FANUC Robot series R-30iB/ R-30iB Plus CONTROLLER P-250iB Mechanical Unit Operator’s Manual MAROB25IB07151E REV C ©2020 FANUC America Corporation This publication contains proprietary information of FANUC America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC America Corporation. FANUC America Corporation 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 • Original Instructions Thank you very much for purchasing FANUC Robot. Before using the Robot, be sure to read the "FANUC Robot SAFETY HANDBOOK (B-80687EN)" and understand the content. • No part of this manual may be reproduced in any form. • The appearance and specifications of this product 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 endeavor to include all pertinent matters. There are, however, a very large number of operations that must not or cannot be performed, and if the manual contained them all, it would be enormous in volume. It is, therefore, requested to assume that any operations that are not explicitly described as being possible are "not possible". SAFETY PRECAUTIONS SAFETY PRECAUTIONS This chapter must be read before using the robot. For detailed functions of the robot operation, read the relevant operator's manual to understand fully its specification. For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral equipment installed in a work cell. For safe use of FANUC robots, you must read and follow the instructions in “FANUC Robot SAFETY HANDBOOK (B-80687EN)”. 1 DEFINITION OF USER The personnel can be classified as follows. Operator: • Turns the robot controller power on/off • Starts the robot program from operator panel Programmer or Teaching operator: • Operates the robot • Teaches the robot inside the safety fence Maintenance technician: • Operates the robot • Teaches the robot inside the safety fence • Performs maintenance (repair, adjustment, replacement) - Operator is not allowed to work in the safety fence. Programmer/Teaching operator and maintenance technician is allowed to work in the safety fence. To work inside the safety fence, the person must be trained on proper robot operation. Works carried out in the safety fence include transportation, installation, teaching, adjustment, and maintenance. s-1 SAFETY PRECAUTIONS Table 1 (a) lists the work outside the safety fence. In this table, the symbol “” means the work allowed to be carried out by the worker. Table 1 (a) List of work outside the fence Operator Turn power ON/OFF to Robot controller Select operating mode (AUTO, T1, T2) Select remote/local mode Select robot program with teach pendant Select robot program with external device Start robot program with operator’s panel Start robot program with teach pendant Reset alarm with operator’s panel Reset alarm with teach pendant Set data on teach pendant Teaching with teach pendant Emergency stop with operator’s panel Emergency stop with teach pendant Operator’s panel maintenance Teach pendant maintenance Programmer or Teaching operator Maintenance technician In the robot operating, programming and maintenance, the operator, programmer/teaching operator and maintenance technician take care of their safety using at least the following safety protectors. • • • Use clothes, uniform, overall adequate for the work Safety shoes Helmet 2 DEFINITION OF SAFETY NOTATIONS To ensure the safety of users 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". contents of each "WARNING", "CAUTION" and "NOTE" before using the robot. Symbol WARNING CAUTION NOTE • Definitions Used if hazard resulting in the death or serious injury of the user will be expected to occur if he or she fails to follow the approved procedure. Used if a hazard resulting in the minor or moderate injury of the user, or equipment damage may be expected to occur if he or she fails to follow the approved procedure. Used if a supplementary explanation not related to any of WARNING and CAUTION is to be indicated. Check this manual thoroughly, and keep it handy for the future reference. s-2 Read the 1. PAINT ROBOT SAFETY Today’s highly automated paint booths require that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between any moving machinery along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment is usually provided by the paint shop supervisor. CAUTION Ensure that all ground cables remain connected. Never operate the paint robot with ground provisions disconnected. Otherwise, you could injure personnel or damage equipment. Paint robots are operated in three modes: • Teach or manual mode • Automatic mode, including automatic or Production mode • Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is operated at full production speed. It is initiated at the System Control Console (SCC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth whenever automatic mode is initiated at the SCC or MCP. 1.1 Paint System Safety Features Process technicians and maintenance personnel must become familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features (in addition to other standard robot safety features): • Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are. • Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are. • An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. • Additional safety components for Paint systems such as Light curtains, door switches etc. are defined by a Risk Assessment. • System safety devices are monitored by hardware circuits and/or a safety PLC. The robots are interlocked to the hardware circuits and/or safety PLC. 1.2 Staying Safe While Operating the Paint Robot When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. WARNING Never bypass, strap, or otherwise deactivate the robot purge system for any reason. Deactivating the purge system might result in an explosion serious injury or death. WARNING Enclosures shall not be opened unless the area is known to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time. • • • • • • • Know the work area of the entire paint station. Know the work envelope of the robot and hood/deck and door opening devices. Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move. Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled. Be aware of signals and/or operations that could start up paint process application equipment such as guns or bells. Be aware of potential air pressure buildup behind paint robot access covers. Be aware of all safety precautions when dispensing of paint is required. ps-1 1.3 Special Precautions for Combustible Dusts (Powder Paint) When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot. • Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust cannot enter the robot. • A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. • Do not energize the robot until you have performed the following steps. (1) (2) Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust. When the dust has been removed, the covers must be replaced immediately. Immediately after the covers are replaced, run a complete purge cycle. The robot can now be energized. (3) (4) (5) 1.4 Staying Safe While Operating Paint Application Equipment When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. WARNING When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electrical Code. Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process. (1) (2) (3) (4) (5) (6) (7) (8) Avoid any accumulation of combustible vapors or coating matter. Follow all manufacturer recommended cleaning procedures. Make sure all interlocks are operational. No smoking. Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material. Disable all air and paint pressure to the bell. Verify that the lines are not under pressure. Be aware of potential hazards presented by paint process hardware, such as rotating or spinning components on the paint applicator. 1.5 Staying Safe During Maintenance When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot. (1) (2) (3) (4) Paint robots operate in a potentially explosive environment. Use caution when working with electric tools. Be sure all covers and inspection plates are in good repair and in place. Whenever possible, turn off the main electrical disconnect before you clean the robot. When using solvents, observe the following: Wear eye protection and protective gloves during application and removal. Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation. If there is contact with the skin, wash with water. Follow the Original Equipment Manufacturer’s Material Safety Data Sheets. ps-2 TABLE OF CONTENTS MAROB25IB07151E REV C TABLE OF CONTENTS Safety .........................................................................................................................................................................................................................................................................................................................................s-1 Table of Contents..........................................................................................................................................................................................................................................................................................................................1 Table of Figures ............................................................................................................................................................................................................................................................................................................................3 1 Overview .....................................................................................................................................................................................................................................................................................................................................5 1.1 Robot Configurations................................................................................................................................................................................................................................................................................................................................................... 5 1.2 Coordinate System Overview ...................................................................................................................................................................................................................................................................................................................................... 6 1.3 Major Components and Drive Overview ..................................................................................................................................................................................................................................................................................................................... 7 2 Basic Specifications ................................................................................................................................................................................................................................................................................................................13 2.1 P-250iB Robot Work Envelope ................................................................................................................................................................................................................................................................................................................................. 14 2.1.1 Work Envelope - Metal Outer Arm (P-250iB/15), R-30iB Controller .............................................................................................................................................................................................................................................................. 14 2.1.2 Work Envelope - Metal Outer Arm (P-250iB/15), R-30iB Plus Controller ...................................................................................................................................................................................................................................................... 16 2.1.3 Work Envelope - Plastic Outer Arm (P-250iB/15P), R-30iB Controller ........................................................................................................................................................................................................................................................... 18 2.1.4 Work Envelope - Plastic Outer Arm (P-250iB/15P), R-30iB Plus Controller ................................................................................................................................................................................................................................................... 20 3 Transportation and Installation ...............................................................................................................................................................................................................................................................................................23 3.1 Shipping and Handling .............................................................................................................................................................................................................................................................................................................................................. 24 3.2 Installation ................................................................................................................................................................................................................................................................................................................................................................. 31 3.2.1 Rigid Conduit Connection.................................................................................................................................................................................................................................................................................................................................. 31 3.2.2 ROX Connection ................................................................................................................................................................................................................................................................................................................................................ 33 3.2.3 Flex Field Connection ........................................................................................................................................................................................................................................................................................................................................ 34 3.2.4 No-Pour Seal Off Flex Field Connection ........................................................................................................................................................................................................................................................................................................... 35 4 Connecting the End of Arm Tooling .......................................................................................................................................................................................................................................................................................37 4.1 Metal Outer Arm Interface (P-250iB/15) .................................................................................................................................................................................................................................................................................................................. 38 4.2 Plastic Outer Arm (P-250iB/15P) Interface ............................................................................................................................................................................................................................................................................................................... 42 4.3 Inner Arm Interface ................................................................................................................................................................................................................................................................................................................................................... 45 4.4 Turret Interface .......................................................................................................................................................................................................................................................................................................................................................... 46 4.5 Iron Pedestal Interface ............................................................................................................................................................................................................................................................................................................................................... 47 4.6 Aluminum Wall Base Interface ................................................................................................................................................................................................................................................................................................................................. 49 4.7 Foot Loads ................................................................................................................................................................................................................................................................................................................................................................. 51 4.7.1 Metal Outer Arm (P-250iB/15) .......................................................................................................................................................................................................................................................................................................................... 51 4.7.2 Plastic Outer Arm (P-250iB/15P) ...................................................................................................................................................................................................................................................................................................................... 52 4.8 Robot Payload Setting ............................................................................................................................................................................................................................................................................................................................................... 53 4.8.1 Overview ............................................................................................................................................................................................................................................................................................................................................................ 53 4.8.2 Setting the Active Payload Schedule ................................................................................................................................................................................................................................................................................................................. 53 4.8.3 Setup of Payload Schedules ............................................................................................................................................................................................................................................................................................................................... 56 4.8.4 Setting Up Arm Load Information ..................................................................................................................................................................................................................................................................................................................... 69 5 Purge System ...........................................................................................................................................................................................................................................................................................................................71 6 Mastering ..................................................................................................................................................................................................................................................................................................................................75 Overview.................................................................................................................................................................................................................................................................................................................................................................... 75 6.1 6.2 Resetting Alarms and Preparing For Mastering......................................................................................................................................................................................................................................................................................................... 76 6.3 Saving and Restoring Mastering Data ....................................................................................................................................................................................................................................................................................................................... 78 6.4 Single Axis Mastering ............................................................................................................................................................................................................................................................................................................................................... 79 -1- MAROB25IB07151E REV C TABLE OF CONTENTS 6.5 Quick Mastering ........................................................................................................................................................................................................................................................................................................................................................ 81 6.6 Mastering To A Fixture (Fixture Position Master) .................................................................................................................................................................................................................................................................................................... 85 6.7 Zero Degree Mastering .............................................................................................................................................................................................................................................................................................................................................. 87 6.8 P-250iB Mastering Locations .................................................................................................................................................................................................................................................................................................................................... 