICAL INDUSTRY CO., LTD.
2
3
4
Permissible concentration
5.0％
Diluted to 20 parts of water
2.0％
Diluted to 50 parts of water.
5.0％
Diluted to 20 parts of water.
3.0％
Diluted to 33 parts of water.
3.0％
Diluted to 33 parts of water.
5.0％
Diluted to 20 parts of water.
3.3％
Diluted to 30 parts of water.
3.3％
Diluted to 30 parts of water.
Note that applying a cleaning liquid not included in the specification or one beyond its permissible
concentration or temperature even if it is included in the specification to the robot may results in
serious damage to the robot.
The cables connecting the robot, controller, and external battery are not resistant to any cleaning
liquid. So, install them in such a way that no cleaning liquid will be splashed to the cables.
Be sure to perform air purge by regulated pressure.(See Section 5.2.) Please do the air purge
whenever the robot is stopping or the power supply is cut. The air purge stop causes the flood and
the be dewy in the mechanism.
- 17 -
3.BASIC SPECIFICATIONS
3.1.3
1
2
3
B-83494EN/04
Cautions for 7C,7LC (Clean class 10)
As for the clean specification, only the robot mechanical unit satisfies clean class 10. Note that none
of the controller, the cables between the controller and robot, and teach pendant does not meet the
clean specification.
When using liquids in cleaning, see 1 and 4 in Subsection 3.1.1.
If gaskets are dismounted during parts replacement or inspection, replace them with new ones.
3.1.4
IP69K (option)
Definition of IP69K is below.
Robot are sprayed at high pressure via a flat jet nozzle from at angles of 0º,30º,60º,90º.
- each for at least 30 seconds.
The nozzle is held 100 to 150mm from the robot
-at a water pressure of 80-100 bars and a temperature of 80℃
-the quantity of water is 14-16 L/minute
After testing, water must not be present inside the robot.
3.2
MECHANICAL UNIT OPERATION AREA AND
INTERFERENCE AREA
Fig. 3.2 (a),(b) show the robot interference area. When installing peripheral devices, be careful to clear
away any objects that are the robot and the robot’s motion path in normal operation.
- 18 -
3.BASIC SPECIFICATIONS
B-83494EN/04
-170 DEG
-180 DEG(OPTION)
0 DEG
+180 DEG(OPTION)
R
17
R7
+170 DEG
0
20
15
0
R
(+50,+997)
50
MOTION RANGE OF
J5 AXIS CENTER
10
0°
30°
(-154,+587)
(-2,+471)
0
28
°
145°
75
75
6°
R
35
335
330
80 (*1)
92 (*2)
J5-AXIS CENTER
J3 AXIS REAR
352 INTERFERENCE AREA
°
(-617,+330)
280°
(+717,+330)
(+200,+330)
330
(+145,+214)
(-176,+91)
(0,0)
11
2°
(-182,-52)
(-275,-64)
(*1) Except 7C
(*2) 7C
(+432,-216)
(+145,-264)
(+239,-277)
Fig. 3.2 (a) Interference area
(Standard,7H,7C,7WP)
NOTE
Fig. 3.2 (a) is an example of Standard, please read J5-axis as J4-axis throughout
these figures in case of 7H.
- 19 -
3.BASIC SPECIFICATIONS
B-83494EN/04
-170 DEG
-180 DEG(OPTION)
+180 DEG(OPTION)
0 DEG
R
1
R 91
+170 DEG
6
23
(+50,+1191)
J3 AXIS REAR
INTERFERENCE AREA
510
J5 AXIS CENTER
80 (7L)
92 (7LC)
420
50
35
MOTION RANGE OF
J5 AXIS CENTER
R 7
5
(-187,+627)
(-811,+330)
280°
(+236,+330)
(+145,+171)
(-248,+94)
(0,0)
11
(-276,-154)
7°
(+544,-376)
(-383,-168)
(+145,-421)
(+302,-452)
Fig. 3.2 (b) Interference area
(7L,7LC)
- 20 -
330
145°
7°
0°
°
67 100°
(+911,+330)
440
28
(-37,+494)
3.BASIC SPECIFICATIONS
B-83494EN/04
3.3
ZERO POINT POSITION AND MOTION LIMIT
Zero point and software motion limit are provided for each controlled axis. The robot cannot exceed the
software motion limit unless there is a failure of the system causing loss of zero point position or there is
a system error.
Exceeding the software motion limit of a controlled axis is called overtravel (OT).
detected at both ends of the motion limit for each axis.
Overtravel is
In addition, the motion range limit by a mechanical stopper is also prepared to improve safety.
Fig.3.3 (a) shows position of mechanical stopper. Don’t reconstruct the mechanical stopper. There is a
possibility that the robot doesn't stop normally.
J5-axis stroke end
（upper side and lower side）
Detail B
B
J1-axis mechanical stopper
Spec.：
spring pin：A6-PS-8X20S
J3-axis mechanical stopper
Spec.：
J3 stopper：A290-7142-X427
spring pin：A6-PS-8X20S
Section A-A
Note： When assembling J3 stopper to
spring pin, apply cemedine super X
（clear）.
J2-axis stroke end
(front and back)
A
Fig. 3.3 (a)
A
Position of mechanical stopper
Fig.3.3 (b) - (j) show the zero point , motion limit and maximum stopping distance (stopping distance in
condition of max speed and max load) of each axis.
Only in case of J1-axis and J3-axis ,robot stops by transforming mechanical stopper. When the
mechanical stopper is transformed, the exchange is needed. See Fig.3.3 (a) about replacing J3-axis
mechanical stopper. Contact FANUC about replacing J1-axis mechanical stopper.
* The motion range can be changed.
"AXIS LIMIT SETUP".
For information on how to change the motion range, see Chapter 6,
- 21 -
3.BASIC SPECIFICATIONS
B-83494EN/04
- 170°
-170°Stroke end （Lower limit）
-175°The max stopping distance (position）
0°
+175°The max stopping distance (position）
+170°Stroke end （Upper limit）
+ 170°
Fig. 3.3 (b) J1-axis motion limit (J1-axis 340ºturn specification)
-180°
0°
±180°Stroke end （Upper limit, lower limit）
+180°
Fig. 3.3 (c) J1-axis motion limit (J1-axis 360ºturn specification)
- 22 -
3.BASIC SPECIFICATIONS
B-83494EN/04
0°
-
+ 14
5°
0°
10
-100°Stroke end
（Lower limit）
-102°The max stopping
distance (position)
+145°Stroke end
（Upper limit）
+147°The max stopping
distance (position)
Fig. 3.3 (d) J2-axis motion limit
+205°
0°
°
-70
+205°Stroke end
（Upper limit）
+209°The max stopping
distance （position）
-70°Stroke end
（Lower limit）
-72°The max stopping
distance （position）
Fig.3.3 (e) J3-axis motion limit
(Standard,7H,7C,7WP)
- 23 -
3.BASIC SPECIFICATIONS
B-83494EN/04
+ 21
3°
0°
°
70
+213°Stroke end
（Upper limit）
+217°The max stoppoing
distance （position）
-70°Stroke end
（Lower limit）
-72°The max stoppoing
distance （position）
Fig. 3.3 (f)
J3-axis motion limit
(7L,7LC)
Software restriction
0°
-190°Stroke end （Lower limit）
+190°Stroke end （Upper limit）
Note） There is no mechanical stopper.
Fig. 3.3 (g) J4-axis motion limit
(Except 7H)
- 24 -
3.BASIC SPECIFICATIONS
B-83494EN/04
+125°Stroke end （Upper limit）
25 °
1
+
+128°The max stoppoing
distance (position）
0°
- 1
25°
-128°The max stoppoing
distance (position）
-125°Stroke end （Lower limit）
Fig. 3.3 (h) J5-axis motion limit (Except 7H)
J4-axis motion limit (7H Horizontal wrist zero specification )
+215v Stroke end (Upper limit)
215°
+218v The max stopping
distance (position)
-38v The max stopping
distance (position)
35°
0°
Fig. 3.3 (i)
-35v Stroke end (Lower limit)
J4-axis motion limit (7H Downward wrist zero specification )
- 25 -
3.BASIC SPECIFICATIONS
B-83494EN/04
Software restriction
-360°Stroke end
（Lower limit）
+360°Stroke end
（Upper limit）
+360°
0°
-360°
Note) There is no mechanical stopper.
Fig. 3.3 (j) J6-axis motion limit (Except 7H)
J5-axis motion limit (7H)
- 26 -
3.BASIC SPECIFICATIONS
B-83494EN/04
3.4
WRIST LOAD CONDITIONS
Fig. 3.4 (a) to (d) are diagram to limit loads applied to the wrist.
・ Apply a load within the region indicated in the graph.
・ Apply the conditions of the allowable load moment and the allowable load inertia. See Section 3.1
about the allowable load moment and the allowable load inertia.
・ See Section 4.1 about mounting of end effector.
Z (cm)
65
60.5
60
1kg
55
50
45
40.4
40
2kg
35
31.5
26.1
22.5
19.7
16.2
30
3kg
25
4kg
5kg
20
6kg
7kg
15
10
5
30
35
40
X,Y (cm)
38.7
25
20
27.3
15
22.2
10
13.7
15.4
17.0
19.1
8cm
5
Fig. 3.4 (a) Wrist load diagram (Standard, 7L, 7WP)
- 27 -
3.BASIC SPECIFICATIONS
B-83494EN/04
Z (cm)
65
60.5
60
1kg
55
50
45
40.4
2kg
40
35
31.5
26.1
3kg
30
5kg
22.5
19.7
16.2
4kg
25
20
6kg
7kg
15
10
12.0
10.2
5.8
6.8
8.2
8cm
15
20
25
X,Y (cm)
21.3
10
5
14.9
5
Fig. 3.4 (b) Wrist load diagram (7H standard mode)
- 28 -
3.BASIC SPECIFICATIONS
B-83494EN/04
Z (cm)
65
60.5
60
1kg
55
50
45
40.4
40
2kg
35
31.5
26.1
16.2
4kg
25
5kg
22.5
19.7
3kg
30
20
6kg
7kg
15
10
5
25
30
35
40
X,Y (cm)
38.7
20
27.3
15
18.7
10
8.0
9.4
11.2
14.0
8cm
5
Fig. 3.4 (c) Wrist load diagram (7H High inertia mode)
- 29 -
3.BASIC SPECIFICATIONS
B-83494EN/04
Z (cm)
65
59.3
60
1kg
55
50
45
39.2
40
2kg
35
30.3
24.9
30
3kg
25
4kg
21.3
18.5
15.0
5kg
20
6kg
7kg
15
10
25
20
30
35
Fig. 3.4 (d) Wrist load diagram (7C,7LC)
- 30 -
40
38.7
15
27.3
10
22.2
5
13.7
15.4
17.0
19.1
9.2cm
5
X,Y (cm)
3.BASIC SPECIFICATIONS
B-83494EN/04
3.5
LOAD CONDITION ON EQUIPMENT MOUNTING FACE
The equipment can be installed as shown in Fig.3.5.When equipment is installed, total weight of installed
equipment, hand and work must not exceed 7kg. Please refer to Chapter 4 for the size on the equipment
installation side.
Equipment mounting face
Equipment (1kg or less)
Fig. 3.5
3.6
Load condition of equipment mounting face
OPERATING AREA FOR INCLINATION INSTALLATION
If applied load on the robot exceeds 5kg , when the robot is installed on an angle, the operating area is
limited as the angle. The robot can’t stop except for the ranges that are shown in the figure 3.6 (b) to (c).
If payload is less than 5kg, there is no restriction of motion range. 7H Downward wrist zero specification
is restricted to floor mount and upside-down mount.
Movement area (2)
123
°
Movement area (1)
57°
O
φ: Angle of mounting surface
Fig. 3.6 (a) Installation angle area
- 31 -
3.BASIC SPECIFICATIONS
B-83494EN/04
Motion range of J5 axis
rotation center
J5 axis roation center
R
R 9 717 (
11 Sta
(7L ndar
,7L d,7H
C)
, 7W
P)
Fig. 3.6 (b) Installation areA (1) Operation area
(0º≦φ≦57º, 123º≦φ≦180º)
J5 axis roation center
56°
( 594 )(Standard,7H,7WP) ( 594 )(Standard,7H,7WP)
( 756 ) (7L,7LC)
( 756 ) (7L,7LC)
Motion range of J5 axis
rotation center
56°
0
Fig. 3.6 (c) Installation areA (2) Operation area
(57º<φ<123º)
- 32 -
4.MECHANICAL COUPLING TO THE ROBOT
B-83494EN/04
4
MECHANICAL COUPLING TO THE ROBOT
4.1
MECHANICAL COUPLING OF END EFFECTOR TO WRIST
Fig. 4.1 is the diagrams for installing end effectors on the wrist. Select screws and positioning pins of a
length that matches the depth of the tapped and pin holes. Fasten the bolt for fixing the end effector
with following torque.
