FANUC Robotics
R-J3iB Controller
ARC Mate 120iB, 120iB/10L
M-16iB/20, M-16iB/10L
Maintenance Manual
MARMI120I07021E REV. A
B–81765EN/01
This publication contains proprietary information of FANUC Robotics
North America, Inc. furnished for customer use only. No other uses
are authorized without the express written permission of FANUC
Robotics North America, Inc.
FANUC Robotics North America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253
The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for printing. FANUC
Robotics North America, Inc, hereinafter referred to as FANUC
Robotics, reserves the right to discontinue models at any time or to
change specifications or design without notice and without incurring
obligations.
FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics’ products and/or systems. Such
systems consist of robots, extended axes, robot controllers,
application software, the KARELâ programming language,
INSIGHTâ vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training
Course(s) be permitted to install, operate, use, perform procedures
on, repair, and/or maintain FANUC Robotics’ products and/or
systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of
system installed and application performed at the customer site.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in accordance
with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it
has not been tested for compliance with the limits for Class A
computing devices pursuant to subpart J of Part 15 of FCC
Rules, which are designed to provide reasonable protection
against such interference. Operation of the equipment in a
residential area is likely to cause interference, in which case
the user, at his own expense, will be required to take
whatever measure may be required to correct the
interference.
FANUC Robotics conducts courses on its systems and products on
a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics North America, Inc.
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
Copyright ã2002 by FANUC Robotics North America, Inc.
All Rights Reserved
The information illustrated or contained herein is not to be
reproduced, copied, translated into another language, or transmitted
in whole or in part in any way without the prior written consent of
FANUC Robotics North America, Inc.
AccuStatâ, ArcToolâ, DispenseToolâ, FANUC LASER DRILLâ,
KARELâ, INSIGHTâ, INSIGHT IIâ, PaintToolâ, PaintWorksâ,
PalletToolâ, SOCKETSâ, SOFT PARTSâ SpotToolâ,
TorchMateâ, and YagToolâ are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:
AccuAirÔ AccuCalÔ AccuChopÔ AccuFlowÔ AccuPathÔ
AccuSealÔ ARC MateÔ ARC Mate Sr. Ô ARC Mate System 1Ô
ARC Mate System 2Ô ARC Mate System 3Ô ARC Mate System
4Ô ARC Mate System 5Ô ARCWorks ProÔ AssistToolÔ
AutoNormalÔ AutoTCPÔ BellToolÔ BODYWorksÔ Cal MateÔ Cell
FinderÔ Center FinderÔ Clean WallÔ CollisionGuardÔ
DispenseToolÔ F-100Ô F-200iÔ FabToolÔ FANUC LASER
DRILLÔ FlexibellÔ FlexToolÔ HandlingToolÔ HandlingWorksÔ
INSIGHTÔ INSIGHT IIÔ IntelliTrakÔ Integrated Process SolutionÔ
Intelligent Assist DeviceÔ IPC -Integrated Pump ControlÔ IPD
Integral Pneumatic DispenserÔ ISA Integral Servo ApplicatorÔ ISD
Integral Servo DispenserÔ Laser Mate System 3Ô Laser Mate
System 4Ô LaserProÔ LaserToolÔ LR ToolÔ MIG EyeÔ
MotionPartsÔ NoBotsÔ Paint StickÔ PaintProÔ PaintTool 100Ô
PAINTWorksÔ PAINTWorks IIÔ PAINTWorks IIIÔ PalletMateÔ
PalletMate PCÔ PalletTool PCÔ PayloadIDÔ RecipToolÔ
RemovalToolÔ Robo ChopÔ Robo SprayÔ S-420iÔ S-430iÔ
ShapeGenÔ SoftFloatÔ SOFÔ PARTSÔ SpotTool+Ô SR MateÔ
SR ShotToolÔ SureWeldÔ SYSTEM R-J2 ControllerÔ SYSTEM RJ3 ControllerÔ SYSTEM R-J3iB ControllerÔ TCP MateÔ
TurboMoveÔ TorchMateÔ visLOCÔ visPRO-3DÔ visTRACÔ
WebServerÔ WebTPÔ YagToolÔ
Conventions
This manual includes information essential to the safety of
personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set it
apart from other text.
CAUTION
Information appearing under CAUTION concerns the protection of
equipment, software, and data. It is boxed to set it apart from
other text.
NOTE Information appearing next to NOTE concerns related
information or useful hints.
MARMI120I07021E REV A
Safety-1
FANUC Robotics is not and does not represent itself as an expert in
safety systems, safety equipment, or the specific safety aspects of
your company and/or its work force. It is the responsibility of the
owner, employer, or user to take all necessary steps to guarantee
the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation
can best be determined by safety system professionals. FANUC
Robotics therefore, recommends that each customer consult with
such professionals in order to provide a workplace that allows for
the safe application, use, and operation of FANUC Robotic systems.
According to the industry standard ANSI/RIA R15.06, the owner or
user is advised to consult the standards to ensure compliance with
its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for the
training of the operator of a robot system to recognize and respond
to known hazards associated with your robotic system and to be
aware of the recommended operating procedures for your particular
application and robot installation.
FANUC Robotics therefore, recommends that all personnel who
intend to operate, program, repair, or otherwise use the robotics
system be trained in an approved FANUC Robotics training course
and become familiar with the proper operation of the system.
Persons responsible for programming the system–including the
design, implementation, and debugging of application programs–
must be familiar with the recommended programming procedures
for your application and robot installation.
The following guidelines are provided to emphasize the importance
of safety in the workplace.
Safety-2
CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION
MARMI120I07021E REV A
Safety is essential whenever robots are used. Keep in mind the
following factors with regard to safety:
·
·
·
·
·
·
Keeping People and
Equipment Safe
The safety of people is always of primary importance in any
situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider the
following:
·
·
·
·
·
Using Safety
Enhancing Devices
People
External devices
Robot(s)
Tooling
Workpiece
Always give appropriate attention to the work area that surrounds
the robot. The safety of the work area can be enhanced by the
installation of some or all of the following devices:
·
·
·
·
·
·
·
·
·
Setting Up a Safe
Workcell
The safety of people and equipment
Use of safety enhancing devices
Techniques for safe teaching and manual operation of the
robot(s)
Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcell
Proper maintenance of the robot
Safety fences, barriers, or chains
Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches
A safe workcell is essential to protect people and equipment.
Observe the following guidelines to ensure that the workcell is set
up safely. These suggestions are intended to supplement and not
replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.
·
Sponsor your personnel for training in approved FANUC
Robotics training course(s) related to your application. Never
permit untrained personnel to operate the robots.
Safety-3
MARMI120I07021E REV A
·
Install a lockout device that uses an access code to prevent
unauthorized persons from operating the robot.
·
Use anti–tie–down logic to prevent the operator from bypassing
safety measures.
·
Arrange the workcell so the operator faces the workcell and can
see what is going on inside the cell.
·
Clearly identify the work envelope of each robot in the system
with floor markings, signs, and special barriers. The work
envelope is the area defined by the maximum motion range of
the robot, including any tooling attached to the wrist flange that
extend this range.
·
Position all controllers outside the robot work envelope.
·
Never rely on software as the primary safety element.
·
Mount an adequate number of EMERGENCY STOP buttons or
switches within easy reach of the operator and at critical points
inside and around the outside of the workcell.
·
Install flashing lights and/or audible warning devices that
activate whenever the robot is operating, that is, whenever
power is applied to the servo drive system. Audible warning
devices shall exceed the ambient noise level at the end–use
application.
·
Wherever possible, install safety fences to protect against
unauthorized entry by personnel into the work envelope.
·
Install special guarding that prevents the operator from reaching
into restricted areas of the work envelope.
·
Use interlocks.
·
Use presence or proximity sensing devices such as light
curtains, mats, and capacitance and vision systems to enhance
safety.
·
Periodically check the safety joints or safety clutches that can be
optionally installed between the robot wrist flange and tooling. If
the tooling strikes an object, these devices dislodge, remove
power from the system, and help to minimize damage to the
tooling and robot.
Safety-4
Staying Safe While
Teaching or Manually
Operating the Robot
MARMI120I07021E REV A
·
Make sure all external devices are properly filtered, grounded,
shielded, and suppressed to prevent hazardous motion due to
the effects of electro–magnetic interference (EMI), radio
frequency interference (RFI), and electro–static discharge
(ESD).
·
Make provisions for power lockout/tagout at the controller.
·
Eliminate pinch points. Pinch points are areas where personnel
could get trapped between a moving robot and other equipment.
·
Provide enough room inside the workcell to permit personnel to
teach the robot and perform maintenance safely.
·
Program the robot to load and unload material safely.
·
If high voltage electrostatics are present, be sure to provide
appropriate interlocks, warning, and beacons.
·
If materials are being applied at dangerously high pressure,
provide electrical interlocks for lockout of material flow and
pressure.
Advise all personnel who must teach the robot or otherwise
manually operate the robot to observe the following rules:
·
·
·
·
·
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
Know whether or not you are using an intrinsically safe teach
pendant if you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to
make sure that no potentially hazardous conditions exist. The
work envelope is the area defined by the maximum motion
range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or
debris. Immediately report unsafe working conditions to the
supervisor or safety department.
FANUC Robotics recommends that no one enter the work
envelope of a robot that is on, except for robot teaching
operations. However, if you must enter the work envelope, be
sure all safeguards are in place, check the teach pendant
DEADMAN switch for proper operation, and place the robot in
teach mode. Take the teach pendant with you, turn it on, and be
prepared to release the DEADMAN switch. Only the person
with the teach pendant should be in the work envelope.
Safety-5
MARMI120I07021E REV A
WARNING
Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in
serious injury and death.
·
·
·
Know the path that can be used to escape from a moving robot;
make sure the escape path is never blocked.
Isolate the robot from all remote control signals that can cause
motion while data is being taught.
Test any program being run for the first time in the following
manner:
WARNING
Stay outside the robot work envelope whenever a program is
being run. Failure to do so can result in injury.
-
·
Staying Safe During
Automatic Operation
Using a low motion speed, single step the program for at
least one full cycle.
- Using a low motion speed, test run the program continuously
for at least one full cycle.
- Using the programmed speed, test run the program
continuously for at least one full cycle.
Make sure all personnel are outside the work envelope before
running production.
Advise all personnel who operate the robot during production to
observe the following rules:
·
Make sure all safety provisions are present and active.
·
Know the entire workcell area. The workcell includes the robot
and its work envelope, plus the area occupied by all external
devices and other equipment with which the robot interacts.
·
Understand the complete task the robot is programmed to
perform before initiating automatic operation.
·
Make sure all personnel are outside the work envelope before
operating the robot.
Safety-6
Staying Safe During
Inspection
Staying Safe During
Maintenance
MARMI120I07021E REV A
·
Never enter or allow others to enter the work envelope during
automatic operation of the robot.
·
Know the location and status of all switches, sensors, and
control signals that could cause the robot to move.
·
Know where the EMERGENCY STOP buttons are located on
both the robot control and external control devices. Be prepared
to press these buttons in an emergency.
·
Never assume that a program is complete if the robot is not
moving. The robot could be waiting for an input signal that will
permit it to continue activity.
·
If the robot is running in a pattern, do not assume it will continue
to run in the same pattern.
·
Never try to stop the robot, or break its motion, with your body.
The only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.
When inspecting the robot, be sure to
·
Turn off power at the controller.
·
Lock out and tag out the power source at the controller
according to the policies of your plant.
·
Turn off the compressed air source and relieve the air pressure.
·
If robot motion is not needed for inspecting the electrical circuits,
press the EMERGENCY STOP button on the operator panel.
·
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
·
If power is needed to check the robot motion or electrical
circuits, be prepared to press the EMERGENCY STOP button,
in an emergency.
·
Be aware that when you remove a servomotor or brake, the
associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.
When performing maintenance on your robot system, observe the
following rules:
Safety-7
MARMI120I07021E REV A
·
Never enter the work envelope while the robot or a program is in
operation.
·
Before entering the work envelope, visually inspect the workcell
to make sure no potentially hazardous conditions exist.
·
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
·
Consider all or any overlapping work envelopes of adjoining
robots when standing in a work envelope.
·
Test the teach pendant for proper operation before entering the
work envelope.
·
If it is necessary for you to enter the robot work envelope while
power is turned on, you must be sure that you are in control of
the robot. Be sure to take the teach pendant with you, press the
DEADMAN switch, and turn the teach pendant on. Be prepared
to release the DEADMAN switch to turn off servo power to the
robot immediately.
·
Whenever possible, perform maintenance with the power turned
off. Before you open the controller front panel or enter the work
envelope, turn off and lock out the 3–phase power source at the
controller.
·
Be aware that when you remove a servomotor or brake, the
associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
HIGH VOLTAGE IS PRESENT at the input side whenever the
controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.
·
Release or block all stored energy. Before working on the
pneumatic system, shut off the system air supply and purge the
air lines.
Safety-8
MARMI120I07021E REV A
·
Isolate the robot from all remote control signals. If maintenance
must be done when the power is on, make sure the person
inside the work envelope has sole control of the robot. The
teach pendant must be held by this person.
·
Make sure personnel cannot get trapped between the moving
robot and other equipment. Know the path that can be used to
escape from a moving robot. Make sure the escape route is
never blocked.
·
Use blocks, mechanical stops, and pins to prevent hazardous
movement by the robot. Make sure that such devices do not
create pinch points that could trap personnel.
WARNING
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result in
serious personal injury and component destruction.
·
Be aware that when you remove a servomotor or brake, the
associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.
·
When replacing or installing components, make sure dirt and
debris do not enter the system.
·
Use only specified parts for replacement. To avoid fires and
damage to parts in the controller, never use nonspecified fuses.
·
Before restarting a robot, make sure no one is inside the work
envelope; be sure that the robot and all external devices are
operating normally.
KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE
Certain programming and mechanical measures are useful in
keeping the machine tools and other external devices safe. Some
of these measures are outlined below. Make sure you know all
associated measures for safe use of such devices.
Programming Safety
Precautions
Implement the following programming safety measures to prevent
damage to machine tools and other external devices.
Safety-9
MARMI120I07021E REV A
Mechanical Safety
Precautions
·
Back–check limit switches in the workcell to make sure they do
not fail.
·
Implement ‘‘failure routines” in programs that will provide
appropriate robot actions if an external device or another robot
in the workcell fails.
·
Use handshaking protocol to synchronize robot and external
device operations.
·
Program the robot to check the condition of all external devices
during an operating cycle.
Implement the following mechanical safety measures to prevent
damage to machine tools and other external devices.
·
Make sure the workcell is clean and free of oil, water, and
debris.
·
Use software limits, limit switches, and mechanical hardstops to
prevent undesired movement of the robot into the work area of
machine tools and external devices.
KEEPING THE
ROBOT SAFE
Observe the following operating and programming guidelines to
prevent damage to the robot.
Operating Safety
Precautions
The following measures are designed to prevent damage to the
robot during operation.
Programming Safety
Precautions
·
Use a low override speed to increase your control over the robot
when jogging the robot.
·
Visualize the movement the robot will make before you press
the jog keys on the teach pendant.
·
Make sure the work envelope is clean and free of oil, water, or
debris.
·
Use circuit breakers to guard against electrical overload.
The following safety measures are designed to prevent damage to
the robot during programming:
·
Establish interference zones to prevent collisions when two or
more robots share a work area.
Safety-10
MARMI120I07021E REV A
·
Make sure that the program ends with the robot near or at the
home position.
·
Be aware of signals or other operations that could trigger
operation of tooling resulting in personal injury or equipment
damage.
·
In dispensing applications, be aware of all safety guidelines with
respect to the dispensing materials.
NOTE Any deviation from the methods and safety practices
described in this manual must conform to the approved standards of
your company. If you have questions, see your supervisor.
ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS
Process technicians are sometimes required to enter the paint
booth, for example, during daily or routine calibration or while
teaching new paths to a robot. Maintenance personal also must
work inside the paint booth periodically.
Whenever personnel are working inside the paint booth, ventilation
equipment must be used. Instruction on the proper use of
ventilating equipment usually is provided by the paint shop
supervisor.
Although paint booth hazards have been minimized, potential
dangers still exist. Therefore, today’s highly automated paint booth
requires that process and maintenance personnel have full
awareness of the system and its capabilities. They must
understand the interaction that occurs between the vehicle moving
along the conveyor and the robot(s), hood/deck and door opening
devices, and high–voltage electrostatic tools.
Paint robots are operated in three modes:
· Teach or manual mode
· Automatic mode, including automatic and exercise operation
· 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 initiated at the System
Operator Console (SOC) or Manual Control Panel (MCP), if
available, and can be monitored from outside the paint booth. All
personnel must remain outside of the booth or in a designated safe
Safety-11
MARMI120I07021E REV A
area within the booth whenever automatic mode is initiated at the
SOC or MCP.
In automatic mode, the robots will execute the path movements they
were taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines
that require them to remain in the paint booth, they must stay in a
designated safe area.
Paint System Safety
Features
Process technicians and maintenance personnel must become
totally 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:
·
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.
·
EMERGENCY STOP buttons are located on the robot controller
and teach pendant. Become familiar with the locations of all E–
STOP buttons.
·
An intrinsically safe teach pendant is used when teaching in
hazardous paint atmospheres.
·
A DEADMAN switch is located on each teach pendant. When this
switch is held in, and the teach pendant is on, power is applied to the
robot servo system. If the engaged DEADMAN switch is released
during robot operation, power is removed from the servo system, all
axis brakes are applied, and the robot comes to an EMERGENCY
STOP. Safety interlocks within the system might also E–STOP other
robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is
released on a bypassed robot.
Safety-12
MARMI120I07021E REV A
·
Overtravel by robot axes is prevented by software limits. All of
the major and minor axes are governed by software limits. Limit
switches and hardstops also limit travel by the major axes.
·
EMERGENCY STOP limit switches and photoelectric eyes
might be part of your system. Limit switches, located on the
entrance/exit doors of each booth, will EMERGENCY STOP all
equipment in the booth if a door is opened while the system is
operating in automatic or manual mode. For some systems,
signals to these switches are inactive when the switch on the
SCC is in teach mode.
When present, photoelectric eyes are sometimes used to
monitor unauthorized intrusion through the entrance/exit
silhouette openings.
·
Staying Safe While
Operating the Paint
Robot
System status is monitored by computer. Severe conditions
result in automatic system shutdown.
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
Observe all safety rules and guidelines to avoid injury.
WARNING
Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in
serious injury and death.
·
Know the work area of the entire paint station (workcell).
·
Know the work envelope of the robot and hood/deck and door
opening devices.
·
Be aware of overlapping work envelopes of adjacent robots.
·
Know where all red, mushroom–shaped EMERGENCY STOP
buttons are located.
Safety-13
MARMI120I07021E REV A
Staying Safe While
Operating Paint
Application Equipment
·
Know the location and status of all switches, sensors, and/or
control signals that might cause the robot, conveyor, and
opening devices to move.
·
Make sure that the work area near the robot is clean and free of
water, oil, and debris. Report unsafe conditions to your
supervisor.
·
Become familiar with the complete task the robot will perform
BEFORE starting automatic mode.
·
Make sure all personnel are outside the paint booth before you
turn on power to the robot servo system.
·
Never enter the work envelope or paint booth before you turn off
power to the robot servo system.
·
Never enter the work envelope during automatic operation
unless a safe area has been designated.
·
Never wear watches, rings, neckties, scarves, or loose clothing
that could get caught in moving machinery.
·
Remove all metallic objects, such as rings, watches, and belts,
before entering a booth when the electrostatic devices are
enabled.
