FANUC Robot M-410iB/160
FANUC Robot M-410iB/300
MECHANICAL UNIT
MAINTENANCE MANUAL
MARMI416300301E REV. F
This publication contains proprietary information
of FANUC Robotics America Corporation furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC Robotics America Corporation.
FANUC Robotics America Corporation
3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253
B-81995EN/06
This manual can be used with controllers labeled R-30iA or R-J3iC. If you have
a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this
manual.
Copyrights and Trademarks
This new publication contains proprietary information of FANUC Robotics
America Corporation furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics America
Corporation.
The descriptions and specifications contained in this manual were in effect at the
time this manual was approved for printing. FANUC Robotics America
Corporation, 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 KAREL® programming language,
INSIGHT® 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
radiofrequency 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 the company's world headquarters in Rochester Hills,
Michigan. For additional information contact
FANUC Robotics America Corporation
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
For customer assistance, including Technical Support, Service, Parts & Part
Repair, and Marketing Requests, contact the Customer Resource Center, 24
hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers
should call 011-1-248-377-7159.
Send your comments and suggestions about this manual to:
product.documentation@fanucrobotics.com
Copyright ©2012 by FANUC Robotics America Corporation
All Rights Reserved
The information illustrated or contained herein is not to be
reproduced, copied, downloaded, translated into another language, published in
any physical or electronic format, including internet, or transmitted in whole or
in part in any way without the prior written consent of FANUC Robotics
America Corporation.
AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®,
SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® 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:
AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™,
AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™,
ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™,
ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™,
AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™,
Center Finder™, Clean Wall™, DualARM™, LR Tool™,
MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint
Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks
II™, PAINTWorks III™, PalletMate™, PalletMate PC™,
PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™,
Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™,
SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR
ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3
Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™,
SYSTEM R-30iA Controller™, SYSTEM R-30iB Controller™, TCP Mate™,
TorchMate™, TripleARM™, TurboMove™, visLOC™, visPRO-3D™,
visTRAC™, WebServer™, WebTP™, and YagTool™.
•
©FANUC CORPORATION 2012
No part of this manual may be reproduced in any form.
•
All specifications and designs are subject to change without notice.
Patents
One or more of the following U.S. patents might be related to the FANUC
Robotics products described in this manual.
FANUC Robotics America Corporation Patent List
4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745
5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944
5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218
5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092
6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621
6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143
6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,518,980 6,540,104
6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773
6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422
7,399,363
FANUC CORPORATION Patent List
4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207
4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594
4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035
5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019
5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360
5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057
5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,418,441 5,432,316
5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297
5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758
5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194
5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167
5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955
5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295
5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138
5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135
5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,911,892 5,912,540
5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044
6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693
6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898
6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011
6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139
6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012
6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979
6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588
6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,845,296 6,853,881
6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165
7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848
7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294
7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873
7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488
7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192
7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions
WARNING
Information appearing under the "WARNING" caption concerns the protection of
personnel. It is boxed and bolded to set it apart from the surrounding text.
CAUTION
Information appearing under the "CAUTION" caption concerns the protection of
equipment, software, and data. It is boxed and bolded to set it apart from the
surrounding text.
Note Information appearing next to NOTE concerns related information or useful hints.
•
Original Instructions
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
Safety
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 be best
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 Robotics 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.
Ensure that the robot being used is appropriate for the application. Robots used in
classified (hazardous) locations must be certified for this use.
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.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION
Safety is essential whenever robots are used. Keep in mind the following factors with
regard to safety:

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
i
Safety
Keeping People Safe
The safety of people is always of primary importance in any situation. When applying
safety measures to your robotic system, consider the following:
 External devices
 Robot(s)
 Tooling
 Workpiece
Using Safety Enhancing Devices
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:
 Safety fences, barriers, or chains
 Light curtains
 Interlocks
 Pressure mats
 Floor markings
 Warning lights
 Mechanical stops
 EMERGENCY STOP buttons
 DEADMAN switches
Setting Up a Safe Workcell
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.

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.




ii
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.
Safety










Never rely on software or firmware based controllers as the primary safety element
unless they comply with applicable current robot safety standards.
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.
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.
Staying Safe While Teaching or Manually Operating the Robot
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.
iii
Safety



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.
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.
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.
-

Staying Safe During Automatic Operation
Advise all personnel who operate the robot during production to observe the following
rules:
 Make sure all safety provisions are present and active.
iv
Safety



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.

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 its 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.



Staying Safe During Inspection
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.

Staying Safe During Maintenance
When performing maintenance on your robot system, observe the following rules:
 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.
v
Safety






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.

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.
vi
Safety




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.
 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.
Mechanical Safety Precautions
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 DCS (Dual Check Safety), software limits, limit switches, and mechanical hardstops to prevent
undesired movement of the robot into the work area of machine tools and external devices.
vii
Safety
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.
 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.
Programming Safety Precautions
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.
 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
personnel 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.
viii
Safety
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.
CAUTION
Ensure that all ground cables remain connected. Never operate the paint robot with
ground provisions disconnected. Otherwise, you could injure personnel or damage
equipment.
Paint robots are operated in three modes:
 Teach or manual mode
 Automatic mode, including automatic 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 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.
ix
Safety




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 or pressed harder 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.

Overtravel by robot axes is prevented by software limits. All of the major and minor
axes are governed by software limits. DCS (Dual Check Safety), 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 SOC is in teach mode.

When present, photoelectric eyes are sometimes used to monitor unauthorized
intrusion through the entrance/exit silhouette openings.

System status is monitored by computer. Severe conditions result in automatic
system shutdown.
Staying Safe While Operating the Paint Robot
When you work in or near the paint booth, observe the following rules, in addition to all
rules for safe operation that apply to all robot systems.
WARNING
Observe all safety rules and guidelines to avoid injury.
x
Safety
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.
WARNING
Enclosures shall not be opened unless the area is known to be nonhazardous or
all power has been removed from devices within the enclosure. Power shall not be
restored after the enclosure has been opened until all combustible dusts have
been removed from the interior of the enclosure and the enclosure purged. Refer
to the Purge chapter for the required purge time.




Know the work area of the entire paint station (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.

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.
xi
Safety
Special Precautions for Combustible Dusts (Powder Paint)
When the robot is used in a location where combustible dusts are found, such as the
application of powder paint, the following special precautions are required to insure that
there are no combustible dusts inside the robot.
 Purge maintenance air should be maintained at all times, even when the robot power
is off. This will insure that dust can not enter the robot.

1.
2.
3.
4.
5.
A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed
to dust when maintenance air is not present, it will be necessary to remove the covers
and clean out any accumulated dust. Do not energize the robot until you have
performed the following steps.
Before covers are removed, the exterior of the robot should be cleaned to remove
accumulated dust.
When cleaning and removing accumulated dust, either on the outside or inside of the
robot, be sure to use methods appropriate for the type of dust that exists. Usually lint
free rags dampened with water are acceptable. Do not use a vacuum cleaner to
remove dust as it can generate static electricity and cause an explosion unless special
precautions are taken.
Thoroughly clean the interior of the robot with a lint free rag to remove any
accumulated dust.
When the dust has been removed, the covers must be replaced immediately.
Immediately after the covers are replaced, run a complete purge cycle. The robot can
now be energized.
Staying Safe While Operating Paint Application Equipment
When you work with paint application equipment, observe the following rules, in
addition to all rules for safe operation that apply to all robot systems.
WARNING
When working with electrostatic paint equipment, follow all national and local codes
as well as all safety guidelines within your organization. Also reference the
following standards: NFPA 33 Standards for Spray Application Using Flammable or
Combustible Materials, and NFPA 70 National Electrical Code.





xii
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.
Safety

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.