CAUTION
Notice the tooling coupling depth to wrist flange should be shorter than the
flange coupling length.
0
-0.025
φ5H7
O5H7depth
深さ77
User
tap
ユーザタップ
2-M3
5
2-M3depth
深さ5
51
1.5
O3
25.5
(80 (*1))
(92 (*2)) 18
45°
51
25.5
80 (*1)
18 92 (*2)
O 40 h7
4.5
area)
4.5(h7
(h7範囲)
O 20 H7
User
tap
ユーザタップ
2-M3
15
2-M3depth
深さ5
+0.021
0
NOTE
Don’t use a pin without tap for removal at wrist flange.
Wrist
rotation
手首回転中心
center
33(H7
area)
(H7範囲)
(*1)
(*1)Standard,7H,7L,7WP
標準,7H,7L,7WP
(*2)
(*2)7C,7LC
7C,7LC
4-M5
depth
8
4-M5
深さ8
equally
spaced
周上等配
Fig. 4.1
Surface for installing the end effector
NOTE：Figure is example with J6-axis reducer bolt cover (A05B-1142-J001)
User tap(2-M3) is for piping and wiring to the end effector
4.2
EQUIPMENT MOUNTING FACE
As shown in Fig. 4.2 tapped holes are provided to install equipment to the robot.
CAUTION
Never perform additional machining operations such as drilling or tapping on the
robot body. This can seriously affect the safety and function of the robot.
NOTE
Note that the use of a tapped hole not shown in the following figure is not
assured. Please do not tighten both with the tightening bolts used for mechanical
unit.
NOTE
Equipments should be installed so that mechanical unit cable does not interfere.
If equipments interfere, the mechanical unit cable might be disconnected, and
unexpected troubles might occur.
- 33 -
4.MECHANICAL COUPLING TO THE ROBOT
B-83494EN/04
93
76.5
（ 50 )
46
46
39
2-M6 depth 9
2-M8 depth 16
（for mastering fixture）
45
Equipment mounting are
2-M6 depth 10
33
190
41
152
190
51
35
88.5
100 97
2-M6 depth 10
33
Fig. 4.2
41
Equipment mounting faces
- 34 -
4.MECHANICAL COUPLING TO THE ROBOT
B-83494EN/04
4.3
LOAD SETTING
NOTE
Set load condition parameter before robot runs. Do not operate the robot in over
payload. Don’t exceed allowable payload including connection cables and its
swing. Operation in over payload may occur troubles such as reducer life
reduction.
CAUTION WHEN PERFORMING LOAD ESTIMATION AFTER PARTS
REPLACEMENT
If wrist axes (J5/J6-axis) motors or reducers are replaced, estimation accuracy
may go down. Perform the calibration for load estimation before performing load
estimation. Refer to Chapter 9 “LOAD ESTIMATION” in R-30iB/R-30iB Mate
Controller Optional Function OPERATOR’S MANUAL (B-83284EN-2).
Motion performance screens
The operation motion performance screens include the MOTION PERFORMANCE screen, MOTION
PAYLOAD SET screen, and payload information and equipment information on the robot.
1
Press the [MENU] key to display the screen menu.
2
Select “6 SYSTEM” from the next page,
3
Press F1 ([TYPE]) key to bring up the screen menu.
4
Select “MOTION.” The MOTION PERFORMANCE screen appears.
MOTION PERFORMANCE
Group1
No. PAYLOAD[kg]
1
2
3
4
5
6
7
8
9
10
7.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
JOINT 10%
Comment
[
[
[
[
[
[
[
[
[
[
Active PAYLOAD number =0
[ TYPE] GROUP DETAIL ARMLOAD
IDENT
5
]
]
]
]
]
]
]
]
]
]
SETING >
>
Ten different pieces of payload information can be set using condition Nos. 1 to 10 on this screen.
Place the cursor on one of the numbers, and click F3 (DETAIL). The MOTION PAYLOAD SET
screen appears.
- 35 -
4.MECHANICAL COUPLING TO THE ROBOT
B-83494EN/04
MOTION PAYLOAD SET
1
2
3
4
5
6
7
8
Group1
Schedule No [
1]:
PAYLOAD
PAYLOAD CENTER
PAYLOAD CENTER
PAYLOAD CENTER
PAYLOAD INERTIA
PAYLOAD INERTIA
PAYLOAD INERTIA
JOINT
X
Y
Z
X
Y
Z
100 %
[ Comment
]
[ kg ]
7.00
[ cm ]
-13.72
[ cm ]
0.00
[ cm ]
11.954
[kgfcms^2 ] 138.974
[kgfcms^2 ] 169.538
[kgfcms^2 ] 102.039
[ TYPE ] GROUP NUMBER DEFAULT HELP
X
Center of robot
ロボットの
end effector mounting face
X
エンドエフェクタ取付面
中心
y
Z
xg (cm)
Iy (kgf・cm・s2 )
Mass
m (kg)
質量m(kg)
Center of
gravity
重心
Center of
重心
gravity
Iz (kgf・cm・s2 )
yg (cm)
Ix (kgf・cm・s2)
zg (cm)
Fig. 4.3 Standard tool coordinate
6
7
8
9
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]).
Press 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.
Press the PREV key to return to the MOTION PERFORMANCE screen. Click F5 ([SETIND]), and
enter the desired payload setting condition number.
On the list screen, pressing F4 ARMLOAD brings you to the device-setting screen.
MOTION ARMLOAD SET
JOINT
100%
Group 1
1 ARM LOAD AXIS #1 [kg]
2 ARM LOAD AXIS #3 [kg]
[
10
TYPE
]
GROUP
0.00
1.00
DEFAULT
HELP
Specify the mass of the loads on the J2 base and J3 arm. When you enter ARMLOAD AXIS #1[kg]:
Mass of the load on the J2 base and ARMLOAD AXIS #3[kg]:
Mass of the load on the J3 arm, the confirmation message “Path and Cycle time will change. Set
it?” appears. Select F4 YES or F5 NO. Once the mass of a device is entered, it is put in effect by
turning the power off and on again.
- 36 -
4.MECHANICAL COUPLING TO THE ROBOT
B-83494EN/04
4.4
HIGH INERTIA MODE (LR Mate 200iD/7H)
High Inertia Option
Two servo motion parameters are prepared depending on the magnitude of load inertia. The best addition
and subtraction velocity operation can be achieved by setting the parameter matched to the load inertia
mode. The parameter is changed by the following methods.
1
2
3
Turn ON the controller with “PREV” and “NEXT” key pressed.
Then select “3. Controlled start”.
Press MENU key and select “9. MAINTENANCE”.
You will see a screen similar to the following.
Press arrow (↑,↓) keys and move the cursor to “LR Mate 200iD/7H” . Then press F4, MANUAL.
ROBOT MAINTENANCE
1/10
Setup Robot System Variables
Group
1
4
Robot Library/Option
LR Mate 200iD/7H
Ext Axes
0
Set “Standard Inertia Mode” or “High Inertia Mode” on the INERTIA MODE SETTING screen.
******** Group 1 Initialization ********
-------
INERTIA MODE SETTING
1. Standard Inertia Mode
2. High Inertia Mode
-------
Select Inertia Mode (1 or 2)->
5
Press FCTN key and select “1. START (COLD)”.
Robot is set in standard inertia mode when robot is shipped.
- 37 -
5.PIPING AND WIRING TO THE END EFFECTOR
5
B-83494EN/04
PIPING AND WIRING TO THE END
EFFECTOR
WARNING
・ Use mechanical unit cables that have required user interface.
・ Do not add user cable or hose to inside of mechanical unit.
・ Please do not obstruct the movement of the mechanical unit cable when cables are
added to outside of mechanical unit.
・ Please do not perform remodeling (Adding a protective cover and fix an outside cable
more) obstructing the behavior of the outcrop of the cable.
・ Please do not interfere with the other parts of mechanical unit when equipment is
installed in the robot.
・ Cut unnecessary length of wire rod. Make insulation processing like winding acetate
tape. (See Fig.5)
・ If you can not prevent electrostatic charge of work and end effector, keep away an
end effector (hand) cable from an end effector and a work as much as possible, when
wiring it. When they come to close unavoidable, make insulation processing between
them.
・ Be sure to seal connectors of hand side and robot side and terminal parts of cables,
to prevent water from entering the mechanical unit. Also, attach cover to unused
connector.
・ Check looseness of connector and damage of coating of cables routinely.
・ When these attentions are not kept and cable failure occur, it may cause troubles
such as incorrect action of the end effector, robot stops due to an alarm, incorrect
action of the robot etc. In addition, electric shock could occur when touching the
power cables.
End effec tor (hand) c able
Cut unnec essary length of unused wire rod
Insulation processing
Fig.5 Treatment method of end effector (hand) cable
- 38 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
5.1
AIR SUPPLY (OPTION)
Air supply holes (Rc1/4) are prepared on the J1–axis connector panel for end effector as shown in Fig.5.1
(b).
Optional solenoid valves can be mounted as shown in Tables 5.1. Plugs are inserted in all the ports used
for supplying air before the robot is shipped. To use the air circuit, you must remove the plugs and
connect the couplings with the ports.
When the solenoid valve is to be replaced, the entire manifold should be replaced.
Table 5.1 Optional solenoid valves
Option spec.
A05B-1142-H001
A05B-1142-H002
A05B-1142-H003
A05B-1142-H004
A05B-1142-H005
A05B-1142-H006
Model
Standard,
Description
Path 2 air piping, RO
connector output
7H,7C
(without solenoid valve)
Standard,
7H,7WP
Standard,
7H,7WP
Standard,
7H,7WP
Standard,
7H,7WP
Standard,
7H,7WP
Standard,
A05B-1142-H007
A05B-1142-H009
A05B-1142-H011
Solenoid (Manifold) spec.
Remarks
RO
―
―
―
2 positionX1
RO1 to 2
2 positionX2
RO1 to 4
2 positionX3
RO1 to 6
A97L-0218-0130#D1
Double solenoids X1
(manufactured by SMC)
A97L-0218-0130#D2
Double solenoids X2
(manufactured by SMC)
A97L-0218-0130#D3
Double solenoids X3
(manufactured by SMC)
Double solenoids X3
Double solenoids X3
A97L-0218-0130#D3B
3 position
(manufactured by SMC)
(closed center)X3
RO1 to 6
A97L-0218-0130#D3R
3 position
(manufactured by SMC)
(exhaust center)X3
―
―
―
RO1 to 6
7H,7C,
Without air piping, RO
connector output
7WP
(without solenoid valve)
Standard,
Path 2 air piping, RO
connector output
―
―
―
(without solenoid valve)
Path 2 air piping, RO
connector output
―
―
―
2 positionX1
RO1 to 6
2 positionX2
RO1 to 6
2 positionX3
RO1 to 6
2 positionX1
RO1 to 2
2 positionX2
RO1 to 4
2 positionX1
RO1 to 6
2 positionX2
RO1 to 6
7H
7L,7LC
(without solenoid valve)
A05B-1142-H012
7L
Double solenoids X1
A05B-1142-H013
7L
Double solenoids X2
A05B-1142-H014
7L
Double solenoids X3
A05B-1142-H022
7C
Double solenoids X1
A05B-1142-H023
7C
Double solenoids X2
A05B-1142-H032
7LC
Double solenoids X1
A05B-1142-H033
7LC
Double solenoids X2
A97L-0218-0130#D1
(manufactured by SMC)
A97L-0218-0130#D2
(manufactured by SMC)
A97L-0218-0130#D3
(manufactured by SMC)
A97L-0218-0130#D1
(manufactured by SMC)
A97L-0218-0130#D2
(manufactured by SMC)
A97L-0218-0130#D1
(manufactured by SMC)
A97L-0218-0130#D2
(manufactured by SMC)
2
Available section area of the solenoid valve：1.98mm (CV value：0.11)
- 39 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
NOTE
1 When the air circuit is not used, reinstall the plugs as originally installed for the
purpose of dust and water protection.