·
Stay out of areas where you might get trapped between a
moving robot, conveyor, or opening device and another object.
·
Be aware of signals and/or operations that could result in the
triggering of guns or bells.
·
Be aware of all safety precautions when dispensing of paint is
required.
·
Follow the procedures described in this manual.
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.
Safety-14
Staying Safe During
Maintenance
MARMI120I07021E REV A
·
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.
·
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 bell.
·
Verify that the lines are not under pressure.
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.
·
Paint robots operate in a potentially explosive environment. Use
caution when working with electric tools.
·
When a maintenance technician is repairing or adjusting a robot,
the work area is under the control of that technician. All
personnel not participating in the maintenance must stay out of
the area.
·
For some maintenance procedures, station a second person at
the control panel within reach of the EMERGENCY STOP
button. This person must understand the robot and associated
potential hazards.
Safety-15
MARMI120I07021E REV A
·
Be sure all covers and inspection plates are in good repair and
in place.
·
Always return the robot to the ‘‘home’’ position before you
disarm it.
·
Never use machine power to aid in removing any component
from the robot.
·
During robot operations, be aware of the robot’s movements.
Excess vibration, unusual sounds, and so forth, can alert you to
potential problems.
·
Whenever possible, turn off the main electrical disconnect
before you clean the robot.
·
When using vinyl resin 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.
When using paint remover observe the following:
-
Eye protection, protective rubber gloves, boots, and apron
are required during booth cleaning.
-
Adequate ventilation is required. Overexposure could cause
drowsiness.
-
If there is contact with the skin or eyes, rinse with water for
at least 15 minutes.
B–81765EN/01
PREFACE
PREFACE
This manual explains the maintenance and connection procedures for the
mechanical units (R–J3iB controller) of the following robots. Before
replacing the parts, determine the specification number of the mechanical
unit.:
Abbreviation
Mechanical unit
specification No.
ARC Mate 120iB
A05B–1216–B201
FANUC Robot M–16iB/20
M–16iB/20
A05B–1216–B202
FANUC Robot ARC Mate
120iB/10L
ARC Mate
120iB/10L
A05B–1216–B301
M–16iB/10L
A05B–1216–B302
Model name
FANUC Robot ARC Mate 120iB
FANUC Robot M–16iB/10L
p–1
PREFACE
TYPE
NO.
DATE
B–81765EN/01
(1)
(2)
(3)
(4)
TOTAL WEIGHT WITH CONTROLLER
TOTAL WEIGHT WITHOUT CONTROLLER
1)
:
:
(5)
(6)
kg
kg
OSHINO–MURA,
YAMANASHIPREF. JAPAN
No.
(1)
(2)
(3)
(4)
(5)
CONTENTS
MODEL
TYPE
No.
DATE
WEIGHT
(Without controller)
FANUC Robot ARC Mate 120iB A05B–1216–B201
LETTERS
FANUC Robot M–16iB/20
A05B–1216–B202
FANUC Robot ARC Mate
120iB/10L
A05B–1216–B301
FANUC Robot M–16iB/10L
A05B–1216–B302
220 kg
PRINT
SERIAL
NO.
PRINT
PRODUCTION
YEAR AND
MONTH
Positon of label indicating mechanical unit specification number
p–2
220 kg
220 kg
220 kg
PREFACE
B–81765EN/01
Specifications
M–16iB/20
ARC Mate 120iB
Item
Type
Controlled axes
Installation
Motion range
g
Maximum speed
p
Articulated type
6 axes (J1, J2, J3, J4, J5, J6)
Floor, Upside–dowm (Wall & Angle mount)
J1 axis
J2 axis
J3 axis
J4 axis
J5 axis
J6 axis
J1 axis
J2 axis
J3 axis
J4 axis
J5 axis
J6 axis
460° (8.03rad)
455° (7.94rad)
400° (6.98rad)
280° (4.89rad)
900° (15.71rad)
165°/s (2.88rad/s)
165°/s (2.88rad/s)
175°/s (3.05rad/s)
350°/s (6.11rad/s)
340°/s (5.93rad/s)
520°/s (9.08rad/s)
20kg
Max. load capacity on J3 catting
Allowable load moment at wrist J4 axis
39.2N·m
22.0N·m
(4.0kgf·m)
(2.2kgf·m)
39.2N·m
22.0N·m
(4.0kgf·m)
(2.2kgf·m)
19.6N·m
9.8N·m
(2.0kgf·m)
(1.0kgf·m)
0.88kg·m2
0.63kg·m2
(9.0kgf·cm·s2)
(6.4kgf·cm·s2)
0.88kg·m2
0.63kg·m2
(9.0kgf·cm·s2)
(6.4kgf·cm·s2)
0.25kg·m2
0.15kg·m2
(2.5kgf·cm·s2)
(1.5kgf·cm·s2)
Electric servo drive by AC servo motor
J6 axis
J4 axis
J5 axis
J6 axis
Drive method
Repeatability
"0.08mm
Weight of mechanical unit
"0.10mm
220kg
Ambient temperature : 0 – 45°C
Ambient humidity
: Normally :75%RH or less
: Short time 95%RH or less
(within 1 month)
(No dew or frost allowed)
Height
Required facilities (when no option is provided)
10kg
12kg
J5 axis
Installation environment
(Note 1)
340° (5.93rad)
250° (4.36rad)
Max. load capacity at wrist
Allowable load inertia at wrist
M–16iB/10L
ARC Mate 120iB/10L
: Up to 1,000 meters above the sea level
requires, no particular provision for
attitude.
Vibration
: 0.5G (4.9m/s2) or less
Average power consumption: 1.0 kW
Input power supply capacity: 3.0 kVA
NOTE
1 Under the installation condition within ( ), the J1 and J2 axis motion range will be limited.
p–3
PREFACE
B–81765EN/01
Dust–proof/waterproof performance of M–16iB/20/10L
Normal specification
Wrist+J3 arm
IP67
Other part
IP54
NOTE
Definition of IP code
Definition of IP 67
6=Dust–tight
7=Protection from water immersion
Definition of IP 54
5=Dust–protected
4=Protection from splashing water
Performance of resistant chemicals and resistant solvents
(1) The robot (including severe dust/liquid protection model) cannot be
used with the following liquids because there is fear that rubber parts
(packing, oil seal, O ring etc.) will corrode.
(a) Organic solvents
(b) Coolant including chlorine / gasoline
(c) Amine washing lotion
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, that will harm NBR
(2) When the robots work in the environment, using water or liquid,
complete draining of J1 base must be done. Incomplete draining of
J1 base will make the robot break down.
p–4
PREFACE
B–81765EN/01
RELATED MANUALS
Safety handbook
For the FANUC Robot series, the following manuals are available:
B–80687EN
All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook
R–J3iB controller
Setup and Operations
manual
SPOT TOOL
B–81464EN–1
HANDLING TOOL
B–81464EN–2
ARC TOOL
B–81464EN–3
SEALING TOOL
B–81464EN–4
Maintenance manual
B–81465EN
B–81465EN–1
(European
specification)
Mechanical unit
Maintenance manual
FANUC Robot, ARC Mate
120iB, M–16iB
B–81765EN
Intended readers :
All persons who use FANUC Robot, system designer
Topics :
Safety items for robot system design, operation, maintenance
Intended readers :
Operator, programmer, maintenance person, system designer
Topics :
Robot functions, operations, programming, setup, interfaces, alarms
Use :
Robot operation, teaching, system design
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to peripheral equipment, maintenance
Use :
Installation, start–up, connection, maintenance
Intended readers :
Maintenance person, system designer
Topics :
Installation, connection to the controller, maintenance
Use :
installation, start–up, connection, maintenance
p–5
Table of Contents
B–81765EN/01
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s–1
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–1
I. MAINTENANCE
1. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.1
J1–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.2
J2–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.3
J3–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
1.4
J4–AXIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
1.5
J5– AND J6–AXIS DRIVE MECHANISMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
1.6
SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS . . . . . . . . . . . . . . .
10
2. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.1
DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
2.2
QUARTERLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
2.3
YEARLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
2.4
ONE– AND HALF–YEAR PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
2.5
THREE–YEAR PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
2.6
MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
3.1
GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
3.2
GREASE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
3.3
REPLACING THE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
4.1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
4.2
TROUBLES AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
5. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
5.1
5.2
REFERENCE POSITION AND MOVING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Alarms and Preparing for Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering to a Fixture (Master Position Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zero Position Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Axis Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Confirming Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
35
36
41
44
46
49
51
5.3
J5–AXIS GEAR BACKLASH ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
5.4
BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
c–1
Table of Contents
B–81765EN/01
6. COMPONENT REPLACEMENT AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . .
55
6.1
REPLACING THE J1–AXIS MOTOR M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
6.2
REPLACING THE J1–AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
6.3
REPLACING THE J2–AXIS MOTOR M2
..........................................
60
6.4
REPLACING THE J2–AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
6.5
REPLACING THE J3–AXIS MOTOR M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
6.6
REPLACING THE J3–AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
6.7
REPLACING THE J4–AXIS MOTOR M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
6.8
REPLACING THE J4–AXIS GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
6.9
REPLACING THE J5–AXIS MOTOR M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
6.10
REPLACING THE J5–AXIS GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
6.11
REPLACING THE J6–AXIS MOTOR M6 AND REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
7. PIPING AND WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
7.1
PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
7.2
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
7.3
CABLE MOUNTING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
8. CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
8.1
CABLE DRESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
8.2
REPLACING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
II. CONNECTION
1. ROBOT OUTLINE DRAWING AND OPERATION AREA DIAGRAM . . . . . . . . . .
1.1
OUTLINE DRAWING AND OPERATION AREA DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
100
2. MOUNTING DEVICES ON THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.1
WRIST SECTION END EFFECTOR MOUNTING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
2.2
WRIST LOAD CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
2.3
DEVICE MOUNTING SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
2.4
SETTING THE SYSTEM VARIABLES FOR SHORTEST–TIME CONTROL . . . . . . . . . . . . . . .
114
2.5
END EFFECTOR AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117
2.6
END EFFECTOR INPUT SIGNALS (RDI/RDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
2.7
CONNECTOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119
3. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.1
TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121
3.2
STORING THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
123
3.3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124
3.4
MAINTENANCE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
128
3.5
ASSEMBLING THE ROBOT FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
131
3.6
AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132
c–2
Table of Contents
B–81765EN/01
3.7
INSTALLATION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134
APPENDIX
A. SPARE PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
B. INTERNAL MECHANICAL UNIT CONNECTION DIAGRAMS . . . . . . . . . . . . . . . 143
C. PERIODIC INSPECTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
D. MOUNTING BOLT TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
c–3
I. MAINTENANCE
1
1. CONFIGURATION
MAINTENANCE
B–81765EN/01
CONFIGURATION
Fig. 1 shows the configuration of the mechanical unit.
J3–axis arm
J4–axis
AC servo motor
(M4)
J3–axis casing
J5–axis AC servo motor (M5)
J3–axis
AC servo
motor (M3)
J1–axis
AC servo
motor (M1)
Wrist unit
J6–axis AC servo motor (M6)
J2–axis arm
J2–axis base
J1–axis base
J2–axis AC servo motor (M2)
Fig 1 (a) Mechanical unit configuration (ARC Mate 120iB, M–16iB/20)
3
1. CONFIGURATION
MAINTENANCE
J4–axis
AC servo
motor (M4)
B–81765EN/01
J3–axis
casing
J3–axis arm
J5–axis AC servo motor (M5)
J3–axis
AC servo
motor for (M3)
J1–axis
AC servo
motor (M1)
Wrist unit
J2–axis arm
J6–axis
AC servo motor
(M6)
J2–axis base
J1–axis base
J2–axis
AC servo motor (M2)
Fig 1 (b) Mechanical unit configuration (ARC Mate 120iB/10L, M–16iB/10L)
4
MAINTENANCE
B–81765EN/01
1.1
J1–AXIS DRIVE
MECHANISM
1. CONFIGURATION
Fig. 1.1 shows the J1–axis drive mechanism.
The J1–axis drive mechanism is configured in such a way that the J2–axis
base is rotated by reducing the rotation speed of an AC servo motor with
a reducer.
The J2–axis base is supported on the J1–axis base through the reducer.
J2–axis base
J1–axis AC servo motor
α M8/4000i
J1–axis reducer
J1–axis base
Fig 1.1 J1–axis drive mechanism
5
1. CONFIGURATION
MAINTENANCE
1.2
J2–AXIS DRIVE
MECHANISM
B–81765EN/01
Fig. 1.2 shows the J2–axis drive mechanism. The J2–axis drive
mechanism is configured in such a way that the J2–axis arm is rotated by
reducing the rotation speed of an AC servo motor with a reducer.
The J2–axis arm is supported on the J2–axis base through the reducer.
J2–axis base
J2–axis arm
J2–axis AC
servo motor
α M8/4000i
J2–axis reducer
Fig 1.2 J2–axis drive mechanism
6
B–81765EN/01
1.3
J3–AXIS DRIVE
MECHANISM
1. CONFIGURATION
MAINTENANCE
Fig. 1.3 shows the J3–axis drive mechanism. The J3–axis drive
mechanism is configured in such a way that the J3–axis casing is rotated
by reducing the rotation speed of an AC servo motor with a reducer.
The J3–axis casing is supported on the J2–axis arm through the reducer.
J3–axis
reducer
J3–axis casing
J2–axis arm
Fig 1.3 J3–axis drive mechanism
7
J3–axis AC
servo motor
α M2/5000i
1. CONFIGURATION
1.4
J4–AXIS DRIVE
MECHANISM
MAINTENANCE
B–81765EN/01
Fig. 1.4 shows the J4–axis drive mechanism. The J4–axis drive
mechanism is configured in such a way that the J3–axis arm is rotated by
reducing the rotation speed of an AC servo motor with a two–stage gear.
J3–axis arm
Final gear
Second gear
Input gear
J3–axis
casing
J4–axis AC
servo motor
α M2/5000i
Fig 1.4 J4–axis drive mechanism
8
MAINTENANCE
B–81765EN/01
1.5
1. CONFIGURATION
Fig. 1.5 shows the J5– and J6–axis drive mechanisms. The J5–axis drive
mechanism is configured in such a way that the J6–axis unit is rotated by
reducing the rotation speed of an AC servo motor with a three–stage gear.
The J6–axis drive mechanism is configured in such a way that the output
flange is rotated by reducing the rotation speed of an AC servo motor with
a reducer.
J5– AND J6–AXIS
DRIVE MECHANISMS
J5–axis AC servo motor
β M0.5/4000
J6–axis unit
J6–axis AC
servo motor
β M0.5/4000
J3–axis
arm
Output
flange
J6–axis
reducer
Input gear
Final gear
Second gear
Third gear
Fig 1.5 J5– and J6–axis drive mechanisms
9
1. CONFIGURATION
1.6
SPECIFICATIONS OF
THE MAJOR
MECHANICAL UNIT
COMPONENTS
MAINTENANCE
B–81765EN/01
1) Motors
M–16iB/20, ARC Mate 120iB,
M–16iB/10L, ARC Mate 120iB/10L
Motor
Specification
Model
Axis
M1, M2
A06B-0235-B605
M8/4000i
J1, J2
M3, M4
A06B-0212-B605
M2/5000i
J3, J4
M5, M6
A06B-0115-B275#0008
M0.5/4000
J5, J6
2) Reducers
Specification
Axis
A97L-0218-0303#37
J1
A97L-0218-0304#175
J2
A97L-0218-0305#37
J3
A97L-0218-0306
J6
3) Gears
Specification
Axis
A290-7216-X511
J5
A290-7216-V501
J5
A290-7216-V502
J5
A290-7216-X514
J5
4) J4–axis gearbox
Specification
A290-7216-K401
5) Wrist flange
Specification
A290-7216-V503
6) Stoppers
Specification
Axis
A290-7216-X241
J1
A290-7216-X323
J2
A290-7215-X323
J3
10
Note) 340° stopper
B–81765EN/01
2
MAINTENANCE
2. PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Performing daily inspection, periodic inspection, and maintenance can
keep the performance of robots in a stable state for a long period.
NOTE
The periodic maintenance procedures described in this
chapter assume that the FANUC robot is used for up to 3840
hours a year. When using the robot beyond this total
operating time, correct the maintenance frequencies shown
in this chapter by calculation in proportion to the difference
between the actual operating time and 3840 hours/year.
11
2. PREVENTIVE MAINTENANCE
2.1
DAILY INSPECTION
MAINTENANCE
B–81765EN/01
Clean and maintain each component of robots during everyday system
operations. At the same time, check the components to see if there is a
crack or break in them. Also check and maintain the following items as
required.
a) Before automatic operation
No.
Inspection item
Inspection procedure
1
Pneumatic pressure
check
2
Check on the amount of Put the pneumatic pressure
oil mist
system in operation and check
the amount of oil dripping. If the
measured amount of oil dripping
does not meet the rating (one
drop/10 to 20 seconds), make
adjustments, using the oil adjustment knob. The oiler becomes empty after 10 to 20 days
of normal operation.
For
machines
with a
three–piece
pneumatic
option
Make a pneumatic pressure
check, using the three–piece
pneumatic option shown in Fig.
2.1.
If the measured pneumatic
pressure does not fall in the
range between 0.5 and 0.7 MPa
(5 and 7 kg/cm2), make adjustments, using the regulator pressure setting handle.
3
Check on the amount of Check to see if the amount of oil
oil
in the three–piece option is within the rated level shown in Fig.
2.1.
4
Check for leakage from Check to see if a joint or hose
the piping
leaks.
If you find a problem, tighten the
joint or replace any defective
component.
5
Whether cables are abnormal
Mechanical unit
See Chapter 8.
6
Battery voltage check
Make sure that when the power
is turned on, the BLAL alarm
has not been raised. If the BLAL
alarm has been raised, replace
the battery as directed in Section 3.3.
7
Whether there is any abnormal vibra- Check that each axis is running
tion, noise, or heat generation in motors smoothly.
8
Whether there is a change to position- Check to see if there is any dising precision
placement from the previous
position and there are variations
in the stop position.
12
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B–81765EN/01
No.
Inspection item
Inspection procedure
9
Reliable operation of peripheral equip- Check to see if the machine opment
erates exactly according to
directions from the robot and
peripheral equipment.
10
Check on the operation of the J2– and See Section 4.2.
J3–axis brakes.
Oiler’s oil inlet
Oiler adjustment knob
Check oiler’s oil level
Oiler
Pressure gauge
Regulator pressure setting handle
Filter
Fig 2.1 Three–piece pneumatic option
b) After automatic operation
Once you are finished with automatic operation, bring the robot to its
reference position, and turn it off.
No.
1
Inspection item
Component cleaning
and inspection
13
Inspection procedure
Clean and maintain each component. At the
same time, check the components to see if
there is a crack or break in them.
2. PREVENTIVE MAINTENANCE
2.2
QUARTERLY
INSPECTION
2.3
YEARLY INSPECTION
MAINTENANCE
Inspect the following items at regular intervals of three months. Increase
the locations and the frequency of inspection if the conditions under
which the robot is used and the environment in which it runs require so.
No.
ONE– AND
HALF–YEAR
PERIODIC
INSPECTION
Inspection item
Inspection procedure
1
Loose connector
Check that the motor connectors or other connectors are not loose.
2
Loose bolt
Check that the cover retaining bolts or external
bolts are not loose.
3
Debris removal
Remove any spatter, debris, and dust from the
mechanical unit.
Inspect the following item at regular intervals of one year.
No.
1
2.4
B–81765EN/01
Inspection item
J6 Greasing
Inspection procedure
See Section 3.1.
Perform the following inspection/maintenance item at regular intervals of
one year and half.