Staying Safe During Maintenance
When you perform maintenance on the painter system, observe the following rules, and
all other maintenance safety rules that apply to all robot installations. Only qualified,
trained service or maintenance personnel should perform repair work on a robot.
 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.
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.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
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. Then seek medical attention as soon as possible.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
xiii
B-81995EN/06
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
Thank you for purchasing FANUC Robot.
This chapter describes the precautions which must be observed to ensure the safe use of the robot.
Before attempting to use the robot, be sure to read this chapter thoroughly.
Before using the functions related to robot operation, read the relevant operator's manual to become
familiar with those functions.
If any description in this chapter differs from that in the other part of this manual, the description given in
this chapter shall take precedence.
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
WORKING PERSON
The personnel can be classified as follows.
Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel
Programmer or teaching operator:
• Operates the robot
• Teaches robot inside the safety fence
Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)
-
-
An operator cannot work inside the safety fence.
A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc..
To work inside the fence, the person must be trained on proper robot operation.
During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following
safety precautions.
-
Use adequate clothing or uniforms during system operation
Wear safety shoes
Use helmet
s-1
SAFETY PRECAUTIONS
2
B-81995EN/06
DEFINITION OF WARNING, CAUTION AND
NOTE
To ensure the safety of user and prevent damage to the machine, this manual indicates each precaution on
safety with "Warning" or "Caution" according to its severity. Supplementary information is indicated by
"Note". Read the contents of each "Warning", "Caution" and "Note" before attempting to use the
oscillator.
WARNING
Applied when there is a danger of the user being injured or when there is a
danger of both the user being injured and the equipment being damaged if the
approved procedure is not observed.
CAUTION
Applied when there is a danger of the equipment being damaged, if the
approved procedure is not observed.
NOTE
Notes are used to indicate supplementary information other than Warnings and
Cautions.
•
3
Read this manual carefully, and store it in a sales place.
WORKING PERSON SAFETY
Working person safety is the primary safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure
working person safety.
(1) Have the robot system working persons attend the training courses held by FANUC.
FANUC provides various training courses. Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is
waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working
person safety, provide the system with an alarm to indicate visually or aurally that the robot is in
motion.
(3) Install a safety fence with a gate so that no working person can enter the work area without passing
through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that
the robot is stopped as the safety gate is opened.
The controller is designed to receive this interlocking signal of the door switch. When the gate
is opened and this signal received, the controller stops the robot (Please refer to "STOP
TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see
Fig.2 (a) and Fig.2 (b).
s-2
B-81995EN/06
SAFETY PRECAUTIONS
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools
such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm
that stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the
power of the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on
when it is locked with a padlock.
(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot
(10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation
with gloved fingers could cause an operation error.
(11) Programs, system variables, and other information can be saved on memory card or USB memories.
Be sure to save the data periodically in case the data is lost in an accident.
(12) The robot should be transported and installed by accurately following the procedures recommended
by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe
injury to workers.
(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.
Then, the speed should be gradually increased to check the operation of the robot.
(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the
same time, a check must be made to ensure that there is no risk of hazardous situations. If detected,
such a situation should be eliminated before the operation.
(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and
peripheral equipment can be adversely affected, or workers can be severely injured.
- Avoid using the robot in a flammable environment.
- Avoid using the robot in an explosive environment.
- Avoid using the robot in an environment full of radiation.
- Avoid using the robot under water or at high humidity.
- Avoid using the robot to carry a person or animal.
- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)
(16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external
emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong
connection.
(17) When preparing trestle, please consider security for installation and maintenance work in high place
according to Fig.3 (c). Please consider footstep and safety bolt mounting position.
s-3
SAFETY PRECAUTIONS
Interlocking device and safety plug that
are activated if the gate is opened.
Safety fence
Fig. 3 (a)
Dual chain
Emergency stop board
orPanel
Panelboard
board
EAS1
EAS11
EAS2
EAS21
Single chain
Panel board
FENCE1
FENCE2
B-81995EN/06
Safety fence and safety gate
(Note)
（Note）
In case
caseofofR-30iB
R-30iA
In
TerminalsEAS1,EAS11,EAS2,EAS21
EAS1,EAS11,EAS2,EAS21
FENCE1,FENCE2
Terminals
areorprovided
on the
are provided
onboard.
the operation box or on the terminal block
emergency
stop
of the printed circuit boar d.
In
, R-J3iB
In case
caseR-30iA
of R-30iA
Mate
Terminals
areare
provided
on the
TerminalsEAS1,EAS11,EAS2,EAS21
EAS1,EAS11,EAS2,EAS21
provided
emergency
stop board
connector
panel
on the emergency
stoporboard
or connector
panel.
(in case of Open air type)
In case R-30iA Mate
TermianlsEAS1,EAS11,EAS2,EAS21
FENCE1,FENCE2 ar e provided
Terminals
or FENCE1,FENCE2
on the emergency stop board.
are provided on the emergency stop board or in the connector
panel
(Open
air type). manual for details.
Refer of
to CRM65
controller
maintenance
Refer to the ELECTRICAL CONNCETIONS Chapter of
CONNECTION of controller maintenance manual for details.
Fig. 3 (b) Limit switch circuit diagram of the safety fence
s-4
SAFETY PRECAUTIONS
B-81995EN/06
Hook for safety belt
Fence
Steps
Trestle
Footstep
for maintenance
Fig.3 (c) Footstep for maintenance
3.1
OPERATOR SAFETY
The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.
(1) If you do not have to operate the robot, turn off the power of the robot controller or press the
EMERGENCY STOP button, and then proceed with necessary work.
(2) Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering
the work area unexpectedly and to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.
The robot controller is designed to be connected to an external EMERGENCY STOP button.
With this connection, the controller stops the robot operation (Please refer to "STOP TYPE
OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external
EMERGENCY STOP button is pressed. See the diagram below for connection.
Dual chain
External stop button
Emergency stop boa rd
Panel board
(Note)
Connect EES1 and EES11, EES2 and EES21 or EMGIN1
and EMGIN2
o r Pane l boa rd
EES1
EES11
EES2
EES21
Single chain
External stop button
Panel board
EMGIN1
EMGIN2
In（Note）
case R-30iB
EES1,EES11,EES2,EES21
are on
emergenc
y stop board
Connect EES1and EES11,EES2
andthe
EES21or
EMGIN1and
EMGIN2.
case R-30iA
of R-30iA, R-J3iB
InIn case
EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
EES1,EES11,EES2,EES21 or EMGIN1, EMGIN2 are on the
panel
board.
In case
of R-30iA Mate
EES1,EES11,EES2,EES21 are on the emergency stop board
or
connector
panel
(in case of Open air type).
In case R-30iA
Mate
EMGIN1,EMGIN2 are on the emergency stop board.
Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2
are
provided
on the emergency
board
or in for
thedetails.
connector
Refer
to the maintenance
manual stop
of the
controller
panel of CRM65 (Open air type).
Refe r to the ELECTRICAL CONNCETIONS Ch apter
CONNECTION of controller maintenance manual for details.
Fig.3.1 Connection diagram for external emergency stop button
s-5
of
SAFETY PRECAUTIONS
3.2
B-81995EN/06
SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the work area of the robot. The operator must ensure
the safety of the teach pendant operator especially.
(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal
operating condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and
other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN
switch on the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
(5) Programming should be done outside the area of the safety fence as far as possible. If programming
needs to be done in the area of the safety fence, the programmer should take the following
precautions:
－ Before entering the area of the safety fence, ensure that there is no risk of dangerous situations
in the area.
－ Be prepared to press the emergency stop button whenever necessary.
－ Robot motions should be made at low speeds.
－ Before starting programming, check the entire system status to ensure that no remote instruction
to the peripheral equipment or motion would be dangerous to the user.
Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent
other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened
with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The
programmer should understand that the safety gate is disabled and is responsible for keeping other people from
entering the inside of the safety fence. (In case of R-30iA Mate Controller standard specification, there is no mode
switch. The automatic operation mode and the teach mode is selected by teach pendant enable switch.)
Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting
status.
(a)
Disable: The DEADMAN switch is disabled.
(b)
Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iB/R-30iA/ R-30iA Mate employs a
3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is
pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the
switch strongly, the robot stops immediately.
The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator
should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.
The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the
validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator
panel, the teach pendant enable switch and the remote condition on the software.
s-6
SAFETY PRECAUTIONS
B-81995EN/06
In case of R-30iB/R-30iA controller or CE or RIA specification of R-30iA Mate controller
Mode
Teach pendant
enable switch
Software
remote
condition
Local
Remote
Local
Off
Remote
Local
On
T1, T2
Remote
mode
Local
Off
Remote
T1,T2 mode: DEADMAN switch is effective.
On
AUTO
mode
Teach pendant
Operator panel
Peripheral device
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
In case of standard specification of R-30iA Mate controller
Teach pendant enable switch
Software remote condition
Teach pendant
Peripheral device
On
Off
Ignored
Local
Remote
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
(6) (Only when R-30iB/R-30iA Controller or CE or RIA specification of R-30iA Mate controller is
selected.) To start the system using the operator’s panel, make certain that nobody is the robot work
area and that there are no abnormal conditions in the robot work area.
(7) When a program is completed, be sure to carry out a test run according to the procedure below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low
speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test run above, execute it in the
automatic operation mode.
(8) While operating the system in the automatic operation mode, the teach pendant operator should
leave the robot work area.
3.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer personnel, pay utmost attention to the following.
(1) During operation, never enter the robot work area.
(2) A hazardous situation may arise when the robot or the system, are kept with their power-on during
maintenance operations. Therefore, for any maintenance operation, the robot and the system should
be put into the power-off state. If necessary, a lock should be in place in order to prevent any other
person from turning on the robot and/or the system. In case maintenance needs to be executed in the
power-on state, the emergency stop button must be pressed.
(3) If it becomes necessary to enter the robot operation range while the power is on, press the
emergency stop button on the operator panel, or the teach pendant before entering the range. The
maintenance personnel must indicate that maintenance work is in progress and be careful not to
allow other people to operate the robot carelessly.
(4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire
system in order to make sure no dangerous situations exist. In case the worker needs to enter the
safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status
must be carefully monitored.
s-7
SAFETY PRECAUTIONS
B-81995EN/06
(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off
and the pressure in the piping should be reduced to zero.
(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition.
(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working
nearby, make certain that their escape path is not obstructed.
(9) When a tool is mounted on the robot, or when any moving device other than the robot is installed,
such as belt conveyor, pay careful attention to its motion.
(10) If necessary, have a worker who is familiar with the robot system stand beside the operator panel
and observe the work being performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an
accident may occur, causing damage to the robot and injury to the worker.
(12) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.
(13) When handling each unit or printed circuit board in the controller during inspection, turn off the
circuit breaker to protect against electric shock.
If there are two cabinets, turn off the both circuit breaker.
(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction
or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.
Such a fuse may cause a fire.
(15) When restarting the robot system after completing maintenance work, make sure in advance that
there is no person in the work area and that the robot and the peripheral devices are not abnormal.
(16) When a motor or brake is removed, the robot arm should be supported with a crane or other
equipment beforehand so that the arm would not fall during the removal.
(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent
dangerous falls.
(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated
state, the worker should wear heat-resistant gloves or use other protective tools.
－ Servo motor
－ Inside the controller
－ Reducer
－ Gearbox
－ Wrist unit
(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause
any danger.
(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to
protect maintenance workers from excessive load. Otherwise, the maintenance workers would be
severely injured.
(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot
would be adversely affected. In addition, a misstep can cause injury to the worker.
(22) When performing maintenance work in high place, secure a footstep and wear safety belt.
(23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the
floor around the robot and within the safety fence.
(24) When a part is replaced, all bolts and other related components should put back into their original
places. A careful check must be given to ensure that no components are missing or left not mounted.
(25) In case robot motion is required during maintenance, the following precautions should be taken :
- Foresee an escape route. And during the maintenance motion itself, monitor continuously the
whole system so that your escape route will not become blocked by the robot, or by peripheral
equipment.
- Always pay attention to potentially dangerous situations, and be prepared to press the emergency
stop button whenever necessary.
s-8
B-81995EN/06
SAFETY PRECAUTIONS
(26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller
maintenance manual.) A failure to do the periodical inspection can adversely affect the performance
or service life of the robot and may cause an accident
(27) After a part is replaced, a test execution should be given for the robot according to a predetermined
method. (See the program execution of “Operator’s manual of the controller”.) During the test
execution, the maintenance staff should work outside the safety fence.
4
4.1
SAFETY OF THE TOOLS AND
PERIPHERAL DEVICES
PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the
program to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect
the states of all devices in the system and can be stopped according to the states.
4.2
PRECAUTIONS FOR MECHANISM
(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does
not strike against its peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
•
Use mechanical unit cable that have required user interface.
•
Don’t add user cable or hose to inside of mechanical unit.
•
Please do not obstruct the movement of the mechanical unit cable when cables are added to
outside of mechanical unit.
•
In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.
•
Please do not interfere with the other parts of mechanical unit when install equipments in the
robot.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please
avoid the system construction that power-off stop would be operated routinely. (Refer to bad case
example.) Please execute power-off stop after reducing the speed of the robot and stopping it by
hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type.)
(Bad case example)
•
Whenever poor product is generated, a line stops by emergency stop.
•
When alteration was necessary, safety switch is operated by opening safety fence and
power-off stop is executed for the robot during operation.
•
An operator pushes the emergency stop button frequently, and a line stops.
s-9
SAFETY PRECAUTIONS
B-81995EN/06
•
An area sensor or a mat switch connected to safety signal operate routinely and power-off stop
is executed for the robot.
(6) Robot stops urgently when collision detection alarm (SV050) etc. occurs. The frequent urgent stop
by alarm causes the trouble of the robot, too. So remove the causes of the alarm.
5
SAFETY OF THE ROBOT MECHANISM
5.1
PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can
manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the
jog mode.
5.2
PRECAUTIONS IN PROGRAMMING
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the
motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has
terminated.
5.3
PRECAUTIONS FOR MECHANISMS
(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,
and dust.
5.4
PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER
IN EMERGENCY OR ABNORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit
can be used to move the robot axes without drive power.
Please order following unit and cable.
Name
Brake release unit
Robot connection cable
Power cable
Specification
A05B-2450-J350 (Input voltage AC100-115V single phase)
A05B-2450-J351 (Input voltage AC200-240V single phase)
A05B-2450-J360 (5m), (except A cabinet integrated type controller)
A05B-2450-J361 (10m), (except A cabinet controller integrated type controller)
A05B-2525-J045 (5m), (A cabinet integrated type controller)
A05B-2525-J046 (10m), (A cabinet integrated type controller)
A05B-2525-J010 (5m) (AC100-150V type)
A05B-2525-J011 (10m) (AC100-150V type)
A05B-2450-J364 (5m) (AC200-240V type)
A05B-2450-J365 (10m) (AC200-240V type)
(2) Please make sure that adequate numbers of brake release units are available and readily accessible
for robot system before installation.
(3) Regarding how to use brake release unit, please refer to Robot controller maintenance manual.
s-10
SAFETY PRECAUTIONS
B-81995EN/06
NOTE
Robot systems installed without adequate number of brake release units or similar
means are not in compliance with EN ISO 10218-1 and the Machinery Directive
and therefore cannot bear the CE marking.
CAUTION
Robot arm would fall down by releasing its brake because of gravity. Especially
because spring balancer is used for J2-axis, it is hard to predict J2-arm
movement by the condition of Robot posture and end effecter. Therefore, it is
strongly recommended to take adequate measures such as hanging Robot arm
by a crane before releasing a brake.
In case of releasing J2-axis motor brake
Method of supporting robot arm
Use M12 eyebolt
(sling 1pcs)
Use M12 eyebolt
(sling 1pcs)
Lever block(2pcs)
Sling(2pcs)
？
？
Unpredictable
Fig. 5.4 (a) Releasing J2 motor brake and measures
Method of releasing motor brake
Method of supporting robot arm
Use M12 eyebolt (sling 1pcs)
Fall down
Fig.5.4 (b) Releasing J3 motor brake and measures
s-11
SAFETY PRECAUTIONS
6
SAFETY OF THE END EFFECTOR
6.1
PRECAUTIONS IN PROGRAMMING
B-81995EN/06
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time
delay after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of
the end effector.
7
STOP TYPE OF ROBOT
The following three robot stop types exist:
Power-Off Stop (Category 0 following IEC 60204-1)
Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
An alarm is generated and servo power is turned off.
The robot operation is stopped immediately. Execution of the program is paused.
Controlled stop (Category 1 following IEC 60204-1)
The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
An alarm is generated and servo power is turned off.
Hold (Category 2 following IEC 60204-1)
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.
When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off
stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop
pattern is different according to the controller type or option configuration.
s-12
SAFETY PRECAUTIONS
B-81995EN/06
There are the following 3 Stop patterns.
Stop
pattern
A
B
C
P-Stop:
C-Stop:
-:
Mode
Emergency
stop
button
External
Emergency
stop
FENCE open
SVOFF input
Servo
disconnect
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
C-Stop
P-Stop
C-Stop
-
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
AUTO
T1
T2
AUTO
T1
T2
AUTO
T1
T2
Power-Off stop
Controlled stop
Disable
The following table indicates the Stop pattern according to the controller type or option configuration.
R-30iB
Option
Standard
Controlled stop by E-Stop
A (*)
C (*)
(A05B-2600-J570)
(*) R-30iB does not have servo disconnect.
Option
Standard
Stop type set (Stop pattern C)
(A05B-2500-J570)
Standard
(Single)
R-30iA
Standard
RIA
(Dual)
type
CE
type
R-30iA Mate
RIA
Standard
type
CE
type
B (*)
A
A
A
A (**)
A
A
N/A
N/A
C
C
N/A
C
C
(*) R-30iA standard (single) does not have servo disconnect.
(**) R-30iA Mate Standard does not have servo disconnect, and the stop type of SVOFF input is
Power-Off stop.
The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please
refer to "Software version" in operator's manual of controller for the detail of software version screen.
"Controlled stop by E-Stop" option
When "Controlled stop by E-Stop" (A05B-2600-J570) option (In case of R-30iA/R-30iA Mate, it is Stop
type set (Stop pattern C) (A05B-2500-J570)) is specified, the stop type of the following alarms becomes
Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is
the normal operation of the system.
Alarm
SRVO-001 Operator panel E-stop
SRVO-002 Teach pendant E-stop
SRVO-007 External emergency stops
SRVO-194 Servo disconnect
SRVO-218 Ext.E-stop/Servo Disconnect
SRVO-408 DCS SSO Ext Emergency Stop
SRVO-409 DCS SSO Servo Disconnect
Condition
Operator panel emergency stop is pressed.
Teach pendant emergency stop is pressed.
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA/R-30iB controller)
Servo disconnect input (SD4-SD41, SD5-SD51) is open.
(R-30iA controller)
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA Mate/R-30iB controller)
In DCS Safe I/O connect function, SSO[3] is OFF.
In DCS Safe I/O connect function, SSO[4] is OFF.
s-13
SAFETY PRECAUTIONS
B-81995EN/06
Controlled stop is different from Power-Off stop as follows:
In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
In Controlled stop, physical impact is less than Power-Off stop. This function is effective for
systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be
minimized.
The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the
operator's manual of a particular robot model for the data of stopping distance and stopping time.
In case of R-30iA or R-30iA Mate, this function is available only in CE or RIA type hardware.
When this option is loaded, this function cannot be disabled.
The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.
s-14
SAFETY PRECAUTIONS
B-81995EN/06
8
WARNING LABEL
(1) Greasing and degreasing label
1)
必ず排脂口を開けて給脂して下さい。
Ｏｐｅｎ ｔｈｅ ｇｒｅａｓｅ ｏｕｔｌｅｔ
ａｔ ｇｒｅａｓｉｎｇ．
必须在排脂口打开的状态下供脂。
2)
手動式ポンプを使用して給脂を行って
下さい。
Ｕｓｅ ａ ｈａｎｄ ｐｕｍｐ ａｔ
ｇｒｅａｓｉｎｇ．
请使用手动式供脂泵进行供脂。
3）
必ず指定グリスを使用して下さい。
Ｕｓｅ ｄｅｓｉｇｎａｔｅｄ ｇｒｅａｓｅ
ａｔ ｇｒｅａｓｉｎｇ．
必须使用指定的润滑脂。
Fig. 8 (a) Greasing and degreasing label
Description
When greasing and degreasing, observe the instructions indicated on this label.
1)
2)
3)
Open the grease outlet at greasing.
Use a hand pump at greasing.
Use designated grease at greasing.
CAUTION
See section I.3 ″ PERIODIC MAINTENANCE for explanations about specified
greases, the amount of grease to be supplied, and the locations of grease and
degrease outlets for individual models.
(2) Disassembly prohibitive label
Fig. 8 (b) Disassembly prohibitive label
Description
Do not disassemble the balance unit. It is very dangerous because a spring is loaded in it.
s-15
SAFETY PRECAUTIONS
B-81995EN/06
(3) Step-on prohibitive label
Fig. 8 (c) Step-on prohibitive label
Description
Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you
may get hurt if you lose your footing as well.
(4) High-temperature warning label
Fig. 8 (d) High-temperature warning label
Description
Be cautious about a section where this label is affixed, as the section generates heat. If you have to
inevitably touch such a section when it is hot, use a protective provision such as heat-resistant gloves.
s-16
B-81995EN/06
SAFETY PRECAUTIONS
(5) Transportation label
Fig. 8 (e) Transportation label
Description
When transporting the robot, observe the instructions indicated on this label.
1)
Using a forklift
•
Use a forklift having a load capacity of 3,000 kg or greater.
•
Keep the total weight of the robot to be transported to within 2,200 kg, because the withstand
load of the forklift bracket (option) is 5,390 N (550 kgf).
2)
Using a crane
•
Use a crane having a load capacity of 3,000 kg or greater.
•
Use at least four slings each having a withstand load of 9,800 N (1,000 kgf) or greater.
•
Use at least four eyebolts each having a withstand load of 9,310 N (950 kgf) or greater.
CAUTION
See section II.3.1 TRANSPORTATION for explanations about the posture a
specific model should take when it is transported.
s-17
SAFETY PRECAUTIONS
(6) Balancer replacement label
Fig. 8 (f) Balancer replacement label
Description
When replacing the balancer, observe the instructions indicated on this label.
•
When replacing the balancer, keep the J2 axis at 0°.
•
The mass of the balancer is 110 kg.
(7) Transportation prohibitive label
ア イボ ルト を 横引
し ない こ と
Do not pull eyebolt
sideways
禁止横向拉拽吊环螺钉
Fig. 8 (g) Transportation prohibitive label
Description
Keep the following in mind when transporting the robot.
•
Do not pull eyebolts sideways
s-18
B-81995EN/06
B-81995EN/06
SAFETY PRECAUTIONS
(8) Range of motion and payload mark label
Below label is added when CE specification is specified.
0DEG