90 7 Checks and Maintenance ......................................................................................................................................................................................................................................................................................................103 8 Troubleshooting.....................................................................................................................................................................................................................................................................................................................109 8.1 Mechanical Unit Troubleshooting ........................................................................................................................................................................................................................................................................................................................... 110 8.2 P-250iB Purge cycle troubleshooting ...................................................................................................................................................................................................................................................................................................................... 111 8.2.1 P-250iB Purge Procedure and Troubleshooting ............................................................................................................................................................................................................................................................................................... 111 9 Engineering Guidelines .........................................................................................................................................................................................................................................................................................................113 9.1 LOCTITE SPEC - EG-00008 .................................................................................................................................................................................................................................................................................................................................. 114 9.2 TORQUE SPEC - EG-00010................................................................................................................................................................................................................................................................................................................................... 124 -2- TABLE OF FIGURES MAROB25IB07151E REV C TABLE OF FIGURES Figure 1-1 DOC-6263-910-001, COORDINATE SYSTEM OVERVIEW...................................................................................................................................................................................................................................................................... 6 Figure 1-1 DOC-6263-910-001, ROBOT MODELS........................................................................................................................................................................................................................................................................................................ 8 Figure 1-2 DOC-6263-910-002, INTERNAL COMPONENTS - METAL OUTER ARM (P-250iB/15), IRON PEDESTAL ...................................................................................................................................................................................... 9 Figure 1-3 DOC-6263-910-003, INTERNAL COMPONENTS - METAL OUTER ARM (P-250iB/15), ALUMINUM WALL BASE ..................................................................................................................................................................... 10 Figure 1-4 DOC-6263-910-017, INTERNAL COMPONENTS - PLASTIC OUTER ARM (P-250iB/15P) ................................................................................................................................................................................................................ 11 Figure 2-1 ET-6263-820-001_SHT1, FULL ENVELOPE ............................................................................................................................................................................................................................................................................................. 14 Figure 2-2 ET-6263-820-001_SHT2, Restricted Envelope ............................................................................................................................................................................................................................................................................................ 15 Figure 2-3 ET-6263-820-101_SHT1, Restricted Envelope ............................................................................................................................................................................................................................................................................................ 16 Figure 2-4 ET-6263-820-101_SHT2, Restricted Envelope ............................................................................................................................................................................................................................................................................................ 17 Figure 2-5 ET-6263-821-001_SHT1, FULL ENVELOPE ............................................................................................................................................................................................................................................................................................. 18 Figure 2-6 ET-6263-821-001_SHT2, Restricted Envelope ............................................................................................................................................................................................................................................................................................ 19 Figure 2-7 ET-6263-821-101_SHT1, Restricted Envelope ............................................................................................................................................................................................................................................................................................ 20 Figure 2-8 ET-6263-820-101_SHT2, Restricted Envelope ............................................................................................................................................................................................................................................................................................ 21 Figure 3-1 ET-6263-820-005_SHT1, Sea & Truck ........................................................................................................................................................................................................................................................................................................ 24 Figure 3-2 ET-6263-820-005_SHT2, PEDESTAL LOW FREIGHT ............................................................................................................................................................................................................................................................................. 25 Figure 3-3 ET-6263-820-005_SHT3, UPRIGHT WALL BASE SHIPPING................................................................................................................................................................................................................................................................. 26 Figure 3-4 ET-6263-820-005_SHT4, LAY DOWN OVERSEA.................................................................................................................................................................................................................................................................................... 27 Figure 3-5 ET-6263-820-005_SHT5, PEDESTAL PALLET LAYOUT ....................................................................................................................................................................................................................................................................... 28 Figure 3-6 ET-6263-820-005_SHT6, WALL BASE PALLET LAYOUT..................................................................................................................................................................................................................................................................... 29 Figure 3-7 ET-6263-820-005_SHT7, LAY DOWN PALLET LIFTING....................................................................................................................................................................................................................................................................... 30 Figure 3-8 ET-6263-820-004_SHT1, CONDUIT CONNECTION INFORMATION ................................................................................................................................................................................................................................................... 31 Figure 3-9 ET-6263-820-004_SHT2, CONDUIT CONNECTION INFORMATION ................................................................................................................................................................................................................................................... 32 Figure 3-10 ET-6263-820-004_SHT3, ROX CONNECTION ....................................................................................................................................................................................................................................................................................... 33 Figure 3-11 EO-6263-137-000, FLEX FIELD CONNECTION .................................................................................................................................................................................................................................................................................... 34 Figure 3-12 EO-6263-138-000, FLEX FIELD CONNECTION .................................................................................................................................................................................................................................................................................... 35 Figure 4-1 ET-6263-820-002_SHT7, PAYLOAD & PROCESS INTERFACE ............................................................................................................................................................................................................................................................ 38 Figure 4-2 ET-6263-820-002_SHT1, PAYLOAD & INTERFACE .............................................................................................................................................................................................................................................................................. 39 Figure 4-3 ET-6263-820-002_SHT2, WRIST INTERFACE ........................................................................................................................................................................................................................................................................................ 40 Figure 4-4 ET-6263-820-002_SHT3, OUTER ARM INTERFACE .............................................................................................................................................................................................................................................................................. 41 Figure 4-5 ET-6263-820-002_SHT7, PAYLOAD & PROCESS INTERFACE ............................................................................................................................................................................................................................................................ 42 Figure 4-6 ET-6263-821-002_SHT1, PAYLOAD & INTERFACE .............................................................................................................................................................................................................................................................................. 43 Figure 4-8 ET-6263-821-002_SHT2, OUTER ARM INTERFACE .............................................................................................................................................................................................................................................................................. 44 Figure 4-9 ET-6263-820-002_SHT4, INNER ARM INTERFACE ............................................................................................................................................................................................................................................................................... 45 Figure 4-10 ET-6263-820-002_SHT5, TURRET INTERFACE .................................................................................................................................................................................................................................................................................... 46 Figure 4-11 ET-6263-820-003_SHT2, FLOOR MOUNT LOADING ........................................................................................................................................................................................................................................................................... 47 Figure 4-12 ET-6263-820-003_SHT3, FLOOR MOUNT LEVELING JACK .............................................................................................................................................................................................................................................................. 48 Figure 4-13 ET-6263-820-002_SHT6, PAYLOAD & INTERFACE ............................................................................................................................................................................................................................................................................ 49 Figure 4-14 ET-6263-820-003_SHT5, WALL BASE LOADING ................................................................................................................................................................................................................................................................................. 50 Figure 4-15 ET-6263-820-003_SHT6, FOOT LOADS .................................................................................................................................................................................................................................................................................................. 51 Figure 4-16 ET-6263-821-003_SHT6, FOOT LOADS .................................................................................................................................................................................................................................................................................................. 52 Figure 4-17 Inertia Formula Example .............................................................................................................................................................................................................................................................................................................................. 60 -3- MAROB25IB07151E REV C TABLE OF FIGURES Figure 4-18 Inertia Equations ........................................................................................................................................................................................................................................................................................................................................... 61 Figure 4-19 Valid Payload Configuration for Accurate Estimation ................................................................................................................................................................................................................................................................................ 66 Figure 4-20 J5 and J6 Orientation for POS1 .................................................................................................................................................................................................................................................................................................................... 66 Figure 4-21 Acceleration Equation .................................................................................................................................................................................................................................................................................................................................. 68 Figure 5-1 DOC-6263-910-008, PEDESTAL PURGE LAYOUT ................................................................................................................................................................................................................................................................................. 72 Figure 5-2 DOC-6263-910-009, WALL BASE PURGE LAYOUT .............................................................................................................................................................................................................................................................................. 73 Figure 5-3 DOC-6263-910-006, PNEUMATIC SCHEMATIC ..................................................................................................................................................................................................................................................................................... 74 Figure 6-1 ET-6263-820-006_SHT1, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 90 Figure 6-2 ET-6263-820-006_SHT2, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 91 Figure 6-3 ET-6263-820-006_SHT3, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 92 Figure 6-4 ET-6263-820-006_SHT4, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 93 Figure 6-5 ET-6263-820-006_SHT5, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 94 Figure 6-6 ET-6263-820-006_SHT6, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 95 Figure 6-7 ET-6263-820-006_SHT7, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 96 Figure 6-8 ET-6263-820-006_SHT8, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 97 Figure 6-9 ET-6263-820-006_SHT9, MASTERING & ZERO POSITION ................................................................................................................................................................................................................................................................... 98 Figure 6-10 ET-6263-820-006_SHT10, MASTERING & ZERO POSITION............................................................................................................................................................................................................................................................... 99 Figure 6-11 ET-6263-820-006_SHT11, MASTERING & ZERO POSITION............................................................................................................................................................................................................................................................. 100 Figure 6-12 ET-6263-820-006_SHT12, MASTERING & ZERO POSITION............................................................................................................................................................................................................................................................. 101 Figure 7-1 ET-6263-820-007_SHT1, INITIAL AND REBUILD ................................................................................................................................................................................................................................................................................ 104 Figure 7-2 ET-6263-820-007_SHT2, MAINTENANCE- FLOOR, ANGLE, SHELF MOUNT................................................................................................................................................................................................................................. 105 Figure 7-3 ET-6263-820-007_SHT3, LUBRICATION REQUIREMENTS ................................................................................................................................................................................................................................................................ 106 Figure 7-4 ET-6263-820-008_SHT1, LUBE EXPANSION CONNECTION .............................................................................................................................................................................................................................................................. 107 Figure 9-1 EG-00008 Sheet 1 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 114 Figure 9-2 EG-00008 Sheet 2 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 115 Figure 9-3 EG-00008 Sheet 3 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 116 Figure 9-4 EG-00008 Sheet 4 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 117 Figure 9-5 EG-00008 Sheet 5 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 118 Figure 9-6 EG-00008 Sheet 6 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 119 Figure 9-7 EG-00008 Sheet 7 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 120 Figure 9-8 EG-00008 Sheet 8 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 121 Figure 9-9 EG-00008 Sheet 9 of 10, LOCTITE APPLICATION ................................................................................................................................................................................................................................................................................ 122 Figure 9-10 EG-00008 Sheet 10 of 10, LOCTITE APPLICATION ............................................................................................................................................................................................................................................................................ 123 Figure 9-11 EG-00010 Sheet 1 of 5, TORQUE SPECIFICATION ............................................................................................................................................................................................................................................................................. 124 Figure 9-12 EG-00010 Sheet 2 of 5, TORQUE SPECIFICATION ............................................................................................................................................................................................................................................................................. 125 Figure 9-13 EG-00010 Sheet 3 of 5, TORQUE SPECIFICATION ............................................................................................................................................................................................................................................................................. 126 Figure 9-14 EG-00010 Sheet 4 of 5, TORQUE SPECIFICATION ............................................................................................................................................................................................................................................................................. 127 Figure 9-15 EG-00010 Sheet 5 of 5, TORQUE SPECIFICATION ............................................................................................................................................................................................................................................................................. 