2 Attach an air filter with a mesh size of 5μm or better on the upstream side near
the robot. Compressed air including much drainage causes valve malfunctions.
Take action to prevent the entry of drainage, and also drain the air filter
periodically.
3 For 7C and 7LC, remove the exhaust port plug before using it. (Fig.5.1 (a))
Exhaust port for 7C and 7LC
Fig.5.1 (a) Exhaust port plug for 7C and 7LC
- 40 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
B
内蔵電磁弁排気ポート
Exhaust
port for integrated
(7C,7LC以外)
solenoid
valve
(Except 7C,7LC)
A
EE(*)
Air
AIR11
(ユーザ用エア)
(user
air)
Rc1/4
Airエア入口
inlet Rc1/4
別置バッテリケーブル
Relay
connector
中継コネクタ
for remote
battery cable
A05B-1142-H341
A05B-1143-H341
AIR 2
A05B-1142-H301,H306,H321,H341,H501指定時
: (電磁弁用エア
(オプション))
A05B-1142-H301,H306
,H321,H341,H501are
specified
(air for solenoid valve (option)
A05B-1142-H302,H307,H322,H502指定時 :are
(ユーザ用エア)
A05B-1142-H302,H307,H322,H502
specified (user air)
イーサネットケーブル
付加軸モータケーブル
Ethernet
cable
Additional
axis motor cable
Ethernet
cable
インタフェース
イーサネットケーブル
Camera
cable
(パワー、ブレーキ線)
カメラケーブル
(power,brake
line) interface
interface
インタフェース
interface
インタフェース
インタフェース
interface
エア入口
Air
inlet Rc1/4
Rc1/4
Air
AIR22
Force sensor
cable
(電磁弁用エア
(オプション))
力センサケーブル
(air
for solenoid
valve)
interface
is specified
インタフェース A05B-1142-H303
A05B-1142-H303指定時
エア入口
Air
inlet Rc1/4
Rc1/4
付加軸モータケーブル
Additional axis
motor cable A05B-1142-H304
A05B-1142-H304指定時
A05B-1142-H305指定時
A05B-1142-H305
is specified
is specified
(パルスコーダ線)
(Pulsecoderインタフェース
line) interface
Air
inlet Rc1/4
エア入口
Rc1/4
Camera
cable
カメラケーブル
インタフェース
interface
Airエア入口
inlet Rc1/4
Rc1/4
Ethernet
イーサネットケーブル
cable
インタフェース
interface
Air 2
AIR 2
(air for solenoid
valve)
(電磁弁用エア）
Force sensor cable
力センサケーブル
interface
AIR 2AIR 2
インタフェース
A05B-1142-H351,H356
are specified
(air for
solenoid valve (option)
A05B-1142-H351,H356指定時
: (電磁弁用エア
(オプション))
A05B-1142-H352,H357指定時
: (ユーザ用エア)
A05B-1142-H352,H357
are specified
(user air)
Air
AIR1 1
(ユーザ用エア）
(user
air)
A05B-1142-H353指定時
A05B-1142-H353
is specified
A05B-1142-H351,H352,H356,H357指定時
A05B-1142-H351,H352,H356,H357
are specified
RO3
M5
RO5
M5
RO1
M5
RO4
M5
RO2
M5 (If
there is no solenoid
M5it is AIR 2)
valve,
(電磁弁なしの時はAIR 2)
16
A05B-1142-H355指定時
A05B-1142-H355
is specified
16
10
M5 深さ 4
(ユーザ用エア)
エア入口
Rc1/4
Air
inlet Rc1/4
RO6
M5
Detail
B
詳細 B
161616 36
Double
solenoid X1
ダブルソレノイドX1
ダブルソレノイドX2
Double
solenoid X2
ダブルソレノイドX3
Double solenoid X3
RO1-6
RO1～6(電磁弁オプション選択時)
(When
solenoid valve option
is specified)
Detail
詳細 AA
(*)(*)LR
The end
cannot
be used for LR Mate 200iD/7WP.
Mateeffector
200iD/7WP
ではエンドエフェクタは使用できません。
Fig. 5.1 (b)
Air pressure
Air supply
2
2
Supply air pressure
0.49 to 0.69MPa(5 to 7kgf/cm ),
Setting: 0.49MPa(5kgf/cm )
Amount of consumption
Maximum instantaneous amount 120Nl/min (0.12Nm /min)
3
*The air should be dry. Do not use oiled compressed air.
NOTE
The user air and the solenoid valve is not available when the IP69K option is specified
- 41 -
5.PIPING AND WIRING TO THE END EFFECTOR
5.2
B-83494EN/04
INSTALLING THE AIR PURGE KIT
Air purge kit , air purge kit with a monitor port are preparatory as the option, and use it, please.
prepared air purge kit.
Use the
・ Air purge kit (A05B-1142-J061,J064)
Set the air purge pressure to 10 kPa (0.01 MPa, 0.1 kgf/cm2) or less. Air purge regulator kit
(A05B-1138-J062) is appropriate for controlling the purge pressure.
・ Air purge kit with a monitor port (A05B-1142-J062,J063,J065)
This is air purge with purge monitor port. By adding a pressure sensor etc. to the port, the robot inside
pressure can be monitored. If the monitor port is not utilized, be sure to close the port by a plug. Air purge
regulator kit (A05B-1138-J062) is appropriate for controlling the purge pressure. Combination with
mechanical unit cables and solenoid valves has some restrictions. Set the air purge pressure to 10 kPa
(0.01 MPa, 0.1 kgf/cm2) or less.
NOTE
1 It is recommended that a dedicated air pressure source be used for an air purge.
Do not use the same air pressure source for both the air purge kit and others.
Otherwise, the dryer capacity is exceeded and water or oil remains in air,
causing serious damage to the robot.
2 After installing the robot, perform a air purge at all times.
Even when the robot is not operating, an air purge is required if it is placed in a
bad condition. Intermittent purge sometimes causes liquid entrance or internal
dew.
3 When removing the air tube from the air inlet of the J1 connector panel, replace
the joint together. Be careful to prevent cleaning fluids from entering into the
joint. Otherwise, rubbers in the joint are degraded and the robot may be
damaged.
4 Air purge kit cannot be used when using 7C or 7LC in the clean room. It causes
particle generation. Except for clean room, such as food environment is
acceptable.
- 42 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
60
140
2-Φ11
70
220
100
(33)
(335)
272
158
59
PURGE connector
(J1 connector panel)
41
180
(101)
Air outlet
(O6 Air tube)
187
11
Pneumatic
air outlet
170
35
14
22
95
4-Φ7
Pressure gauge
7
Air inlet
(O10 Air tube)
7
S
O
O
S
Pressure adjustment knob
Fig 5.2 (a) Air purge kit outside dimensions
Inlet for air purge
Fig 5.2 (b) Inlet for air purge
(A05B-1142-J061,J064 for backside connector plate)
- 43 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
Inlet for air purge
Fig 5.2 (c) Inlet for air purge
(A05B-1142-J061,J064 for bottom connector plate)
Inlet for air purge
Purge pressure
monitor port
Fig 5.2 (d) Inlet for air purge
(A05B-1142-J062,J63,J065 for backside connector plate)
- 44 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
Inlet for air purge
Purge pressure
monitor port
Fig 5.2 (e) Inlet for air purge
5.3
(A05B-1142-J062,J63,J065 for bottom connector plate)
INTERFACE FOR OPTION CABLE (OPTION)
Fig. 5.3 shows the position of the EE interface.
EE interface (RI/RO signal) is prepared .
NOTE
1 The connector to be plugged into the interface and the cable attached to that
connector should be prepared by the customer.
2 Please cover the unused connector and air port reliably by a metal cap (option)
and a plug. If the covering is loose, unexpected substances will enter into the
robot and cause any troubles. At ex-factory, the interfaces are covered by easy
caps in order to avoid dust during transportation. Please keep in mind that the
cap doesn’t work enough as a protect means in factory environment.
3 Please do the waterproof processing of the hand cable surely to prevent the
flood in the mechanism.
Moreover, the wound of the cover of the cable causes the flood so exchange it,
please when it is damaged.
(1) EE interface(RI/RO signal)
Fig. 5.3 shows the pin layout for the EE interface (RI/RO signal).
- 45 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
Cap
A05B-1142-H301,H303,H306,H321,H351,H353,
H356,H501,H503 is selected
Plug connector
(Outside FANUC delivery scope.)
EE
8
RO7
6
7
RO8
12
RI6
5
9
0V
11
RI5
24V
10
0V
4
1
24V
3
RI4
RI1
2
RI3
RI2
Waterproof processing
XHBK: Hand broken signal
A05B-1142-H302,H305,H307,H322,H352,H355,
H357,H502 is selected
EE
1
2
3
4
0V
0V
0V
0V
5
6
7
8
9
10
RO1
RO2
RO3
RO4
RO5
RO6
11
12
13
14
15
16
RI1
RI2
RI3
RI4
RI5
RI6
17
18
19
20
Cap
XHBK
24V
24V
24V
EE
Force sensor
EE
Camera
A05B-1142-H301,H302,H306,H307, A05B-1142-H303,H323,H353,
H321,H322,H351,H352,H356,H357, H503
H501,H502
EE
Ethernet
A05B-1142-H305,H355
Fig. 5.3
EE interface (RI/RO signal)
- 46 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83494EN/04
CAUTION
1 For wiring of the peripheral device to the EE interface, refer to -Chapter
“ELECTROCAL CONNECTIONS” of manuals below, too.
R-30iB/Mate CONTROLLER MAINTENANCE MANUAL (B-83525EN)
R-30iB Mate Controller Open Air MAINTENANCE MANUAL (B-83555EN)
2 This interface is not available when the IP69K option is specified.
Connector specifications
Table 5.3 (a), (b)show the connector parts supported by the end effector interface. Some of these parts are
available as an option from FANUC. (Table 5.3 (a), (b))
Maker
Hirose Electric
Co. Ltd.
Table 5.3 (a) Supported connector (user side)
Manufacturer specification
Remarks
Plug：RM15WTPZ-12P(71)
Straight type connector
Clamp：JR13WCC-*(72)
∗indicates an applicable cable diameter selected from the
following:
∗：φ5，6，7，8，9，10mm
For A05B-1142-H301,H303,H306,H321,H351,H353,H356,H501
,H503
Plug：RM15WTLP-12P(71)
Elbow type connector
Clamp：JR13WCC-*(72)
∗indicates an applicable cable diameter selected from the
following:
∗：φ5，6，7，8，9，10mm
For A05B-1142-H301,H303,H306,H321,H351,H353,H356,H501
,H503
Plug：RM15WTLP-20P
Elbow type connector
Clamp：JR13WCC-*(72)
*indicates an applicable cable diameter selected from the
following:
*：φ5，6，7，8，9，10mm
For A05B-1142-H302,H305,H307,H322,H352,H355,H357,H502
NOTE
For details, such as the dimensions, refer to the related catalogs offered by the
respective manufacturers, or contact your local FANUC representative.
Table 5.3 (b) Supported option
Option specification
A05B-1137-J057
A05B-1137-J058
A05B-1139-J059
A05B-1142-K052
A05B-1142-K053
Remarks
Straight type connector (12-pins)
Applicable cable diameter：8mm
Elbow type connector (12-pins)
Applicable cable diameter：9mm
Elbow type connector (20-pins)
Applicable cable diameter：9mm
Cable with elbow type connector (12-pins)
Length： 300mm
Cable with elbow type connector (20-pins)
Length： 300mm
NOTE
See Appendix C, "OPTIONAL CONNECTOR WIRING PROCEDURE" for
explanations about how to wire optional connectors.
- 47 -
6.AXIS LIMIT SETUP
6
B-83494EN/04
AXIS LIMIT SETUP
Axis limits define the motion range of the robot. The operating range of the robot axes can be restricted
because of:
・ Used work area limitations
・ Tooling and fixture interference points
・ Cable and hose lengths
The software method used to prevent the robot from going beyond the necessary motion range.
・ Axis limit software settings (All axes)
WARNING
Changing the motion range of any axis affects the operation range of the robot.
To avoid trouble, carefully consider a possible effect of the change to the
movable range of each axis in advance. Otherwise, it is likely that an unexpected
condition occurs; for example, an alarm may occur in a previous taught position.
6.1
SOFTWARE SETTING
Upper and lower axis limits about motion range can be changed by software settings. The limits can be
set for all axes. The robot stops the motion if the robot reaches to the limits.