FLANGE CENTER
法兰盘中心
B
+180DEG
-180DEG
MOTION RANGE OF
FLANGE CENTER
A
M-410iB/160
M-410iB/300
M-410iB/450
M-410iB/700
A
(mm)
3143
3143
3130
3143
B
(mm)
2880
2880
2696
2870
C
(mm)
78
78
238
88
C
法兰盘中心的
动作范围
MAX. PAYLOAD
(kg)
160
300
450
700
Fig.8 (h) Range of motion and payload mark label
s-19
PREFACE
B-81995EN/06
PREFACE
This manual explains the maintenance and connection procedures for the mechanical units of the following
robots:
Mechanical unit
specification No.
Model name
FANUC Robot M-410iB/160
FANUC Robot M-410iB/300
FANUC Robot M-410iB/160
FANUC Robot M-410iB/300
A05B-1041-B201
A05B-1041-B203
A05B-1041-B211
A05B-1041-B213
Maximum load
160kg
300kg
160kg
300kg
Remarks
R-J3iB
R-30iA
R-30iB
The label stating the mechanical unit specification number is affixed in the position shown below. Before
reading this manual, determine the specification number of the mechanical unit.
CAUTION
Note that the models for the R-J3iB controller and those for the R-30iA/R-30iB
controller partly differ in the specifications of mechanical unit cables.
(1)
TYPE
NO.
DATE
(2)
(3)
(4)
TOTAL WEIGHT WITH CONTROLLER :
TOTAL WEIGHT WITHOUT CONTROLLER:
(5) kg
(6) kg
Position of label indicating mechanical unit specification number
No.
(1)
CONTENTS
MODEL
LETTERS
FANUC Robot M-410iB/160
FANUC Robot M-410iB/300
FANUC Robot M-410iB/160
FANUC Robot M-410iB/300
Table 1
(2)
(3)
(4)
TYPE
No.
DATE
PRINT
SERIAL
NO.
PRINT
PRODUCTION
YEAR AND
MONTH
A05B-1041-B201
A05B-1041-B203
A05B-1041-B211
A05B-1041-B213
p-1
(5)
WEIGHT kg
(With controller)
1940
1940
1940
1940
PREFACE
ITEM
Controlled axes
Installation
Motion
J1-axis
range
J2-axis
(Maximum
J3-axis
speed)
J4-axis
(Note 1)
Max. load capacity at wrist
(Note 2)
Allowable load inertia at
wrist
Drive method
Repeatability
Weight
Acoustic noise level
Installation requirement
Specifications
M-410iB/160
360º (130º/s)
144º (130º/s)
136º (135º/s)
540º (300º/s)
B-81995EN/06
M-410iB/300
4 axes (J1, J2, J3, J4)
Floor mount
6.28rad (2.27rad/s)
360º (85º/s) 6.28rad (1.48rad/s)
2.51rad (2.27rad/s)
144º (90º/s) 2.51rad (1.57rad/s)
2.37rad (2.36rad/s)
136º (100º/s) 2.37rad (1.75rad/s)
9.42rad (5.24rad/s)
540º (190ºs) 9.42rad (3.32rad/s)
160 kg
300 kg
2
78kg-m2
137kg-m
2
(800kgf-cm-sec )
(1400kgf-cm-sec2)
Electric servo drive by AC servo motor
±0.5 mm
1940 kg
Less than 70dB
NOTE
This value is equivalent continuous A-weighted sound pressure level that applied with
ISO11201 (EN31201). This value is measured with the following conditions.
- Maximum load and speed
- Operating mode is AUTO
Ambient temperature : 0 to 45℃ (Note 3)
Ambient humidity
Normally : 75%RH or less (No dew, nor frost allowed)
Short time (within one month) : Max. 95%RH
Height:
Up to 1,000 meters above the sea level requires, no particular provision for
attitude.
Vibration: 0.5G or less
Free of corrosive gases (Note 4)
NOTE
1 The robot does not arrive at each axial maximum speed at the short movement
distance.
2 In case of M-410iB, avoid keeping J3 arm horizontally with max payload for a long
time to prevent occurrence of the overheat alarm.
3 When robot is used in low temperature environment that is near to 0ºC,or robot is
not operated for a long time in the environment that is less than 0ºC in a holiday or
the night, because viscous resistance of the drive train is so big that may cause
occurrence of collision detect alarm (SRVO –050) etc. In this case, we
recommend performing the warm up operation for several minutes.
4 Contact the service representative, if the robot is to be used in an environment or a
place subjected to severe vibrations, heavy dust, cutting oil splash and or other
foreign substances.
p-2
PREFACE
B-81995EN/06
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Intended readers:
All persons who use FANUC Robot, system designer
Topics:
All persons who use the FANUC Robot and system designer Safety items for robot system design, operation,
maintenance
must read and understand thoroughly this handbook
R-J3iB
Intended readers:
Setup and Operations manual
Operator, programmer, maintenance person, system
controller
designer
HANDLING TOOL
Topics:
B-81464EN-2
Robot functions, operations, programming, setup,
interfaces, alarms
Use:
Robot operation, teaching, system design
Intended readers:
Maintenance manual
Maintenance person, system designer
Topics:
B-81465EN
Installation, connection to peripheral equipment,
B-81465EN-1 (For Europe)
maintenance
Use:
Installation, start-up, connection, maintenance
R-30iA
Intended readers:
Setup and Operations manual
Operator, programmer, maintenance person, system
controller
designer
HANDLING TOOL
Topics:
B-83124EN-2
Robot functions, operations, programming, setup,
ALARM CODE LIST
interfaces, alarms
B-83124EN-6
Use:
Robot operation, teaching, system design
Intended readers:
Maintenance manual
Maintenance person, system designer
Topics:
B-82595EN
Installation, connection to peripheral equipment,
B-82595EN-1 (For Europe)
maintenance
B-82595EN-2 (For RIA)
Use:
Installation, start-up, connection, maintenance
Safety handbook
B-80687EN
p-3
PREFACE
R-30iB
controller
OPERATOR'S MANUAL (Basic Function)
B-83284EN
OPERATOR'S MANUAL (Alarm Code List)
B-83284EN-1
Optional Function OPERATOR'S MANUAL
B-83284EN-2
Maintenance manual
B-83195EN
Mechanical
unit
Maintenance manual
FANUC Robot M-410iB/160,300
B-81995EN
p-4
B-81995EN/06
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
TABLE OF CONTENTS
B-81995EN/06
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
PREFACE ....................................................................................................p-1
I. MAINTENANCE
1
CONFIGURATION .................................................................................. 3
1.1
1.2
1.3
1.4
2
PREVENTIVE MAINTENANCE............................................................... 6
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
J1-AXIS DRIVE MECHANISM....................................................................... 3
J2-AXIS DRIVE MECHANISM....................................................................... 4
J3-AXIS DRIVE MECHANISM....................................................................... 4
J4-AXIS DRIVE MECHANISM....................................................................... 5
DAILY CHECKS ............................................................................................ 6
FIRST 1-MONTH (320 hours) CHECKS........................................................ 8
FIRST 3-MONTH (960 hours)CHECKS......................................................... 8
3-MONTH (960 hours) CHECKS ................................................................. 11
1-YEAR (3,840 hours)CHECKS................................................................... 11
1.5-YEAR (5,760 hours) CHECKS............................................................... 12
3-YEAR (11,520 hours)CHECKS................................................................. 12
4-YEAR (15,360 hours) CHECKS................................................................ 12
MAINTENANCE TOOLS ............................................................................. 12
PERIODIC MAINTENANCE .................................................................. 14
3.1
REPLACING GREASE OF THE DRIVE MECHANISM ............................... 14
3.1.1
3.2
3.3
3.4
4
PROCEDURE FOR RELEASING REMAINING PRESSURE WITHIN THE
GREASE BATH ........................................................................................... 17
SUPPLYING GREASE ................................................................................ 18
REPLACING THE BATTERIES ................................................................... 20
TROUBLE SHOOTING ......................................................................... 21
4.1
4.2
4.3
5
Grease Replacement Procedure of M-410iB/160, 300 ...........................................15
GENERAL ................................................................................................... 21
FAILURES, CAUSES AND MEASURES ..................................................... 21
BACKLASH MEASUREMENT..................................................................... 28
ADJUSTMENTS.................................................................................... 30
5.1
5.2
5.3
5.4
5.5
ADJUSTING LIMIT SWITCHES AND DOGS (OPTION) ............................. 30
ZERO POINT POSITION AND MOTION LIMIT OF J2-AXIS TO J4-AXIS... 32
J1-AXIS STROKE MODIFICATION (OPTION)............................................ 34
SOFTWARE SETTING................................................................................ 36
MASTERING ............................................................................................... 37
5.5.1
5.5.2
5.5.3
General ...................................................................................................................37
Resetting Alarms and Preparing for Mastering ......................................................38
Fixture Position Master ..........................................................................................38
5.5.3.1
Attaching the mastering fixture ......................................................................... 38
c-1
TABLE OF CONTENTS
5.5.3.2
5.5.4
5.5.5
5.5.6
5.5.7
5.6
6
B-81995EN/06
Mastering ........................................................................................................... 41
Zero Degree Mastering...........................................................................................42
Quick Mastering .....................................................................................................44
Single Axis Mastering ............................................................................................46
Mastering Data Entry .............................................................................................48
CHECKING THE MASTERING ................................................................... 50
REPLACING PARTS ............................................................................ 52
6.1
6.2
NOTE FOR PART REPLACEMENT............................................................ 52
M-410iB/160, 300 ........................................................................................ 52
6.2.1
6.2.2
6.2.3
6.2.4
6.3
6.4
6.5
6.6
Replacing the J1-Axis Motor and Reducer ............................................................52
Replacing the J2-Axis Motor and Reducer ............................................................57
Replacing the J3-Axis Motor and Reducer ............................................................60
Replacing the J4-Axis Motor and Reducer ............................................................63
SEALANT APPLICATION............................................................................ 66
REPLACING THE WRIST UNIT .................................................................. 67
REPLACING THE OPTIONAL J1-AXIS LIMIT SWITCH (OPTION) ............ 70
REPLACING THE BALANCER.................................................................... 71
7
PIPING AND WIRING ........................................................................... 73
8
REPLACING CABLES .......................................................................... 74
8.1
8.2
CABLE FORMING ....................................................................................... 75
CABLE REPLACEMENT ............................................................................. 81
II. CONNECTION
1
ROBOT INTERFERENCE AREA.......................................................... 91
2
MECHANICAL COUPLING TO THE ROBOT....................................... 92
2.1
2.2
2.3
2.4
LOAD CONDITION AT WRIST.................................................................... 92
MECHANICAL COUPLING OF END EFFECTOR TO WRIST .................... 95
EQUIPMENT MOUNTING FACE ................................................................ 96
LOAD SETTING .......................................................................................... 97
2.4.1
2.5
2.6
3
Switching between Modes......................................................................................99
AIR SUPPLY.............................................................................................. 101
OPTION CABLE INTERFACE ................................................................... 103
TRANSPORTATION AND INSTALLATION ....................................... 111
3.1
3.2
3.3
3.4
TRANSPORTATION.................................................................................. 111
INSTALLATION ......................................................................................... 112
MAINTENANCE AREA .............................................................................. 119
INSTALLATION CONDITION .................................................................... 119
c-2
TABLE OF CONTENTS
B-81995EN/06
APPENDIX
A
SPARE PARTS LISTS ........................................................................ 123
B
CONNECTION DIAGRAM................................................................... 125
C
PERIODIC MAINTENANCE ................................................................ 134
D
STRENGTH OF BOLT AND BOLT TORQUE LIST............................ 136
c-3
I. MAINTENANCE
1
1.CONFIGURATION
MAINTENANCE
B-81995EN/06
CONFIGURATION
The configuration of the mechanical unit is shown in Fig. 1.
Link base
J3 arm
drive link 2
J3 arm
J4-axis AC
servo motor (M4)
Wrist posture
hold link
J3 arm
drive link 1
J2 base
J4 casing
J1-axis AC
servo motor (M1)
Balancer
J3-axis AC
servo motor (M3)
J1 base
J2 arm
J2-axis AC
servo motor (M2)
Fig. 1 Mechanical unit configuration
1.1
J1-AXIS DRIVE MECHANISM
Fig. 1.1 shows the J1-axis drive mechanism.
Rotation of the J1-axis motor fixed on the J2 base is input to the reducer via the center gear, and the reduced
rotation rotates the J2 base.
J1-axis motor (M1)
Center gear
Input gear
J2 base
J1 base
J1-axis reducer
Fig. 1.1 J1-axis drive mechanism
-3-
1.CONFIGURATION
1.2
MAINTENANCE
B-81995EN/06
J2-AXIS DRIVE MECHANISM
Fig. 1.2 shows the J2-axis drive mechanism.
Rotation of the J2-axis motor fixed on the J2 base is directly fed to the reducer, and the reduced rotation
rotates the J2 arm.
J2 arm
J2-axis motor (M2)
Input gear
J2-axis reducer
J2 base
Fig. 1.2 J2-axis drive mechanism
1.3
J3-AXIS DRIVE MECHANISM
Fig. 1.3 shows the J3-axis drive mechanism.
Rotation of the J3-axis motor fixed on the J2 base is directly fed to the reducer, and the reduced rotation
rotates the J3 arm through the link 1 and link 2.
Link 2
J3-axis motor (M3)
Link 1
J3-axis reducer
Input gear
J2 base
Fig. 1.3 J3-axis drive mechanism
-4-
1.4
1.CONFIGURATION
MAINTENANCE
B-81995EN/06
J4-AXIS DRIVE MECHANISM
Fig. 1.4 shows the J4-axis drive mechanism.
Rotation of the J4-axis motor fixed on the J4 axis gearbox is input to the reducer through the center gear,
and the reduced rotation rotates the wrist flange.
J4-axis motor (M4)
Input gear
Center gear
J4 base
J4-axis reducer (Hollow type)
Wrist flange
Fig. 1.4 J4-axis drive mechanism
NOTE
A non-excited brake is incorporated in the motors for all axes (J1, J2, J3, and J4
axes) and actuates at power off or in an emergency.
-5-
2.PREVENTIVE MAINTENANCE
2
MAINTENANCE
B-81995EN/06
PREVENTIVE MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
NOTE
The periodic maintenance procedures described in this chapter assume that the
FANUC robot is used for up to 3,840 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 3,840 hours/year.
2.1
DAILY CHECKS
Clean each part, and visually check component parts for damage before daily system operation. Check the
following items as the occasion demands.
1) Before turning on power
Item
1
Check items
Oil exudation
Check points
Check there is oil exudation on sealed part of each joint parts.(Note 1)
Note 1 About exudation of oil
Check items
-
-
Check there is exudation of oil on sealed part of each joint parts.
Oil exudation may be attached (Slightly a loot oil stick) to outside of lip depend on the movement
condition or environment of the circumference. If this oil contents change to a state of dew, it may fail
depend on the movement.
You can prevent oil spot from falling down by wiping the oil contents which is accumulated to under part
of oil seal before operation.
Also, motors may become the high temperature and the internal pressure of grease bath or oil bath may
rise by frequent repetition movement and use in the high temperature environment.
In these cases, you can return internal pressure by releasing grease out let or oil outlet just after operation
of robot. (When opening grease outlet or oil outlet, refer to Section 3.1 and pay attention grease or oil is
not scattered.)
-6-
2.PREVENTIVE MAINTENANCE
MAINTENANCE
B-81995EN/06
Fig.2.1 (a) Check parts of oil exudation
Check items
Wipe off the oil contents of each joint part which has oil seal.
Item
Check items
When air control set is combined
Check points
1
Air pressure
2
Lubricator oil mist quantity
3
4
Lubricator oil level
Leakage from hose
5
Drain
Check air pressure using the pressure gauge on the air regulator as shown
in
Fig.2.1 (b). If it does not meet the specified pressure of 0.49 to 0.69 MPa
(5-7 kgf/cm2), adjust it using the regulator pressure setting handle.
Check the drop quantity during wrist or hand motion. If it does not meet the
specified value (1 drop/10-20 sec), adjust it using the lubricator control
knob. Under normal usage the lubricator becomes empty in about 10 to 20
days under normal operation.
Check to see that the lubricator level is within the specified level.
Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as
required.
Check drain and release it. When quantity of the drain is remarkable,
examine the setting of the air dryer to the air supply side.
Lubricator
Oil inlet
Adjusting knob
Lubricator
mist amount check
Lubricator
Filter
Regulator
pressure
setting
Pressure gauge
Fig.2.1 (b) Air control set (option)
-7-
2.PREVENTIVE MAINTENANCE
2)
MAINTENANCE
B-81995EN/06
After automatic operation
Item
Check items
1
Vibration, abnormal
noises, and motor heating
2
Changing repeatability
3
Peripheral devices for
proper operation
Brakes for each axis
4
2.2
Check points
Check whether the robot moves along and about the axes smoothly without
unusual vibration or sounds. Also, check whether the temperature of the
motors is excessively high.
Check to see that the stop positions of the robot have not deviated from the
previous stop positions.
Check whether the peripheral devices operate properly according to
commands from the robot.
Check that the end effector drops within 0.2 mm when the power is cut.
FIRST 1-MONTH (320 hours) CHECKS
Check the following items once every one-month (320 hours). Additional inspection areas and times should
be added to the table according to the robot’s working conditions, environment, etc. Then every 3 months
thereafter. (See the Section 2.4.)
Item
1
2.3
Check items
Ventilation portion of
controller
Check points
If the ventilation portion of the controller is dusty, turn off power and clean the
unit.
FIRST 3-MONTH (960 hours)CHECKS
Check the following items at the first quarterly inspection, then every year thereafter.(See the Section 2.5.)
Item
Check items
1
Cables used in
mechanical unit
2
Retightening external
main bolts
Check the mechanical
stopper and adjustable
mechanical stopper
Cleaning and checking
each part
Check the end effector
(hand) cable
Check the teach pendant
cable, operation box
connecting cable and
robot connecting cable
3
4
5
6
Note 1
Check points
Check whether the jackets of the mechanical unit cables are damaged. Also
check whether the cables are excessively bent or unevenly twisted. Check that
the connectors of the motors and connector panels are securely engaged.
(Note 1)
Retighten the end-effecter mounting bolts and external main bolts.(Note 2)
Check the looseness of mounting bolts of mechanical stopper and adjustable
mechanical stopper. Particular, check swing stopper of J1-axis rotates
smoothly (Note 3)
Clean each part (remove chips, etc.) and check component parts for cracks
and flaws. (Note 4)
Confirm whether there is wound in the cable.
Check whether the cable connected to the teach pendant and robot is unevenly
twisted.
Inspection points and check items of the mechanical unit cables and
connectors
Inspection points of the mechanical unit cables
Movable parts of J1, the upper side and lower side of link for wrist posture maintenance of rear side of J2
arm, movable part in uniting part of J2 to J3 and J3 to J4 and fixed department cable who interferes easily in
peripherals
-8-
MAINTENANCE
B-81995EN/06
2.PREVENTIVE MAINTENANCE
Check items
For cables with a cable protection sheet, open the protection sheet before making the check.
Check the cables for a sheath break and wear.
If wires of the cable appear, replace it.
Remove the cover
Fig 2.3 (a) Check items of Mechanical unit cable
Inspection points of the connectors
-
Power/brake connectors of the motor exposed externally.
Robot connection cables, user cables and earth terminal.
Check items
-
Circular connector: Check the connector for looseness by turning it manually.
Square connector: Check the connector for disengagement of its lever.
Earth terminal: Check the connector for looseness.
RM2
RM1
RP1
AIR 11
AI R21
AS1
When integrated type
controller is selected.
Fig 2.3 (b) Check items of connector
Note 2
-
Points to be retightened
The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need
to be retightened.
The bolts exposed to the outside of the robot need to be retightened.
For the tightening torque, see the recommended bolt tightening torque shown in the Appendix.
-9-
2.PREVENTIVE MAINTENANCE
MAINTENANCE
B-81995EN/06
A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater
than the recommended torque, the loose prevention agent may be removed. So, follow the
recommended tightening torque when retightening them.
Note 3 Check of mechanical stopper and adjustable mechanical stopper.
-
Check the looseness of stopper mounting bolts. If they are loose, they are needed to be retightened.
Especially, check the looseness of mounting bolts of J1-axis swing stopper.
Check that J1-axis swing stopper rotates smoothly.
Check the looseness of bolts
and stopper rotate smoothly.
Fig.2.3 (c) Check of mechanical stopper and adjustable mechanical stopper.
Note 4
-
Cleaning
Necessary cleaning points, dust on the flat part, sedimentation of spatters
Clean sediments periodically.
In particular, clean the following points carefully.
1) Vicinity of the balancer rod and shaft
→ If chippings or spatters are attached to the bushing, abnormal wear may be caused.
2) Vicinity of the wrist axis and oil seal
→ If chippings or spatters are attached to the oil seal, an oil leak may be occurred.
Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly
wears due to rubbing against the welding cable or hand cable.
Check if there is a trace of a collision around the hand.
Check the reducer or grease bath for an oil leak.
→ If oil can be found a day after wiping oil, an oil leak may be caused.
- 10 -
MAINTENANCE
B-81995EN/06
2.PREVENTIVE MAINTENANCE
Fig 2.3 (d) Cleaning part
2.4
3-MONTH (960 hours) CHECKS
Check the following item at the first one-months (320 hours), then every 3-month thereafter. (See the
Subsection .2.2.)
Item
1
2.5
Check items
Check points
Ventilation portion of controller
(See Section 2.2.)
1-YEAR (3,840 hours)CHECKS
Check the following items once every year.
Item
Check items
1
2
3
Cables used in mechanical unit
Retightening external main bolts
Check the mechanical stopper and adjustable
mechanical stopper
Cleaning each parts and inspection
Check the end effector (hand) cable
Check the robot cable, teach pendant cable and
robot connecting cable
4
5
6
Check points
- 11 -
(See Section 2.3.)
(See Section 2.3.)
(See Section 2.3.)
(See Section 2.3.)
(See Section 2.3.)
(See Section 2.3.)
2.PREVENTIVE MAINTENANCE
2.6
MAINTENANCE
B-81995EN/06
1.5-YEAR (5,760 hours) CHECKS
Check the following item once every 1.5 year.
Item
1
Check items
Check points
Battery
2.7
Replace battery in the mechanical unit. (See Section 3.4.)
3-YEAR (11,520 hours)CHECKS
Check the following items once every 3 years.
Item
1
2
Check items
Check points
Grease of each axis reducer
Grease of bearing
2.8
Replace grease of each axis reducer.(See Section 3.1.)
Supply grease to each connection of bearing.
(See Section 3.3.)
4-YEAR (15,360 hours) CHECKS
Check the following items once every 4 years (15,360 hours).
Item
1
2.9
Check items
Check points
Replace the mechanical unit cable
Replace mechanical unit cable. (See Chapter 8.)
MAINTENANCE TOOLS
The following tools and instruments are required for the maintenance procedures contained in this manual.
1)
Measuring instruments
Instruments
Dial gauge accuracy
Slide calipers
Push/pull tension gauge
2)
Accuracy/Capacity
1/100 mm accuracy
150 mm capacity
98N (10 kgf) accuracy
Tools
Cross-point (+) screwdrivers:
Conventional (-) screwdrivers:
Box screw drivers:
Hex key set:
T-shaped hexagonal wrench:
Torque wrenches for hexagonal:
Monkey spanner:
Monkey spanner torque:
Socket wrenches:
Socket torque wrenches:
Separator
Gear puller
Taper reamer
Pliers
Applications
Measurement of positioning and backlash
Measurement of backlash
Large, medium, and small sizes
Large, medium, and small sizes
M6 (Grease nipple)
Width across flats 2.5, 3, 5, 6, 8, 10, 12, 14,17 (For
replacing parts)
M6
Width across flats 5, 6, 8, 10, 12, 14,17 (For replacing
parts)
Medium and small sizes
8 mm and 24 mm wide across wrenches flats (those usable
for the torque settings listed in Table 2.6 (b))
Sockets M5, M10, and M20
Sockets M5, M10, and M20
- 12 -
MAINTENANCE
B-81995EN/06
2.PREVENTIVE MAINTENANCE
Long-nose pliers
Diagonal cutting pliers
Grease gun
Flashlight
Oil seal press-fit fixture (for J3-axis reducer) (Fig.2.9)
(
(400S)
,
C1
A
5
95
5
30°
( 4 )
(400S)
18
(400S)
(O 73 )
(O 65 )
O 75
O 80
O 85
O 110
(400S)
5
X903
8511013
MARKING
刻印"X903,8511013"
SECTION A-A
SECTION
断面
Fig.2.9 Oil seal press-fit fixture (for J3-axis reducer)
- 13 -
A
,
)
3.PERIODIC MAINTENANCE
MAINTENANCE
B-81995EN/06
3
PERIODIC MAINTENANCE
3.1
REPLACING GREASE OF THE DRIVE MECHANISM
Replace the grease of the reducers of J1, J2, J3, and J4 axes, every three years or 11,520 hours by using the
following procedures.
Table 3.1 (a) Grease for 3-year periodical replacement
Models
Supply position
Grease name
M-410iB/160
M-410iB/300
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
Kyodo yushi
VIGOGREASE RE0
Spec.:
A98L-0040-0174
NOTE
Quantity
6990g (8030ml)
1370g (1570ml)
1030g (1180ml)
1220g (1400ml)
Gun tip
pressure
0.15 MPa or
less (NOTE)
When using a hand pump, apply grease approximately once per 1.5 seconds.
For grease replacement or replenishment, use the postures indicated below.
Table 3.1 (b) Postures for greasing
Robot
Supply position
M-410iB/160
M-410iB/300
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
Posture
J1
J2
J3
J4
-
100º
-125º
0º
NOTE
In a high-duty environment where, for example, a cooling unit (fan) is used, grease
must be replaced every half the specified standard period.
1
2
3
4
5
6
CAUTION
If greasing is performed incorrectly, the internal pressure of the grease bath may
suddenly increase, possibly causing damage to the seal, which would in turn lead
to grease leakage and abnormal operation. When performing greasing, therefore,
observe the following cautions.
Before starting to grease, open the grease outlet (remove the plug or bolt from the
grease outlet).
Supply grease slowly without applying excessive force, using a manual pump.
Whenever possible, avoid using a compressed-air pump, powered by the factory
air supply.
Even when using a compressed-air pump unavoidably, set the gun tip pressure
(see Table 3.1 (a).) to 0.15MPa or less during application of grease.
Use grease only of the specified type. Grease of a type other than that specified
may damage the reducer or lead to other problems.
After applying grease, release the remaining pressure within the grease bath as
described in the procedure in Section 3.2.
To prevent accidents caused by slipping, completely remove any excess grease
from the floor or robot.
- 14 -
B-81995EN/06
MAINTENANCE
3.PERIODIC MAINTENANCE
CAUTION
7 If no old grease is pushed out from the grease outlet soon or if only an extremely
