< > M-20+B
MECHANICAL UNIT
OPERATOR'S MANUAL
B-83754EN/01
•
Original Instructions
Thank you very much for purchasing FANUC Robot.
Before using the Robot, be sure to read the "FANUC Robot SAFETY HANDBOOK (B-80687EN)"
and understand the content.
• No part of this manual may be reproduced in any form.
• The appearance and specifications of this product are subject to change without notice.
The products in this manual are controlled based on Japan's “Foreign Exchange and
Foreign Trade Law". The export from Japan may be subject to an export license by the
government of Japan. Further, re-export to another country may be subject to the license
of the government of the country from where the product is re-exported. Furthermore, the
product may also be controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual, we endeavor to include all pertinent matters. There are, however, a very
large number of operations that must not or cannot be performed, and if the manual
contained them all, it would be enormous in volume. It is, therefore, requested to assume
that any operations that are not explicitly described as being possible are "not possible".
SAFETY PRECAUTIONS
B-83754EN/01
SAFETY PRECAUTIONS
This chapter describes the precautions which must be observed to ensure the safe use of the robot.
Before attempting to use the robot, be sure to read this chapter thoroughly.
Before using the functions related to robot operation, read the relevant operator's manual to become
familiar with those functions.
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
DEFINITION OF USER
The user can be classified as follows.
Operator:
 Turns the robot controller power ON/OFF
 Starts the robot program with operator’s panel
Programmer:
 Operates the robot
 Teaches the robot inside the safety fence
Maintenance engineer:
 Operates the robot
 Teaches the robot inside the safety fence
 Maintenance (repair, adjustment, replacement)
-
-
“An operator” cannot work inside the safety fence
“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 safety fence, the person must be trained on proper robot operation.
During the operation, programming, and maintenance of your robotic system, programmer, teaching
operator and maintenance engineer must operate with circumspection by using following safety
precautions.
-
Adequate clothes for the operation
Safety shoes
A helmet
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SAFETY PRECAUTIONS
2
B-83754EN/01
DEFINITION OF SAFETY NOTATIONS
To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution
on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is
indicated by "NOTE". Please read each "WARNING", "CAUTION" and "NOTE" before attempting
to use the robots.
Symbol
Definitions
WARNING
Used if hazard resulting in the death or serious injury of the user will be expected to
occur if he or she fails to follow the approved procedure.
Used if a hazard resulting in the minor or moderate injury of the user, or equipment
damage may be expected to occur if he or she fails to follow the approved procedure.
Used if a supplementary explanation not related to any of WARNING, and CAUTION
is to be indicated.
CAUTION
NOTE

3
Check this manual thoroughly, and keep it handy for the future reference.
USER SAFETY
User safety is the primary safety consideration. As it is very dangerous to enter the operating area of the
robot during its automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions.
safety.
Careful consideration must be made to ensure user
(1) We obligate the User to take a FANUC training courses.
FANUC provides various training courses.
details.
Contact your local FANUC representative for
(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 user 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 user can enter the safety fence inside 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
safety fence 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, refer to below Fig.3 (b).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Recommend to install the peripheral device outside of the motion range.
(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 user enters the motion range.
(8) If necessary, install a safety lock so that no one except the user in charge can turn the power on the
robot.
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SAFETY PRECAUTIONS
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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, make sure to turn the power off the robot.
(10) Operators must take the gloves off while manipulating the operator’s panel or teach pendant.
Operation with gloved fingers may 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 must be transported and installed by accurate procedure 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) Do not operate the robot under the following conditions. Otherwise, the robot and peripheral
equipment can be adversely affected, or workers can be severely injured.
Flammable
Explosive
Massive dose of Radiation
Under water, high (heavy) Humidity
Transport human or animals
Stepladder (climb or hang down)
Outdoor
(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) In preparing the trestle, please secure the maintenance engineer safety at high place in reference to
Fig. 3 (c). Design with the Scaffolding and Safety-belt with circumspection.
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SAFETY PRECAUTIONS
B-83754EN/01
RP1
Pulsecoder
RI/RO,XHBK,XROT
RM1
Motor power/brake
EARTH
Safety
安全柵fence
Interlocking
device and safety plug that are activated if the gate is opened.
扉が開いたときに作動するインタロック装置および安全プラグ
Fig. 3 (a)
Safety fence and safety gate
WARNING
When you close a fence, please confirm that there is not a person from all
directions of the robot.
Dual chain
Emergency stop board
orPanel
Panelboard
board
EAS1
EAS11
EAS2
EAS21
Single chain
Panel board
(Note)
（Note）
In case
of R-30iA
For
the R-30iB,
the R-30iB Mate
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.
Refer
the ELECTRICAL
CONNCETIONS Chapter of
In casetoof R-30iA
Mate
CONNECTION
of
Terminals EAS1,EAS11,EAS2,EAS21 are provided
R-30iB
controller maintenance
(B-83195EN)
on the emergency
stop board manual
or connector
panel. or
(in caseMate
of Open
air type)
R-30iB
controller
maintenance manual (B-83525EN)
for details.
Termianls FENCE1,FENCE2 ar e provided
on the emergency stop board.
Refer to controller maintenance manual for details.
FENCE1
FENCE2
Fig. 3 (b) Connection diagram for the signal of safety fence
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Hook for safety belt
Fence
Steps
Trestle
Pedestal
for maintenance
Fig. 3 (c) Pedestal 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. Operator cannot work inside the safety fence.
(1) If you don’t need to operate the robot, turn the power off the robot controller, or press the
“EMERGENCY STOP” button, and then proceed your work.
(2) Operate the robot system outside of the robot motion range.
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering
the dangerous area unexpectedly and the worker from entering a hazardous area.
(4) Install one or more necessary quantity of EMERGENCY STOP button(s) within the operator’s reach
in appropriate location(s) based on the system layout.
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 board
Panel board
or Panel board
EES1
EES11
EES2
EES21
Single chain
External stop button
(Note)
Connect EES1 and EES11, EES2 and EES21
（Note）
For
the R-30iB, the R-30iB Mate
Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
EES1,EES11,EES2,EES21 are on the emergency stop board
In case of R-30iA
EES1,EES11,EES2,EES21
or EMGIN1,EMGIN2
are on the panel
board. of
Refer
to the ELECTRICAL
CONNCETIONS
Chapter
CONNECTION
of
In case of R-30iA Mate
EES1,EES11,EES2,EES21
are on the
emergency
stop boardor
R-30iB
controller maintenance
manual
(B-83195EN)
or connector
(in casemaintenance
of Open air type).
R-30iB
Matepanel
controller
manual (B-83525EN)
EMGIN1,EMGIN2 are on the emergency stop board.
for details.
Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2
Fig. 3.1 Connection diagram for external emergency stop button
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SAFETY PRECAUTIONS
3.2
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SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the motion range of the robot. Please ensure the safety
of programmer.
(1) Unless it is specifically necessary to enter the robot motion range, 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
condition.
(3) If it is inevitable to enter the robot motion range 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 motion range.
(5) Programming must be done outside of the safety fence as far as possible. If programming needs to be
done in the area of the safety fence, the programmer must take the following precautions:
Before entering the safety fence area, ensure that there is no risk of hazardous situation in the
area.
Be ready to press the emergency stop button whenever it is necessary.
Operate the Robot at low speed.
Before starting programming, check the entire system status to ensure that no remote
instruction to the peripheral equipment or motion would harm 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.
Teach pendant is provided with a switch to enable/disable robot operation from teach pendant and DEADMAN
switch as well as emergency stop button. These button and switch function as follows:
(1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type) when pressed.
(2) DEADMAN switch: Functions are different depending on the teach pendant enable/disable switch setting
status.
(a)
Enable: Servo power is turned off and robot stops when the operator releases the DEADMAN switch
or when the operator presses the switch strongly.
(b)
Disable: The DEADMAN switch is disabled.
(Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed
to its intermediate point. When the operator releases the DEADMAN switch or presses the switch
strongly, the robot stops immediately.
The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator
should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.
Based on the risk assessment by FANUC, number of operation of DEADMAN switch should not exceed about
10000 times per year.
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.
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Mode
Teach pendant
enable switch
Software remote
condition
Local
Remote
Local
Off
Remote
Local
On
Remote
T1, T2
mode
Local
Off
Remote
T1,T2 mode: DEADMAN switch is effective.
AUTO
mode
On
Teach pendant
Operator panel
Peripheral
device
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
(6) To start the system using the operator’s panel, make certain that nobody is in the robot motion range
and that there are no abnormal conditions in the robot motion range.
(7) When a program is completed, be sure to carry out the test operation according to the following
procedure.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low
speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed, and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test operation above, execute it in
the automatic operation mode.
(8) While operating the system in the automatic operation mode, the teach pendant operator must leave
the safety fence.
3.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer personnel, pay utmost attention to the following.
(1) Must never be in the area during its operation.
(2) A hazardous situation may occur 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 must 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 area while the power is on, press the emergency
stop button on the operator panel, or the teach pendant before entering the area. 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 engineer must check the entire
system in order to make sure that there is no dangerous situation around. In case the worker needs to
enter the safety area whilst a dangerous situation exists, extreme care must be taken, and entire
system status must be carefully monitored.
(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off
and the pressure in the piping should be reduced to zero.
(6) Before the start of maintenance, check the robot and its peripheral devices are all in the normal
condition.
(7) Do not operate the robot in the automatic mode while anybody is in the robot motion range.
(8) In maintaining the robot parallel to a wall or instrument, or when multiple workers are working
nearby, make certain that their escape path is not obstructed.
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SAFETY PRECAUTIONS
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(9) When a tool is mounted on the robot, or any moving device other than the robot is installed, such as
belt conveyor, careful attention required for those motion.
(10) Assign an expert near the operator panel who can press the EMERGENCY STOP button whenever
he sees the potential danger.
(11) In case of replacing a part, please contact your local FANUC representative. Wrong procedure may
cause the serious damage to the robot and the worker.
(12) Make sure that no impurity into the system in while (in) replacing or reinstalling components.
(13) Turn off the circuit breaker to protect again electric shock in handling each unit or printed circuit
board in the controller during inspection. 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 not only a damage to the internal parts of the controller but also a fire.
(15) When restarting the robot system after completing maintenance work, make sure in advance that
there is no person in the motion range and that the robot and the peripheral devices are not abnormal.
(16) In case of remove the motor or brake, suspend the arm by crane or other equipment beforehand to
avoid falling.
(17) Whenever grease is spilled on the floor, remove them as soon as possible to prevent from falling.
(18) The following parts are heated. If a maintenance engineer 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 of the controller