No.
1
Inspection item
Battery replacement
Inspection procedure
Replace the battery in the mechanical unit.
(See Section 3.3.)
2.5
THREE–YEAR
PERIODIC
INSPECTION
No.
Inspection item
1
J1–J5 Grease replacement
14
Inspection procedure
See Section 3.2.
2.6
MAINTENANCE
TOOLS
2. PREVENTIVE MAINTENANCE
MAINTENANCE
B–81765EN/01
You should have the following instruments and tools ready for
maintenance.
a) Measuring instruments
Instrument
Condition
Dial gauge
1/100mm
Calipers
150mm
b) Tools
Phillips screwdrivers
Flat–blade screwdrivers
Box wrenches
Allen wrenches
Torque wrench
Long T wrenches
Adjustable wrenches
Pliers
Long–nose pliers
Cutting pliers
Both–ended wrench
Grease gun
C–ring pliers
Flashlight
15
Use
For positioning precision and backlash
measurement
(large, medium, and small sizes)
(large, medium, and small sizes)
(M3 to M6)
(M3 to M16)
(M5 and M6)
(medium and small sizes)
3. PERIODIC MAINTENANCE
3
MAINTENANCE
PERIODIC MAINTENANCE
16
B–81765EN/01
3.1
GREASING
3. PERIODIC MAINTENANCE
MAINTENANCE
B–81765EN/01
Following is the greasing procedure for J6–axis reducer.
When greasing the robot, keep its power turned off.
i) Replenish the J6–axis reducer with grease every 12 months or after
3840 hours of operation.
ii) See Fig. 3.1 and Table 3.1 for greasing points and the method.
Table. 3.1 Greasing points
No.
1
Greasing
point
J6–axis
reducer
Specified
grease
Moly White
RE No.00
(Specification:
A97L-0040-0119)
Amount
of
grease
40cc
Greasing method
Replace the flat–head bolts
and sealing washers of the
J6–axis grease inlet and outlet, and attach the supplied
grease nipple of the J6–axis to
the grease inlet of the J6–axis.
After greasing, remove the
grease nipple, and attach the
flat–head bolts and sealing
washers to the grease inlet
and outlet.
CAUTION
If you grease incorrectly, the pressure in the grease bath
may increase steeply, leading to a broken seal, which will
eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated in
Section 3.2.
17
3. PERIODIC MAINTENANCE
MAINTENANCE
B–81765EN/01
J5–axis gear box
Bolt+Seal washer
(Greasing point)
J5–axis gear box
Bolt+Seal washer
(Bleed hole)
J6–axis reducer
Bolt+Seal washer
(Bleed hole)
J3–axis
reducer
Plug
(Bleed hole)
J6–axis reducer
Bolt+Seal washer
(Greasing point)
J1–axis
reducer
Seal bolt
(Bleed hole)
J4–axis gear box
Bolt+Seal washer
(Bleed hole)
J2–axis
reducer
Seal bolt
(Bleed hole)
J1–axis reducer
Grease nipple
(Greasing point)
J4–axis gear box
Grease nipple
(Greasing point)
J3–axis reducer
Grease nipple
(Greasing point)
J2–axis reducer
Grease nipple
(Greasing point)
Fig 3.1 Greasing points
18
B–81765EN/01
3.2
GREASE
REPLACEMENT
MAINTENANCE
3. PERIODIC MAINTENANCE
Follow the procedure stated below to replace the grease in the J1–, J2–,
and J3–axis reducers and the J4– and J5–axis gearboxes once every three
years or after 11,520 hours of operation. See Fig. 3.1 for greasing points.
1) Remove the seal bolts from the J1–, J2–axis grease outlets shown in
Fig. 3.1. Also remove the plug of J3–axis grease outlet, the flat–bolts
and sealing washers from the J4– and J5–axis grease outlets.
2) Uncap the grease nipples at the J1–, J2–, J3–, and J4–axis grease inlets.
When the J5–axis grease is supplied remove the flat–head bolt from
the J5–axis grease inlet and attach the grease nipple to the J3–axis or
J4–axis grease inlet.
3) Supply the grease specified in Table 3.2 to the J1–, J2–, and J3–axis
reducers, and J4– and J5–axis gearboxes through their respective
grease nipples. Keep greasing until the new grease pushes out the old
grease and comes out from each grease outlet. Ensure that the amount
of the newly supplied grease equals the amount of the drained grease
so that the grease bath will not become full.
4) Wind sealing tape around the J1–, J2–axis seal bolts and J3–axis plug
you removed, and attach them to the respective grease outlets.
5) Attach the J4– and J5–axis flat–head bolts and the J4– and J5–axis
sealing washers to the respective grease inlets and outlets.
6) When finally returning the grease nipple used at another location to the
original position, be sure to wind sealing tape around the threads part.
In addition, be sure to cap the grease nipple for each axis.
Table. 3.2 Grease to be replaced at regular intervals of three years
Specified grease
Amount of
grease to be
applied (cc)
Robot posture when
greased
980cc
–
550cc
J2=0°
J3–axis reducer
550cc
J3=0°
J4–axis gearbox
1030cc
J3=0°
J5–axis gearbox
400cc
J3=–90°
Kyodo Yushi
J1–axis reducer
J2–axis reducer
19
Moly White RE No.00
(Specification:
A98L-0040-0119#2.4KG)
3. PERIODIC MAINTENANCE
MAINTENANCE
B–81765EN/01
CAUTION
If you grease incorrectly, the pressure in the grease bath will
increase, leading to a broken seal, which will eventually cause
grease leakage or malfunction.
When greasing, be sure to follow the cautions stated below.
1 Before starting greasing, open the grease outlets (remove
bolts and the like from the grease outlets).
2 Using a manual greasing pump, grease gently and slowly.
3 Avoid using a pneumatic pump driven from a factory
pneumatic line as much as possible.
If you cannot avoid using it, observe a greasing speed of 15
cc/s or lower and a pressure of 75 kgf/cm2 or lower.
4 Be sure to use the specified grease. Otherwise, damage to
reducers or a similar abnormality may occur.
5 Before capping the grease outlets, make sure that a grease
flow from the grease outlet has stopped (the remaining
pressure has been released).
6 Wipe off any grease from the floor and robot completely, so
no one will slip on it.
20
MAINTENANCE
B–81765EN/01
3. PERIODIC MAINTENANCE
When replacing or supplying grease, keep the robot in the posture shown
in Fig. 3.2.
J1 to J4–axis Posture
J5–axis Posture
Fig 3.2 Robot posture for greasing
21
3. PERIODIC MAINTENANCE
3.3
REPLACING THE
BATTERIES
MAINTENANCE
B–81765EN/01
The position data of each axis is preserved by the backup batteries. The
batteries need to be replaced every 1.5 year. Also use the following
procedure to replace when the backup battery voltage drop alarm occurs.
1 Keep the power on. Press the EMERGENCY STOP button to
prohibit the robot motion.
NOTE
Never turn off the robot controller power when replacing the
batteries. Otherwise, all position data will be lost and
mastering will be required again.
2
3
4
5
Remove the battery case cap.
Take out the old batteries from the battery case.
Insert new batteries into the battery case.
Pay attention to the direction of batteries.
Close the battery case cap.
Battery spec. : A98L–0031–0005
(1.5V size–D)
Fig.3.3 Replacing Batteries
22
4. TROUBLESHOOTING
4
MAINTENANCE
TROUBLESHOOTING
23
B–81765EN/01
B–81765EN/01
4.1
OVERVIEW
MAINTENANCE
4. TROUBLESHOOTING
A problem with a mechanical unit may occur due to a combination of
multiple causes. It is difficult to find out the true cause, and an incorrect
measure may make the problem worse. When troubleshooting, it is
important to get hold of the situation of any error accurately and take a
correct measure.
24
4. TROUBLESHOOTING
4.2
TROUBLES AND
CAUSES
MAINTENANCE
B–81765EN/01
Table 4.2 (a) lists the major troubles in the mechanical unit and their
causes. If you cannot find a cause accurately or do not know what measure
to take, please contact FANUC.
Note, however, that lower values of backlash and drop levels listed,
respectively, in Table 4.2 (b), (d) and Table 4.2 (c), (e) are not abnormal.
Table 4.2 (a) Major troubles and causes (1/3)
Symptom
BZAL alarm issued
(battery zero)
Cause
Measure
Remark
The voltage of the memory Replace the battery, and per- See Section 3.3.
backup battery has dropped. form simplified mastering.
See Section 5.3.
Broken pulse coder signal Replace the cable, and per- See Section 8.2.
cable
form simplified mastering.
See Section 5.3.
Incorrect positioning
Something hit the robot.
Correct the taught point.
Robot is not hanged down to Tighten hanging bolts or
floor correctly.
replace if needed.
See Section 3.2 of Part II,
“Connection”.
Peripheral equipment has Tighten hanging bolts or
shifted.
replace if needed.
Load too heavy
Reduce the load.
Load on the wrist:
Limit the operating condition.
Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection”.
Incorrect parameter setting
Correct it.
Refer to “Operator’s Manual”.
Broken cable
Replace the cable.
See Section 8.2.
Pulse coder error
Replace the motor.
See Sections 6.1 to 6.11.
Backlash in the mechanical
unit –– see the next section.
25
4. TROUBLESHOOTING
MAINTENANCE
B–81765EN/01
Table 4.2 (a) Major troubles and causes (2/3)
Symptom
Vibration
Cause
The robot
mounted.
is
Measure
not firmly Tighten the mounting screws.
Remark
See Section 3.2 of Part II,
“Connection”.
The floor is vibrating (espe- Re–examine the location of
cially when the robot is installation.
installed on the second floor
or above).
Load too heavy
Reduce the load.
Limit the operating condition
Load on the wrist:
Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection”.
Servo is not correctly adjust- Adjust the servo section.
ment.
Contact FANUC.
Broken cable
Replace the cable.
See Section 8.2.
Robot not grounded
Ground the robot.
Refer to “Maintenance Manual for the Controller”.
Defective motor
Replace the motor.
See Sections 6.1 to 6.11.
Defective axis printed–circuit Replace the axis printed–cir- Refer to “Maintenance Manuboard
cuit board.
al for the Controller”.
Defective reducer
Replace the reducer.
See Sections 6.2 to 6.11.
Invalid time constant setting
Change the time constant.
Refer to “Operator’s Manual”.
Backlash in the mechanical
unit –– see the next section.
Backlash or wobbling
Abnormal sound
Loose screw or pin
Tighten it (and apply Loctite
to it if specified so)
Defective reducer
Replace the reducer.
See Sections 6.2 to 6.11.
Gear is not correctly adjust- Adjust the gear.
ment.
See Section 5.7.
Worn gear
Adjust or replace the gear.
Contact FANUC.
Worn bearing
Replace the bearing.
Contact FANUC.
Broken casting or other part
Replace the broken compo- Contact FANUC.
nent.
Insufficient grease for gear or Apply grease.
reducer
See Sections 3.1 and 3.2.
Foreign matter in gear or re- Wash the gear or reducer See Sections 6.2 to 6.11, 3.1,
ducer
and apply grease.
and 3.2.
Gear is not correctly adjust- Adjust the gear.
ment.
Contact FANUC.
Worn gear
Adjust or replace the gear.
Contact FANUC.
Worn bearing
Replace the bearing.
Contact FANUC.
Servo section maladjustment Adjust the servo section.
26
Contact FANUC.
4. TROUBLESHOOTING
MAINTENANCE
B–81765EN/01
Table 4.2 (a) Major troubles and causes (3/3)
Symptom
Abnormal heat generation
Arm drop at power turn–off
Cause
Measure
Remark
Insufficient grease for gear or Apply grease.
reducer
See Sections 3.1 and 3.2.
Non–specified grease used
Replace the grease.
See Sections 3.1 and 3.2.
Load too heavy
Reduce the load.
Load on the wrist:
Limit the operating condition.
Refer to “Descriptions”.
Peripheral equipment:
See Section 2.2 of Part II,
“Connection.”
Gear maladjustment
Adjust the gear.
Invalid time constant setting
Change the time constant Refer to “Operator’s Manual”.
setting.
Too large a brake gap
Replace the motor.
Contact FANUC.
See Sections 6.1 to 6.11.
Brake drive relay contact de- Replace the relay
position
Grease leakage
Refer to “Maintenance Manual for the Controller”.
Deteriorated or broken
O–ring, oil seal, or gasket
Replace the O–ring, oil seal, Contact FANUC.
or gasket.
Broken casting or other part
Replace the broken compo- Contact FANUC.
nent.
Loose screw
Tighten it.
Table 4.2 (b) Permissible Backlash Value (ARC Mate 120iB, M–16iB/20)
J1
J2
J3
J4
J5
J6
Angle conversion (arc–min)
2.5
2.5
2.5
3.0
4.5
3.0
Displacement conversion (mm)
1.21
0.56
0.54
0.17
0.26
0.17
Distance between the rotation
center and dial indicator (mm)
1660
770
740
200
200
200
Table 4.2 (c) Allowable arm drop (ARC Mate 120iB, M–16iB/20)
At power turn–off time
5mm
At emergency stop time
5mm
Table 4.2 (d) Permissible Backlash Value (ARC Mate 120iB/10L, M–16iB/10L)
J1
J2
J3
J4
J5
J6
Angle conversion (arc–min)
2.5
2.5
2.5
3.0
4.5
3.0
Displacement conversion (mm)
1.37
0.56
0.70
0.17
0.26
0.17
Distance between the rotation
center and dial indicator (mm)
1880
770
960
200
200
200
Table 4.2 (e) Allowable arm drop (ARC Mate 120iB/10L, M–16iB/10L)
At power turn–off time
5mm
At emergency stop time
5mm
27
MAINTENANCE
B–81765EN/01
5
5. ADJUSTMENTS
ADJUSTMENTS
Each part of the robot mechanical units is set to the best condition before
the robot is shipped to the customer. The customer does not need to make
adjustments on the robot when it is delivered.
If a mechanical unit of the robot has a large backlash because of a
long–term use or component replacement, make adjustments using to this
section.
28
5. ADJUSTMENTS
5.1
REFERENCE
POSITION AND
MOVING RANGE
MAINTENANCE
B–81765EN/01
1) Reference position and operation limit
Each controlled axis is provided with a reference position and
operation limit.
A state in which a controlled axis has reached its operation limit is
known as overtravel (OT). For each axis, an overtravel condition can
be detected at the both ends of it. As long as the robot does not
encounter a servo section error or system error that causes a reference
position to be lost, the robot is controlled in such a way that it will not
go out of its operation area.
Fig. 5.1 (a) to Fig. 5.1 (g) show the reference position and operation
area (stroke) of each axis and their mechanical stopper positions.
Fig. 5.1 (h) shows the operation directions (+/– directions) of each
axis.
Stroke
Stroke end
Stroke end
Mechanical stopper
Mechanical stopper
Fig 5.1 (a) J1–axis swiveling (typically 340°)
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
Note)Motion limit is restricted by the
J3–axis position
Mechanical
stopper
Stroke
Stroke end
Stroke end
Mechanical stopper
Fig 5.1 (b) J2–axis rotation
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
29
B–81765EN/01
5. ADJUSTMENTS
MAINTENANCE
Note)Motion limit is restricted by the
J2–axis position
Stroke
Stroke end
Stroke end
Fig 5.1 (c) J3–axis rotation
ARC Mate 120iB, M–16iB/20
Note)Motion limit is restricted by the
J2–axis position
Stroke
Stroke end
Stroke end
Fig 5.1 (d) J3–axis rotation
ARC Mate 120iB/10L, M–16iB/10L
30
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
Stroke
Stroke end
Stroke end
Note)J4–axis doesn’t have the mechanical stopper.
Fig 5.1 (e) J4–axis rotation
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
Stroke end
Mechanical stopper
Stroke
Stroke end
Mechanical stopper
Fig 5.1 (f) J5–axis wrist rotation
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
31
B–81765EN/01
MAINTENANCE
5. ADJUSTMENTS
Stroke
Stroke end
Stroke end
Fig 5.1 (g) J6–axis wrist rotation
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
J3–axis arm
Interference angle
J2–axis arm
Interference angle
Stroke end
Mechanical stopper
Stroke end
Mechanical stopper
Fig 5.1 (h) J2/J3 limit interference angle
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
32
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
J3–axis
J4–axis
–
+
+ +
–
–
J6–axis
–
J2–axis
J5–axis
+
–
–
+
J1–axis
+
Fig 5.1 (i) Operation directions of each axis
ARC Mate 120iB, M–16iB/20
J3–axis
J4–axis
+
–
J6–axis
–
+
+
–
+
–
J2–axis
J5–axis
–
–
+
J1–axis
+
Fig 5.1 (j) Operation directions of each axis
ARC Mate 120iB/10L, M–16iB/10L
33
B–81765EN/01
MAINTENANCE
5. ADJUSTMENTS
5.2
Mastering is an operation performed to associate the angle of each robot
axis with the pulse count value supplied from the absolute pulse coder
connected to the corresponding axis motor. To be specific, mastering is
an operation for obtaining the pulse count value corresponding to the zero
position.
5.2.1
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis.
MASTERING
General
Mastering is factory–performed. It is unnecessary to perform mastering
in daily operations. However, mastering becomes necessary after:
D Motor replacement.
D Pulse coder replacement.
D Reducer replacement.
D Cable replacement.
D Batteries for pulse count backup in the mechanical unit have gone dead.
NOTE
Robot data (including mastering data) and pulse coder data
are backed up by their respective backup batteries. Data will
be lost if the batteries go dead. Replace the batteries in the
control and mechanical units periodically. An alarm will be
issued to warn the user of a low battery voltage.
Mastering method
Table 5.2.1 Types of Mastering
Jig position mastering This is performed using a mastering jig before the
machine is shipped from the factory.
Zero-position master- This is performed with all axes set at the 0–degree posiing (eye mark mastion. A zero–position mark (eye mark) is attached to
tering)
each robot axis. This mastering is performed with all
axes aligned to their respective eye marks.
Quick mastering
This is performed at a user–specified position. The corresponding count value is obtained from the rotation
speed of the pulse coder connected to the relevant
motor and the rotation angle within one rotation. Quick
mastering uses the fact that the absolute value of a rotation angle within one rotation will not be lost.
One-axis mastering
This is performed for one axis at a time. The mastering
position for each axis can be specified by the user. This
is useful in performing mastering on a specific axis.
Mastering data entry
Mastering data is entered directly.
Once mastering is performed, it is necessary to carry out positioning, or
calibration. Positioning is an operation in which the control unit reads the
current pulse count value to sense the current position of the robot.
When the battery backup of the pulse coder is interrupted by cable
replacement, you can perform quick mastering to perform calibration to
the original position. When the phase of the pulse coder is changed
mechanically as a result of replacement of the motor, reducer, and so forth,
you cannot perform quick mastering. In this case, you must perform jig
position mastering to calibrate the position accurately.
34
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
NOTE
If mastering is performed incorrectly, the robot may behave
unexpectedly. This is very dangerous. So, the positioning
screen is designed to appear only when the
$MASTER_ENB system variable is 1 or 2. After performing
positioning, press F5 [DONE] on the positioning screen.
The $MASTER_ENB system variable is reset to 0
automatically, thus hiding the positioning screen.
5.2.2
Resetting Alarms and
Preparing for
Mastering
Alarm displayed
Before performing mastering because a motor is replaced, it is necessary
to release the relevant alarm and display the positioning menu.
“Servo 062 BZAL” or “Servo 075 Pulse mismatch”
Procedure
Preparing the Robot for
Mastering
Step
1 To reset the “Servo 062 BZAL” alarm, follow steps 1 to 7.
1
2
3
4
5
6
7
Press MENUS.