Procedure
Setting Up Axis Limits
1
2
3
4
Press [MENU] key.
Select SYSTEM.
Press F1, [TYPE] to bring up the screen menu.
Select Axis Limits. You will see a screen similar to the following.
System Axis Limits
Group1
AXIS
GROUP
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
LOWER
-180.00
-100.00
-70.00
-190.00
-125.00
-360.00
0.00
0.00
0.00
[ TYPE]
NOTE
0.00 indicates the robot does not have these axes.
- 48 -
JOINT 100%
1/16
UPPER
180.00
145.00
205.00
190.00
125.00
360.00
0.00
0.00
0.00
deg
deg
deg
deg
deg
deg
mm
mm
mm
6.AXIS LIMIT SETUP
B-83494EN/04
5
Move the cursor to the axis limit to be set. Type the new value using the numeric keys on the teach
pendant.
System Axis Limits
Group1
AXIS
GROUP
2
1
JOINT 100%
1/16
LOWER
UPPER
-100.00
145.00
deg
[ TYPE]
6
7
Perform the setting for all axes.
Turn off the controller and then turn it back on again in the cold start mode so the new information
can be used.
WARNING
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.
- 49 -
7.CHECKS AND MAINTENANCE
7
B-83494EN/04
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
(See the APPENDIX A PERIODIC MAINTENANCE TABLE.)
NOTE
The periodic maintenance procedures described in this chapter assume that
the FANUC robot is used for up to 3840 hours a year. In cases where robot use
exceeds 3840 hours/year, adjust the given maintenance frequencies
accordingly. The ratio of actual operation time/year vs. the 3840 hours/year
should be used to calculate the new (higher) frequencies. For example, when
using the robot 7680 hours a year, the maintenance frequency should be
doubled – i.e. the time interval should be divided by 2.
7.1
PERIODIC MAINTENANCE
7.1.1
Daily Checks
Clean each part, and visually check component parts for damage before daily system operation. Check the
following items when necessary.
Check items
Oil seepage
Air control set
Air purge kit
Vibration, abnormal
noises
Repeatability
Peripheral devices for
proper operation
Brakes for each axis
Warnings
Check points and management
Check there is oil on the sealed part of each joint. If there is an oil seepage, clean them.
⇒”7.2.1 Confirmation of Oil Seepage”
( When air control set or air purge kit is used)
⇒”7.2.2 Confirmation of the Air Control Set and Air Purge kit”
Check whether vibration or abnormal noises occur.
When vibration or abnormal noises occur, perform measures referring to the following
section:
⇒”3.2 FAILURES,CAUSES AND MEASURES”(symptom：Vibration, Noise)
Check to see that the taught positions of the robot have not deviated from the previous
taught positions. When displacement occurs, perform the measures as described in the
following section:
⇒”3.2 FAILURES,CAUSES AND MEASURES”(symptom：Displacement)
Check whether the peripheral devices operate properly according to commands from the
robot and the peripheral devices.
Check that the end effector drops within 2 mm when servo power is turned off.
If the end effector (hand) drops, perform the measures as described in the following
section:
⇒”3.2 FAILURES,CAUSES AND MEASURES”(symptom：Dropping axis)
Check whether unexpected warnings occur in the alarm screen on the teach pendant. If
unexpected warnings occur, perform the measures as described in the following manual:
⇒”R-30iB/R-30iB Mate CONTROLLER OPERATOR’S MANUAL (Alarm Code
List)(B-83284EN-1)”
- 50 -
7.CHECKS AND MAINTENANCE
B-83494EN/04
7.1.2
Periodic Check and Maintenance
Check the following items at the intervals recommended below based on the total operating time
or the accumulated operating time, which ever comes first.
Check and maintenance
intervals
(Operation time, Operation
accumulated time)
1
month
320h
3
months
960h
○
○
1
year
3840h
1st
check
○
○
Check for water
(except 7WP)
○
Only
1st
check
○
○
Only
1st
Check
○
4
years
15360h
Cleaning the
controller
ventilation
system
Check for
external
damage or
peeling paint
Only
○
2
years
7680h
Check and
maintenance
item
○
Only
1st
Check for
damages
to the teach
pendant cable, the
operation box
connection cable
or the robot
connection cable
Check for
damage to the
end effector
(hand)
cable and
external
batteries cable
Check the
exposed
connectors
Check points, management and
maintenance method
Periodic
maintenance
No.
If the controller ventilation system is dusty, turn off
power and clean the unit.
13
Check whether the robot has external damage due
to the interference with the peripheral devices or
peeling paint. If an interference occurs, eliminate
the cause. Also, if the external damage is serious
and causes a problem in which the robot cannot
be used, replace the damaged parts.
Check whether the robot is subjected to water or
cutting oils. If water is found, remove the cause
and wipe off the liquid.
Check whether the cable connected to the teach
pendant, operation box and robot are unevenly
twisted or damaged. If damage is found, replace the
damaged cables.
1
2
12
Check whether the end effector cables and external
batteries cable are unevenly twisted or damaged. If
damage is found, replace the damaged cables.
8
Check the exposed connectors.
⇒”7.2.3 Check the Connectors”
3
Retighten the end effector mounting bolts.
Refer to the following section for tightening torque
information:
⇒”4.1 MECHANICAL COUPLING OF END
EFFECTOR TO WRIST”
4
check
○
Only
1st
check
○
Retightening the
end effector
mounting bolts
- 51 -
7.CHECKS AND MAINTENANCE
Check and maintenance
intervals
(Operation time, Operation
accumulated time)
1
month
320h
Check and
maintenance
item
3
months
960h
1
year
3840h
○
○
Retightening the
external main
bolts
○
Check the
mechanical
stopper
○
Clean spatters,
sawdust and
dust
○
Replacing the
mechanical unit
batteries
Replenish grease
to each axis
reducer
2
years
7680h
4
years
15360h
Only
1st
check
○
Only
1st
check
○
Only
1st
check
○
(*)
○
(*)
○
○
Replacing the
mechanical unit
cable
Replacing the
controller
batteries
B-83494EN/04
Check points, management and
maintenance method
Retighten the robot installation bolts, bolts to be
removed for inspection, and bolts exposed to the
outside. Refer to the recommended bolt
tightening torque guidelines at the end of the
manual. An adhesive to prevent bolts from
loosening is applied to some bolts. If the bolts are
tightened with greater than the recommended
torque, the adhesive might be removed.
Therefore, follow the recommended bolt
tightening torque guidelines when retightening the
bolts.
Check the spring pin of J1/J3-axis mechanical
stopper is not transformed, if it is transformed,
replace it by new one.
⇒”7.2.4 Check of the Mechanical Stopper ”
Check that spatters, sawdust, or dust does not exist
on the robot main body. If dust has accumulated,
remove it. Especially, clean the robot movable parts
well (each joint).
For 7WP
-Remove sludge and foreign materials in the cleaner.
-Replace the cleaner periodically.
-Wash the strainer, and replace it periodically.
-Clean the joints of mechanical unit and clean the
foreign materials.
For arc welding robot
The insulation failure occurs when the spatter has
collected around the wrist flange or welding torch,
and there is a possibility of damaging the robot
mechanism by the welding current.
(See Appendix D)
Replace the mechanical unit batteries
⇒”7.3.1 Replacing the batteries”
Replenish grease to each axis reducer
(*) Periodic interval differs according to the model.
7C, 7LC : 2 years (7680 hours)
Except 7C, 7LC : 4 years (15360 hours)
⇒”7.3.2 REPLENISH THE GREASE OF THE
DRIVE MECHANISM”
Replace the mechanical unit cable
Contact your local FANUC representative for
information regarding replacing the cable.
Replace the controller batteries
⇒Chapter 7 Replacing batteries of R-30iB
MATE CONTROLLER MAINTENANCE MANUAL
(B-83525EN) R-30iB MATE CONTROLLER Open
Air MAINTENANCE MANUAL (B-83555EN)”
- 52 -
Periodic
maintenance
No.
5
6
7
9
10
11
14
7.CHECKS AND MAINTENANCE
B-83494EN/04
7.2
CHECK POINTS
7.2.1
Confirmation of Oil Seepage
Check items
Check to see whether there is an oil seepage on the rotating parts of each joint axis.
Fig. 7.2.1 Check points of oil seepage
Management
・ Oil might accumulate on the outside of the seal lip depending on the movement condition or
environment of the axis. If the oil changes to a state of liquid，the oil might fall depending on the
axis movement. To prevent oil spots, be sure to wipe away any accumulated oil under the axis
components before you operate the robot.
・ Also，motors might become hot and the internal pressure of the grease bath might rise by frequent
repetitive movement and use in high temperature environments. In these cases, normal internal
can be achieved by venting the grease inlet. (When opening the grease inlet, refer to
Subsection .7.3.2 and ensure that grease is not expelled onto the machine or tooling.)
・ If you must wipe oil frequently, and opening the grease outlet does not stop the seepage, perform
the measures below.
⇒”9.2 FAILURES,CAUSES AND MEASURES”(symptom：Grease leakage)
- 53 -
7.CHECKS AND MAINTENANCE
7.2.2
B-83494EN/04
Confirmation of the Air Control Set and Air Purge kit
When an air control set or an purge kit is used, check the items below.
Item
When air control
set is provided.
2
Air pressure
Leakage
from hose
Drain
3
When air purge kit
is provided.
Supply
pressure
5
Dryer
6
Drain
Check air pressure using the pressure gauge on the air regulator as
shown in Fig.7.2.2 (a). If it does not meet the specified pressure of
0.49MPa (5 kg/cm2), adjust it using the regulator pressure setting
handle.
Check the joints, tubes, etc. for leaks.
Repair leaks, or replace parts, as required.
Check drain and release it. When quantity of the drain is remarkable,
examine the setting of the air dryer to the air supply side.
Check the supply pressure using the air purge kit shown in Fig.7.2.2
(b). If it does not meet the specified pressure of 10 KPa (0.1 kgf/cm2),
adjust it using the regulator pressure setting handle.
Check whether the color of the dew point checker is blue. When it is
not blue, identify the cause and replace the dryer. Maintenance for air
purge kit, refer to the operator’s manual attached kit.
Check drain. When quantity of the drain is remarkable, examine the
setting of the air dryer to the air supply side.
Pressure
Adjusting Knob
2-6.5×16.5
Length round hole
Rc1/4
AIR OUTLET
Pressure gauge
Rc1/4
AIR SUPPLY
Fig. 7.2.2 (a) Air control set (option)
Dew point checker
2-7x11
Length round hole
Air outlet
(O6 Air tube)
Pressure gauge
Pneumatic
air outlet
Air inlet
(O10 air tube)
Pressure adjustment knob
S
O
4
Check points
S
O
1
Check items
Dryer unit
Fig. 7.2.2 (b) Air purge kit (option)
- 54 -
7.CHECKS AND MAINTENANCE
B-83494EN/04
7.2.3
Check the Connectors
Inspection points of the connectors
・ Robot connection cables, earth terminal and user cables
Check items
・ Circular connector: Check the connector for tightness by turning it manually.
・ Square connector: Check the connector for engagement of its lever.
・ Earth terminal: Check the connector for tightness.
Fig. 7.2.3 Connector Inspection points
7.2.4
Check of Mechanical Stopper
・ Check the spring pin of J1/J3-axis mechanical stopper is not transformed, if it is transformed, replace
it by new one.
- 55 -
7.CHECKS AND MAINTENANCE
B-83494EN/04
J1-axisJ1軸機械式ストッパ
mechanical stopper
Spec. : 仕様：
Spring pin : A6-PS-8X20S
スプリングピン：A6-PS-8X20S
J3-axis mechanical stopper
Spec.J3軸機械式ストッパ
:
仕様：
J3 stopper
: A290-7142-X427
J3ストッパ：A290-7142-X427
spring スプリングピン：A6-PS-8X20S
ping A6-PS-8X20S
Note
: When assembling the J3 stopper
注：J3ストッパをスプリングピンに組み
付ける時はセメダイン
to the
spring pin, applyスーパーX
（クリア）を塗布して下さい。
CEMEDINE SUPER X (CLEAR).
断面 A-A
Section
A-A
A
A
Fig. 7.2.4 Check of mechanical stopper
7.3
MAINTENANCE
7.3.1
Replacing the Batteries
(1-Year Periodic Inspection If Built-in Batteries Are Specified)
(1.5-Year Periodic Inspection If External Batteries Are
Specified)
The position data of each axis is preserved by the backup batteries. If built-in batteries are in use,
replace them every year. If external batteries are in use, replace them every year and a half. Also use
the following procedure to replace when the backup battery voltage drop alarm occurs.