Reducer

Gearbox

Wrist unit
(19) Maintenance must be done with appropriate lightning. Be careful that those lightning will not cause
any further danger.
(20) When a motor, reducer, or other heavy load is handled, a crane or other equipmenthould be used to
protect maintenance engineers from excessive load. Otherwise, the maintenance engineers would be
severely injured.
(21) Must never climb or step on the robot even in the maintenance. If it is attempted, the robot would be
adversely affected. In addition, a misstep can cause injury to the worker.
(22) Secure a pedestal and wear the safety belt in performing the maintenance work in high place.
(23) Remove all the spilled oil or water and metal chips around the robot in the safety fence after
completing the maintenance.
(24) All the related bolts and components must return to the original place in replacing the parts. If some
parts are missing or left (remained), repeat the replacement work until complete the installation.
(25) In case robot motion is required during maintenance, the following precautions should be taken :

Secure 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.

Keep vigilant attention for the potential danger. and to press the emergency stop button
whenever it is necessary.
(26) Periodic inspection required. (Refer to the robot mechanical manual and controller maintenance
manual.) A failure to do the periodical inspection can may adversely affect the performance or
service life of the robot and may cause an accident
(27) After replacing some parts, a test run required by the predetermined method. (See TESTING section
of “Controller operator’s manual”. During the test run, the maintenance staff must work outside the
safety fence.
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SAFETY PRECAUTIONS
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4
4.1
SAFETY OF THE TOOLS AND
PERIPHERAL EQUIPMENT
PRECAUTIONS IN PROGRAMMING
(1) Adopt a limit switch or other sensor to detect a dangerous state 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 in order not to 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, operate the robot where insulated from the
influence of grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Adopt limit switches or mechanical stoppers to limit the robot motion, and avoid the robot from
collisions against peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. Failure to follow precautions
may cause mechanical troubles.

Use mechanical unit cable that have required user interface.

Do not add user cable or hose to inside of mechanical unit.

Please do not obstruct the movement of the mechanical unit 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.

When installing user peripheral equipment on the robot mechanical unit, please pay attention
that equipment does not interfere with the robot itself.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please
avoid the system construction that power-off stop would be operated routinely. (Refer to bad case
example.) Please perform power-off stop after reducing the speed of the robot and stopping it by
hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type.)
(Bad case example)

Whenever poor product is generated, a line stops by emergency stop and power-off of the robot
is incurred.

When alteration is necessary, safety switch is operated by opening safety fence and power-off
stop is incurred for the robot during operation.

An operator pushes the emergency stop button frequently, and a line stops.

An area sensor or a mat switch connected to safety signal operates routinely and power-off stop
is incurred for the robot.

Power-off stop is regularly incurred due to an inappropriate setting for Dual Check Safety
(DCS).
(6) Power-off stop of Robot is executed when collision detection alarm (SRVO-050) etc. occurs. Please
try to avoid unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the
causes of the alarm.
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SAFETY PRECAUTIONS
5
5.1
B-83754EN/01
SAFETY OF THE ROBOT MECHANICAL
UNIT
PRECAUTIONS IN OPERATION
(1) 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 to comprehend the robot movement by the key in advance.
5.2
PRECAUTIONS IN PROGRAMMING
(1) Design to arrange avoiding mutual interfere when various robot’s operation area crossover
significantly.
(2) Be sure to specify the predetermined work origin in a motion program so that the robot starts from
the origin and terminates at the origin. Make it possible for the operator to distinguish easily that the
robot motion has terminated at a glance.
5.3
PRECAUTIONS FOR MECHANISMS
Keep the motion range 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 sandwiched 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
(Input voltage AC100-115V single phase)
A05B-2450-J350
(Input voltage AC200-240V single phase)
A05B-2450-J351
A05B-2525-J047 (5m)
A05B-2525-J048 (10m)
A05B-2525-J010 (5m) (AC100-115V Power plug) (*)
A05B-2525-J011 (10m) (AC100-115V Power plug) (*)
A05B-2450-J364 (5m) (AC100-115V or AC200-240V No power plug)
A05B-2450-J365 (10m) (AC100-115V or AC200-240V No power plug)
(*) These do not support CE marking.
(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.
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CAUTION
Robot systems installed without adequate number of brake release units or
similar means are neither in compliance with EN ISO 10218-1 nor with the
Machinery Directive and therefore cannot bear the CE marking.
WARNING
Robot arm would fall down by releasing its brake because of gravity. 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 the J2-axis motor brake
J2軸モータブレーキを解除する場合
In case
of releasing the J3-axis motor brake
J3軸モータブレーキを解除する場合
Fall落下
down
Fall
down
落下
Fall
down
落下
Method of supporting the robot arm
アーム支持方法
Sling
スリング
(*) This figure is an example of floor mount.
The
direction of fall is different according
図は床置き設置時の例です。
(*)
to 設置角度によっては落下方向が異なり
the installation angle, so support
ますので重力の影響を考慮し適切に支
theえてください。
robot appropriately in consideration
of the influence of the gravity.
Fig. 5.4 Arm operation by the release of J2,J3-axis motor brake and measures
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6
SAFETY OF THE END EFFECTOR
6.1
PRECAUTIONS IN PROGRAMMING
(1) Circumspect program with sufficient delay required for the program after executing some control
command in adopting actuators (pneumatic, hydraulic, and electric)
(2) Adopt limit switches for the end effector, and control the robot system by monitoring the state.
7
STOP TYPE OF ROBOT
There are following three types of Stopping Robot.
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.
“Power-Off stop” performs following processing.