Press NEXT and select [SYSTEM].
Press F1 [TYPE], and select [Variables] from the menu.
Place the cursor on $MCR then press the enter key.
Place the cursor on $SPC_RESET, then press F4 [TRUE]. The
message “TRUE” appears and disappears immediately.
If the message “TRUE” did not appear, retry by repeating the
above step several times.
Switch the controller power off and on again.
2 To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to 3.
1
2
3
When the controller power is switched on again, the message
“Servo 075 Pulse mismatch” appears again.
Rotate the axis for which the message mentioned above has
appeared through 10 in either direction.
Press [FAULT RESET]. The alarm is reset.
3 Display the mastering menu by following steps 1 to 6.
1
2
3
4
5
6
Press MENUS.
Press NEXT and select [SYSTEM].
Press F1 [TYPE], and select [Variables] from the menu.
Place the cursor on $MASTER_ENB, then key in “1” and press
[ENTER].
Press F1 [TYPE], and select [Master/Cal] from the menu.
Select the desired mastering type from the [Master/Cal] menu.
35
B–81765EN/01
5.2.3
Mastering to a Fixture
(Master Position
Master)
MAINTENANCE
5. ADJUSTMENTS
Fixture mastering is performed using a mastering jig. This mastering is
carried out in the predetermined jig position.
Fixture mastering is accurate because a dedicated mastering jig is used.
Fixture mastering is factory–performed. It is unnecessary to perform it in
daily operations.
When mastering the robot, arrange the robot to meet the following
conditions.
D Make the robot mounting base horizontal within 1 mm.
D Remove the hand and other parts from the wrist.
D Set the robot in the condition protected from an external force.
NOTE
When the robot is being subjected to mastering, it does not
make a axis limit check. Pay sufficient attention to the
operation of the robot axes.
Mounting the
mastering jig
Install the mastering jig. The mastering jig used is common to the
M–16iB/20, ARC Mate 120iB, M–16iB/10L, and ARC Mate 120iB/10L.
1) Assembling the fixture base
Assemble the fixture base B and C as shown in Fig.5.2.3 (a).
Mastering
fixture B
Mastering
fixture C
Fig.5.2.3 (a) Assembling fixture base
2) Mounting dial indicator.
As shown in Fig. 5.2.3 (b), mount the dial indicator on the fixture base.
Adjust the dial gauge to 3.00 mm using the calibration block, and
tighten it with M5 bolt as shown in Fig.5.2.3 (b). (Do not tighten the
bolt too strongly or the dial indicator will be broken.)
36
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
Gauge Block
0
Gauge A
3
Gauge B
Gauge D
Gauge C
Gauge F
Gauge E
Fig.5.2.3 (b) Mounting dial indicator
3) Mounting fixture base
Mount the fixture on the J1–axis base with bolts as shown in
Fig.5.2.3(c).
M12×25(2)
Washer M12(2)
Pin
A290–7215–X955
A290–7215–X956
Fig.5.2.3 (c) Mounting fixture base
37
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
4) Mounting the fixture to the wrist
Manually feed the wrist axis to the position J4 = J5 = J6 = 0°. Mount
mastering jig A on the wrist flange with the orientation shown in Fig.
5.2.3 (d).
After mounting the jig, remove pin A290–7022–X965. Note that if
the pin is left attached, it will collide with the mastering jig.
Mastering
fixture A
Pin
A290–7022–X965
M6×12(2)
Washer M6(2)
Fig.5.2.3 (d) Mounting fixture to wrist
Mastering
1) Press MENUS.
2) Press NEXT and select SYSTEM.
3) Press F1, [TYPE].
4) Select Master/Cal.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ]
LOAD
38
RES_PCA
DONE
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
5) Release brake control, and jog the robot into a posture for mastering.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM_GROUP.SSV_OFF_ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the control unit
power off and on again.
a) Slowly move the robot by axial feed so that the values of dial
indicators A to F shown in Fig. 5.2.3 (b) range from 2 mm to 3 mm.
b) Move the J6 axis so that dial indicators A and B read the same
value.
c) Move the J4 axis so that dial indicators D and F read the same value.
d) Move the J1 axis so that dial indicator C reads 3.00 mm.
e) Move the J5 axis so that dial indicator E reads the same value as
the values of dial indicators D and F.
f) Move the J6 axis so that dial indicators A and B read the same
value.
g) Make a rectangular feed (with an override of up to 1%) so that dial
indicators A, B, D, E, and F read 3.00 mm.
h) Repeat the above steps until all the dial indicators read 3.00 mm.
6) Select Fixture Position Master.
7) Press F4, YES. Mastering will be performed automatically.
8) After calibration is completed, press F5 [DONE].
NOTE
No check is made on the axis movable range during
mastering. Be very careful when running the robot.
Continuing axis movement may result in the mechanical
stopper being bumped.
9) Reset the brake control release settings to the original state. Set
system variables $PARAM_GROUP, $SV_OFF_ALL, and
$SV_OFF_ENB to their original values, then turn off then back on
the power.
10)After mastering, update the mastering data in the data sheet attached
at the shipment with new mastering data (#DMR_GROUP and
$MASTER_COUN[1] to [6]).
39
MAINTENANCE
B–81765EN/01
MASTERING POSITION
AXIS
POSITION
J1
0°
J2
66.4976°
J3
–133.243°
J4
0°
J5
42.243°
J6
–90°
Fig.5.2.3 (e) Mastering attitude (ARC Mate 120iB, M–16iB/20)
MASTERING POSITION
AXIS
POSITION
J1
0°
J2
31.6241°
J3
–103.792°
J4
0°
J5
13.792°
J6
–90°
Fig.5.2.3 (f) Mastering attitude (ARC Mate 120iB/10L, M–16iB/10L)
40
5. ADJUSTMENTS
5. ADJUSTMENTS
MAINTENANCE
5.2.4
B–81765EN/01
Zero–position mastering (eye mark mastering) is performed with all axes
set at the 0–degree position. A zero–position mark (eye mark) is attached
to each robot axis. This mastering is performed with all axes set at the
0–degree position using their respective eye marks.
Zero Position
Mastering
Zero–position mastering involves a visual check. It cannot be so accurate.
It should be used only as a quick–fix method.
Procedure
Mastering to Zero
Degrees
Step
1 Press MENUS.
2 Select NEXT and press SYSTEM.
3 Press F1, [TYPE].
4 Select Master/Cal.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ]
LOAD
RES_PCA
DONE
5 Release brake control, and jog the robot into a posture for mastering.
NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM GROUP.SSV OFF ENB[*]: FALSE (for all axes)
After changing the system variables, switch the control unit
power off and on again.
6 Select Zero Position Master.
7 Press F4, YES. Mastering will be performed automatically.
8 After calibration is completed, press F5[DONE].
9 Reset the brake control release settings to the original state. Set
system variables $PARAM_GROUP, $SV_OFF_ALL, and
$SV_OFF_ENB to their original values, then turn off then back on
the power.
41
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
Table 5.2.4 Attitude with position marks aligned
Axis
Position
J1–axis
J2–axis
J3–axis
J4–axis
J5–axis
J6–axis
0 deg
0 deg
0 deg
0 deg
0 deg
0 deg
J4–axis
J6–axis
J3–axis
J2–axis
J5–axis
J1–axis
Fig.5.2.4 (a) Zero degree position arrow mark for each axis (ARC Mate 120iB, M–16iB/20)
42
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
J4–axis
J6–axis
J3–axis
J2–axis
J5–axis
J1–axis
Fig.5.2.4 (b) Zero degree position arrow mark for each axis (ARC Mate 120iB/10L, M–16iB/10L)
43
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
5.2.5
Quick mastering is performed at a user–specified position. The
corresponding count value is obtained from the rotation speed of the pulse
coder connected to the relevant motor and the rotation angle within one
rotation. Quick mastering uses the fact that the absolute value of a rotation
angle within one rotation will not be lost.
Quick Mastering
Quick mastering is factory–performed at the position indicated in Table
5.2.4. Do not change the setting unless there is any problem.
If it is impossible to set the robot at the position mentioned above, it is
necessary to re–set the quick mastering reference position using the
following method. (It would be convenient to set up a marker that can
work in place of the eye mark.)
NOTE
1 Quick mastering can be used, if the pulse count value is lost,
for example, because a low voltage has been detected on
the backup battery for the pulse counter.
2 Quick mastering cannot be used, after the pulse coder is
replaced or after the mastering data is lost from the robot
control unit.
Procedure
Recording the Quick
Master Reference
Position
Step
1 Select SYSTEM.
2 Select Master/Cal.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ]
LOAD
RES_PCA
DONE
3 Release brake control, and jog the robot to the quick mastering
reference position.
Set quick master ref? [NO]
4 Move the cursor to SET QUICK MASTER REF and press ENTER.
Press F4, YES.
44
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
NOTE
If the robot has lost mastery due to mechanical disassembly
or repair, you cannot perform this procedure. In this case,
master to a fixture or master to zero degrees to restore robot
mastery.
Procedure
Quick Mastering
Step
1 Display the Master/Cal screen.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ]
LOAD
RES_PCA
DONE
2 Release brake control, and jog the robot to the quick mastering
reference position.
Quick master? [NO]
3 Move the cursor to QUICK MASTER and press ENTER. Press F4,
YES. Quick mastering data is memorized.
4 Move the cursor to CALIBRATE and press ENTER. Calibration is
executed.
5 After completing the calibration, press F5 Done.
6 Reset the brake control release settings to the original state. Set
system variables $PARAM_GROUP, $SV_OFF_ALL, and
$SV_OFF_ENB to their original values, then turn off then back on
the power.
7 After mastering, update the mastering data in the data sheet attached
at the shipment with new mastering data (#DMR_GROUP and
$MASTER_COUN[1] to [6]).
45
5.2.6
Single Axis Mastering
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
Single axis mastering is performed for one axis at a time. The mastering
position for each axis can be specified by the user.
Single axis mastering can be used, if mastering data for a specific axis is
lost, for example, because a low voltage has been detected on the pulse
counter backup battery or because the pulse coder has been replaced.
SINGLE AXIS MASTER
ACTUAL AXIS (MATR POS)
J1
25.255
(0.000)
J2
25.550
(0.000)
J3
–50.000
(0.000)
J4
12.500
(0.000)
J5
31.250
(0.000)
J6
43.382
(0.000)
E1
0.000
(0.000)
E2
0.000
(0.000)
E3
0.000
(0.000)
JOINT 33%
(SEL) [ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
GROUP
EXE
Table 5.2.6 Items Set in Single Axis Mastering
Item
Description
Current position
(Actual axis)
The current position of the robot is displayed for each
axis in degree units.
Mastering position
(Matra pos)
A mastering position is specified for an axis to be subjected to single axis mastering. It would be convenient
to set to it to the 0_ position.
SEL
This item is set to 1 for an axis to be subjected to
single axis mastering. Usually, it is 0.
ST
This item indicates whether single axis mastering has
been completed for the corresponding axis. It cannot
be changed directly by the user.
The value of the item is reflected in
$EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis mastering
is necessary.
1 : Mastering data has been lost. (Mastering has been
performed only for the other interactive axes.) Single
axis mastering is necessary.
2 : Mastering has been completed.
46
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
Procedure
Mastering a Single Axis
Step
1 Select SYSTEM.
2 Select Master/Cal.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ]
LOAD
RES_PCA
3 Select 4, Single Axis Master. You will see a screen similar to the
following.
SINGLE AXIS MASTER
ACTUAL POS
J1
25.255
J2
25.550
J3 –50.000
J4
12.500
J5
31.250
J6
43.382
E1
0.000
E2
0.000
E3
0.000
(MSTR POS)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
[ TYPE ]
JOINT 10%
1/9
(SEL) [ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[2]
(0)
[2]
(0)
[2]
GROUP
EXEC
4 Move the cursor to the SEL column for the unmastered axis and press
the numeric key “1.” Setting of SEL is available for one or more axes.
5 Turn off brake control as required, then jog the robot to the mastering
position.
6 Enter axis data for the mastering position.
(0.000)
(0.000)
JOINT 30%
5/9
(0)
[2]
(0)
[2]
SINGLE AXIS MASTER
J5
J6
31.250
43.382
(0.000)
(90.000)
JOINT 30%
5/9
(0)
[2]
(0)
[2]
GROUP
47
EXEC
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
7 Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0, and
ST is re–set to 2 or 1.
GROUP
SINGLE AXIS MASTER
EXEC
F5
ACTUAL AXIS
25.255
25.550
–50.000
12.500
0.000
90.000
0.000
0.000
0.000
J1
J2
J3
J4
J5
J6
E1
E2
E3
(MATR POS)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(90.000)
(0.000)
(0.000)
(0.000)
JOINT 30%
1/9
(SEL) [ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
GROUP
EXEC
8 When single axis mastering is completed, press the previous page key
to resume the previous screen.
SYSTEM Master/Cal
BACK
1
2
3
4
5
6
JOINT 30%
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ’ENTER’ or number key to select.
[ TYPE ]
DONE
9 Select [6 CALIBRATE], then press F4 [YES]. Positioning is
performed.
10
After positioning is completed, press F5 [DONE].
DONE
F5
11 Reset the brake control release settings to the original state. Set
system variables $PARAM_GROUP, $SV_OFF_ALL, and
$SV_OFF_ENB to their original values, then turn off then back on
the power.
48
5. ADJUSTMENTS
MAINTENANCE
5.2.7
B–81765EN/01
This function enables mastering data values to be assigned directly to a
system variable. It can be used if mastering data has been lost but the pulse
count is preserved.
Mastering Data Entry
Mastering data entry
method
Step
1 Press MENUS, then press NEXT and select SYSTEM.
2 Press F1, [TYPE]. Select [Variables]. The system variable screen
appears.
SYSTEM Variables
1
2
3
4
5
6
$AP MAXAX
$AP PLUGGED
$AP TOTALAX
$AP USENUM
$AUTOINIT
$BLT
JOINT 10%
1/98
536870912
4
16777216
[12] of Byte
2
19920216
[ TYPE ]
3 Change the mastering data.
The mastering data is saved to the $DMR_GRP.$MASTER_COUN
system variable.
SYSTEM Variables
13 $DMR GRP
14 $ENC STAT
JOINT 10%
DMR GRPT
[2] of ENC STATT
[ TYPE ]
4 Select $DMR_GRP.
JOINT 30%
DMR GRPT
[2] of ENC STATT
ENTER
SYSTEM Variables
$DMR
GRP
1
[1]
JOINT 10%
1/1
DMR GRPT
SYSTEM Variables
$DMR GRP [1]
1
$MASTER DONE
2
$OT MINUS
3
$OT PLUS
4
$MASTER COUN
5
$REF DONE
6
$REF POS
7
$REF COUNT
8
$BCKLSH SIGN
[ TYPE ]
49
JOINT 10%
1/8
FALSE
[9] of
[9] of
[9] of
FALSE
[9] of
[9] of
[9] of
Boolean
Boolean
Integer
Real
Integer
Boolean
TRUE
FALSE
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
5 Select $MASTER_COUN, and enter the mastering data you have
recorded.
JOINT 30%
FALSE
[9] of Boolean
[9] of Boolean
[9] of Integer
ENTER
SYSTEM Variables
$DMR GRP [1].$MASTER
1
[1]
2
[2]
3
[3]
4
[4]
5
[5]
6
[6]
7
[7]
8
[8]
9
[9]
JOINT 10%
COUN
1/9
95678329
10223045
3020442
304055030
20497709
2039490
0
0
0
6 Press the PREV key.
7 Set $MASTER_DONE to TRUE.
TRUE
FALSE
F4
SYSTEM Variables
$DMR GRP [1]
1
$MASTER DONE
2
$OT MINUS
[ TYPE ]
JOINT 10%
1/8
TRUE
[9] of Boolean
TRUE
8 Press F1, [TYPE]. Select [Master/cal].
9 Select [6 CALIBRATE], then press F4 [YES].
10
After completing calibration, press F5 [DONE].
DONE
F5
50
FALSE
5. ADJUSTMENTS
MAINTENANCE
B–81765EN/01
5.2.8
1) Confirming that mastering was performed normally
Confirming Mastering
Usually, positioning is performed automatically when the power is
turned on. To confirm that mastering was performed normally, check
that the current–position display matches the actual position of the
robot, using this procedure.
a) Replay the taught operation of the robot to set each axis to zero
degrees, and visually check that the zero–degree position marks
shown in Fig. 5.2 are aligned.
b) Replay a specific portion of the program, and check that the robot
has moved to the taught position.
2) Possible alarms in positioning
The following paragraphs describe alarms that may occur in
positioning and explain how to handle them.
a) BZAL alarm
This alarm is raised if the voltage of the pulse coder backup battery
becomes 0V when the controller power is off. Mastering must be
performed again because the counter has already lost data.
b) BLAL alarm
This alarm indicates that the voltage of the pulse coder backup
battery is too low to run the pulse coder. If this alarm is issued,
replace the backup battery soon while keeping the power on, and
check whether the current–position data is correct, using a method
described in item (1).
c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and
SPHAL alarms
If any of these alarms is issued, contact your FANUC service
representative. A motor may have to be replaced.
51
B–81765EN/01
5.3
J5–AXIS GEAR
BACKLASH
ADJUSTMENTS
5. ADJUSTMENTS
MAINTENANCE
If the backlash in the J5–axis is greater than the allowable value (output
axis angle of 4.5 minutes) listed in Table 4.2 (b), (d), make backlash
adjustments, using this procedure. (See Fig. 5.3.)
The J5–axis structure is common to the ARC Mate 120iB, M–16iB/20,
ARC Mate 120iB/10L, and M–16iB/10L.
1 Place the robot in a posture of J3 = 0°, J4 = +90° and J5 = J6 = 0°.
2 Remove the twelve M5 10 flat–head bolts, and dismount the J5–axis
gearbox cover (A290–7216–X524) from the J3 arm (A290–7216–
X402 and X404), and suck internal grease.
3 Adjust the gear 3 assembly and gear J5–4, then adjust the gear 2
assembly and gear 3 assembly.
J3 arm
A290–7216–X402, X404
Input Gear
A290–7216–X511
Gear 3 assembly
A290–7216–V502
Gear J5–4
J6 Housing
Gear 2 assembly
A290–7216–V501
Bolt with washer :
M6 14 (4pcs)
Plane washer (4pcs)
Very low
head bolt
M5 10 (12pcs)
Seal bolt with washer :
M6 12 (10pcs)
Cover
A290–7216–X524
Gear 3 assembly
A290–7216–V502
Just loosen
this two bolts.
Adjust the backlash
by turning the gear
3 assembly around
this bolt.
Fig 5.3 J5–axis gear backlash adjustments
1) Gear 3 assembly and gear J5–4 backlash adjustments
1 Remove the four M6 14 seal bolts with a washer, and retract the
gear 2 assembly (A290–7216–V501) to such a point that it will not
be engaged with the gear 3 assembly (A290–7216–V502).
2 Of the 10 M6 12 seal bolts with a washer securing the gear 3
assembly, loosen but leave the two bolts shown in the figure, and
remove the other eight bolts.
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5. ADJUSTMENTS
MAINTENANCE
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3 Rotating the gear 3 assembly in the right and left directions about
the reference bolt changes the amount of the backlash with J5–4.
Shift the position of the gear 3 assembly so that the backlash can
be reduced, and temporarily secure the assembly with the
remaining two bolts.
4 Rotate the J6 housing (gear J5–4) within the stroke (±140°), and
check whether the rotation is abnormally heavy and any portion has
a serious backlash. Repeat the above operation until the backlash
is reduced to within the maximum allowable value and the
engagement and rotation torque becomes appropriate.