Procedure of replacing the battery (if built-in batteries are specified)
1
Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION
Be sure to keep the power supply turned on. Replacing the batteries with the
power supply turned off causes all current position data to be lost. Therefore,
mastering will be required again.
2
3
4
Remove the battery case cap.( Fig. 7.3.1 (a)) If it cannot be removed, tap it to side direction with a
plastic hammer.
Loosen the plate screw and take out the lid of the battery box and replace battery. Battery can be
taken out by pulling the stick which is center of the battery box.
Assemble them in the reversed sequence. Pay attention to the direction of batteries.
It is necessary to exchange gasket.
- 56 -
7.CHECKS AND MAINTENANCE
B-83494EN/04
C battery (4 pcs)
FANUC spec.：A98L-0031-0027
The battery can be taken out
by pulling this stick
Plate screw M4X12(2 pcs)
Lid of battery box
Gasket
Standard,7H : A290-7139-X253
7C,7LC : A290-7142-X249
Standard,7H,7L
Bolt with plate processing
hex-head hole
M4X20(4 pcs)
7C,7LC
Stainless hex-head hole bolt
M4X20(4 pcs) & washer
Battery box cover
Fig. 7.3.1 (a) Replacing the battery (if built-in batteries are specified)
Procedure of replacing the battery (if external batteries are specified)
1
During battery replacement, hold down the emergency stop button for the sake of safety.
CAUTION
Be sure to keep the power supply turned on. Replacing the batteries with the
power supply turned off causes all current position data to be lost. Therefore,
mastering will be required again.
2
3
4
5
Uncap the battery case (Fig. 7.3.1 (b)).
Take out the old batteries from the battery case.
Insert new batteries into the battery case while observing their correct orientation.
Cap the battery case.
- 57 -
7.CHECKS AND MAINTENANCE
B-83494EN/04
External battery box
Battery cable
Diameter About O5mm
(Max O5.5mm)
Battery case
Case cap
Spec. of battery :A98L-0031-0005
(D battery alkali 4pcs)
Fig. 7.3.1 (b) Replacing the battery (if external batteries are specified)
Fig. 7.3.1 (c) shows the external size of external battery box.
When the battery box needs to be built into the controller or other internal units, refer to the outer
dimensions shown in Fig. 7.3.1 (c)
The battery box can be fixed by using M4 flat–head screws. (The bolts do not come with the system.)
A maximum of six terminals can be attached to the backplane of the battery box.
Fig. 7.3.1 (c) Outer dimensions of the battery box
- 58 -
7.CHECKS AND MAINTENANCE
B-83494EN/04
7.3.2
Replenish the Grease of the Drive Mechanism
(4 years (15360 hours) checks)
For, Standard, 7H, 7L, 7WP, supply the grease of the reducers every four years or 15360 hours by using
the following procedures.
For, 7C,7LC supply the grease of the reducers every two years or 7680 hours by using the following
procedures.
For the grease name and quantity, see the Table 7.3.2 (a).
Table 7.3.2 (a) Grease for 4-year (15360 hours) or 2-year (7680 hours) periodical greasing
Greasing points
Greasing amount
Models
Specified grease
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
J5-axis reducer
J6-axis reducer
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
J5-axis reducer
J6-axis reducer
2.7g(3ml)
2.7g(3ml)
1.8g(2ml)
1.8g(2ml)
1.8g(2ml)
1.8g(2ml)
0.9g(1ml)
0.9g(1ml)
0.9g(1ml)
0.9g(1ml)
0.9g(1ml)
0.9g(1ml)
Except 7C,7LC
7C,7LC
Harmonic grease 4BNo.2
Spec: A98L-0040-0230
MOBIL, SHC POLYREX 005
Spec: A98L-0040-0259
For grease replacement, use the arbitrary postures.
CAUTION
The following maintenance kits are prepared for the grease greasing.
-Greasing kit: (for Standard,7H,7WP) A05B-1142-K021
(This a set of greasing syringe and grease in tube. (80g))
-Greasing kit (for 7C,7LC) : A05B-1142-K023
(This a set of greasing syringe and grease in tube. (80g))
-Grease in tube: A05B-1139-K022 (for Standard,7H,7WP) (grease in tube. (80g))
-Grease in tube: A05B-1139-K024 (for 7C,7LC) (grease in tube. (80g))
LR Mate 200iD/7H does not have J6-axis.
NOTE
Failure to follow proper lubrication procedures may cause the suddenly increase
of the grease bath internal pressure and the damage to the seal, which could
lead to grease leakage and abnormal operation. When greasing, observe the
following cautions.
1 Use specified grease. Use of non-approved grease may damage the reducer or
lead to other problems. Do no use Harmonic grease SK-3
2 To prevent slipping accidents and catching fire, completely remove any excess
grease from the floor or robot.
3 Please fill a necessary amount to the injection syringe after softening grease in
the tube massaging it by the hand when you use the grease greasing kit. Please
install the nozzle in the point of the injection syringe. Please remove the nozzle
and do the cap when you do not use the injection syringe.
- 59 -
7.CHECKS AND MAINTENANCE
1
2
3
4
B-83494EN/04
Turn off the controller power.
Remove the seal bolts of the grease inlet .
Supply a regulated amount of grease by using the injection syringe. Please note that grease might
come out immediately after the grease has been supplied, or during the greasing. Even in this case,
please do not supply grease beyond the regulated amount specified.
Replace seal bolts by new one. When reusing the seal bolt, be sure to seal it with seal tape.
J6-axis
reducer grease inlet
J6軸減速機給脂口
シールボルト
Seal
bolt M4X6M4X6
J5軸減速機給脂口
J5-axis
reducer grease inlet
シールボルト
Seal
bolt M4X6M4X6
J4-axis
reducer grease inlet
J4軸減速機給脂口
シールボルト
Seal
bolt M4X6 M4X6
J3-axis reducer
J3軸減速機給脂口
grease inlet M4X6
シールボルト
Seal bolt M4X6
J1-axis reducer
J1軸減速機給脂口
grease
inlet M8X10
シールボルト
Seal bolt M8X10
J2-axis reducer
J2軸減速機給脂口
grease
inlet M4X6
シールボルト
Seal bolt M4X6
Fig. 7.3.2 Applying grease of the reducer
Table 7.3.2 (b)
Spec. of seal bolts
Specifications
Parts name
Seal bolt
Seal bolt
7.4
A97L-0318-0410#040606EN
A97L-0318-0410#081010S
Remarks
J2 - J6-axis grease inlet
J1-axis grease inlet
5 pcs/1 robot
STORAGE
To store the robot, set it to the same posture as that used for transportation. (See Section 1.1.)
- 60 -
8.MASTERING
B-83494EN/04
8
MASTERING
Mastering is an operation performed to associate the angle of each robot axis with the pulse count value
supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific,
mastering is an operation for obtaining the pulse count value corresponding to the zero position.
8.1
GENERAL
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering becomes necessary after:
・
・
・
・
・
Motor replacement.
Pulsecoder replacement
Reducer replacement
Cable replacement
Batteries for pulse count backup in the mechanical unit have gone dead
CAUTION
Robot data (including mastering data) and Pulsecoder data are backed up by
their respective backup batteries. Data will be lost if the batteries go dead.
Replace the batteries in the controller and mechanical units periodically. An
alarm will be issued to warn the user of a low battery voltage.
Types of Mastering
There are following mastering methods. If 7DC2 (V8.20P) or former software is installed, "Quick
Mastering for Single Axis" has not been supported.
Table 8.1 Type of mastering
Fixture position
mastering
Zero-position mastering
(witness mark
mastering)
Quick mastering
Quick mastering for
single axis
Single-axis mastering
Mastering data entry
This is performed using a mastering fixture before the machine is shipped from the
factory.
This is performed with all axes set at the 0-degree position. A zero-position mark
(witness mark) is attached to each robot axis. This mastering is performed with all axes
aligned to their respective witness marks.
This is performed at a user-specified position. The corresponding count value is
obtained from the rotation speed of the Pulsecoder connected to the relevant motor and
the rotation angle within one rotation. Quick mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost. (All axes at the same time)
This is performed at a user-specified position for one axis. The corresponding count
value is obtained from the rotation speed of the Pulsecoder connected to the relevant
motor and the rotation angle within one rotation. Quick mastering uses the fact that the
absolute value of a rotation angle within one rotation will not be lost.
This is performed for one axis at a time. The mastering position for each axis can be
specified by the user. This is useful in performing mastering on a specific axis.
Mastering data is entered directly.
Once mastering is performed, you must carry out positioning, or calibration. Positioning is an operation in
which the controller reads the current pulse count value to sense the current position of the robot.
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8.MASTERING
B-83494EN/04
This section describes zero-position mastering, quick mastering, quick mastering for single axis,
single-axis mastering, and mastering data entry. For more detailed mastering (fixture position mastering),
contact your local FANUC representative.
CAUTION
If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. So, the Master/Cal screen is designed to appear only when the
$MASTER_ENB system variable is 1 or 2. After performing positioning, press F5
[DONE] on the Master/Cal screen. The $MASTER_ENB system variable is reset
to 0 automatically, thus hiding the Master/Cal screen.
CAUTION
It is recommended that the current mastering data be backed up before
mastering is performed.
CAUTION
When the motion range is mechanically 360 degrees or more, if any of the axes
(J1-axis and J4-axis) to which the cables are connected is turned one turn in the
correct mastering position, the cables in the mechanical unit are damaged. If the
correct rotation position is not clear because the axis is moved too much during
mastering, remove the connector panel or cover, check the states of the internal
cables, and perform mastering in the correct position. For the checking
procedure, see Fig. 8.1 (a) and 8.1 (b).
Connector panel
Bolt
M4X12 (5)
Tightening torque 2.0Nm
Comfirm cable is
not twisted
when J1=0v
Fig. 8.1 (a) Confirming the state of cable (J1-axis)
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8.MASTERING
B-83494EN/04
O ring
A290-7142-X409
Bolt
M4X10 (4)
Tightening torque 2.0Nm
Comfirm cable is
not twisted
when J4=0v
J3 cover
Fig. 8.1 (b) Confirming the state of cable (J4-axis)
8.2
RESETTING ALARMS AND PREPARING FOR
MASTERING
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse not established”
Procedure
1
Display the positioning menu by following steps 1 to 6.
(1) Press [MENU] 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] again, and select [Master/Cal] from the menu.
(6) Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
(1) Press [MENU] key.
(2) Press [0 NEXT] and select [6 SYSTEM].
(3) Press F1 [TYPE], and select [Master/Cal] from the menu.
(4) Press the F3 RES_PCA, then press F4 [YES].
(5) Turn off the controller power and on again.
3
To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 2.
(1) When the controller power is turned on again, the message “Servo 075 Pulse not established”
appears again.
(2) Move the axis for which the message mentioned above has appeared till alarm disappears when
press [FAULT RESET] in either direction.
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8.MASTERING
8.3
B-83494EN/04
ZERO POSITION MASTERING
Zero-position mastering (witness mark mastering) is performed with all axes set at the 0-degree position.
A zero-position mark (witness mark) is attached to each robot axis.(Fig.8.3) This mastering is performed
with all axes set at the 0-degree position using their respective witness marks.
Zero-position mastering involves a visual check. It cannot be so accurate. It should be used only as a
quick-fix method.
Procedure of Zero-position Mastering
1.
2.
3.
4.
Press [MENU] key to display the screen menu.
Select [0 NEXT] and press [6 SYSTEM].
Press F1 [TYPE], display the screen change menu.
Select [Master/Cal]. The positioning screen appears.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
5.
LOAD
RES_PCA
DONE
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, turn off the controller power and on again.
6
Select [Zero Position Master]. Press F4 [YES].
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <12200039> <2000319>
[ TYPE ] LOAD RES_PCA
DONE
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8.MASTERING
B-83494EN/04
7
Select [7 CALIBRATE] and press F4 [YES]. Mastering will be performed automatically.
Alternatively, turn off the controller power and on again. Turning on the power always causes
positioning to be performed.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
8.
After positioning is completed, press F5 [DONE].
DONE
F5
9.
Return brake control to original setting, and turn off the controller power and on again.
Axis
Table 8.3 Posture with position marks aligned
Position
J1-axis
J2-axis
J3-axis
0 deg
0 deg
0 deg ( When J2-axis is 0 deg.)