An alarm is generated, and then the servo power turns off. Instantly the robot stops.

Execution of the program is paused.
Frequent Power-Off stop of the robot during operation can cause mechanical problems of the robot.
Avoid system designs that require routine or frequent Power-Off stop conditions.
Controlled stop (Category 1 following IEC 60204-1)
The robot is decelerated until it stops, and servo power is turned off.
“Controlled stop” performs following processing.

The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. The program
execution is paused.

An alarm is generated, and then the servo power turns off.
Hold (Category 2 following IEC 60204-1)
The robot is decelerated until it stops, and servo power remains on.
“Hold” performs following processing.

The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING
The stopping distance and time of Controlled stop are longer than those 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-83754EN/01
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/ R-30iB Mate
Option
Standard
Controlled stop by E-Stop
A (*)
C (*)
(A05B-2600-J570)
(*) R-30iB / R-30iB Mate does not have servo disconnect. R-30iB Mate does not have SVOFF input.
The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please
refer to "Software version" in operator's manual of controller for the detail of software version screen.
"Controlled stop by E-Stop" option
When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following
alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off
stop which is the normal operation of the system.
Alarm
Condition
SRVO-001 Operator panel E-stop
SRVO-002 Teach pendant E-stop
SRVO-007 External emergency stops
SRVO-408 DCS SSO Ext Emergency Stop
SRVO-409 DCS SSO Servo Disconnect
Operator panel emergency stop is pressed.
Teach pendant emergency stop is pressed.
External emergency stop input (EES1-EES11, EES2-EES21) is open.
In DCS Safe I/O connect function, SSO[3] is OFF.
In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows:

In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.

In Controlled stop, physical impact is less than Power-Off stop. This function is effective for
systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be
minimized.

The stopping distance and time of Controlled stop is longer than the those 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 time.
When this option is loaded, this function cannot be disabled.
The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
s-13
SAFETY PRECAUTIONS
B-83754EN/01
WARNING
The stopping distance and time of Controlled stop are longer than those 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.
8
(1)
WARNING & CAUTION LABEL
Greasing and degreasing label
Fig. 8 (a) Greasing and degreasing label
Description
When greasing and degreasing, observe the instructions indicated on this label.
(1) Open the grease outlet at greasing.
(2) Use a hand pump at greasing.
(3) Use designated grease at greasing.
CAUTION
See Subsection 7.3.2 and 7.3.3 for explanations about specified grease, the
grease amount, and the locations of grease inlets and outlets for individual
models.
s-14
SAFETY PRECAUTIONS
B-83754EN/01
(2)
Step-on prohibitive label
Fig. 8 (b) 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.
(3)
High-temperature warning label
Fig. 8 (c) 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 tool as heat-resistant gloves.
s-15
SAFETY PRECAUTIONS
(4)
B-83754EN/01
Transportation label
300kg
250kg×2
150kg×2
300kg
Fig. 8 (d) Transportation label
Description
When transporting the robot, observe the instructions indicated on this label.
(1) Using a crane

Use a crane with a load capacity of 2940N (300kgf) or greater.

Use two slings with each load capacity of 2450 N (250 kgf) or greater, sling the robot as
shown Chapter 1 of operator’s manual.

Use two M12 eyebolts with each load capacity of 1470 N (150 kgf) or greater.
(2) Using a forklift