5 When you have completed adjustments, use new 10 M6 12 seal
bolts with a washer to secure the gear 3 assembly with the specified
torque. Remove also the two bolts used during adjustments, and
replace them with new seal bolts.
NOTE
Once you loosen seal bolts, sealing properties deteriorate,
which can lead to grease leakage.
When assembling the gear, use new seal bolts.
2) Gear 2 assembly and gear 3 assembly backlash adjustments
1 Shift the gear 2 assembly in a direction vertical to the gear 3
assembly and input gear (A290–7216–X511) so that the backlash
is reduced, and fix the gear 2 assembly to the J3 arm with two
M6 12 seal bolts with a washer.
2 Rotate the gear 2 assembly, and check the operation of the J5–axis
by operating it within its stroke (–140° to +140°). Repeat step 1
for reducing the backlash until the gears will not interfere with each
other.
When you have completed adjustments, use new four M6 14
bolts with a washer (with Loctite 262 applied) and plain washers,
and tighten them to the specified torque to secure the assembly.
3 Make sure that the total backlash in the J5–axis unit is lower than
the maximum allowable value (output axis angle of 4.5 minutes)
listed in Table 4.2 (b), (d). If the requirement is not satisfied, go
back to 1 of procedure (1).
4 Fix the J5–axis gearbox cover to the J3 arm with twelve M5 10
flat–head bolts.
5 Apply the specified grease to the J5–axis gearbox by following the
grease replacement procedure stated in Section 3.2.
6 Perform mastering as stated in Section 5.2.
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5.4
BRAKE RELEASE
MAINTENANCE
5. ADJUSTMENTS
When the robot power is off, the brakes of the robot can be released using
the brake release unit (option). In this case, the robot can be put in a
different position. Observe Notes 1 to 4 given below.
NOTE
1 When releasing the brakes of the J2–axis or J3–axis motor
(M2 or M3), support the robot with a crane as shown in Fig.
5.4.
2 When releasing the brakes of the J4–axis to J6–axis motor
(M4 to M6), support the end effector with a crane so that it
will not fall.
3 When releasing the brakes of motors, use slings having a
sufficient tensile strength.
4 Do not release the brakes of more than one motor
simultaneously.
Fig.5.4 Brake release for J2–axis motor
54
6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
6
MAINTENANCE
B–81765EN/01
COMPONENT REPLACEMENT AND ADJUSTMENTS
Adjustments are needed after a component is replaced.
The following table lists components and the adjustment items that must
be made after the components are replaced. After replacing a component,
make necessary adjustments according to this table.
A common replacement method is applied to all of the ARC Mate 120iB,
M–16iB/20, ARC Mate 120iB/10L, and M–16iB/10L.
Replacement component
Adjustment item
Motor
(a) Mastering
J1–, J2–, and J3–axis reducers
(a) Mastering
J4–axis gearbox
(a) Mastering
J5–axis gear
(a) Mastering
J6–axis reducer
(a) Mastering
NOTE
Be very careful when dismounting and mounting the heavy
components that are listed below.
Component
Weight
All components from J3–axis arm to wrist unit
(See Fig. 6.8.)
15kg
All components from J3–axis reducer to wrist unit
(See Fig. 6.6.)
50kg
All components from J2–axis arm to wrist unit
(See Fig. 6.4. (a).)
70kg
All components from J2–axis base to wrist unit
(See Fig. 6.2 (a) and (b).)
130kg
NOTE
Reducer bolt torques might be different than the bolt torque
listed in the Appendix for the same size bolt. The bolt torque
for the reducer bolts is specified by the reducer
manufacturer.
55
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6.1
REPLACING THE
J1–AXIS MOTOR M1
MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
1 Turn off the controller power.
2 Remove the J1–axis motor connector.
3 Remove the four M8 20 motor mounting bolts. Dismount the motor
from the J1–axis unit. When dismounting the motor, be careful of the
grease that may drop from the motor if the robot is suspended from a
ceiling or mounted on a wall.
4 Remove the M10 hexagonal nut from the motor shaft, and pull out the
gear (A290–7216–X211).
5 Remove the C–ring (GV–30) from the gear, replace the bearing
(B16006) with a new one, and then attach the C–ring again.
6 Attach the gear to a new motor (A06B–0235–B605).
7 Attach an M10 spring washer, apply Loctite 242 to the M10 threaded
portion of the motor, and tighten the M10 nut with a tightening torque
of [16.7 Nm].
8 Make sure that the O–ring (JB–ORIA–G105) is correctly attached to
the J2 base (A290–7216–X301) portion where the J1–axis motor is to
be mounted, and fasten them with four M8 20 bolts.
9 Attach the cable connector to the J1–axis motor.
10 According to Section 3.2, supply the J1–axis grease bath with the
specified grease.
11 While referencing Chapter 5, perform mastering.
NOTE
If there is a danger that the J1–axis section may swivel, for
example, because the robot is installed on a tilted surface,
fix the J1–axis section during replacement work, for
example, by pushing the J1–axis mechanical stopper
against the J1–axis section.
56
6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
MAINTENANCE
J1–axis motor
B–81765EN/01
M8 20 (4pcs)
M1
Washer M8 (4pcs)
O–ring G105
C–ring GV-30
Bearing B16006
Gear A290-7216-X211
Screw washer M10
Hexagonal nut M10
Loctite 242
16.7 Nm
Fig 6.1 Replacing the J1–axis motor
57
B–81765EN/01
6.2
REPLACING THE
J1–AXIS REDUCER
MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
1 Put the robot in such a position that the J2 base and the portions above
it can be suspended with a crane or the like (hereafter abbreviated as
a crane), and then turn off the controller power.
2 While referencing Section 8.2, replace the cable clamp (A2907216-X331) the J2 base (A290–7216–X301) and pull out the J1–axis
hollow pipe section toward the upper portion of the J2 base.
3 While referencing Section 6.1, remove the J1–axis motor from the J2
base.
4 As shown in Fig. 6.2, remove the eleven M10 45 bolts that fasten the
J2 base to the J1–axis reducer.
5 While referencing Section 3.1 of Part II, “Connection,” hoist the J2
base and portions above it slowly.
6 As shown in Fig. 6.2, remove the O–ring (ARP568–173), bearing, and
center gear (A290–7216–X212).
7 Remove the six M14 85 bolts that fasten the J1–axis reducer to the
J1 base (A290–7216–X201), and dismount the reducer.
8 Remove the O–ring (ARP568–165) from the reducer.
9 Attach the O–ring (ARP568–165) to a new reducer (A97L–0218–
0303#37), and fasten the new reducer to the J1 base with six M14 85
bolts (by applying Loctite 262 and tightening with a torque of [129
Nm]).
10 Mount the center gear, bearing (with Loctite 675 applied to its outer
ring), and O–ring (ARP568-173) to the reducer.
11 Fasten the J2 base to the reducer with eleven M10 50 bolts (by
applying Loctite 262 and tightening with a torque of [73.5 Nm]). Be
careful not to let the pipe damage the oil seal.
12 According to Section 6.1, mount the J1–axis motor on the J2 base.
13 According to Section 8.2, put the cable that was removed before back
to the previous place.
14 According to Section 3.2, supply the J1–axis grease bath with the
specified grease.
15 While referencing Chapter 5, perform mastering.
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6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
MAINTENANCE
B–81765EN/01
J1–axis motor
M1
M10 45 (11pcs)
Washer M10 (11pcs)
Loctite 262
73.5 Nm
O–ring G105
J2–axis base
O–ring
ARP568-173
Bearing
Loctite 675
(Outer ring)
M14 85 (6pcs)
Washer M14 (6pcs)
Loctite 262
129 Nm
Center gear
J1–axis reducer
O–ring
ARP568-165
J1–axis base
Fig 6.2 Replacing the J1–axis reducer
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6.3
REPLACING THE
J2–AXIS MOTOR M2
MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
1 Push the J2–axis section against the mechanical stopper, suspend it
with a crane, or fix it in such a way that it will not swivel when the
motor is dismounted, for example, by placing it in the direction of
gravity.
NOTE
If the J2–axis section is not pushed against the stopper
correctly, or it is not placed in the direction of gravity, there
is a danger that the J2–axis section will swivel when the
J2–axis motor is removed.
2 Turn off the controller power.
3 Remove the J2–axis motor connector.
4 Remove the four M8 20 motor mounting bolts, and dismount the
motor from the J2 base.
5 Remove the M6 45 bolt that fastens the input spline, and dismount
the input spline. Also remove the draw bolt from the motor shaft.
6 Apply Loctite 242 to the threaded portion of a new motor
(A06B–0235–B605), and tighten the draw nut with a torque of [16.7
Nm].
7 Put the input spline over the draw nut, attach a spring washer to the bolt
M6 45, apply Loctite 242, and tighten with a torque of [11.8 Nm].
8 Make sure that the O–ring (G115) is correctly attached to the J2 base
(A290–7216–X301) portion where the motor is to be mounted, and
fasten the motor to the J2 base with four M8 20 bolts are binded by
seal tape. Do not force in the motor. Otherwise, the input spline may
not settle in the correct place, possibly causing break down (if the
spline is engaged correctly, the motor will be mounted smoothly).
9 Attach the cable connector to the J2–axis motor.
10 According to Section 3.2, supply the J2–axis grease bath with the
specified grease.
11 While referencing Chapter 5, perform mastering.
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6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
MAINTENANCE
Bolt M6 45
Washer M6
Loctite 242
11.8 Nm
J2–axis base
Loctite 242
J2–axis motor
Seal bolt
M8 20 (4pcs)
Washer
M8 (4pcs)
Draw nut
16.7 Nm
Input spline
O–ring G115
Fig 6.3 Replacing the J2–axis motor
61
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B–81765EN/01
6.4
REPLACING THE
J2–AXIS REDUCER
MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
1 Put the robot in such a posture that the J2 arm (A290–7216–X302) and
the components on it can be suspended with a crane, and then turn off
the controller power.
2 Suspend the J2 arm and the components on it with a crane so that they
will not drop when the J2 arm is dismounted.
3 As shown in Fig. 6.4 (a), remove the twelve M12 55 bolts that fasten
the J2 arm, dismount from the tip of the J2 arm and plate
(A290–7216–X321) from the J2–axis reducer. Be careful not to allow
an excessive load to be put on the cables (because the cables are left
attached when the reducer is dismounted).
4 Remove the O–ring (ARP568–166) from between the J2 arm and
reducer.
5 Remove the twelve M10 35 bolts that fasten the J2–axis reducer to
the J2 base, and dismount the J2–axis reducer from the J2 base.
6 Remove the O–ring (G190) from between the reducer and J2 base.
7 Attach the O–ring (G190) to a new reducer (A97L–0218–0304#175),
insert it into the J2 base, and fasten them with twelve M10 35 bolts (by
applying Loctite 262 and tightening with a torque of [74 Nm]).
8 Degrease both the J2 arm and the J2–axis reducer surfaces that are to
meet each other, and as shown in Fig. 6.4 (b), apply sealant (Loctite
No. 518) to the J2 arm surface on which the J2 reducer is to be
mounted.
9 Attach the O–ring (ARP568–166) to the J2 arm, insert the plate, and
fasten the J2 arm to the J2 reducer with twelve M12 55 bolts (by
applying Loctite 262 and tightening with a torque of [128 Nm]).
10 According to the grease replacement procedure described in Section
3.2, supply the J2–axis grease bath with the specified grease.
11 While referencing Chapter 5, perform mastering.
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6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
MAINTENANCE
B–81765EN/01
J2–axis arm
M10 35 (12pcs)
Washer M10 (12pcs)
Loctite 262
74 Nm
M12 55 (12pcs)
Washer M12
(12pcs)
Loctite 262
128 Nm
O–ring G190
Plate
O–ring ARP568-166
J2–axis
base
J2–axis reducer
Fig 6.4 (a) Replacing the J2–axis reducer
Fig 6.4 (b) Applying sealant to the J2–axis reducer
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B–81765EN/01
MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
NOTE
Observe the following cautions when applying sealant
(Loctite No. 518).
1 Cleaning the surface where sealant is to be applied
1) Remove dust from the surface and the inside of the
threaded holes, for example, by blowing it off.
2) Degrease the surface completely with a cloth dampened
with solvent. Do not spray solvent directly onto the
surface.
3) Wipe off any solvent from the surface with a dry cloth.
Make sure that no solvent is left in the threaded holes or
on any other portion.
4) Always use a new surface of a cloth so that the grease
once wiped up with the cloth will not get on the degreased
surface.
2 Allowing time during which the sealant can cure
To let the applied sealant cure, avoid running the robot and
applying grease for at least four hours after the sealant is
applied.
3 Wiping off excessive sealant
After attaching the cover, wipe off any excessive sealant
that comes out from the sealed section with a cloth or
spatula. Do not use solvent.
64
6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
6.5
REPLACING THE
J3–AXIS MOTOR M3
MAINTENANCE
B–81765EN/01
1 Push the J3–axis section to the mechanical stopper, suspend it with a
crane, or fix it in such a way that it will not swivel when the motor is
dismounted, for example, by placing it in the direction of gravity.
NOTE
If the J3–axis section is not pushed against the stopper
correctly, or it is not placed in the direction of gravity, there
is a danger that J3–axis section will swivel when the J3–axis
motor is removed.
2 Turn off the controller power.
3 Remove the connector of a cable leading to the J3–axis motor.
4 Remove the three M6 14 bolts that fasten the J3–axis motor to the
J3 casing (A290–7216–X401), and dismount the motor and O–ring
(G75).
5 Remove the M6 nut from the motor shaft, and dismount the input gear
(A290–7216–X411).
6 Attach an accompanying woodruff key to the shaft of a new motor
(A06B–0212–B605).
7 Attach an input gear and an M6 spring washer to the shaft, apply
Loctite 242 to the threaded section of the shaft, and fasten the gear with
an M6 nut by tightening with a torque of [3.2 Nm].
8 Attach the O–ring (G75) and fasten the motor to the J3–axis casing
with three M6 14 bolts.
9 Attach the cable connector to the J3–axis motor.
10 According to Section 3.2, supply the J3–axis grease bath with the
specified grease.
11 While referencing Chapter 5, perform mastering.
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B–81765EN/01
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
MAINTENANCE
Input gear
J3–axis motor
M6 14
(3pcs)
Washer
M6 (3pcs)
Screw washer M6
J3–axis casing
Hexagonal nut M6
Loctite 242
3.2 Nm
O–ring G75
Fig 6.5 Replacing the J3–axis motor
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6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
6.6
MAINTENANCE
B–81765EN/01
1 Put the robot in such a posture that the J3–axis section and the
components on it can be suspended with a crane, and then turn off the
controller power.
2 While referencing Section 8.2, remove the cable from the J3–axis
section and pull out the cable from the J3–axis reducer.
3 Suspend the J3–axis section and the components on it with a crane so
that they will not drop when the reducer is dismounted from the J2 arm.
4 As shown in Fig. 6.6, remove the eight M8 60 bolts that fasten the
J3–axis reducer to the J2 arm, and dismount the J3 arm unit from the
J2 arm and unload down the J3 arm unit.
5 Remove eleven M6 30 bolts that fasten the J3–axis reducer to the J3
casing (A290–7216–X401), dismount the J3–axis reducer from the J3
casing.
6 Remove the O–ring (ARP568-163), the pipe (A290-7216-X421), the
center gear and the bearing from the reducer.
7 Make sure that an O–ring (S44) is mounted properly on the pipe that
was removed, and attach the pipe to a new reducer (A97L–0218–
0305#37). Also attach the center gear, bearing (with Loctite 675
applied to its outer ring), and the O–ring (ARP568–163) to the reducer.
8 Mount the reducer on the J3 casing, and fasten them with eleven
M6 65 bolts (by applying Loctite 262 and tightening with a torque
of [15.7 Nm]).
9 Suspend the J3–axis section and the components on it with a crane and
insert the plate, and fasten the J2 arm and J3–axis reducer with eight
M8 60 bolts (by applying Loctite 262 and tightening with a torque
of [37.2 Nm]).
10 While referencing Section 8.2, dress the cable into the previous form.
11 According to Section 3.2, supply the J3–axis grease bath with the
specified grease.
12 While referencing Chapter 5, perform mastering.
REPLACING THE
J3–AXIS REDUCER
M8 60 (8pcs)
Washer M8 (8pcs)
Loctite 262
O–ring S44
37.2 Nm
Pipe
J3–axis casing
O–ring
ARP568-163
J3–axis
reducer
Plate
M6 65 (11pcs)
Washer M6 (11pcs)
Loctite 262
15.7 Nm
J2–axis arm
Fig 6.6 Replacing the J3–axis reducer
67
Bearing
Loctite 675
(Outer ring)
Center gear
MAINTENANCE
B–81765EN/01
6.7
REPLACING THE
J4–AXIS MOTOR M4
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
1 Place the robot in a posture of J4 = –90°. Keep this condition until step
<10> (mastering). Note that if the operation for setting the zero–degree
position is performed incorrectly, the cable may be twisted more than
allowed, leading to a broken cable. If the robot is in a posture of J3 =
–90°, grease will not drop when the motor is dismounted.
2 Turn off the controller power.
3 Remove the connector of a cable leading to the J4–axis motor.
4 As shown in Fig. 6.7, remove the three M6 14 bolts that fasten the
J4–axis motor to the J3 casing (A290–7216–X401), and dismount the
motor.
5 Remove the nut (A290–7215–X412) that fastens the J4–1 gear
(A290–7215–X411) to the motor shaft, and dismount the J4–1 gear
and M6 spring washer.
6 Attach an accompanying woodruff key to the shaft of a new motor
(A06B–0212–B605). Attach the J4–1 gear to the shaft, apply Loctite
242 to the threaded section of the shaft, and fasten the gear with a nut
by tightening with a torque of [9 Nm].
7 Make sure that the O–ring (G75) is put accurately in the J3 casing
portion where the motor is to be mounted, and fasten the motor to the
J3 casing with three M6 14 bolts.
8 Attach the cable connector to the J4–axis motor.
9 According to Section 3.2, supply the J4–axis grease bath with the
specified grease.
10 While referencing Chapter 5, perform mastering.
O–ring G75
J4–axis motor
Screw washer
M6
J3–axis casing
M4
M6 14
(3pcs)
Washer M6 (3pcs)
Gear J4–1
Nut
Loctite 242
9 Nm
Fig 6.7 Replacing the J4–axis motor
68
6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
6.8
REPLACING THE
J4–AXIS GEARBOX
MAINTENANCE
B–81765EN/01
1 Turn off the controller power.
2 According to Section 8.2, remove the cables that run from the
J3–/J4–axis motor connectors through the clamps on the J3 casing and
in the J3 arm, and take them out from the J3 arm unit.
3 Suspend the J3 arm with a crane. Remove the nine M8 95 bolts that
fasten the J3 arm to the J4 gearbox unit, and dismount the J3 arm. (See
Fig. 6.8.)
4 Suspend the J4–axis gearbox unit above the J3 casing (A290–7216–
X401) through an M6 eyebolt with a crane. Remove the eight M8 60
bolts that fasten the J4 gearbox unit to the J2 arm, and dismount the
J4 gearbox unit from the J2 arm. Remove the plate (A290-7216-X322)
at the same time.
5 According to the procedures described in Sections 6.5, 6.6, and 6.7,
dismount the J3– and J4–axis motors and J3–axis reducer.
6 According to the procedures described in Sections 6.6 and 6.7, mount
the J4–axis motor and J3–axis reducer on a new J4–axis gearbox
(A05B–1216–K401).