small amount of old grease is pushed out when new grease is supplied into the
grease inlet, it is likely that grease is leaking because of a damaged sealing or a
similar break.
3.1.1
Grease Replacement Procedure of M-410iB/160, 300
Grease replacement procedure for the J1-axis, J2-axis, J3-axis, and J4-axis reducers
CAUTION
Be careful not to confuse the grease inlet of the J4-axis reducer with the grease
inlet of the wrist link bearing in Fig. 3.3 (c) of Section 3.3 because they are close to
each other.
1
2
3
4
5
Move the robot to the greasing posture described in Section 3.1.
Turn off the controller power.
Remove the seal bolt shown the Fig. 3.1.1 (a), (b), and (c) from the grease outlet.
Supply new grease until new grease is output from the grease outlet.
After applying grease, release the remaining pressure within the grease bath as described in the
procedure in Section 3.2.
J1-axis reducer
grease outlet
M6X8(Seal bolt)
J1-axis reducer
grease inlet
Grease nipple
Fig.3.1.1 (a) Replacing grease of J1-axis reducer
- 15 -
3.PERIODIC MAINTENANCE
MAINTENANCE
B-81995EN/06
J2-axis reducer
grease outlet
M6X8 (Seal bolt)
J2-axis reducer
grease inlet
Grease nipple
Fig.3.1.1 (b) Replacing grease of J2-axis reducer
J3-axis reducer
grease outlet
M6X8 (seal bolt)
J3-axis reducer
grease inlet
Grease nipple
Fig.3.1.1 (c) Replacing grease of J3-axis reducer
- 16 -
3.PERIODIC MAINTENANCE
MAINTENANCE
B-81995EN/06
J4-axis reducer
grease inlet
Grease nipple
J4-axis reducer
grease outlet
Taper plug Rc1/8
Fig.3.1.1 (d) Replacing grease of J4-axis reducer
3.2
PROCEDURE FOR RELEASING REMAINING PRESSURE
WITHIN THE GREASE BATH
To release the remaining pressure in the grease bath after applying grease, operate the robot for 20 minutes
or more as described in the table below with the grease nipple of the grease inlet and the seal bolt of the
grease outlet left open for the J1-axis reducer and J4-axis reducer, and the seal bolt of the grease outlet left
open for the J2-axis reducer and J3-axis reducer.
Attach the reclaim bags under the grease inlet and grease outlet to prevent spilled grease from splattering.
Operating axis
Grease
replacement part
J1-axis
J1-axis reducer
Axis angle of 80° or
more
OVR 50%
J2-axis reducer
Arbitrary
J3-axis reducer
J4-axis reducer
J2-axis
J3-axis
J4-axis
Arbitrary
Axis angle of 90° or
more
OVR 50%
Arbitrary
Axis angle of 60° or
more
OVR 100%
Arbitrary
Arbitrary
Arbitrary
Axis angle of 60° or
more
OVR 100%
If the above operations cannot be performed due to local circumstances, the same count operation is
necessary. (When only an axis angle of 30° can be set instead of 60°, perform the operation for 40 minutes,
which is double the specified time of 20 minutes.)
When multiple axes are greased at the same time, the axes can be run at the same time.
After the above operation is performed, attach the grease nipple to the grease inlet and the seal bolt to the
grease outlet. When the seal bolt or grease nipple is reused, be sure to seal it with seal tape.
- 17 -
3.PERIODIC MAINTENANCE
3.3
MAINTENANCE
B-81995EN/06
SUPPLYING GREASE
Be sure to supply grease to the machine at the timing (cumulative operation time or period whichever
earlier) specified in Table 3.3 (a). Adjust the greasing timing if your robot is installed in an adverse
environment. Supply grease immediately if water is splashed to the robot. When supplying grease, observe
the precautions described in Section 3.1. Table 3.3 (a), Fig. 3.3 (a), and Fig. 3.3 (b) indicate the parts of the
robot to be greased. Table 3.3 (b) lists alternative greases.
NOTE
If the robot is used at the high-duty that requires a cooling unit (fan), shorten the
standard greasing cycle to half.
Table 3.3 (a) Greasing
Robot
model
Supply position
Specified grease
J3 arm connecting
position bearing
greasing point
Greasing
method
Cumulative
operation time
(duration)
Supply grease
through a
grease nipple.
11520 hours
(3 years)
Amount of
grease
20ml
(Two points)
J3-axis base cross
M-410iB/160
SHELL ALVANIA GREASE S2
roller bearing
M-410iB/300
(Spec.: A97L–0001–0179#2) 20ml
connecting
position
Wrist connecting
position bearing
10ml
(Two points)
NOTE
After grease is supplied, old grease is pushed out from the bearing's rotating
section. Wipe off the old grease immediately after greasing and when required
after operations of 50 to 100 hours since the greasing.
Table 3.3 (b) Substitutes for ALVANIA GREASE S2
MOBIL OIL
ESSO STANDARD
JX Nippon Oil & Energy Corporation
JX Nippon Oil & Energy Corporation
IDEMITSU KOHSAN
COSMO OIL
Shell
MOBILACKS GREASE NO.2
VICON NO.2
NIPPON MITSUBISHI MULTINOC 2
EPNOC AP-2
EPONEX GREASE NO.2
DYNAMAX NO.2
Shell Gadus S2 V100 2
- 18 -
MAINTENANCE
B-81995EN/06
3.PERIODIC MAINTENANCE
Seal bolt (M6X8) at the bearing
grease outlet for J3 arm connecting
part
A
Detail A
Grease nipple at the
bearing grease inlet
for J3 arm connecting part
Fig.3.3 (a) Greasing for bearing J3 arm connection (2 points)
CAUTION
1 Before greasing, remove the stopper or seal bolt at the grease outlet.
2 Apply grease slowly with a manual pump.
Grease nipple at the
cross roller bearing
greasing point for
connecting J3 base
Fig.3.3 (b) Greasing for cross roller bearing J3 base
- 19 -
3.PERIODIC MAINTENANCE
MAINTENANCE
B-81995EN/06
Grease nipple at the bearing
greasing point for wrist connecting part
Grease nipple at the bearing
greasing point for wrist connecting part
Fig.3.3 (c) Greasing for bearing wrist connection (2 points)
3.4
REPLACING THE BATTERIES
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every
1.5 years. 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 robot motion.
CAUTION
Replacing the batteries with the power supply turned off causes all current position
data to be lost. Therefore, mastering will be required again.
2
3
4
5
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.
RM2
RM1
RP1
AIR11
AIR21
AS1
Remote type controller
Integrated type controlller
Battery spec. : A98L-0031-0005
(D size (alkali), 4 pcs)
Case cap
電池の交換(1年に1回)は,NCの
電源を入れた状態で行なって下さい.
交換用電池にはアルカリ-マンガン
乾電池(AM1)を使用して下さい.
Battery case
Wｈｅｎ ｒｅｐｌａｃｉｎｇ ｂａｔｔｅｒｉｅｓ(ｏｎｃｅ ａ ｙｅａｒ)
ｂｅ ｓｕｒｅ ｔｈａｔ ｔｈｅ ｃｏｎｔｒｏｌ ｐｏ ｗｅｒ ｉｓ ｏｎ.
Oｎｌｙ ｔｈｅ ａｌｋａｌｉｎｅ ｍａｎｇｎｅｓｅ ｄｉｏｘｉｄｅ
ｂａｔｔｅｒｉｅｓ(AM1) ｓｈｏｕｌｄ ｂｅ ｕｓｅｄ.
Fig.3.4 Replacing batteries
- 20 -
MAINTENANCE
B-81995EN/06
4
TROUBLE SHOOTING
4.1
GENERAL
4.TROUBLE SHOOTING
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems
may become further complicated, if they are not corrected properly. Therefore, it is necessary to keep an
accurate record of problems and to take proper corrective actions.
4.2
FAILURES, CAUSES AND MEASURES
Table 4.2 (a) lists the major failures, causes and measures that may occur in the mechanical unit and their
probable causes. If you cannot pinpoint a failure cause or which measures to apply, contact FANUC.
Symptom
Vibration
Noise
Table 4.2 (a) Failures, causes and measures
Description
Cause
-The J1 base lifts off the floor
plate as the robot operates.
-There is a gap between the J1
base and floor plate.
-A J1 base retaining bolt is
loose.
-Apply epoxy to the floor surface
and re-install the plate.
-Vibration becomes more
serious when the robot adopts a
specific posture.
-If the operating speed of the
robot is reduced, vibration
stops.
-Vibration is most noticeable
when the robot is accelerating.
-Vibration occurs when two or
more axes operate at the same
time.
[J1 base fastening]
-It is likely that the robot J1 base
is not securely fastened to the
floor plate.
-Probable causes are a loose
bolt, an insufficient degree of
surface flatness, or foreign
material caught between the
J1-base plate and floor plate.
-If the robot is not securely
fastened to the floor plate, the
J1 base lifts the floor plate as
the robot operates, allowing the
base and floor plates to strike
each other that, in turn, lead to
vibration.
[Rack or floor]
-It is likely that the rack or floor is
not sufficiently rigid.
-If the rack or floor is not
sufficiently rigid, reaction from
the robot deforms the rack or
floor, leading to vibration.
[Overload]
-It is likely that the load on the
robot is greater than the
maximum rating.
-It is likely that the robot control
program is too demanding for
the robot hardware.
- 21 -
Measure
-If a bolt is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Adjust the floor plate surface
flatness to within the specified
tolerance.
-If there is any foreign material
between the J1 base and floor
plate, remove it.
-Reinforce the rack or floor to
make it more rigid.
-If it is impossible to reinforce
the rack or floor, modify the
robot control program; doing so
might reduce the amount of
vibration.
-Check the maximum load that
the robot can handle once more.
If the robot is found to be
overloaded, reduce the load, or
modify the robot control
program.
-Vibration in a specific portion
can be reduced by modifying the
robot control program while
slowing the robot and reducing
its acceleration (to minimize the
influence on the entire cycle
time).
4.TROUBLE SHOOTING
Symptom
Vibration
Noise
(Continued)
Description
-Vibration or noise was first
noticed after the robot collided
with an object or the robot was
overloaded for a long period.
-The grease of the vibrating or
noise occurring axis has not
been exchanged for a long
period.
MAINTENANCE
Cause
[Broken gear, bearing, or
reducer]
- It is likely that collision or
overload applied an excessive
force on the drive mechanism,
thus damaging the geartooth
surface or rolling surface of a
bearing, or reducer.
- It is likely that prolonged use of
the robot while overloaded
caused fretting of the gear tooth
surface or rolling surface of a
bearing, or reducer due to
resulting metal fatigue.
- It is likely that foreign material
caught in a gear, bearing, or
within a reducer caused damage
on the gear tooth surface or
rolling surface of the bearing, or
reducer.
- It is likely that foreign material
caught in a gear, bearing, or
within a reducer cause vibration.
- It is likely that, because the
grease has not been changed
for a long period, fretting
occurred on the gear tooth
surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate cyclic
vibration and noise.
- 22 -
B-81995EN/06
Measure
-Operate one axis at a time to
determine which axis is
vibrating.
-Find the source of the vibration
while referring to the drive
mechanism drawing of each
axis given in the related
maintenance manual.
-Remove the motor, and check
whether there are any fretting
on a gear tooth surface. If any
fretting is found, replace the
gear.
Note) Even a small amount of
damage on a gear tooth
surface can generate a large
amount of noise. Therefore, it
is necessary to check each
gear tooth surface carefully.
-Check whether any other gear
in the drive mechanism is
abnormal. If all the gears are
found to be satisfactory, the
reducer must be replaced.
-If there is foreign material
caught in a gear, or if a gear
tooth is missing, replace the
gear. Also, remove all the
grease from the gearbox and
wash the inside of the gearbox.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-If nothing changes after a gear
or reducer is replaced, it is
likely that a bearing is
damaged.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
Regularly
changing the grease with a
specified type can help prevent
problems.
MAINTENANCE
B-81995EN/06
Symptom
Vibration
Noise
(Continued)
Description
Cause
-The cause of problem cannot
be identified from examination
of the floor, rack, or mechanical
section.
[Controller, cable, and motor]
-If a failure occurs in a controller
circuit, preventing control
commands from being supplied
to the motor normally, or
preventing motor information
from being sent to the controller
normally, vibration might occur.
-If the Pulsecoder develops a
fault, vibration might occur
because information about the
motor position cannot be
transferred to the controller
accurately.
-If the motor becomes defective,
vibration might occur because
the motor cannot deliver its
rated performance.
-If a power line in a movable
cable of the mechanical section
has an intermittent break,
vibration might occur because
the motor cannot accurately
respond to commands.
-If a Pulsecoder wire in a
movable part of the mechanical
section has an intermittent
break, vibration might occur
because commands cannot be
sent to the motor accurately.
-If a connection cable between
them has an intermittent break,
vibration might occur.
-If the power source voltage
drops below the rating, vibration
might occur.
-If a robot control parameter is
set to an invalid value, vibration
might occur.
- 23 -
4.TROUBLE SHOOTING
Measure
-Refer to the controller
Maintenance Manual for
troubleshooting related to the
controller and amplifier.
-Replace the Pulsecoder for the
motor of the axis that is
vibrating, and check whether the
vibration still occurs.
-Also, replace the motor of the
axis that is vibrating, and check
whether vibration still occurs.
For the method of replacement,
contact FANUC.
-Check that the robot is supplied
with the rated voltage.
-Check whether the sheath of
the power cord is damaged. If
so, replace the power cord, and
check whether vibration still
occurs.
-Check whether the sheath of
the cable connecting the
mechanical section and
controller is damaged. If so,
replace the connection cable,
and check whether vibration still
occurs.
-If vibration occurs only when
the robot assumes a specific
posture, it is likely that a cable in
the mechanical unit is broken.
-Shake the movable part cable
while the robot is at rest, and
check whether an alarm occurs.
If an alarm or any other
abnormal condition occurs,
replace the mechanical unit
cable.
-Check that the robot control
parameter is set to a valid value.
If it is set to an invalid value,
correct it. Contact FANUC for
further information if necessary.
4.TROUBLE SHOOTING
Symptom
Vibration
Noise
(Continued)
Description
-There is some relationship
between the vibration of the
robot and the operation of a
machine near the robot.
-There is an unusual sound after
replacement of grease.
-There is an unusual sound after
a long period.
-There is an unusual sound
during operation at low speed.
Rattling
MAINTENANCE
-While the robot is not supplied
with power, pushing it with the
hand causes part of the
mechanical unit to wobble.
-There is a gap on the mounting
surface of the mechanical unit.
Cause
[Noise from a nearby machine]
-If the robot is not grounded
properly, electrical noise is
induced on the grounding wire,
preventing commands from
being transferred accurately,
thus leading to vibration.
-If the robot is grounded at an
unsuitable point, its grounding
potential becomes unstable,
and noise is likely to be induced
on the grounding line, thus
leading to vibration.
-There may be an unusual
sound when using other than the
specified grease.
-Even for the specified grease,
there may be an unusual sound
during operation at low speed
immediately after replacement
or after a long period.
[Mechanical section coupling
bolt]
-It is likely that overloading or a
collision has loosened a
mounting bolt in the robot
mechanical section.
- 24 -
B-81995EN/06
Measure
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
-Use the specified grease.
-When there is an unusual
sound even for specified
grease, perform operation for
one or two days on an
experiment. Generally, a usual
sound will disappear.
-Check that the following bolts
for each axis are tight. If any of
these bolts is loose, apply
LOCTITE and tighten it to the
appropriate torque.
-Motor retaining bolt
-Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-Arm retaining bolt
-Casting retaining bolt
-End effecter retaining bolt
MAINTENANCE
B-81995EN/06
Symptom
Description
Cause
Rattling
(Continued)
-Backlash is greater than the
tolerance stated in the
applicable maintenance
manual.
[Increase in backlash]
-It is likely that excessive force
applied to the drive mechanism,
due to a collision or overloading,
has broken a gear or the inside
of the reducer, resulting in an
increase in the amount of
backlash.
- It is likely that prolonged use in
overload conditions has caused
the tooth surfaces of a gear and
the reducer to wear out,
resulting in an increase in the
amount of backlash.
-It is likely that prolonged use
without changing the grease has
caused the tooth surfaces of a
gear and the inside of the
reducer to wear out, resulting in
an increase in the amount of
backlash.
Motor
overheating
-The ambient temperature of the
installation location increases,
causing the motor to overheat.
-After a cover was attached to
the motor, the motor
overheated.
-After the robot control program
or the load was changed, the
motor overheated.
[Ambient temperature]
-It is likely that a rise in the
ambient temperature or
attaching the motor cover
prevented the motor from
releasing heat efficiently, thus
leading to overheating.
[Operating condition]
-It is likely that the robot was
operated with the maximum
average current exceeded.
- 25 -
4.TROUBLE SHOOTING
Measure
-Operate one axis at a time to
determine which axis has the
increased backlash.
-Remove the motor, and check
whether any of its gears are
broken. If any gear is broken,
replace it.
-Check whether any other gear
of the drive mechanism is
damage. If there is no damage
gear, replace the reducer.
-If the reducer is broken, or if a
gear tooth is missing, replace
the relevant component. Also,
remove all the grease from the
gearbox and wash the inside of
the gearbox.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the robot within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
The teach pendant can be used
to monitor the average current.
Check the average current when
the robot control program is
running. The allowable average
current is specified for the robot
according to its ambient
temperature. Contact FANUC
for further information.
-Relaxing the robot control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of the
motor well ventilated enables
the motor to release heat
efficiently, thus preventing
overheating. Using a fan to
direct air at the motor is also
effective.
-If there is a source of heat near
the motor, it is advisable to
install shielding to protect the
motor from heat radiation.
4.TROUBLE SHOOTING
Symptom
Motor
overheating
(Continued)
B-81995EN/06
Description
Cause
Measure
-After a control parameter was
changed, the motor overheated.
[Parameter]
-If data input for a workpiece is
invalid, the robot cannot be
accelerated or decelerated
normally, so the average current
increases, leading to
overheating.
[Mechanical section problems]
-It is likely that problems
occurred in the mechanical unit
drive mechanism, thus placing
an excessive load on the motor.
[Motor problems]
-It is likely that a failure of the
motor brake resulted in the
motor running with the brake
applied, thus placing an
excessive load on the motor.
-It is likely that a failure of the
motor prevented it from
delivering its rated performance,
thus causing an excessive
current to flow through the
motor.
[Poor sealing]
-Probable causes are a crack in
the casting, a broken O-ring, a
damaged oil seal, or a loose
seal bolt.
-A crack in a casting can occur
due to excessive force that
might be caused in collision.
-An O-ring can be damaged if it
is trapped or cut during
disassembling or
re-assembling.
-An oil seal might be damaged if
extraneous dust scratches the
lip of the oil seal.
-A loose seal bolt might allow
grease to leak along the
threads.
-Problems with the grease
nipple or threads.
-Input an appropriate parameter
as described in CONTROLLER
OPERATOR’S MANUAL.
-Symptom other than stated
above
Grease
leakage
MAINTENANCE
-Grease is leaking from the
mechanical unit.
- 26 -
-Repair the mechanical unit
while referring to the above
descriptions of vibration, noise,
and rattling.
-Check that, when the servo
system is energized, the brake
is released.
If the brake remains applied to
the motor all the time, replace
the motor.
-If the average current falls after
the motor is replaced, it
indicates that the first motor was
faulty.
-If a crack develops in the
casting, sealant can be used as
a quick-fix to prevent further
grease leakage. However, the
component should be replaced
as soon as possible, because
the crack might extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer (case and shaft)
coupling section
-Wrist coupling section
-J3 arm coupling section
-Inside the wrist
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Inside the wrist
-Seal bolts are used in the
locations stated below.
-Grease drain outlet
-Replace the grease nipple.
MAINTENANCE
B-81995EN/06
Symptom
Description
Dropping axis -An axis drops because the
brake does not function.
-An axis drops gradually when it
should be at rest.
Displacement -The robot operates at a point
other than the taught position.
-The repeatability is not within
the tolerance.
-Displacement occurs only in a
specific peripheral unit.
-Displacement occurred after a
parameter was changed.
BZAL alarm
occurred
-BZAL is displayed on the
controller screen
4.TROUBLE SHOOTING
Cause
Measure
[Brake drive relay and motor]
-It is likely that brake drive relay
contacts are stuck to each other
to keep the brake current
flowing, thus preventing the
brake from operating when the
motor is deenergized.
-It is likely that the brake shoe
has worn out or the brake main
body is damaged, preventing
the brake from operating
efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
[Mechanical section problems]
-If the repeatability is unstable,
probable causes are a failure in
the drive mechanism or a loose
bolt.
-If the repeatability becomes
stable, it is likely that a collision
imposed an excessive load,
leading to slipping on the base
surface or the mating surface of
an arm or reducer.
-It is likely that the Pulsecoder is
abnormal.
[Peripheral unit displacement]
-It is likely that an external force
was applied to the peripheral
unit, thus shifting its position
relative to the robot.
[Parameter]
-It is likely that the mastering
data was rewritten in such a way
that the robot origin was shifted.
-Check whether the brake drive
relay contacts are stuck to each
other. If they are found to be
stuck, replace the relay.
-If the brake shoe is worn out, if
the brake main body is
damaged, or if oil or grease has
entered the motor, replace the
motor.
-The voltage of the memory
backup battery may be low.
-The Pulsecoder cable may be
broken.
- 27 -
-If the repeatability is unstable,
repair the mechanical section by
referring to the above
descriptions of vibration, noise,
and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the Pulsecoder is abnormal,
replace the motor or the
Pulsecoder.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
-Re-enter the previous
mastering data, which is known
to be correct.
-If correct mastering data is
unavailable, perform mastering
again.
-Replace the battery.
-Replace the cable.
4.TROUBLE SHOOTING
4.3
MAINTENANCE
B-81995EN/06
BACKLASH MEASUREMENT
Measurement method
1.
2.
3.
Maintain the robot in a specified posture. (See Table 4.3 (a) and (b).)
Apply positive and negative loads to each axis as shown in Fig. 4.3 (a).
Remove the loads and measure the displacement.
Calculate the backlash using the following expression.
Stop position
0
+10kgf
Firtst step
(Do not measure)
-10kgf
+10kgf
L1
-10kgf
Second step
(B2 =L1+ L2)
0kgf
f
L2
+10kgf
Third step
(B3=L3+ L4)
0kgf
L3
-10kgf
0kgf
L4
Fig.4.3 (a) Backlash measurement method
Backlash B is represented by the following expression.
B=
NOTE
Use dial gauge and push-pull gauge.
- 28 -
B2 + B3
2
4.TROUBLE SHOOTING
MAINTENANCE
B-81995EN/06
Measurement position
<1> J1-axis measurement posture
<3> J3-axis measurement posture
Center of wrist
mounting part
end effector
end effector
Trestle
Loading position
When measuring backlash,press
gauge to test work vertically.
3067
end effector
Trestle
Center of mounting
face of wrist
Loading position
When measuring backlash,press
gauge to test work vertically.
<4> J4-axis measurement posture
<2> J2-axis measurement posture
Trestle
When measuring backlash,press
gauge to test work vertically.
end
effector
[Standard trestle]
Loading position
230
end effector
280
Trestle
Loading position
Gauge
56
When measuring backlash,press
gauge to test work vertically.
Gauge
138
[M-410iB/160]
[M-410iB/300]
Fig.4.3 (b) Backlash measurement posture
Table.4.3 (a) Measurement posture and tolerance value of backlash (M-410iB/160)
Measured axis
J1-axis
J2-axis
J3-axis
J4-axis
J1-axis
-30º
-44.5º
-33º
-35.5º
Posture
J2-axis
J3-axis
88º
-13º
0º
-52º
48º
-90º
35º
-66º
J4-axis
-90º
-90º
0º
-98º
Tolerance
value (mm)
1.74
0.85
0.85
0.18
Table.4.3 (a) Measurement posture and tolerance value of backlash (M-410iB/300)
Measured axis
J1-axis
J2-axis
J3-axis
J4-axis
J1-axis
-29.5º
-45º
-33º
-35.5º
Posture
J2-axis
J3-axis
81º
-10º
0º
-58º
41º
-90º
30º
-66º
J4-axis
-90º
-90º
0º
-98º
Tolerance
value (mm)
1.44
0.69
0.79
0.25
NOTE
When measuring backlash under circumstances where the distance between the
rotation center and the dial gauge or is different from those in the above table, make
angle and displacement conversions according to the table.
- 29 -
5.ADJUSTMENTS
5
MAINTENANCE
B-81995EN/06
ADJUSTMENTS
Each part of the mechanical unit is carefully adjusted at the factory before shipment. Therefore, it is usually
unnecessary for the customer to make adjustments at the time of delivery. However, after a long period of
use or after parts are replaced, adjustments may be required.
5.1
Zero point position and motion limit
Zero point and motion limits are provided for each controlled axis. Reaching the operation limit of
controlled axis is called overtravel (OT). Overtravel is detected at J1-axis only (option). Overtravel
detection function is not prepared at J2-axis to J4 axis.
The robot cannot exceed the motion range unless there is a failure of the system causing loss of the
zero point position, or there is a system error.
Fig. 5.1 (a) shows the zero point, motion limit OT detection point and point of mechanical stopper of
J1-axis.
180°
180°
1)
ADJUSTING LIMIT SWITCHES AND DOGS (OPTION)
Mechanical
stopper
-180°
Mechanical
stopper
OT (option)
+180°
1°
2.5°
OT (option)
1°
2.5°
Fig. 5.1 (a) Zero point and motion limit of J1-axis
2)
How to adjust the J1-axis limit switch
1. Set the $MOR_GRP.$CAL_DONE system parameter to FALSE. This disables the stroke end
specified by the software. As a result, the operator can rotate the robot around the J1-axis by a jog
feed which goes beyond the stroke end.
2. Loosen the two M6×10 bolts and two M4×25 bolts that secure the J1-axis limit switch.
- 30 -
MAINTENANCE
B-81995EN/06
3.
4.
5.
6.
7.
5.ADJUSTMENTS
Adjust the switch position so that the robot activates the limit switch when approximately 1.0
degree from each stroke end. When the dog is pressed, only one side of the pushing width
indication lines on the end of the switch must be hidden.
When the limit switch operates and detects overtravel (OT), the robot stops, and an error message,
"OVERTRAVEL", is displayed. To restart the robot, hold on the SHIFT key and press the
RESET key. Then, while holding on the SHIFT key, release the J1 axis from the limit by JOG
feed.
Check that the robot also activates the limit switch when the robot is approx. 1.0 degree from the
opposite stroke end in the same way as above. If the limit switch does not operate at the position,
adjust the position of the switch again.
Set the $MOR_GRP.$CAL_DONE system parameter to TRUE.
Turn off the power, then turn it on again to restart the controller.
Service coverage restriction dog
Limit switch retaining bolt
M4×25
Washer
(horizontal position adjustment)
J1-axis +180°
Idle stroke setting
indication
Make an adjustment so that
only this line is hidden.
J1-axis -180°
Idle stroke setting indication line
Fig. 5.1 (b) Adjusting J1-axis OT (option)
- 31 -
Limit switch retaining bolt
M6×10
Washer
(vertical position adjustment)
5.ADJUSTMENTS
5.2
MAINTENANCE
B-81995EN/06
ZERO POINT POSITION AND MOTION LIMIT OF J2-AXIS
TO J4-AXIS
Fig. 5.2 (a) to (c) show zero point position and motion area and mechanical stopper of each axis.
Stroke 144º
Mechanical
Mechanical
Fig. 5.2 (a) J2-axis
Mechanical stopper
J2-axis arm
J3-axis arm
Mechanical
stopper
Stroke 136°
Nearest
angle
between
J2-axis and J3-axis