Use a forklift with a load capacity of 2940N (300kgf) or greater.
NOTE
See Section 1.1 TRANSPORTATION of operator’s manual for explanations
about the posture a specific model should take when it is transported.
s-16
SAFETY PRECAUTIONS
B-83754EN/01
(5)
Transportation prohibitive label
(When transport equipment option A05B-1226-H072 is specified.)
輸送部材に衝撃を
与えないこと
Do not have impact
on this part
禁止撞击搬运用部件
輸送部材にチェーン
などを掛けないこと
Do not chain, pry,
or strap on this part
禁止在搬运用部件上使
用锁链等物品固定或者
搬运机器人
Fig. 8 (e) Transportation prohibitive label
Description
Keep the following in mind when transporting the robot.
(1) Prevent the forks of the forklift from having impact on a transport equipment
(2) Do not thread a chain or the like through transport equipment.
(6)
Greasing label (if greasing kit A05B-1226-K031 is specified)
Fig. 8 (f) Greasing label
Description
When using a grease kit, observe the instructions indicated on this label.
1) Before filling the cylinder with grease from tube, squeeze the tube to make the grease in it soft.
2) Pushing in the plunger by 2.5 mm causes a grease of 1 ml to be pushed out.
s-17
SAFETY PRECAUTIONS
(7)
B-83754EN/01
Installation label
Fig. 8 (g) Installation label
Description
Assemble attached washers at installation of robot.
(8)
Operating space and payload label
Below label is added when CE specification is specified.
Fig. 8 (h) Operating space and payload label
150731
s-18
PREFACE
B-83754EN/01
PREFACE
This manual explains the operation procedures for the mechanical units of the following robots:
Model name
FANUC Robot M-20iB/25
Mechanical unit specification No.
Maximum load
A05B-1226-B201
25kg
(2)
(3)
(4)
(1)
(2)
TYPE
NO.
DATE
TYPE
NO.
DATE
(3)
(4)
(1)
WEIGHT
( 5) kg
WEIGHT
(5) kg
The label stating the mechanical unit specification number is affixed in the following position. Before
reading this manual, verify the specification number of the mechanical unit.
Position of label indicating mechanical unit specification number
TABLE 1)
(1)
(2)
(3)
(4)
CONTENTS
Model name
TYPE
No.
DATE
LETTERS
FANUC Robot
M-20iB/25
A05B-1226-B201
p-1
SERIAL NO.
IS PRINTED
PRODUCTION
YEAR AND
MONTH ARE
PRINTED
(5)
WEIGHT kg
(Without
controller)
210
PREFACE
B-83754EN/01
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
SAFETY HANDBOOK B-80687EN
All persons who use the FANUC Robot and
system designer must read and understand
thoroughly this handbook
R-30iB/
OPERATOR’S MANUAL
R-30iB Mate
(Basic Operation)
controller
B-83284EN
OPERATOR’S MANUAL
(Alarm Code List)
B-83284EN-1
OPERATOR’S MANUAL
(Optional Function)
B-83284EN-2
ARC WELDING FUNCTION
OPERATOR’S MANUAL
B-83284EN-3
Spot WELDING FUNCTION
OPERATOR’S MANUAL
B-83284EN-4
DISPENSE FUNCTION
OPERATOR’S MANUAL
B-83284EN-5
MAINTENANCE MANUAL
R-30iB
: B-83195EN
R-30iB Mate : B-83525EN
Intended readers: Operator ,system designer
Safety items for robot system design,
operation, maintenance
Topics:
Intended readers: Operator, programmer, maintenance engineer,
system designer
Robot functions, operations, programming,
Topics:
setup, interfaces, alarms
Robot operation, teaching, system design
Use:
Intended readers: Maintenance engineer, system designer
Installation, connection to peripheral
Topics:
equipment, maintenance
Installation, start-up, connection, maintenance
Use:
This manual uses following terms.
Name
Terms in this manual
Connection cable between robot and controller
Robot mechanical unit
Robot connection cable
Mechanical unit
p-2
TABLE OF CONTENTS
B-83754EN/01
TABLE OF CONTENTS
SAFETY PRECAUTIONS ............................................................................ s-1
PREFACE ....................................................................................................p-1
1
TRANSPORTATION AND INSTALLATION ........................................... 1
1.1
1.2
TRANSPORTATION ...................................................................................... 1
INSTALLATION ............................................................................................. 3
1.2.1
1.2.2
1.3
1.4
2
3.3
3.4
3.5
AIR SUPPLY (OPTION) .............................................................................. 27
AIR PIPING (OPTION) ................................................................................ 28
INTERFACE FOR OPTION CABLE (OPTION) ........................................... 29
AXIS LIMIT SETUP ............................................................................... 35
6.1
6.2
7
END EFFECTOR INSTALLATION TO WRIST ............................................ 21
EQUIPMENT MOUNTING FACE ................................................................ 22
LOAD SETTING .......................................................................................... 24
PIPING AND WIRING TO THE END EFFECTOR................................. 26
5.1
5.2
5.3
6
ROBOT CONFIGURATION ........................................................................... 9
MECHANICAL UNIT EXTERNAL DIMENSIONS AND WORK
ENVELOPE ................................................................................................. 11
ZERO POINT POSITION AND MOTION LIMIT ........................................... 12
WRIST LOAD CONDITIONS ....................................................................... 17
OPERATING AREA FOR INCLINATION INSTALLATION .......................... 18
EQUIPMENT INSTALLATION TO THE ROBOT .................................. 21
4.1
4.2
4.3
5
CONNECTION WITH THE CONTROLLER ................................................... 8
BASIC SPECIFICATIONS....................................................................... 9
3.1
3.2
4
MAINTENANCE AREA .................................................................................. 7
INSTALLATION CONDITIONS ...................................................................... 7
CONNECTION WITH THE CONTROLLER ............................................ 8
2.1
3
Installation Method................................................................................................... 4
Angle of Mounting Surface Setting.......................................................................... 6
SOFTWARE SETTING ................................................................................ 36
ADJUSTABLE MECHANICAL STOPPER SETTING (OPTION).................. 37
CHECKS AND MAINTENANCE ........................................................... 39
7.1
PERIODIC MAINTENANCE ........................................................................ 39
7.1.1
7.1.2
7.2
CHECK POINTS .......................................................................................... 42
7.2.1
7.2.2
7.2.3
7.2.4
7.3
Daily Checks .......................................................................................................... 39
Periodic Check and Maintenance ........................................................................... 40
Confirmation of Oil Seepage .................................................................................. 42
Confirmation of the Air Control Set ....................................................................... 43
Check the Mechanical Unit Connectors ................................................................. 44
Check of Fixed Mechanical Stopper and Adjustable Mechanical Stopper ............ 45
MAINTENANCE........................................................................................... 45
7.3.1
Replacing the Batteries (1.5 year checks) .............................................................. 45
c-1
TABLE OF CONTENTS
7.3.2
Replacing the Grease of the J1 to J3 Axis Reducers
(3 years (11520 hours) checks) .............................................................................. 47
7.3.2.1
7.3.3
7.4
8
Procedure for releasing remaining pressure from the grease bath (J1 to
J3-axis)............................................................................................................... 49
Grease Supplying Procedure for J4 to J6-axis Reducer(4 years (15360 hours)
periodical check) .................................................................................................... 50
STORAGE ................................................................................................... 51
MASTERING ......................................................................................... 52
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9
B-83754EN/01
OVERVIEW ................................................................................................. 52
RESETTING ALARMS AND PREPARING FOR MASTERING ................... 54
ZERO POSITION MASTERING .................................................................. 55
QUICK MASTERING ................................................................................... 58
QUICK MASTERING FOR SINGLE AXIS ................................................... 60
SINGLE AXIS MASTERING ........................................................................ 62
MASTERING DATA ENTRY ........................................................................ 64