7 Do not forget to insert an O–ring.
8 Fasten the J4–axis gearbox unit with eight M8 60 bolts (by applying
Loctite 262 and tightening with a torque of [37.2 Nm]).
9 According to the procedure described in Section 6.5, mount the
J3–axis motor.
10 Suspend the J3 arm with a crane, fasten to the J4–axis gear box with
nine M8 95 bolts (by applying Loctite 262 and tightening with a
torque of [37.2 Nm]).
11 According to Section 8.2, dress the cables that run from the clamp on
the J3 casing through the clamp in the J3 arm into the previous form.
Attach the J3 and J4–axis motor connectors.
12 According to Section 3.2, supply the J3– and J4–axis grease baths with
the specified grease.
13 While referencing Chapter 5, perform mastering.
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MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
J4–axis gear box
M8 95
(9pcs)
Washer M8
(9pcs)
Loctite 262
37.2 Nm
J3–axis
arm
Fig 6.8 Replacing the J4–axis gear box
70
6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
6.9
REPLACING THE
J5–AXIS MOTOR M5
MAINTENANCE
B–81765EN/01
1 Place the robot in a posture of J4 = –90°.
2 Turn off the controller power.
3 As shown in Fig. 6.9 (a), remove the six M6 16 bolts, pull out the
J5–2 cover (A290–7216–X502), rotate it to the position shown in the
figure, and fasten it to the J3 arm (A290–7216–X402, X404)
temporarily with a bolt while taking care to avoid having the cable
caught in between.
4 Remove the M5M1 inline cable connector and then the pulse coder
connector from the J5–axis motor.
5 Remove the four M5 12 sealing bolts with a washer that fasten the
J5–axis motor, and dismount the motor from the J3 arm.
If the arm is a long type (M–16iB/10L or ARC Mate 120iB/10L),
remove the two common M5 14 bolts with a washer used for the
J5–axis motor and support (A290–7216–X535) as well as the two
M5 12 sealing bolts with a washer that fasten the J5–axis motor.
(See Fig. 6.9 (b).)
6 Remove the gasket from between the motor and J3 arm.
7 Remove the M3 8 setscrew that fastens the J5–1 gear (A290–7216–
X511) to the motor shaft, and pull out the J5–1 gear.
8 Remove the cables from the motor.
9 Mount a new motor (A06B–0115–B275#0008) on the J5–1 gear,
attach a new key (JB–HKY–3X3X–8A) and washer, and fasten the
motor with the M3 8 setscrew (by applying Loctite 242 and
tightening with a torque of [1.5 Nm]).
10 Attach the cables that were detached at the above mentioned to the
motor.
11 Attach a new gasket (A98L–0040–0042#07) to the motor flange with
Alvania grease, fasten the motor to the J3 arm with four new M5 12
seal bolts with a washer. Be sure to use new seal bolts. Otherwise,
grease may leak.
If the arm is a long type, fasten the motor with the two M5 14 bolts
with a washer on the support side as well as the two M5 12 bolts with
a washer (by applying Loctite 262).
12 Attach the inline cable connectors, attach the connector of the pulse
coder, and dress the cables into the previous form.
13 Not to have non–bound cable portions caught between the gasket and
motor flange, fasten the J5–2 cover with six M6 16 bolts (by
applying Loctite 242 and tightening with a torque of [15.7 Nm]).
14 According to Section 3.2, supply the J5–axis grease bath with the
specified grease.
15 While referencing Chapter 5, perform mastering.
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
Seal bolt with washer
M5 12 (4pcs)
J5–axis motor
M5
Gear J5–1
Key
Washer
Low head bolt M3 8
Loctite 242
1.3 Nm
Gasket
M6 8 (6pcs)
Washer M6 (6pcs)
Loctite 242
15.7 Nm
Cover J5–1
Temporary fixing to
the cover J5–2 with
one bolt M6 16
J3–axis arm
Fig 6.9 (a) Replacing the J5–axis motor
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6
COMPONENT REPLACEMENT
AND ADJUSTMENTS
MAINTENANCE
Seal bolt with washer M5 14 (2pcs)
Loctite 262
B–81765EN/01
Seal bolt with washer
M5 12 (2pcs)
Support
J5–axis motor
M5
Key
Gear J5–1
Washer
Low head bolt M3 8
Loctite 242
1.3 Nm
Gasket
M6 16 (6pcs)
Washer M6 (6pcs)
Loctite 242
15.7 Nm
Cover J5–2
J3–axis arm
Temporary fixing to
the cover J5–2 with
one bolt M6 16
Fig 6.9 (b) Replacing the J5–axis motor (long arm)
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6.10
REPLACING THE
J5–AXIS GEAR
MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
1 To replace the J5–1 gear, follow the motor replacement procedure
stated in Section 6.9.
2 Place the robot in a posture of J3 = 0°, J4 = +90° and J5 = 0°.
3 Turn off the controller power.
4 According to Section 6.9, dismount the J5–axis motor.
5 As shown in Fig. 6.10, remove the twelve M5 10 very flat–head
bolts, and dismount the J5–1 cover (A290–7216–X524).
6 Remove the four M6 12 bolts with a washer and the plane washer
that fasten the gear 2 assembly (A290–7216–V501), and dismount the
gear 2 assembly from the J3 arm.
7 Remove the ten M6 12 seal bolts with a washer that fasten the gear
3 assembly (A290–7216–V502), and dismount the gear 3 assembly
from the J3 arm.
8 Remove the ten M6 35 seal bolts with a washer that fasten the J5–4
gear (A290–7216–X514), and dismount the J5–4 gear from the J3
arm.
9 Fasten a new J5–4 gear to the J3 arm with ten M6 35 bolts (by
tightening with a torque of [15.7 Nm]). Be sure to use new seal bolts.
Otherwise, grease may leak.
10 According to the backlash adjustment procedure described in Section
5.3, make backlash adjustments on a new gear 3 assembly, and fasten
it to the J3 arm.
11 According to the backlash adjustment procedure described in Section
5.3, make backlash adjustments on a new gear 2 assembly, and fasten
it to the J3 arm.
12 Once the backlash adjustments described in Section 5.3 are
completed, fasten the J5–1 cover to the J3 arm with twelve M5 10
flat–head bolts by tightening them with a torque of [4 Nm].
13 According to Section 3.2, supply the J5–axis grease bath with the
specified grease.
14 While referencing Chapter 5, perform mastering.
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COMPONENT REPLACEMENT
AND ADJUSTMENTS
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J3–axis arm
Gear 3 assembly
A290–7216–V502
Gear 2 assembly
A290–7216–V501
Bolt with washer
M6 14 (4pcs)
Plane washer M6 (4pcs)
Gear J5–4
Seal bolt with washer
M6 35 (10pcs)
15.7 Nm
Very low head
bolt M5 10
(12pcs) 4 Nm
Seal bolt with washer
M6 12 (10pcs)
Cover J5–1
Fig 6.10 Replacing the J5–axis gear
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6.11
REPLACING THE
J6–AXIS MOTOR M6
AND REDUCER
MAINTENANCE
6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
1) Replacing the J6–axis motor M6
1 Place the robot in a posture of J4 = –90° and J5 = 0°.
2 Turn off the controller power.
3 As shown in Fig. 6.11 (a), remove the four M5 30 bolts, pull out the
wrist flange by about 3 cm from the J6 housing (A290–7216–X501),
and then remove the two M3 6 bolts that fasten the clamp
(A290–7216–X534). After this, pull out the wrist flange completely
from the J6 housing slowly while paying attention to the cables.
4 Remove the connector from the J6–axis motor.
5 Remove the four M5 12 bolts with a washer that fasten the motor
to the wrist flange, and dismount the motor from the wrist flange.
6 Remove the gasket from between the motor and wrist flange.
7 Remove the M3 8 bolts and washers (A290–7215–X532), and
dismount the reducer wave generator from the motor.
8 Fasten the wave generator to the shaft of a new motor
(A06B–0115–B275#0008) with M3 8 bolts by applying Loctite
242 and tightening with a torque of [2 Nm]. (Do not forget to insert
washers [A290–7215–X532].) Also apply a plenty of grease
(Moly White RE No. 00) around the wave generator.
9 Attach a new gasket (A97L–0040–0042#07) to the motor flange
with Alvania grease, and fasten the motor to the wrist flange with
four M5 12 bolts with a washer (by applying Loctite 262). Be
sure to use a new gasket so as to prevent grease leakage.
10 Pass a new gasket (A290–7215–X533) over the cable. Attach the
motor cable connector. It will be convenient that you hook the
gasket on the parallel pins on the J6 housing.
11 Insert the wrist flange into the J6 housing until it has yet to go about
3 cm, and mount the clamp (A290–7216–X534) to the wrist flange
with two M3 6 bolts.
12 After making sure that the gasket is placed properly between the J6
housing and wrist flange, fasten the wrist flange equipped with the
motor to the J6 housing with four M5 30 bolts by (applying
Loctite 262 and) tightening with a torque of [9 Nm]. At this point,
while referencing Section 8.2, be careful to keep non–bound
movable cable portions in the J5–axis hollow section from being
caught in the J6 housing. If the robot is assembled and put in
operation with the cables caught, it is likely that the service life of
the cables may be badly shortened.
13 As described in Section 3.2, supply the J6–axis grease bath with the
specified grease.
14 While referencing Chapter 5, perform mastering.
2) Replacing the J6–axis reducer
1 Turn off the controller power.
2 Following procedure (1) on the previous page, dismount the wrist
flange from the J6 housing (A290-7216-X501). Also dismount the
motor from the wrist flange, then wave generator from the motor.
3 Following procedure (1) on the previous page, mount the wave
generator of a new reducer to the motor, and apply a plenty of
grease around the wave generator.
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AND ADJUSTMENTS
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4 As shown in Fig. 6.11 (b), remove the twelve M3 40 bolts with
a washer that fasten the adapter (A290–7216–X543) to the
cross–roller ring, and dismount the adapter (A290–7216–X543)
from the cross–roller ring.
5 Remove the twelve M3 15 bolts with a washer that fasten the
circular spline, adapter (A290–7215–X543), and dismount the
adapter from the circular spline. Mount and fasten a new circular
spline with twelve M3 15 bolts with a washer (by applying
Loctite 262 and tightening with a torque of [2 Nm]).
6 Remove the eight M5 12 bolts that fasten the flex spline, and
dismount the flex spline from the cross–roller ring and flange.
7 Position a new flex spline and the flange with two φ3 8 parallel
pins, and fasten it with eight M5 12 bolts with a washer (by
applying Loctite 262 and tightening with a torque of [9 Nm]).
8 After making sure that the O–ring (S71) is set properly in the
adapter (A290–7216–X543), mount the cross–roller ring on the
adapter, and fasten them with twelve M3 40 bolts with a washer
(by applying Loctite 262 and tightening a torque of [2 Nm]).
9 While referencing (1) in Section 6.11, mount the motor, and also
mount the wrist flange to the J6 housing.
10 According to Section 3.2, supply the J6–axis grease bath with the
specified grease.
11 While referencing Chapter 5, perform mastering.
J6–axis housing
Parallel pin (2pcs)
J6–axis motor
M6
Wrist flange
M5 30 (4pcs)
Washer M5 (4pcs)
Gasket
M3 6 (2pcs)
Clamp
Fig 6.11 (a) Replacing the J6–axis motor and reducer
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6. COMPONENT REPLACEMENT AND
ADJUSTMENTS
MAINTENANCE
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Bolt with washer
M5 12 (4pcs)
Loctite 262
J6–axis motor
Gasket
M6
Adapter
O–ring S71
Circular spline
Wave generator
Flange
Washer
φ3 8 (2pcs)
M3 8
Loctite 242
2 Nm
Flex spline
Bolt with washer
M3 15 (12pcs)
Loctite 262
9 Nm
Bolt with washer
M5 12 (8pcs)
Loctite 262
2 Nm
Cross roller ring
Bolt with washer
M3 40 (12pcs)
Loctite 262
2 Nm
Fig 6.11 (b) Replacing the J6–axis reducer
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7
MAINTENANCE
PIPING AND WIRING
79
7. PIPING AND WIRING
7. PIPING AND WIRING
7.1
PIPING DRAWING
MAINTENANCE
B–81765EN/01
Fig. 7.1 (a) and (b) show the diagram of piping in the mechanical unit.
The piping diagram of ARC Mate 120iB/10L and M–16iB/10L are same
configurations.
Panel union
Rc 3/8 female
Air tube
Outside diameter : 8mm
Inside diameter : 5mm
Panel union
Rc 3/8 female
Fig 7.1 (a) Piping diagram
Panel union
NPT 1/4 female (2pcs)
Air tube (2pcs)
Outside diameter : 6.35mm (1/4I)
Inside diameter : 4.23mm
Panel union
NPT 1/4 female (2pcs)
Fig 7.1 (b) Piping diagram (LECO W/F)
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7. PIPING AND WIRING
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7.2
Fig. 7.2 (a) and Fig. 7.2 (b) show the diagrams of wiring in the mechanical
unit.
WIRING DIAGRAMS
Controller
Mechanical unit
J1–axis motor
J1–axis connector board
J2–axis motor
J3–axis motor
J4–axis motor
J5–axis motor
J6–axis motor
K101 : 5 pin
K102 : 24 pin
Earth
Panel union
Famale Rc 3/8
Battery
End effector
Air
Panel union
Famale Rc 3/8
J3–axis casing
connector board
Fig 7.2 (a) Wiring in the mechanical unit stand alone type controller (Standard)
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
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7. PIPING AND WIRING
Controller
MAINTENANCE
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Mechanical unit
J1–axis connector panel
J1–axis motor
J2–axis motor
J3–axis motor
J4–axis motor
J5–axis motor
J6–axis motor
5 pin
Earth
Battery
Panel union
Famale NPT 1/4
Air
Panel union
Famale NPT 1/4
Air
End effector
Panel union
Famale NPT 1/4
Panel union
Famale NPT 1/4
J3–axis casing
connector panel
Fig 7.2 (b) Wiring in the mechanical unit stand alone type controller (LECO W/F)
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L
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7. PIPING AND WIRING
MAINTENANCE
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7.3
CABLE MOUNTING
DIAGRAM
Make the following visual checks to see if there are any cable
abnormalties:
1) Whether the swiveling motion of the robot has caused any local torsion
or bending in the swiveling section.
2) Whether the cables leading to the J2– or J3–axis sections have worn
each other during operation.
3) Whether the route of cables leading to the end effector is appropriate
for the operation of the wrist and the service operation of the robot.
Fig. 7.3 (a) and (b) are the mounting diagram of cables in the
mechanical unit.
K302
K201
K202
K101, K102
K301
Fig 7.3 (a) Cables in the mechanical unit
(ARC Mate 120iB, M–16iB/20)
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K302
K201
K202
K131, K132
K301
Fig 7.3 (b) Cables in the mechanical unit
(ARC Mate 120iB/10L, M–16iB/10L)
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8. CABLE REPLACEMENT
8
MAINTENANCE
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CABLE REPLACEMENT
Replace the cables of the robot once every four years. If a cable is broken
or damaged, replace it according to the procedure described in this
chapter.
Cautions in handling the
pulse coder cable
When transporting, installing, or maintaining the robot, do not detach the
pulse coder cables carelessly. The cables are provided with the marking
tie and label shown below. If you detached any cable with the marking
tie, you need to perform mastering for the robot.
Do not detach any connector unless you replace a motor, pulse coder,
reducer, or cable.
Fig 8 (a) Marking tie
Fig 8 (b) Label
If there is a break in or any other damage to a cable, replace the cable
according to the procedure described in this chapter. If the connector of
a pulse coder cable (K101, K102, K131, K132, K201, or K202) is
detached, the data about the absolute position of the robot is lost. Once
any of these cables is replaced, perform quick mastering while referencing
Section 5.3. If the data is lost because of a break in a cable, also perform
quick mastering to calibrate the robot into the previous absolute position.
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8.1
CABLE DRESSING
MAINTENANCE
8. CABLE REPLACEMENT
After a cable is replaced individually rather than in kit, clamp it with
rubber bushings and nylon ties (cable ties) at the specified positions listed
in Table 8.1. Otherwise, the cable may sag or become too tight, leading
to a break in the cable.
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Table 8.1 (a) Cable clamp positions
Mark
Cable clamp positions
87
Mark
No.
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MAINTENANCE
8. CABLE REPLACEMENT
Table 8.1 (b) Cable clamp position
Mark
Cable clamp positions
88
Mark
No.
8. CABLE REPLACEMENT
8.2
REPLACING CABLES
MAINTENANCE
B–81765EN/01
Place the robot in a posture of all axes = 0_, and turn off the controller
power.
If the controller is a separate type
1) Replacing the cable kit
1 Remove, from the robot, the cables for connecting the mechanical
section.
2 As shown in Fig. 8.2 (a), remove the two M6 10 bolts from the
J1 connector board, and separate the plate (A290–7216–X221).
Also remove the four M10 16 bolts to detach the J1 connector
board from the J1 base, and remove the grounding cable from the
J1 base.
Cut nylon ties that bind rubber boots to release them. Separate the
RM1 and RP1 connector inserts from the connector housings on
the J1 connector board (by once removing the connector housings
from the J1 connector board as the rubber boots may get entangled,
thus making it hard to separate them).
3 Remove the GB1 terminal from the battery box. Also remove the
air hose.
4 Remove all connectors from the J1–/J2–axis motor.
5 While referring to Fig. 8.2 (b), remove, from the J2 base, the two
M6 10 bolts that fasten the cable cover and then the cable cover.
Also remove the two M8 12 bolts that fasten the plate on the J2
base.
6 Pull out the cables from the inside of the J1 base toward the upper
section of the J1 hollow pipe slowly while exercising care to avoid
having the connector inserts caught inside the pipe. Pulling the
cables by force may lead to a broken wire.
7 While referring to Fig. 8.2 (c), cut nylon ties for the J2–/J3–axis
Cornex cover and then remove the cover from the cable kit.
Remove the four M8 12 cable kit mounting bolts from the J2 arm,
and dismount the cable kit from the J2 arm.
8 While referring to Section 6.9, remove the J5–2 cover and J5–axis
motor connector. As shown in Fig. 8.2 (d), remove the M5M1,
M6M1, and M6P1 inline cable connectors, and then the two
M4 6 sealing bolts that fasten the J5–2 clamp (A290–7216–
X531).
9 While referring to Section 6.11, remove the wrist flange unit and
J6–axis motor connector, and then pull out the wrist cable from the
J6 housing side. Cut the nylon ties that fasten the J6 clamp
(A290–7216–X534) and the J5–2 clamp (A290–7216–X531) (as
well as the support (A290–7216–X529)), and separate them from
the cables.
10 While referring to Fig. 8.2 (e), remove the four M6 16 bolts that
fasten the J3 casing rear plate (A290–7216–X450), and detach the
plate and bushings.
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MAINTENANCE
8. CABLE REPLACEMENT
11 As shown in Fig. 8.2 (d), remove the two M5 8 bolts that fasten
the J5–1 clamp (A290–7216–X525), dismount and take out the
J5–1 clamp from the J3 arm. Remove the connector from the J5–1
clamp, cut the nylon ties, and take out the cables from the wrist by
pulling them toward the back of the J3 casing. In this case,
clamping the cables with nylon ties as shown in the figure, using
inline connector holes in the J6, will make it easy to pull the cables.
If the arm is a long type (M–16iB/10L or ARC Mate 120iB/10L),
remove the plate (A290–7216–X536) from the support (A290–
7216–X535).