Fig. 5.2 (b) J3-axis
- 32 -
5.ADJUSTMENTS
MAINTENANCE
B-81995EN/06
Note)
J4-axis does not have the mechanical
Fig. 5.2 (c) J4-axis
Fig.5.2 (d) shows the position of mechanical stopper. Only in case of J1-axis, robot stops by transforming
mechanical stopper. Only in case of J1 axis, robot stops by transforming mechanical stopper. Be sure to
exchange transformed stopper to new one. Tight the bolts according to Appendix. Replace mechanical
stopper of J1- axis referring to Fig.5.2 (d). Don’t reconstruct the mechanical stopper. There is a possibility
that the robot doesn't stop normally.
J2/J3-axis interference angle
mechanical stopper
(plus side)
J2/J3-axis interference angle
mechanical stopper
(minus side)
J2-axis
mechanical stopper
(minus side)
J1-axis mechanical
stopper
(Fixed side)
J2-axis
mechanical stopper
(plus side)
J1-axis mehcanical stopper
(Common to plus side and minus side)
Spec. ：A290-7041-X312
Bolt M12X30 (5)
Washer (5)
J3-axis
mechanical stopper
(minus side)
J3-axis
mechanical stopper
(plus side)
Fig.5.2 (d) Position of mechanical stopper
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5.ADJUSTMENTS
5.3
MAINTENANCE
B-81995EN/06
J1-AXIS STROKE MODIFICATION (OPTION)
The J1-axis stroke can be limited depending on the operating environment of the robot. The stroke can be
changed by changing the locations of the dog and mechanical stopper and the settings of the parameters
using the following procedure. (See Fig. 5.3 (a) to (b) and Table 5.3)
The stroke can be changed every 45 degrees in the upper limit of +45 degrees to + 180 degrees and the lower
limit of -180 degrees to -45 degrees.
Front of Robot
Note) Standard stroke
-180° to +180°
Modification of stroke
lower limit
Upper limit
Fig. 5.3 (a) Modifying J1-axis stroke (option)
(a) Changing the mechanical stopper and the dog (option) position.
Change the mechanical position and the dog position as shown in Fig. 5.3 (b).
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MAINTENANCE
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5.ADJUSTMENTS
Pendulum stopper
振り子ストッパ
Motion range
stopper
動control
作範囲
規制用
Mounting bolt
ストッパ固定
M16×45
ボルト
washer
M16×45
シ
Motion range
動作範囲規制用
control stopper
ストッパ
Limit switch
リミットスイッチ
Mechanical
機械的ストッパ
stopper
Negative-side
Stroke Limit
Positive-side stroke Limit
Fig. 5.3 (b) Modification of J1-axis stroke (option)
(b) Changing system variables
When changing the dog and mechanical stopper, also be sure to change the following system variables
according to the required strokes.
After changing system variables, turn the power off then back on again. (The stroke setting described
above can be made also by selecting "SYSTEM" using the "MENUS" key, then selecting "Axis limit"
menu using F1 (TYPE). Refer to the Controller Operator's Manual for details.
WARNING
After changing system variables, be sure to run the robot at a low speed and make
sure that the robot stops at the ends of the stroke.
Positions
-180º
-135º
-90º
-45º
0º
+45º
+90º
+135º
+180º
Table 5.3 Modification of system variable
System variable
Upper stroke limit
Lower stroke limit
$PARAM_GROUP.
$PARAM_GROUP
$UPPERLIMS[1]
$LOWERLIMS[1]
-180
-135
-90
-45
0
0
45
90
135
180
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5.ADJUSTMENTS
MAINTENANCE
B-81995EN/06
WARNING
1 If a collision should occur, the J1 axis stopper becomes deformed to absorb
energy, so that the robot can stop safely. If the stopper is deformed by mistake,
replace it.
2 Do not add threaded holes to the frame, or do not use a self-made stopper to
control the J1 stroke at any angle other than the one specified; otherwise, robot
operation may be dangerous.
5.4
SOFTWARE SETTING
Axis limit software settings are upper and lower motion degree limitations. The limits can be set for all
robot axes and will stop robot motion if the robot is calibrated.
Procedure Setting up Axis Limits
1
2
3
4
Press MENUS.
Select SYSTEM. Press [0 NEXT] and select [6 SYSTEM]
Press F1, [TYPE].
Select Axis Limits. You will see a screen similar to the following.
System Axis Limits
JOINT
100%
1/16
AXIS
1
2
3
4
5
6
7
8
9
[ TYPE ]
GROUP
1
1
1
1
1
1
0
0
0
LOWER
-150.00
-60.00
-110.00
-240.00
0.00
0.00
0.00
0.00
0.00
UPPER
150.00
75.00
50.00
240.00
0.00
0 00
0.00
0.00
0.00
dg
dg
dg
dg
mm
mm
mm
mm
mm
NOTE
0 indicates the robot does not have these axes.
5
Move the cursor to the axis limit you want to set.
CAUTION
Do not depend on J1 axis limit software settings to control the motion range of your
robot. Use the axis limit switches or hardstops also; otherwise, injury to personnel
or damage to equipment could occur.
6
7
Type the new value using the numeric keys on the teach pendant.
Repeat Steps 5 through 6 until you are finished setting the axis limits.
CAUTION
You must turn off the controller and then turn it back on to use the new information;
otherwise, injury to personnel or damage to equipment could occur.
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MAINTENANCE
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8
5.ADJUSTMENTS
Turn off the controller power and then turn it back on again in the cold start mode so the new
information can be used.
5.5
MASTERING
Mastering is an operation performed to associate the angle of each robot axis with the pulse count value
supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific, mastering
is an operation for obtaining the pulse count value corresponding to the zero position.
5.5.1
General
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering becomes necessary after:
Motor replacement.
Pulsecoder replacement.
Reducer replacement.
Cable replacement.
Batteries for pulse count backup in the mechanical unit have gone dead.
CAUTION
Robot data (including mastering data) and Pulsecoder data are backed up by their
respective backup batteries. Data will be lost if the batteries go dead. Replace the
batteries in the control and mechanical units periodically. An alarm will be issued to
warn the user of a low battery voltage.
Mastering method
Table 5.5.1 Types of mastering
Fixture position mastering
This is performed using a mastering fixture before the machine is shipped from the
factory.
Zero–position mastering (witness This is performed with all axes set at the 0-degree position. A zero-position mark
mark mastering)
(witness mark) is attached to each robot axis. This mastering is performed with all
axes aligned to their respective witness marks.
Quick mastering
This is performed at a user-specified position. The corresponding count value is
obtained from the rotation speed of the Pulsecoder connected to the relevant
motor and the rotation angle within one rotation. Quick mastering uses the fact that
the absolute value of a rotation angle within one rotation will not be lost.
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 controller reads the current pulse count value to sense the current position of the
robot.
CAUTION
If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. Therefore, 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.
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5.ADJUSTMENTS
MAINTENANCE
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NOTE
It is recommended that you back up the current mastering data before performing
mastering.
5.5.2
Resetting Alarms and Preparing for Mastering
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse not established”
Procedure
1
Display the positioning menu by following steps 1 to 6.
1
Press the screen selection key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4
Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER].
5
Press F1 [TYPE], and select[Master/Cal] from the menu.
6
Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
1
Press the screen selection key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press F1 [TYPE], and select [Master/Cal] from the menu.
4
Press the F3 RES_PCA, then press F4 [TRUE].
5
Turn off the controller power and on again
3
To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 3.
1
When the controller power is turned on again, the message “Servo 075 Pulse not established”
appears again.
2
Move the axis for which the message mentioned above has appeared till alarm disappears when
press [FAULT RESET] in either direction.
5.5.3
Fixture Position Master
Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the
predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering fixture is used.
Fixture position 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.
-
Make the robot mounting base horizontal within 1 mm. (Set the robot mounting surface so that the
levelness of the entire surface is 1 mm or less.)
Remove the hand and other parts from the wrist.
Set the robot in the condition protected from an external force.
5.5.3.1
Attaching the mastering fixture
(1) Assemble the fixture base as shown in Fig. 5.5.3.1 (a).
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5.ADJUSTMENTS
MAINTENANCE
B-81995EN/06
Bolt M6×20
Plate
Base
Plate
Bolt M6×20
Fig.5.5.3.1 (a) Assembling the fixture base
(2) Attach the fixture base to the robot as shown in Fig. 5.5.3.1 (b).
Hexagonal pin
((f16)
φ16)
Bolts
(M16 45)
(M16×45)
Parallel pin
(f16)
(φ16)
Robot
front
Note) Note the direction of a hexagonal pin.
Hexagonal pin ((f16)
φ16)
Fig.5.5.3.1 (b) Attaching the fixture base
(3) As shown in Fig. 5.5.3.1 (c), set the dial gauge to a reading of 3.00 mm, using a calibration block, and
fasten it with an M5 bolt.
CAUTION
Do not fasten the M5 bolt too firmly, because the dial gauge might break.
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5.ADJUSTMENTS
MAINTENANCE
B-81995EN/06
Bolt
M5×10
Calibration block
Fig.5.5.3.1 (c) Attaching a dial gauge
(4) Attach the fixture to the wrist as shown in Fig. 5.5.3.1 (d).
Bolt (M10×25, 4pcs)
Bolt (M10 25, 4 pcs)
Diamond
φ10)
Diamond pin
pin ((f10)
Round
Roundpin
pin (f10)
(φ10)
Note the
direction of a
diamond pin.
Fig.5.5.3.1 (d) Attaching the fixture to the wrist
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MAINTENANCE
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5.5.3.2
5.ADJUSTMENTS
Mastering
1)
2)
3)
4)
Press MENUS.
Press [0 NEXT] and select SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
5)
Release brake control, and jog the robot into a posture for mastering. See the Fig. 5.5.3.2 (a) and (b) for
the mastering posture.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM_GROUP.SV_OFF_ENB[*]: FALSE (for all axes)
After changing the system variables, turn off the controller power and on again.
6)
7)
8)
9)
Select Fixture Position Master.
Press F4, YES. Mastering will be performed automatically.
Alternatively, turn off the controller power and on again. Turning on the controller power always
causes positioning to be performed.
After positioning is completed, press F5 [DONE].
Return brake control to original setting, and turn off the controller power and on again.
CAUTION
No check is made on the axis movable range during mastering. Be very careful
when running the robot. Continuing axis movement may result in the mechanical
stopper being bumped.
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5.ADJUSTMENTS
MAINTENANCE
B-81995EN/06
AXIS
J1
J2
J3
J4
ANGLE
-12.326°
+53.072°
-111.983°
12.326°
Fig.5.5.3.2 (a) Posture for mastering
5.5.4
Zero Degree Mastering
Zero-position mastering (witness mark mastering) is performed with all axes set at the 0-degree position. A
zero-position mark (witness mark) is attached to each robot axis. This mastering is performed with all axes
set at the 0-degree position using their respective witness marks.
Zero-position mastering involves a visual check. It cannot be so accurate. It should be used only as a
quick-fix method.
Procedure Mastering to Zero Degrees
1
2
3
4
Press MENUS.
Select NEXT and press SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
5
Release brake control, and jog the robot into a posture for mastering.
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MAINTENANCE
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5.ADJUSTMENTS
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM GROUP.SV OFF ENB[*]: FALSE
(for all axes)
After changing the system variables, turn off the controller power and on again.
6
7
8
9
Select Zero Position Master.
Press F4, YES. Mastering will be performed automatically. Alternatively, turn off the controller
power and on again. Turning on the controller power always causes positioning to be performed.
After positioning is completed, press F5 [DONE].
Return brake control to original setting, and turn off the controller power and on again.
Axis
J1-axis
J2-axis
J3-axis
J4-axis
Table 5.5.4 Posture with position marks aligned
Position
M-410iB/160
0 deg
0 deg
0 deg
0 deg
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M-410iB/300
0 deg
0 deg
0 deg
0 deg
5.ADJUSTMENTS
MAINTENANCE
B-81995EN/06
J3-axis
J3
J4-axis
J2
J2-axis
J3-axis
J2-axis
J4-axis
J1-axis
J1-axis
Table 5.5.4 Posture with position marks aligned
5.5.5
Quick Mastering
Quick mastering is performed at a user-specified position. The corresponding count value is obtained from
the rotation speed of the Pulsecoder connected to the relevant motor and the rotation angle within one
rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not
be lost.
Quick mastering is factory-performed at the position indicated in Table 5.5.5. Do not change the setting
unless there is any problem.
If it is impossible to set the robot at the position mentioned above, it is necessary to re-set the quick
mastering reference position using the following method. (It would be convenient to set up a marker that
can work in place of the witness mark.)
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B-81995EN/06
MAINTENANCE
5.ADJUSTMENTS
CAUTION
1 Quick mastering can be used, if the pulse count value is lost, for example, because
a low voltage has been detected on the backup battery for the pulse counter.
2 Quick mastering cannot be used, after the Pulsecoder is replaced or after the
mastering data is lost from the robot controller.
Procedure Recording the Quick Mastering Reference Position
1
2
Select SYSTEM.
Select Master/Cal.
3
4
Release brake control, and jog the robot to the quick mastering reference position.
Move the cursor to SET QUICK MASTER REF and press ENTER. Press F4, YES.
Set quick master ref? [NO]
CAUTION
If the robot has lost mastery due to mechanical disassembly or repair, you cannot
perform this procedure. In this case, Fixture position mastering or zero –position
mastering to restore robot mastery.
Procedure Quick Mastering
1
Display the Master/Cal screen
2
3
Release brake control, and jog the robot to the quick mastering reference position.
Move the cursor to QUICK MASTER and press ENTER. Press F4, YES. Quick mastering data is
memorized.
Quick master? [NO]
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5.ADJUSTMENTS
4
5
6
MAINTENANCE
B-81995EN/06
Move the cursor to CALIBRATE and press ENTER. Calibration is executed. Calibration is executed
by power on again.
After completing the calibration, press F5 Done.
Return brake control to original setting, and turn off the controller power and on again.
5.5.6
Single Axis Mastering
Single axis mastering is performed for one axis at a time. The mastering position for each axis can be
specified by the user.
Single axis mastering can be used, if mastering data for a specific axis is lost, for example, because a low
voltage has been detected on the pulse counter backup battery or because the Pulsecoder has been replaced.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
25.255
25.550
-50.000
12.500
31.250
43.382
0.000
0.000
0.000
JOINT 30%
(MSTR POS)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
[ TYPE ]
Item
Current position
(ACTUAL POS)
Mastering position
(MSTR POS)
SEL
ST
1/9
[ST]
[2]
[2]
[2]
[2]
[2]
[2]
[2]
[2]
[2]
GROUP EXEC
Table 5.5.6 Items Set in Single Axis Mastering
Description
The current position of the robot is displayed for each axis in degree units.
A mastering position is specified for an axis to be subjected to single axis
mastering. It would be convenient to set to it to the 0ºposition.
This item is set to 1 for an axis to be subjected to single axis mastering.
Usually, it is 0.
This item indicates whether single axis mastering has been completed for
the corresponding axis. It cannot be changed directly by the user.
The value of the item is reflected in $EACHMST_DON (1 to 9).
0: Mastering data has been lost. Single axis mastering is necessary.
1: Mastering data has been lost. (Mastering has been performed only for the
other interactive axes.) Single axis mastering is necessary.
2: Mastering has been completed.
Procedure Mastering a Single Axis
1
2
(SEL)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
Select SYSTEM.
Select Master/Cal.
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MAINTENANCE
5.ADJUSTMENTS
3
Select 4, Single Axis Master. You will see a screen similar to the following.
4
5
6
Move the cursor to the SEL column for the unmastered axis and press the numeric key "1." Setting of
SEL is available for one or more axes.
Turn off brake control as required, then jog the robot to the mastering position.
Enter axis data for the mastering position.
7
Press F5 [EXEC]. Mastering is performed. Therefore, SEL is reset to 0, and ST is re-set to 2 or 1.
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5.ADJUSTMENTS
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8
When single axis mastering is completed, press the previous page key to resume the previous screen.
9
10
Select [6 CALIBRATE], then press F4 [YES]. Positioning is performed.
Alternatively, turn off the controller power and on again. Positioning is performed.
After positioning is completed, press F5 [DONE].
11
Return brake control to original setting, and turn off the controller power and on again.
5.5.7
Mastering Data Entry
This function enables mastering data values to be assigned directly to a system variable. It can be used if
mastering data has been lost but the pulse count is preserved.
Mastering data entry method
1
2
Press MENUS, then press NEXT and select SYSTEM.
Press F1, [TYPE]. Select [Variables]. The system variable screen appears.
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B-81995EN/06
MAINTENANCE
5.ADJUSTMENTS
3
Change the mastering data.
The mastering data is saved to the $DMR_GRP.$MASTER_COUN system variable.
4
Select $DMR_GRP.
5
Select $MASTER_COUN, and enter the mastering data you have recorded.
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5.ADJUSTMENTS
MAINTENANCE
6
7
Press the PREV key.
Set $MASTER_DONE to TRUE.
8
9
Display the positioning screen, and select [6 CALIBRATE], then press F4 [YES].
After completing positioning, press F5 [DONE].
5.6
1
B-81995EN/06
CHECKING THE MASTERING
Checking whether mastering has been made correctly
Usually, positioning is performed automatically at power-on. To check whether mastering has been
made correctly, note whether the displayed current position agrees with the actual robot position. Use
the procedure described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0rad) positions. Check that the zero-degree position
marks indicated in Subsection 5.5.4 are aligned. There is no need to use any visual aid.
(3) Using fixtures, set the robot to the mastering position in the same way as when performing
mastering. Check that the displayed current position agrees with the actual mastering position.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described below 2. Alternatively, the mastering data in system
variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation error
or some other reason.
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MAINTENANCE
5.ADJUSTMENTS
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value of
the system variable on the data sheet.
2
Alarms that may be output during mastering and remedy for it
(1) BZAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery falls to 0 V while the power
to the controller is disconnected. Also, if Pulsecoder connector is removed for replacing cables
etc. this alarm is output because voltage becomes to 0. To clear the alarm, fit a new battery,
execute the pulse reset (See Subsection 5.5.2.), then turn the power off then on again and confirm
alarm is not output.
Battery might be weak if you can’t reset alarm, then replace battery to new one , perform pulse
reset , turn off and on the controller power.Note that, if this alarm occurs, all data originally held
by the Pulsecoder will have been lost. Mastering must be performed again.
(2) BLAL alarm
This alarm is output if the voltage of the Pulsecoder's backup battery has fallen to a level where
backup is no longer possible. If this alarm is output, fit a new battery immediately while keeping
the power turned on. Check whether the current position data is valid, using the procedure
described in 1.
(3) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL, alarms
Contact the FANUC because the Pulsecoder may be defective.
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6.REPLACING PARTS
6
MAINTENANCE
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REPLACING PARTS
This section describes the replacement procedures for the major components of the mechanical section.
When replacing mechanical components, be sure to follow the respective procedures. See Section 8 for
how to replace the cables and limit switches.
6.1
NOTE FOR PART REPLACEMENT
Once motors, reducers, and gears are replaced, mastering becomes necessary. Perform mastering according
to Section 5.5 after any of these components is replaced.
Be very careful when carrying and assembling the heavy components listed below.
In case of reusing seal bolts for M-410iB/160, 300 observe following notes strictly. (If possible, change
them to new seal bolts)
However, please use seal tape for the seal bolt of reducer
1) Apply LOCTITE 242 when reusing seal bolts.
2) Notice the following note.
Remove excessive bits of sealant on the seal bolt.
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps.
Be sure to wipe the excess LOCTITE after tightening screw.
6.2
M-410iB/160, 300
6.2.1
Replacing the J1-Axis Motor and Reducer
(1) Replacing the J1-axis (M1)
Disassembling
1.
2.
3.
4.
5.
6.
Set dial gauges at J1-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the motor connector cover mounting bolt (M8×16) from the J1-axis motor, and
dismount the motor connector cover.
Remove the three cables from the J1-axis motor.
Remove the three J1-axis motor mounting bolts (M12×30), and dismount the J1-axis motor while
exercising care to avoid damaging the gear mounted on the J1-axis motor shaft.
Remove the nut from the end of the J1-axis motor shaft, and dismount the gear. Do not remove
the motor auxiliary seal because the seal will be removed with the J1-axis motor.
Assembling
1.
2.
Polish the J2 base surface on which the J1-axis motor is to be mounted, using an oil stone.
Apply grease to the inside of a new motor auxiliary seal, and mount it on a new J1-axis motor.
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6.REPLACING PARTS
NOTE
A motor whose specification number is terminated with #S000 has the built-in
auxiliary seal.
3.
4.
5.
6.
7.
8.
9.
Mount the gear on the shaft of the new J1-axis motor, apply LOCTITE 242 to the thread section
at the end of the J1-axis motor shaft, and then fasten them with a nut and washer by applying a
torque of 118 N･m (12 kgf･m).
Place the O ring in the O ring groove in the J2 base surface on which the J1-axis motor is to be
mounted.
While exercising care to avoid damaging the gear and O ring, mount the J1-axis motor on the J2
base, and fasten them with three bolts (M12×30) and washers (see the bolt tightening torque table
in the appendix).
Attach the three cables to the motor.
Attach the motor connector cover, and fasten it with a bolt (M8×16).
Supply grease referring to Subsection 3.1.
Perform single axis mastering (see Section 5.5).
Motor mounting bolt
(M12X30(3 pcs))
Washer (3 pcs)
Motor connector cover
Motor connector cover
mounting bolt
(M8X16)
*Motor auxiliary seal
Gear
Washer
Nut
Apply LOCTITE 242
Tightening torque 118N・m (12kgf・m)
O ring
(*) A motor whose specification number is
terminated with #S000 has the built-in auxiliary seal.
Fig.6.2.1 (a) Replacing the J1-axis motor
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6.REPLACING PARTS
MAINTENANCE
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(2) Replacing the J1-axis reducer
Disassembling
1.
Record the Quick Master Reference Position referring to Subsection 5.5.5 of MAINTENANCE.
( It is set in 0°for all axes when robot is shipped.)
2. Set dial gauges at J1-axis, and prepare for single axis mastering after replacement.
3. Control the robot posture so that J3-axis is set to -30 degrees or less, and turn off the controller
power.
4. Remove the bolts (two M16×60 bolts) which are front of the robot (see Fig. 6.2.1 (b)).
5. Turn on the controller power again, control the robot posture as shown in Fig. 6.2.1 (c).
6. Turn off the controller power.
7. Remove the J1-axis motor (see (1) of Section 6.2.1).
8. Drain grease for the J1-axis reducer from the hole used to mount the J1-axis motor.
9. (Integrated type controller type)
Follow steps (1) to (8) in Section 8.2, "Replacement Procedure (Integrated type controller
Type)."
(Remote type controller type)
Follow steps (1) to (7) in Section 8.2, "Replacement Procedure (Remote type controller Type)."
10. Remove the J2 base mounting bolts (nine M16×60 bolts), and hang the robot body to separate it
from the J1 unit (see Fig. 6.2.1 (c)).
11. Remove the center gear.
12. Remove the J1-axis reducer mounting bolts (nine M20×150 bolts), and remove the J1-axis
reducer from the J1 base.
Assembling
1.
2.
3.
4.
5.
6.
7.
8.
9.
Polish the J2 base reducer mounting surface and J1-axis motor mounting surface by using an oil
stone.
Apply sealant (LOCTITE Gasket Eliminator 518) to the connection surface between the J1-axis
reducer and the J1 base.
Mount the J1-axis reducer on the J1 base. Then, thread bolts (nine M20×150 bolts) through
washers, apply LOCTITE 262 to them, and tighten them with a torque of 539 N･m (55 kgf･m)
after .
At this time, align the grease path of the reducer with that of the J1 base to enable greasing (see
Fig. 6.2.1 (e)).
Attach the center gear and O ring so that they are not damaged. Mount the robot body on the J1
unit. Then, thread the bolts (nine M16×60 bolts) through washers, applying LOCTITE 262 to
them, and tighten them with a torque of 319 N･m (32.5 kgf･m) after .
Mount the J1-axis motor (see (1) of Subsection 6.2.1)
Route and secure the cable (see Chapter 8).
Supply grease referring to Subsection 3.1.
Perform quick mastering then perform single axis mastering for J1-axis. (see Subsection 5.5.5
and 5.5.6).
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B-81995EN/06
6.REPLACING PARTS
MAINTENANCE
Bolt
M16X60
Fig.6.2.1 (b) Replacement bolt position to remove the J1 reducer
Replacement Attitude
J2
-44 (deg)
J3
-25 (deg)
Eyebolt
M12 (4pcs)
Fig.6.2.1 (c) Posture of J1 reducer for replacement
- 55 -
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
Bolt M16X60 (9 pcs)
LOCTITE 262
Tightening torque 319N・m
(32.5kgf・m)
Washer
Bolt M20X150 (9 pcs)
LOCTITE 262
Tightening torque 539N・m
(55kgf・m)
Washer
Center gear
O ring
JB-OR1A-G415
Reducer
Pipe
J1 base
Fig.6.2.1 (d) Replacing the J1-axis reducer
- 56 -
MAINTENANCE
B-81995EN/06
6.REPLACING PARTS
When attaching the reducer to the
J1 base, align their grease paths
to enable greasing.
Rc 1/8
Fig.6.2.1 (e) Alignment of grease paths during attachment of the J1-axis reducer
6.2.2
Replacing the J2-Axis Motor and Reducer
(1) Replacing the J2-axis (M2)
Disassembling
1.
2.
3.
4.
5.
6.
7.
8.
Set dial gauges at J2-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Suspend the robot to keep the J2 arm from falling down (see Fig. 6.2.2 (a)).
Remove the motor connector cover mounting bolt (M8×16) from the J2-axis motor, and
dismount the motor connector cover.
Remove the three cables from the J2-axis motor.
Remove the four J2-axis motor mounting seal bolts (M12×30), and dismount the J2-axis motor
while exercising care to avoid damaging the input gear mounted on the J2-axis motor shaft.
Remove the nut from the end of the J2-axis motor shaft, and dismount the input gear.