128 -4- 1 1 OVERVIEW MAROB25IB07151E REV C OVERVIEW The P-250iB is a six axis robot, designed for efficient process equipment integration with features such as a hollow-wrist, an option for two motors on the outer arm for gear pumps, inner arm designed to integrate paint application equipment easily, and multiple hose routing options. The P-250iB has the ability to “flip-over” axis 2 and 3 to provide a very large work envelope and maximum flexibility for painting. The offset-arm design provides excellent near reach capability. The P-250iB robot is capable of paint speeds of up to 1500 mm/sec. J1 limited to 80 deg/sec. Fan tip must be 1050 mm from J1 to achieve 1500 mm/sec. Refer to 365mm "keyhole" work envelope dimensions. The wrist payload is 15 kg at a 50 mm radial and 300 mm axial offset. 1.1 Robot Configurations This manual supports the following robot configurations: • P-250iB/15, 1400mm Metal Outer Arm • P-250iB/15P, 1350mm Plastic Outer Arm This manual supports the following mounting configurations: • Iron Pedestal o Floor o Angle o Wall o Invert • Aluminum Wall Base o Wall o Shelf o Invert Shelf -5- MAROB25IB07151E REV C 1 1.2 Coordinate System Overview Figure 1-1 DOC-6263-910-001, COORDINATE SYSTEM OVERVIEW J3 J3 J4 J4 J6 J6 J5 J5 J2 J2 J1 J1 LEFT HAND COORDINATE SYSTEM RIGHT HAND COORDINATE SYSTEM RIGHT INNER ARM OFFSET SHOWN (NO CHANGE FOR LEFT INNER ARM OFFSET RIGHT INNER ARM OFFSET SHOWN (NO CHANGE FOR LEFT INNER ARM OFFSET -6- OVERVIEW 1 OVERVIEW MAROB25IB07151E REV C 1.3 Major Components and Drive Overview The robot uses both gear trains and RV (rotating vector) reducers. Axes 1, 2 and 3 use an RV reducer that is driven by an intermediate gear. Axes 4, 5 and 6 use planetary reducers with drive shafts and a 140 degree hollow offset wrist. The wrist has spur gear reduction and bevel gears. -7- MAROB25IB07151E REV C 1 Figure 1-2 DOC-6263-910-001, ROBOT MODELS WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. OUTER ARM UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS WRIST ASSEMBLY OUTER ARM TURRET INNER ARM INNER ARM TURRET ALUMINUM WALL BASE WRIST ASSEMBLY IRON PEDESTAL P-250iB IRON PEDESTAL P-250iB ALUMINUM WALL BASE SHOWN FLOOR MOUNTED WITH RH ARM OFFSET AND METAL OUTER ARM SHOWN WALL MOUNTED WITH LH ARM OFFSET AND METAL OUTER ARM DOC-6263-910-001 ROBOT MODELS -8- REV B SHEET 1 OF 1 OVERVIEW 1 OVERVIEW MAROB25IB07151E REV C Figure 1-3 DOC-6263-910-002, INTERNAL COMPONENTS - METAL OUTER ARM (P-250iB/15), IRON PEDESTAL WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. AXIS 6 ROTATION UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS AXIS 4 ROTATION AXIS 3 MOTOR AXIS 4 MOTOR 2K MOTOR AXIS 3 REDUCER AXIS 6 MOTOR 2K MOTOR REDUCER AXIS 4 REDUCER AXIS 6 REDUCER 2K ROTATION 1K ROTATION AXIS 5 REDUCER 1K MOTOR REDUCER AXIS 5 MOTOR 1K MOTOR AXIS 5 ROTATION AXIS 3 ROTATION AXIS 2 REDUCER AXIS 2 ROTATION AXIS 2 MOTOR AXIS 1 MOTOR AXIS 1 REDUCER AXIS 1 ROTATION PRESSURE SWITCH FLOW SWITCH DOC-6263-910-002 INTERNAL COMPONENTS -9- REV A SHEET 1 OF 1 MAROB25IB07151E REV C 1 Figure 1-4 DOC-6263-910-003, INTERNAL COMPONENTS - METAL OUTER ARM (P-250iB/15), ALUMINUM WALL BASE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment AXIS 2 ROTATION AXIS 3 ROTATION WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. AXIS 1 REDUCER UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS AXIS 3 REDUCER AXIS 1 ROTATION AXIS 2 REDUCER PRESSURE SWITCH FLOW SWITCH AXIS 2 MOTOR AXIS 5 MOTOR 2K MOTOR AXIS 3 MOTOR 1K MOTOR 2K REDUCER 1K REDUCER AXIS 4 MOTOR AXIS 6 MOTOR AXIS 5 REDUCER 2K ROTATION AXIS 4 REDUCER 1K ROTATION AXIS 6 REDUCER AXIS 1 MOTOR AXIS 5 ROTATION AXIS 4 ROTATION AXIS 6 ROTATION DOC-6263-910-003 INTERNAL COMPONENTS -10- REV A SHEET 1 OF 1 OVERVIEW 1 OVERVIEW MAROB25IB07151E REV C Figure 1-5 DOC-6263-910-017, INTERNAL COMPONENTS - PLASTIC OUTER ARM (P-250iB/15P) WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. AXIS 3 MOTOR UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS A6 ROTATION A4 ROTATION 1K MOTOR AXIS 3 REDUCER 1K REDUCER AXIS 6 MOTOR AXIS 3 ROTATION 1K ROTATION AXIS 6 REDUCER AXIS 4 REDUCER A5 REDUCER AXIS 4 MOTOR A5 MOTOR A5 ROTATION NOTE: INNER ARM, TURRET & PEDESTAL SAME AS METAL OUTER ARM (P-250iB/15) P-250iB/15P PEDESTAL MOUNT -11- DOC-6263-910-017 REV H SHEET 1 OF 1 2 2 BASIC SPECIFICATIONS MAROB25IB07151E REV C BASIC SPECIFICATIONS -13- MAROB25IB07151E REV C 2 2.1 P-250iB Robot Work Envelope 2.1.1 Work Envelope - Metal Outer Arm (P-250iB/15), R-30iB Controller Figure 2-1 ET-6263-820-001_SHT1, FULL ENVELOPE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS FULL WORK ENVELOPE +J1 "A" 20° 82 20° R458.00 CLEARANCE (POINT A) CABLES R2800 ARMS SHOWN IN ZERO POSITION POINT USED TO GENERATE ENVELOPE R2800 1400 J32 1400 R365 +J2 820 650 50° ARMS SHOWN IN ZERO POSITION 500 ALUMINUM BASE NOTES: FULL WORK ENVELOPE 1. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. 2. SEE ET-6263-820-001 SHEET 2 FOR DRAWINGS OF RESTRICTED ENVELOPES. 3. RESTRICTED ENVELOPES ARE FOR ROBOTS EQUIPPED WITH FAC PROCESS HARDWARE. IRON PEDESTAL [ET-6263-820-001_SHT1] REV G1 UNRESTRICTED WORK ENVELOPE - R-30iB -14- BASIC SPECIFICATIONS 2 BASIC SPECIFICATIONS MAROB25IB07151E REV C Figure 2-2 ET-6263-820-001_SHT2, Restricted Envelope WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 95° ARMS SHOWN IN ZERO POSITION UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS RESTRICTED WORK ENVELOPE 1 +J1 "A" 1400 R1400 500 45° CABLES R458 CLEARANCE (POINT A) R2797 528 23° +J1 R2797.00 40° 105° 95° 20° 5° ARMS SHOWN IN ZERO POSITION POINT USED TO GENERATE ENVELOPE (SEE NOTE 2) RESTRICTED WORK ENVELOPE 2 (SEE NOTE 4) R1400 R2797 POINT USED TO GENERATE ENVELOPE (SEE NOTE 2) RESTRICTED WORK ENVELOPE 2 CONVEYOR FLOW RESTRICTED WORK ENVELOPE 1 45° 1400 23° R486 R2797 J32 1400 1400 +J2 40° 820 5° IRON PEDESTAL 528 ARMS SHOWN IN ZERO POSITION NOTES: 650 500 1. 2. 3. 4. SEE SHEET 1 FOR JOINT MOTION LIMITS AND DRAWING OF FULL ENVELOPE. SEE SHEET 1 FOR DEFINITION OF POINT USED TO GENERATE ENVELOPE. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. SEE ET-6263-820-010 FOR ADDITIONAL RESTRICTION FOR PATHS WITH DOMINATE J1 MOTION. ALUMINUM BASE [ET-6263-820-001_SHT2] P-250iB WORK ENVELOPE -15- REV G1 MAROB25IB07151E REV C 2 BASIC SPECIFICATIONS 2.1.2 Work Envelope - Metal Outer Arm (P-250iB/15), R-30iB Plus Controller Figure 2-3 ET-6263-820-101_SHT1, Restricted Envelope WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS +J1 "A" 20° FULL WORK ENVELOPE 20° R458.00 CLEARANCE (POINT A) CABLES R2800 ARMS SHOWN IN ZERO POSITION R2800 POINT USED TO GENERATE ENVELOPE (SEE NOTE 2) 1400 J32 1400 R365 +J2 820 650 50° ARMS SHOWN IN ZERO POSITION NOTES: 1. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. 500 2. SEE ET-6263-820-002 SHEET 2 FOR DEFINITION OF POINT USED TO GENERATE ENVELOPE. ALUMINUM BASE FULL WORK ENVELOPE 3. SEE ET-6263-820-001 SHEET 2 FOR DRAWINGS OF RESTRICTED ENVELOPES. IRON PEDESTAL [ET-6263-820-101_SHT1] UNRESTRICTED WORK ENVELOPE -16- REV B2 2 BASIC SPECIFICATIONS MAROB25IB07151E REV C Figure 2-4 ET-6263-820-101_SHT2, Restricted Envelope WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 95° ARMS SHOWN IN ZERO POSITION UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS RESTRICTED WORK ENVELOPE 1 +J1 "A" 1400 R1400 500 45° CABLES R458 CLEARANCE (POINT A) R2797 528 +J1 105° R2797.00 95° 23° RESTRICTED WORK ENVELOPE 2 (SEE NOTE 4) 35° 37° 5° ARMS SHOWN IN ZERO POSITION R2797 POINT USED TO GENERATE ENVELOPE (SEE NOTE 3) POINT USED TO GENERATE ENVELOPE (SEE NOTE 3) R1400 RESTRICTED WORK ENVELOPE 2 CONVEYOR FLOW RESTRICTED WORK ENVELOPE 1 1400 45° 23° R486 R2797 J32 1400 NOTES: 1400 +J2 35° 820 1. SEE SHEET 1 FOR JOINT MOTION LIMITS AND DRAWING OF FULL ENVELOPE. 2. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. 528 5° ARMS SHOWN IN ZERO POSITION 3. SEE ET-6263-820-002 SHEET 2 FOR DEFINITION OF POINT USED TO GENERATE ENVELOPE. 650 IRON PEDESTAL 4. SEE ET-6263-820-010 FOR ADDITIONAL RESTRICTION FOR PATHS WITH DOMINATE J1 MOTION. 500 ALUMINUM BASE [ET-6263-820-101_SHT2] P-250iB WORK ENVELOPE -17- REV B2 MAROB25IB07151E REV C 2 BASIC SPECIFICATIONS 2.1.3 Work Envelope - Plastic Outer Arm (P-250iB/15P), R-30iB Controller Figure 2-5 ET-6263-821-001_SHT1, FULL ENVELOPE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 95° ARMS SHOWN IN ZERO POSITION RESTRICTED WORK ENVELOPE 1 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS "A" +J1 92 CABLES R458 CLEARANCE (POINT A) 95° R2747 POINT USED TO GENERATE ENVELOPE (SEE NOTE 3) DETAIL A SCALE 1 : 4 R1350 1350 45° 23° R486 RESTRICTED WORK ENVELOPE 1 A R2747 1400 J32 1400 +J2 820 5° IRON PEDESTAL NOTES: 40° 1. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. ARMS SHOWN IN ZERO POSITION 3. 650 SEE ET-6263-821-001 SHEET 2 FOR DRAWING OF RESTRICTED 2 ENVELOPE. 528 500 ALUMINUM BASE PLASTIC OUTER ARM [ET-6263-821-001_SHT1] UNRESTRICTED WORK ENVELOPE -18- REV G1 2 BASIC SPECIFICATIONS MAROB25IB07151E REV C Figure 2-6 ET-6263-821-001_SHT2, Restricted Envelope WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS R2747 500 1400 R1350 45° 528 23° +J1 105° 40° 20° 5° R2747 POINT USED TO GENERATE ENVELOPE (SEE NOTE 3) RESTRICTED WORK ENVELOPE 2 RESTRICTED WORK ENVELOPE 2 CONVEYOR FLOW NOTES: 1. SEE SHEET 1 FOR JOINT MOTION LIMITS AND DRAWING OF RESTRICTED ENVELOPE 1. 2. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. • 3. ROBOT ARMS SHOWN IN ZERO POSITION. 4. SEE ET-6263-821-002 SHEET 2 FOR DEFINITION OF POINT USED TO GENERATE ENVELOPE. 5. SEE ET-6263-820-010 FOR ADDITIONAL RESTRICTION FOR PATHS WITH DOMINATE J1 MOTION. [ET-6263-821-001_SHT2] P-250iB WORK ENVELOPE -19- REV E MAROB25IB07151E REV C 2 BASIC SPECIFICATIONS 2.1.4 Work Envelope - Plastic Outer Arm (P-250iB/15P), R-30iB Plus Controller Figure 2-7 ET-6263-821-101_SHT1, Restricted Envelope WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 95° ARMS SHOWN IN ZERO POSITION RESTRICTED WORK ENVELOPE 1 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS "A" +J1 CABLES R458 CLEARANCE (POINT A) 1350 95° R2747 SLED OUTER ARM POINT USED TO GENERATE ENVELOPE (SEE NOTE 3) NOTE: SLED OUTER ARM DIMENSIONS AND ENVELOPE ARE IDENTICAL TO SCWB PLASTIC ARM SHOWN R1350 RESTRICTED WORK ENVELOPE 1 45° 1350 23° R486 R2747 1400 J32 1400 +J2 5° IRON PEDESTAL NOTES: 35° 820 1. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. ARMS SHOWN IN ZERO POSITION 2. SEE ET-6263-821-002 SHEET 2 FOR DEFINITION OF POINT USED TO GENERATE ENVELOPE. 650 528 3. SEE ET-6263-821-001 SHEET 2 FOR DRAWING OF RESTRICTED 2 ENVELOPE. 500 ALUMINUM BASE [ET-6263-821-101_SHT1] REV C2 RESTRICTED WORK ENVELOPE - R-30iB PLUS -20- 2 BASIC SPECIFICATIONS MAROB25IB07151E REV C Figure 2-8 ET-6263-820-101_SHT2, Restricted Envelope WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS R2747 500 1400 R1350 45° 528 23° +J1 105° 35° 37° 5° R2747 POINT USED TO GENERATE ENVELOPE (SEE NOTE 3) RESTRICTED WORK ENVELOPE 2 RESTRICTED WORK ENVELOPE 2 CONVEYOR FLOW NOTES: 1. SEE SHEET 1 FOR JOINT MOTION LIMITS AND DRAWING OF RESTRICTED ENVELOPE 1. 2. WORK ENVELOPE SHOWN AT SOFT LIMITS WITH TURRET EYEBOLT REMOVED. • 3. ROBOT ARMS SHOWN IN ZERO POSITION. 4. SEE ET-6263-821-002 SHEET 2 FOR DEFINITION OF POINT USED TO GENERATE ENVELOPE. 5. SEE ET-6263-820-010 FOR ADDITIONAL RESTRICTION FOR PATHS WITH DOMINATE J1 MOTION. [ET-6263-821-101_SHT2] P-250iB WORK ENVELOPE -21- REV C2 3 3 TRANSPORTATION AND INSTALLATION MAROB25IB07151E REV C TRANSPORTATION AND INSTALLATION -23- MAROB25IB07151E REV C 3 TRANSPORTATION AND INSTALLATION 3.1 Shipping and Handling Figure 3-1 ET-6263-820-005_SHT1, Sea & Truck WARNING PEDESTAL MOUNT SHIPPING POSITION FOR TRUC K FRONT OF PEDESTAL Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment FRONT OF PEDESTAL WARNING AXIS 1 ROTATED TO IMPROVE STABILITY Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. AXIS 1 ROTATED TO IMPROVE STABILITY 1183 1183 219 40° 212 40° 16.0 406 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 56 29.9 760 29.9 760 16.0 406 56 CENTER OF GRAVITY CENTER OF GRAVITY STRAP AROUND HUB BETWEEN ARMS STRAP AROUND HUB BETWEEN ARMS 60.5 1537 60.5 1537 45° LIFTING EYEBOLT LOCATION 212 20° 80.2 2038 45° LIFTING EYEBOLT LOCATION 219 80.2 2038 20° 803 803 CENTER OF GRAVITY CENTER OF GRAVITY NOTES: 1. BARE ROBOT WEIGHT: 553 Kg 2. PAYLOAD WEIGHT: WRIST: 15 Kg MAX J3 ARM: 15Kg MAX J2 ARM: 15 Kg MAX J1 TURRET: 5Kg MAX 3. WEIGHT OF CRATE NOT INCLUDED. 4. CG LOCATION IS WITH NO PAYLOADS RH ROBOT LH ROBOT [ET-6263-820-005_SHT1] SEA OR TRUCK -24- REV F5 SHEET 1 OF 1 3 TRANSPORTATION AND INSTALLATION MAROB25IB07151E REV C Figure 3-2 ET-6263-820-005_SHT2, PEDESTAL LOW FREIGHT WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment PEDESTAL MOUN T SHIPPING POSITION LOW FREIGHT 11.9 302 CENTER OF GRAVITY WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 76.41 1940.9 2.4 60 40° UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 12.2 310 FRONT OF PEDESTAL 40° 11.9 302 CENTER OF GRAVITY CENTER OF GRAVITY 29.93 760.2 11° 2.2 56 46° 25.2 639 SLING CHOKED AROUND ARM HUB LH ROBOT SLING ATTACHED TO TURRET EYEBOLT 12.2 310 ENSURE ARM LIFTS FIRST CENTER OF GRAVITY ENSURE PEDESTAL TOUCHES FIRST 11° 57.2 1452 PLASTIC ARM 46° NEVER LEAVE ROBOT IN SHIPPING POSITION WITHOUT SUPPORT POST ATTACHED SEE VIEW A 51.3 1303 METAL ARM SUPPORT POST ASM EO-6263-704-000 METAL ARM 25.2 640 SUPPORT POST ASM EO-6263-707-000 PLASTIC ARM VIEW A PRE-DRILL WITH 1/4" PILOT HOLES PRIOR TO INSTALLING 3/8" X 2" LAG SCREWS TO PREVENT SPLITTING THE POST. RH ROBOT 31.86 809.3 NOTE: REFER TO MASS DATA ON SHEET 1 [ET-6263-820-005_SHT2] PEDESTAL LOW FREIGHT -25- REV F2 MAROB25IB07151E REV C 3 TRANSPORTATION AND INSTALLATION Figure 3-3 ET-6263-820-005_SHT3, UPRIGHT WALL BASE SHIPPING WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment UPRIGHT WALL BASE SHIPPING POSITION TRUCK OR OVERSEA CENTER OF GRAVITY WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 10.2 258 2.0 52 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 29.93 760.2 2.2 56 10.3 262 CENTER OF GRAVITY SLING CHOKED AROUND ARM HUB SLING ATTACHED TO TURRET EYEBOLT VIEW A 70° ENSURE ARM LIFTS FIRST PRE-DRILL WITH 1/4" PILOT HOLES PRIOR TO INSTALLING 3/8" X 2" LAG SCREWS TO PREVENT SPLITTING THE POST. 70° 10.3 262 CENTER OF GRAVITY CENTER OF GRAVITY 10.2 258 SEE VIEW A 61.13 1552.7 30° 30° SEE EO-6263-710-000 FOR SUPPORT POST 29.2 742 ENSURE PEDESTAL TOUCHES FIRST NEVER LEAVE ROBOT IN SHIPPING POSITION WITHOUT SUPPORT POST ATTACHED 29.2 742 79.74 2025.3 RH ROBOT LH ROBOT NOTES: 1. REFER TO MASS DATA ON SHEET 1 2. USE LAY DOWN SHIPPING POSITION FOR PROCESS HOSES WHICH EXTEND BELOW WALL BASE (SEE SHEET 4). [ET-6263-820-005_SHT3] UPRIGHT WALL BASE SHIPPING -26- REV C2 3 TRANSPORTATION AND INSTALLATION MAROB25IB07151E REV C Figure 3-4 ET-6263-820-005_SHT4, LAY DOWN OVERSEA WARNING LAY DOWN WALL BASE SHIPPING POSITION FOR OVERSEA Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING 5° RH PALLET .4 10 RH PALLET 5° RH PALLET Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. .3 7 RH PALLET UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 5° LH PALLET 1.5 37 LH PALLET 15° TYP 5° LH PALLET 1.6 40 LH PALLET 15° TYP 37.5 953 CENTER OF GRAVITY CENTER OF GRAVITY 37.5 953 35.67 906.0 33.63 854.2 20.7 527 16.5 419 LH INNER ARM UPSTREAM MOUNT RH INNER ARM UPSTREAM MOUNT 97.65 2480.2 97.65 2480.2 5° LH PALLET 5° LH PALLET .4 11 LH PALLET .31 8 LH PALLET 1.4 36 RH PALLET 1.5 39 RH PALLET 5° RH PALLET 5° RH PALLET 15° TYP 15° TYP CENTER OF GRAVITY CENTER OF GRAVITY 37.6 956 37.6 956 35.67 906.0 33.63 854.2 20.7 527 16.5 419 RH INNER ARM DOWNSTREAM MOUN T 97.57 2478.3 LH INNER ARM DOWNSTREAM MOUNT NOTE: 1. 2. REFER TO MASS DATA ON SHEET 1 IF ROBOT IS EQUIPPED WITH 1K PROCESS ROUTING INNER ARM POSITION IS ALWAYS AT 0° TO AXIS 1. -27- 97.57 2478.3 [ET-6263-820-005_SHT4] LAY DOWN OVERSEA REV A MAROB25IB07151E REV C 3 TRANSPORTATION AND INSTALLATION Figure 3-5 ET-6263-820-005_SHT5, PEDESTAL PALLET LAYOUT WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment PALLET LAYOUT FOR PEDESTAL ROBOTS WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. CONTROLLER CONTROLLER UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 90.00 2286.0 89.00 2260.6 CABLES 55.00 1397.0 CABLES CABLES PALL90X55-P250 CONTROLLER 57.00 1447.8 PALL90X55-P250 CABLES CONTROLLER 86.75 2203.4 63.16 1604.3 LH ARM TRUC K PALLET LH ARM OVERSEA PALLET RH ARM TRUC K PALLET 58.28 1480.4 RH ARM OVERSEA PALLET MATERIAL: PINE FOR INTERNATIONAL SHIPPING ALL WOOD MUST BE STERILIZED TO ISPM -15 STANDARD AND DISPLAY THIS STAMP EVERY 2 ft: I P P C US - 000 HT [ET-6263-820-005_SHT5] PEDESTAL PALLET LAYOUT -28- REV B2 3 TRANSPORTATION AND INSTALLATION MAROB25IB07151E REV C Figure 3-6 ET-6263-820-005_SHT6, WALL BASE PALLET LAYOUT WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment MISC ITEMS (LH) PALL-P250WM (RH) PALL-P250WM 5° 5° WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. CONTROLLER UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS (RH) PALL-P250WM CABLE ENTRY CABLES LH ARM RIGHT CABLE ENTRY ARM VERTICLE CABLE ENTRY CABLES CONTROLLER 15° 15° CABLE PENETRATION RH ARM CABLE ENTRY UP CABLE PENETRATION CABLE TIE CRANK ARM TO OUTER ARM TO RELEAVE HOSES FROM TOUCHING CRANK SHAFT RH ARM CABLE ENTRY DOWN (RH) PALL-P250WM (LH) PALL-P250WM 5° 5° MISC ITEMS LH ARM LEFT CABLE ENTRY 20° LH ARM UPSTREAM MOUNT 1K PROCESS NOTE: LH ARM UPSTREAM SHOWN. POSITIONS FOR RH ARM UPSTREAM MOUNT SAME. LH / RH ARM DOWNSTREAM MOUNT USE LH PALLET WITH SYMETRIC ROBOT POSITION 20° 30° 68.97 1751.7 MATERIAL: PINE FOR INTERNATIONAL SHIPPING 15° 90.00 2286.0 CABLE PENETRATION RH ARM CABLE ENTRY UP RH ARM CABLE ENTRY DOWN UPRIGHT WALL BAS E LH ARM SHOWN 15° ALL WOOD MUST BE STERILIZED TO ISPM -15 STANDARD AND DISPLAY THIS STAMP EVERY 2 ft: I P P C US - 000 HT LAY DOWN WALL BASE FOR LH ARMS PALLET LAYOUT IS SYMETRICALLY OPPOSITE [ET-6263-820-005_SHT6] WALL BASE PALLET LAYOUT -29- REV B1 MAROB25IB07151E REV C 3 TRANSPORTATION AND INSTALLATION Figure 3-7 ET-6263-820-005_SHT7, LAY DOWN PALLET LIFTING WARNING FORK 1 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment FORK 2 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS CHOKE AROUND INNER ARM CHAIN FALL ALLOW ARM TO ROTATE IN SLING RAISE CHAIN TO ROTATE ROBOT EYBOLTS ON BASE STEP 1 STEP 2 ATTACH SLING AROUND INNER ARM TO FORK 1 ATTACH CHAIN FALL TO EYEBOLT ON SIDE WHICH IS GOING UP AND FORK 2 ATTACH SLING TO OPPOSITE EYEBOLT ON BASE AND FORK 2 REMOVE ALL MOUNTING HARDWARE FROM PALLET RAISE CHAIN FALL UNTIL ROBOT IS IN MOUNTING POSITION RAISE FORKS TO MOUNT ROBOT TO STRUCTURE REMOVING ROBOT FROM PALLET FORK 2 FORK 1 ALLOW ARM TO ROTATE IN SLING CHAIN FALL RAISE CHAIN TO ROTATE ROBOT CHOKE AROUND INNER ARM EYBOLTS ON BASE STEP 1 STEP 2 ATTACH SLING AROUND INNER ARM TO FORK 1 ATTACH CHAIN FALL TO EYEBOLT ON LOWER SIDE AND FORK 2 ATTACH SLING TO OPPOSITE EYEBOLT ON BASE AND FORK 2 LOWER ROBOT DOWN TO JUST OVER THE PALLET RAISE CHAIN FALL UNTIL ROBOT IS IN SHIPPING POSITION LOWER FORKS TO MOUNT ROBOT TO PALLET ADD SUPPORT BRACKET AND ROBOT MOUNTING SCREWS BEFORE REMOVING STRAPS ADD ING ROBOT TO PALLET [ET-6263-820-005_SHT7] LAY DOWN PALLET LIFTING -30- REV A 3 TRANSPORTATION AND INSTALLATION MAROB25IB07151E REV C 3.2 Installation 3.2.1 Rigid Conduit Connection Figure 3-8 ET-6263-820-004_SHT1, CONDUIT CONNECTION INFORMATION WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment LEAVE PLUG IN FOR SEAL OFFS LESS THAN 18 INCHES FROM BOOTH WALL WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. EO-3505-137-006 REF CROUSE - HINDS #EYS86SA APPLY HDWMO00003886O (LOCTITE #80724 NO MORE LEAKS) TO THREADS ON BOTH ENDS PRIOR TO ASSEMBLY UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS PURGE AIR INLET FITTING LOCATED IN PEDESTAL OR WALL BASE FIELD INSTALLATION GUIDELINES: 1. 2. 3. 4. WALL BAS E PLACE ROBOT IN BOOTH. PULL CABLES THROUGH CONDUIT CONNECT CABLES TO CONTROLLER. POWER UP THE CONTROLLER AND MANUALLY JOG THE ROBOT TO ENSURE THAT ALL THE CABLES ARE FUNCTIONING CORRECTLY. 5. INSTALL “CHICO A” COMPOUND IN SEAL OFF FITTINGS. USE OATEY #31166 PLUMBER'S PUTTY TO ENSURE THAT THE COMPOUND DOES NOT FLOW BEYOND EITHER SIDE OF THE SEAL-OFF AS SHOWN. 6. START PURGE CYCLE. VERIFY THAT THERE IS NO AIR LEAKING THRU ANY OF THE SEAL-OFFS TO OUTSIDE THE BOOTH WALL. IF AIR IS LEAKING, USE THE “CHICO A” COMPOUND TO SEAL LEAK. 7. AFTER COMPLETION OF ALL FIELD INSTALLATION, MAKE SURE THAT THE BOOTH WALL IS AIR TIGHT BETWEEN THE HAZARDOUS AND NON-HAZARDOUS ENVIRONMENTS. PEDESTAL MATERIAL: CHICO "A" SEAL COMPOUND WATER MIX POWDER DENSITY = 1203.5 KG/M^3 TEMPERATURE: 0 C TO 150 C NOTE: CABLES MUST BE SPACED AWAY FROM EACH OTHER AND COMPLETELY ENCLOSED IN SEALING COMPOUND INSIDE OF SEALOFF. SECTION A-A BOOTH WALL IF THIS DIMENSION EXCEEDS 18 INCHES, THEN A SECOND SEAL OFF IS REQUIRED. SEE SHEET 2 AREA FOR SEAL COMPOUND INTERCONNECT CABLES TO CONTROLLER A A OATEY #31166 PLUMBER'S PUTTY FANUC PART#: HDWMO000056797O TO BE SUPPLIED BY FIELD INSTALLATION CONTRACTOR SEAL COMPOUND NOT TO GO BEYOND SEAL-OFF FITTING [ET-6263-820-004_SHT1] CONDUIT CONNECTION INFORMATION -31- REV B1 MAROB25IB07151E REV C 3 TRANSPORTATION AND INSTALLATION Figure 3-9 ET-6263-820-004_SHT2, CONDUIT CONNECTION INFORMATION WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment IF SEAL OFF IS MORE THAN 18 INCHES FROM PEDESTAL INTERFACE REMOVE PLUG, SEE SHEET 1 AND REPLACE WITH TUBING, EO-HOSE-011-010 REF 10.0 O.D X 7.0 I.D NYLON TUBING MAXIUM LENGTH 14700mm PLACE END OF TUBE AS SHOWN. CUT TO LENGTH AS NEEDED WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. OVER 18.O INCHES TO PEDESTAL INTERFACE REFER TO PURGE SCHEMATIC DRAWING AND PURGE & CABLE ROUTING DRAWINGS FOR MORE INFORMATION UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 122 PURGE AIR INLET FITTING LOCATED IN PEDESTAL OR WALL BASE WSHLM050092012S REF M5 LOCK WASHER WALL MATERIAL: CHICO "A" SEAL COMPOUND WATER MIX POWDER DENSITY = 1203.5 KG/M^3 TEMPERATURE: 0 C TO 150 C CLPMM006002013O REF HEYCO #3324 CABLE CLAMP WALL NUTMM005080002S REF M5 X 0.8 HEX CAP NUT B RIGID CONDUIT AREA FOR SEAL COMPOUND SHHMM005080016S REF ADJUST LENGTH OF M5 X 0.8 HEX HEAD SCREW IF RIGID CONDUIT IS NOT SCHEDULE 40. APPLY PERMATEX #80724 NO MORE LEAKS HDWMO0000038860 SECURE TUBING AS SHOWN SECTION B-B SCALE 1 : 2 B INTERCONNECT CABLES TO CONTROLLER AIR FLOW EO-HOSE-011-010 REF LENGTH = 14700mm MAX. NOTE: TUBING TO BE INSTALLED WITH CABLES TO AVOID KINKING OATEY #31166 PLUMBER'S PUTTY FANUC PART#: HDWMO000056797O TO BE SUPPLIED BY FIELD INSTALLATION CONTRACTOR FITMO000001259O REF PARKER # 22-6 UNION FITTING FOR OVER 18 INCHES FROM PEDESTAL TO FITTING SEAL COMPOUND NOT TO GO BEYOND SEAL-OFF FITTING [ET-6263-820-004_SHT2] REV A CONDUIT CONNECTION INFORMATION -32- SHEET 1 OF 1 3 TRANSPORTATION AND INSTALLATION MAROB25IB07151E REV C 3.2.2 ROX Connection Figure 3-10 ET-6263-820-004_SHT3, ROX CONNECTION WARNING 4X M8 X 1.25 X 25 SOCKET HEAD CAP SCREW TORQUE : MIN. 8Nm [5.9 ft-lbs] Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment 6.7 ENET1 CABLE OPTIONAL 6.7 I.S. GROUND OPTIONAL 6.7 ENET2 CABLE OPTIONAL WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 6.7 GROUND INTERCONNECT CABLE UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 20.9 POWER 7, 8, 9, SHIELDED OPTIONAL 19.3 5V 1-9 & 24V PROCESS OPTIONAL NO CABLE 22.2 ENCODER & BATT 1-9 19.8 POWER 1-6 & BRK 1-9 8.0 PROCESS AIR LINE (BA) OPTIONAL Ø16.0 PROCESS AIR LINE (TURB) OPTIONAL 6X SHHMM006100045S TORQUE: 13.5Nm [10.0 ft-lbs] Ø16.0 PROCESS AIR LINE (SA) OPTIONAL PEDESTAL WALL BAS E SIDE PENETRATION WALL BAS E BACK PENETRATION SEAL OFF AT BOOTH WALL TO REGIONAL REQUIREMENTS (SEE NOTE 1) BOOTH WALL LEAVE PLUG IN FOR ROX CONNECTION INTERCONNECT CABLES TO THE CONTROLLER PUR GE AIR INLET FITTING LOCATED IN PEDESTAL OR WALL BASE NOTE: 1. SEAL OFF AT THE BOOTH WALL FOR ROX-TYPE CONNECTION MUST BE IN ACCORDANCE WITH REGIONAL REQUIREMENTS. (THIS OPTION CAN NOT BE USED IN NORTH AMERICA) 2. APPLY LOCTITE 242-31 HDWMO000001836O TO FASTENERS 6mm OR LARGER. 3. CABLE DESIGNATIONS AND LOCATIONS ARE THE SAME BETWEEN VARIANTS. -33- [ET-6263-820-004_SHT3] ROX CONNECTION REV B1 MAROB25IB07151E REV C 3 TRANSPORTATION AND INSTALLATION 3.2.3 Flex Field Connection Figure 3-11 EO-6263-137-000, FLEX FIELD CONNECTION WARNING EO-5133-137-002 B Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damge equipment EO-3505-137-006 CLPME000000050O TORQUE TO 15 IN-LBS EO3505-137-004B APPLY HDWMO000003886O SEALER TO THREADS PRIOR TO ASSEMBLY FITMO000001290O WARNING EE-0928-101-003 CLPME000000050O TORQUE TO 15 IN-LBS Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. SSHCM004070012S UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS CONNECT GROUND WIRE FROM HOSE ASSEMBLY AS SHOWN WALL EO3505-137-004A APPLY HDWMO000003886O SEALER TO THREADS PRIOR TO ASSEMBLY 6X SHHMM006100030S SSHCM008125012S WSHMM080140160C CONNECT GROUND WIRE FROM HOSE ASSEMBLY AS SHOWN EO-5133-137-001 B SECTION B-B NOTE: CABLES MUST BE SPACED AWAY FROM EACH OTHER AND COMPLETELY ENCLOSED IN SEALING COMPOUND INSIDE OF SEALOFF. ELECTRIC CABLE FLEX FIELD PURGE LINE (TUBEM100000013O) 92.0 FIELD INSTALLATION GUIDELINES: GROUND CABLE FOR PEDESTAL SECTION D-D WALL CUTOUT SEE NOTE 2 MATERIAL: CHICO "A" SEAL COMPOUND WATER MIX POWDER DENSITY = 1203.5 KG/M^3 TEMPERATURE: 0 C TO 150 C PEDESTAL REF. SEE CABLE & ROUTING DRAWING FOR ROUTING OF THESE LINES IN THE PEDESTAL. B 19848 MAX DETAIL C SCALE 1 : 1 378 AIR FLOW A D A WALL NUTMM005080002S WSHLM050092012S SFHCM005080012S (FITMO000001259O) SECTION A-A SCALE 1 : 1 CLPMM006002013O EXTERNAL EARTH CONNECTION FACILITY SECURE GROUND WIRE WITH M8 X 16 STAINLESS STEEL SOCKET HEAD CAP SCREW & STAR WASHER (SSHCM008125016S) (WSHMM080170000S) A EO-HOSE-011-010 LENGTH =C NOTE: TUBING TO BE INSTALLED WITH CABLES TO AVOID KINKING FITMO000001259O D INTERCONNECT CABLES TO CONTROLLER AREA FOR SEAL COMPOUND 1. PLACE ROBOT IN BOOTH. 