12 While referring to Fig. 8.2 (c), remove the two M6 10 bolts that
retain the plate (A290–7216–X441), and pull out the cables from
the hollow section of the J3 reducer in the following sequence:
(i)
Air hose
(ii) J3P and J4P
(iii) Cable part that extends beyond the Teflon tube
(iv) EE1
(v) EE8 or W/F2
(vi) J3M and J4M
Note that, if this sequence is not observed precisely, it is impossible
to pull out the cables.
When installing the cables, reverse the procedure.
13 Remove the cable kit completely from the robot main body.
14 Mount a new cable kit by reversing the above procedure.
First, while referring to Fig. 8.2 (f), mount the J6 clamp
(A290–7216–X534) and the J5–2 clamp (A290–7216–X531) to
the K202 wrist cable by observing the clamp–to–clamp distance
(205 mm) precisely (as measured with a rule). Also exercise
sufficient care to avoid having twisted pairs entangled.
15 When assembling the J5–axis section, make sure that unbundled
twisted pairs will not be entangled in the hollow section or caught
in the J6 housing. When mounting the J5–2 clamp (A290–7216–
X531) to the J5–2 cover, use two new M4 6 sealing bolts. After
passing the wrist cable in the J5–axis hollow section, attach a nylon
tie to the hole in the J5–2 clamp (A290–7216–X531) to fasten the
cable.
16 When attaching the J5–2 cover to the J3 arm, make sure that the
unbundled twisted pairs are not caught in between. (If it is likely
that the unbundled wires may be rubbed against the edge of a sheet
metal, bind them with nylon ties or the like to keep them away from
the sheet metal.)
17 When attaching the plate (A290–7216–X441) to the plate
(A290–7216–X442) for the J3 casing, place the plates in such a
way that, when the plate (A290–7216–X441) is concave as viewed
from the top, the cable from the J2 arm side will look natural (with
no twist).
Twist the plate (A290–7216–X441) to 90_ from the current
position in such a way that the plate looks concave as viewed from
the front, and then mount it to the plate (A290–7216–X442).
18 Mount the cable kit by following steps 7 to 2 in the stated order.
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19 Put the rubber boots back to the previous position.
Before mounting the J1 connector board on the J1 base, push the
OT strapping connectors into the rubber boots, and bind the
openings of both the RM1 and RP1 rubber boots with nylon ties.
Mount the J1 connector board to the J1 base while exercising care
to avoid having the unbundled wires caught in between.
20 Put the J2–/J3–axis Cornex cover back onto the cable kit, and
fasten it with a nylon tie; keep the nylon tie rather loose.
M6 10 (2pcs)
Plate
A290-7216-X221
J1–axis connector board
M10 16 (4pcs)
Fig 8.2 (a) Replacing the cable kit
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8. CABLE REPLACEMENT
M8 12 (2pcs)
Cable cover
M6 10 (2pcs)
Fig 8.2 (b) Replacing the cable kit
Cornex cover
M8 12 (4pcs)
Cornex cover
Fig 8.2 (c) Replacing the cable kit
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Clamp J5-1
M5 8 (2pcs)
Seal bolt
M4 6 (2pcs)
Clamp J5-2
Nylon band
Support
A290-7216-X535
Plate
A290-7216-X536
M5 8 (2pcs)
Fig 8.2 (d) Replacing the cable kit
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8. CABLE REPLACEMENT
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Bush
Plate
A290-7216-X430
M6 16 (4pcs)
Plate
A290-7216-X442
Plate
A290-7216-X441
M6 10 (2pcs)
Fig 8.2 (e) Replacing the cable kit
Make this length meet the
specification precisely.
Make sure that the wires will not be
rubbed against one another.
Do not use a nylon tie in this section.
Clamp J5–2
Clamp J6
Attach a Teflon sheet like this.
Fig 8.2 (f) Replacing the cable kit
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8. CABLE REPLACEMENT
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2) Replacing the cables separately
1 While referencing item (1) of Section 8.2, dismount the cable kit
from the robot main body, and remove the J2–/J3–axis Cornex
cover.
2 While referencing Fig. 8.2 (g), dismount the clamp and grommet
from the cable kit, and replace the cables. After cable replacement,
mount the clamp and grommet, but do not tighten the mounting
bolts.
3 Mount the cable kit on the robot main body as before. (See (1) of
Section 8.2.) Arrange the cables inside and outside the J2–/J3–axis
movable section by shifting the wires so that they are at regular
intervals and look natural. After their length is adjusted, tighten the
mounting bolts for the grommet retaining clamp.
4 Mount the Cornex cover as before. (Tighten the nylon tie but not
firmly.)
Clamp
Grommet
Fig 8.2 (g) Replacing the cable kit
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II. CONNECTION
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1
CONNECTION
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
ROBOT OUTLINE DRAWING AND OPERATION AREA
DIAGRAM
99
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
1.1
OUTLINE DRAWING
AND OPERATION
AREA DIAGRAM
CONNECTION
B–81765EN/01
Fig. 1.1 (a) shows the outline drawing and operation area diagram of a
robot with a separate controller.
When installing a peripheral device, be careful not to let it interfere with
the robot main body. While referencing Section 3.2, use 4–18 through
holes in the base to install the peripheral device.
Fig. 1.1 (b), (c), (e) and (f) show the operation diagrams of the robot.
Motion range of
J5–axis rotation center
Motion limit
Motion limit
Motion range of
J5–axis rotation center
Fig 1.1 (a) Outline drawing and operation area diagram of a robot with a separate controller
(ARC Mate 120iB, M–16iB/20)
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CONNECTION
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
Fig 1.1 (b) Operation diagram of a robot with a separate controller (No. 1)
(ARC Mate 120iB, M–16iB/20)
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1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
CONNECTION
Fig 1.1 (c) Operation diagram of a robot with a separate controller (No. 2)
(ARC Mate 120iB, M–16iB/20)
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CONNECTION
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
Motion range of
J5–axis rotation center
Motion limit
Motion limit
Motion range of
J5–axis rotation center
Fig 1.1 (d) Outline drawing and operation area diagram of the stand alone type controller
(ARC Mate 120iB/10L, M–16iB/10L)
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1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
CONNECTION
Fig 1.1 (e) Operation diagram of the stand alone type controller (No. 1)
(ARC Mate 120iB/10L, M–16iB/10L)
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CONNECTION
1. ROBOT OUTLINE DRAWING AND
OPERATION AREA DIAGRAM
Fig 1.1 (f) Operation diagram of the stand alone type controller (No. 2)
(ARC Mate 120iB/10L, M–16iB/10L)
105
2. MOUNTING DEVICES
ON THE ROBOT
2
CONNECTION
MOUNTING DEVICES ON THE ROBOT
106
B–81765EN/01
CONNECTION
B–81765EN/01
2.1
WRIST SECTION END
EFFECTOR
MOUNTING
SURFACE
2. MOUNTING DEVICES
ON THE ROBOT
1) Mounting surface for an ISO flange–type end effector (standard)
Fig. 2.1 shows the end effector mounting surface at the tip of the wrist.
The end effector is engaged using a 50h7 spigot or 25H7 socket,
positioned using a 1–6H7 reamed hole, and fastened using four M6
self–tapping screws. As for the M6 self–tapping screws, select those
not longer than the tapping depth (10 mm).
depth 10
depth 10
equally spaced
on circumference
Fig 2.1 Mounting surface for the ISO flange type end effector
107
2. MOUNTING DEVICES
ON THE ROBOT
2.2
WRIST LOAD
CONDITIONS
CONNECTION
B–81765EN/01
Fig. 2 (a) and (b) are the allowable load curves of the wrist of the robot.
Use the robot with the load conditions kept within the range shown on the
graph.
Fig 2.2 (a) Wrist section allowable load conditions (ARC Mate 120iB, M–16iB/20)
108
B–81765EN/01
CONNECTION
2. MOUNTING DEVICES
ON THE ROBOT
Fig 2.2 (b) Wrist section allowable load conditions (ARC Mate 120iB/10L, M–16iB/10L)
109
2. MOUNTING DEVICES
ON THE ROBOT
2.3
DEVICE MOUNTING
SURFACES
CONNECTION
B–81765EN/01
(1) ARC Mate 120iB, M–16iB/20
As shown in Fig. 2.3 (a), there are two device mounting surfaces.
NOTE
1 Keep the gravity center of devices mounted on device
mounting surfaces A and B within the area shown by
hatching in Fig. 2.3 (b).
2 The mass of each device mounted on a device mounting
surface shall satisfy the Fig. 2.3 (a) condition:
W : Mass (kg) of the device on the end effector
mounting surface
A : Mass (kg) of the device on device
mounting surface A
B : Mass (kg) of the device on device
mounting surface B
3 As for the mass (W) of device on the end effecter mounting
surface, observe the conditions stated in Section 2.2.
4–M6 depth 10
Center of J4–axis
rotation
Center of J3–axis
rotation
Mounting surface A
3–M6 depth 10
Center of J4–axis rotation
Mounting surface B
Fig 2.3 (a) Device mounting surface dimensions (ARC Mate 120iB, M–16iB/20)
110
B–81765EN/01
CONNECTION
2. MOUNTING DEVICES
ON THE ROBOT
Mounting surface B
Mounting surface A
Fig 2.3 (b) Gravity center dimensions of device mounting surface (ARC Mate 120iB, M–16iB/20)
111
2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
B–81765EN/01
(2) ARC Mate 120iB/10L, M–16iB/10L
As shown in Fig. 2.3 (c), there are two device mounting surfaces.
NOTE
1 Keep the gravity center of devices mounted on device
mounting surfaces A and B within the area shown by
hatching in Fig. 2.3 (d).
2 The mass of each device mounted on a device mounting
surface shall satisfy the following condition:
1) A)Bx12 (Kg)
where A : Mass (kg) of the device on device
mounting surface A
B : Mass (kg) of the device on device
mounting surface B
3 As for the mass (W) of device on the end effecter mounting
surface, observe the conditions stated in Section 2.2.
4–M6 depth 10
Center of J4–axis rotation
Center of J3–axis rotation
Mounting surface A
3–M6 depth 10
Center of J4–axis
rotation
Mounting surface B
Fig 2.3 (c) Device mounting surface dimensions (ARC Mate 120iB/10L, M–16iB/10L)
112
B–81765EN/01
CONNECTION
2. MOUNTING DEVICES
ON THE ROBOT
Mounting surface B
Mounting surface A
Fig 2.3 (d) Gravity center dimensions of device mounting surface (ARC Mate 120iB/10L, M–16iB/10L)
113
2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
B–81765EN/01
2.4
Setting up appropriately the load conditions, such as mass, moment, and
inertia, of the wrist section and hand mounted on the J3–axis arm of a
robot enables effective use of the robot.
Wrist axis load moment
Load the following system variables with the wrist section load moment
represented using an integer (kgf–m : Input 10 times the following values).
[Input examples]
$PARAM_GROUP.$AXISMOMENT[4] : 40 (J4–axis load moment)
[Example of 4 kgf–m]
$PARAM_GROUP.$AXISMOMENT[5] : 40 (J5–axis load moment)
[Example of 4 kgf–m]
$PARAM_GROUP.$AXISMOMENT[6] : 20 (J6–axis load moment)
[Example of 2 kgf–m]
Wrist axis load inertia
Load the following system variables with the wrist section load inertia
represented using an integer (kgf–cm–S2 : Input 10 times the following
values).
[Input examples]
$PARAM_GROUP.$AXISINERTIA[4] : 90 (J4–axis load inertia)
[Example of 9.0 kgf–cm–S2]
$PARAM_GROUP.$AXISINERTIA[5] : 90 (J5–axis load inertia)
[Example of 9.0 kgf–cm–S2]
$PARAM_GROUP.$AXISINERTIA[6] : 26 (J6–axis load inertia)
[Example of 2.6 kgf–cm–S2]
Mass of the loads
mounted on the J3–axis
arm
Load the following system variable with the mass of the loads mounted
on the J3–axis arm represented using an integer (kg)
[Input examples]
$PARAM_GROUP.$ARM_LOAD[1] : 12 (mass of the load on the
J3–axis arm)
Operation performance
screens
The operation performance screens include the list screen, load setting
screen, and device setting screen. These screens are used to set up
information about loads and that about devices on the robot.
SETTING THE
SYSTEM VARIABLES
FOR
SHORTEST–TIME
CONTROL
1
2
3
4
Press the screen selection key to display the screen menu.
Select SYSTEM on the next page.
Press F1 TYPE. The screen switching menu appears.
Press F1 Motion Performance. The list screen appears.
114
2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
B–81765EN/01
MOTION PERFORMANCE
Group1
No.
PAYLOAD[kg]
1
6.34
2
0.00
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
8
0.00
9
0.00
10
0.00
10%
Comment
[
[
[
[
[
[
[
[
[
[
]
]
]
]
]
]
]
]
]
]
Active PAYLOAD number = 1
[ TYPE ] GROUP DETAIL ARMLOAD SETIND >
>
5 On this screen, you can set up ten different types of load information
(condition No. 1 to No. 10). Place the cursor on the line of a desired
condition number, and press F3 DETAIL. The load setting screen
appears.
MOTION PAYLOAD SET
1.
2.
3.
4.
5.
6.
7.
JOINT
Group 1
Schedule No[
1]:[Comment
PAYLOAD
[kg]
PAYLOAD CENTER X [cm]
PAYLOAD CENTER Y [cm]
PAYLOAD CENTER Z [cm]
PAYLOAD INERTIA X [kgfcms^2]
PAYLOAD INERTIA Y [kgfcms^2]
PAYLOAD INERTIA Z [kgfcms^2]
[ TYPE ]
GROUP
NUMBER
DEFAULT
10%
]
6.34
–7.99
0.00
6.44
0.13
0.14
0.07
HELP
6 On this screen, specify the mass and gravity center position of the load
and the inertia around the gravity center. The X, Y, and Z directions
displayed on the screen correspond to the standard tool coordinates
(with no tool coordinate system set up). When you enter values, the
confirmation message “Path and Cycletime will change. Set it?”
appears. Select F4 YES or F5 NO.
7 Pressing F3 NUMBER brings you to the load setting screen for
another condition number. In a multigroup system, pressing F2
GROUP brings you to the setting screen for another group.
8 Press the previous page key to return to the list screen. Press F5
SETIND, and enter a desired load setting condition number.
9 On the list screen, pressing F4 ARMLOAD brings you to the device
setting screen.
115
2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
B–81765EN/01
MOTION ARMLOAD SET
Group 1
1 ARM LOAD AXIS #1
2 ARM LOAD AXIS #3
[ TYPE ]
GROUP
JOINT
[kg]
[kg]
DEFAULT
10%
0.00
12.25
HELP
10 Specify the mass of the loads on the J2–axis base and J3–axis arm.
When you enter
ARMLOAD AXIS #1[kg] : Mass of the load on the J2–axis base and
ARMLOAD AXIS #3[kg] : Mass of the load on the J3–axis arm,
the confirmation message “Path and Cycletime will change. Set it?”
appears. Select F4 YES or F5 NO.
Once the mass of a device is entered, it is put in effect by turning the
power off and on again.
116
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2.5
END EFFECTOR AIR
PIPING
CONNECTION
2. MOUNTING DEVICES
ON THE ROBOT
In the robot mechanical unit, an air pipe whose inlet is on the J1–axis
connector panel and outlet is behind the J3 casing is provided. See Fig.
7.1 of Part I, “Maintenance,” for explanations about the piping routes.
The joint diameter for the air pipe inlet and outlet is RC3/8 female. (When
LECO W/F is specified, the joint diameter is HPT1/4 female.) No joint
is supplied together with the option. The customer shall arrange for the
joints that match the tubes to be used.
117
2. MOUNTING DEVICES
ON THE ROBOT
2.6
END EFFECTOR
INPUT SIGNALS
(RDI/RDO)
CONNECTION
B–81765EN/01
There are end effector connectors for connecting peripheral devices
behind the J3 casing. Fig. 2.6 (a) and Fig. 2.6 (b) show the pin
arrangement of end effector connectors. Refer to “R–J3iB Controller
Maintenance Manual” for details of input–common settings.
Mechanical unit (K101, K131)
End effector
Fig 2.6 (a) End effector signal arrangement
(one RDI signal and one RDO signal)
Mechanical unit (K102, K132)
End effector
Fig 2.6 (b) End effector signal arrangement (eight RDI signals and eight RDO signals)
118
2.7
CONNECTOR
SPECIFICATIONS
2. MOUNTING DEVICES
ON THE ROBOT
CONNECTION
B–81765EN/01
Table 2.7 (a) lists the makers and models of the connectors used on the
robot mechanical unit. Table 2.7 (b) lists the makers and models of the
connectors used on the mechanical unit of the robot with Lincoln W/F
cable option. Table 2.7 (c) lists the makers and models of the connectors
to be used on user–prepared devices.
Table 2.7 (a) Connector specifications (on the mechanical unit side)
Output side
(J3–axis casing)
Cable name
Maker
RDI/O 1
JMWR1305F
Daiichi Denshi Kogyo K.K.
RDI/O 8
JMCR2524F
Daiichi Denshi Kogyo K.K.
Table 2.7 (b) Connector specifications (on the mechanical unit side)
Cable name
Output side
Lincoln
W/F
cable
MS3100A20–27 SY
(J1–axis base)
MS3100A20–27 PY
(J3–axis casing)
Maker
Japan Aviation
Electronics
Industry LTD
Industry,
LTD.
Table 2.7 (c) Connector specifications (on the user side)
Output side
(J3–axis casing)
Cable name
Maker
RDI/O 1
JMSP1305M
Daiichi Denshi Kogyo K.K.
RDI/O 8
JMSP2524M
Daiichi Denshi Kogyo K.K.
NOTE
For detailed descriptions of the dimensions of the
connectors, contact FANUC or refer to the respective
catalogs available from the maker.
119
B–81765EN/01
3
CONNECTION
3. TRANSPORTATION AND
INSTALLATION
TRANSPORTATION AND INSTALLATION
120
3. TRANSPORTATION AND
INSTALLATION
3.1
TRANSPORTATION
CONNECTION
B–81765EN/01
1) Installation procedure
1 Using JOINT, rotate the J3–axis section in the positive direction to
such a position that the transportation stopper can be removed.
2 Remove the J3 transportation stopper (red).
3 Using JOINT, rotate the J2–axis section in the positive direction to
such a position that the J2–axis transportation stopper can be
removed.
4 Remove the J2–axis transportation stoppers(red).
5 Remove the two M10 eyebolts from the J2 base. Now you are
ready to install the robot.
NOTE
Be sure to remove the M10 eyebolt from the J2 base. If it
is not removed, it will interfere with the operation of the robot
main body, possibly resulting in the robot being damaged.
NOTE
If an overtravel alarm is issued at 3, hold down the shift key
and press the alarm reset key. Then, while holding down the
shift key, feed the J2–axis section to such a position, using
JOINT, that the overtravel condition is released.
2) Carrying the robot with a crane
The robot can be carried by suspending it with a crane. To lift the
robot, hook a strap on the two M10 eyebolts. Once the robot is
installed, remove the transportation stoppers. (See Fig. 3.1.)
These stoppers are bolts for preventing the swiveling axes of the robot
from moving during its transportation. The stoppers are painted or
plated in red. Before starting to operate the robot, be sure to remove
these stoppers.
NOTE
Be careful not to let the suspending sling get caught on the
connectors of the motors; the connectors may be damaged
if the sling get caught on it.
121
Position during shipment
J1–axis
J2–axis
J3–axis
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81765EN/01
Note)
1. Weight of machine unit : 220 kg
2. Eye bolts comply with JIS B1168
[Load capacity
: 150kg/1pcs]
3. Quantity eye bolt
Sling
J4–axis
J5–axis
J6–axis
: 2pcs
: 2pcs
Crane
Load capacity : 300 kg
Sling
Load capacity : 250 kg
M10 eye bolt
M10 eye bolt
Fig 3.1 Transportation with a crane
122
3. TRANSPORTATION AND
INSTALLATION
3.2
STORING THE
ROBOT
CONNECTION
B–81765EN/01
When storing the robot, keep it in the posture shown in Fig. 3.1.