Remove the draw bolt from the end of the J2-axis motor shaft. Do not remove the motor auxiliary
seal because the new seal will be used.
Assembling
1.
2.
Using an oil stone, polish the J2-axis motor flange surface on which the J2-axis motor is to be
mounted.
Apply grease to the inside of a new motor auxiliary seal, and mount it on a new J2-axis motor.
NOTE
A motor whose specification number is terminated with #S000 has the built-in
auxiliary seal.
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6.REPLACING PARTS
MAINTENANCE
3.
B-81995EN/06
Apply LOCTITE 242 to the thread section at the end of the J2-axis motor shaft, mount the draw
bolt, and then fasten them with a tightening torque of 118 N･m (12 kgf･m).
4. Mount the input gear on the draw bolt, and apply LOCTITE 242 to the thread section at the end of
the draw bolt, and then fasten them with two nuts by applying a tightening torque of 26.5 N･m
(2.7 kgf･m)
5. Apply grease to an O ring, and attach it in the O ring groove in the J2-axis motor flange.
6. While exercising care to avoid damaging the input gear and O ring, mount the J2-axis motor on
the J2-axis motor flange, and fasten them with four seal bolts (M12×30) and washers (see the bolt
tightening torque table in the appendix).
7. Attach the three cables to the J2-axis motor.
8. Mount the motor connector cover, and fasten it with a bolt (M8×16).
9. Supply grease referring to Subsection 3.1.
10. Perform single axis mastering referring to Subsection 5.5.6 of MAINTENANCE.
Eyebolt
M12 (2 pcs)
Fig.6.2.2 (a) Posture at replacing J2-axis motor and reducer
- 58 -
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
J2-axis motor
mounting face
O ring
Nut
Input gear
Draw bolt
Apply LOCTITE 242
Tightening torque 118N・m (12kgf・m)
Washer
Seal bolt
(M12X30 (4 pcs))
Washer
Motor connector
cover
Motor connector cover
mounting bolt
(M8X16)
*Motor auxiliary seal
(*) A motor whose specification number is
terminated with #S000 has the built-in auxiliary seal.
Fig.6.2.2 (b) Replacing the J2-axis motor
(2) Replacing the J2-axis reducer
Disassembling
1.
2.
3.
4.
5.
6.
7.
8.
Set dial gauges at J2-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Suspend the robot to keep the J2 arm from falling down (see Fig. 6.2.2 (a)).
Dismount the J2-axis motor (see Subsection 6.2.2 (1)).
Using a vacuum cleaner, drain grease from the J2-axis reducer through the hole in which the
J2-axis motor was before dismounted.
Remove the twenty four J2-axis motors flange mounting bolts (M12×70), and dismount the
J2-axis motor flange.
Remove the three taper pins from the J2-axis reducer.
Remove the three J2-axis reducer mounting bolts (M16×150), and dismounts the J2-axis reducer.
Assembling
1.
2.
3.
Apply grease to O ring, and attach it in the O ring groove in the J2 arm surface on which the
J2-axis reducer is to be mounted.
While exercising care to avoid damaging O ring, mount a new J2-axis reducer on the J2 arm. At
this time, push the reducer until it reaches the J2 base, and temporarily secure the reducer with the
bolts (two M12×70 bolts) so that it does not rotate.
Put the motor in the reducer and turn it manually to adjust the phase of the reducer. Position the
reducer and J2 arm with the parallel pin, pass the three J2-axis reducer mounting bolts
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6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
(M16×150) through washers, apply LOCTITE 262 to the bolts, and tighten the bolts with a
tightening torque of 319 N⋅m (32.5 kgf⋅m).
4. Mask the entire reducer with tape or other material. Bore a reamer hole for the taper pin by using
a reamer with its tip cut by 5 mm. Be sure to clear chippings.
5. Apply LOCTITE 242 to three taper pins, and knock them in.
6. Apply grease to O ring, and attach it in the O ring groove in the J2-axis reducer surface on which
the J2-axis motor flange is to be mounted.
7. While exercising care to avoid damaging O ring, mount the J2-axis motor flange on the J2-axis
reducer.
Pass washers on 24 bolts (M12×70), apply LOCTITE 262 to the bolts, and then tighten them with
a torque of 128 N･m (13.1 kgf･m).
8. Mount the J2-axis motor (see (1) of Subsection 6.2.2).
9. Supply grease referring to Subsection 3.1.
10. Perform single axis mastering (see Section 5.5).
Bolt
M16X150 (3 pcs)
LOCTITE 262
Tighteninig torque 319Nm (32.5kgf・m)
O ring
A290-7031-Z204
Reducer
Washer
(3 pcs)
O ring
JB-OR1A-G300
J2-axis motor flange
Washer (24 pcs)
Bolt
M12X70 (24 pcs)
LOCTITE 262
Tightening torque 128Nm (13.1kgf・m)
Taper pin
LOCTITE 242
Fig.6.2.2 (c) Replacing the J2-axis reducer
6.2.3
Replacing the J3-Axis Motor and Reducer
(1) Replacing the J3-axis (M3)
Disassembling
1.
2.
3.
4.
5.
6.
7.
8.
Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Suspend the robot to keep the J3 arm from falling down (Fig. 6.2.3 (a)).
Remove the motor connector cover mounting bolt (M8×16) from the J3-axis motor, and
dismount the motor connector cover.
Remove the three cables from the J3-axis motor.
Remove the four J3-axis motor mounting seal bolts (M12×30), and dismount the J3-axis motor
while exercising care to avoid damaging input gear mounted on the J3-axis motor shaft.
Remove the nut from the end of the J3-axis motor shaft, and dismount the input gear.
Remove the draw bolt from the end of the J3-axis motor shaft. Do not remove the motor auxiliary
seal because a new one will be used.
Assembling
1.
Using an oil stone, polish the J3-axis motor flange surface on which the J3-axis motor is to be
mounted.
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B-81995EN/06
2.
MAINTENANCE
6.REPLACING PARTS
Apply grease to the inside of a new motor auxiliary seal, and mount it on a new J3-axis motor.
NOTE
A motor whose specification number is terminated with #S000 has the built-in
auxiliary seal.
3.
Apply LOCTITE 242 to the thread section at the end of the J3-axis motor shaft, mount the draw
bolt, and then fasten them with a tightening torque of 118N･m (12 kgf･m).
4. Mount the input gear to the draw bolt, apply LOCTITE 242 to the thread section at the end of the
draw bolt, and then fasten them with nut and washer by applying a tightening torque of 26.5N･
m (2.7 kgf･m)
5. Apply grease to an O ring, and attach it in the O ring groove in the J3-axis motor flange.
6. While exercising care to avoid damaging the input gear and O ring, mount the J3-axis motor on
the J3-axis motor flange, and fasten them with four seal bolts (M12×30) and washers (see the bolt
tightening torque table in the appendix).
7. Attach the three cables to the J3-axis motor.
8. Mount the motor connector cover, and fasten it with a bolt (M8×16).
9. Supply grease referring to Subsection 3.1.
10. Perform single axis mastering (see Section 5.5).
Eyebolt
M12 (2 pcs)
Fig.6.2.3 (a) Posture at replacing J3-axis motor and reducer
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6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
J3-axis motor
mounting face
Input gear
Draw bolt
Apply LOCTITE 242
Tightening torque 118N・m (12kgf・m)
*Motor auxiliary seal
Washer
Seal bolt
(M12X30 (4 pcs))
Motor connector cover
Washer
Motor connector cover
mounting bolt
Nut
(M8X16)
Apply LOCTITE 242
Tightening torque 26.5N・m (2.7kgf・m)
O ring
JB-OR1A-G125
(*) A motor whose specification number is
terminated with #S000 has the built-in auxiliary seal.
Fig.6.2.3 (b) Replacing the J3-axis motor
(2) Replacing the J3-axis reducer
Disassembling
1.
2.
3.
4.
5.
Set dial gauges at J3-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Suspend the robot to keep the J3 arm from falling down (see Fig. 6.2.3 (a)).
Dismount the J3-axis motor (see (1) of Subsection 6.2.3).
Using a vacuum cleaner, drain grease from the J3-axis reducer through the hole in which the
J3-axis motor was before dismounted.
6. Remove the sixteen J3-axis motor flange mounting bolts (M12×60), and dismount the motor
flange.
7. Remove the three taper pins from the J3-axis reducer.
8. Remove the three J3-axis reducer mounting bolts (M16×140), and dismount the J3-axis reducer.
9. Remove shaft mounting bolt (M12×100 (8 pcs)) and washer (8 pcs) and remove shaft (bearing is
attached).
10. Remove O ring.
Assembling
1.
2.
3.
4.
Replace O ring of shaft part to new one and install it.
Replace bearing to new articles and install it during being careful to oil seal. If oil seal is broken,
replace it to new one. Use fixture of Fig.2.9.
Install shaft.
Apply grease to O ring, and attach it in the O ring groove in the J3 link surface on which the
J3-axis reducer is to be mounted.
- 62 -
5.
6.
7.
8.
9.
10.
11.
12.
13.
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
While exercising care to avoid damaging O ring, mount a new J3-axis reducer on the J3 arm link.
At this time, push the reducer until it reaches the J2 base, and temporarily secure the reducer with
the bolts (two M12×60 bolts) so that it does not rotate.
Put the motor in the reducer and turn it manually to adjust the phase of the reducer. Position the
reducer and J3 arm with the parallel pin, pass the three J3-axis reducer mounting bolts
(M16×140) through washers, apply LOCTITE 262 to the bolts, and tighten the bolts with a
tightening torque of 319 N⋅m (32.5 kgf⋅m).
Mask the entire reducer with tape or other material. Bore a reamer hole for the taper pin by using
a reamer with its tip cut by 5 cm. Be sure to clear chippings.
Apply LOCTITE 242 to three taper pins, and knock them in.
Apply grease to O ring, and attach it in the O ring groove in the J3-axis reducer surface on which
the J3-axis motor flange is to be mounted.
While exercising care to avoid damaging O ring, mount the J3-axis motor flange on the J3-axis
reducer.
Pass washer on 16 bolts (M12×60), apply LOCTITE 262 to the bolts, and tighten them with a
torque of 128 N･m (13.1 kgf･m).
Mount the J3-axis motor (see (1) of Subsection 6.2.3).
Supply grease referring to Subsection 3.1.
Perform single axis mastering (see Section 5.5).
Washer (8 pcs)
Bolt
M12X100 (8 pcs)
Reducer
Washer (3 pcs)
Oil seal
A98L-0040-0047#08511013
Bolt
M16X150 (3 pcs)
LOCTITE 262
Tightening torque 319N・m (32.5kgf・m)
Washer (24 pcs)
Bolt
M12X70 (24 pcs)
LOCTITE 262
Tightening torque 128N・m (13.1kgf・m)
Shaft
J3-axis motor flange
O ring
A290-7031-Z204
Bearing
A97L-0001-0194#1700000 (2 pcs)
O ring
JB-OR1A-G300
Taper pin
LOCTITE 242
O ring
JB-OR1A-G80
Fig.6.2.3 (c) Replacing the J3-axis reducer
6.2.4
Replacing the J4-Axis Motor and Reducer
(1) Replacing the J4-axis motor
Disassembling
1.
2.
3.
4.
5.
Set dial gauges at J4-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the three cables from the J4-axis motor.
While exercising care to avoid damaging the gear mounted on the shaft of the J4-axis motor, pull
out the three J4-axis motor mounting bolts (M8×20) and the washer.
Remove the nut from the end of the J4-axis motor shaft, and dismount the gear.
- 63 -
6.REPLACING PARTS
6.
MAINTENANCE
B-81995EN/06
Do not remove the motor auxiliary seal because a new one will be used.
Assembling
1.
2.
Using an oil stone, polish the wrist unit surface from which the motor was dismounted.
Apply grease to the inside of a new motor auxiliary seal, and attach the seal to a new J4-axis
motor.
NOTE
A motor whose specification number is terminated with #S000 has the built-in
auxiliary seal.
3.
4.
5.
6.
7.
8.
Attach the gear to the new J4-axis motor shaft, apply LOCTITE 242 to the thread section at the
tip of the J4-axis motor shaft, secure it with nuts and washers with a torque of 16.7 N･m (1.7 kgf･
m).
Apply grease to the O ring, and attach it in the O ring groove of the J4 casing.
Mount the J4-axis motor in the J4 casing so that the gear tooth surface and O ring are not
damaged, and secure it with the bolts (three M8×20 bolts) and washers (see the bolt tightening
torque list in the appendix).
Connect the three cables to the motor.
Supply grease referring to Subsection 3.1.
Perform single axis mastering referring to Subsection 5.5.6.
Motor mounting bolt
(M8X20 (3 pcs))
Washer
*Motor auxiliary seal
Gear
Spring washer
Nut
Apply LOCTITE 242
Tightening torque 16.7N・m (1.7kgf・m)
O ring
A98L-0001-0347#S115
(*) A motor whose specification number is
terminated with #S000 has the built-in auxiliary seal.
Fig.6.2.4 (a) Replacing the J4-axis motor
- 64 -
MAINTENANCE
B-81995EN/06
6.REPLACING PARTS
(2) Replacing the J4-axis reducer
Disassembling
1.
2.
3.
4.
5.
6.
7.
8.
Set dial gauges at J4-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the hand and workpiece from the wrist.
Remove the J4-axis motor (see (1) of Section 6.2.4).
Remove the wrist flange mounting bolts (eight M8×75 bolts) and washers, and remove the
reducer unit from the wrist.
Remove the wrist flange mounting bolts (six M8×75 bolts) and washers, and remove the wrist
flange from the reducer unit.
Remove the pipe and center gear from the reducer unit.
Replace the reducer.
Assembling
1.
2.
3.
4.
5.
6.
7.
8.
Attach the pipe to a new J4-axis reducer with the bolts (four M4y10 bolts) and washers. At this
time, make sure the O ring is attached in the O ring groove of the pipe.
Apply sealant to the wrist flange (see Section 6.4).
Attach the wrist flange to which sealant was applied to the reducer unit. At this time, align the
grease outlet of the wrist flange with the grease outlet of the reducer (Fig. 6.2.4 (c)). Thread the
bolts (six M12×80 bolts) through washers, apply LOCTITE 262 to the bolts, and tighten them
with a torque of 128 Nm (13.1 kgf･m).
Attach the center gear to the reducer unit. Attach the O ring to which grease was applied in the O
ring groove of the J4-axis reducer.
Mount the reducer unit in the J4 casing so that the O ring and center gear are not damaged.
Thread the bolts (eight M8×75 bolts) through the washers, apply LOCTITE 262 to the bolts, and
tighten them with a torque of 37 Nm (3.8 kgf･m).
Mount the J4-axis motor (see (1) of Subsection 6.2.4).
Supply grease referring to Subsection 3.1.
Perform single axis mastering referring to Subsection 5.5.6.
- 65 -
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
Center gear
O ring
A290-7207-X342
Bolt M12X80 (6 pcs)
LOCTITE 262
Tightening torque 128Nm
(13.1kgf・m)
Washer
Washer
Reducer
Bolt M8X75 (8 pcs)
LOCTITE 262
Tightening torque 37Nm
(3.8kgf・m)
Pipe
O ring
JB-OR1A-G60
Wrist flange
Bolt
M6X12
Plate
Pipe mounting bolt
M6X12 (4 pcs)
Washer
Washer
Fig.6.2.4 (b) Replacing the J4-axis reducer
Grease outlet
RV reducer
Wrist flange
Note) Align the grease outlet of the wrist flange with that of the reducer.
Fig.6.2.4 (c) Alignment the wrist flange and the reducer
6.3
SEALANT APPLICATION
Washing and degreasing the surfaces to be sealed
1
After dismounting the reducer from the arm, apply releasant (LOCTITE Gasket Remover etc.) to the
arm’s surface from which the reducer was dismounted, then wait until the sealant (LOCTITE 518)
- 66 -
MAINTENANCE
B-81995EN/06
2
3
4
6.REPLACING PARTS
becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a
spatula.
Blow air onto the surface to be sealed to remove dust from the tapped holes.
Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a
cloth dampened with oil and grease remover. Do not spray oil and grease remover directly onto the
surface.
Polish the arm’s surface to be sealed with an oilstone, and degrease it with removal and cleaner again.
CAUTION
Oil may drip from the inside of the reducer. After degreasing, make sure that no oil
is dripping.
Applying sealant
5
6
Make sure that the reducer and the arm are dry (with no oil and grease remover remaining). If they are
still wet with oil and grease remover, wipe them dry. 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. Make sure that no ingredient
of oil and grease remover is left in the threaded holes or on any other portion. If ingredient is left, it
may prevent stiffening of sealant.
Apply sealant (LOCTITE 518) to the surfaces.
CAUTION
The portions to which sealant is to be applied vary from one axis to another. See
descriptions about reducer replacement for the relevant axes for details.
Assembling
7
8
9
To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as
quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was
wiped off, apply again.
After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get
closer.
After attaching the reducer, wipe off any excessive sealant that comes out from the sealed section with
a cloth or spatula. Do not use oil and grease remover.
CAUTION
Do not grease or move the reducer before the sealant sets, as it may allow grease
to leak. Before greasing or moving, wait for about at least one hour after the
reducer is mounted.
6.4
REPLACING THE WRIST UNIT
This section describes the procedure for replacing the wrist unit. To replace only the J4-axis reducer, see
the Subsection 6.2.4.
1.
2.
3.
4.
Set dial gauges at J4-axis, and prepare for single axis mastering after replacement.
Turn off the controller power.
Unload hands or workpiece from the wrist, place the workbench or the like under the wrist unit, and
secure the wrist unit.
Remove the J3 link from the wrist unit by following steps.
- Remove the rubber cap from both ends of the J3 link.
- Remove the bolts (four M6×12 bolts) from both ends of the J3 link.
- Remove the bolts (eight M8×20 bolts) from the J3 base-side shaft of the J3 link.
- Remove the J3 link from the wrist unit.
- 67 -
6.REPLACING PARTS
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
MAINTENANCE
B-81995EN/06
Remove the shaft unit from the wrist unit (see the Fig. 6.4 (a)).
Remove the wrist cover mounting bolts on the motor side, and remove the cover (see the Fig. 6.4 (b)).
Remove the bearing nuts of the shaft that connects between the J3 arm and the wrist unit (see Fig. 6.4
(b)).
Remove the Nilos ring from the taper roller bearing for connecting the wrist unit (see Fig. 6.4 (b)).
Remove the shaft mounting bolts from the wrist unit, and remove the shaft (see Fig. 6.4 (b)).
For the wrist unit and J3 arm link on the other side, repeat steps 7 to 9 (see Fig. 6.4 (c)).
Assemble the wrist unit to replace in the reversed order, and tighten the bearing nuts removed in step 6
with a rotation start forth of 17.6 N to 21.6 N (1.8 kgf to 2.2 kgf) (see Fig. 6.4 (d)). When the
tightening torque of the bolt is not indicated, see the tightening torque list in Appendix D.
Assemble the J3 link.
Supply grease referring to Subsection 3.1.
Perform single axis mastering referring to Subsection 5.5.6.
Bolt
M6X12 (2 pcs)
J3 link cover
Shaft unit
J3 link
Bolt
M8X25 (8 pcs)
Washer
Fig. 6.4 (a) Replacing the wrist unit
- 68 -
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
Bearing
Cover
Shaft
Cover mounting bolt
M6X10 (4 pcs)
Shaft unit mounting bolt
M10X100 (6 pcs)
Nilos ring
Bearing nut
Fig. 6.4 (b) Replacing the wrist unit
Bearing nut
Bearing
Washer
Shaft unit mounting bolt
M10X90 (6 pcs)
Cover mounting bolt
M6X10 (4 pcs)
Cover
Shaft
Nilos ring
Fig. 6.4 (c) Replacing the wrist unit
- 69 -
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
Adjust the rotation start force
to 17.6N 21.6N ( 1.8kgf to 2.2kgf)
during assembly of the bearing nuts.
90°
R
Spring balance
568
Wire
Fig. 6.4 (d) Replacing the wrist unit
6.5
REPLACING THE OPTIONAL J1-AXIS LIMIT SWITCH
(OPTION)
1
2
3
4
Remove the limit switch from the metal plate of mounting limit switch.
Disconnect the cable from the limit switch.
Replace the limit switch with a new one.
Reassemble the unit by reversing the above procedure.
Those bolts for which no tightening torque is specified must be tightened according to the
APPENDIX D BOLT TIGHTENING TORQUE TABLE.
Adjust the limit switch. (See Section 5.1)
5
- 70 -
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
A
A
J1 base
Limit switch unit
View A
Metal plate of
mounting limit switch
Nylon band
Limit switch mounting bolt
M4X25
Washer
Limit switch
Mounting bolt of
mounting metal
plate for limit switch
M6X10
Washer
Cable K106
Limit switch
Fig. 6.5 Replacing the limit switches
6.6
REPLACING THE BALANCER
Disassembling
1
2
3
4
5
6
7
Set the J2-axis to 0°
Turn off the controller power.
Attach the M8 eyebolt to the balancer and hoist it with the crane.
Remove the rubber cap at the top of the balancer.
Remove the two cover sheet metal fixing bolts (M6×10) and remove the cover sheet metal.
Remove the four balancer positioning bolts (M6×16).
Remove both ends of the balancer from the shaft and remove the balancer.
Assembling
1
2
3
4
Attach two balancer positioning bolts 1 (M6×16) to the outside of a new balancer.
Hoist the new balancer with the crane, insert the top into the shaft a little to hook it, and insert the
balancer while depressing the knuckle part at the bottom with a bar.
At this time, be sure to avoid the seal part of the balancer rod being scratched by the bar.
Insert positioning bolts 1 at both ends of the balancer until they reach the shaft and attach two balancer
positioning bolts 2 (M6×16) to the inside of the balancer.
Attach the rubber cap and cover sheet metal.
WARNING
Never disassemble the balancer. If the balancer is carelessly disassembled, the
large spring included in the balancer pops out, posing a significant risk. When
replacing the balancer, be sure to replace the whole balancer unit.
- 71 -
6.REPLACING PARTS
MAINTENANCE
B-81995EN/06
M8 eyebolt (2 pcs)
Rubber cap
Positioning bolt
M6X16(2 pcs)
(attach after the
balancer is inserted.)
Positioning bolt
M6X16(2 pcs)
(attach before the
balancer is inserted.)
Bar
(Used during
assembling.)
M6X10 (2 pcs)
Cover sheet
metal
Fig 6.6 Replacing the balancer
- 72 -
B-81995EN/06
7
7.PIPING AND WIRING
MAINTENANCE
PIPING AND WIRING
Fig. 7 (a) and (b) show the piping diagram of the M-410iB/160 and 300.
K101 (J1 to J4 Pulsecoder,EE R-J3iB controller)
K102 (J1 to J4 power,brake)
K103 (J1 to J5 Pulsecoder,EE R-J3iB controller)
K104 (J1 to J5 power,brake)
K105 (for AS)
K151 (J1 to J4 Pulsecoder,EE R-30iA/R-30iB controller)
K152 (J1 to J4 power,brake R-30iA controller)
K153 (J1 to J5 Pulsecoder,EE R-30iA/R-30iB controller)
K154 (J1 to J5 power,brake R-30iA controller)
K162 (J1 to J4 power,brake R-30iB controller)
K164 (J1 to J5 power,brake R-30iB controller)
K903 (Camera cable)
K106 (Limit switch)
K708 (Zipper tube)
Fig.7 (a) Piping diagram (Integrated type controller)
K201
K202
K203
K204
K107
K251
K253
K905
(J1 to J4 Pulsecoder.EE
(J1 to J4 power,brake)
(J1 to J5 Pulsecoder,EE
(J1 to J5 power,brake)
(for AS)
(J1 to J4 Pulsecoder,EE
(J1 to J5 Pulsecoder,EE
(Camera cable)
R-J3iB controller)
R-J3iB controller)
R-30iA/R-30iB controller)
R-30iA/R-30iB controller)
K106 (Limit switch)
Fig.7 (b) Piping diagram (Remote type controller)
- 73 -
8.REPLACING CABLES
8
MAINTENANCE
B-81995EN/06
REPLACING CABLES
Replace the cables every about four years (or 15,360 hours operating). When the cable is broken or
damaged, or shows signs of wear, replace it according to this chapter.
Precautions to be observed when handling the Pulsecoder cable
The Pulsecoder cable is provided with a marking tie, as shown Fig. 8 (a), to warn against disconnecting the
cable during transportation, installation, or maintenance. If the cable with the marking tie is disconnected,
mastering must be performed again. Therefore, do not disconnect the cable except when replacement of the
motor, the Pulsecoder, the reducer and the cable is necessary.
The connector of J1, J2 and J3-axis are provided with a Pulsecoder connector cover, as shown in Fig. 8 (b),
to protect the connectors.
Before removing the connectors for cable replacement or other purposes, remove the connector covers. In
this case, turning the bolt may also turn the cover, possibly causing damage to the connector. When
removing the cover, hold it to prevent it from turning.
Fig.8 (a) Marking Tie
Pulsecoder connector cover
(J1-axis)
Pulsecoder connector cover
(J2-axis)
Pulsecoder connector cover
(J3-axis)
Fig.8 (b) Pulsecoder connector cover
- 74 -
8.1
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
CABLE FORMING
Table 8.1 (a) and (b) show the cable clamp position.
When replacing cables, clamp the cable by a nylon band at the position specified in Fig. 8.1 (a) and (b).
Otherwise, cables are loosened or forcedly pulled to cause their disconnection. Refer to the Fig. 8.1 (c) to
(h) for the cable clamp position.
J4-axis clamp
Clamp near the wrist of the J3 arm
Clamp on J3 base
Clamp 2 on the J2 link
Clamp 1 on the J2 base
Clamp 2 on the J2 base
Clamp under the J1 base
Clamp on the output of
controllerl
Fig.8.1 (a) Cable clamping position (Integrated type controller)
- 75 -
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
J4-axis clamp
Clamp near the wrist of the J3 arm
Clamp on J3 base
Clamp 2 on the J2 link
Clamp 1 on the J2 base
Clamp 2 on the J2 base
Clamp under the J1 base
Clamp on the output of
J1 connector panel
Fig.8.1 (b) Cable clamping position (Remote type controller)
(Note) M4M5P
AS
EE
M4 M
M
1M
M3 M
M2 M
AIR
1
M4P
123P
AIR2
(Note) M5M
(Note) When servo hand option
is specified.
SECTIO
N BB'
B
(SQ1)
EE
GB1
B'
EE
(FAN)
(M5M)
(M4M)
M4M5P
(SQ1)
M1M
GB1
(FAN)
M5M
M45P
(M1M)
TP
M123P
M2M
M3M
M123P
A
M3M
M4M
M2M
(Note 1) Align the markings with each other, centered around the sponge
(Note2) Do not pull out the stopping of the unused part.
A'
SECTION AA' (R-J3iB,R-30iA)
SECTION AA' (R-30iB)
Fig.8.1 (c) Cable clamp (Integrated type controller)
- 76 -
B-81995EN/06
MAINTENANCE
(*) When servo hand option is specified.
Fig.8.1 (d) Cable clamp (Remote type controller)
- 77 -
8.REPLACING CABLES
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
Marking alignment position
(Center of the two nylon bands)
Marking alignment position
(*) M4M5p
Marking alignment position
A
(*) M5M
Note)
(*)
WhenWhen
servoservo
handhand
option
option is
is specified.
specified.
Marking
alignment position
M4P
(*) M4M5p
M4P
(*) M4M5p
(*) M4M5p
(*) M5M
(*) M5M
(*) M5M
Fig.8.1 (e) Cable clamp
- 78 -
B-81995EN/06
MAINTENANCE
Fig.8.1 (f) Cable clamp
- 79 -
8.REPLACING CABLES
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
(*) M5M
(*) M5M
(*) M4M5P
(*) M4M5P
(*) M5M
(*) M4M5P
Marking alignment position
(Center of the two nylon bands)
(*)
When When
servo hand
specified.
Note)
servooption
hand isoption
is specified.
Fig.8.1 (g) Cable clamp
- 80 -
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
MARKING LOCATION
(THE CENTER OF TWO CABLE
FASTEN NYLON BANDS)
DO NOT USE
NYLON BAND TO THESE PARTS.
MARKING LOCATION
(THE CENTER OF TWO CABLE
FASTEN NYLON BANDS)
D
E
F
G
D'
E'
F'
G'
(*) M5M
(*) M5M
(*) M5M
AIR 2
(*) M4M5P
M4P
(*) M4M5P
M4P
M4P
M4M
M4M
M4M
EE
AS
EE
AS
EE
AS
AIR 1
AIR 1
AIR 1
SECTION DD' SECTION EE'
(*) M5M
AIR 2
AIR 2
AIR 2
(*) M4M5P
(*) M4M5P
M4M
M4P
EE AS
AIR 1
SECTION FF' SECTION GG'
PUT SHEET TO BOTH SIDE
OF INSIDE J3 ARM.
I
EE MARKING LOCATION
AS2
I'
凸側
SALIENT SID E
SET SALIENT SIDE OF AIR HOSE TO BOTTOM DIRECTION
(HATCHING AREA).
MARKING LOCATION
(THE CENTER OF TWO CABLE
FASTEN NYLON BANDS)
Fig.8.1 (h) Cable clamp
8.2
CABLE REPLACEMENT
This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables.
If you need to replace a specific cable (because, for example, it is damaged), do so by referencing this
section.
Cable replacement makes it necessary to perform mastering. Before attempting replacement, therefore, see
Section 5.5.
Replacement Procedure (Integrated type controller)
(1) Record the Quick Master Reference Position referring to Subsection 5.5.5 of MAINTENANCE. ( It is
set in 0°for all axes when robot is shipped.)
(2) Turn off the controller power, then disconnect all cable connectors to the robot main body from the
controller (Fig. 8.2 (a),(b)).
- 81 -
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
(3) Remove the cable clamp (Fig. 8.2 (c)) on the rear of the controller.
(4) Detach the metal plate from the controller exit, then detach the two metal plates securing the rubber
clamp (Fig. 8.2 (c)).
(5) Release cables from a rubber clamp. Pull all cables connected to the robot main body out of the
controller (Fig. 8.2 (c)).
(6) Remove the air hoses and AS cable (when the AS option is specified) from the connector plate (Fig.
8.2 (c)).
(7) Remove the cover sheet metal from the battery box, and detach the battery cable terminals from the
terminal board on the rear of the battery box (see Fig. 8.2 (c)).
(8) Remove the bolt from the cable clamp in the lower section of the J1 base, and dismount the cable
clamp in the J2 base, then pull the cables out of the J2 base (see Fig. 8.2 (d)).