2. LOCATE THE NEAREST LOCATION ON THE BOOTH WALL FOR CABLES TO EXIT. CUTØ 92mm HOLE AS SHOWN. 3. MOUNT ASSEMBLY TO THE BOOTH WALL AS SHOWN. 4. TO ADJUST LENGTH OF HOSE ASM. (A). REMOVE CLAMP (CLPME000000050O) FROM THE END CLOSEST TO THE WALL AND REMOVE FROM FITTING (EO3505-137-004B). CUT TO THE SMALLEST LENGTH NEEDED WITHOUT KINKS LEAVING 200mm OF WIRE. REMOVE AIR LINE FROM FITTING (FITMO000001259O), CUT TO REMOVE EXCESS LENGTH. REATTACH TO FITTING. RECONNECT HOSE ASM. TO FITTING AND SECURE CLAMP. 5. CONNECT GROUND WIRES ON BOTH ENDS OF HOSE ASSEMBLY (A) TO GROUND SCREWS AT LOCATIONS SHOWN ON DRAWING. 6. CONNECT CABLES TO CONTROLLER. 7. POWER UP THE CONTROLLER AND MANUALLY JOG THE ROBOT TO ENSURE THAT ALL THE CABLES ARE FUNCTIONING CORRECTLY. 8. SEAL THE CABLE ENTRANCE AT THE INSIDE OF THE SEAL-OFF (EO-3505-137-006) BY USING “CHICO A” COMPOUND. USE OATEY #31166 PLUMBER'S PUTTY TO ENSURE THAT THE COMPOUND DOES NOT FLOW BEYOND EITHER SIDE OF THE SEAL-OFF AS SHOWN. 9. START PURGE CYCLE AND MAKE SURE THAT THE PURGE AIR FLOWS OUT OF THE PURGE FITTING (FITMO000001259O) LOCATED INSIDE OF HOSE FITTING (EO3505-137-004B). 10. START PURGE CYCLE. VERIFY THAT THERE IS NO AIR LEAKING THRU THE SEAL-OFF (EO-3505-137-006) TO OUTSIDE THE BOOTH WALL. IF AIR IS LEAKING, USE THE “CHICO A” COMPOUND TO SEAL LEAK. 11. AFTER COMPLETION OF ALL FIELD INSTALLATION, MAKE SURE THAT THE BOOTH WALL IS AIR TIGHT BETWEEN THE HAZARDOUS AND NON-HAZARDOUS ENVIRONMENTS. NOTES: OATEY #31166 PLUMBER'S PUTTY FANUC PART#: HDWMO000056797O TO BE SUPPLIED BY FIELD INSTALLATION CONTRACTOR (CLPM006002013O) SEAL COMPOUND NOT TO GO BEYOND SEAL-OFF FITTING 1. APPLY LOCTITE 242-31 HDWMO000001836O TO FASTENERS 6mm OR LARGER LOCTITE 222-31 HDWMO000003367O TO FASTENERS 5mm OR SMALLER. Standard Hardware Descriptions FANUC Part No. SFHCM005080012S SHHMM006100030S SSHCM004070012S SSHCM008125012S WSHLM050092012S Description M5 X 0.8 X 12mm LG. Stainless Steel Socket Flat Head Screw M6 X 1.0 X 30mm LG. Stainless Steel Hex Head Machine Screw M4 X 0.7 X 12mm LG. Stainless Steel Socket Head Cap M8 X 1.25 X 12mm LG. Stainless Steel Socket Head Cap M5 Stainless Steel Lock Washer [EO-6263-137-000] FLEX FIELD CONNECTION -34- REV D SHEET 1 OF 1 3 TRANSPORTATION AND INSTALLATION MAROB25IB07151E REV C 3.2.4 No-Pour Seal Off Flex Field Connection Figure 3-12 EO-6263-138-000, FLEX FIELD CONNECTION CLPME000000050O TORQUE TO 15 IN-LBS B WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment SSHCM006100012S WSHMM064110007C CONNECT GROUND WIRE FROM HOSE ASSEMBLY AS SHOWN EO-5133-137-002 SEE NOTE 1 EO6996-138-001A CLPME000000050O TORQUE TO 15 IN-LBS 6X SSHCM006100012S WARNING EE-0928-101-003 Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. SSHCM004070012S CONNECT GROUND WIRE FROM HOSE ASSEMBLY AS SHOWN UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 6X SHHMM006100030S EO3505-137-004A APPLY HDWMO000003886O SEALER TO THREADS PRIOR TO ASSEMBLY BOOTH WALL SEE NOTE 5 EO-6996-138-002 SEE NOTE 1 B EO-5133-137-001 EO3505-137-004B APPLY HDWMO000003886O SEALER TO THREADS PRIOR TO ASSEMBLY SECTION B-B FLEX FIELD PURGE LINE 320 SEE CABLE & ROUTING DRAWING FOR ROUTING OF THESE LINES IN THE PEDESTAL. B 19840MAX DETAIL C PEDESTAL REF. ETHERNET GROUND A PWR 8-9 OPTIONAL A NUTMM005080002S 2X WSHFM050110001P SFHCM005080012S I.S. GROUND ENC CLPMM091015127O AIR FLOW PWR 1-6 A SECTION A-A EO-HOSE-011-010 LENGTH =C SEE NOTE 6 EO-9999-600-051 SEE NOTES 2,3,4 5V/24V 200±20 FIELD INSTALLATION GUIDELINES: 1. PLACE ROBOT IN BOOTH. 2. LOCATE THE NEAREST LOCATION ON THE BOOTH WALL FOR CABLES TO EXIT. 3. MOUNT ASSEMBLY TO THE BOOTH WALL AS SHOWN. 4. TO ADJUST LENGTH OF HOSE ASM. (A). REMOVE CLAMP (CLPME000000050O) FROM THE END CLOSEST TO THE WALL AND REMOVE FROM FITTING (EO3505-137-004B). CUT TO THE SMALLEST LENGTH NEEDED WITHOUT KINKS LEAVING 200mm OF WIRE. REMOVE AIR LINE FROM FITTING, CUT TO REMOVE EXCESS LENGTH. REATTACH TO FITTING. RECONNECT HOSE ASM. TO FITTING AND SECURE CLAMP. 5. CONNECT GROUND WIRES ON BOTH ENDS OF HOSE ASSEMBLY (A) TO GROUND SCREWS AT LOCATIONS SHOWN ON DRAWING. 6. CONNECT CABLES TO CONTROLLER. 7. POWER UP THE CONTROLLER AND MANUALLY JOG THE ROBOT TO ENSURE THAT ALL THE CABLES ARE FUNCTIONING CORRECTLY. 8. START PURGE CYCLE AND MAKE SURE THAT THE PURGE AIR FLOWS OUT OF THE PURGE FITTING LOCATED INSIDE OF HOSE FITTING (EO3505-137-004B). 9. AFTER COMPLETION OF ALL FIELD INSTALLATION, MAKE SURE THAT THE BOOTH WALL IS AIR TIGHT BETWEEN THE HAZARDOUS AND NON-HAZARDOUS ENVIRONMENTS. NOTES: 1. APPLY PERMATEX HI-TAC PART NO. HDWMO000001819O TO ATTACH GASKET. 2. FOR LUBRICATE OF MODULES FOLLOW ROXTEC'S INSTRUCTIONS SUPPLIED WITH ASSEMBLY. 3. USE ROX SLIDE CALIPER# TOOLROXCALIPER TO DETERMINE PROPER NUMBER OF LAYERS TO REMOVE. 4. TORQUE NUTS TO APPROXIMATLY 6-7 N-M. 5. USE BOOTH WALL OPENING TEMPLATE (EG-00850) FOR HOLE PATTERN 6. ENUSRE PURGE AIR TUBING (EO-HOSE-011-010) HAS ENOUGH SLACK SO FLEX FIELD TUBING (ITEM A) CAN PULLED OFF THE FITTING (EO3505-137-004B) FAR ENOUGH FOR THE PURGE AIR TUBING TO BE DISCONNECTED FROM ITS FITTING (CLPMM091015127O). ALSO, WHEN INSTALLING PURGE AIR TUBING WITH CABLES, AVOID ANY KINKING -35- ASSEMBLY PART NO. DESCRIPTION PART # (A) EO6263-134-000A EO6263-134-000B 10M FLEX FIELD LENGTH 15M FLEX FIELD LENGTH EO3505-137-005A EO3505-137-005B LENGTH (B) 9840mm MAX 14840mm MAX 10100mm 15100mm EO6263-134-000C 20M FLEX FIELD LENGTH EO3505-137-005C 19840mm MAX 20100mm EO6263-134-000D EO6263-134-000E 5M FLEX FIELD LENGTH 4M FLEX FIELD LENGTH EO3505-137-005D EO3505-137-005E 4840mm MAX 4000.0mm MAX 5100mm 4250mm [EO-6263-134-000] FLEX FIELD / ROX CONNECTION LENGTH (C) REV B3 SHEET 1 OF 1 MAROB25IB07151E REV C 3 -36- TRANSPORTATION AND INSTALLATION 4 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C CONNECTING THE END OF ARM TOOLING -37- MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING 4.1 Metal Outer Arm Interface (P-250iB/15) Figure 4-1 ET-6263-820-002_SHT7, PAYLOAD & PROCESS INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING ARM PROCESS CABLE & HOSE PENETRATION THRU THIS PLATE Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS J3 INNER ARM J1 TURRET PROCESS CABLE & HOSE PENETRATION THRU THIS PLATE (BOTH SIDES OF TURRET) J2 ALUMINUM BASE PROCESS CABLE & HOSE PENETRATION THRU THIS PLATE IRON PEDESTAL PROCESS CABLE & HOSE PENETRATION SIDE OPTION (BOTH SIDES) PROCESS CABLE & HOSE PENETRATION REAR OPTION REQUIREMENTS FOR CUSTOMER SUPPLIED PROCESS HARDWARE INSIDE INNER ARM: 1. Use only FANUC America Corporation-supplied cable & hose bundles in the following areas: • Bundles routed inside the purged robot arm through robot joints (J1, J2, J3) • Bundles routed through the purged / hazardous penetrations indicated. 2. Unused air lines inside the inner arm must be capped with fittings: 3. See electrical manual for electrical requirements. [ET-6263-820-002_SHT7] PAYLOAD & PROCESS INTERFACE -38- REV G 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C Figure 4-2 ET-6263-820-002_SHT1, PAYLOAD & INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment AXIS 4 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Z UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 15 Kg MAX J3 PAYLOAD 700 MAX R250 MAX AXIS 5 J3 PAYLOAD REF AXIS 6 X, Y 15 Kg MAX WRIST PAYLOAD 15 Kg MAX J2 PAYLOAD J2 PAYLOAD REF R290 MAX 700 MAX 5 Kg MAX J1 PAYLOAD R375 MAX WRIST PAYLOAD AXIS MAX MOMENT (Nm) MAX INERTIA (kg m^2) 4 5 6 65 55 7.4 3.0 2.1 0.07 NOTE: REFER TO EG-00574 P-250iB OPEN ARCHITECTURE FOR PROCESS HARDWARE [ET-6263-820-002_SHT1] PAYLOAD & INTERFACE -39- REV F3 SHEET 1 OF 1 MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING Figure 4-3 ET-6263-820-002_SHT2, WRIST INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 5.012 + 0.012 0 10.0 0.36 A B 70° 0 - 0.05 0.1 A B A 110 + 0.05 0 0.1 A B 73 6X 60° 100 B 12 6X M5 X 0.8 12.0 0.36 A B 68 HOLLOW PAS SAGE [ET-6263-820-002_SHT2] WRIST INTERFACE -40- REV C SHEET 1 OF 1 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C Figure 4-4 ET-6263-820-002_SHT3, OUTER ARM INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment AXIS 4 CENTER OF ROTATION WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 90 10 7.5 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 68.0 HOLLOW PASSAGE NO PROCESS MOTOR SECTION A-A 35 NO PROCESS MOTORS 155 660 8X M6 X1.0 44 440 6 PROCESS AXIS MAX TORQUE = 21.3 Nm CONTINUOUS TORQUE = 5.5 Nm MAX SPEED = 500 RPM 220 390 A 172 72 B 144 41 9X B 6.85 THRU 2X 172 +0.012 5.985 0.000 THRU A 54 230.0 227.0 887.4 202.0 SECTION A-A (1) PROCESS MOTORS 5 h8 16 j6 155.0 c 119.0 PROCESS AXES (2) MAX TORQUE = 21.3 Nm CONTINUOUS TORQUE = 5.5 Nm MAX SPEED = 500 RPM 44 83.0 21.5 18 21 c 36.0 155 SECTION B-B SCALE 1 : 4 4X M10 X1.5 20 BOTH SIDES 11.0 8.0 0 35 41 PROCESS PLATE MOUNTING DIMENSIONS 90 7.5 SECTION A-A (2) PROCESS MOTORS [ET-6263-820-002_SHT3] OUTER ARM INTERFACE -41- REV E1 MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING 4.2 Plastic Outer Arm (P-250iB/15P) Interface Figure 4-5 ET-6263-820-002_SHT7, PAYLOAD & PROCESS INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment ARM PROCESS HOSE PENETRATION THRU THIS PLATE WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. J3 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS J1 INNER ARM TURRET PROCESS CABLE & HOSE PENETRATION THRU THIS PLATE (BOTH SIDES OF TURRET) J2 IRON PEDESTAL ALUMINUM WALL BASE PROCESS CABLE & HOSE PENETRATION PROCESS CABLE & HOSE PENETRATION SIDE OPTION (BOTH SIDES) PROCESS CABLE & HOSE PENETRATION REAR OPTION REQUIREMENTS FOR CUSTOMER SUPPLIED PROCESS HARDWARE INSIDE INNER ARM: 1. USE ONLY FANUC AMERICA CORPORATION SUPPLIED CABLE & HOSE BUNDLES IN THE FOLLOWING AREAS: • BUNDLES ROUTED INSIDE THE PURGED ROBOT ARM THROUGH ROBOT JOINTS (J1, J2, J3) • BUNDLES ROUTED THROUGH THE PURGED / HAZARDOUS PENETRATIONS INDICATED. 2. UNUSED AIR LINES INSIDE THE INNER ARM MUST BE CAPPED WITH FITTINGS 3. SEE ELECTRICAL MANUAL FOR ELECTRICAL REQUIREMENTS. [ET-6263-821-002_SHT6] REV A CUSTOMER HARDWARE INSIDE ARM -42- SHEET 1 OF 1 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C Figure 4-6 ET-6263-821-002_SHT1, PAYLOAD & INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING 62.0 HOLLOW PASSAGE THROUGH WRIST Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 84 +Z UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 15 Kg MAX J3 PAYLOAD 700 MAX lcgxx lcgyy lcgzz 5.012+0.012 0.000 +X 52 7.6 62.00 6X M6X1.0 12.5 PAYLOAD C.G. 35° +Y 5° 6X 60° PLASTIC WRIST INTERFACE Z (mm) 825 J2 PAYLOAD REF R322 MAX MAX SPEED: 1200 mm/s 15 Kg MAX J2 PAYLOAD 3 kg 785 557 438 367 315 700 MAX 6 kg 528 9 kg 12 kg 15 kg 414 346 300 5 Kg MAX J1 PAYLOAD R375 MAX X,Y (mm) NOT TO SCALE WRIST PAYLOAD P-250iB/15P SLED OUTER ARM ONLY AXIS MAX MOMENT (Nm) MAX INERTIA (kg m^2) 4 5 6 68 57 7.4 3.2 2.2 0.07 NOTE: REFER TO EG-00574 P-250iB OPEN ARCHITECTURE FOR PROCESS HARDWARE [ET-6263-821-002_SHT1] PAYLOAD & INTERFACE -43- REV A SHEET 1 OF 1 MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING Figure 4-7 ET-6263-821-002_SHT2, OUTER ARM INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment 4X M4x0.7 20 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. A UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 2X 11.0 74.0 63.0 51.0 40.0 C L WRIST 0 4X 31.0 4X91.0 4X 18.5 22X M6x1.0 THRU 2X 64.0 4X 73.5 A SECTION A-A NO PROCESS MOTORS SURFACE IN-LINE WITH CENTER OF AXIS 3 36.0 4x 10mm 8.0 3x 6mm 13x 4mm C LWRIST 62.0 AIR MANIFOLD SECTION A-A 1 PROCESS MOTOR SECTION A-A 2 PROCESS MOTORS [ET-6263-821-002_SHT2] OUTER ARM INTERFACE -44- REV A SHEET 1 OF 1 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C 4.3 Inner Arm Interface Figure 4-8 ET-6263-820-002_SHT4, INNER ARM INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 75 4X M16 X 2.0 -6H THD. 40 190 5X M6 X 1.0 -6H THD. 15 (SUB PLATE MTG) 65 95 138 M8 X 1.25 -6H THD. 17 3 HOLES 2 PLACES 115 540 1280 960 260 65 130 740 125.0 2.5° 490 385 320 135 60 3/8 BSPP THD. (EXHAUST PORT) 144 140 [ET-6263-820-002_SHT4] INNER ARM INTERFACE -45- REV D2 MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING 4.4 Turret Interface Figure 4-9 ET-6263-820-002_SHT5, TURRET INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment 120.0 4X 6.85 THRU WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. 94.0 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS PROCESS PLATE MOUNTING DIMENSIONS 2X +0.015 8.015 0.000 10 100 3X M12X1.75 - 6H 24.0 14 1X M12X1.75 - 6H 105.5 340 340 235.7 119 REF 119 REF 33 33 3.9 SCREW PROTRUSION 50 143 REF 480 143 REF 198 198 3X M12X1.75 - 6H 24 [ET-6263-820-002_SHT5] TURRET INTERFACE -46- REV E2 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C 4.5 Iron Pedestal Interface Figure 4-10 ET-6263-820-003_SHT2, FLOOR MOUNT LOADING WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment 2x 500.0 M20 X 2.5 BOLT BLACK PARTIALLY THREADED DIN 912 GRADE 12.9 TORQUE TO 546 N-m [4830 IN-LB] 2x 250.0 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. FRONT OF PEDESTAL A M20 LOCK WASHER PLATED DIN 7980 M20 TP200 WASHER ZINC PLATED DIN 125A A UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS PEDESTAL 242.0 50.0 MINIMUM ENGAGEMENT 2X 280.0 STEEL OR ALUMINUM 30,000 PSI MIN. YIELD M20 X 2.5 - 6H THD. 2x 560.0 0.0 SECTION A-A (FLOOR, ANGLE, WALL, OR INVERT MOUNT) 8X LOCATING SURFACES [3/4-10] ASTM A 563 GRADE DH NUT TORQUE TO 150 FT-LBS 203 N-m) 242.0 HILTI #HAS-E 3/4-10 x 10 LG THREADED ROD [3/4"] ASTM F 436 HARDENED FLAT WASHER ZINC PLATED ANSI B18.22.1 TYPE A PEDESTAL CONCRETE MINIMUM CONCRETE CAPACITY Fc=2000 PSI (13.8 MPa) 6.75 171.5 MINIMUM ENGAGEMENT SECTION A-A NOTES: 1. FOLLOW HILTI INSTALLATION INSTRUCTIONS PER PRODUCT TECHNICAL GUIDE HIT RE 500 EPOXY ADHESIVE ANCHOR 4.2.6 FILL HOLE APPROXIMATLEY 1/2 TO 1/3 FULL OF HILTI ADHESIVE RE 500. APPORXIMATE ADHESIVE VOLUME REQUIRED PER ANCHOR = 6.75 IN X 0.326IN^3/IN = 2.2 IN^3. CLEAN OIL FROM STUD AND NUT. (FLOOR MOUNT ONLY) 2. HILTI INSTALLATION IS FOR FLOOR MOUNT ONLY. [ET-6263-820-003_SHT2] FLOOR MOUNT LOADING -47- REV B2 MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING Figure 4-11 ET-6263-820-003_SHT3, FLOOR MOUNT LEVELING JACK WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment 2x 495.0 2x 250.0 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. FRONT OF PEDESTAL UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 242.0 2x 280.0 UNBRAKO 1/2-13 X 4.75"LG 1960 SERIES SHCS TORQUE TO 161 N-m [1420 IN-LB] (EO-0989-140-008) 0.0 2x 555.0 1"-14 UNS-2B THD. 47.6 22.0 242.0 19.6 12.7 [0.77 0.50] 1.77 45.0 BOOTH STRUCTURE TO BE PROVIDED BY OTHERS 6.4 [.25] TYP. ALL FEET MAT'L 1018 STL. 6.4 [.25] DETAIL A LEVELING JACK OPTION (FLOOR MOUNT ONLY) A INSTALL WITHIN [0.002 IN] PER FOOT NOTE: 1. LEVELING JACK OPTION IS FOR FLOOR MOUNT ONLY. [ET-6263-820-003_SHT3] FLOOR MOUNT LEVELING JACK -48- REV B 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C 4.6 Aluminum Wall Base Interface Figure 4-12 ET-6263-820-002_SHT6, PAYLOAD & INTERFACE WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 303 3x M8x1.25 x +0.015 10.015 0.000 2x 125 16.0 15.0 145 85 85 125 145 2x +0.015 10.015 0.000 15.0 52.5 105 3x M8x1.25 x 16.0 355 [ET-6263-820-002_SHT6] PAYLOAD & INTERFACE -49- REV D2 MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING Figure 4-13 ET-6263-820-003_SHT5, WALL BASE LOADING WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS A M20 X 2.5 BOLT PARTIALLY THREADED DACROMET COATED DIN 912 GRADE 12.9 TORQUE TO 546 N-m [4830 IN-LB] A 275.0 M20 NORD-LOCK WASHER ZINC PLATED WALL BASE 95.0 45.0 MINIMUM ENGAGEMENT 2X 610.0 0 STEEL OR ALUMINUM 30,000 PSI MIN. YIELD FRONT OF WALL BASE 95.0 M20 X 2.5 - 6H THD. SECTION A-A (WALL OR SHELF MOUNT) 2X 305.0 275.0 8X LOCATING SURFACES 2X 205.0 2X 410.0 [ET-6263-820-003_SHT5] WALL BASE MOUNTING INTERFACE -50- REV C1 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C 4.7 Foot Loads 4.7.1 Metal Outer Arm (P-250iB/15) Figure 4-14 ET-6263-820-003_SHT6, FOOT LOADS WARNING Fz Fz Mz Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment Fy Mz Mx WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Fy Fx My Fz My UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS Mx Mz Fz g Mz g g Fx WALL MOUNT ALUMINUM BASE Fz g Mx g Fy Mx My Fx FLOOR MOUNT IRON PEDESTAL Fx SHELF MOUNT ALUMINUM BASE INVERT MOUNT IRON PEDESTAL Mz Fy Fy My 30° Fx Fz Mx Mz My Fy Fx Product Fy g Mx My g Mount Floor & Invert 45 Deg Pitch Iron pedestal Angle 30 Deg Roll Angle Fx ANGLE MOUNT IRON PEDESTAL HORIZONTAL PLANE ANGLE MOUNT ALUMINUM BASE Mz Fz My Mx Wall WALL MOUNT IRON PEDESTAL Shelf 30 Deg Aluminum Roll Angle base Wall LOADS ON THE SUPPORT STRUCTURE AT THE ROBOT BASE (3) Max dynamic (2) Max gravity (1) Mx (Nm) My (Nm) Mz (Nm) Fx (N) Fy (N) Fz (N) Mx (Nm) My (Nm) +11,930 +11,930 +8,430 +4,440 +4,440 -1,450 +3,120 +3,120 -11,930 +11,910 -11,930 +16,710 -8,430 +7,500 -4,440 +8,580 -4,440 +4,370 -10,180 +220 -3,120 +3,120 -3,120 +5,730 -11,910 +15,270 -7,050 +11,920 -7,500 +6,580 -220 +4,370 -4,370 +1,440 -8,520 -710 -3,120 +4,930 -400 +3,120 -8,490 +8,370 -8,370 +11,420 -11,420 +14,150 -11,840 +18,690 -5,070 +16,290 -8,400 +15,530 -8,140 +11,880 -11,880 +10,650 -10,650 +8,320 -4,370 +4,370 -4,370 +4,440 -4,440 +4,370 -7,300 +4,370 -4,370 +4,440 -4,440 +1,510 -9,450 -1,530 -10,260 -1,290 -10,030 -580 -1,210 +3,100 -3,100 +3,120 -3,120 +4,430 +50 +6,810 +1,240 +5,800 -330 +5,830 -8,580 +16,950 -5,320 -8,750 +12,480 -2,510 -11,120 +10,480 -10,480 -4,370 +4,370 -4,370 -7,220 +4,370 -4,370 -9,310 -1,370 -10,110 -1,700 +5,810 +240 +2,760 +5,830 -190 Fz (N) -5,820 -5,870 -5,870 -5,900 -5,660 -5,700 -5,740 Notes 1. Coordinate system for angle mount gravity loads is rotated about Y-axis so that Z-axis is vertical. 2. Max dynamic includes gravity 3. Foot loads include max rated payloads on arms & wrist. [ET-6263-820-003_SHT6] -51- REV H SHEET 1 OF 1 MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING 4.7.2 Plastic Outer Arm (P-250iB/15P) Figure 4-15 ET-6263-821-003_SHT6, FOOT LOADS WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment Fz Mz WARNING Mx Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Fy Fz Fx My Mz UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS Fz g Fz Fz Mz Mz Mx g Fy Fy Fx My g Mx FLOOR MOUNT IRON PEDESTAL Fx INVERT MOUNT IRON PEDESTAL Mx Fy Fy g My Fx My SHELF MOUNT ALUMINUM BASE WALL MOUNT ALUMINUM BASE Fz Mz Mz Fz Mx My Fx Fy Fy g Mx My g Fx ANGLE MOUNT IRON PEDESTAL WALL MOUNT IRON PEDESTAL [ET-6263-821-003_SHT6] FOOT LOADS -52- REV A 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C 4.8 Robot Payload Setting 4.8.1 Overview Robot payload is the weight of the robot end-of-arm tooling and work piece. If you have not set up the proper robot payload during software installation, or if you need to change the robot payload because you have changed end-of-arm tooling or the work piece, you must set the robot payload. Note Be sure to set payload values as accurately as possible. The more accurate the values, the more effective features such as Collision Guard will be. Note More accurate values can also improve position accuracy and cycle time. You can define up to ten different payload schedules. You can then specify a payload schedule by using the payload setup screens and by using the payload teach pendant program instructions. You can set up payload schedules from the MOTION PERFORMANCE screen. Refer to Section 4.8.2 for more information on the payload teach pendant program instructions. 4.8.2 Setting the Active Payload Schedule You can set the active payload schedule: • Manually (Procedure 4-1 ) • In a teach pendant instruction ( Procedure 4-2 ) Refer to Table 4-1 through Table 4-4 for information on each Payload screen item. Table 4-1 MOTION PERFORMANCE Screen Items ITEM No. PAYLOAD[kg] Comment DESCRIPTION This item displays the payload schedule number. This item displays the payload in kilograms. This item displays any comments associated with each payload schedule. -53- MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING Table 4-2 MOTION/PAYLOAD SET Screen Items ITEM Schedule No [ ] PAYLOAD Units: kg PAYLOAD CENTER X Units: cm PAYLOAD CENTER Y Units: cm PAYLOAD CENTER Z Units: cm PAYLOAD INERTIA X Units: kgfcms^2 PAYLOAD INERTIA Y Units: kgfcms^2 PAYLOAD INERTIA Z Units: kgfcms^2 DESCRIPTION This item displays the payload schedule number. This item is the weight of the end-of-arm tooling.Note : There are 2.21 pounds in a kilogram. This item is the up and down offset of the payload center of gravity from the center of the faceplate. Positive (+) values are up. There are 0.39 inches per centimeter. This item is the side offset of the payload center of gravity from the center of the faceplate. Positive (+) values are to the right of the faceplate when viewed from behind the faceplate. There are 0.39 inches per centimeter. This item is the offset of the payload center of gravity from the center of the faceplate. Positive (+) values are out from the faceplate. There are 0.39 inches per centimeter. This item is the moment of inertia of the payload around an axis parallel to the X-direction for the tool frame and through the center of gravity of the payload. This item is the moment of inertia of the payload around an axis parallel to the Y-direction for the tool frame and through the center of gravity of the payload. This item is the moment of inertia of the payload around an axis parallel to the Z-direction for the tool frame and through the center of gravity of the payload. Procedure 4-1 Manually Setting the Active Payload Schedule Note You cannot update payload values when a program is running or if the active schedule number is the same as the schedule you want to modify. Conditions • SRDY is on. • No motion commands have been issued. • $PARAM_GROUP[].$MOUNT_ANGLE has not been set. • Robot mastering/calibration has been performed. Steps 1. Press MENUS. 2. Select SYSTEM. 3. Press F1, [TYPE]. 4. Select Motion. You will see a screen similar to the following -54- 4 CONNECTING THE END OF ARM TOOLING MOTION PERFORMANCE Group 1 No. PAYLOAD[kg] Comment 1 120.00 [ 2 120.00 [ 3 120.00 [ 4 120.00 [ 5 120.00 [ 6 120.00 [ 7 120.00 [ 8 120.00 [ 9 120.00 [ 10 120.00 [ Active PAYLOAD number = 1 MAROB25IB07151E REV C ] ] ] ] ] ] ] ] ] ] 5. To set the active payload, you must do the following: a. Press PREV until the payload schedule listing screen is displayed. b. Press F5, SETIND. Note If you see the message, "Running program already exists," you will not be able to change the index. You cannot change the index when a teach pendant program is running. Check whether any teach pendant program is running and abort it, if possible. Then, repeat the step. c. Type the number of the payload schedule you want and press ENTER. Procedure 4-2 Using Teach Pendant Instructions to Set the Active Payload Schedule Note Some applications and the Collision Guard function require the proper setting of payload information. If the payload changes during your application, you must use the PAYLOAD[x] instruction to select the appropriate payload schedule. Note The PAYLOAD[x] instruction allows you to specify the payload schedule to use. You can specify up to 10 different sets of payload information. Each set of payload information corresponds to a schedule number. Conditions You have set up the payload schedule that corresponds to the one you specify. For a multi-group application, you must use the PAYLOAD[GPx:y] instruction to select the appropriate payload schedule, y, for the specified motion group, x. Refer to the Program Elements for details on the PAYLOAD[GPx:y] instruction. Steps 1. Edit the teach pendant program in which you want to include PAYLOAD instructions. a. Press NEXT, until F2, [INST], is displayed then press F2, [INST]. b. Select Payload and press ENTER. c. Select PAYLOAD[...] and press ENTER. 