Be very careful when the robot is in any other posture, because it can fall
down.
If it is likely that the robot may fall down, fix it or take any other measure
to keep it in place.
123
CONNECTION
B–81765EN/01
3.3
3. TRANSPORTATION AND
INSTALLATION
Fig. 3.3 (a) shows the dimensions of the base of the robot main body.
INSTALLATION
Mounting face
4–18 through
26 facing depth 5
Front
J1 rotation center
Mounting face
Fig 3.3 (a) Dimensions of the base of the robot main body
124
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81765EN/01
Fig. 3.3 (b) shows an example of installing the robot. In this example, the
sole plate is fixed with four M20 chemical anchors (in strength category
4.8), and the robot base is fastened to the sole plate with four M16 35
bolts (in strength category 12.9). If compatibility must be maintained in
teaching the robot after the robot mechanical unit is replaced, use the butt
surface.
NOTE
The customer shall arrange for the positioning pin, anchor
bolts, and sole plate.
Mounting face
4–24 through
4–M16 through
J1 rotation center
Mounting face
Robot J1 base
Chemical anchor
Robot fixing bolt
M20 (4pcs)
Strength class
: 4.8
Tightening torque : 186 Nm
M16 35 (4pcs)
Strength class
: 12.9
Tightening torque : 314 Nm
Fig 3.3 (b) Example of installing the robot
125
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81765EN/01
Fig. 3.3 (c) and Table 3.3 (a) and (b) explain what load is put on the J1 base
when the robot is at a rest, accelerating or decelerating, and at an
emergency stop.
MV
FH
FV
MH
Fig 3.3 (c) Load and moment applied to the J1 base (ARC Mate 120iB, M–16iB/20)
Table 3.3 (a) Load and moment applied to the J1 base (ARC Mate 120iB, M–16iB/20)
Bending moment
MV[kgfm](Nm)
Vertical load
FV[kgf](N)
Torsion moment
MH[kgfm](Nm)
Horizontal load
FH[kgf](N)
At rest
[126](1231)
[259](2541)
[0](0)
[0](0)
Accelerating or
decelerating
[471](4616)
[380](3723)
[177](1737)
[244](3396)
[1261](12359)
[743](7282)
[575](5633)
[534](5231)
State
At an emergency stop
126
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81765EN/01
MV
FH
FV
MH
Fig 3.3 (d) Load and moment applied to the J1 base (ARC Mate 120iB/10L, M–16iB/10L)
Table 3.3 (b) Load and moment applied to the J1 base (ARC Mate 120iB/10L, M–16iB/10L)
Bending moment
MV[kgfm](Nm)
Vertical load
FV[kgf](N)
Torsion moment
MH[kgfm](Nm)
Horizontal load
FH[kgf](N)
At rest
[126](1231)
[259](2541)
[0](0)
[0](0)
Accelerating or
decelerating
[471](4616)
[380](3723)
[177](1737)
[244](3396)
[1261](12359)
[743](7282)
[575](5633)
[534](5231)
State
At an emergency stop
127
CONNECTION
B–81765EN/01
3.4
3. TRANSPORTATION AND
INSTALLATION
Fig. 3.4 (a) and (b) show the clearance required in maintaining the robot.
MAINTENANCE
CLEARANCE
Mastering area
Maintenance area
Fig 3.4 (a) Maintenance clearance layout (ARC Mate 120iB, M–16iB/20)
Mastering area
Maintenance area
Fig 3.4 (b) Maintenance clearance layout (ARC Mate 120iB/10L, M–16iB/10L)
128
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81765EN/01
The robot must be kept in the posture shown in Fig. 3.4 (c) and (d) during
mastering. Provide such a clearance around the robot that the robot can
take a posture of J1 = 0°.
MASTERING POSITION
AXIS
POSITION
J1
0°
J2
66.4976°
J3
–133.243°
J4
0°
J5
42.243°
J6
–90°
Fig 3.4 (c) Robot posture for mastering (ARC Mate 120iB, M–16iB/20)
129
CONNECTION
B–81765EN/01
3. TRANSPORTATION AND
INSTALLATION
MASTERING POSITION
AXIS
POSITION
J1
0°
J2
31.6241°
J3
–103.792°
J4
0°
J5
13.792°
J6
–90°
Fig 3.4 (d) Robot posture for mastering (ARC Mate 120iB/10L, M–16iB/10L)
130
3. TRANSPORTATION AND
INSTALLATION
3.5
ASSEMBLING THE
ROBOT FOR
INSTALLATION
CONNECTION
B–81765EN/01
If a separate controller is selected for the robot, the robot connection
cables are detached from the connector board of the mechanical unit (they
are left connected to the controller) when the robot is shipped. When
installing the robot, attach the cables to the connector board of the
mechanical unit shown in Fig. 3.5.
When attaching the connectors, be careful not to pull the cables that have
HARTING connectors.
The customer shall arrange for installation of cable ducts between the
robot main body and its controller.
Fig 3.5 Cable connection panel for the robot mechanical unit
131
CONNECTION
B–81765EN/01
3.6
3. TRANSPORTATION AND
INSTALLATION
Fig. 3.6 (a) shows the air piping of the robot.
If the three–piece pneumatic option is selected, it comes with the air pipe
to be installed between it and the mechanical unit. To use the option, the
customer shall arrange for a three–piece pneumatic option mounting
section that has the self–tapping screw holes whose dimensions and
layout are specified in Fig. 3.6 (b) and for its installation.
The following figure assumes that the FANUC three–piece pneumatic
option is selected. When the customer selects another option, refer to the
interfaces in the following figure to prepare the required parts.
AIR PIPING
Three–piece pneumatic (option)
Specifications
Straight nipple
Panel union
Elbow nipple
Air tube length 3m
(Outside diameter 10 mm,
Inside diameter 6.5 mm)
Fig 3.6 (a) Air piping
132
To be prepared by the customer
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81765EN/01
Fill the oiler in the three–piece pneumatic option with any turbine oil
between #90 and #140 to the specified level.
The customer shall arrange for mounting bolts.
Air filter
Lubricator
Fig 3.6 (b) Three–piece pneumatic option
133
3.7
3. TRANSPORTATION AND
INSTALLATION
CONNECTION
B–81765EN/01
Table 3.7 lists the installation conditions for the robot.
INSTALLATION
CONDITIONS
Table 3.7 Installation conditions
Item
Pneumatic Supply air
pressure
pressure
Consumption
Specification
0.5 to 0.7 MPa (5 to 7 kg/cm2)
(set at 0.5 MPa (5 kg/cm2))
Maximum instantaneous amount: 150 NI/min
(Note 1)
Mechanical unit mass
About 220 kg: Without controller
About 320 kg: With controller
Allowable ambient
temperature
0 to 45°C
Allowable ambient humidity
Regularly: 75%RH or below
Short period (within one month):
95%RH (maximum) or below
No condensation is allowed.
Atmosphere
There shall be no corrosive gas (Note 2).
Vibration
0.5 G or less
NOTE
1 This is the capacity of the three–piece pneumatic option.
Use the robot at or below this value.
2 If you cannot avoid using the robot in an adverse
environment with respect to vibration, dust, or coolant,
contact FANUC.
134
APPENDIX
A
A. SPARE PARTS LISTS
APPENDIX
B–81765EN/01
SPARE PARTS LISTS
Table A (a) Cables
A) ARC Mate 120iB : A05B–1216–H201
(RDI/O 1, Air, Stand alone type)
Cable
Specification
Remark
K101
A05B-1216-D001
J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T191
J5 power inline cable
K202
A660-4004-T192
J6 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
B) ARC Mate 120iB, M–16iB/20 : A05B–1216–H202
(RDI/O 8, Air, Stand alone type)
Cable
Specification
Remark
K102
A05B-1216-D002
J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T191
J5 power inline cable
K202
A660-4004-T192
J6 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
C) ARC Mate 120iB : A05B–1216–H203
(RDI/O 1, Air, Lincoln W/F, Stand alone type)
Cable
Specification
K101
A05B-1216-D001
J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T191
J5 power inline cable
K202
A660-4004-T192
J6 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
K301
A660-2005-T764
Lincoln W/F J1 side
K302
A660-2005-T765
Lincoln W/F J3 side
137
Remark
A. SPARE PARTS LISTS
APPENDIX
B–81765EN/01
D) ARC Mate 120iB/10L : A05B–1216–H231
(RDI/O 1, Air, Stand alone type)
Cable
Specification
Remark
K131
A05B-1216-D031
J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T191
J5 power inline cable
K202
A660-4004-T192
J6 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
E) ARC Mate 120iB/10L, M–16iB/10L : A05B–1216–H232
(RDI/O 8, Air, Stand alone type)
Cable
Specification
Remark
K132
A05B-1216-D032
J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T191
J5 power inline cable
K202
A660-4004-T192
J6 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
F) ARC Mate 120iB/10L : A05B–1216–H233
(RDI/O 1, Air, Lincoln W/F, Stand alone type)
Cable
Specification
K131
A05B-1216-D031
J1, J2, J3, J4, J5, and J6 power cables
J1, J2, J3, J4, J5, and J6 pulse coder cables
K201
A660-4004-T191
J5 power inline cable
K202
A660-4004-T192
J6 power and pulse coder inline connector cable
A660-2005-T088
OT jumper connector
K301
A660-2005-T764
Lincoln W/F J1 side
K302
A660-2005-T765
Lincoln W/F J3 side
138
Remark
B–81765EN/01
A. SPARE PARTS LISTS
APPENDIX
Table A (b) Motors
ARC Mate 120iB
M–16iB/20
ARC Mate 120iB/10L
M–16iB/20
A05B–1216–B201
A05B–1216–B202
A05B–1216–B301
A05B–1216–B302
Specifications
Axis
Remarks
A06B-0235-B605
J1, J2
αM8/4000i with a brake
A06B-0212-B605
J3, J4
αM2/5000i with a brake
A06B–0115–B275#0008
J5, J6
βM0.5/4000 with a brake
Table A (c) Reducers
Specifications
Axis
A97L–0218–0303#37
J1
A97L–0218–0304#175
J2
A97L–0218–0305#37
J3
A97L–0218–0306
J6
Table A (d) Motor auxiliary seals
Specifications
Axis
A98L–0004–0771#A03TP
J1/J2
A98L–0004–0771#A01TP
J3/J4
Table A (e) Gear
Specifications
Axis
A290–7216–X511
J5
A290–7216–V501
J5
A290–7216–V502
J5
A290–7216–X514
J5
Table A (f) J4–axis gear box
Specifications
A290–7216–K401
Axis
J4
Table A (g) Cover
Specifications
Remarks
A05B–1216–H351
J2–axis cable protect cover (Standard)
A05B–1216–H352
J2–axis cable protect cover
(Lincoln electric wire feed cable is specified)
139
A. SPARE PARTS LISTS
APPENDIX
B–81765EN/01
Table A (h) Battery
Specifications
Remarks
A98L–0031–0005
R20
Quantity
1.5 V
4
Table A (i) Grease
Name
Specifications
Moly White RE No. 00
A98L–0040–0119#3.1KG (For one machine)
Table A (j) Grease nipple
Name
Specifications
Axis
Grease nipple [Elbow type] (1/8)
A97L–0218–0013#B110
J1
Grease nipple (1/8)
A97L–0218–0013#A110
J2
Grease nipple (M6)
A97L–0218–0013#A610
J3 ~ J6
Table A (k) O–ring
Name
Specifications
Location of use
ARP568–165
A98L–0040–0041#165
Between J1RV and J1 base
ARP568–173
A98L–0040–0041#173
Between J1RV and J2 base
SO70
A98L–0001–0347#S70
J1 pipe
G105
JB–OR1A–G105
J1 motor
G115
JB–OR1A–G115
J2 motor
G190
JB–OR1A–G190
Between J2RV and J2 base
ARP568–166
A98L–0040–0041#166
Between J2RV and J2 arm
G75
JB–OR1A–G75
J3 motor, J4 motor
Between J3 arm and J4 center
gear
SO44
A98L–0001–0347#S44
J3 pipe
ARP568–163
A98L–0040–0041#163
Between J3RV and J3 casing
SO53
A98L–0001–0347#S53
Between J5 cross roller and J6
housing
SO71
A98L–0001–0347#S71
Between J6 cross roller and
adapter
Table A (l) Gaskets
Specifications
Location of use
A98L–0040–0042#07
J5/J6 motor
A290–7216–X527
Between cover J5-2 and J3 arm
A290–7216–X533
Between wrist flange and J6 housing
140
B–81765EN/01
A. SPARE PARTS LISTS
APPENDIX
Table A (m) Stoppers
Specifications
Axis
A290–7216–X241
J1
A290–7216–X323
J2
A290–7215–X323
J3
Note) 340° stopper
for standard
Table A (n) Seal bolts
Specifications
Location of use
Quantity
A97L–0218–0417#081010
J1/J2 bleed hole
3
A97L–0218–0417#082020
J2 motor
4
A97L–0218–0621#051212
J5 motor
4
A97L–0218–0621#063510
J5-4 gear
10
A97L–0218–0621#061212
Gear 1 assembly, Gear 2
assembly
14
A97L–0218–0423#040606
Clamp J5-2
2
141
B–81765EN/01
B
APPENDIX
B. INTERNAL MECHANICAL UNIT
CONNECTION DIAGRAMS
INTERNAL MECHANICAL UNIT CONNECTION DIAGRAMS
143
B. INTERNAL MECHANICAL UNIT
CONNECTION DIAGRAMS
APPENDIX
Fig B Internal mechanical unit connection diagram
ARC Mate 120iB, M–16iB/20, ARC Mate 120iB/10L, M–16iB/10L stand alone type
(A05B–1216–H201, H202, H231, H232)
144
B–81765EN/01
B–81765EN/01
APPENDIX
145
B. INTERNAL MECHANICAL UNIT
CONNECTION DIAGRAMS
C. PERIODIC INSPECTION TABLE
C
APPENDIX
PERIODIC INSPECTION TABLE
146
B–81765EN/01
B–81765EN/01
APPENDIX
147
C. PERIODIC INSPECTION TABLE
D MOUNTING BOLT TORQUE LIST
D
APPENDIX
MOUNTING BOLT TORQUE LIST
148
B–81765EN/01
D MOUNTING BOLT TORQUE LIST
APPENDIX
B–81765EN/01
If no tightening torque is specified for a bolt, tighten it according to this
table.
Recommended bolt tightening torque
Unit: Nm (kgf–cm)
Hexagon socket head bolt (steel
in strength category 12.9)
Hexagon socket head bolt
(stainless)
Hexagon socket head boss bolt
Hexagon socket head flush bolt
(steel in strength category 12.9)
Tightening torque
Tightening torque
Tightening torque
Nominal
diameter
Upper limit
Lower limit
Upper limit
Lower limit
Upper limit
M3
1.8(18)
1.3(13)
0.76(7.7)
0.53(5.4)
M4
4.0(41)
2.8(29)
1.8(18)
1.3(13)
1.8(18)
1.3(13)
M5
7.9(81)
5.6(57)
3.4(35)
2.5(25)
4.0(41)
2.8(29)
M6
14(140)
9.6(98)
5.8(60)
4.1(42)
7.9(81)
5.6(57)
M8
32(330)
23(230)
14(145)
9.8(100)
14(140)
9.6(98)
M10
66(670)
46(470)
27(280)
19(195)
32(330)
23(230)
M12
110(1150)
78(800)
48(490)
33(340)
—
—
(M14)
180(1850)
130(1300)
76(780)
53(545)
—
—
M16
270(2800)
190(1900)
120(1200)
82(840)
—
—
(M18)
380(3900)
260(2700)
160(1650)
110(1150)
—
—
M20
530(5400)
370(3800)
230(2300)
160(1600)
—
—
(M22)
730(7450)
510(5200)
—
—
—
—
M24
930(9500)
650(6600)
—
—
—
—
(M27)
1400(14000)
940(9800)
—
—
—
—
M30
1800(18500)
1300(13000)
—
—
—
—
M36
3200(33000)
2300(23000)
—
—
—
—
149
—
Lower limit
—
Index
B–81765EN/01
[A]
J2–Axis Drive Mechanism, 6
J3–Axis Drive Mechanism, 7
Adjustments, 28
J4–Axis Drive Mechanism, 8
Air Piping, 132
J5– and J6–Axis Drive Mechanisms, 9
Assembling the Robot for Installation, 131
J5–Axis Gear Backlash Adjustments, 52
[B]
[M]
Brake Release, 54
Maintenance Clearance, 128
Maintenance Tools, 15
Mastering, 34
[C]
Mastering Data Entry, 49
Cable Dressing, 86
Mastering to a Fixture (Master Position Master), 36
Cable Mounting Diagram, 83
Mounting Bolt Torque List, 148
Cable Replacement, 85
Mounting Devices on the Robot, 106
Component Replacement and Adjustments, 55
Configuration, 3
[O]
Confirming Mastering, 51
Connector Specifications, 119
One– and Half–Year Periodic Inspection, 14
Outline Drawing and Operation Area Diagram, 100
Overview, 24
[D]
Daily Inspection, 12
[P]
Device Mounting Surfaces, 110
Periodic Inspection Table, 146
Periodic Maintenance, 16
[E]
Piping and Wiring, 79
End Effector Air Piping, 117
Piping Drawing, 80
End Effector Input Signals (RDI/RDO), 118
Preventive Maintenance, 11
[Q]
[G]
Grease Replacement, 19
Quarterly Inspection, 14
Greasing, 17
Quick Mastering, 44
[R]
[I]
Installation, 124
Reference Position and Moving Range, 29
Installation Conditions, 134
Replacing Cables, 89
Replacing the Batteries, 22
Internal Mechanical Unit Connection Diagrams, 143
Replacing the J1–Axis Motor M1 , 56
Replacing the J1–Axis Reducer, 58
[J]
Replacing the J2–Axis Motor M2 , 60
J1–Axis Drive Mechanism, 5
Replacing the J2–Axis Reducer, 62
i–1
Index
B–81765EN/01
[T]
Replacing the J3–Axis Motor M3 , 65
Replacing the J3–Axis Reducer, 67
Three–Year Periodic Inspection, 14
Replacing the J4–Axis Gearbox, 69
Transportation, 121
Replacing the J4–Axis Motor M4 , 68
Transportation and Installation, 120
Replacing the J5–Axis Gear, 74
Troubles and Causes, 25
Replacing the J5–Axis Motor M5 , 71
Troubleshooting, 23
Replacing the J6–Axis Motor M6 and Reducer, 76
[W]
Resetting Alarms and Preparing for Mastering, 35
Robot Outline Drawing and Operation Area Diagram,
99
Wiring Diagrams, 81
Wrist Load Conditions, 108
Wrist Section End Effector Mounting Surface, 107
[S]
Setting the System Variables for Shortest–Time Control, 114
[Y]
Yearly Inspection, 14
Single Axis Mastering, 46
Spare Parts Lists, 137
Specifications of the Major Mechanical Unit Components, 10
[Z]
Storing the Robot, 123
Zero Position Mastering, 41
i–2
Revision Record
FANUC Robot ARC Mate 120iB, ARC Mate 120iB/10L, M–16iB/20, M–16iB/10L MAINTENANCE MANUAL (B–81765EN)
01
Jul., 2002
Edition
Date
Contents
Edition
Date
Contents