(9) Remove all the cable connectors from the motors for the J1- to J4-axes.
(10) Remove the wrist EE plate from the wrist and then remove the cable, air hose, and AS cable (option)
from the wrist EE plate.
Remove the bolts of the cable clamp for the J4 casing (see Fig. 8.2 (f)).
(11) Remove the Teflon seat attached to the cable near the wrist link. (The removed Teflon seat is attached
again after the old cable is replaced.)
(12) Remove the bolts for cable clamps within the J3 arm (see Fig. 8.2 (e)).
(13) Draw the cable fixing sponge within the J3 arm from the through hole on the J3 arm (see Fig. 8.2 (e)).
(14) Remove the plate of the J3 base section, and remove the bolts for the cable clamp attached to the J3
base section (see Fig. 8.2 (d)).
(15) Remove the bolts for the cable clamp attached to the J2 link section (see Fig. 8.2 (d)).
(16) Remove the bolts for the cable clamp attached to the J2 base (see Fig. 8.2 (d)).
(17) Remove the cable from the robot body, and replace it with a new one.
(18) Perform assembling in the reversed order. For cable harnessing and the clamp position, see Section
8.1.
(19) Turn on the power. Clear an alarm that occurs as described in Subsection 5.5.2.
(20) Perform quick mastering referring to Subsection 5.5.5.
Replacement Procedure (Remote type controller)
(1) Record the Quick Master Reference Position referring to Subsection 5.5.5 of MAINTENANCE. ( It is
set in 0°for all axes when robot is shipped.)
(2) Turn off the controller power, then disconnect all cable connectors to the back of robot pedestal from
the controller (Fig. 8.2 (g)).
(3) Remove air hoses and AS cable (when the AS option is specified) from the panel (Fig. 8.2 (g)).
(4) Remove the connector plate. Since the internal cable is fixed, care must be taken so that the internal
cable is not strongly yanked (see Fig. 8.2 (h)).
(5) Remove the battery cable and earth cable. Cut the cable tie that clamps the J1 connector, and
disconnect the connector.
(6) Remove screws fastening the connector inserts (Fig. 8.2 (h)).
(7) Remove the connector housing, and dismount the connector insert from the housing. Also, dismount
the plate retaining the cable from the connector plate. Then cut off the nylon band clamping the cable
to the plate, and dismount the plate (see Fig. 8.2 (i)).
(8) Follow the cable replacement steps (8) to (16) of the Integrated type controller type.
(9) Assemble cable by reversing steps (8) to (16) of the Integrated type controller type. For cable
harnessing and the clamp position, see Section 8.1.
(10) Temporarily fasten the cable to the cable retaining plate with a nylon band, and temporarily fasten the
cable retaining plate to the connector box. Pull the cable into the connector box so that the cable does
not sag, then fasten it with a nylon band (see Fig. 8.2 (j)).
(11) Attach a new connector housing to the connector plate. Remove the cable retaining plate from the
connector box, and attach it to the connector plate (see Fig. 8.2 (i)).
(12) Install the cable by following steps (1) to (6) in reverse. Connect the air hose so that it matches the
markings on the pedestal connector panel and wrist connector plate.
(13) Turn the power on. Clear an alarm that occurs as described in Subsection 5.5.2.
- 82 -
MAINTENANCE
B-81995EN/06
8.REPLACING CABLES
(14) Perform quick mastering referring to Subsection 5.5.5.
CNJ1
CRF7
Robot M-410iB/160,300
CNJ2
Motor power
J1M
J2M
J3M
CNJ5
J4M
Pulsecoder
RDI/RDO
,XHBK,ROT
CNG
BRAKE
CRR64
CNJ4
CNJ3
Detail of cable connection for servo amplifier
Robot M-410iB/160,300
R-J3iB (Servo amplifier)
ＣＮＪ１Ａ
CRF7
ＣＮＪ１Ｂ
CRR64
ＣＮＪ２Ａ
ＣＮＪ２Ｂ
ＣＮＪ４
CNJ3A
ＣＮＧＣ
CNJ3B
ＣＮＧＢ
Pulsecoder
(Pulsecoder,RDI/RDO
,XHBK,ROT)
ＣＮＧＡ
BRAKE
Motor power
(J4M)
Motor power
(J3M)
Motor power
(J2M)
Motor power
(J1M)
Fig. 8.2 (a) Cable replacement (R-J3iB Integrated type controller type)
- 83 -
8.REPLACING CABLES
CNJ3
MAINTENANCE
CNJ6
CNJ5
CNG
CNJ4
CNJ2
CNJ1
B-81995EN/06
Robot M-410iB/160,300
(R-30iA/R-30iB Controller)
Motor power
J1M
J2M
J3M
J4M
Pulsecoder
RI/RO
HBK,ROT
BRAKE
CRF8
CRR88
・Detail of the cable connection for servo amplifier
R-30iA /R-30iB(Servo amplifier)
Robot M-410iB/160,300
(R-30iA/R-30iB Controller)
CNJ1A
CRF8
CNJ1B
CRR88
CNJ4
CNJ2A
CNJ2B
CNJ3A
CNGC
CNJ3B
CNGB
Pulsecoder
(Pulsecoder,RI/RO,
HBK,ROT)
CNGA
BRAKE
Motor power
(J4M)
Motor power
(J3M)
Motor power
(J2M)
Motor power
(J1M)
Fig. 8.2 (b) Cable replacement (R-30iA/ R-30iB Integrated type controller)
- 84 -
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
Battery box
Battery box
cover metal
plate bolt M6×10
M6 10
Cable clamp
Cable clamp securing
bolt M10×16
M10 16
Phillips
machine screw
Controller exit
metal plate
Air hose
AS cable (option)
Connector panel
Phillips machine
screw
Rubber clamp
Rubber clamp securing
metal plate
Fig. 8.2 (c) Cable replacement (Integrated type controller)
J3 base metal plate
Bolt M6X10 (3)
Clamp on the J2 link
Bolt M6X10 (4)
J3 base metal plate
Bolt M6X10 (3)
Clamp on the J2 link
Bolt M6X10 (4)
J2 base clamp
Bolt M6X10 (2)
Nylon band
Marking position
Clamp under the J1 base
Bolt M6X10 (4)
Nylon band
Fig. 8.2 (d) Cable replacement
- 85 -
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
Cable clamp in the J3 arm
Bolt M6X10
Cable retaining sponge
in the J3 arm
Teflon sheet
Marking (EE)
posiiton
AS2
AIR22
AIR12
EE
Cable clamp in the J3 arm
Bolt M8X12 (2)
Marking position
(Center of the two nylon band)
Marking position
(Center of the two nylon band)
Fig. 8.2 (e) Cable replacement
J4 casing cable clamp
BOLT M8X12
Wrist EE plate
J4 casing
Fig. 8.2 (f) Cable replacement
- 86 -
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
Robot securing connector from controller
Air hose
AS cable
Panel
Fig. 8.2 (g) Cable replacement
Connector plate mounting bolt
M6x10
Connector plate
Connector plate mounting bolt
M6x16
Insert securing bolt
(Four bolts each)
Fig. 8.2 (h) Cable replacement
- 87 -
8.REPLACING CABLES
MAINTENANCE
B-81995EN/06
Connector plate
Plate mounting bolt
M6x10
Housing mounting bolt
Cable mounting plate
M4x10
Fig. 8.2 (i) Cable replacement
Connector box
Connector
Cable mounting plate
Cable
mounting
Plate mounting bolt
Plate
M6×10
mounting
M6 10
View from B
Fig. 8.2 (j) Cable replacement
- 88 -
II. CONNECTION
CONNECTION
B-81995EN/06
1
1.ROBOT INTERFERENCE AREA
ROBOT INTERFERENCE AREA
R
J 6
i n t 2 -a 7 4
er xis
fe m
re o
nc to
e r
ar
ea
Fig.1 shows the external dimensions and operation ranges of the robots.
When installing peripheral devices, be careful to clear away any objects that are in the robot's motion path
in normal operation.
R
89
2
1080
3
R 314
1030
J3-axis rear side
interference area
390
1300
255
Motion range of
wrist tip
310
(1925,2880)
1220
159
(1078,2537)
(3031,2175)
2880
3152
(966,1742)
(3143,1434)
1057.5
1593
1434
(892,1064)
(1846,-78)
892
1107
78
(1082,170)
3143
Fig.1 External dimension
- 91 -
(3025,673)
510
510
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
2
MECHANICAL COUPLING TO THE ROBOT
2.1
LOAD CONDITION AT WRIST
Fig. 2.1 (a) and (b) show the relationships between the horizontal offset of the center of gravity of the
wrist load and the permissible load inertia. See Fig. 2.1 (c) to check whether the center of gravity of the
load is inside or outside of the wrist.
See Fig. 2.1 (d) for explanations about the vertical offset of the center of gravity of the wrist load.
Keep the wrist load within a range graphically shown in Fig. 2.1 (a).
See Fig. 2.1 (e) for explanations about how to calculate the load inertial.
[kgm2]
Allowance wrist load inertia (kgm2 )
90
800
80
70
60
50
80kg
40
120kg
160kg
80kg
120kg
30
160kg
20
10
600
400
200
0
200
400
600 [mm]
Allowable horizontal
offset when center of
gravity falls in outside
range of wrist (rf)
Allowable horizontal offset
when center of gravity falls
in inside range of wrist (ri)
Allowance wrist load inertia (kgm2 )
Fig. 2.1 (a) Line chart of the permissible load for the wrist section (horizontal offset)
800
140
(M-410iB/160)
[kgm2]
120
100
150kg
200kg
80
150kg
300kg
60
300kg
200kg
40
20
600
400
200
0
Allowable horizontal offset
when center of gravity falls
in inside range of wrist (ri)
200
400
600 [mm]
Allowable horizontal
offset when center of
gravity falls in outside
range of wrist (rf)
Fig. 2.1 (b) Line chart of the permissible load for the wrist section (horizontal offset)
- 92 -
(M-410iB/300)
B-81995EN/06
CONNECTION
2.MECHANICAL COUPLING TO THE ROBOT
Inside range of wrist
ri
rf
Outside range of wrist
Fig. 2.1 (c) Allowable wrist load condition
Center of gravity of hand
Allowable vertical
offset for center of gravity
Center of gravity of total load
Center of gravity of workpiece
Fig. 2.1 (d) Allowable wrist load condition
- 93 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
The total inertia around the wrist (J4) axis is the sum of the horizontal offset inertia of a workpiece and
the geometric inertia around the center of gravity of the workpiece. It can be calculated as shown below.
J = Ji + WL2
Ji
W
W
: Mass (kg)
L, l, a, b, r : Length (m)
J
: Inertia (kgm2)
J
L
Note) If a hand or workpiece has a complicated shape, divide it into
simple shapes as shown below. Calculate the geometric inertia
and offset inertia of each shape, then obtain their sum.
Expressions for calculating inertia around the center of gravity (geometric inertia)
r
l
r
a
b
a2+b2
Ji=W 12
l2
Ji =W
12
r2
Ji=W 2
Fig. 2.1 (e) Calculating inertia
- 94 -
2r2
Ji=W 5
B-81995EN/06
2.2
CONNECTION
2.MECHANICAL COUPLING TO THE ROBOT
MECHANICAL COUPLING OF END EFFECTOR TO WRIST
Fig.2.2 is the diagrams for installing end effectors on the wrist. To fasten the end effector, first position it
with two pin holes at C using fitting A or B, then lock it using screws at D. Select screws and positioning
pins of a length that matches the depth of the tapped and pin holes. Fasten the bolt for fixing the end
effector with following torque. (See Appendix D)
76N-m (750kgf-cm)
CAUTION
Notice the tooling coupling depth to wrist flange should be shorter than the
flange coupling length.
SECTION : Section
DP :
Depth
EQ.SP. :
Equally spaced on
the circumference
Fig.2.2 End effector mounting face
- 95 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
2.3
B-81995EN/06
EQUIPMENT MOUNTING FACE
As shown in Fig.2.3 tapped holes are provided to install equipment to the robot.
CAUTION
Never perform additional machining operation such as drilling or tapping on the
robot body. This can seriously affect the safety and function of the robot.
NOTE
Note that the use of a tapped hole not shown in the following figure is not
assured. Please do not tighten both with the conclusion bolt in the mechanism.
NOTE
Please do not interfere with the mechanical unit cable when equipment is
installed in the robot.
There is a possibility that the mechanical unit cable is disconnected and the
trouble not anticipated occurs.
178
447
2-M12 THROUGH
50
25
25
26
4
2-M12 DEPTH 20
DETAIL A
159
97
310
120
A
Fig.2.3 Dimension of equipment mounting face
- 96 -
252
4-M8 DEPTH 12
60
50
182
2-M12 THROUGH
CONNECTION
B-81995EN/06
2.4
2.MECHANICAL COUPLING TO THE ROBOT
LOAD SETTING
NOTE
Set load condition parameter before robot runs. Do not operate the robot in over
payload. Don’t exceed allowable payload including connection cables and its
swing. Operation in over payload may occur troubles such as reducer life
reduction.
The motion performance screens include the MOTION PERFORMANCE screen, MOTION PAYLOAD
SET screen, and MOTION ARMLOAD SET screen. These screens are used to specify payload
information and equipment information on the robot.
1
Click the [MENUS] key to display the screen menu.
2
Select "6 SYSTEM" from the next page.
3
Click F1 ([TYPE]).
4
Select "MOTION." The MOTION PERFORMANCE screen appears.
MOTION PERFORMANCE
Group1
No.
PAYLOAD[kg]
1
160.00
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
Comment
[
[
[
[
[
[
[
[
[
[
]
]
]
]
]
]
]
]
]
]
Active PAYLOAD number = 0
[ TYPE ] GROUP DETAIL ARMLOAD SETIND >
INDENT
>
5
Ten different pieces of payload information can be set using condition Nos. 1 to 10 on this screen.
Place the cursor on one of the numbers, and click F3 (DETAIL). The MOTION PAYLOAD SET
screen appears.
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
- 97 -
DEFAULT
10%
]
160.00
25.00
0.00
15.00
2.79
4.17
3.77
HELP
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
Center
手首フランジ
of robot flange
xg(cm)
zg(cm)
X
2
Iy(kg・cm)
Z
Center重心
of gravity
質量m(kg)
Mass
m(kg)
Center重心
of gravity
yg(cm)
2
Ix(kg・cm)
X
Y
6
7
8
9
Set the payload, gravity center position, and inertia around the gravity center on the MOTION
PAYLOAD SET screen. The X, Y, and Z directions displayed on this screen correspond to the
respective standard tool coordinates (with no tool coordinate system set up). When values are
entered, the following message appears: "Path and Cycletime will change. Set it?" Respond to
the message with F4 ([YES]) or F5 ([NO]).
Clicking F3 ([NUMBER]) will bring you to the MOTION PAYLOAD SET screen for another
condition number. For a multigroup system, clicking F2 ([GROUP]) will bring you to the
MOTION PAYLOAD SET screen for another group.
Click the previous page key to return to the MOTION PERFORMANCE screen. Click F5
([SETIND]), and enter the desired payload setting condition number.
On the MOTION PERFORMANCE screen, click F4 ([ARMLOAD]) to display the MOTION
ARMLOAD SET screen.
- 98 -
CONNECTION
B-81995EN/06
2.MECHANICAL COUPLING TO THE ROBOT
MOTION ARMLOAD SET
Group 1
1 ARM LOAD AXIS #1
2 ARM LOAD AXIS #3
[ TYPE ]
2.4.1
JOINT
[kg]
[kg]
GROUP
DEFAULT
10%
0.00
0.00
HELP
Switching between Modes
There are two different parameter settings for the M-40iB/160 according to the amplitude of the load.
(The factory-shipped parameter setting is for standard mode.)
Allowable load at wrist
J4-axis
M-410iB
Standard
inertia mode
High
inertia mode
160kg
100kg
The parameters are automatically set according to the load settings made in Section 2.4.
Software series
Software version
V6.10P (7D80)
V6.20P (7D81)
V6.30P (7D82)
V6.33P (7D85)
V7-20P (7DA1) or later
95 and later
47 and later
45 and later
08 and later
All versions
Mechanical unit
All models
CAUTION
Set the load properly as described in Section 2.4.
If a workpiece heavier than the allowable load in the high speed mode is used in
the high speed mode, mechanical parts may degrade earlier.
Set the parameters based on the load, as described later.
(Parameter settings appropriate for the standard inertia mode are made before shipment.)
Software series
Software version
V6.10P (7D80)
V6.20P (7D81)
V6.30P (7D82)
V6.33P (7D85)
94 and earlier
46 and earlier
44 and earlier
07 and earlier
Mechanical unit
All models
CAUTION
If a workpiece with inertia exceeding the allowable inertia in the standard inertia
mode is used in the mode, parts of the mechanical unit may degrade earlier.
- 99 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
To set the parameters, execute the setting program (JDGLOAD.PC) installed before shipment. This
program sets the parameters based on the currently-used load inertia of the load settings made in Section
2.4
Setting method (Software version is V6 or before)
The setting program is called in program.
In particular, when load settings are switched with PAYLOAD instruction, execute this program.
[Example of program]
1: PAYLOAD [1]
2: CALL JDGLOAD (i)
For input parameter i of JDGLOAD, specify the group number of the robot. When input parameter i is
omitted, the setting of group 1 is done.
Checking the settings (Software version is V6 or before)
Executing the setting program displays the settings made on the user screen. To display the user screen,
press the MENUS key and then select "9 USER."
[Information displayed on the user screen]
For standard settings:
Standard payload set. (GP: x, Payload: y)
For high settings:
100kg payload set. (GP: x, Payload: y)
x represents the group number for which the parameter was set. y represents the load setting number
used for evaluation.
When checking the current settings only without switching parameters, specify the group number added
by 100 for input parameter i of JDGLOAD and then execute the program. This displays the current
parameter settings of the group on the user screen.
[Information displayed on the user screen]
For standard inertia load settings: Standard payload type now (GP: x)
For high inertia load settings:
100kg payload type now (GP: x)
x represents the group number whose parameter was checked.
Exception processing (Software version is V6 or before)
In the following cases, exception processing is performed. Parameters are not changed and a message
describing the exception processing appears on the user screen.
1
When none of load setting condition numbers (Nos. 1 to 10) is selected
[Information displayed on the user screen]
Payload number 0 is invalid. (GP: x)
When this message appears, select the load setting condition on the motion performance screen or
set the load setting condition with the PAYLOAD instruction.
2
When the group specified by input parameter i of JDGLOAD does not exist
[Information displayed on the user screen]
Incorrect group number
When this message appears, specify the correct group number.
3
When the group specified by input parameter i of JDGLOAD is not M-410iB/160
- 100 -
B-81995EN/06
2.MECHANICAL COUPLING TO THE ROBOT
CONNECTION
[Information displayed on the user screen]
This group is not M-410iB/160
When this message appears, specify the correct group number.
2.5
AIR SUPPLY
There is an air-pressure supply opening for supplying air to the end effector. As coupling is not supplied,
it will be necessary to prepare couplings that suit to the hose size.
Panel union
Rc3/8 female
(Air outlet side)
AIR 11
AIR22
(This does not exist
when servo hand cable
or camera cable (A05B-1041-H952
is specified.)
AIR 12
AIR 21
(This does not exist
when servo hand cable
or camera cable (A05B-1041-H952
is specified.)
Panel union
Rc3/8 female
(Air inlet side)
Fig. 2.5 (a) Air-pressure supply connection (Integrated type controller)
- 101 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
AIR22
(This does not exist
when servo hand cable
or camera cable
(A05B-1041-H962
is specified.)
Panel union
Rc3/8 female
(Air outlet side)
AIR 12
AIR 11
AIR 21
(This does not exist
when servo hand cable
or camera cable
(A05B-1041-H962
is specified.)
View A
Panel union
Rc3/8 female
(Air inlet side)
View A
Fig. 2.5 (b) Air-pressure supply connection (Remote type controller)
- 102 -
CONNECTION
B-81995EN/06
2.6
2.MECHANICAL COUPLING TO THE ROBOT
OPTION CABLE INTERFACE
WARNING
・ Use mechanical unit cables that have required user interface.
・ Don’t add user cable or hose to inside of mechanical unit.
・ Please do not obstruct the movement of the mechanical unit cable when cables are
added to outside of mechanical unit.
・ Please do not perform remodeling (Adding a protective cover and fix an outside cable
more) obstructing the behavior of the outcrop of the cable.
・ Please do not interfere with the other parts of mechanical unit when equipment is
installed in the robot.
・ Cut unnecessary length of wire rod. Make insulation processing like winding acetate
tape. (See Fig.2.6 (a))
・ If you can not prevent electrostatic charge of work and end effector, keep away an end
effector (a hand) cable from an end effector and a work as much as possible, when
wiring it. When they come to close unavoidable, make insulation processing between
them.
Be
sure to seal connectors of hand side and robot side and terminal parts of cables,
・
to prevent water from entering the mechanical unit. Also, attach cover to unused
connector.
・ Check looseness of connector and wound of coating of cables routinely.
When these attentions are not kept, unexpected troubles might occur.
End effector (hand) cable
Cut unnecessary length of unused wire rod
Insulation processing
Fig.2.6 (a) Treatment method of end effector (hand) cable
Fig. 2.6 (b) to (f) show the interface position of the option cable. EE interface (RDI/RDO or RI/RO) , user
cable (signal line) , servo hand cable and camera cable are prepared. The user cable (signal lines option) ,
servo hand cable and camera cable are prepared as an option.
- 103 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B
B
A
A
Integrated type controller
B-81995EN/06
Remote type controller
Fig. 2.6 (b) Interface position for option cable
- 104 -
2.MECHANICAL COUPLING TO THE ROBOT
CONNECTION
B-81995EN/06
(Air inlet)
(Air outlet)
EE interface
A
With EE and AIRX2
Spec. of mechanical unit cable :
A05B-1041-H201 (R-J3iB)
A05B-1041-H301 (R-30iA)
B
User cable (signal)
interface
(Air inlet)
(Air outlet)
User cable (signal)
interface
EE interface
A
B
With EE , user cable (signal) and AIRX2
Spec. of mechanical unit cable :
A05B-1041-H202 (R-J3iB)
A05B-1041-H302 (R-30iA)
A05B-1041-H402 (R-30iB)
Servo hand cable
interface (M5P)
(Air inlet)
Servo hand cable
interface (M5M)
EE interface
(Air outlet)
A
B
With EE , servo hand cable and AIRX1
Spec. of mechanical unit cable :
A05B-1041-H203 (R-J3iB)
A05B-1041-H303 (R-30iA)
User cable (signal)
interface
User cable (signal)
interface
(Air inlet)
Servo hand cable
interface (M5P)
Servo hand cable
interface (M5M)
EE interface
(Air outlet)
A
B
With EE , user cable (signal) and servo hand cable and AIRX1
Spec. of mechanical unit cable :
A05B-1041-H204 (R-J3iB)
A05B-1041-H304 (R-30iA)
A05B-1041-H404 (R-30iB)
Fig. 2.6 (c) Interface for the option cable (Remote type controller) (1/2)
- 105 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
Camera cable
interface
Camera cable
interface
(Air outlet)
(Air inlet)
User cable (signal)
interface
User cable (signal)
interface
A
B
With EE , user cable (signal) , camera cable and AIRX2
Spec. of mechanical unit cable :
A05B-1041-H951 (R-30iA)
A05B-1041-H971 (R-30iB)
User cable (signal)
interface
User cable (signal)
interface
(Air inlet)
Camera cable
interface
(Air outlet)
A
B
EE interface
With EE , camera cable and AIRX1
Spec. of mechanical unit cable :
A05B-1041-H952 (R-30iA)
A05B-1041-H972 (R-30iB)
Fig. 2.6 (d) Interface for the option cable (Remote type controller) (2/2)
- 106 -
CONNECTION
B-81995EN/06
2.MECHANICAL COUPLING TO THE ROBOT
(Air inlet)
(Air outlet)
EE interface
A
B
With EE and AIRX2
Spec. of mechanical unit cable :
A05B-1041-H205 (R-J3iB)
A05B-1041-H305 (R-30iA/R-30iB)
(Air inlet)
(Air outlet)
User cable (signal)
interface
User cable (signal)
interface
EE interface
A
B
With EE , user cable (signal) and AIRX2
Spec. of mechanical unit cable :
A05B-1041-H206 (R-J3iB)
A05B-1041-H306 (R-30iA/R-30iB)
Servo hand cable
interface (M5P)
(Air inlet)
Servo hand cable
interface (M5M)
EE interface
(Air outlet)
A
B
With EE , servo hand cable and AIRX1
Spec. of mechanical unit cable :
A05B-1041-H207 (R-J3iB)
A05B-1041-H307 (R-30iA/R-30iB)
User cable (signal)
interface
(Air inlet)
Servo hand cable
interface (M5P)
Servo hand cable
interface (M5M)
EE interface
User cable (signal)
interface
(Air outlet)
A
B
With EE , user cable (signal) and servo hand cable and AIRX1
Spec. of mechanical unit cable :
A05B-1041-H208 (R-J3iB)
A05B-1041-H308 (R-30iA/R-30iB)
Fig. 2.6 (e) Interface for the option cable (Integrated type controller) (1/2)
- 107 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
User cable (signal)
interface
(Air inlet)
Camera cable
interface
Camera cable
interface
(Air outlet)
User cable (signal)
interface
EE interface
A
B
With EE , camera cable and AIRX1
Spec. of mechanical unit cable : A05B-1041-H963 (R-30iA/R-30iB)
Fig. 2.6 (f) Interface for the option cable (Integrated type controller) (2/2)
(1) EE interface (RDI/RDO or RI/RO)
Fig. 2.6 (g) and (h) shows pin layout for EE interface (RDI/RDO or RI/RO).
WARNING
The RDO signal for the R-J3iB controller and the RO signal for the
R-30iA/R-30iB controller are incompatible with each other because different
output formats are used. For details, refer to the Chapter 4 of CONNECTION
of maintenance manuals for the controller, too.
EE interface (RDI/RDO) (Wrist side)
A63L-0001-0234#R2524F(Fujikura.Ltd)
4
RDO4
9
RDI1
15
RDI5
3
RDO3
8
0V
2
RDO2
7
XHBK
1
RDO1
6
RDO6
5
RDO5
14
13
12
11
10
RDI3
XPPABN
RDI4
RDI2
RDI8
20
19
18
17
16
24V
24V
24V
24V
RDI6
24
23
22
21
RDI7
RDO8
RDO7
Controller
Comformable connector
A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
End
effector
Please prepare by user.
XHBK : Hand broken
XPPABN : Pneumatic pressure abnormal
Fig. 2.6 (g) Pin layout for the EE interface (RDI/RDO)(R-J3iB controller)
- 108 -
2.MECHANICAL COUPLING TO THE ROBOT
CONNECTION
B-81995EN/06
Comformable connector
A63L-0001-0234#S2524M
(Fujikura:JMSP2524M)
EE interface (RI/RO) (Wrist side)
A63L-0001-0234#R2524F(Fujikura.Ltd)
4
RO4
9
RI1
15
RI5
3
RO3
7
XHBK
8
0V
14
XPPABN
20
19
24V
24V
24
RI7
Controller
2
RO2
13
RI8
1
RO1
6
RO6
12
RI4
11
RI3
18
24V
23
0V
10
RI2
17
24V
22
RO8
End
effector
5
RO5
16
RI6
21
RO7
Please prepare by user.
XHBK : Hand broken
XPPABN : Pneumatic pressure abnormal
Fig. 2.6 (h) Pin layout for the EE interface (RI/RO) (R-30iA/R-30iB controller)
(2) User cable (signal line) interface (Option)
Fig. 2.6 (i) shows pin layout for user cable (signal line) interface.
Conformable connector
A63L-0001-0234#S2524MX(Fujikura)
(Fujikura;JMSP2524F)
User interface (AS2) (Wrist side)
A63L-0001-0234#R2524FX(DDK)
4
S4
9
S9
15
S15
3
S3
8
S8
14
S14
20
S20
2
S2
7
S7
13
S13
19
S19
12
S12
18
S18
23
S23
17
S17
22
S22
End
Effector
5
S5
11
S11
10
S10
16
S16
21
S21
}
24
S24
1
S1
6
S6
The customer should
prepare these devices
The customer should
prepare these devices
}
User interface (AS1) (J1 side)
A63L-0001-0234#W2524M(DDK)
1
S1
External
signal
5
S5
10
S10
2
S2
6
S6
11
S11
16
S16
12
S12
17
S17
21
S21
3
S3
13
S13
18
S18
22
S22
4
S4
8
S8
7
S7
9
S9
14
S14
19
S19
23
S23
15
S15
20
S21
2
24
S24
Conformable connector
A63L-0001-0234#S2524F(DDK)
(DDK;JMSP2524F)
Fig. 2.6 (i) Pin layout for the user cable (signal line) interface (option)
- 109 -
2.MECHANICAL COUPLING TO THE ROBOT CONNECTION
B-81995EN/06
(3) Servo hand cable interface (option)
Fig. 2.6 (j) show the position for the servo hand cable interface (option) connector.
Comfortable connector
MS 3106B 20-15P
Please prepare
by customer.
Servo hand interface (M5M)(Wrist side)
20-15S (3.5SQ 23A)
F
A J5U1
E BKC(J5) G J5G1
B J5V1
D BK(J5)
C J5W1
Servo hand interface (M5P)(Wrist side)
16S-1S(1.25SQ 13A)
F 6V(BT5) A PRQJ5
E 0V(E1)
G 0V(BT5) B XPRQJ5
D 5V(E1)
C FG
Servo motor
Please prepare
by customer.
Comfortable connector
MS 3106B 16-1P
CONTROLLER
Fig. 2.6 (j) Pin layout for the servo hand cable interface
NOTE
A connector prepared by the customer for the servo cable interface (option) must
be a straight type; (an elbow type cannot pass through the hole in the J4 axis.)
- 110 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-81995EN/06
3
TRANSPORTATION AND INSTALLATION
3.1
TRANSPORTATION
The robot can be transported by crane or forklift.
CAUTION
When peripherals are installed on a robot, the center of gravity of the robot
changes and the robot might become unstable while being transported.
Robot becomes unstable when it is transported with the end effector applied to
wrist, and it is dangerous.
Please be sure to remove end effector when robot is transported.
Use the forklift pockets only to transport the robot with a forklift. Do not use the
forklift pockets to secure the robot.
Before moving the robot by using forklift pockets, check and tighten any loose
bolts on the forklift pockets.
Do not pull eyebolts sideways.
Prevent the forks of the forklift from having impact on transport equipment.
Do not thread a chain or the like through transport equipment.
Transport posture
Axis name
J1
J2
J3
J4
M16 bolt
(4 pcs)
M16 plain washer
(4 pcs)
M16 bolt
(4 pcs)
M16 plain washer
(4 pcs)
Posture
0 DEG.
102 DEG.
-126 DEG.
0 DEG.
Section A-A
1150
188
188
2199
88
88
102°
A
A
12 6
°
Center of
gravity
Transport equipment
1440
1080
2667
M24 eyebolt (2 pcs)
spacer (2 pcs)
(A290-7039-X052)
Fig.3.1 (a) Transportation using a crane
- 111 -
3.TRANSPORTATION AND INSTALLATION CONNECTION
B-81995EN/06
Transport posture
Posture
0 DEG.
102 DEG.
-126 DEG.
0 DEG.
Axis name
J1
J2
J3
J4
M16 bolt
(4 pcs)
M16 plain washer
(4 pcs)
M16 bolt
(4 pcs)
M16 plain washer
(4 pcs)
Section A-A
Forklift
bracket
1150
188
188
88
88
102°
A
2199
A
126
°
Center of
gravity
Transport equipment
1440
1080
2667
Fig.3.1 (b) Transportation using a forklift
NOTE
Mechanical unit weight: 2.0 tons (including the controller)