0 deg (Note 1)
90 deg (When J3-axis is 0 deg.) (Note 2)
0 deg
0 deg
J4-axis
J5-axis
J6-axis
(Note 1) Except 7H Downward wrist zero specification
(Note 2) 7H Downward wrist zero specification
NOTE
There is no J6-axis for LR Mate 200iD/7H.
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8.MASTERING
B-83494EN/04
Scribe mark J5
(For 7H, J4)
A
Scribe mark J3
Scribe mark J2
Scribe mark J1
Pin position when
J6-axis 0v position
(For 7H, J5)
Scribe mark J4
Detail A
Fig. 8.3 Marking position
8.4
QUICK MASTERING
Quick mastering is performed at a user-specified position for one axis. The pulse count value is obtained
from the rotation times of the Pulsecoder connected to the relevant motor and the rotation angle within
one rotation. Quick mastering uses the character that the absolute value of a rotation angle within one
rotation will not be lost.
Quick mastering is factory-performed at the position indicated in Table 8.3. Do not change the setting
unless there is any problem.
If it is impossible to set the robot at the position mentioned above, it is necessary to re-set the quick
mastering reference position using the following method. (It would be convenient to set up a marker that
can work in place of the witness mark.)
CAUTION
1 Quick 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 Quick mastering cannot be used, after the Pulsecoder is replaced or after the
mastering data is lost from the robot controller.
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8.MASTERING
B-83494EN/04
Procedure Recording the Quick Mastering Reference Position
1
2
Select [6 SYSTEM].
Select [Master/Cal]. The positioning screen appears.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
3
4
LOAD
RES_PCA
DONE
Release brake control, and jog the robot to the quick mastering reference position.
Move the cursor to [6 SET QUICK MASTER REF] and press [ENTER].
Press F4 [YES]. Quick mastering reference position is memorized.
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
CAUTION
If the robot has lost mastery due to mechanical disassembly or repair, you
cannot perform this procedure. In this case, Fixture position mastering or zero
position mastering to restore robot mastery.
Procedure of Quick Mastering
1
Display the Master/Cal screen.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Not Mastered!
Quick master? [NO]
2
3
Release brake control, and jog the robot to the quick mastering reference position.
Move the cursor to [QUICK MASTER] and press [ENTER]. Press F4 [YES]. Quick mastering data
is memorized.
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8.MASTERING
B-83494EN/04
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
4
Move the cursor to CALIBRATE and press ENTER.
executed by power on again.
After completing the calibration, press F5 Done.
5
Calibration is executed.
Calibration is
DONE
F5
6
Return brake control to original setting, and turn off the controller power and on again.
8.5
QUICK MASTERING FOR SINGLE AXIS
Quick mastering is performed at a user-specified position for one axis. The pulse count value is obtained
from the rotation times of the Pulsecoder connected to the relevant motor and the rotation angle within
one rotation. Quick mastering uses the character that the absolute value of a rotation angle within one
rotation will not be lost.
Quick mastering is factory-performed at the position indicated in Table 8.3. Do not change the setting
unless there is any problem.
If setting the robot at the position mentioned above is impossible, you must re-set the quick mastering
reference position using the following method. (It would be convenient to set up a marker that can work
in place of the witness mark.)
CAUTION
1 Quick 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 Quick mastering cannot be used, after the Pulsecoder is replaced or after the
mastering data is lost from the robot controller.
Procedure Recording the Quick Mastering Reference Position
1
2
Select [6 SYSTEM].
Select [Master/Cal]. The positioning screen appears.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
LOAD
RES_PCA
- 68 -
DONE
8.MASTERING
B-83494EN/04
3
4
Release brake control, and jog the robot to the quick mastering reference position.
Move the cursor to [SET QUICK MASTER REF] and press [ENTER].
Press F4 [YES]. Quick mastering reference position is memorized.
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
CAUTION
If the robot has lost mastery due to mechanical disassembly or repair, you
cannot perform this procedure. In this case, Fixture position mastering or zero
position mastering to restore robot mastery.
Procedure of Quick Mastering
1
Display the Master/Cal screen.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Not Mastered!
Quick master? [NO]
2
Select [4 QUICK MASTER FOR SINGLE AXIS]. You will see the quick master for single axis
screen .
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
(
0.000)
(
0.000)
(
0.000)
J OINT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
3
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.
- 69 -
8.MASTERING
B-83494EN/04
SINGLE AXIS MASTER
J5
J6
ACTUAL POS
0.000
0.000
AUTO
(MSTR POS)
0.000)
(
(
0.000)
JOINT 10%
1/9
(SEL) [ST]
(0)
[2]
(0)
[0]
EXEC
4
5
6
7
Turn off brake control, then jog the robot to the quick mastering reference position.
Press F5 [EXEC]. Mastering is performed. So, [SEL] is reset to 0, and [ST] is re-set to 2 or 1.
Move the cursor to CALIBRATE and press ENTER. Calibration is executed. Calibration is
executed by power on again.
After completing the calibration, press F5 Done.
DONE
F5
8
Return brake control to original setting, and turn off the controller power and on again.
8.6
SINGLE AXIS MASTERING
Single axis mastering is performed for one axis at a time. The mastering position for each axis can be
specified by the user.
Single axis mastering can be used, if mastering data for a specific axis is lost, for example, because a low
voltage has been detected on the pulse counter backup battery or because the Pulsecoder has been
replaced.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
(
0.000)
(
0.000)
(
0.000)
J OINT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
Table 8.6
Item
Current position
(ACTUAL AXIS)
Mastering position
(MSTR POS)
SEL
ST
Items set in single axis mastering
Description
The current position of the robot is displayed for each axis in degree units.
A mastering position is specified for an axis to be subjected to single axis mastering. It
would be convenient to set to it to the 0_ position.
This item is set to 1 for an axis to be subjected to single axis mastering. Usually, it is 0.
This item indicates whether single axis mastering has been completed for the
corresponding axis. It cannot be changed directly by the user.
The value of the item is reflected in $EACHMST_DON
(1 to 9).
0 :Mastering data has been lost. Single axis mastering is necessary.
1 :Mastering data has been lost. (Mastering has been
performed only for the other interactive axes.) Single axis
mastering is necessary.
2 :Mastering has been completed.
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8.MASTERING
B-83494EN/04
Procedure of Single axis mastering
1
2
Select [6 SYSTEM].
Select [Master/Cal]. The positioning screen appears.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
LOAD
RES_PCA
DONE
3 Select [5 Single Axis Master]. You will see a screen similar to the following.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
(
0.000)
(
0.000)
0.000)
(
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
JO INT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
4
5
6
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.
Turn off brake control, then jog the robot to the mastering position.
Enter axis data for the mastering position.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
(
0.000)
(
0.000)
0.000)
(
(
0.000)
(
90.000)
(
0.000)
(
0.000)
(
0.000)
JO INT 10%
6/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(1)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
7
Press F5 [EXEC]. Mastering is performed. So, [SEL] is reset to 0, and [ST] is re-set to 2 or 1.
- 71 -
8.MASTERING
B-83494EN/04
SINGLE AXIS MASTER
AUTO
EXEC
J1
J2
J3
J4
J5
J6
E1
E2
E3
F5
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
90.000
0.000
0.000
0.000
(MSTR POS)
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
(
0.000)
(
0.000)
(
0.000)
JOINT 10%
6/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(1)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
8
When single axis mastering is completed, press the previous page key to resume the previous screen.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
LOAD
RES_PCA
DONE
9.
Select [7 CALIBRATE], then press F4 [YES]. Positioning is performed. Alternatively, turn off the
controller power and on again. Positioning is performed.
10. After positioning is completed, press F5 [DONE].
DONE
F5
11. Return brake control to original setting, and turn off the controller power and on again.
8.7
MASTERING DATA ENTRY
This function enables mastering data values to be assigned directly to a system variable. It can be used if
mastering data has been lost but the pulse count is preserved.
Mastering data entry method
1
2
Press [MENU] key, then press [0 NEXT] and select [6 SYSTEM].
Press F1 [TYPE]. Select [Variables]. The system variable screen appears.
- 72 -
8.MASTERING
B-83494EN/04
SYSTEM Variables
1
2
3
4
5
6
$AAVM_GRP
$AAVM_WRK
$ABSPOS_GRP
$ACC_MAXLMT
$ACC_MINLMT
$ACC_PRE_EXE
[ TYPE ]
3
AUTO
JOINT 10%
1/669
AAVM_GRP_T
AAVM_WRK_T
ABSPOS_GRP_T
0
0
0
DETAIL
Change the mastering data.
The mastering data is saved to the $DMR_GRP.$MASTER_COUN system variable.
SYSTEM Variables
135
136
AUTO
$DMR_GRP
$DMSW_CFG
JOINT 10%
1/669
DMR_GRP_T
DMSW_CFG_T
[ TYPE ]
4
Select $DMR_GRP.
SYSTEM Variables
$DMR_GRP
1
[1]
[ TYPE ]
AUTO
JOINT 10%
1/1
DMR_GRP_T
DETAIL
SYSTEM Variables
$DMR_GRP
1
2
3
4
5
6
AUTO
$MASTER_DONE
$OT_MINUS
$OT_PLUS
$NASTER_COUN
$REF_DONE
$REF_POS
[ TYPE ]
5
J OINT 10%
1/29
FALSE
[9] of BOO LEAN
[9] of BO OLEAN
[9] of INTEGER
FALSE
[9] of REAL
TRUE
FALSE
Select $MASTER_COUN, and enter the mastering data you have recorded.
SYSTEM Variables
AUTO
$DMR_GRP[1].$MASTER_CO UN
1
[1]
95678329
2
[2]
10223045
3
[3]
3020442
4
[4]
30405503
5
[5]
20497709
6
[6]
2039490
7
[7]
0
8
[8]
0
9
[9]
0
[ TYPE ]
- 73 -
JOINT 10%
1/9
8.MASTERING
6
7
B-83494EN/04
Press the PREV key.
Set $MASTER_DONE to TRUE.
SYSTEM Variables
$DMR_GRP
1
2
AUTO
$MASTER_DONE
$OT_MINUS
TRUE
[9] of BOO LEAN
[ TYPE ]
8
9
JOINT 10%
1/29
TRUE
FALSE
Display the positioning screen, and select [6 CALIBRATE], then press F4 [YES].
After completing positioning, press F5 [DONE].
DONE
F5
8.8
1
CHECKING THE MASTERING
Checking whether mastering has been made correctly
Usually, positioning is performed automatically at power-on. To check whether mastering has
been made correctly, note whether the displayed current position agrees with the actual robot
position. Use the procedure described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0rad) positions. Check that the zero-degree position
marks indicated in Section 8.3 are aligned. There is no need to use any visual aid.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described below 2. Alternatively, the mastering data in system
variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation
error or some other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value
of the system variable on the data sheet.
2
Alarms that may be output during mastering and remedy for it
(1) BZAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery falls to 0 V while the
power to the controller is disconnected. Also, if Pulsecoder connector is removed for replacing
cables etc. this alarm is output because voltage becomes to 0. To clear the alarm, fit a new
battery, execute the pulse reset (See section 8.2.), then turn the power off then on again and
confirm alarm is not output.
Battery might be weak if you can’t reset alarm, then replace battery to new one , perform pulse
reset , turn off and on the controller power. Note that, if this alarm occurs, all data originally
held by the Pulsecoder will have been lost. Mastering must be performed again.
(2) BLAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery has fallen to a level where
backup is no longer possible. If this alarm is output, fit a new battery immediately while
keeping the power turned on. Check whether the current position data is valid, using the
procedure described in 1.
(3) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL, alarms
Contact the FANUC because the Pulsecoder may be defective.
- 74 -
9.TROUBLESHOOTING
B-83494EN/04
9
TROUBLESHOOTING
9.1
OVERVIEW
The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from
many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. So, it is
necessary to analyze the symptoms of the failure precisely so that the true cause can be found.
9.2
FAILURES, CAUSES AND MEASURES
Table 9.2 lists the major failures, causes and measures that may occur in the mechanical unit and their
probable causes. If you cannot pinpoint a failure cause or which measures to apply, contact your local
FANUC representative.
Symptom
Vibration
Noise
Table 9.2 Failures, causes and measures
Description
Cause
-The J1 base lifts off the
floor plate as the robot
operates.
-There is a gap bfetween the
J1 base and floor plate.
-A J1 base retaining bolt is
loose.