VERIFYING MASTERING ........................................................................... 66
TROUBLESHOOTING .......................................................................... 67
9.1
TROUBLESHOOTING ................................................................................. 67
APPENDIX
A
PERIODIC MAINTENANCE TABLE ..................................................... 75
B
STRENGTH OF BOLT AND BOLT TORQUE LIST .............................. 78
C
INSULATION ABOUT ARC WELDING ROBOT................................... 79
D
CONTROL OF MULTIPLE ROBOTS .................................................... 80
c-2
1.TRANSPORTATION AND INSTALLATION
B-83754EN/01
1
TRANSPORTATION AND INSTALLATION
1.1
TRANSPORTATION
Use a crane or a forklift to transport the robot. When transporting the robot, be sure to change the posture
of the robot to that shown below and lift by using the eyebolts and the transport equipment at their points.
CAUTION
When hoisting or lowering the robot with a crane or forklift, move it slowly, and
with great care. When placing the robot on the floor, exercise care to prevent
the installation surface of the robot from striking the floor.
1
2
3
4
WARNING
Robot becomes unstable when it is transported with the end effector or
equipment is installed, and it is dangerous. Make sure to remove end effector
when robot is transported. (Except light cargo such as welding torch or wire
feeder)
Employ the transport equipment only for the transportation means. Fixing the
robot with the transport equipment is prohibited.
Before moving the robot by using crane, check and tighten any loose bolts on
the forklift pockets.
Do not pull eyebolts sideways.
CAUTION
Before moving the J2-axis section, be sure to remove the eyebolt from the J2
base so that the J2-axis stopper does not interfere with the eyebolt.
1)
Transportation using a crane (Fig. 1.1 (a))
Fasten the M12 eyebolts to the two points of the robot base and lift the robot by the two slings. In
this case, please intersect and hang two Slings as shown in figure.
CAUTION
When lifting the robot, be careful not to damage motors, connectors, or cables of
the robot by slings.
2)
Transporting the robot with a forklift (Fig. 1.1 (b))
When transporting a robot with a forklift, use special transport equipment. Transport equipment is
prepared as the option.
-1-
1.TRANSPORTATION AND INSTALLATION
B-83754EN/01
Note)
注)
1. Robot
mass : 210kg
1.ロボット総重量
210kg
2.アイボルトはJISB1168に準拠のこと
2. Eyebolt
complied with JIS B 1168.
3.数量アイボルト 2個
3. Quantityスリング
eyebolt 22個
pcs
sling
2 pcs
621
Crane
クレーン
可搬質量:
Capacity300kg
min.: 300 kg
スリング
可搬質量:
Sling 250kg
Capacity min. : 250 kg
Center of
ロボット重心
gravity
1690
M12
eyebolt
M12アイボルト
Robot posture
ロボット輸送姿勢
on transportation
J1
0°
J2 -10°
J3 -70°
J4
0°
J5
0°
J6
0°
234
149
280
280
Fig. 1.1 (a) Transportation using a crane
621
Robot posture
onロボット輸送姿勢
transportation
J1 0°
J2 -10°
J3 -70°
J4 0°
J5 0°
J6 0°
Forklift
capacity
フォークリフト許容重量
300kg
Min.
300kg
100
100
Center of
ロボット重心
gravity
200
200
456
456
Bracket
(2 pcs)
ブラケット
(2個)
A290-7222-X37
A290-7222-X371
Note)
注)
1. ロボット総重量
Robot mass : 210kg
210kg
Fig. 1.1 (b) Transportation using a forklift
WARNING
Be careful not to strike the transport equipment with the forklift forks.
-2-
1.TRANSPORTATION AND INSTALLATION
B-83754EN/01
1.2
INSTALLATION
Fig. 1.2 shows the robot base dimensions. Avoid placing any object in front of the robot on the mounting
face to facilitate the installation of the mastering fixture.
The strength of the chemical anchor depends on the concrete strength. See the design guideline of the
manufacturer for the execution of the chemical anchor and consider the safety ratio sufficiently before
use.
383
157
150
157
300
20
4-φ8
through
4O18
貫通
20
343
173 ±0.2
157
20
Locating surface
突き当て面
173 ±0.2
157
20
33
A
A
150
J1-axis
rotation center
J1軸回転中心
300
Fig. 1.2 Dimensions of the robot base
-3-
Section
A-A
断面 A-A
1.TRANSPORTATION AND INSTALLATION
1.2.1
B-83754EN/01
Installation Method
Fig. 1.2.1 (a) shows an example of installing the robot. In this example, the floor plate is fixed with four
M20 chemical anchors (tensile strength 400N/mm2 or more), and the robot base is fastened to the floor
plate with four M16X65 bolts (tensile strength 1200N/mm2 or more). If compatibility must be maintained
in teaching the robot after the robot mechanical unit is replaced, use the locating surface.
4-φ24
4-O24 Through
貫通
173 ±0.2
突き当て面
Locating
surface
400
300
173 ±0.2
4-M16 Through
4-M16貫通
50
150
Locating
surface
突き当て面
50
150
300
Rotation center of
J1軸旋回中心
J1 axis
400
Chemical anchor
M20(4pcs)
ケミカルアンカ
Tensile strength: 400N/mm2
M20(4本)
or more
引張強度:
以上
Tightening400N/mm2
torque: 186Nm
締付トルク: 186Nm
ロボットJ1ベース
Robot J1 base
200
(Depth)
200
(埋め込み深さ)
ハイテンションワッシャ
High
tensile washer
A97L-0140-0471#16(4枚)
A97L-0140-0471#16(4pcs)
ロボット固定ボルト
Robot
mounting bolt
M16X65(4本)
M16X65(4pcs)
引張強度: 1200N/mm2 以上 2
Tensile
strength: 1200N/mm
締付トルク: 318Nm
or more
Tightening torque: 318Nm
Fig. 1.2.1 (a) Example of installing the robot
WARNING
The customer shall arrange for the positioning pin, anchor bolts, and floor plate. Don’t
perform leveling at the robot base directly using a push bolt or a wedge. For fixing the robot
base, use four hexagon socket head bolt M16X65 (tensile strength 1200N/mm2 or more)
and tighten them with regulated tightening torque 318Nm.
Flatness of robot installation surface must be less than or equal to 0.5mm. Inclination of
robot installation surface must be less than or equal to 0.5º. If robot base is placed on
uneven ground, it may result in the base breakage or low performance of the robot.
-4-
1.TRANSPORTATION AND INSTALLATION
B-83754EN/01
Fig. 1.2.1 (b) and Table 1.2.1 (a) show the force and moment applied to the Robot base. Table 1.2.1 (b),
(c) indicates the stopping distance and time of the J1 through J3 axes until the robot stopping by
Power-Off stop or by Controlled stop after input of the stop signal. Refer to the data when considering the
strength of the installation face.
Table 1.2.1 (a) Force and moment that act on J1 base
During stillness
During acceleration
or deceleration
During
Power-Off stop
Model
Vertical moment
MV [Nm](kgfm)
Force in vertical
direction
FV [N] (kgf)
Horizontal
moment
MH [Nm] (kgfm)
Force in
horizontal
direction
FH [N] (kgf)
1526 (156)
2605 (266)
0 (0)
0(0)
5760 (588)
5204 (531)
1803 (184)
3436 (351)
7811 (797)
7069 (721)
6626 (676)
4028 (411)
Table 1.2.1 (b) Stopping time and distance until the robot stopping
by Power-Off stop after input of stop signal
J1-axis
J2-axis
Stopping time [ms]
Stopping distance [deg] (rad)
M-20iB/25
260
26.8(0.47)
260
25.4(0.44)
J3-axis
220
27.8(0.49)
*Max payload and max speed
Model
Table 1.2.1 (c) Stopping time and distance until the robot stopping
by Controlled stop after input of stop signal
J1-axis
J2-axis
M-20iB/25
Stopping time [ms]
Stopping distance [deg] (rad)
460
54.8(0.96)
460
54.2(0.95)
*Max payload and max speed
MV
FV
FH
MH
Fig. 1.2.1 (b) Force and moment that acts on J1 base
-5-
J3-axis
484
71.5(1.25)
1.TRANSPORTATION AND INSTALLATION
1.2.2
B-83754EN/01
Angle of Mounting Surface Setting
If robot is used except floor mount, be sure to set the mounting angle referring to the procedure below.
Refer to specification of Section 3.1 about installation specifications.
1
2
3
Turn on the controller with the [PREV] and the [NEXT] key pressed. Then select [3 Controlled
start].
Press the [MENU] key and select [9 MAINTENANCE].
Select the robot which you set mount angle and press the [ENTER] key.
ROBOT MAINTENANCE
CTRL START MANU
Setup Robot System Variables
Group Robot Library/Option Ext Axes
1
M-20iB/25
0
[TYPE]ORD NO
4
5
AUTO
MANUAL
Press the [F4] key.
Press the [ENTER] key until screen below is displayed.
*******Group 1 Initialization************
**************M-20iB/25*****************
--- MOUNT ANGLE SETTING --0 [deg] : floor mount type
90 [deg] : wall mount type
180 [deg] : upside-down mount type
Set mount_angle (0-180[deg])->
Default value = 0
6
Input mount angle referring to Fig.1.2.2.
+
Angle of
設置角度
Mounting surface
Fig.1.2.2 Mounting angle
-6-
1.TRANSPORTATION AND INSTALLATION
B-83754EN/01
7
Press the [ENTER] key until screen below is displayed again.
ROBOT MAINTENANCE
CTRL START MANU
Setup Robot System Variables
Group Robot Library/Option Ext Axes
1
M-20iB/25
0
[TYPE]ORD NO
8
AUTO
MANUAL
Press the [FCTN] key and select [1 START (COLD)].
1.3
MAINTENANCE AREA
Fig. 1.3 shows the maintenance area of the mechanical unit. Be sure to leave enough room for the robot to
be mastered. See Chapter 8 for the mastering.
650
900
500
300
300
500
Mastering
area
マスタリング領域
1175
Maintenance area
保守スペース
Fig. 1.3 Maintenance area
1.4
INSTALLATION CONDITIONS
Refer to Section 3.1 for installation conditions.
-7-
2.CONNECTION WITH THE CONTROLLER
B-83754EN/01
2
CONNECTION WITH THE CONTROLLER
2.1
CONNECTION WITH THE CONTROLLER
The robot is connected with the controller via the power and signal cable and earth cable. Connect these
cables to the connectors on the back of the base.
For details on air and option cables, see Chapter 5.
WARNING