2. Type the value of the of the payload schedule: • Direct - type a schedule number and press ENTER. • Indirect - select INDIRECT, type a register number, and press ENTER. -55- MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING 4.8.3 Setup of Payload Schedules There are two ways of setting the payload schedule parameters: • Manual entry - Refer to Procedure 4-3 for more details. • Automatic estimation - Refer to Procedure 4-4 for more details. Note Automatic robot payload estimation is available for some robot models. If your robot model does not have the payload setting feature, the message, "IDENT is not supported to this robot," will be displayed when you press F2, IDENT. If you change any mechanical parts on the robot, such as a motor, you need to perform payload calibration before payload estimation. If you do not want to perform payload estimation, but want to return the payload settings to the default values, you can reset them to the default values. Table 4-3 lists the items on the Motion/Payload ID screen. Table 4-4 lists the items on the Motion/ID POS1 ID screen. Use Procedure 4-3 to set up the Robot Payload Schedule. Table 4-3 MOTION/PAYLOAD ID Items ITEM PAYLOAD ESTIMATION MASS IS KNOWN CALIBRATION MODE CALIBRATION STATUS DESCRIPTION This item allows you to estimate payload automatically. This item allows you to set whether or not the mass is known and the value, ranging from 0 to 999.99 kg. This item allows you to calibrate the robot. This item indicates whether the robot has been calibrated. -56- 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C Table 4-4 MOTION/ID POS1 ID Items ITEM POSITION FOR ESTIMATION J5 Default: -90.000 J6 Default: -90.000 SPEED Range: 1% - 100% Low default: 1% High default: 100% ACCL Range: 1% - 100% Low default: 1% High default: 100% DESCRIPTION This item can be changed, depending on whether you want to use POSITION1 or POSITION2 for estimation. This item displays the J5 robot position. This item displays the J6 robot position. This item displays the Low and High speeds. This item displays the Low and High acceleration rates. Procedure 4-3 Manually Setting Robot Payload Schedule Note You cannot update payload values when a program is running and the active schedule number is the same as the schedule you want to modify. Conditions • SRDY is on. • No motion commands have been issued. • $PARAM_GROUP[].$MOUNT_ANGLE has not been set. • Robot mastering/calibration has been performed. • The active payload schedule is set. Refer to Section 4.8.2 . Steps 1. Press MENUS. 2. Select SYSTEM. 3. Press F1, [TYPE]. 4. Select Motion. You will see a screen similar to the following. -57- MAROB25IB07151E REV C 4 MOTION PERFORMANCE Group 1 No. PAYLOAD[kg] Comment 1 120.00 [ 2 120.00 [ 3 120.00 [ 4 120.00 [ 5 120.00 [ 6 120.00 [ 7 120.00 [ 8 120.00 [ 9 120.00 [ 10 120.00 [ Active PAYLOAD number = 1 CONNECTING THE END OF ARM TOOLING ] ] ] ] ] ] ] ] ] ] 5. To set up payload information manually for the schedule you chose, move the cursor the payload schedule you want and press F3, DETAIL. You will see a screen similar to the following. MOTION/PAYLOAD SET Group 1 1 Schedule No[ 1]: 2 PAYLOAD 3 PAYLOAD CENTER X 4 PAYLOAD CENTER Y 5 PAYLOAD CENTER Z 6 PAYLOAD INERTIA X 7 PAYLOAD INERTIA Y 8 PAYLOAD INERTIA Z [******************] [kg] 120.00 [cm] 30.00 [cm] 25.00 [cm] 25.00 [kgfcms^2] 77.00 [kgfcms^2] 306.00 [kgfcms^2] 306.00 a. To display help for the items on the screen, press F5, HELP. To display more information, use the arrow keys. When you are finished displaying help information, press PREV. b. To set the value, move the cursor to the items you want to set and set them as desired. When you set payload, you set the values of several items related to payload. Refer to Table 4-5 for a short description of the items you must set. Direction is relative to the robot tool frame with x, y, z, w, p, and r set to zero and robot joint angles at the zero positions. Refer to Figure 4-18 for additional equations used to calculate payload inertias. -58- 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C Table 4-5 SYSTEM Payload Screen Payload (kg) This item is the weight of the end-of-arm tooling. There are 2.21 pounds in a kilogram. Payload Center X (cm) This item is the up and down offset of the payload center of gravity from the center of the faceplate. Positive (+) values are up. There are 0.39 inches per centimeter. Payload Center Y (cm) This item is the side offset of the payload center of gravity from the center of the faceplate. Positive (+) values are to the right of the faceplate when viewed from behind the faceplate. There are 0.39 inches per centimeter. Payload Center Z (cm) This item is the offset of the payload center of gravity from the center of the faceplate. Positive (+) values are out from the faceplate. There are 0.39 inches per centimeter. Payload Inertia X (kgfcm s 2 ) This item is the moment of inertia of the payload around an axis parallel to the X-direction for the tool frame and through the center of gravity of the payload. Payload Inertia Y (kgfcms 2 ) This item is the moment of inertia of the payload around an axis parallel to the Y-direction for the tool frame and through the center of gravity of the payload. Payload Inertia Z (kgfcms 2 ) This item is the moment of inertia of the payload around an axis parallel to the Z-direction for the tool frame and through the center of gravity of the payload. Arm load axis #1 (kg) This item is the additional weight mounted to axis 1. Arm load axis #3 (kg) This item is the additional weight mounted to axis 3. -59- MAROB25IB07151E REV C 4 Figure 4-16 Inertia Formula Example -60- CONNECTING THE END OF ARM TOOLING 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C Figure 4-17 Inertia Equations 6. To select a different motion group, press F2, GROUP, and specify the motion group you want. 7. To select a different schedule number, press F3, NUMBER, and enter the number of the payload schedule for which you want to set up payload information manually. 8. To set payload values to the default values set at FANUC America Corporation, press and hold SHIFT and press F4, DEFAULT, and then perform one of the following: • To confirm the change to the factory default values, press F4, YES. • To cancel the default settings and return to the previous settings, press F4, NO. -61- MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING Procedure 4-4 Automatic Payload Estimation Note You cannot update payload values when a program is running and the active schedule number is the same as the displayed schedule you want to modify. Conditions • SRDY is on. • No motion commands have been issued. • $PARAM_GROUP[].$MOUNT_ANGLE has not been set. • Robot mastering/calibration has been performed. Steps 1. Press MENUS. 2. Select SYSTEM. 3. Press F1, [TYPE]. 4. Select Motion. You will see a screen similar to the following. MOTION PERFORMANCE Group 1 No. PAYLOAD[kg] Comment 1 120.00 [ 2 120.00 [ 3 120.00 [ 4 120.00 [ 5 120.00 [ 6 120.00 [ 7 120.00 [ 8 120.00 [ 9 120.00 [ 10 120.00 [ Active PAYLOAD number = 1 ] ] ] ] ] ] ] ] ] ] Note Automatic robot payload estimation is available for some robot models. If your robot model does not have the payload setting feature, the message, "IDENT is not supported to this robot," will be displayed when you presscF2, IDENT. 5. To perform automatic payload estimation: a. Press PREV until the payload schedule listing screen is displayed. b. Press NEXT, >, and then press F2, IDENT. You will see a screen similar to the following. -62- 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C MOTION/PAYLOAD ID Group 1 Schedule No[ 1]: [****************] 1 PAYLOAD ESTIMATION ********** Previous Estimated value (Maximum) Payload [Kg] : 0.00 ( 165.00)**** Axis Moment [Nm] J4: 0.00E+00 ( 9.02E+02) J5: 0.00E+00 ( 9.02E+02) J6: 0.00E+00 ( 4.41E+02) Axis Inertia [Kgf cm^2] J4: 0.00E+00 ( 8.82E+05) J5: 0.00E+00 ( 8.82E+05) J6: 0.00E+00 ( 4.41E+05) 2 MASS IS KNOWN [NO ] 165.000 [Kg] 3 CALIBRATION MODE [OFF] 4 CALIBRATION STATUS c. Check the calibration status: • If the status is DONE, continue to Step 7 . • If the status is not DONE, you must perform payload calibration first. Refer to Step 6 . 6. If calibration status is not DONE, perform the following steps for Payload Calibration: Note If the calibration values for the robot are known, they may be entered directly into the system variables. The values are entered at $PLCL_GRP [n] .$TRQ_MGN []. Set the proper values for each axis. When this is done, set $PLCL_GRP [n] .$CALIB_STAT=1. Note If axis 5 or axis 6 motors are replaced, the robot must be re-calibrated. To ensure that this is done, set $PLCL_GRP[n].$CALIB_STAT=0, when one of these motors are replaced. This will change the calibration status from DONE, back to ****. After calibration is completed, $PLCL_GRP[n].$CALIB.STAT will be set to 1. CAUTION: Do not use calibration data from a different robot. Otherwise, estimation might become inaccurate. a. Make sure that the end-of-arm tooling is not attached to the robot arm. CAUTION: Make sure the end-of-arm tooling is not attached to the robot arm. Otherwise, payload calibration will not be correct. b. Jog the robot to the position of the calibration. The suggested position for calibration is the zero position for all axes. Note When the calibration is executed, the J5 and J6 axes move between POS1 and POS2, set on the ID POS1 and ID POS2 screens. Axes 1-4 will not move during calibration. c. For calibration, the values of POS1 and POS2 must be set to the default. d. Press NEXT, >, and then press F4, DETAIL. You will see a screen similar to the following. -63- MAROB25IB07151E REV C 4 MOTION/ID POS1 Group 1 1 POSITION for ESTIMATION POSITION1 J1 <**********> J2 <**********> J3 <**********> J4 <**********> 2 J5 < -90.000> 3 J6 < -90.000> J7 <**********> J8 <**********> J9 <**********> 4 SPEED Low < 1%> High <100%> 5 ACCEL Low <100%> High <100%> e. Press F2, POS2. You will see a screen similar to the following. MOTION/ID POS2 Group 1 1 POSITION for ESTIMATION POSITION2 J1 <**********> J2 <**********> J3 <**********> J4 <**********> 2 J5 < 90.000> 3 J6 < 90.000> J7 <**********> J8 <**********> J9 <**********> 4 SPEED Low < 1%> High <100%> 5 ACCEL Low <100%> High <100%> Note: Speed and accel must be set to DEFAULT. The default values are shown on the above screen. f. Press F3, DEFAULT. g. Press PREV until the PAYLOAD ID screen is displayed. h. Move the cursor to CALIBRATION MODE and press F4, ON. Note After calibration has been performed, CALIBRATION MODE automatically turns OFF. CAUTION: Do not change the CALIBRATION MODE during the calibration estimation process. Otherwise, the calibration will be incorrect or incomplete. i. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. j. Move the cursor to Calibration Status. k. Press F4, EXEC. You will see a screen similar to the following. -64- CONNECTING THE END OF ARM TOOLING 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C Robot moves and estimates. Ready? YES NO WARNING: In the next step, the robot will move. Make sure all personnel and unnecessary equipment are out of the workcell and that all safeguards are in place; otherwise, you could injure personnel or damage equipment. l. Decide whether to run the calibration: • To run the calibration, press F4, YES. • To cancel the calibration, press F5, NO. When the robot has stopped moving, the payload calibration has been completed and you can continue to payload estimation. 7. Continue the automatic payload estimation: a. Jog the robot to the position of the estimation. CAUTION: If calibration status is not DONE, you must perform calibration ( Step 6 ) before payload estimation. If you do not perform calibration first, the payload estimation will be incorrect. Note When the estimation is executed, the J5 and J6 axes move between POS1 and POS2, set on the ID POS1 and ID POS2 screens, and the other axes keep the current positions. ( Step 7f and Step 7h ) Note If the axis of J5 rotation is vertical (J4 is at ±90 degrees), the estimation cannot be done. Make sure that the axis of J5 rotation is as horizontal as possible. b. Press F3, NUMBER, and enter the number of the payload schedule for which you want to perform payload estimation. c. If the mass of the payload is known, move the cursor to MASS IS KNOWN, select YES, type the mass of the payload, and press ENTER. Note Specifying the value of the mass is recommended. d. A good estimation needs the following conditions: • The range of J5 between POS1 and POS2 is 180 degrees. • The range of J6 between POS1 and POS2 is 180 degrees. • The x and/or y CG values of the payload to be estimated must be significant for the payload to be a viable candidate for estimation. If both the x and y values are near or at zero the estimation might be inaccurate. See Figure 4-19 for more detail. .• POS1 and POS2 are recommended to be set such that the (user-estimated) center of gravity (CG) will be on the plane formed by the axis of rotation of J5 and the axis or rotation of J6. See Figure 4-20 . -65- MAROB25IB07151E REV C 4 Figure 4-18 Valid Payload Configuration for Accurate Estimation Figure 4-19 J5 and J6 Orientation for POS1 e. Press NEXT, >, and then press F4, DETAIL. You will see a screen similar to the following. -66- CONNECTING THE END OF ARM TOOLING 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C MOTION/ID POS1 Group 1 1 POSITION for ESTIMATION POSITION1 J1 <**********> J2 <**********> J3 <**********> J4 <**********> 2 J5 < -90.000> 3 J6 < -90.000> J7 <**********> J8 <**********> J9 <**********> 4 SPEED Low < 1%> High <100%> 5 ACCEL Low <100%> High <100%> f. Perform one of the following: • Type the angle of each axis of POS1 (in degrees),or • Jog axes J5 and J6 to the position you want to record as POS1 and press SHIFT and F5, RECORD, to record the J5 and J6 axis positions. g. Press F2, POS.2. You will see a screen similar to the following. MOTION/ID POS2 Group 1 1 POSITION for ESTIMATION POSITION2 J1 <**********> J2 <**********> J3 <**********> J4 <**********> 2 J5 < 90.000> 3 J6 < 90.000> J7 <**********> J8 <**********> J9 <**********> 4 SPEED Low < 1%> High <100%> 5 ACCEL Low <100%> High <100%> h. Perform one of the following: • Type the angle of each axis of POS2 (in degrees),or • Jog axes J5 and J6 to the position you want to record as POS2 and press SHIFT and F5, RECORD, to record the J5 and J6 axis positions. i. The high and low accel values (item 5 on the previous Motion/ID POS1 screen) can be modified, under certain conditions, to optimize estimation. If the actual mass of the payload is less than the maximum for the robot model, then refer to Figure 4-21 for the equation to calculate the new values. -67- MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING Figure 4-20 Acceleration Equation • If calculated values exceed the maximum value of 255, set the values to 255. The high and low accel values must be set to the same number. • If excessive vibration occurs during estimation, reduce the values and repeat the estimation. Continue to reduce the values until the vibration diminishes. j. Press PREV until the PAYLOAD ID screen is displayed. k. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. l. Press F4, EXEC. You will see a screen similar to the following. Robot moves and estimates. Ready? YES NO WARNING: In the next step, the robot will move. Make sure all personnel and unnecessary equipment are out of the workcell and that all safeguards are in place; otherwise, you could injure personnel or damage equipment. m. Decide whether to run the payload estimation: • To run the calibration, press F4, YES. • To cancel the calibration, press F5, NO. The robot will perform the estimation at the current robot position for axes 1 through 4. When the robot has stopped moving, the payload has been estimated and the screen will be updated to the new values. WARNING: Do not attempt to adjust the override while the robot performs the estimation. This will cause the results to be inaccurate. n. Press F5, APPLY, to apply the estimated value to the payload schedule. You will see a screen similar to the following. Path and Cycletime will change. Set it? YES NO WARNING: Make sure that the payload schedule you define matches the correct payload information before you continue; otherwise, the robot will not move the way you expect, and could injure personnel or damage equipment. o. Decide whether to accept the estimated payload: • To accept the payload, press F4, YES. • To reject the payload, press F5, NO. -68- 4 CONNECTING THE END OF ARM TOOLING MAROB25IB07151E REV C p. If the load is over the specification, you will see a screen similar to the following. Load is OVER spec ! Accept ? YES NO q. Decide whether to accept the estimated payload: • To accept the payload, press F4, YES. • To reject the payload, press F5, NO. 8. To select a different motion group, press F2, GROUP, and specify the motion group you want. Note If you see the message, "Running program already exists," you will not be able to change the index. You cannot change the index when a teach pendant program is running. Note If you have installed the Material Handling Shell option, the program MULTI_IO.TP runs every time you turn on the controller. You cannot abort this program. To avoid getting this message, go to MENUS, SETUP, Shell Config. Set the Using Multiio task item to NO from YES and then turn off the controller and turn it on. After you have set the index and want to run MULTI_IO.TP again, go back to the Shell Config screen, set NO to YES, and then cycle power again. 4.8.4 Setting Up Arm Load Information Table 4-6 displays the items you can set up on the Motion/Armload screen. Use Procedure 4-5 to set up arm load information. Table 4-6 MOTION/ARMLOAD SET Items ITEM DESCRIPTION ARM LOAD AXIS #1 [kg] Units: kg This item is the additional weight mounted to axis 1. ARM LOAD AXIS #3 [kg] Units: kg This item is the additional weight mounted to axis 3. Procedure 4-5 Arm Load Information Steps 1. To set arm load information, press PREV until the payload schedule listing screen is displayed, and press F4, ARMLOAD. You will see a screen similar to the following. MOTION PERFORMANCE Group 1 1 ARM LOAD AXIS #1 [kg] 250.00 2 ARM LOAD AXIS #3 [kg] 20.00 Please power off/on after modification -69- MAROB25IB07151E REV C 4 CONNECTING THE END OF ARM TOOLING a. To display help for the items on the screen, press F5, HELP. To display more information, use the arrow keys. When you are finished displaying help information, press PREV. b. Move the cursor to the item you want to set and set it as desired. Note Arm load includes any additional weight, such as tooling that is mounted on robot axes. 2. When you are finished setting all arm load payload information, CYCLE POWER. a. Press FCTN. b. Select CYCLE POWER, and press ENTER. c. Select OK and press ENTER. -70- 5 5 PURGE SYSTEM MAROB25IB07151E REV C PURGE SYSTEM For purge system troubleshooting, refer to Chapter 3 Troubleshooting. The Purge and Pressurization control system for the P-250iB cell is based on the FANUC America Corporation Purge Module II (EE-5404-001-002 & EE-5404-001-008). This performs the following functions: • Turn on and off the purge solenoid for the control of purge and pressurization air flow • Monitor the status of the various pressure switches and flow switches • Initiate and monitor the purge timing functions • Enable the robot controller to be turned on The major components of this system include: • The Purge Module II in the main controller • Purge solenoid located inside an enclosure mounted on the side of the main controller • Redundant pressure and flow switches in purge cavity The P-250iB robots need to be purged and pressurized. The Purge sequence for all units is initiated at each main controller. When the Purge Enable pushbutton is activated, the purge air solenoid(s) is turned on. The Purge Module II monitors the pressure switches (PS) and flow switches (FS) for each unit. When the purge is compete the Purge Module II turns off the purge air and allows maintenance air to flow through the robot. Additionally the Purge Complete indicator for that controller is then activated and the controller may be turned on. All robot units have series circuits for their PS and FS functions. -71- MAROB25IB07151E REV C 5 Figure 5-1 DOC-6263-910-008, PEDESTAL PURGE LAYOUT WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. AXIS 3 HOUSING PURGE LOOP UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS INNER ARM PURGE LINE PURGE SOLENOID MOUNTED TO CONTROLLER TYPICAL ALL CONFIGURATIONS AIR OUT TURRET PURGE LOOP AIR IN Ø16 AIR SUPPLY TO ROBOT PURGE SWITCH NOTE: EXHAUST BLUE TUBING = PURGE AIR RED ARROWS = AIR FLOW FLEX FIELD PURGE LINE (PLUGGED IF USING ROX INTERFACE) IRON PEDESTAL ROBOT DOC-6263-910-008 PEDESTAL PURGE LAYOUT -72- REV A SHEET 1 OF 1 PURGE SYSTEM 5 PURGE SYSTEM MAROB25IB07151E REV C Figure 5-2 DOC-6263-910-009, WALL BASE PURGE LAYOUT WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. P-250iB/15 AXIS 3 HOUSING PURGE LOOP UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS INNER ARM PURGE LINE EXHAUST TURRET PURGE LOOP PURGE AIR INLET FLEX FIELD PURGE LINE (PLUGGED IF USING ROX INTERFACE) PURGE SWITCH NOTE: BLUE TUBING = PURGE AIR RED ARROWS = AIR FLOW DOC-6263-910-009 WALL BASE PURGE LAYOUT -73- REV A SHEET 1 OF 1 MAROB25IB07151E REV C 5 Figure 5-3 DOC-6263-910-006, PNEUMATIC SCHEMATIC WARNING PURGE SEQUENCE ABNORMAL PROCESSING 1. 1. THE OPERATOR CONNECTS AIR SUPPLY TO ROBOT(1). PRESSURE SWITCH (10) CLOSES, AND REMAINS CLOSED AS LONG AS AIR IS SUPPLIED (0.272 kPa MIN). THE OPERATOR PROVIDES POWER TO CONTROLLER TERMINALS (2). AFTER POWER IS PROVIDED, THE PURGE FAULT INDICATION (3) TURNS ON. THE OPERATOR PRESSES AND HOLDS PURGE ENABLE BUTTON(4). PURGE CONTROL MODULE (9) SWITCHES THE SOLENOID VALVE (5) TO DISTRIBUTION LINES (6) TO START FLOW OF PURGE AIR. AIR WILL BE DISTRIBUTED THROUGHOUT ROBOT CAVITY BY DISTRIBUTION LINES (6). FLOW IS MONITORED BY THE FLOW SWITCH (7) AT AIR OUTLET. WHEN FLOW REACHES 850 L/MIN, FLOW SWITCH (7) CLOSES THE ELECTRIC CONTACTS, FLOW INDICATION (8) WILL COME ON AND THE CONTROL MODULE (9) START TIMING. AT THE SAME TIME, PURGE FAULT INDICATION (3) TURNS OFF. WHEN FLOW INDICATION COMES ON (8) , THE OPERATOR CAN RELEASE THE PURGE ENABLE BUTTON (4). PURGE FLOW CONTINUES FOR 5.3 MINUTES TO ENSURE 10 AIR CHANGES. TIME IS MEASURED BY HARDWARE LOGIC IN THE PURGE CONTROL MODULE (9). (MINIMUM PURGE TIME) = 10*(TOTAL CAPACITY OF ROBOT AND HOSE) / (FLOW RATE) = 10x315/850 = 3.7 MINUTES. AFTER 5.3 MINUTES, PURGE IS COMPLETE. PURGE CONTROL MODULE (9) SWITCHES THE SOLENOID VALVE (5) TO MAINTENANCE AIR (15), AND CLOSES THE OUTPUT CONTACTS (11) TO PROVIDE POWER TO ROBOT CONTROLLER, AND TURNS THE PURGE COMPLETE INDICATION (14) ON. THE AIR PRESSURE IN THE CAVITY DECREASES, AND CHECK VALVE (13) CLOSES TO PREVENT LOSS OF MAINTENANCE AIR. ROBOT CAN NOW BE TURNED ON AND OFF AS DESIRED. 2. 3. 4. 5. 6. (1) 7. 8. 9. HAZARD OUS LOCATION 2. 3. 4. 5. IF FLOW SWITCH (7) DOES NOT CLOSE DUE TO NOTSUFFICIENT AIR FLOW, ETC., TIMING WILL NOT START. AND THEREFORE, YOU WILL NOT BE ABLE TO TURN THE ROBOT CONTROLLER POWER ON. IF THE PRESSURE SWITCH (10) IS NOT CLOSED DUE TO NOT-ENOUGH AIR PRESSURE (< 0.272 kPa), TIMING WILL NOT START. AND THEREFORE, YOU WILL NOT BE ABLE TO TURN THE ROBOT CONTROLLER POWER ON. IF THE FLOW SWITCH (7) OPENS AFTER PURGING HAS STARTED, TIMER (9) WILL BE RESET, PURGE FAULT INDICATION (8) WILL LIGHT. AND THEREFORE, YOU WILL NOT BE ABLE TO TURN THE ROBOT CONTROLLER POWER ON. AFTER PURGE IS COMPLETE, IF PRESSURE SWITCH (10) OPENS, THE OUTPUT CONTACTS (11) WILL OPEN, THE PURGE COMPLETE INDICATION (14) WILL GO OUT, AND PURGE FAULT INDICATION (8) WILL BE ON. AND THEREFORE, THE ROBOT CONTROLLER POWER IS IMMEDIATELY SHUT DOWN. RELIEF VALVE (13) WILL OPEN AT 1.893 kPa TO PREVENT EXCESSIVE PRESSURE IN THE EVENT OF AN AIR SUPPLY FAILURE. Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS NORMAL POWER ON/OFF SEQUENCE 1. AS LONG AS PURGE IS COMPLETE, ROBOT MAY BE TURNED ON AND OFF AS DESIRED. PAINT COMPONENT CABINET ~ REF. NON HAZARDOUS PURGE CAVITY TURRET INNER ARM PURGE AIR TO ROBOT OUTER ARM FLOW CONTROL VALVE SET @ 1.99 - 2.49 kPa [8-10 " H2O] (MAINTENANCE AIR) 6 AIR PURGE DISTRIBUTION FLEX FIELD ONLY PLUGGED RIGID CONDUIT 15 FAIL REGULATOR MAXIMUM INTERNAL ROBOT PRESSURE = 13.79 kPa [ 55.36 in OF H20] REDUNDANT N.O. PRESSURE SWITCHES CLOSE - 0.172 kPa [0.69 in OF H20] MIN - 0.172 kPa [0.69 in OF H20] MAX - 0.272 kPa [1.09 in OF H2 0] 7 10 PURGE SWITCH EO9999-703-000H3 OR EO9999-708-000H3 REDUNDANT FLOW SWITCHES DEACTIVATION: [850+6%-0 SLPM] 13 FLAME ARRESTOR CHECK VALVE CRACKING PRESSURE 1.893 kPa [7.6 in OF H20] MAXIMUM SPECIFIED INTERNAL ROBOT PRESSURE = 10.34 kPa [41.5 IN OFH20, 1.5 PSI] PURGE CONTROL MO DU LE (9) FLOW SW ITCH INPUT PRESSURE SW ITCH INPUT INPUT PRESSURE 414 - 448 kPa [60-65 PSI @ 1300 SLPM DYNAMIC] SO LENOID OUTPUT 5 1 EE-5404-001-002 (SINGLE ARM) EE-5404-001-008 (DUAL ARM) AIR SUPPLY (2) POWER 200VAC (11) OUTPUT CO NTACTS (4) PURGE ENABLE (8) FLO W IND ICATIO N (14) PURGE COM PLETE IND ICATIO N (3) PURGE FAULT IND ICATION (12) POWER TO ROBO T CONTRO LLER MAXIMUM FLOW SWITCH ACTIVATION 1300 SLPM FOR FM INCLUDES LEAKAGE @[60 psi] 413.7 kpa INLET PRESSURE AIR SUPPLY MUST BE FROM NON-HAZARDOUS AREA PURGE SOLENOID VALVE MAXIMUM LEAKGE FLOW = 110 SLPM P-250iB PEDESTAL & WALL BASE MOUNT PNEUMATIC SCHEMATIC DOC-6263-910-019 PURGE SYSTEM OVERVIEW -74- REV A SHEET 1 OF 1 PURGE SYSTEM 6 6 MASTERING MAROB25IB07151E REV C MASTERING 6.1 Overview When you master a robot you define the physical location of the robot by synchronizing the mechanical information with the robot’s positional information. A robot must be mastered to operate properly. Robots are usually mastered before they leave FANUC America Corporation. However, it is possible that a robot might lose its mastering data and need to be remastered. The robot axes are controlled by a closed loop servo system. The controller outputs a command signal to drive each motor. A feedback device mounted on the motor, called a serial pulse coder, sends a signal back to the controller. During robot operation, the controller constantly analyzes the feedback signal, and modifies the command signal to maintain proper location and velocity of the end effector at all times. For the robot to move accurately to recorded positions, the controller has to "know" the position of each axis. It does this by comparing the serial pulse coder reading during operation with a reading taken at a known mechanical reference point on the robot. Mastering records the serial pulse coder reading at a known mechanical reference point. This mastering data is stored with other user data in the controller memory and backed up by a lithium battery so that it is maintained when the controller is shut down. When the controller is shut down under normal conditions, each serial pulse coder’s present reading is maintained in the pulse coder by backup batteries on the robot. (These batteries might be located in the controller or the robot auxiliary panel on P-series robots.) When the controller is turned on, the controller requests the stored reading from the serial pulse coder. When the controller receives the pulse coder reading, the servo system can operate normally. This process is called calibration. Calibration occurs automatically each time the controller is turned on. When pulse coder backup battery power is interrupted while the controller is powered down, calibration fails at power up and the only robot motion possible is joint mode jogging. To restore proper operation, the robot must be mastered and calibrated. WARNING: When calibration has failed, the axis software travel limits will be ignored, allowing the robot to be jogged farther than normal. Be careful when jogging the robot in an uncalibrated condition or you could injure personnel or damage equipment. WARNING: If the robot has been configured with DCS (Dual Check Safety), consult the DCS manual for mastering instructions. Note The following procedures might be password-protected on your robot. If passwords have been set, you will need access at the Install level to perform mastering. Obtain the Install level password and log in at the Install level, or you will be unable to perform the following procedures. Before mastering the robot, you must clear any faults that prevent servo power from being restored or that prevent mastering completion. Use Procedure 6-1 to clear common faults related to mastering and to prepare the robot for mastering. For more detailed information on fault recovery, refer to the FANUC America Corporation Controller Maintenance Manual. If you are using a FANUC America Corporation A-series robot you should use a mastering fixture to master your robot. Fixture mastering is performed on FANUC America Corporation P-series robots by aligning mastering pins and surfaces on the robot. Refer to the Mechanical Unit Service Manual specific to your robot model for procedures on how to set up and use a mastering fixture. If you are using a FANUC America Corporation M-series or S-series robot you can either master to a fixture or you can master to zero degrees. Refer to the Mechanical Unit Service Manual specific to your robot model for more -75- MAROB25IB07151E REV C 6 MASTERING information about either of these methods. If you are using a FANUC America Corporation P-series robot, and you have zero degree witness marks scored onto your robot, then you can master the robot to zero degrees. Refer to the Mechanical Unit Service Manual specific to your robot model for procedures on how to master your robot. Quick mastering is a convenient way to master a robot after you have recorded a reference position. You cannot quick master a robot unless the reference position was taught before mastering was lost. CAUTION: Record the quick master reference position after the robot is installed to preserve the factory mastering settings for future remastering. Table 6-1 SYSTEM Master/Cal Items ITEM DESCRIPTION SET QUICK MASTER REF This item allows you to set master reference positions. You can save the master reference positions to the default device in case the robot has lost mastery due to an electrical or software problem. FIXTURE POSITION MASTER This item allows you to master the robot to a fixture. When you master to a fixture, you use a mastering fixture to align the robot axes and then record their serial pulse coder readings. You can master any robot to a fixture. SINGLE AXIS MASTER This item allows you to master a single axis of the robot. You can master a single axis of any robot provided that there is a reference mark at a known position on that axis. When a single axis of a robot is mastered, mastering data for the other axes remains unchanged. QUICK MASTER This item allows you to quick master the robot. Quick mastering allows you to minimize the time required to remaster the robot using a reference position you established when the robot was properly mastered. You cannot quick master the robot unless you have previously recorded this quick master reference position. Record the quick master reference position when the robot is properly mastered. The best time to record the quick master reference position is when the robot is still factory-mastered. ZERO POSITION MASTER CALIBRATE Message Field This item allows you to master the robot to zero degrees. When you master to zero degrees, you position all axes at their zero degree witness marks and record their serial pulse coder readings. You can master any M-series or S-series robot to zero degrees. If you are using a FANUC America Corporation P-series robot, and you have witness marks scored onto your robot, you can master the robot to zero degrees. This item allows you to calibrate the robot. This item is a status area at the bottom of the screen that lets you know when the robot has been successfully mastered or calibrated. 6.2 Resetting Alarms and Preparing For Mastering When you turn on the robot after pulse coder backup battery power has been interrupted you will see a SRVO-062 BZAL alarm. You might also see a SRVO-038 Pulse Mismatch alarm. Before mastering the robot you must reset these alarms and rotate the motor of each axis that lost battery power to prepare the robot for mastering. Use Procedure 6-1 to reset these alarms and prepare the robot for mastering. Procedure 6-1 Preparing the Robot for Mastering Conditions • You see a SRVO-062 BZAL or SRVO-038 Servo mismatch alarm. • You are not mastering a P-200 robot. -76- 6 MASTERING MAROB25IB07151E REV C Steps 1. If necessary, replace the robot batteries with four new 1.5 volt alkaline batteries, size D. Observe the direction arrows in the battery box for proper orientation of the batteries. 2. Press MENUS. 3. Select SYSTEM. 4. Press F1, [TYPE]. 5. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6 a. Move the cursor to VARIABLE and press ENTER. b. Move the cursor to $MASTER_ENB. c. Press the numeric key "1" and then press ENTER on the teach pendant. d. Press F1, [TYPE]. 6. Select Master/Cal. You will see a screen similar to the following. WARNING: For the M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), and M-16iL (ARC Mate 120iL) robots, setting TORQUE to OFF using the F4, TORQUE function key on the SYSTEM Master/Cal screen releases the robot brakes. When the brakes are released, the robot arm will drop suddenly unless it is supported. DO NOT use this function key unless instructed to do so, otherwise, you could injure personnel or damage equipment. SYSTEM Master/Cal TORQUE = ON 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Note F4, TORQUE does not appear on the Master/Cal screen for all robot models. When F4, TORQUE appears on the Master/Cal screen, it allows the robot brakes to be released. 7. Press F3, RES_PCA. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Reset pulse coder alarm? [NO] 8. Press F4, YES. You will see a screen similar to the following. -77- MAROB25IB07151E REV C 6 MASTERING SYSTEM Master/Cal TORQUE = ON 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Pulse coder alarm reset! Note If you exit the Master/Cal screen by pressing F5, DONE, the Master/Cal screen will be hidden. Master/Cal will not be available by pressing F1, [TYPE]. To display the Master/Cal screen again, perform Step 1 through Step 6 . 9. Turn off the controller. 10. Wait a few seconds, then turn the power disconnect circuit breaker on to turn the controller on again. 11. If the SRVO-062 BZAL alarm is still present; there is a battery, cable or pulsecoder problem. Refer to the FANUC America Corporation Controller Maintenance Manual for further information. 12. If a SRVO-038 Pulse Mismatch alarm is present at this time, repeat Step 1 through Step 8 to reset it. It is not necessary to restart the robot after resetting to clear this alarm. 13. If a SRVO-075 Pulse Not Established alarm is present at this time, press the RESET key to clear it. 14. Rotate each axis that lost battery power by at least one motor revolution in either direction. Failure to do so will result in the SRVO-075 Pulse Not Established alarm recurring and mastering will not be possible. a. For each rotary axis, jog at least twenty degrees. b. For each linear axis, jog at least thirty millimeters. 15. Perform any of the mastering procedures from the MASTER/CAL menu. 6.3 Saving and Restoring Mastering Data You can save the master reference positions to the default device in case the robot has lost mastery due to an electrical or software problem. Use Procedure 6-2 to save and restore master reference position data. Procedure 6-2 Saving and Restoring Master Reference Position Data Conditions • The robot is mastered. Refer to Section 6.4 through Section6.6 to choose a mastering method and master your robot. • The default device is set. • The robot is on and is working properly. Steps 1. Press MENUS. 2. Select SYSTEM. 3. Press F1, [TYPE]. 4. Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 5 a. Select VARIABLE from the [TYPE] menu. b. Move the cursor to $MASTER_ENB. c. Press the numeric key "1" and then press ENTER on the teach pendant. d. Press F1, [TYPE]. e. Select Master/Cal. You will see a screen similar to the following. -78- 6 MASTERING MAROB25IB07151E REV C SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ‘Enter’ or number key to select. Note F4, TORQUE does not appear on the Master/Cal screen for all robot models. When F4, TORQUE appears on the Master/Cal screen, it allows the robot brakes to be released. 5. Press FCTN. 6. Select SAVE. The file SYSMAST.SV is copied to the default device. 7. To restore the saved file, press F2, LOAD. 6.4 Single Axis Mastering You can master a single axis of any robot provided that there is a reference mark at a known position on that axis. When a single axis of a robot is mastered, mastering data for the other axes remains unchanged. Use Procedure 6-3 to master a single axis. Procedure 6-3 Mastering a Single Axis Conditions • You have cleared any servo faults that prevent you from jogging the robot. • You have jogged each axis that has lost mastering at least one motor turn. See Procedure 6-1 Steps 1. Jog the unmastered axis of the robot to the single axis mastering position. • For M-series or S-series robots only: Using the joint coordinate system, jog the unmastered axis of the robot to the zero degree witness mark. If you are single axis mastering the J2-axis, the J3-axis must first be lined up at its zero degree mark. Otherwise the positions of the other axes are unimportant. Refer to the Mechanical Service Manual specific to your robot model for the location of the zero degree witness marks. • For P-series robots only: Using the joint coordinate system, jog the unmastered axis of the robot to the standard mastering location and align the mark, pin or surface using a mastering block or straight edge as required. If you are single axis mastering the J3-axis, the J2-axis must first be lined up at its standard mastering location. Otherwise, the positions of the other axes are not important. 2. Press MENUS. 3. Select SYSTEM. 4. Press F1, [TYPE]. 5. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6 a. Select VARIABLE. b. Move the cursor to $MASTER_ENB. c. Press the numeric key "1" and then press ENTER on the teach pendant. d. Press F1, [TYPE]. 6. Select Master/Cal. You will see a screen similar to the following. -79- MAROB25IB07151E REV C 6 SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Note F4, TORQUE does not appear on the Master/Cal screen for all robot models. When F4, TORQUE appears on the Master/Cal screen, it allows the robot brakes to be released. 7. Move the cursor to SINGLE AXIS MASTER and press ENTER. You will see a screen similar to the following SINGLE AXIS MASTER ACTUAL POS (MSTR POS) J1 0.000 ( 0.000) J2 3.514 ( 35.000) J3 -7.164 ( -100.000) J4 -35.366 ( 0.000) J5 -1.275 ( -80.000) J6 4.571 ( 0.000) E1 0.000 ( 0.000) E2 0.000 ( 0.000) E3 0.000 ( 0.000) (SEL) (0) (0) (0) (0) (0) (0) (0) (0) (0) [ST] [2] [0] [2] [2] [2] [2] [0] [0] [0] Note A "0" in the [ST] column indicates that the axis is unmastered. 8. Move the cursor to the (MSTR POS) column and move it up or down to the unmastered axis. (Any unmastered axis will have the number 0 in the [ST] column). 9. For M-series or S-series robots only: Enter the position where single axis mastering is to be performed in the (MSTR POS) column for the unmastered axis. a. For robots where single axis mastering is performed at the zero degree position, press the numeric key "0" and press ENTER. b. For robots where single axis mastering is performed at the fixture position, enter the fixture position and press ENTER. Note Some P-series robots are single axis mastered at the fixture position. All other robots are single axis mastered at the zero degree position. 10. Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. 11. Press F4, GROUP. Enter the appropriate group number. Enter 1 for a left robot or 2 for a right robot. The left and right designation is determined by looking downstream of the conveyer travel. 12. Move the cursor to the SEL column and move it up or down to the unmastered axis. 13. Press the numeric key "1" and press ENTER. 14. Press F5, EXEC. Mastering will be performed automatically. You will see a screen similar to the following. -80- MASTERING 6 MASTERING MAROB25IB07151E REV C SINGLE AXIS MASTER ACTUAL POS (MSTR POS) J1 0.000 ( 0.000) J2 3.514 ( 0.000) J3 -7.164 (-100.000) J4 -35.366 ( 0.000) J5 -1.275 ( -80.000) J6 4.571 ( 0.000) E1 0.000 ( 0.000) E2 0.000 ( 0.000) E3 0.000 ( 0.000) (SEL) (0) (0) (0) (0) (0) (0) (0) (0) (0) [ST] [2] [2] [2] [2] [2] [2] [0] [0] [0] Note The J2 axis is now mastered and a 2 is displayed in the [ST] column. 15. Press PREV. 16. Move the cursor to CALIBRATE and press ENTER. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Calibrate ? [NO] 17. Press F4, YES. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <0.000> <0.000> <-7.164> <-35.366> <-1.275> <4.571> Note If you exit the Master/Cal screen by pressing F5, DONE, the Master/Cal screen will be hidden. Master/Cal will not be available by pressing 1, [TYPE]. To display the Master/Cal screen again perform Step 1 through Step 6 6.5 Quick Mastering Quick mastering allows you to minimize the time required to remaster the robot using a reference position you established when the robot was properly mastered. You cannot quick master the robot unless you have previously recorded this quick master reference position. Record the quick master reference position when the robot is properly mastered. The best time to record the quick master reference position is when the robot is still factory-mastered. -81- MAROB25IB07151E REV C 6 MASTERING If calibration fails because pulse coder backup battery power has been interrupted, you can use this reference position to master the robot in a minimum amount of time. When the zero position marks do not line up because of mechanical disassembly or repair, you must master to a fixture or perform zero degree mastering. You can define a quick master reference position and perform quick mastering on any robot model. Use Procedure 6-4 to record the quick master reference position. Use Procedure 6-5 to quick master the robot. CAUTION: Record the quick master reference position after the robot is installed to preserve the factory mastering settings for future remastering. Procedure 6-4 Recording the Quick Master Reference Position Conditions • The robot is properly mastered. Steps 1. Align each axis of the robot with the reference mark you have chosen as a quick master reference position. Note It is convenient to use the zero degree marks for the quick master reference position Refer to the Mechanical Unit Service Manual specific to your robot model for the location of the zero degree marks. But if you prefer, you can use any robot position as long as you scribe witness marks on each axis at the reference point. 2. Press MENUS. 3. Select SYSTEM. 4. Press F1, [TYPE]. 5. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6 a. Select VARIABLE. b. Move the cursor to $MASTER_ENB. c. Press the numeric key "1" and then press ENTER on the teach pendant. d. Press F1, [TYPE]. 6. Select Master/Cal. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Note F4, TORQUE does not appear on the Master/Cal screen for all robot models. When F4, TORQUE appears on the Master/Cal screen, it allows the robot brakes to be released. 7. Move the cursor to SET QUICK MASTER REF and press ENTER. You will see a screen similar to the following. -82- 6 MASTERING MAROB25IB07151E REV C SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Set quick master reference ? [NO] 8. Press F4, YES. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Quick Master Reference Set! Note If you exit the Master/Cal screen by pressing F5, DONE, the Master/Cal screen will be hidden. Master/Cal will not be available by pressing F1, [TYPE]. To display the Master/Cal screen again, perform Step 1 through Step 6 Procedure 6-5 Quick Mastering the Robot Conditions • Calibration has failed because backup battery power has been interrupted. Note If the zero degree marks do not line up because of mechanical disassembly or repair, you cannot perform this procedure. In this case, master to a fixture or master to zero degrees to restore robot mastering. • The quick master reference position was recorded before calibration failed. • You have cleared any servo faults that prevent you from jogging the robot. • You have jogged each axis that has lost mastering at least one motor turn. See Procedure 6-1 Steps 1. Jog the robot to the quick master reference position that has previously been recorded. 2. Press MENUS. 3. Select SYSTEM. 4. Press F1, [TYPE]. 5. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6 a. Select VARIABLE. b. Move the cursor to $MASTER_ENB. c. Press the numeric key "1" and then press ENTER on the teach pendant. d. Press F1, [TYPE]. 6. Move the cursor to Master/Cal and press ENTER. You will see a screen similar to the following. -83- MAROB25IB07151E REV C 6 SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Note F4, TORQUE does not appear on the Master/Cal screen for all robot models. When F4, TORQUE appears on the Master/Cal screen, it allows the robot brakes to be released. 7. Move the cursor to QUICK MASTER and press ENTER. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Quick master ? [NO] 8. Press F4, YES. Mastering will be performed automatically. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> 9. Move the cursor to CALIBRATE and press ENTER. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Calibrate ? [NO] 10. Press F4, YES. You will see a screen similar to the following. -84- MASTERING 6 MASTERING MAROB25IB07151E REV C SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <0.003> <-0.0012> <-0.050> <0.009> <0.015> <-0.002> Note If you exit the Master/Cal screen by pressing F5, DONE, the Master/Cal screen will be hidden. Master/Cal will not be available by pressing F1, [TYPE]. To display the Master/Cal screen again, perform Step 1 through Step 6 6.6 Mastering To A Fixture (Fixture Position Master) When you master to a fixture, you use a mastering fixture to align the robot axes and then record their serial pulse coder readings. You can master any robot to a fixture. P-series paint robots do not use fixtures. A mastering block, and in some cases, a steel straight edge or ruler is used to align mastering surfaces on P-series paint robots. A mastering block is used for aligning the mastering surfaces of the modular in-booth rail. Use Procedure 6-6 to master to a fixture. Note that not all steps refer to paint robots. Procedure 6-6 Mastering to a Fixture Conditions • You have the appropriate mastering fixture for your robot. (P-series robots require the robot to be put in a fixture position only. They do not actually use a fixture.) • You have cleared any servo faults that prevent you from jogging the robot. • You have jogged each axis that has lost mastering at least one motor turn. See Procedure 6-1 Steps 1. If automatic brake control is enabled, disable it as follows; otherwise continue to Step 2 . This step is not for paint robots. a. Press MENUS. b. Select SYSTEM. c. Press F1, [TYPE]. d. Select VARIABLE. e. Move the cursor to $PARAM_GROUP and press ENTER twice. f. Move the cursor to $SV_OFF_ALL and press F5, FALSE. g. Move the cursor to $SV_OFF_ENB and press ENTER. h. Move the cursor to each line where the value is TRUE, and press F5, FALSE. i. Turn off the controller. j. Turn on the controller. 2. Install the mastering fixture on the robot and jog the robot into the mastering position. Refer to the Mechanical Service Manual specific to your robot model for the procedures for setup and use of a mastering fixture. For P-series robots align the mastering surfaces using the appropriate mastering block or straight edge. The modular in-booth rail uses a block. 3. Press MENUS. 4. Select SYSTEM. 5. Press F1, [TYPE]. 6. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 7 -85- MAROB25IB07151E REV C 6 a. Move the cursor to VARIABLE and press ENTER. b. Move the cursor to $MASTER_ENB. c. Press the numeric key "1" and then press ENTER on the teach pendant. d. Press F1, [TYPE]. 7. Select Master/Cal. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Note F4, TORQUE does not appear on the Master/Cal screen for all robot models. When F4, TORQUE appears on the Master/Cal screen, it allows the robot brakes to be released. This step is not for paint robots. 8. Move the cursor to FIXTURE POSITION MASTER and press ENTER. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Master at master position ? [NO] 9. Press F4, YES. Mastering will be performed automatically. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> 10. Move the cursor to CALIBRATE and press ENTER. You will see a screen similar to the following. -86- MASTERING 6 MASTERING MAROB25IB07151E REV C SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Calibrate ? [NO] 11. Press F4, YES. You will see a screen similar to the following SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <0.000> <29.226> <-100.625> <0.000> <-79.375> <0.000> Note If you exit the Master/Cal screen by pressing F5, DONE, the Master/Cal screen will be hidden. Master/Cal will not appear on the SYSTEM F1, [TYPE] submenu. To see the Master/Cal screen again perform Step 1 through Step 7. Steps 12 —15 are not for paint robots. 12. For all robots except paint robots, move the wrist clear of the mastering fixture and remove the mastering fixture from the robot. Refer to the Mechanical Service Manual or Mechanical Connection and Maintenance Manual specific to your robot model on how to use a mastering fixture. 