-Apply epoxy to the floor
surface and re-install the
plate.
-Vibration becomes more
serious when the robot
adopts a specific posture.
-If the operating speed of the
robot is reduced, vibration
stops.
-Vibration is most noticeable
when the robot is
accelerating.
-Vibration occurs when two
or more axes operate at the
same time.
[J1 base fastening]
-It is likely that the robot J1 base is
not securely fastened to the floor
plate.
-Probable causes are a loose bolt,
an insuffcient degree of surface
flatness, or foreign material caught
between the floor plate and floor
plate.
-If the robot is not securely fastened
to the floor plate, the J1 base lifts
the floor plate as the robot operates,
allowing the base and floor plates to
strike each other wihich, in turn,
leads to vibration.
[Rack or floor]
-It is likely that the rack or floor is not
suffciently rigid.
-If the rack or floor is not sufficiently
rigid, reaction from the robot
deforms the rack or floor, leading to
vibration.
[Overload]
-It is likely that the load on the robot
is greater than the maximum rating.
-It is likely that the robot control
program is too demanding for the
robot hardware.
-It is likely that the ACCELERATION
value is excessive.
- 75 -
Measure
-If a bolt is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Adjust the floor plate surface
flatness to within the specified
tolenrance.
-If there is any foreign
material between the J1 base
and floor plate, remove it.
-Reinforce the rack or floor to
make it more rigid.
-If it is impossible to reinforce
the rack or floor, modify the
robot control program; doing
so might reduce the amount
of vibration.
-Check the maximum load
that the robot can handle
once more. If the robot is
found to be overloaded,
reduce the load, or modify the
robot control program.
-Vibration in a specific portion
can be reduced by modifying
the robot control program
while slowig the robot and
reducing its acceleration (to
minimize the influenece on
the entire cycle time).
9.TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
B-83494EN/04
Description
Cause
-Vibration was first noticed
after the robot collided with
an object or the robot was
overloaded for a long period.
-The grease of the vibrating
axis has not been
replenished for a long
period.
[Broken gear, bearing, or reducer]
- It is likely that collision or overload
applied an excessive force on the
drive mechanism, thus damaging
the geartooth surface or rolling
surface of a bearing, or reducer.
- It is likely that prolonged use of the
robot while overloaded caused
fretting of the gear tooth surface or
rolling surface of a bearing, or
reducer due to resulting metal
fatigue.
- It is likely that foreign material
caught in a gear, bearing, or within a
reducer caused damage on the gear
tooth surface or rolling surface of the
bearing, or reducer.
- It is likely that foreign material
caught in a gear, bearing, or within a
reducer cause vibration.
- It is likely that, because the grease
has not been replenished for a long
period, fretting occurred on the gear
tooth surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate cyclic
vibration and noise.
- 76 -
Measure
-Operate one axis at a time to
determine which axis is
vibrating.
-Remove the motor, and
replace the gear , the bearing,
and the reducer. For the
spec. of parts and the method
of replacement, contact
FANUC.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly greasing with a
specified type can help
prevent problems.
9.TROUBLESHOOTING
B-83494EN/04
Symptom
Vibration
Noise
(Continued)
Description
Cause
-The cause of problem
cannot be identified from
examination of the floor,
rack, or mechanical section.
[Controller, cable, and motor]
-If a failure occurs in a controller
circuit, preventing control commands
from being supplied to the motor
normally, or preventing motor
information from being sent to the
controller normally, vibration might
occur.
-If the Pulsecoder develops a fault,
vibration might occur because
information about the motor position
cannot be transferred to the
controller accurately.
-If the motor becomes defective,
vibration might occur because the
motor cannot deliver its rated
performance.
-If a power line in a movable cable of
the mechanical section has an
intermittent break, vibration might
occur because the motor cannot
accurately respond to commands.
-If a Pulsecoder wire in a movable
part of the mechanical section has
an intermittent break, vibration might
occur because commands cannot
be sent to the motor accurately.
-If a connection cable between them
has an intermittent break, vibration
might occur.
-If the power cable between them
has an intermittent break, vibration
might occur.
-If the power source voltage drops
below the rating, vibration might
occur.
-If a robot control parameter is set to
an invalid value, vibration might
occur.
-There is some relationship
between the vibration of the
robot and the operation of a
machine near the robot.
[Noise from a nearby machine]
-If the robot is not grounded
properly, electrical noise is induced
on the grounding wire, preventing
commands from being transferred
accurately, thus leading to vibration.
-If the robot is grounded at an
unsuitable point, its grounding
potential becomes unstable, and
noise is likely to be induced on the
grounding line, thus leading to
vibration.
- 77 -
Measure
Refer to the Controller
Maintenance Manual for
troubleshooting related to
the controller and amplifier.
- Replace the Pulsecoder for
the motor of the axis that is
vibrating, and check whether
the vibration still occurs.
- Also, replace the motor of
the axis that is vibrating, and
check whether vibration still
occurs. For the method of
replacement, contact your
local FANUC representative.
- If vibration occurs only when
the robot assumes a specific
posture, it is likely that a
cable in the mechanical unit
is broken.
- Check whether the sheath of
the cable connecting the
mechanical section and
controller is damaged. If so,
replace the connection
cable, and check whether
vibration still occurs.
- Check whether the sheath of
the power cord is damaged.
If so, replace the power cord,
and check whether vibration
still occurs.
- Check that the robot is
supplied with the rated
voltage.
-Check that the robot control
parameter is set to a valid
value. If it is set to an invalid
value, correct it. Contact
your local FANUC
representative for further information if necessary.
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
9.TROUBLESHOOTING
Symptom
B-83494EN/04
Description
Cause
Measure
-While the robot is not
supplied with power, pushing
it with the hand causes part
of the mechanical unit to
wobble.
-There is a gap on the
mounting face of the
mechanical unit.
[Mechanical section coupling bolt]
-It is likely that overloading or a
collision has loosened a mounting
bolt in the robot mechanical section.
Motor
-The ambient temperature of
overheating the installation location
increases, causing
the motor to overheat.
-After the robot control
program or the load was
changed, the motor
overheated.
[Ambient temperature]
-It is likely that a rise in the ambient
temperature prevented the motor
from releasing heat efficiently, thus
leading to overheating.
[Operating condition]
-It is likely that the robot was
operated with the maximum average
current
exceeded.
-Check that the following bolts
for each axis are tight. If any
of these bolts is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Motor retaining bolt
-Reducer retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
- Reducing the ambient
temperature is the most
effective means of
preventing overheating.
- If there is a source of heat
near the motor, it is
advisable to install shielding
to protect the motor from
heat radiation.
- Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing
overheating.
-The teach pendant can be
used to monitor the average
current. Check the average
current when the robot
control program is running.
. -As for load setting, Input an
appropriate parameter
referring to Section 4.3.
Rattling
- After a control parameter
(load setting etc.) was
changed, the motor
overheated.
-Symptom other than stated
above
[Parameter]
- If data input for a workpiece is
invalid, the robot cannot be
accelerated or decelerated normally,
so the average current increases,
leading to overheating.
[Mechanical section problems]
-It is likely that problems occurred in
the mechanical unit drive
mechanism, thus placing an
excessive load on the motor.
[Motor problems]
-It is likely that a failure of the motor
brake resulted in the motor running
with the brake applied, thus placing
an excessive load on the motor.
-It is likely that a failure of the motor
prevented it from delivering its rated
performance, thus causing an
excessive current to flow through the
motor.
- 78 -
-Repair the mechanical unit
while referring to the above
descriptions of vibration,
noise, and rattling.
-Check that, when the servo
system is energized, the
brake is released.
If the brake remains applied
to the motor all the time,
replace the motor.
-If the average current falls
after the motor is replaced, it
indicates that the first motor
was faulty.
9.TROUBLESHOOTING
B-83494EN/04
Symptom
Cause
Measure
Grease
leakage
-Grease is leaking from the
mechanical unit.
Description
[Poor sealing]
-Probable causes are a crack in the
casting, a broken O-ring, a damaged
oil seal, or a loose seal bolt.
-A crack in a casting can occur due
to excessive force that might be
caused in collision.
-An O-ring can be damaged if it is
trapped or cut during disassembling
or re-assembling.
-An oil seal might be damaged if
extraneous dust scratches the lip of
the oil seal.
-A loose seal bolt might allow grease
to leak along the threads.
Dropping
axis
-An axis drops because the
brake does not function.
-An axis drops gradually
when it should be at rest.
[Brake drive relay and motor]
-It is likely that brake drive relay
contacts are stuck to each other to
keep the brake current flowing, thus
preventing the brake from operating
when the motor is deenergized.
-It is likely that the brake shoe has
worn out or the brake main body is
damaged, preventing the brake from
operating efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
[Mechanical section problems]
-If the repeatability is unstable,
probable causes are a failure in the
drive mechanism or a loose bolt.
-If the repeatability becomes stable it
is likely that a collision imposed an
excessive load, leading to slipping
on the base surface or the mating
surface of an arm or reducer.
-It is likely that the Pulsecoder is
abnormal.
-If a crack develops in the
casting, sealant can be used
as a quick-fix to prevent
further grease leakage.
However, the component
should be replaced as soon
as possible, because the
crack might extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer coupling section
-Wrist coupling section
-J3 arm coupling section
-Inside the wrist
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease drain inlet and
outlet
-Check whether the brake
drive relay contacts are stuck
to each other. If they are
found to be stuck, replace the
relay.
-If the brake shoe is worn out,
if the brake main body is
damaged, or if oil or grease
has entered the motor,
replace the motor.
Displacement -The robot operates at a
point other than the taught
position.
-The repeatability is not
within the tolerance.
-Displacement occurs only in
a specific peripheral unit.
[Peripheral unit displacement]
-It is likely that an external force was
applied to the peripheral unit, thus
shifting its position relative to the
robot.
- 79 -
-If the repeatability is
unstable, repair the
mechanical section by
referring to the above
descriptions of vibration,
noise, and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the Pulsecoder is
abnormal, replace the motor
or the Pulsecoder.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
9.TROUBLESHOOTING
Symptom
B-83494EN/04
Description
Cause
Displacement -Displacement occurred after
(Continued) a parameter was changed.
[Parameter]
-It is likely that the mastering data
was rewritten in such a way that
the robot origin was shifted.
BZAL alarm
occured
- It is likely that the voltage of the
memory backup battery is low.
- It is likely that the Pulsecoder cable
is defected.
-BZAL is displayed on the
controller screen
- 80 -
Measure
-Re-enter the previous
mastering data, which is
known to be correct.
-If correct mastering data is
unavailable, perform
mastering again.
-Replace the battery.
-Replace the cable.
APPENDIX
B-83494EN/04
A
APPENDIX
A.PERIODIC MAINTENANCE TABLE
PERIODIC MAINTENANCE TABLE
- 83 -
A.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83494EN/04
FANUC Robot LR Mate 200iD, ARC Mate 50iD ,LR Mate 200iD/7H,7L,
ARC Mate 50iD/7L Periodic Maintenance Table
Working time (H)
Items
Check for external
damage or peeling paint
1
6
9
3
First
Grease
check months months months years
amount
320
960
1920 2880 3840
2
years
4800
5760
6720
7680
8640
9600 10560
0.1H
―
○
○
○
○
○
○
○
○
○
○
○
0.1H
―
○
○
○
○
○
○
○
○
○
○
○
0.2H
―
○
○
○
0.2H
―
○
○
○
2.0H
―
○
○
○
0.1H
―
○
○
○
1.0H
―
○
○
○
○
0.1H
―
○
0.1H
―
0.1H
―
0.5H
14ml
(*1)
12ml
(*2
4.0H
―
0.2H
―
13 Cleaning the ventilator
0.2H
―
○
○
○
14 Replacing battery *3
0.1H
―
1
2 Check for water
3
Check the exposed
connector.(loosening)
4 Tighten the end effector bolt.
Tighten the cover and main
5 bolt.
Mechanical unit
Check
time
Check the mechanical
6 stopper.
Clean spatters, sawdust and
7 dust
Check hand cable and
8 external battery cable (option)
9
Replacing battery.
(if built-in batteries are
specified)
Replacing battery.
(if external batteries are
specified)
10 Greasing the reducers.
Replacing cable of mechanical
11 unit *1
○
○
○
○
○
○
○
○
○
●
●
●
Check the robot cable, teach
Controller
12 pendant cable and robot
○
○
○
connecting cable
○
○
*1 Except 7H
*2 7H
*3 Refer to manual of controller.