Crane permissible load: 3.0 tons or more
Rope permissible load: 1.0 ton or more
Number of ropes used: Four
Forklift permissible load: 3.0 ton or more
3.2
INSTALLATION
(1) Installing the robot using the standard pedestal
Described below is how to install the robot using the standard pedestal, which is factory-assembled
with the robot.
Fig. 3.2 (a) shows the robot base dimensions. Fig. 3.2 (b) shows an actual example of robot
installation. Secure the floor plate (iron plate) to the floor using 16 M20 chemical anchors
(strength class 4.8). Then, secure the robot to the floor plate with eight M20#40 bolts (strength
class 12.9), which are M20 size and at least 40 mm in length.
·
Those bolts for which no tightening torque is specified must be tightened according to the
APPENDIX D BOLT TIGHTENING TORQUE TABLE.
- 112 -
B-81995EN/06
CONNECTION
3.TRANSPORTATION AND INSTALLATION
CAUTION
1 If the robot base is secured directly to the floor with chemical anchors, the
anchors may fail due to fluctuating load during robot operation.
2 Do not provide leveling (with a wedge, for example) between the robot base and
floor plate. Otherwise, any robot vibration may be accentuated due to the robot
not being in close contact with the floor plate.
8-f24
Through hole
Front
Center of rotation
of the J1-axis
Secure the robot, using eight through holes
marked with
.
Fig. 3.2 (a) Installation hole dimensions of the robot base
- 113 -
3.TRANSPORTATION AND INSTALLATION CONNECTION
B-81995EN/06
16-f24 Through hole
Center of rotation
of the J1-axis
Front
Chemical anchor
M20 (16 pcs)
Strength classification 4.8
Robot mounting bolt M20x40 (8 pcs)
Strength classification 12.9
Tightening torque 530Nm (54kgm)
Tightening torque 190Nm (19kgm)
Robot base
Board
Floor face
Fig. 3.2 (b) Sample installation
NOTE
1 The customer should prepare the following parts:
- Eight robot securing bolts: M20#40 (strength class 12.9)
- Sixteen chemical anchors: M20 (strength class 4.8)
- One floor plate: 32t in thickness
2 The customer is responsible for preparation prior to installation (mounting of
anchors, for example)
- 114 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-81995EN/06
Table 3.2 (a), (b) indicate the force and moment applied to the base. Table 3.2 (c),(d) indicates the
coasting time and distance of the J1 through J3 axes until the robot stopping by Power-Off stop or by
Controlled stop after input of the stop signal. Refer to the data when considering the strength of the
installation face.
Table 3.2 (a) Force and moment acting to base <M-410iB/160>
Vertical moment:
MV
Force in vertical direction:
FV
Horizontal moment:
MH
Force in horizontal direction: FH
At stop
At acceleration/deceleration
At emergency stop
14,300 Nm
(1,460 gfm)
20,600 N
(2,100 kgf)
0 Nm
(0 kgfm)
0N
(0 kgf)
44,800 Nm
(4,570 kgfm)
31,600 N
(3,230 kgf)
10,400 Nm
(1,060 kgfm)
13,200 N
(1,340 kgf)
53,600 Nm
(5,470 kgfm)
38,100 N
(3,890 kgf)
11,600 Nm
(1,190 kgfm)
15,700 N
(1,600 kgf)
Table 3.2 (b) Force and moment acting to base <M-410iB/300>
Vertical moment: MV
Force in vertical direction: FV
Horizontal moment: MH
Force in horizontal direction: FH
At stop
At acceleration/deceleration
At emergency stop
19,000 Nm
(1,930 gfm)
22,000 N
(2,240 kgf)
0 Nm
(0 kgfm)
0N
(0 kgf)
56,600 Nm
(5,780 kgfm)
34,800 N
(3,550 kgf)
14,100 Nm
(1,440 kgfm)
9,400 N
(960 kgf)
67,100 Nm
(6,850 kgfm)
41,700 N
(4,260 kgf)
14,400 Nm
(1,470 kgfm)
10,800 N
(1,100 kgf)
Table 3.2 (c) Stopping time and distance until the robot stopping by Power-Off stop after input of stop signal
Model
J1-axis
J2-axis
J3-axis
M-410iB/160
M-410iB/300
*
*
Stopping time [ms]
Stopping distance [deg] (rad)
Stopping time [ms]
Stopping distance [deg] (rad)
730
47.5 (0.83)
610
25.9 (0.45)
200
5.0 (0.23)
185
8.3 (0.14)
168
11.3 (0.20)
135
6.9 (0.12)
Max payload and max speed
Max. payload, and max. inertia posture
Table 3.2 (d) Stopping time and distance until the robot stopping by Controlled stop after input of stop signal
Model
J1-axis
J2-axis
J3-axis
M-410iB/160
M-410iB/300
*
*
Stopping time [ms]
Stopping distance [deg] (rad)
Stopping time [ms]
Stopping distance [deg] (rad)
Max payload and max speed
Max. payload, and max. inertia posture
- 115 -
1036
71.4 (1.25)
788
35.7 (0.62)
1036
70.3 (1.23)
788
37.9 (0.66)
1044
74.2 (1.29)
788
42.2 (0.74)
3.TRANSPORTATION AND INSTALLATION CONNECTION
B-81995EN/06
Base
Fig. 3.2 (c) Force and moment acting to the base
(2) Installing the robot without using the standard pedestal
A robot with remote controller can be installed on a customer-prepared pedestal, without using the
standard pedestal, which is factory-assembled with the robot.
Fig. 3.2 (d) shows how to remove the standard pedestal from the robot. First put the robot in the
posture of J1-axis = 0°, J2-axis = -44°, J3-axis = -25°, and J4-axis = 0°, then prepare to sling
up the robot portion above the J1 base with rope. Remove the J1-axis mounting bolts (sixteen M16
×65 bolts), and separate the J1 base from the pedestal.
Fig. 3.2 (e) shows the installation interface for the robot. Design a pedestal while taking care of the
following points:
Provide space required when replacing the J1-axis motor.
Provide space required when mounting and dismounting the mastering jig.
Provide space for periodic maintenance (such as battery exchange and degreasing)
Avoid interference of the robot with the cables and connector box.
Make sure that the setup is strong enough to withstand the force and moment listed in Table 3.2
(a) and (b).
To fasten the J1 base to the pedestal, use sixteen bolts having a size of M16 (in strength class 12.9)
and a length of at least 65 mm.
- 116 -
CONNECTION
B-81995EN/06
Note)
Machine weight
Crane capacity
Sling capacity
Sling
3.TRANSPORTATION AND INSTALLATION
1.7 ton
2.5 ton or more
1.0 ton or more
4 pcs
Robot posture
Axis
J1
J2
J3
J4
Posture
0°
-44°
-25°
0°
J1 base mounting bolt
M16X65 (16 pcs)
Washer
Forklift bracket
J1 base
Frame
Fig. 3.2 (d) How to remove the pedestal (Remote controller type)
- 117 -
3.TRANSPORTATION AND INSTALLATION CONNECTION
B-81995EN/06
178
242
(500)
357
60
Battery box
Mastering fixture
214
250
Robot connection cable
65
290
65
160
160
290
65
65
Hａｎ-46 EEM
65
340
210
Hａｎ -46EEM
210
340
65
880
65
Tap for earth
16-φ18Through
spot hole O26 depth 20 (Back side)
J1 base mounting trhoug hole
65
Mastering fixture
880
Grease inlet
Fig. 3.2 (e) Installation interface for the robot without a standard pedestal (Remote controller type)
- 118 -
B-81995EN/06
3.3
3.TRANSPORTATION AND INSTALLATION
CONNECTION
MAINTENANCE AREA
Fig. 3.3 shows the maintenance area of the mechanical unit.
Mastering
area
Mastering
area
Maintenance area of controller
(only for integrated controller)
Fig. 3.3 Maintenance area
3.4
INSTALLATION CONDITION
Refer to specification of “PREFACE” about installation specifications.
- 119 -
APPENDIX
A.SPARE PARTS LISTS
APPENDIX
B-81995EN/06
A
SPARE PARTS LISTS
No.
Specifications
K101
K102
K103
K104
K151
K152
K153
K154
K162
K164
K201
K202
K203
K204
K251
K253
K105
K106
K107
K903
K905
K708
A660-8014-T731
A660-4004-T286
A660-8014-T733
A660-4004-T287
A660-8015-T881
A660-4004-T607
A660-8015-T882
A660-4004-T608
A660-4005-T270
A660-4005-T271
A660-8014-T863
A660-8014-T864
A660-8014-T865
A660-8014-T866
A660-8015-T883
A660-8015-T884
A660-2005-T924
A660-8014-T737
A660-2005-T953
A05B-1041-D005
A05B-1041-D007
A660-8012-T572
Table A (a) Cables
Functions
Remarks
For CE, R-J3iB integrated type controller
J1 to J4-axis Pulsecoder, EE
For CE, R-J3iB integrated type controller
J1 to J4-axis power, brake
For CE, R-J3iB integrated type controller
J1 to J5-axis Pulsecoder, EE
For CE, R-J3iB integrated type controller
J1 to J5-axis power, brake
For CE, R-30iA/R-30iB integrated type controller
J1 to J4-axis Pulsecoder, EE
For CE, R-30iA integrated type controller
J1 to J4-axis power, brake
For CE, R-30iA/R-30iB integrated type controller
J1 to J5-axis Pulsecoder, EE
For CE, R-30iA integrated type controller
J1 to J5-axis power, brake
For CE, R-30iB integrated type controller
J1 to J4-axis power, brake
For CE, R-30iB integrated type controller
J1 to J5-axis power, brake
For CE, R-J3iB remote type controller
J1 to J4-axis Pulsecoder, EE
J1 to J4-axis power, brake
For CE, Remote type controller
For CE, R-J3iB remote type controller
J1 to J5-axis Pulsecoder, EE
J1 to J5-axis power, brake
For CE, Remote type controller
For CE, R-30iA remote type controller
J1 to J4-axis Pulsecoder, EE
For CE, R-30iA remote type controller
J1 to J5-axis Pulsecoder, EE
AS cable
For CE, Integrated type controller
OT cable
For CE, Integrated type controller
AS cable
For CE, Remote type controller
Camera cable
For CE, Integrated type controller
Camera cable
For CE, Remote type controller
Zipper tube
For CE, Integrated type controller
Table A (b) Motor
Specifications
Axis
J1, J2, J3
A06B-0268-B605#S000
J4
A06B-0223-B605#S000
Table A (c) Reducer
Specifications
Axis
J1-axis reducer
J2-axis reducer
J3-axis reducer
J4-axis reducer
Remarks
(ModelαM30/4000i)
(Modelα30/4000is)
ModelαiS30/4000
(Modelα4/4000i)
ModelαiF4/4000
Model
M-410iB/160,300
M-410iB/160
M-410iB/300
M-410iB/160
M-410iB/300
M-410iB/160,300
A97L-0218-0314#400C-36
A97L-0118-0896#380A-171
A97L-0118-0896#450E-210
A97L-0118-0941#250A-141
A97L-0118-0941#250A-185
A97L-0218-0315#50C-33
Table A (d) Input gear kit
Name
Input gear kit
M-410iB/160
Input gear kit
M-410iB/300
Specifications
J2
J3
J2
J3
A97L-0218-0245#171
A97L-0218-0227#141
A97L-0218-0245#210
A97L-0218-0227#185
- 123 -
A.SPARE PARTS LISTS
Name
J1 -axis penduium stopper
J1 -axis motion range control stopper
Name
Battery
Grease
Grease
Name
A290-7039-V201
A05B-1039-K201
Bearing
Remarks
1.5V size D (alkali) (4 pcs / 1 robot)
VIGOGREASE RE0
Shell Alvania grease S2
Table A (g) Teflon sheet
Specifications
Table A (h) Bearing
Specifications
A97L-0001-0194#1700000
Name
Remarks
Standard stopper
Optional stopper
Table A (f) Battery grease
Specifications
A290-7041-X421
Name
B-81995EN/06
Table A (e) Stopper
Specifications
A98L-0031-0005
A98L-0040-0174#10.6KG
A97L-0001-0179#2-2.5KG
Teflon sheet
Oil seal
APPENDIX
Table A (i) Oil seal
Specifications
A98L-0040-0047#08511013
- 124 -
Remarks
For cable kit
Remarks
J3-axis reducer (2 pcs / 1 robot)
Remarks
J3-axis reducer
B-81995EN/06
B
APPENDIX
CONNECTION DIAGRAM
- 125 -
B.CONNECTION DIAGRAM
B.CONNECTION DIAGRAM
APPENDIX
Fig.B (a) Internal connection diagram (Integrated R-J3iB controller)
- 126 -
B-81995EN/06
B-81995EN/06
APPENDIX
- 127 -
B.CONNECTION DIAGRAM
B.CONNECTION DIAGRAM
APPENDIX
Fig.B (b) Internal connection diagram (Remote R-J3iB controller)
- 128 -
B-81995EN/06
B-81995EN/06
APPENDIX
- 129 -
B.CONNECTION DIAGRAM
B.CONNECTION DIAGRAM
APPENDIX
B-81995EN/06
CONTROLLER
CNJ1A
0721#3HASKX
1 J1U1
2 J1V1
3 J1W1
0721#3HASKX
CNJ1B
1 J1U1
2 J1V1
3 J1W1
CNJ2A
0721#3HASKX
1 J2U1
2 J2V1
3 J2W1
CNJ2B
0721#3HASKX
1 J2U1
2 J2V1
3 J2W1
CNJ3A
0721#3HASKX
1 J3U1
2 J3V1
3 J3W1
CNJ3B
0721#3HASKX
1 J3U1
2 J3V1
3 J3W1
CNJ4
0984#H03SSX
1 J4U
2 J4V
3 J4W
0984#H03SSX
CNJ5
1 J5U1
2 J5V1
3 J5W1
K154 (R-30iA)
A660-4004-T608
K164 (R-30iB)
A660-4005-T271
(SERVO HAND OPTION)
K152 (R-30iA)
A660-4004-T607
K162 (R-30iB)
A660-4005-T270
0726#031KSX
0727#ASM(3)
0726#031KSX
0727#ASM(3)
0726#031KSX
0727#ASM(3)
0726#031KSX
0727#ASM(3)
0726#031KSX
0727#ASM(3)
0726#031KSX
0727#ASM(3)
0996#031KSX
0997#ASL(3)
0996#031KSX
0997#ASL(3)
0984#H03SSX
CNJ6
1 (J6U1)
2 (J6V1)
3 (J6W1)
CNGA
0721#3HASKY
1 J1G1
2 J2G1
3 J3G1
0721#3HASKY
CNGB
1 J1G1
2 J2G1
3 J3G1
0984#H03SSY
CNGC
1 J4G1
2 J5G1
3 (J6G1)
0726#031KSY
0727#ASM(3)
0726#031KSY
0727#ASM(3)
0996#031KSY
0997#ASL(3)
CRR88 D3200M(YY)
A1 BK(J1),BK(J2) B1 BKC(J1,J2)
A2 BK(J3)
B2 BKC(J3)
A3 BK(J4),BK(J5),(BK(J6)) B3 BKC(J4,J5,(J6))
CRF8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
A63L-0002-0008#H48S
A
XPRQJ1
XPRQJ2
XPRQJ3
XPRQJ4
XPRQJ5
(XPRQJ6)
B
PRQJ1
PRQJ2
PRQJ3
PRQJ4
PRQJ5
(PRQJ6)
RI 1
RI 3
RI 5
RI 7
XPPABN
RO 2
RO 4
RO 6
RO 8
RI 2
RI 4
RI 6
RI 8
RO 1
RO 3
RO 5
RO 7
XHBK
XROT
0V(G1,G2)
24V(A1,A2,A3,A4,A5)
24VIN(A1,A2,A3,A4,A5)
C
5V(A1,A2)
5V(A3,A4)
5V(B1,B2)
5V(B3,B4)
5V(C1)
(5V)
0V(A1,A2)
0V(A3,A4)
0V(B1,B2)
0V(B3,B4)
0V(C1)
(0V)
K151
A660-8015-T881
031KSFY
K153
A660-8015-T882
(SERVO HAND OPTION)
031KSY
24VF(A1)
24VIN(A1)
2 XROT
1
3
K106
A660-8014-T737
K109
A05B-1037-D001
Fig.B (c) Internal connection diagram (Integrated R-30iA/R-30iB controller)
- 130 -
APPENDIX
B-81995EN/06
0648#82222SD
0749#12A1
A66L-0001-0401#30
J1 MOTOR (αiS30/4000)
M1M
22-22P(8.0SQ 46A)
A J1U1
B J1V1
0848#A10SL1
0850(8)
0648#810SL3SJ
0653#04AC
M1P
8 5V(A1)
9 5V(A2)
10 0V(A1)
M1BK
A BK(J1)
C J1W1
D J1G1
10SL1(0.3SQ 3A)
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3 DRAIN
0V(BT1)
7
0V(A2)
10SL-3P(1.25SQ 13A)
B BKC(J1)
C
B.CONNECTION DIAGRAM
0648#82222SD
0749#12A1
J2 MOTOR (αiS30/4000)
M2M
A J2U1
B J2V1
M2P
0848#A10SL1
0850(8)
8 5V(A3)
9 5V(A4)
10 0V(A3)
0648#810SL3SJ
0653#04AC
M2BK
A BK(J2)
0648#82222SD
0749#12A1
0848#A10SL1
0850(8)
0648#810SL3SJ
0653#04AC
10SL1(0.3SQ 3A)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3 DRAIN
0V(BT2)
7
0V(A4)
10SL-3P(1.25SQ 13A)
B BKC(J2)
C
J3 MOTOR (αiS30/4000)
22-22P(8.0SQ 46A)
M3M
A J3U1
B J3V1
A66L-0001-0401#30
22-22P(8.0SQ 46A)
C J2W1
D J2G1
M3P
8 5V(B1)
9 5V(B2)
10 0V(B1)
M3BK
A BK(J3)
C J3W1
D J3G1
10SL1(0.3SQ 3A)
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3 DRAIN
0V(BT3)
7
0V(B2)
10SL-3P(1.25SQ 13A)
B BKC(J3)
C
A66L-0001-0401#30
0881#1810S
0881#10C
J4 MOTOR (αiF/4000)
M4M
22-22P(8.0SQ 46A)
A J4U1
B J4V1
M4P
0848#B10SL1
0850(8)
A66L-0001-0401#10
A66L-0001-0464#1 (A66L-0001-0464#2:SERVO HAND OPTION)
A66L-0001-0459
8 5V(B3)
9 5V(B4)
10 0V(B3)
0648#810SL3SJ
0653#04AC
M4BK
A BK(J4)
A66L-0001-0459
M5M
A J5U1
B J5V1
C J5W1
A66L-0001-0163#5
GB1
D BK(J5)
E BKC(J5)
C J4W1
D J4G1
10SL1(0.3SQ 3A)
4 6V(BT4)
1
5 XPRQJ4
2
6 PRQJ4
3 DRAIN
0V(BT4)
7
0V(B4)
10SL-3P(1.25SQ 13A)
B BKC(J4)
C
20-15S(3.5SQ 23A)
F
G J5G1
6V(BT1,BT2,BT3,
BT4,BT5)
+
M5P
A PRQJ5
B XPRQJ5
C FG
BATTERY
0V(BT1,BT2,BT3,
BT4,BT5)
END EFFECTOR INTERFACE
USER INTERFACE/SIGNAL (OPTION)
AS1
1
2
3
4
5
6
7
8
ZIPPER TUBE
K708
A660-8012-T572
S1
S2
S3
S4
S5
S6
S7
S8
9
10
11
12
13
14
15
16
16S-1S(1.25SQ 13A)
D 5V(C1)
F 6V(BT5)
E 0V(C1)
G 0V(BT5)
EE
A63L-0001-0234#W2524M
(0.5SQ 5A) φ9.6-φ15
17 S17
S9
18 S18
S10
S11
19 S19
20 S20
S12
21 S21
S13
22 S22
S14
S15
23 S23
24 S24
S16
1
2
3
4
5
6
7
8
RO 1
RO 2
RO 3
RO 4
RO 5
RO 6
XHBK
0V(G1)
9
10
11
12
13
14
15
16
A63L-0001-0234#R2524F
(0.5SQ 5A) φ9.6-φ15
17 24VF(A2) 24VIN(A2)
RI 1
18 24VF(A3) 24VIN(A3)
RI 2
19 24VF(A4) 24VIN(A4)
RI 3
20 24VF(A5) 24VIN(A5)
RI 4
21 RO 7
RI 8
XPPABN 22 RO 8
23 0V(G2)
RI 5
24 RI 7
RI 6
USER INTERFACE/SIGNAL (OPTION)
AS2
K105
A660-2005-T924
XROT
SQ1:J1 AXIS LIMIT SWITCH
(OPTION:A05B-141-H212)
COM
DUMMY(OPTION:A05B-1037-H211)
SQ1
24E
NC
:MOVABLE
FANUC Robot M-410iB/160,300
CIRCUIT DIAGRAM (CE)
R-30iA/R-30iB INTEGRATED TYPE CONTROLLER
CABLE:A05B-1041-H301 to H304,H402,H404
,H951,H952,H971 and H972
- 131 -
1
2
3
4
5
6
7
8
S1
S2
S3
S4
S5
S6
S7
S8
9
10
11
12
13
14
15
16
A63L-0001-0234#R2524FX
(0.5SQ 5A) φ9.6-φ15
17 S17
S9
18 S18
S10
19 S19
S11
20 S20
S12
21 S21
S13
22 S22
S14
23 S23
S15
S16
24 S24
B.CONNECTION DIAGRAM
APPENDIX
B-81995EN/06
J1 CONNECTOR BOX
RM2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
J1U1
J1U1
J2U1
J2U1
J3U1
J3U1
J1V1
J1V1
J2V1
Han 46EE
(4.0SQ 16A)
M TYPE
17 J2V1
18 J3V1
19 J3V1
20
21
22
23
24 J1W1
25 J1W1
26 J2W1
27 J2W1
28 J3W1
29 J3W1
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
RM1
M TYPE
1
17 J2V1
18 J3V1
2 J1U1
19 J3V1
3 J1U1
20 J4V1
4 J2U1
21 J5V1
5 J2U1
22
6 J3U1
23 BK(J2)
7 J3U1
24 J1W1
8 J4U1
9 J5U1
25 J1W1
26 J2W1
10
11 BK(J1)
27 J2W1
12 BKC(J1,J2) 28 J3W1
13 BKC(J3,J4,J5) 29 J3W1
14 J1V1
30 J4W1
15 J1V1
31 J5W1
16 J2V1
K202
J1G1
J1G1
J2G1
J2G1
J3G1
J3G1
K204
A66L-0001-0401#30
A660-8014-T664 A660-8014-T866
(SERVO HAND OPTION)
Han 46EE
(4.0SQ 16A)
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
BK(J3)
J1G1
J1G1
J2G1
J2G1
J3G1
J3G1
J4G1
J5G1
BK(J4)
BK(J5)
GB1
6V(BT1,BT2,BT3,
BT4,BT5)
+
BATTERY
0V(BT1,BT2,BT3,
BT4,BT5)
RP1
M TYPE
1 RI1
15 RI3
16 XPPABN
2 RI7
17 RO3
3 RO1
18 24VF(A1,A2,A3,A4)
4 RO7
5 5V(A1,A2,A3,A4) 19 5V(C1)
20 PRQJ3
6 PRQJ1
7 XPRQJ1
21 XPRQJ3
8 RI2
22 RI4
9 RI8
23 XHBK
10 RO2
24 RO4
11 RO8
25 0V(D1,D2)
12 5V(B1,B2,B3,B4) 26 0V(A1,A2,A3,A4)
13 PRQJ2
27 PRQJ4
14 XPRQJ2
28 XPRQJ4
Han 42DD
(2.5SQ 10A)
29
30
31
32
33
34
35
36
37
38
39
40
41
42
RI5
XROT
RO5
K251
A660-8015-T883
K253
A660-8015-T884
(SERVO HAND OPTION)
A66L-0001-0464#3
0V(B1,B2,B3,B4)
PRQJ5
XPRQJ5
RI6
24E(OT)
RO6
0V(C1)
031KSFY
031KSY
USER INTERFACE/SIGNAL (OPTION)
1 24EOT
2 XROT
3
AS1
1
2
3
4
5
6
7
8
S1
S2
S3
S4
S5
S6
S7
S8
9
10
11
12
13
14
15
16
A63L-0001-0234#W2524M
(0.5SQ 5A) φ9.6-φ15
S9
17 S17
S10
18 S18
S11
19 S19
S12
20 S20
S13
21 S21
S14
22 S22
S15
23 S23
S16
24 S24
K106
A660-8014-T737
SQ1:J1 AXIS LIMIT SWITCH
(OPTION:A05B-1041-H212)
K109
A05B-1037-D001
DUMMY(OPTION:A05B-1037-H211)
Fig.B (d) Internal connection diagram (Remote R-30iA/R-30iB controller)
- 132 -
J1 MOTOR (αiS30/4000)
22-22P(8.0SQ 46A)
M1M
0648#82222SD
0749#12A1
B.CONNECTION DIAGRAM
APPENDIX
B-81995EN/06
A J1U1
B J1V1
0848#A10SL1
0850(8)
M1P
8 5V(A1)
9 5V(A2)
10 0V(A1)
0648#810SL3SJ
0653#04AC
M1BK
A BK(J1)
C J1W1
D J1G1
10SL1(0.3SQ 3A)
4 6V(BT1)
1
5 XPRQJ1
2
6 PRQJ1
3 DRAIN
0V(BT1)
7
0V(A2)
10SL-3P(1.25SQ 13A)
B BKC(J1)
C
0648#82222SD
0749#12A1
J2 MOTOR (αiS30/4000)
22-22P(8.0SQ 46A)
M2M
A J2U1
B J2V1
0848#A10SL1
0850(8)
M2P
8 5V(A3)
9 5V(A4)
10 0V(A3)
0648#810SL3SJ
0653#04AC
M2BK
A BK(J2)
A66L-0001-0401#30
0648#82222SD
0749#12A1
C J2W1
D J2G1
10SL1(0.3SQ 3A)
4 6V(BT2)
1
5 XPRQJ2
2
6 PRQJ2
3 DRAIN
0V(BT2)
7
0V(A4)
10SL-3P(1.25SQ 13A)
B BKC(J2)
C
J3 MOTOR (αiS30/4000)
M3M
22-22P(8.0SQ 46A)
A J3U1
B J3V1
0848#A10SL1
0850(8)
M3P
8 5V(B1)
9 5V(B2)
10 0V(B1)
0648#810SL3SJ
0653#04AC
M3BK
A BK(J3)
C J3W1
D J3G1
10SL1(0.3SQ 3A)
4 6V(BT3)
1
5 XPRQJ3
2
6 PRQJ3
3 DRAIN
0V(BT3)
7
0V(B2)
10SL-3P(1.25SQ 13A)
B BKC(J3)
C
A66L-0001-0401#30
J4 MOTOR (αiF/4000)
M4M
22-22P(8.0SQ 46A)
0881#1810S
0881#10C
A J4U1
B J4V1
A66L-0001-0401#10
A66L-0001-0464#1 (A66L-0001-0464#2:SERVO HAND OPTION)
A66L-0001-0459
0848#B10SL1
0850(8)
M4P
8 5V(B3)
9 5V(B4)
10 0V(B3)
0648#810SL3SJ
0653#04AC
M4BK
A BK(J4)
A66L-0001-0459
K105
A660-2005-T953
M5M
A J5U1
B J5V1
C J5W1
10SL1(0.3SQ 3A)
4 6V(BT4)
1
5 XPRQJ4
2
6 PRQJ4
3 DRAIN
0V(BT4)
7
0V(B4)
10SL-3P(1.25SQ 13A)
B BKC(J4)
C
20-15S(3.5SQ 23A)
D BK(J5)
F
E BKC(J5)
G J5G1
M5P
A PRQJ5
B XPRQJ5
C FG
C J4W1
D J4G1
D
E
16S-1S(1.25SQ 13A)
F 6V(BT5)
5V(C1)
G 0V(BT5)
0V(C1)
END EFFECTOR INTERFACE
EE
1
2
3
4
5
6
7
8
RO1
RO2
RO3
RO4
RO5
RO6
XHBK
0V(D1)
9
10
11
12
13
14
15
16
A63L-0001-0234#R2524F
(0.5SQ 5A) φ9.6-φ15
RI1
17 24VF(A1)
RI2
18 24VF(A2)
RI3
19 24VF(A3)
RI4
20 24VF(A4)
RI8
21 RO7
XPPABN 22 RO8
RI5
23 0V(D2)
RI6
24 RI7
USER INTERFACE/SIGNAL (OPTION)
AS2
XROT
COM
SQ1
24E
NC
:MOVABLE
FANUC Robot M-410iB/160,300
CIRCUIT DIAGRAM (CE)
R-30iA/R-30iB REMOTE CONTROLLER TYPE
CABLE:A05B-1041-H305 to H308 and H963
1
2
3
4
5
6
7
8
- 133 -
S1
S2
S3
S4
S5
S6
S7
S8
9
10
11
12
13
14
15
16
A63L-0001-0234#R2524FX
(0.5SQ 5A) φ9.6-φ15
S9
17 S17
S10
18 S18
S11
19 S19
S12
20 S20
S13
21 S21
S14
22 S22
S15
23 S23
S16
24 S24
C.PERIODIC MAINTENANCE
C
APPENDIX
B-81995EN/06
PERIODIC MAINTENANCE
FANUC Robot M-410iB/160,300
Working time (H)
Check
time
Items
Check the mechanical cable.
1
(damaged or twisted)
Check the motor connector.
2
(loosening)
Periodic Maintenance Table
Grease First
6
9
3
amount check months months months 1 year
320
960 1920 2880 3840 4800
2
years
5760
6720
7680
0.2H
―
○
○
○
0.2H
―
○
○
○
0.2H
―
○
○
○
2.0H
―
○
○
○
0.1H
―
○
○
○
1.0H
―
○
○
○
7 cable
0.1H
―
○
○
○
8 Replacing battery.
0.1H
―
0.7H
8030ml
0.5H
1570ml
0.5H
1180ml
0.5H
1400ml
0.1H
each
20ml
0.1H
20ml
0.1H
each
10ml
4.0H
―
0.2H
―
18 Cleaning the ventilator
0.2H
―
19 Replacing battery *2
0.1H
―
3 Tighten the end effector bolt.
Tighten the cover and main
4 bolt.
8640
9600 10560
Check the mechanical stopper
5 and adjustable mechanical
Mechanical unit
stopper
6 Remove spatter and dust etc.
Check the end effector (hand)
Replacing grease of J1 axis
9 reducer
Replacing grease of J2 axis
10 reducer
Replacing grease of J3 axis
11 reducer
Replacing grease of J4 axis
12 gearbox
Apply greasing to bearing of J3
13 arm connection*1
14
15
Controller
16
17
(2 location)
Apply greasing to the J3-axis
cross roller
Apply greasing to connection
parts of wrist *1 (2 locations)
Replacing cable of mechanical
unit *
Check the robot cable, teach
pendant cable and robot
connecting cable
●
○
○
○
*1 Refer to this manual about greasing points.
*2 Refer to manual of controller
*3 ●: requires order of parts
○: does not require order of parts
- 134 -
○
○
○
○
○
○
○
○
○
○
○
○
C.PERIODIC MAINTENANCE
APPENDIX
B-81995EN/06
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720
Item
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
○
○
○
○
○
6
○
○
○
○
○
7
●
●
●
●
8
●
●
●
●
●
●
●
12
●
●
13
●
●
14
●
●
15
Overhaul
●
○
16
○
○
○
○
○
10
11
●
○
9
○
○
○
○
○
○
○
○
○
●
○
○
○
○
○
○
17
○
○
○
18
19
- 135 -
D.STRENGTH OF BOLT AND BOLT TORQUE LIST
D
APPENDIX
B-81995EN/06
STRENGTH OF BOLT AND BOLT TORQUE LIST
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps. Be sure to wipe the excess LOCTITE after tightening bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more
If no tightening torque is specified for a bolt, tighten it according to this table.
Recommended bolt tightening torques
Nominal
diameter
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Hexagon socket head
bolt
(Steel)
Tightening torque
Upper limit Lower limit
1.8
1.3
4.0
2.8
7.9
5.6
14
9.6
32
23
66
46
110
78
180
130
270
190
380
260
530
370
730
510
930
650
1400
960
1800
1300
3200
2300
Unit: Nm
Hexagon socket head
button bolt
Hexagon bolt
Hexagon socket head
Hexagon socket head
(steel)
flush bolt
bolt (stainless)
Low-head bolt
(steel)
Tightening torque
Tightening torque
Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
――――
――――
―――
0.76
0.53 ――――
1.8
1.3
1.8
1.3
1.7
1.2
3.4
2.5
4.0
2.8
3.2
2.3
5.8
4.1
7.9
5.6
5.5
3.8
14
9.8
14
9.6
13
9.3
27
19
32
23
26
19
――――
――――
48
33
45
31
――――
――――
76
53
73
51
――――
――――
120
82
98
69
――――
――――
160
110
140
96
――――
――――
230
160
190
130
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
- 136 -
INDEX
B-81995EN/06
INDEX
<Number>
<M>
M-410iB/160, 300..........................................................52
MAINTENANCE AREA.............................................119
MAINTENANCE TOOLS.............................................12
MASTERING ...........................................................37,41
Mastering Data Entry .....................................................48
MECHANICAL COUPLING OF END EFFECTOR TO
WRIST .......................................................................95
MECHANICAL COUPLING TO THE ROBOT...........92
1.5-YEAR (5,760 hours) CHECKS................................12
1-year (3,840 hours)checks ............................................11
3-MONTH (960 hours) CHECKS..................................11
3-YEAR (11,520 hours)CHECKS..................................12
4-YEAR (15,360 hours) CHECKS.................................12
<A>
ADJUSTING LIMIT SWITCHES AND DOGS
(OPTION)...................................................................30
ADJUSTMENTS ...........................................................30
AIR SUPPLY ...............................................................101
Attaching the mastering fixture......................................38
<N>
NOTE FOR PART REPLACEMENT ...........................52
<O>
<B>
OPTION CABLE INTERFACE ..................................103
BACKLASH MEASUREMENT ...................................28
<P>
<C>
PERIODIC MAINTENANCE ................................14,134
PIPING AND WIRING .................................................73
PREFACE .................................................................... p-1
PREVENTIVE MAINTENANCE ...................................6
PROCEDURE FOR RELEASING REMAINING
PRESSURE WITHIN THE GREASE BATH............17
CABLE FORMING .......................................................75
CABLE REPLACEMENT.............................................81
CHECKING THE MASTERING ..................................50
CONFIGURATION .........................................................3
CONNECTION DIAGRAM ........................................125
<D>
<Q>
DAILY CHECKS.............................................................6
Quick Mastering.............................................................44
<E>
<R>
EQUIPMENT MOUNTING FACE ...............................96
REPLACING CABLES .................................................74
REPLACING GREASE OF THE DRIVE
MECHANISM ...........................................................14
REPLACING PARTS....................................................52
REPLACING THE BALANCER ..................................71
REPLACING THE BATTERIES ..................................20
Replacing the J1-Axis Motor and Reducer ....................52
Replacing the J2-Axis Motor and Reducer ....................57
Replacing the J3-Axis Motor and Reducer ....................60
Replacing the J4-Axis Motor and Reducer ....................63
REPLACING THE OPTIONAL J1-AXIS LIMIT
SWITCH (OPTION) ..................................................70
REPLACING THE WRIST UNIT.................................67
Resetting Alarms and Preparing for Mastering ..............38
ROBOT INTERFERENCE AREA ................................91
<F>
FAILURES, CAUSES AND MEASURES....................21
FIRST 1-MONTH (320 hours) CHECKS ........................8
FIRST 3-MONTH (960 hours)CHECKS .........................8
Fixture Position Master ..................................................38
<G>
GENERAL ................................................................21,37
Grease Replacement Procedure of M-410iB/160, 300 ...15
<I>
INSTALLATION.........................................................112
INSTALLATION CONDITION..................................119
<J>
<S>
J1-AXIS DRIVE MECHANISM .....................................3
J1-AXIS STROKE MODIFICATION (OPTION) .........34
J2-AXIS DRIVE MECHANISM .....................................4
J3-AXIS DRIVE MECHANISM .....................................4
J4-AXIS DRIVE MECHANISM .....................................5
SAFETY PRECAUTIONS ........................................... s-1
SEALANT APPLICATION ..........................................66
Single Axis Mastering....................................................46
SOFTWARE SETTING.................................................36
SPARE PARTS LISTS ................................................123
STRENGTH OF BOLT AND BOLT TORQUE LIST 136
SUPPLYING GREASE .................................................18
Switching between Modes .............................................99
<L>
LOAD CONDITION AT WRIST ..................................92
LOAD SETTING ...........................................................97
i-1
INDEX
B-81995EN/06
<T>
TRANSPORTATION ..................................................111
TRANSPORTATION AND INSTALLATION...........111
TROUBLE SHOOTING ................................................21
<Z>
Zero Degree Mastering ..................................................42
ZERO POINT POSITION AND MOTION LIMIT OF
J2-AXIS TO J4-AXIS ................................................32
i-2
REVISION RECORD
B-81995EN/06
REVISION RECORD
Edition
06
Date
•
•
•
•
•
June,2012
•
05
Feb.,2011
04
Dec., 2007
03
Sep., 2007
02
Aug., 2006
01
July., 2002
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Contents
Addition of R-30iB
Addition of note for low temperature
Addition of note about oil exudation
Change specification of camera cable
Correction of errors
Addition of stop type of robot
Addition of stopping time and distance when controlled stop is executed
Addition note about end effector (hand) cable
Correction of errors
Addition of a procedure to move arms in emergency or abnormal situations
Change of the note of transportation
Addition of Stopping time and distance when emergency stop
Addition of sensor cable
Correction of errors
Change the name of controller (from R-J3iC to R-30iA).
Models with R-J3iC have been added.
The recommended grease types have been changed.
J2, J4-axis cover option is added.
The change of the motor.
WARNING of transportation is added.
Transportation posture is changed.
r-1
B-81995EN/06
* B - 8 1 9 9 5 E N /
0 6 *