13. If you have disabled automatic brake control (this step is not for paint robots) in Step 1 , enable it as follows: a. Press MENUS. b. Select SYSTEM. c. Press F1, [TYPE] d. Select VARIABLE. e. Move the cursor to $PARAM_GROUP and press ENTER twice. f. Move the cursor to $SV_OFF_ALL and press F4, TRUE. g. Move the cursor to $SV_OFF_ENB and press ENTER. h. Move the cursor to each line where you previously changed the value, and press F4, TRUE. 14. Turn off the controller. 15. Wait a few seconds, then press the ON/OFF button on the operator panel to turn the controller on again. 6.7 Zero Degree Mastering When you master to zero degrees, you position all axes at their zero degree witness marks and record their serial pulse coder readings. You can master any M-series or S-series robot to zero degrees. If you are using a FANUC America Corporation P-series robot, and you have witness marks scored onto your robot, you can master the robot to zero degrees. Use Procedure 6-7 to master to zero degrees -87- MAROB25IB07151E REV C 6 Procedure 6-7 Mastering to Zero Degrees Conditions • You have cleared any servo faults that prevent you from jogging the robot. • You have jogged each axis that has lost mastering at least one motor turn. Refer to Procedure 6-1 Steps 1. Using the joint coordinate system, jog each axis of the robot to the zero degree witness mark. Refer to the Mechanical Service Manual specific to your robot model for the location of the witness marks. 2. Press MENUS. 3. Select SYSTEM. 4. Press F1, [TYPE]. 5. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6 a. Select VARIABLE. b. Move the cursor to $MASTER_ENB. c. Press the numeric key "1" and then press ENTER on the teach pendant. d. Press F1, [TYPE]. 6. Select Master/Cal. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Note F4, TORQUE does not appear on the Master/Cal screen for all robot models. When F4, TORQUE appears on the Master/Cal screen, it allows the robot brakes to be released. 7. Move the cursor to ZERO POSITION MASTER and press ENTER. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Master at zero position ? [NO] 8. Press F4, YES. Mastering will be performed automatically. You will see a screen similar to the following. -88- MASTERING 6 MASTERING MAROB25IB07151E REV C SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> 9. Move the cursor to CALIBRATE and press ENTER. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. Calibrate ? [NO] 10. Press F4, YES. You will see a screen similar to the following. SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <0.000> <0.000> <0.000> <0.000> <0.000> <0.000> Note If you exit the Master/Cal screen by pressing F5, DONE, the Master/Cal screen will be hidden. Master/Cal will not be available by pressing F1, [TYPE]. To display the Master/Cal screen again perform Step 1 through Step 6 -89- MAROB25IB07151E REV C 6 6.8 P-250iB Mastering Locations Figure 6-1 ET-6263-820-006_SHT1, MASTERING & ZERO POSITION WARNING Arm offset left Z Robot Robot coordinates Arm offset P5 P6 P7 P8 LH RH LH RH Left Right Right Left J1 +45 -45 +45 -45 Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 +45 -90 0 0 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment J6 0 0 0 0 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Arm offset right Y UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS X Z P1 Arm offset right LH robot coordinates this side of booth Y Z X Y J3 X J2 Arm offset left P3 J3 Z P2 Y Conveyor flow J1 X J2 P5 J3 Robots in zero position J2 P4 P7 RH robot coordinates this side of booth P6 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". J1 J3 J1 J2 J1 Robots in mastered position 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. P8 [ET-6263-820-006_SHT1] MASTERING & ZERO POSITION -90- REV A MASTERING 6 MASTERING MAROB25IB07151E REV C Figure 6-2 ET-6263-820-006_SHT2, MASTERING & ZERO POSITION WARNING Robot Robot coordinates Arm offset P5 P6 P7 LH RH LH P8 RH Master joint angle (deg) Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment Z Left Right Right J1 +45 -45 +45 J2 +45 +45 +45 J3 -90 -90 -90 J4 0 180 180 J5 0 0 0 J6 0 0 0 Left -45 +45 -90 0 0 0 WARNING Robots in zero position Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. P2 Y UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS Z X Arm offset right RH robot coordinates this side of booth Z P4 P1 Y X Robots in master position X P6 Z J2 Arm offset left P3 Arm offset left Y J1 LH robot coordinates this side of booth P8 J1 J3 X Y P5 J1 J2 J2 Arm offset right P7 J3 J1 J3 J2 Conveyor flow J3 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. [ET-6263-820-006_SHT2] MASTERING & ZERO POSITION -91- REV A MAROB25IB07151E REV C 6 Figure 6-3 ET-6263-820-006_SHT3, MASTERING & ZERO POSITION WARNING Z Robot Robot coordinates Arm offset P5 P6 P7 LH RH LH Left Right Right J1 +45 -45 +45 Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 P8 RH Left -45 +45 Arm offset left -90 0 0 J6 0 0 0 0 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS Arm offset right X Z Arm offset right P1 Z LH robot coordinates this side of booth Y X Arm offset left P3 J2 Z J3 Y J1 Conveyor flow X P5 P2 J2 J3 Robots in zero position J1 P4 J3 J1 J2 P7 RH robot coordinates this side of booth J3 P6 J1 J2 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". Robots in mastered position P8 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. [ET-6263-820-006_SHT3] MASTERING & ZERO POSITION -92- REV A MASTERING 6 MASTERING MAROB25IB07151E REV C Figure 6-4 ET-6263-820-006_SHT4, MASTERING & ZERO POSITION WARNING Robot Robot coordinates Arm offset P5 P6 P7 LH RH LH Left Right Right J1 -135 -45 -135 Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 P8 RH Left -45 +45 -90 0 0 J6 0 0 0 0 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Z Robots in zero position Y P2 Arm offset left UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS Arm offset left Arm offset right X Z Z Y X Y P4 Conveyor flow RH robot coordinates this side of booth X Z P1 Y J3 J1 Robots in mastered position X Arm offset right P6 J2 J3 P3 J2 J1 J3 J1 LH robot coordinates this side of booth P8 J2 J2 J3 P5 J1 P7 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. 3. For robots P5 and P7 the "single axis mastering" feature can be used to avoid potential interference with the booth ceiling. [ET-6263-820-006_SHT4] MASTERING & ZERO POSITION -93- REV A MAROB25IB07151E REV C 6 Figure 6-5 ET-6263-820-006_SHT5, MASTERING & ZERO POSITION WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING P1 Z Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Robots in zero position Y Arm offset left X UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS P3 Z LH robot coordinates this side of booth Y Z Y X J1 Robots in master position Arm offset right Z Arm offset right P5 X Conveyor flow P2 X Y Arm offset left P7 J2 P4 J1 J1 J3 RH robot coordinates this side of booth J2 J3 P6 J2 J1 J3 J3 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". J2 P8 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. 3. For robots P6 and P8 the "single axis mastering" feature can be used to avoid potential interference with the booth ceiling. Robot Robot coordinates Arm offset P5 P6 P7 P8 LH RH LH RH Left Right Right Left J1 +45 +135 +45 +135 Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 +45 -90 0 0 J6 0 0 0 0 [ET-6263-820-006_SHT5] MASTERING & ZERO POSITION -94- REV A MASTERING 6 MASTERING MAROB25IB07151E REV C Figure 6-6 ET-6263-820-006_SHT6, MASTERING & ZERO POSITION WARNING P5 P6 P7 LH RH LH Left Right Right J1 +45 -45 +45 Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 P8 RH Left -45 +45 Robot Robot Arm coordinates offset -90 0 0 J6 0 0 0 0 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Z UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS Robots in zero position Y P1 X Z Arm offset left Z Arm offset right Y LH robot coordinates this side of booth P3 X Y X X Arm offset left P2 Arm offset right Z J2 Y Robots in master position P5 J1 X P4 J2 J3 P7 J1 J1 J3 P6 RH robot coordinates this side of booth J2 J3 J1 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". Conyeyor flow P8 J2 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. J3 [ET-6263-820-006_SHT6] MASTERING & ZERO POSITION -95- REV A MAROB25IB07151E REV C 6 Figure 6-7 ET-6263-820-006_SHT7, MASTERING & ZERO POSITION WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Z Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Robots in zero position Y Arm offset left UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS Arm offset right X Z Arm offset right P1 Z LH robot coordinates this side of booth Y X Y X P3 J1 Robots in master position Z Y P2 X Conveyor flow Arm offset left J2 P5 J3 RH robot coordinates this side of booth J1 J1 P4 J2 P8 P7 View A P6 J3 J1 P6 J2 J2 Robot Arm Robot coordinates offset P8 J3 J3 View A P5 P6 P7 LH RH LH Left Right Right J1 -45 -45 -45 P8 RH Left -45 Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 J6 0 0 0 +45 0 -90 0 0 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. [ET-6263-820-006_SHT7] MASTERING & ZERO POSITION -96- REV A MASTERING 6 MASTERING MAROB25IB07151E REV C Figure 6-8 ET-6263-820-006_SHT8, MASTERING & ZERO POSITION WARNING Robot Robots in zero position Z Y P1 Robot Arm coordinates offset P5 P6 P7 LH RH LH Left Right Right J1 +45 +45 +45 P8 RH Left +45 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 J6 0 0 0 +45 0 -90 0 0 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS X Z Y Arm offset left P3 LH robot coordinates this side of booth Z Y X X Robots in mastered position P5 P2 Y Arm offset right Z J1 X Arm offset right Conveyor flow J2 P7 P4 Arm offset left J1 J2 J3 RH robot coordinates this side of booth View A P6 J1 J1 P8 J3 P6 P8 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". J2 J2 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. J3 J3 View A [ET-6263-820-006_SHT8] MASTERING & ZERO POSITION -97- REV A MAROB25IB07151E REV C 6 Figure 6-9 ET-6263-820-006_SHT9, MASTERING & ZERO POSITION WARNING Robot Arm offset left Z Robot Arm coordinates offset P5 P6 P7 LH RH LH Left Right Right J1 +45 -45 +45 P8 RH Left -45 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment Master Joint Angles (deg) J2 J3 J4 J5 +45 -90 0 0 +45 -90 180 0 +45 -90 180 0 J6 0 0 0 +45 0 -90 0 0 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. Arm offset right Y UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS P1 X Z Arm offset right Z Y P3 X LH robot coordinates this side of booth Y X Arm offset left J2 J3 Z X P2 P5 Y Conveyor flow J2 J3 J3 Robots in zero position J1 J2 P7 P4 J1 J3 J2 J1 RH robot coordinates this side of booth P6 J1 NOTE: 1. Align mastering surfaces to establish master joint angles defined in table. Location of major axis mastering surfaces indicated by "J1, J2, J3". 2. See sheet 10, 11, & 12 for detail views of mastering surfaces and for definition of mastered and zero position of wrist axes. Robots in mastered position P8 [ET-6263-820-006_SHT9] MASTERING & ZERO POSITION -98- REV A MASTERING 6 MASTERING MAROB25IB07151E REV C Figure 6-10 ET-6263-820-006_SHT10, MASTERING & ZERO POSITION WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS J1 MASTERING SURFACES ALUMINUM BASE J1 MASTERING SURFACES IRON PEDESTAL NOTE: 1. Align mastering surfaces in a common plane using a straight edge. Mastering surfaces are cross hatched. 2. Align the appropriate set of surfaces as descibed on sheets 1 - 9 for different product variants and mounting orientations. [ET-6263-820-006_SHT10] MASTERING & ZERO POSITION -99- REV A MAROB25IB07151E REV C 6 Figure 6-11 ET-6263-820-006_SHT11, MASTERING & ZERO POSITION WARNING J3 MASTERING SURFACES J2 MASTERING SURFACES J2 MASTERING SURFACES J3 MASTERING SURFACES Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS INNER ARM OFFSET RIGHT INNER ARM OFFSET LEFT NOTE: 1. Align mastering surfaces in a common plane using a straight edge. Mastering surfaces are cross hatched. 2. Align the appropriate set of surfaces as descibed on sheets 1 - 9 for different product variants and mounting orientations. 3. Robot is shown mounted on an iron pedestal. J2 & J3 mastering surfaces are the the same for a robot mounted on an aluminum base. [ET-6263-820-006_SHT11] MASTERING & ZERO POSITION -100- REV A MASTERING 6 MASTERING MAROB25IB07151E REV C Figure 6-12 ET-6263-820-006_SHT12, MASTERING & ZERO POSITION WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS J4 MASTERING SURFACES J5 MASTERING SURFACES J6 MASTERING SURFACES NO PIN PIN NOTE: 1. Align mastering surface tangent with pin using a straight edge. Mastering surface is cross hatched. 2. The J4 zero position with LH inner arm offset = Mastered position. The J4 zero position with RH inner arm offset = 180 deg from the mastered position. ZERO POSITION INNER ARM OFFSET RIGHT ZERO POSITION INNER ARM OFFSET LEFT [ET-6263-820-006_SHT12] MASTERING & ZERO POSITION -101- REV A 7 7 CHECKS AND MAINTENANCE MAROB25IB07151E REV C CHECKS AND MAINTENANCE Optimum performance of the P-250iB robot can be maintained by following the lubrication and periodic general maintenance procedures in this chapter. Note All cleaning procedures require skilled trades or maintenance personnel to be properly trained in performing proper maintenance procedures. Note Follow all Lockout and Safety procedures before you enter the paint booth. Note Wear safety glasses and protective gloves to clean the components. Note Perform the cleaning procedures in a well ventilated area. Lubrication Maintenance • See the following manual pages for lubrication maintenance intervals. Daily Maintenance • Clean the robot surface • Clean the spray gun or applicator. See the appropriate applicator manual for more detailed information Maintenance every 1000 hours • Check the spray gun or applicator lines and cables. • Clean the spray gun or applicator. See the appropriate applicator manual for more detailed information. Maintenance every 4000 hours • Check the robot cables. • Check the paint lines. • Visually check for grease leaks. • Check the reducer grease levels. -103- MAROB25IB07151E REV C 7 CHECKS AND MAINTENANCE Figure 7-1 ET-6263-820-007_SHT1, INITIAL AND REBUILD WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment C AXIS 3 VENT GRAVITY STD. FANUC PART NO. ZINC FREE FANUC PART NO. GREASE TYPE - SIZE HDWMO000004194O HDWMO000004167O LG-01-02 TUBE - 14 OZ. WARNING HDWMO000004195O HDWMO000004168O LG-01-02 PAIL - 35 LB. HDWMO000004196O HDWMO000004169O LG-01-02 KEG - 115 LB. Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. XGMF-16799 VIGO GREASE RE NO. 0 2 KG XGMF-16156 VI GO GREASE RE NO. 0 16 KG OUTER ARM VERTICAL POSITION UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS 20° INITIAL & REBUILD LUBE SPECIFICATIONS Lube port Vent port Assembly location Mounting configuration for sold application Grease type Total amount cubic centimeters (cubic inches) Notes Floor, Angle, Shel f Vigo Grease RE NO. 0 3708 (226.3) 1, 2, 6, 7, 8 Wall Vigo Greas e RE NO. 0 4158 (253.7) 1, 2, 6, 7, 8 B AXIS 2 VENT 1 A 5 Axis 1 RV (iron pedestal or aluminum base) INNER KNUCKLE LUBE PORT A AXIS 1 VENT STORAGE LOCATION Invert Vigo Grease RE NO. 0 +715 (43.6) after ex-factory tests at FRA and before unit is shipped 1, 2, 6, 7, 8 2 B Axis 2 RV Al l Vigo Grease RE NO. 0 3581 (21 8.5 1, 3, 6, 7, 8 3 C Axis 3 RV Al l Vigo Grease RE NO. 0 854 (52.1) 1, 4, 6, 7, 8 4 None Wrist housing bearings & gears All LG-01-02 200 (12.2) 5, 6, 7 5 None Inner knuckle beari ngs & gears All LG-01-02 180 (11.0) 5. 6, 7 6 None Outer k nuckle beari ngs & gears All LG-01-02 150 (9.2) 5, 6, 7 1. Initial & rebuild lubrication is done with robot base and arms positioned as shown. Alternate positions are acceptable providing the full amount of specified grease can be applied to each axis with the specified vent open. 3 IRON PEDESTAL (SHOWN) ALUMINUM WALL BASE (PHANTOM) 3708 (226.3) initial fill AXIS 3 LUBE PORT (REMOVE COVER) 2. Axis 1 drive lubrication procedure depends on the robot’s mounting orientation in the sold application: • Floor, angle and shelf mount: Confirm relief valve is installed in vent port A. Apply grease through lube port 1 per specification table. Reinstall hex plug in lube port 1. GRAVITY • Wall mount: Remove relief valve from vent port A. Apply grease through lube port 1 per specification table. Install hex plug in vent port A and store relief valve in storage location. Connect the grease expansion coil to lube port 1 for ex-factory testing at FRA. Disconnect the coil and plug lube port 1 prior to shipping. Reconnect the coil during installation in the field (see ET-6263-820-008). • Invert mount: Confirm relief valve is installed in vent port A. Apply grease through lube port 1 per specification table. Reinstall hex plug in lube port 1. The initial grease fill volume is same as floor mount since the robot is ex-factory tested standing upright. Upon completion of ex-factory test, add an additional 715cc of grease through lube port 1 and reinstall the hex plug for shipping. Install hex plug in vent port A and relief valve in storage location. Reconnect the coil during installation in the field (see ET-6263-820-008). 3. Axis 2 drive lubrication: Remove hex plug in vent port B. Apply grease through lube port 2 per the specification table. Reinstall hex plugs in vent port B and lube port 2. 2 AXIS 2 LUBE PORT (REMOVE COVER) 4 AXIS 1 LUBE PORT REF VIEW A WRIST HOUSING LUBE PORT 4. Axis 3 drive lubrication: Position the arm so that vent port C is riding high as required for LH or RH inner arm offset configuration. Remove hex plug in vent port C. Apply grease through lube port 3 per specification table. Reinstall hex plugs in vent port C and lube port 3. 5. Wrist lubrication: Brush specified grease on gear teeth and hand pack bearings during assembly. Install wrist on arm and add grease through ports 4, 5, & 6 per specification table. 6. Use Permatex “No more leaks” on threaded plugs and fittings that are removed and reinstalled as part of the lubrication procedure. (COVER REMOVED) 6 7. Use a calibrated grease pump to confirm that the amount of grease applied meets the specifications in the table. OUTER KNUCKLE LUBE PORT 1 AXIS 1 LUBE PORT (REMOVE COVER) 8. Grease gun tip pressure must be under 0.1MPa when greasing the RV drives. A [ET-6263-820-007_SHT1] INITIAL AND REBUILD -104- REV D1 7 CHECKS AND MAINTENANCE MAROB25IB07151E REV C Figure 7-2 ET-6263-820-007_SHT2, MAINTENANCE- FLOOR, ANGLE, SHELF MOUNT WARNING MAINTENANCE LUBE SPECIFICATIONS Assembly location Axis 1 RV (iron pedestal or alumnium base) Axis 2 RV Frequency of lube maintenance (hours) Mounting orientation Vent Fill Level check Initial fill from factory REF 20,000 Floor, Shelf, Angle 1 2 1 3 3708 (226) Wall (see note 1) 1 or 3 1 or 3 2 1 4158 (254) 20,000 Invert 2 1 2 1 4423 (270) 20,000 VIEW A 20,000 Axis 3 RV Drain Floor & Shelf 4 6 4 5 Angle LH arm offset 4 6 4 5 Angle RH arm offset 4 6 4 7 Wall (see note 1) 4 or 6 4 or 6 4 6 Invert 6 4 4 5 Floor, Shelf, Angle, Invert 8 9 8 9 Wall (see note 1) 8 or 9 8 or 9 8 9 Maintenance fill see note 2 Grease type Vigo grease RE NO. 0 3581 (219) see note 2 Vigo grease RE NO. 0 854 (52) see note 2 Vigo grease RE NO. 0 Wrist housing 4,000 All n/a n/a 10 n/a 200 (12) 4.9 (0.3) LG-01-02 Inner knuckle 4,000 All n/a n/a 11 n/a 180 (11) 6.6 (0.4) LG-01-02 Outer knuckle 4,000 All n/a n/a 12 n/a 150 (9) 4.9 (0.3) LG-01-02 NOTE: 1. Select the drain location option that enables the lowest drain position to be achieved by positioning the robot axes within the contraints of the installation. 2. Fill with the amount equal to what was removed using the procedure defined below. Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment Grease volume cc (in3) 10,000 1 (COVER REMOVED) Port location WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS STD. FANUC PART NO. ZINC FREE FANUC PART NO. GREASE TYPE - SIZE HDWMO000004194O HDWMO000004167O LG-01-02 TUBE - 14 OZ. HDWMO000004195O HDWMO000004168O HDWMO000004196O XGMF-16799 HDWMO000004169O XGMF-16156 LG-01-02 PAIL - 35 LB. LG-01-02 KEG - 115 LB. VIGO GREASE RE NO. 0 2 KG VIGO GR EASE RE NO. 0 16 KG 3 LUBRICATION MAINTENANCE REQUIREMENTS - Floor, Invert, Angle, Shelf, Wall 9 8 MAJOR AXES (1, 2, 3): Follow the procedure below to remove as much of the old grease as practical and refill to the original level with fresh grease. Refer to the specification table for frequency of replacement, grease type, and original fill volume. The procedure should be completed one axis at a time. OUTER ARM VERTICAL 20° 1. Use an automatic program to cycle the axis in a repetitive motion to heat up and reduce the viscosity of the grease. 2. Move the robot arms into position to maximize the amount of grease that can be replaced. 3. Remove the cover to access the specified drain port. Connect a drain tube to the drain port. The far end of the drain tube should be connected to a waste vacuum. 4. Remove the plug in the specified vent port to allow air entry as grease is removed. 5. Vacuum grease out the drain port while the crankcase is still warm. 6. Remove the motor and/or motor plate and use a tube attachment to vacuum any additional old grease that can be reached. Use a suitable method to support the weight of the robot arms against gravity before removing the motor / brake. 7. Replace the motor and/or motor plate. 8. Position the arms as shown to establish the proper elevation of the specified level check port. 9. Remove the plug in the level check port and pump fresh grease through the fill port until fresh grease exits the level check port. 10. Replace hex plugs in all ports. 11. Repeat step 1 to warm up the new grease and let it settle to a level fill height in the crankcase. 12. Recheck the level of grease at the level check port. Allow any excess grease to flow out of the crankcase through the level check port or add fresh grease at lube port until grease exits level check port. 13. Replace hex plugs in all ports. Use Permatex “No more leaks” on plug threads the last time they are replaced. 14. Repeat steps 11 - 13 until the crankcase is evenly filled with warm grease to the height of the level check port. 15. Reconnect the grease expansion coil on axis 1 of wall and invert mounted robots. Note: Grease gun tip pressure must be under 0.1MPa to prevent damage to the crankcase seals. GRAVITY 6 11 5 4 10 2 7 12 1 A WRIST AXES (4,5,6): 1. Add fresh grease at the specified lube ports per the frequency, grease type, and amount defined in the specification table. Existing grease is not removed. 2. Use a calibrated grease pump to confirm that the amount of grease applied meets the specifications in the table. OPTIONAL PROCESS AXES (P1, P2): Process axes are lubed for life at the factory. No lube maintenance is required. IRON PEDESTAL FLOOR MOUNT AND ALUMINUM BASE SHELF MOUNT ARMS SHOWN IN REFILL POSITION, LH / RH ARM OFFSET USE SAME ARM POSITIONS SEE SHEET 3 FOR ADDITIONAL ARM POSITIONS [ET-6263-820-007_SHT2] REV A MAINTENANCE- FLOOR, ANGLE, SHELF MOUNT -105- MAROB25IB07151E REV C 7 CHECKS AND MAINTENANCE Figure 7-3 ET-6263-820-007_SHT3, LUBRICATION REQUIREMENTS WARNING 9 6 6 Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment 9 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. GRAVITY RIGHT HAND ARM OFFSET UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS LEFT HAND ARM OFFSET 3 3 IRON PEDESTAL OR ALUMINUM WALL BASE MOUNTED UPSTREAM OR DOWNSTREAM IRON PEDESTAL OR ALUMINUM WALL BASE MOUNTED UPSTREAM OR DOWNSTREAM ROTATE TURRET 15° TO RAISE HEIGHT OF LEVEL CHECK PORT 3 BEFORE FILLING AXIS 1 WALL MOUNTED ROBOT ARMS SHOWN IN REFILL POSITION 9 LEFT HAND ARM OFFSET 20° FOR 45° MOUNT 35° FOR 30° MOUNT 20° FOR 45° MOUNT 35° FOR 30° MOUNT 5 1 SEE SHEET 2 FOR 7 VIEW OF PORT 9 3 MOTOR BROKEN AWAY TO SHOW PORT 5 RIGHT HAND ARM OFFSET 3 LEFT HAND ARM OFFSET (SAME PORT LOCATIONS AS RH) RIGHT HAND ARM OFFSET GRAVITY ROTATE TURRET 40° TO RAISE HEIGHT OF LEVEL CHECK PORT 3 BEFORE FILLING AXIS 1 GRAVITY ANGLE MOUNT ROBOT ARMS SHOWN IN REFILL POSITION INVERT MOUNTED ROBOT ARMS SHOWN IN REFILL POSITION NOTE: SEE SHEET 2 FOR IDENTIFICATION OF NUMBERED PORTS. [ET-6263-820-007_SHT3] LUBRICATION REQUIREMENTS -106- REV D1 7 CHECKS AND MAINTENANCE MAROB25IB07151E REV C Figure 7-4 ET-6263-820-008_SHT1, LUBE EXPANSION CONNECTION WARNING Some components are heavy. Use extreme care and follow proper lifting procedures when you install or remove components. Otherwise you could injure personnel or damage equipment INVERT MOUNT LUBE EXPANSION COIL SHOWN UNPLUGGED COIL CONNECTION NOTICE SEE NOTE 2 WARNING Always disconnect power to the robot before you perform any service or maintenance procedures. Otherwise, you could injure personnel or damage equipment. PLGMM000000017O EO-HOSE -011-010 L=3293.4mm [129.7"] PROVIDES 7.7 CUBIC INCHES FOR GREASE EXPANSION SEE NOTE 1 UNLESS OTHERWISE NOTED: SEE EG-00008 FOR LOCTITE REQUIREMENTS SEE EG-00010 FOR TORQUE SPECIFICATIONS EO-HOSE-011-010 DISCONNECTED FITCO000001476O SEE NOTES 1 & 3 FITMO000002115O DETAIL A SCALE 1 : 4 EO-HOSE -011-010 L=3500mm [137.8"] PROVIDES 8.2 CUBIC INCHES FOR GREASE EXPANSION SEE NOTE 1 EO-HOSE -011-010 L=3293.4mm [129.7"] PROVIDES 7.7 CUBIC INCHES FOR GREASE EXPANSION SEE NOTE 1 FITCO000001476O SEE NOTE 1 COIL CONNECTION NOTICE SEE NOTE 2 WALL MOUNT WALL MOUNT WITH IRON PEDESTAL WITH ALUMINUM BASE COIL CONNECTION NOTICE SEE NOTE 2 NOTE: 1. THE LUBE EXPANSION COIL USED ON AXIS 1 OF WALL AND INVERT MOUNTED ROBOTS IS DISCONNECTED FOR SHIPMENT. IT MUST BE RECONNECTED DURING INSTALLATION AT THE CUSTOMER'S SITE. REMOVE PLUG PLGMM000000017O FROM THE CONNECTOR FITCO000001476O AND CONNECT WITH LUBE EXPANSION COIL EO-HOSE-011-010. 