*4 ●: requires order of parts
○: does not require order of parts
- 84 -
○
○
○
○
○
○
○
A.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83494EN/04
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720
Item
○
○
○
○
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○
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○
○
○
○
○
○
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○
○
○
1
○
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2
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3
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○
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4
○
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5
○
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6
○
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○
○
○
○
○
○
○
○
●
●
●
●
●
○
○
○
7
Overhaul
○
8
9
●
●
○
○
●
●
10
●
11
○
○
○
○
●
○
○
○
○
○
○
○
○
○
○
●
○
○
○
○
○
○
12
○
○
○
13
14
- 85 -
A.PERIODIC MAINTENANCE TABLE
APPENDIX
FANUC Robot LR Mate 200iD/7C, /7LC
Working time (H)
Items
Check for external
Periodic Maintenance Table
1
6
9
3
First
Grease
check months months months years
amount
320
960
1920 2880 3840
2
years
4800
5760
6720
7680
8640
9600 10560
1 damage or peeling paint
0.1H
―
○
○
○
○
○
○
○
○
○
○
○
2 Check for water
0.1H
―
○
○
○
○
○
○
○
○
○
○
○
3 connector.(loosening)
0.2H
―
○
○
○
4 Tighten the end effector bolt.
0.2H
―
○
○
○
2.0H
―
○
○
○
0.1H
―
○
○
○
1.0H
―
○
○
○
○
0.1H
―
○
0.1H
―
0.5H
6ml
11 unit *1
4.0H
―
Check the robot cable, teach
12 pendant cable and robot
connecting cable
0.2H
―
13 Cleaning the ventilator
0.2H
―
○
○
○
14 Replacing battery *1
0.1H
―
Check the exposed
Mechanical unit
Check
time
B-83494EN/04
Tighten the cover and main
5 bolt.
Check the mechanical
6 stopper.
Clean spatters, sawdust and
7 dust
Check hand cable and
8 external battery cable (option)
○
○
○
○
○
○
○
○
○
●
●
Replacing battery.
9 (if built-in batteries are
specified)
10 Greasing the reducers.
Controller
Replacing cable of mechanical
●
○
○
○
*1 Refer to manual of controller.
*2 ●: requires order of parts
○: does not require order of parts
- 86 -
○
○
○
○
○
○
○
○
○
A.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83494EN/04
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720
Item
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1
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2
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3
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4
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5
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6
○
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○
●
●
●
●
●
●
○
○
○
○
●
○
○
○
8
10
11
○
○
7
9
●
○
Overhaul
○
○
○
○
○
○
○
○
○
○
●
○
○
○
○
○
○
12
○
○
○
13
14
- 87 -
A.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83494EN/04
FANUC Robot LR Mate 200iD/7WP
Working time (H)
Items
Check for external
1
6
9
3
First
Grease
check months months months years
amount
320
960
1920 2880 3840
6720
7680
8640
○
○
○
○
○
○
○
○
○
○
○
○
○
3 connector.(loosening)
0.2H
―
○
○
○
4 Tighten the end effector bolt.
0.2H
―
○
○
○
2.0H
―
○
○
○
0.1H
―
○
○
○
1.0H
―
○
0.1H
―
○
9 (if external batteries are
0.1H
―
10 Greasing the reducers.
0.5H
14ml
4.0H
―
0.2H
―
13 Cleaning the ventilator
0.2H
―
14 Replacing battery *1
0.1H
―
Tighten the cover and main
Check the mechanical
6 stopper.
Clean spatters, sawdust and
7 dust
Check hand cable and
8 external battery cable (option)
○
○
○
5760
○
5 bolt.
○
4800
―
Check the exposed
○
2
years
0.1H
1 damage or peeling paint
Mechanical unit
Check
time
Periodic Maintenance Table
○
○
○
○
○
○
9600 10560
○
Replacing battery.
●
specified)
Replacing cable of mechanical
11 unit *1
Check the robot cable, teach
Controller
12 pendant cable and robot
○
○
○
connecting cable
○
○
*1 Refer to manual of controller.
*2 ●: requires order of parts
○: does not require order of parts
- 88 -
○
○
○
○
○
○
○
A.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83494EN/04
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720
○
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○
○
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Item
1
○
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3
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4
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5
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6
○
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○
○
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●
○
○
○
○
○
●
7
Overhaul
○
Overhaul
○
●
8
9
10
11
○
○
○
○
○
○
○
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○
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12
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13
14
- 89 -
B.MOUNTING BOLT TORQUE LIST
B
APPENDIX
B-83494EN/04
MOUNTING BOLT TORQUE LIST
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire length portion of the engaging area of the female threads. If
it is applied to the male threads, the bolts could become loose due to insufficient
adhesion. Clean the bolts and threaded holes and wipe off oil on the engaging
section. Make sure that there is no solvent in the threaded holes. Be sure to wipe
the excess LOCTITE after tightening the bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more
If no tightening torque is specified for a bolt, tighten it according to this table.
Recommended bolt tightening torques
Nominal
diameter
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Hexagon socket head
bolt
(Steel)
Tightening torque
Upper limit Lower limit
1.8
1.3
4.0
2.8
7.9
5.6
14
9.6
32
23
66
46
110
78
180
130
270
190
380
260
530
370
730
510
930
650
1400
960
1800
1300
3200
2300
Unit: Nm
Hexagon socket head
button bolt
Hexagon bolt
Hexagon socket head
Hexagon socket head
(steel)
flush bolt
bolt (stainless)
Low-head bolt
(steel)
Tightening torque
Tightening torque
Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
――――
――――
―――
0.76
0.53 ――――
1.8
1.3
1.8
1.3
1.7
1.2
3.4
2.5
4.0
2.8
3.2
2.3
5.8
4.1
7.9
5.6
5.5
3.8
14
9.8
14
9.6
13
9.3
27
19
32
23
26
19
――――
――――
48
33
45
31
――――
――――
76
53
73
51
――――
――――
120
82
98
69
――――
――――
160
110
140
96
――――
――――
230
160
190
130
――――
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――――
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――――
――――
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――――
――――
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――――
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- 90 -
C
C.OPTIONAL CONNECTOR WIRING PROCEDURE
APPENDIX
B-83494EN/04
OPTIONAL CONNECTOR WIRING
PROCEDURE
Source of information:
Hirose Electric Co., Ltd.
NOTE1
NOTE2
NOTE1)
NOTE2)
Corresponds to A05B-1137-J057.
Corresponds to A05B-1137-J058 and A05B-1139-J059.
- 91 -
D.INSULATION ABOUT ARC WELDING ROBOT
D
D.1
APPENDIX
B-83494EN/04
INSULATION ABOUT ARC WELDING
ROBOT
ABSTRACT
The arc welding robot performs welding, using a welding torch attached to its end effector via a bracket.
Because a high welding current flows through the welding torch, the insulation between the end effector
and torch is dualized.
If no due consideration is taken, a poor insulation caused by a pileup of spatter can allow the welding
current to leak into robot mechanical sections, possibly resulting in the motor being damaged or the
sheaths of cables in the mechanical sections melting.
D.2
-
-
-
-
INSULATION AT THE WRIST
Design the insulation between the end effector and welding torch so that no current will leak from
the end effector. Concretely, when fastening the insulating material inserted between the end
effector and torch bracket, use different bolts on the insulation material and torch bracket.
Insert the insulating material between the torch and torch bracket so that the insulation is dualized.
When installing the insulating material, be sure to set the crack in the torch holder away from that
of the insulating material to prevent spatter from getting in the cracks.
Insert the insulating material between the torch and torch bracket so that the insulation is dualized.
When installing the insulating material, be sure to set the crack in the torch holder away from that
of the insulating material to prevent spatter from getting in the cracks.
Allow a sufficient distance (at least 5 mm) at the insulating materials in case a pileup of spatter
should occur.
Even after the insulation is reinforced, it is likely that, if a pileup of spatter grows excessively,
current may leak. Periodically remove spatter when the robot is in service.
- 92 -
INDEX
B-83494EN/04
INDEX
MECHANICAL COUPLING OF END EFFECTOR
TO WRIST .................................................................. 33
MECHANICAL COUPLING TO THE ROBOT............ 33
MECHANICAL UNIT OPERATION AREA AND
INTERFERENCE AREA............................................ 18
MOUNTING BOLT TORQUE LIST ............................. 90
<A>
ABSTRACT.................................................................... 92
AIR SUPPLY (OPTION)................................................ 39
AXIS LIMIT SETUP ...................................................... 48
<B>
<N>
BASIC SPECIFICATIONS ............................................ 13
Note of Severe Dust /Liquid Specification...................... 17
<C>
<O>
Cautions for 7C,7LC (Clean class 10)............................. 18
Cautions in Selecting the 7WP........................................ 17
Check of Mechanical Stopper ......................................... 55
CHECK POINTS ............................................................ 53
Check the Connectors ..................................................... 55
CHECKING THE MASTERING ................................... 74
CHECKS AND MAINTENANCE ................................. 50
Confirmation of Oil Seepage........................................... 53
Confirmation of the Air Control Set and Air Purge kit ... 54
CONNECTION WITH THE CONTROLLER................ 11
OPERATING AREA FOR INCLINATION
INSTALLATION........................................................ 31
OPTIONAL CONNECTOR WIRING PROCEDURE ... 91
OVERVIEW ................................................................... 75
<P>
Periodic Check and Maintenance.................................... 51
PERIODIC MAINTENANCE ........................................ 50
PERIODIC MAINTENANCE TABLE .......................... 83
PIPING AND WIRING TO THE END EFFECTOR...... 38
PREFACE ......................................................................p-1
<D>
Daily Checks ................................................................... 50
<Q>
<E>
QUICK MASTERING.................................................... 66
QUICK MASTERING FOR SINGLE AXIS .................. 68
EQUIPMENT MOUNTING FACE ................................ 33
<F>
<R>
FAILURES, CAUSES AND MEASURES..................... 75
Replacing the Batteries (1-Year Periodic Inspection
If Built-in Batteries Are Specified) (1.5-Year
Periodic Inspection If External Batteries Are
Specified) .................................................................... 56
Replenish the Grease of the Drive Mechanism (4 years
(15360 hours) checks) ................................................. 59
RESETTING ALARMS AND PREPARING FOR
MASTERING.............................................................. 63
ROBOT CONFIGURATION.......................................... 13
<G>
GENERAL ...................................................................... 61
<H>
HIGH INERTIA MODE (LR Mate 200iD/7H)............... 37
<I>
INSTALLATION..............................................................5
INSTALLATION SPECIFICATIONS ........................... 10
INSTALLING THE AIR PURGE KIT ........................... 42
INSULATION ABOUT ARC WELDING ROBOT ....... 92
INSULATION AT THE WRIST .................................... 92
INTERFACE FOR OPTION CABLE (OPTION)........... 45
IP69K (option) ................................................................ 18
<S>
SAFETY PRECAUTIONS ............................................ s-1
SINGLE AXIS MASTERING ........................................ 70
SOFTWARE SETTING.................................................. 48
STORAGE ...................................................................... 60
STRANSPORTATION AND INSTALLATION.............. 1
<L>
<T>
LOAD CONDITION ON EQUIPMENT MOUNTING
FACE........................................................................... 31
LOAD SETTING ............................................................ 35
TRANSPORTATION ....................................................... 1
TROUBLESHOOTING .................................................. 75
<W>
<M>
WRIST LOAD CONDITIONS ....................................... 27
MAINTENANCE ........................................................... 56
MAINTENANCE AREA..................................................9
MASTERING ................................................................. 61
MASTERING DATA ENTRY ....................................... 72
<Z>
ZERO POINT POSITION AND MOTION LIMIT ........ 21
ZERO POSITION MASTERING ................................... 64
i-1
REVISION RECORD
B-83494EN/04
REVISION RECORD
Edition
04
03
02
01
Date
•
Jan., 2015
•
•
Dec., 2013 •
•
•
•
Jul., 2013
•
•
Dec., 2012
Contents
Addition of quick master for single axis
Correction of errors
Addition of LR Mate 200iD/7H,7C,7WP,7LC
Addition of air purge kit
Correction of errors
Addition of ARC Mate 50iD,LR Mate 200iD/7L, ARC Mate 50iD/7L
Addition of greasing procedure
Addition of insulation about arc welding robot
Correction of errors
r-1
B-83494EN/04
* B - 8 3 4 9 4 E N / 0 4 *