Before turning on controller power, be sure to connect the robot and controller
with the earth line (ground). Otherwise, there is the risk of electrical shock.
CAUTION
1 Before connecting the cables, be sure to turn off the controller power.
2 Don’t use 10m or longer coiled cable without first untying it. The long coiled
cable could heat up and become damaged.
Robot ロボット
mechanical unit
制御装置
Controller
機構部
Robot
connection cable
ロボット接続ケーブル
(power,
signal cable , earth line)
(動力、信号ケーブル、アース線)
Option
Air
エア
Connector for
動力線
Power
line and
信号線ケーブル
Signal
line
用コネクタ
Earth terminal
アース端子 (M8)
(M8)
Fig. 2.1 Cable connection
-8-
3.BASIC SPECIFICATIONS
B-83754EN/01
3
BASIC SPECIFICATIONS
3.1
ROBOT CONFIGURATION
手首ユニット
Wrist unit
AC
servo motor for J5-axis
J5軸用ACサーボモータ
エンドエフェクタ
End
effector
mounting
取付面 face
AC
servo motor for J3-axis
J3軸用ACサーボモータ
J6軸用ACサーボモータ
AC
servo motor for J6-axis
J2
arm
J2アーム
J3アーム
J3 arm
J4軸用ACサーボモータ
AC servo
motor for J4-axis
AC servo
motor for J2-axis
J2軸用ACサーボモータ
J2 base
J2ベース
J1J1ベース
base
AC
servo motor for J1-axis
J1軸用ACサーボモータ
Fig. 3.1 (a) Mechanical unit configuration
J4
+
X
J3
Y
+
+
-
Z
J6 +
-
-
J5
J2
-
+
J1
+
Fig. 3.1 (b) Each axes coordinates and mechanical interface coordinates
NOTE
The end effector mounting face center is 0, 0, 0 of the mechanical interface
coordinates.
-9-
3.BASIC SPECIFICATIONS
B-83754EN/01
Table 3.1 Specifications
Item
Specification
M-20iB/25
Articulated type
6 axes(J1, J2, J3, J4, J5, J6)
Floor, Upside-down, Wall & Angle mount
Model
Type
Controlled axes
Installation
J1-axis
J2-axis
J3-axis
Motion range
J4-axis
J5-axis
J6-axis
Maximum speed
(Note 2)
Upper limit
/Lower limit
Upper limit
/Lower limit
Upper limit
/Lower limit
Upper limit
/Lower limit
Upper limit
/Lower limit
Upper limit
/Lower limit
180º (3.14rad) / -180º (-3.14rad)
140º (2.44rad) / -100º (-1.74rad)
320º (5.58rad) / -149º (-2.60rad)
200º (3.49rad) / -200º (-3.49rad)
145º (2.53rad) / -145º (-2.53rad)
270º (4.71rad) / -270º (-4.71rad)
J1-axis
205º/sec ( 3.58rad/s)
J2-axis
205º/sec ( 3.58rad/s)
J3-axis
260º/sec ( 4.54rad/s)
J4-axis
415º/sec ( 7.24rad/s)
J5-axis
415º/sec ( 7.24rad/s)
Maximum load
J6-axis
At wrist
On J3 arm(Note 4)
J4-axis
880º/sec (15.36rad/s)
25 kg
25 kg
Allowable load
moment at wrist
J5-axis
51.0Nm
Allowable load
inertia at wrist
51.0Nm
J6-axis
31.0Nm
J4-axis
2.20kg.m
2
J5-axis
2.20kg.m
2
2
J6-axis
1.20kg.m
±0.06 mm
210 kg
Repeatability
Mass
Dust proof and drip proof mechanism
Acoustic noise level
Installation environment
(Note 1)
Conform to IP67 (Note 4)
73.3dB (Note 5)
Ambient temperature: 0 to 45℃ (Note 6)
Ambient humidity:
Normally 75%RH or less (No dew or frost allowed)
Short time 95%Rh or less (Within 1 month)
Permissible altitude:
Above the sea 1000m or less
2
Vibration acceleration : 4.9m/s (0.5G) or less
Free of corrosive gases (Note 7)
NOTE
1 Under the installation condition within ( ), the motion range will be limited. See Section 3.5.
2 During of short distance motions, the axis speed may not reach the maximum value stated.
3 Maximum load on J3 arm is influenced by load of wrist. See Section 4.2 for detail.
4 Definition of IP(Dust proof and drip proof mechanism)
Definition of IP67
6→Dust-tight
7→Protection from water immersion
5 This value is equivalent continuous A-weighted sound pressure level, which applied with ISO11201
(EN31201). This value is measured with the following conditions.
Maximum load and speed
Operating mode is AUTO
6 When the robot is used in a low temperature environment that is near to 0ºC, or not operated for a long time
in the environment that is less than 0ºC (during a holiday or during the night), a collision detection alarm
(SRVO-050) etc. may occur since the resistance of the drive mechanism could be high immediately after
starting the operation. In this case, we recommend performing the warm up operation for several minutes.
7 Contact the service representative, if the robot is to be used in an environment or a place subjected to
hot/cold temperatures, severe vibrations, heavy dust, cutting oil splash and or other foreign substances.
- 10 -
3.BASIC SPECIFICATIONS
B-83754EN/01
(1) The robot (including severe dust/liquid protection model) cannot be used with the following liquids.
Potentially these liquids will cause irreversible damage to the rubber parts (such as: gaskets, oil seals,
O-rings etc.). (As exception to this only liquids tested and approved by FANUC can be used with the
robot.)
(a) Organic solvents
(b) Cutting fluid including chlorine / gasoline
(c) Amine type detergent
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, that will harm NBR or CR rubber
(2) When the robots work in a water or liquid environment, completely drain the J1 base. Incomplete
draining of the J1 base will make the robot break down.
(3) Do not use unconfirmed cutting fluid and cleaning fluid.
(4) Do not use the robot immersed in water, neither temporary nor permanent. The robot must not be
wet permanently.
3.2
MECHANICAL UNIT EXTERNAL DIMENSIONS AND
WORK ENVELOPE
R3
18
Fig. 3.2 shows the robot operating space. When installing peripheral devices, be careful not to interfere
with the robot and its operating space.
R 1853
+170 DEG
±0 DEG
-170 DEG
1778
1778
865
100
905
2428
120
75
210
Operating
space of
J5軸回転中心動作領域
J5-axis rotation center
173
308
Fig. 3.2 Operating space
- 11 -
917
650
J5軸回転中心
J5-axis
rotation center
3.BASIC SPECIFICATIONS
3.3
B-83754EN/01
ZERO POINT POSITION AND MOTION LIMIT
Zero point and motion range are provided for each controlled axis. Exceeding the software motion limit
of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit for
each axis. The robot cannot exceed the motion range unless there is a loss of zero point position due to
abnormalities in servo system or system error. In addition, the motion range limit by a mechanical stopper
is also prepared to improve safety.
Fig. 3.3 (a) shows the position of the mechanical stopper. For the J1 to J3-axis, stopping by overtravel
damages the mechanical stopper. If this occurs, replace the stopper with a new one. Don’t reconstruct the
mechanical stopper. There is a possibility that the robot doesn't stop normally.
J3-axis
J3軸機械式ストッパ
mechanical stopper
(プラス側)
(plus side)
J1-axis
mechanical
stopper
J1軸機械式ストッパ
・A290-7226-X206
A290-7226-X206
・ボルト
M12X40
Bolt
M12X40
1 pc1個
(締付けトルク
129Nm)
(Tightening
torque
129Nm)
J3-axis
J3軸機械式ストッパ
mechanical
stopper
(マイナス側)
(minus
side)
断面A-A
A-A
Section
A
J2-axis
J2軸機械式ストッパ
mechanical
stopper
(マイナス側)
(minus
side)
When
J1-axis mechanical
J1軸機械式ストッパ選択時
stopper
is specified
A05B-1226-H051
A ・A290-7226-X207
A05B-1226-H051
・ボルト
M12X20 2個
A290-7226-X207
(締付けトルク
Bolt
M12X20 294Nm)
pcs
(Tightening torque 94Nm)
J2-axis
J2軸機械式ストッパ
mechanical
stopper
(プラス側)
(plus
side)
Fig. 3.3 (a) Position of mechanical stopper
Fig.3.3 (b) to (h) show the zero point and mechanical stopper position of each axis.
* The motion range can be changed. For information on how to change the motion range, see Chapter 6,
“AXIS LIMIT SETUP”.
- 12 -
3.BASIC SPECIFICATIONS
B-83754EN/01
+180°
+180º
Stroke end
u180°
ストロークエンド
0°
-180°
Fig. 3.3 (b) J1-axis motion limit (When mechanical stopper option is not selected)
+ 170°
+172º The maximum stopping
+172° distance
最大停止距離
(位置)
(position)
distance (position)
0°
2°
-172º The
maximum stopping
-172°
最大停止距離
(位置)
2°
+170º
Stroke
end (Upper limit)
+170°
ストロークエンド(上限)
-170º
Stroke
end (Lower limit)
-170°
ストロークエンド(下限)
°
- 170
Fig. 3.3 (c) J1-axis motion limit (When mechanical stopper is selected)
- 13 -
3.BASIC SPECIFICATIONS
B-83754EN/01
10
0°
Note ) Motion
limit is restricted by the position of the J3-axis.
注）J3軸の位置によって動作範囲に
制限を受けます。
14 0
°
-100º
Stroke end (Lowper limit)
-100°ストッパエンド（下限）
1 .5
°
-101.5º
The maximum(位置)
stopping
-101.5v 最大停止距離
distance (position)
1.5°
+140º
Stroke end (Uppper limit)
+140°ストロークエンド（上限）
+141.5º The maximum stopping
+141.5v 最大停止距離 (位置)
distance (position)
Fig. 3.3 (d) J2-axis motion limit
°
220
83
°
J2+J3=-83º
J2+J3=-83v
(下限)
Strokeストロークエンド
end (Lowper limit)
J2+J3=220
v
J2+J3=+220º
ストロークエンド
(上限)limit)
Stroke end (Upper
Note ) Motion limit is restricted by the position of the J2-axis.
注）J2軸の位置によって
動作範囲に制限を受けます。
Fig. 3.3 (e) J3-axis motion limit
- 14 -
3.BASIC SPECIFICATIONS
B-83754EN/01
Note
) There is no mechanical stopper of the J4-axis.
注）J4軸に機械式ストッパはありません。
- 20
0°
+20
0
°
+200º
Stroke end (Upper limit)
+200°ストロークエンド（上限）
-200º
Stroke end (Lower limit)
-200°ストロークエンド（下限）
Fig. 3.3 (f) J4-axis motion limit
Note
) There is no mechanical stopper of the J5-axis.
注）J5軸に機械式ストッパはありません。
+145º
Stroke end
+145°ストロークエンド
(Upper
(上限) limit)
145°
145°
-145º
Stroke end
-145°ストロークエンド
(Lower limit)
(下限)
Fig. 3.3 (g) J5-axis motion limit
- 15 -
3.BASIC SPECIFICATIONS
B-83754EN/01
Note ) There is no mechanical stopper of the J6-axis.
注）J6軸に機械式ストッパはありません。
0°
+270°
-270°
-270º
Stroke end
-270
v ストロークエンド
(Lower limit)
(下限)
+270º
Stroke end
+270
v ストロークエンド
(Upper limit)
(上限)
Fig. 3.3 (h) J6-axis motion limit
- 16 -
3.BASIC SPECIFICATIONS
B-83754EN/01
3.4
WRIST LOAD CONDITIONS
Fig. 3.4 is a diagram showing the allowable load that can be applied to the wrist section.