2. ROBOT IS SHIPPED WITH COIL CONNECTION NOTICE (YELLOW YAPE) HANGING OUT FROM UNDER THE COVER. DISCARD TAPE AFTER EXPANSION COIL IS CONNECTED [ET-6263-820-008_SHT1] LUBE EXPANSION CONNECTION -107- REV A 8 8 TROUBLESHOOTING MAROB25IB07151E REV C TROUBLESHOOTING -109- MAROB25IB07151E REV C 8 TROUBLESHOOTING 8.1 Mechanical Unit Troubleshooting Table 8-1 shows the most common robot mechanical unit problems and their causes. If a cause or remedy is unclear, contact FANUC America Corporation. Table 8-1 Problems and Causes Symptom The robot does not return to the zero position correctly Position offset Vibration Excessive play Unusual noise Over heating Cause Remedy Low voltage of the memory backup battery. Unusual external start signal. Incorrect parameter. The robot has been hit. Incorrect Mastering The robot is not firmly fastened to the base plate. Peripheral device was shifted. Incorrect parameters. Defective pulse coder cable. APC (Absolute Pulse Coder) malfunction. Play in mechanical unit. The robot is not firmly fastened to the base. Excessive floor vibration (especially when installed above the first floor). An incorrect servo adjustment. A defective cable. The robot is not grounded. A defective motor. A defective reducer. Play in the mechanical unit. A loose screw or pin. A defective reducer. An incorrect gear backlash. Worn gears. Worn bearings. A cracked casting. Insufficient gear or reducer lubrications. Foreign matter in a gear or a reducer. Excessive pressure on the bearings. A defective reducer. An incorrect gear adjustment. Worn gears. Worn bearings. Cable pair damage. An incorrect servomotor adjustment. Insufficient gear or reducer lubrication. -110- Replace the battery. Investigate the cause. Revise parameters. Revise the teaching points. Remaster Robot Retighten. Reposition. Revise parameters. Replace the cable. Replace the motor or the pulse coder. Refer to excessive play symptom in this table. Retighten. Investigate the installation location and adjust the robot location if necessary. Adjust the servo. Replace the cable. Connect to ground. Replace the motor. Replace the reducer. Refer to the excessive play symptom in this table. Tighten and apply LOCTITE as specified. Replace the reducer. Adjust the gears. Replace the gears. Replace the bearings. Replace cracked parts. Lubricate. Clean and lubricate. Reduce the pressure on the bearings. Replace the reducer. Adjust the gears. Replace the gears. Replace the bearings. Replace the cable pair. Adjust the servomotor. Lubricate. 8 TROUBLESHOOTING MAROB25IB07151E REV C Symptom The robot drops (10 mm or more) when the power supply is off Grease leakage Cause Remedy Replace with the specified grease. Reduce the pressure on the bearings. Increase maintenance air supply Reduce the load and restrict the movement conditions. Adjust the gears. Revise the time constant. Replace the motor. Replace the relay. Replace the motor and ensure proper grease level. Replace the O-ring, oil seal, or packing. Replace the cracked parts. Tighten the screws. Remove some of the grease. The specified grease was not used. Excessive pressure on bearings. Insufficient maintenance air An excessive load on the wrist. An incorrect gear adjustment. An incorrect time constant. The brake gap is too large. Fused brake drive relay. Intrusion of grease into motor due to excessive quantity of grease. Deteriorated O-ring, oil seal, or packing. A cracked casting. Loose screws. Excessive quantity of grease. 8.2 P-250iB Purge cycle troubleshooting 8.2.1 P-250iB Purge Procedure and Troubleshooting Table 8-2 Possible Purge Cycle Problems PROBLEM Inadequate air flow through the robot or opener Air leakage from robot or opener Pressure switch or air flow switch does not appear to work Inconsistent readings on the pressure gauge CAUSE WHAT TO CHECK FOR Air supply capacity inadequate The air supply is inadequate. Check the air pressure at the pneumatic air supply. Bad seal Look for leakage around cover gaskets and bearing seals, at the cable entrance to the robot, holes where plugs or screws are missing, through unsealed conduit. Defective pressure switch or air flow switch Air leaks or other problems with the pneumatic air distribution Perform the pressure switch test and air flow switch test to check components. Check continuity of the pressure switch and air flow switch, during dynamic test conditions. Check pressure gauge. CAUTION: Both the Pressure Switches and the Air Flow Switches are adjusted and sealed at the factory or authorized vendor. They are not adjustable in the field. If you break or tamper with the seal you will void FM certification on the robot. -111- 9 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C ENGINEERING GUIDELINES -113- MAROB25IB07151E REV C 9 9.1 LOCTITE SPEC - EG-00008 Figure 9-1 EG-00008 Sheet 1 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 1 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 The purpose of this engineering guideline is to define the different Loctite products used at FAC and to provide directions for proper use. This document is intended as a guideline only. Deviations are permitted and override this guideline when explicitly stated on engineering drawings/documentation. 1. Cleaning Surfaces that are to have Loctite applied must be clean. Acetone and Loctite "ODC-Free Cleaner & Degreaser" are approved cleaning agents. Fasteners may be batch cleaned by submerging in acetone. Critical areas where retaining compounds are used must be thoroughly cleaned to remove all preservative. Some preservatives are not visible and the parts may appear clean. Some preservatives contain nitrates which will stop Loctite from curing. All areas where retaining compound is used will have it's final cleaning with acetone. The parts on which retaining compounds are used shall be thoroughly cleaned and "scrubbed" with acetone at least two times with a clean cloth. They may be washed beforehand in a solvent tank. The parts must then be wiped down and blown off before cleaning twice with acetone. 2. Primers The engineering drawings shall call out primer when necessary. Loctite 7649 (Primer N) ND 611 & Loctite 7471 (Primer T) ND 612 Loctite brand primers are used to ensure cure when applying Loctite threadlocker to two inactive metals. Primers will also speed up cure time. -114- ENGINEERING GUIDELINES 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C Figure 9-2 EG-00008 Sheet 2 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 2 of 10 Title: LOCTITE APPLICATION Active Metals Iron Plain Steel Copper Brass Commercial Aluminum Bronze Kovar EG #: EG-00008 Inactive Metals Plated Steel Anodized Aluminum Stainless Steel Galvanized Steel Zinc Natural or Chemical Black Oxide Plastic Dacromet If a primer is required for faster curing, it should be specified on the drawing. Directions for use 1) Clean mating surfaces to ensure all contamination has been removed. 2) Apply primer to both mating surfaces to be bonded. 3) Allow the primer time to evaporate under good ventilation until surfaces are completely dry. 4) After primer is applied, parts should be bonded within 7 days. 3A. Thread Locking – Conventional. Loctite thread lockers are anaerobic and cure when confined in the absence of air between close fitting metal surfaces. Application of the product will prevent loosening of assembled parts that are subject to shock and vibration. Loctite 222 ND 111: -115- MAROB25IB07151E REV C 9 Figure 9-3 EG-00008 Sheet 3 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 3 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 Loctite 222 is a low strength threadlocker designed to lock and seal threaded fasteners, which require easy disassembly. Unless explicitly stated on engineering drawings/documentation, Loctite 222 is to be used on all carbon and stainless steel fasteners 5mm and smaller. The uncured appearance of this product is a purple liquid. Loctite 242 ND 121 or 248(stick): Loctite 242 is a medium strength treadlocker designed to lock and seal threaded fasteners that require normal disassembly with standard hand tools. Unless explicitly stated on engineering drawings/documentation, Loctite 242 is to be used on all carbon and stainless steel fasteners 6mm and above. The uncured appearance of this product is blue. Loctite 262 ND 131 or 268(stick): Loctite 262 is a high strength threadlocker designed to permanently lock and seal threaded fasteners. This product should not be applied unless explicitly stated on engineering drawings/documentation. The uncured appearance of this product is red. Loctite 277 ND 146: Loctite 277 is a high strength threadlocker designed to permanently lock and seal threaded fasteners. This product should not be applied unless explicitly stated on engineering drawings/documentation. The uncured appearance of this product is a red liquid. Directions for use 1) Clean mating surfaces to ensure all contamination has been removed. 2) Apply primer as required and allow to dry. 3) Select the specified product. Shake the liquid products before use. 4) For Thru Holes, apply several drops of the product onto the bolt at the nut engagement area. 5) For Blind Holes, the application method requires that product be applied to both parts. Apply several drops of the product down the internal threads to the bottom of the hole as well as the external treads of mating fastener. If product -116- ENGINEERING GUIDELINES 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C Figure 9-4 EG-00008 Sheet 4 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 4 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 is only applied to the fastener, air pressure will force the liquid threadlocker to escape as the fastener is tightened down. Lack of uniform coverage creates air pockets, causing incomplete cures, which lead to failures. 6) Assemble and tighten as required. Fasteners must be torqued within 3 minutes. 3B. Thread Locking – Pre applied. Loctite Dri Loc STS can be pre applied to fasteners provided the break away torque meets the FAC torque specification EG -00010. For M5 fasteners it should be diluted 50 % by weight and applied as shown below. 4. Retaining Loctite retaining compounds form a strong bond between press-fitted and slip-fitted parts. The product fills the inner space between components and cures to form a strong bond. Loctite 680 is a high viscosity-retaining compound for joining fitted cylindrical parts. The product cures when confined in the absence of air between close fitting metals. -117- MAROB25IB07151E REV C 9 Figure 9-5 EG-00008 Sheet 5 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 5 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 Directions for use 1) Clean mating surfaces to ensure all contamination has been removed. Parts must be cleaned completely. Use acetone and scrub with a clean rag at least two times. 2) If parts are inactive metals or cure speed is too slow, spray with Loctite Primer 7471 or 7649 per the engineering drawing. 3) For Slip Fitted Assemblies, apply adhesive 360 degrees around OD and ID of mating parts. Use a rotating motion during assembly to ensure good coverage. 4) For Press Fitted Assemblies, apply adhesive 360 degrees around OD and ID of mating parts to insure the surfaces are completely coated during assembly. Assemble mating parts. When an undercut is provided, the adhesive shall be applied to the shaft to insure that the undercut is completely filled as the parts are pressed together. 5) Parts should not be disturbed until sufficient handling strength is achieved. Parts using Loctite 680 need to remain in fixture for 10 minutes. Full cure will be developed in 24 hours. 5a. Thread Sealant Loctite “No More Leaks” is a thread sealant, which is designed to be used on tapered threads of plastic fittings that carry water or air. The sealant is solvent based and is non-curing so it shouldn’t be used for lines that carry paint or solvents. It is not a thread locker Directions for use 1) Clean mating surfaces to ensure contamination has been removed. 2) Apply a 360-degree bead of sealant to the leading threads of the male fitting, leaving the first thread free. Force the sealant into the threads to ensure all voids are filled. 3) Assemble and tighten fittings as required. 4) Properly tightened fittings will seal instantly because it does not actually cure. -118- ENGINEERING GUIDELINES 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C Figure 9-6 EG-00008 Sheet 6 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 6 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 100% coverage, sealant forced into thread to eliminate voids. First thread free of sealant . Fitting install, sealant should be visible at the edges. -119- MAROB25IB07151E REV C 9 Figure 9-7 EG-00008 Sheet 7 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 7 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 5b. Thread Sealant and locker A thread sealant will seal and secure metal and plastic pipes and fittings, filling the space between threaded metal parts, and hardening to prevent leakage. It can be used with primer on any metal and plastic fittings that are resistant to solvents such as Delrin (Acetal) or Nylon. The primer contains Acetone so it shouldn’t be used on any plastic such as PVC that isn’t resistant to paint solvents. Loctite 567 (ND 460) is designed for locking and sealing metal tapered threads and fittings. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. The product also provides lubrication, preventing galling between metal pipe threads and fittings. Loctite 554 (ND 446) is similar Loctite 567 (ND 460). It should be used for locking and sealing of threads where maximum solvent resistance is required such as hoses and pipes that carry paint and paint solvents. Directions for use 1) Clean mating surfaces to ensure contamination has been removed. 2) Apply primer to both the male and female threads as required and allow them to dry. 3) Apply a 360-degree bead of sealant to the leading threads of the male fitting, leaving the first thread free. Force the sealant into the threads to ensure all voids are filled. 4) Assemble and tighten fittings as required. 5) Properly tightened fittings will seal instantly and can withstand moderate pressure. For maximum pressure and solvent resistance allow the sealant to cure a minimum of 24 hours. 6. Gasketing Gaskets are used to prevent fluid or gas leaks by forming impervious barriers that must remain intact and leak free for a prolonged period of time. Form-in-place gaskets are applied as a liquid sealant before parts are assembled. After -120- ENGINEERING GUIDELINES 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C Figure 9-8 EG-00008 Sheet 8 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 8 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 assembly, the form-in-place gasket spreads and cures between assembled parts filling gaps, scratches and surface irregularities to provide a durable seal. Loctite 518 ND 730 Gasket Eliminator is medium strength, solvent resistant flexible seal that will not tear or decay. The product cures when confined in the absence of air between close fitting metals. The product will fill gaps up to 0.25mm. Directions for use 1) Clean mating surfaces to ensure all contamination has been removed. The product gives best performance when surfaces are clean and free of grease. 2) Apply product in a continuous bead to one of the mating surfaces. 3) Assemble mating parts. Parts should be tightened as soon as possible after assembly. 4) Low pressure can be used to confirm a complete seal immediately after assembly. Allow time for full cure before applying high pressure. 7. Gasket Adhesives Gasket adhesives are used to bond a gasket to its cover for ease of assembly. Loctite "High Tack" is a flexible material that will bond gaskets to its cover. It can be used on all paper, rubber, cork or metal gaskets. Directions for use 1) Clean mating surfaces to ensure all contamination has been removed. 2) Apply product with brush or spray. 3) Assemble gasket to cover. Parts should be allowed to cure for 5 minutes minimum before the cover/gasket is installed. -121- MAROB25IB07151E REV C 9 Figure 9-9 EG-00008 Sheet 9 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 9 of 10 Title: LOCTITE APPLICATION EG #: EG-00008 4) After each cover removal, verify proper gasket attachment to the cover and reapply Permatex Hy-Tack HDWMO000003630O if necessary. 8. List of the ND Industries part numbers – equivalent to Loctite. Fanuc Item Number: HDWMO000001145O HDWMO000001146O HDWMO000001147O ALT:HDWMO000002362O HDWMO000001836O HDWMO000002312O HDWMO000002362O ALT:HDWMO000001147O HDWMO000002450O HDWMO000003076O HDWMO000003148O HDWMO000003185O HDWMO000003186O Current Item Description LOCTITE #49550 ADHSV 1 OZBOTL LOCTITE #242-41 SEALANT 250CC LOCTITE #271-41 THRDLCKR 250CC LOCTITE #242-31 SEALANT 50CC LOCTITE #515-31 GSKT SEALANT LOCTITE #271-31 SEALANT 50CC LOCTITE #26231 RETAIN COMPOUND LOCTITE #680 RETAIN COMP 50CC LOCTITE #290-41 SEALANT 250CC LOCTITE #PST56747 SEALANT 50M LOCTITE #22241 SEALANT 250CC New Item Description LOCTITE #49550 1oz / ND #39528 LOCTITE #242-41 250cc/ND#12125 LOCTITE #271-41 250cc/ND#14025 LOCTITE #242-31 50cc/ND #12150 LOCTITE #515-31 50cc/ND #73250 LOCTITE #271-31 50cc/ND #14050 LOCTITE #26231 50cc/ND #13150 LOCTITE #680 50cc/ND #54150 LOCTITE #290-31 50cc/ND#15050 LOCTITE#PST56747 50ml/ND#46050 LOCTITE #22241 250cc/ND #11125 -122- ENGINEERING GUIDELINES 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C Figure 9-10 EG-00008 Sheet 10 of 10, LOCTITE APPLICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 10 of 10 Title: LOCTITE APPLICATION HDWMO000003248O HDWMO000003249O HDWMO000003367O HDWMO000003658O HDWMO0000060324O HDWMO000056588O HDWMO000057262O HDWMO000057263O LOCTITE #51831 SEALANT TUBE LOCTITE #51845 SEALANT 300ML LOCTITE #222-31 SEALANT 50 ML LOCTITE #21348 PRIMER N LOCTITE #45440 PRISM 454 ADHES LOCTITE #41650 416 INST ADHEV Loctite #55441 Thread Sealant Locker ND #44650 50cc Same as Loctite #554 EG #: EG-00008 LOCTITE #51831 50ml/ND #73050 LOCTITE #51845 300ml/ND#73025 LOCTITE #222-31 50ml/ND #11150 LOCTITE #21348 PRI N/ND #61118 LOCTITE #45440 20gm/ND #35420 LOCTITE #41650 1oz/ND #31628 Loctite #55441 250cc ND #44625 ND #44650 50cc -123- MAROB25IB07151E REV C 9 9.2 TORQUE SPEC - EG-00010 Figure 9-11 EG-00010 Sheet 1 of 5, TORQUE SPECIFICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Title: Mechanical Development Torque Specifications Page 1 of 5 EG #: EG-00010 Purpose: To define the torque and Loctite specifications for the most common fasteners used. Scope: This torque specification applies only to Products designed in the Mechanical Development department (EO, ET drawing series). Deviations are permitted and override this specification when explicitly stated on the engineering drawing/documentation. Tolerance: - Torque tolerance for all specified values is assumed to be +/- 6% unless otherwise specified on drawing. Specification: For Metric Fasteners Only NOTE: Unless otherwise specified: All threaded fasteners have coarse threads All Stainless Socket Head fasteners and Stainless Hex Head screws and all Hex Head Type Nuts will be grade A2. All Carbon Steel Socket Cap screws will be grade 12.9. All Dacromet plated Carbon Steel Socket Cap screws will be grade 12.9. All zinc plated Carbon Steel Socket Cap screws will be grade 12.9. (torqued to 10.9 spec) All Carbon Steel Shoulder Screws will be grade 12.9. All Carbon Steel Socket Flat Head screws and Carbon Steel Socket Button Head fasteners will be grade 10.9. All Carbon Steel Low Head Socket Cap screws will be grade 8.8. All Carbon Steel Hex head screws will be grade 8.8 All Carbon Steel Hex nuts M6 and larger will be grade 10 All Carbon Steel Hex Nut M5 and smaller will be grade 6 All Carbon Steel Jam Nuts will be grade 4. All Nylon fasteners are Polyamide 6.6 (nylon 6.6) All Brass fasteners are Brass Ms 63 (cold formed) Loctite #222 will be used on all carbon and stainless steel fasteners 5mm and under. Loctite #242 will be used on all carbon and stainless steel fasteners 6mm and over. -124- ENGINEERING GUIDELINES 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C Figure 9-12 EG-00010 Sheet 2 of 5, TORQUE SPECIFICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 2 of 5 Title: Mechanical Development Torque Specifications EG #: EG-00010 A. Standard Torque Specification for grade 12.9 Carbon Steel Socket Cap, grade 10.9 Hex Head Screws and grade 10 Hex Nuts (Except for Fasteners securing covers with gaskets) Dacromet coated Carbon Steel Socket Cap screws Torque (N-m) .5 1.0 1.7 3.9 7.9 13.5 32 64 112 180 280 546 944 1825 3200 M2 x .4 M2.5 x .45 M3 x .5 M4 x .7 M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2.0 M16 x 2.0 M20 x 2.5 M24 x 3.0 M30 x 3.5 M36 x 4.0 Torque (ft-lbs) 0.4 0.7 1.3 2.9 5.9 10.0 23.6 47.2 82.5 132 206 402 696 1346 2360 B. Standard Torque Specification for grade 12.9 Carbon Steel Shoulder screws. Thread Diameter and Pitch M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M16 x 2.0 Shoulder Diameter Torque (N-m) Torque (ft-lbs) M6 M8 M10 M12 M16 M20 7.9 13.5 32 64 112 280 10 23.6 47.2 82.5 206 Torque (in-lbs) 70.0 119.4 -125- MAROB25IB07151E REV C 9 Figure 9-13 EG-00010 Sheet 3 of 5, TORQUE SPECIFICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 3 of 5 Title: Mechanical Development Torque Specifications EG #: EG-00010 C. Standard Torque Specification for all Stainless fasteners and Nuts (Except for Fasteners securing covers with gaskets) M2 x .4 M2.5 x .45 M3 x .5 M4 x .7 M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2.0 M16 x 2.0 M20 x 2.5 M24 x 3.0 M30 x 3.5 M36 x 4.0 Torque (N-m) 0.33 0.66 1.1 2.6 5.4 9.2 22.0 43.5 76.0 121 189 368 636 1263 2207 Torque (ft-lbs) 0.25 0.5 0.8 2.0 4.0 6.8 16.2 32.0 56.0 89.0 138 271 469 932 1628 D. Torque Specification for all Metric Carbon and Stainless Fasteners securing Covers with Gaskets M4 x .7 M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 Torque (N-m) 2.0 4.0 6.3 7.5 8.4 Torque (ft-lbs) 1.5 3.0 4.6 5.5 6.2 -126- ENGINEERING GUIDELINES 9 ENGINEERING GUIDELINES MAROB25IB07151E REV C Figure 9-14 EG-00010 Sheet 4 of 5, TORQUE SPECIFICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 4 of 5 Title: Mechanical Development Torque Specifications EG #: EG-00010 E. Standard Torque Specification for grade 8.8 Carbon Steel Hex Head screws, grade 10.9 Carbon steel Flat Head Socket Screws, grade 10.9 Button Head Socket Screws, grade 8.8 Carbon Steel Low Head Socket Cap Screws, grade 6 Carbon Steel Hex Nuts and all Carbon Steel Jam Nuts (Except for Fasteners securing covers with gaskets), grade 12.9 Zinc plated Carbon Steel Socket Cap screws M2 x .4 M2.5 x .45 M3 x .5 M4 x .7 M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2.0 M16 x 2.0 M20 x 2.5 M24 x 3.0 M30 x 3.5 M36 x 4.0 Torque (N-m) 0.4 0.7 1.0 2.2 4.3 7.5 18.0 36.0 67.0 106.0 161.0 315.0 544.0 1080.0 1890.0 Torque (ft-lbs) 0.3 0.5 0.7 1.6 3.1 5.5 13.2 26.5 49.4 78.0 118.5 232 401 796 1394 F. Standard Torque Specification for all Nylon fasteners and Nuts M3 x .5 M4 x .7 M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2.0 M16 x 2.0 Torque (N-m) 0.1 0.2 0.5 1.0 2.0 3.0 4.0 6.0 7.5 Torque (ft-lbs) 0.07 0.15 0.37 0.74 1.4 2.2 3.0 4.4 5.5 -127- MAROB25IB07151E REV C 9 Figure 9-15 EG-00010 Sheet 5 of 5, TORQUE SPECIFICATION FANUC AMERICA CORPORATION ENGINEERING GUIDELINE Page 5 of 5 Title: Mechanical Development Torque Specifications EG #: EG-00010 G. Standard Torque Specification for all Brass fasteners and Nuts M2 x .4 M2.5 x .45 M3 x .5 M4 x .7 M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 Torque (N-m) 0.14 0.29 0.5 1.2 2.2 3.9 9.0 17.0 Torque (ft-lbs) 0.10 0.21 0.37 0.9 1.6 2.9 6.6 12.5 -128- ENGINEERING GUIDELINES