Apply a load within the region indicated in the graph.
Apply the conditions of the allowable load moment and the allowable load inertia. See Section 3.1
about the allowable load moment and the allowable load inertia.
See Section 4.1 about mounting of end effector.

Z (cm)
65
60
56.2
55
50
5kg
45
40
36.7
35
10kg
30
15kg
24.7 25
20
20kg
16.0 15
10.8 10
25kg
5
X,Y (cm)
30
35
Fig. 3.4 Wrist load diagram
- 17 -
40
45
50
48.9
25
21.1
15.8
20
31.6
15
10
12.7
10cm
5
3.BASIC SPECIFICATIONS
3.5
B-83754EN/01
OPERATING AREA FOR INCLINATION INSTALLATION
When the robot is installed on an angle, the operating area is limited to that angle. The robot can’t rest
except for within the ranges that are shown in the Fig. 3.5 (a) to (d).
Installation angle
area (3)
Installation angle
area (2)
Installation angle
area (1)
Fig. 3.5 (a) Installation angle area
Fig. 3.5 (b) Installation area (1) operating area
(0º≦φ≦50º, 130º≦φ≦180º)
NOTE
In case of a mounted angle (1), there is no operating area restriction.
- 18 -
3.BASIC SPECIFICATIONS
1754
1754
B-83754EN/01
1754
Fig. 3.5 (c) Installation area (2) operating area
(50º<φ≦60º, 120º≦φ<130º)
NOTE
Robot can rest or invert in a solid line range. The operation to a dotted line range
becomes possible when not resting and not inverting.
- 19 -
3.BASIC SPECIFICATIONS
1576
1576
B-83754EN/01
1576
Fig. 3.5 (d) Installation area (3) operating area
(60º<φ<120º)
NOTE
Robot can rest or invert in a solid line range. The operation to a dotted line range
becomes possible when not resting and not inverting.
- 20 -
4.EQUIPMENT INSTALLATION TO THE ROBOT
B-83754EN/01
4
4.1
EQUIPMENT INSTALLATION TO THE
ROBOT
END EFFECTOR INSTALLATION TO WRIST
Fig. 4.1 shows the figures for installing end effectors on the wrist. Select screws and positioning pins of a
length that matches the depth of the tapped holes and pinholes. See Appendix B “Bolt strength and bolt
tightening torque” for tightening torque specifications.
100
CAUTION
Notice the tooling coupling depth to wrist flange should be shorter than the
flange coupling length.
+0.021
O 25 H7( 0 ) (H7
(H7area
範囲6) 6)
0
(h7 area
O 50 h7(-0.025 ) (h7
範囲5.5)
5.5)
70
+0.012
0
O6 H7(
75
Depth 10
10
) 深さ
0
R 10
7-M6 Depth
7-M6
深さ1010
Equally spaced
周上等配
Fig. 4.1 End effector interface
- 21 -
4.EQUIPMENT INSTALLATION TO THE ROBOT
4.2
B-83754EN/01
EQUIPMENT MOUNTING FACE
As shown in Fig. 4.2 (a) to (c), tapped holes are provided to install equipment to the robot. Refer to Fig.
4.2 (c) about load condition of the J3 casing and the J3 arm.
CAUTION
Never perform additional machining operations such as drilling or tapping on the
robot body. This can seriously affect the safety and functions of the robot.
CAUTION
Equipment should be installed on the robot so that it does not interfere with the
mechanical unit cables. If equipment interferes, the mechanical unit cables might
disconnect, and cause unexpected results.
NOTE
Holes not shown are not guaranteed to be usable. Robot mechanical unit
fasteners are not to be used for equipment mounting.
92
M12
M12 Depth
深さ2222
2-M10
2-M10 Depth
深さ2222
209
189
209
208
104
142
2-M12
Depth
24
2-M12
深さ24
102
204
2-M10 Depth
2-M10
深さ2222
Section
B-B
断面
B-B
17.5
35
Section
A-A
断面
A-A
A
A
35
2-M12
24
2-M12Depth
深さ24
117
136
44
35
136
202
136
2-M16
2-M16
深さ23
Depth
23
2-M16
2-M16
Depth 23
294
214
60.5
214
365
深さ23
365
B
M8
Depth
13
M8 深さ13
209
2-M12
2-M12
深さ24
Depth
24
294
B
6.5
208
136
17.5
35
2-M12
2-M12
深さ2424
Depth
164
23.5
209
60.5
121
121
Fig. 4.2 (a) Equipment mounting faces (1/3)
- 22 -
4.EQUIPMENT INSTALLATION TO THE ROBOT
B-83754EN/01
30
15
174.5
96
48
6-M10
Depth
22
6-M10
深さ22
4-M6
8
4-M6Depth
深さ8
120
148
65
10
24
120
15
30
174.5
133
135
136
174.5
120
154
M12
17
M12Depth
深さ17
M12
24
M12Depth
深さ24
Fig. 4.2 (b) Equipment mounting faces (2/3)
W: Mass of the end effector mounting face
A : Mass of devices on the J3 casing
Make W and A meet the following requirements
2-M5 Depth 10
2-M5 Depth 10
2-M5 Depth 12
4-M6 Depth 8
2-M5 Depth 10
2-M5 Depth 10
Fig. 4.2 (c) Equipment mounting faces (3/3)
- 23 -
4.EQUIPMENT INSTALLATION TO THE ROBOT
4.3
B-83754EN/01
LOAD SETTING
NOTE
Set the load condition parameter before operating the robot. Do not operate the
robot in over payload reduction. Don’t exceed allowable payload including
connection cables and its swing, otherwise you could shorten the life of the
reducer.
The operation motion performance screens include the MOTION PERFORMANCE screen, MOTION
PAYLOAD SET screen, and payload information and equipment information on the robot.
1
Press the [MENU] key to display the screen menu.
2
Select “6 SYSTEM” on the next page,
3
Press the F1 ([TYPE]) key to display the screen switch menu.
4
Select “MOTION.” The MOTION PERFORMANCE screen will be displayed.
MOTION PERFORMANCE
Group1
No. PAYLOAD[kg]
1
2
3
4
5
6
7
8
9
10
25.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
JOINT 10%
Comment
[
[
[
[
[
[
[
[
[
[
]
]
]
]
]
]
]
]
]
]
Active PAYLOAD number =0
[ TYPE] GROUP DETAIL ARMLOAD
IDENT
5
SETING >
>
Ten different pieces of payload information can be set using condition No.1 to No.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
- 24 -
DEFAULT
100%
]
25.00
-7.99
0.00
6.44
0.13
0.14
0.07
HELP
4.EQUIPMENT INSTALLATION TO THE ROBOT
B-83754EN/01
X
Center of robot
ロボットの
end effector mounting face
エンドエフェクタ取付面
中心
X
y
Z
xg (cm)
Iy (kgf・cm・s2 )
Mass
m (kg)
質量m(kg)
Center of
重心
gravity
Center
重心of
gravity
Iz (kgf・cm・s2 )
yg (cm)
Ix (kgf・cm・s2)
zg (cm)
Fig. 4.3 Standard tool coordinate
6
7
8
9
Set the payload, gravity center position, and inertia around the gravity center on the MOTION
PAYLOAD SET screen. The X, Y, and Z directions displayed on this screen correspond to the
respective standard tool coordinates (with no tool coordinate system set up). When values are
entered, the following message appears: “Path and Cycle time will change. Set it?” Respond to the
message with F4 ([YES]) or F5 ([NO]).
Pressing F3 ([NUMBER]) will bring you to the MOTION PAYLOAD SET screen for another
condition number. For a multi group system, pressing F2 ([GROUP]) will bring you to the MOTION
PAYLOAD SET screen for another group.
Press [PREV] key to return to the MOTION PERFORMANCE screen. Click F5 ([SETIND]), and
enter the desired payload setting condition number.
On the list screen, pressing F4 ARMLOAD brings you to the device-setting screen.
MOTION ARMLOAD SET
Group 1
1 ARM LOAD AXIS #1 [kg]
2 ARM LOAD AXIS #3 [kg]
[
10
TYPE
]
GROUP
JOINT
100%
0.00
12.00
DEFAULT
HELP
Specify the mass of the loads on the J2 base and J3 casing. When you enter following parameter,
ARMLOAD AXIS #1[kg]: Mass of the load on the J2 base.
(Contact your local FANUC representative if you install equipment on J2 base.)
ARMLOAD AXIS #3[kg]: Mass of the load on the J3 casing,
the confirmation message “Path and Cycle time will change. Set it?” appears. Select F4 YES or F5
NO. Once the mass of a device is entered, it is put in effect by turning the power off and on again.
- 25 -
5.PIPING AND WIRING TO THE END EFFECTOR
5
B-83754EN/01
PIPING AND WIRING TO THE END
EFFECTOR
WARNING
 Only use appropriately-specified mechanical unit cables.
 Do not add user cables or hoses inside of the 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, or secure an
additional outside cable) that obstructs the behavior of the outcrop of the cable.
 When external equipment is installed in the robot, make sure that it does not
interfere with other parts of the robot.
 Cut unnecessary length of wire rod of end effector (hand) cable. Make insulation
processing like winding acetate tape.
 If you cannot 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 too close unavoidably, insulate the
cable from the end effector and work.
 Be sure to seal the connectors of hand side and robot side and terminal parts of
cables, to prevent water from entering the mechanical unit. Also, attach the cover
to unused connector.
 Check that connectors are tight and cable jackets are not damaged routinely.
 When precautions are not followed, damage to cables might occur. Cable failure
may result in incorrect function of end effector, robot faults, or damage to robot
electrical hardware. In addition, electric shock could occur when touching the
power cables.
End effector (hand) cable
Cut unnecessary length of unused wire rod
Insulation processing
Fig. 5 Treatment method of end effector (hand) cable
- 26 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83754EN/01
5.1
AIR SUPPLY (OPTION)
Robot has air inlet and air outlet openings on the J1 base and the J3 casing used to supply air pressure to
the end effector. As couplings are not supplied, it will be necessary to prepare couplings that fit the hose
size. Replace hexagon bolts with new ones when they are removed. When reusing hexagon bolts, be sure
to wind them with seal tape.
パネルユニオンX2
Panel union
2 pcs
Rc 3/8 (Air
メス outlet
(エア出口側)
Rc3/8 female
side)
Hexagon bolt
六角ボルト
M5X25(6)
(6)
M5X25
仕様
: A97L-0318-0409#M52510S
Spec.:A97L-0318-0409#M52510S
エアチューブ×2
Air
tube 2 pcsまたは
or 1 pc
エアチューブ×1
Outside
diameter 8mm
外径 8mm
Inside
diameter 6mm
Arm
cover
アームカバー
内径 6mm
プレート
Plate
アームカバー
Arm
cover
ユーザケーブルクランプ（オプション）
User
cable clamp (option)
仕様 : A05B-1226-K021
Spec.: A05B-1226-K021
パネルユニオンX2
Panel
union 2 pcs
Rc 3/8 メス (エア入口側)
Rc3/8 female
(Air inlet side)
Fig. 5.1 Air supply (option)
Table 5.1 shows solenoid option. When the solenoid valve is to be replaced, the entire manifold should be
replaced.
Option spec.
A05B-1226-H001
Table 5.1 Optional solenoid valves
Description
Solenoid (Manifold) spec.
Path 2 air piping,
RO connector output
(without solenoid valve)
―
A97L-0218-0137#D1
(Made by SMC)
A97L-0218-0137#D2
A05B-1226-H003
Double solenoids X2
(Made by SMC)
A97L-0218-0137#D3
A05B-1226-H004
Double solenoids X3
(Made by SMC)
Available section area of the solenoid valve：1.98mm2 (CV value：0.11)
A05B-1226-H002
Double solenoids X1
- 27 -
Remarks
RO
―
―
2 position x 1
RO1 to 2
2 position x 2
RO1 to 4
2 position x 3
RO1 to 6
5.PIPING AND WIRING TO THE END EFFECTOR
5.2
B-83754EN/01
AIR PIPING (OPTION)
Fig. 5.2 (a) shows how to connect air hose to the robot. If the air control set is specified as an option, the
air hose between the mechanical unit and the air control set is provided. Mount the air control set using
the information in Fig. 5.2 (b). This is outside FANUC delivery scope.
Elbow
nipple
エルボーニップル
R3/8
R3/8
Straight nipple
ストレートニップル
R3/8
Air エアチューブ
tube length 3m
全長3m
Outer
diameter内径6.5mm
10mm
外径10mm
Inside diameter 6.5mm
Dotted
点線内line
Air
control set (option)
エア2点セット（オプション）
Spec.
A05B-1130-J063
仕様 ：: A05B-1130-J063
Fig. 5.2 (a) Air piping (option)
Air control set
The machine tool builder is required to prepare mounting bolts.
16.5
6.5
6.5
16.5
Fig. 5.2 (b) Air control set (option)
NOTE
The capacity values of the air control set are determined as follows.
These values must not be exceeded.
2
Air pressure
Supply air pressure
0.49 to 0.69MPa(5 to 7kgf/cm )
2
Setting: 0.49MPa(5kgf/cm )
Amount of consumption
Maximum instantaneous amount 150Nl/min (0.15Nm /min)
3
- 28 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83754EN/01
5.3
INTERFACE FOR OPTION CABLE (OPTION)
Fig. 5.3 (a) shows the position of the option cable interface. Fig. 5.3 (b) show the option cable interface.
EE interface (RI/RO), user cable (signal line usable to 3D Laser Vision sensor and force sensor), camera
cable, force sensor cable, 3D Laser vision sensor cable and Ethernet cable are optional. Be sure to fix the
tubes around the arm cover inlet. Cable clamp option (A05B-1226-K021) is prepared. Replace the
hexagon bolts with new ones when they are removed. When reusing hexagon bolts, be sure to wind them
with seal tape.
NOTE
Each option cable is written as shown below on the connector panel.
EE(RI/RO) interface : EE
User cable usable to 3D Laser Vision sensor and force sensor : ASi
Camera cable : CAM
Force sensor cable : FS
3D Laser Vision sensor cable : 3DL
Ethernet cable : EN
J3アーム分線盤
J3 arm
connector panel
Hexagon bolt
六角ボルト
M5X25 (6)
(6)
M5X25
Spec.:A97L-0318-0409#M52510S
仕様
: A97L-0318-0409#M52510S
Arm
cover
アームカバー
Plate
プレート
アームカバー
Arm
cover
ユーザケーブルクランプ（オプション）
User cable clamp (option)
仕様
: A05B-1226-K021
Spec.:
A05B-1226-K021
J1 base connector
J1分線盤
panel
Fig. 5.3 (a) Interface for option cable (option)
- 29 -
5.PIPING AND WIRING TO THE END EFFECTOR
J1 connector
J1分線盤 panel
J3
connector panel
J3分線盤
(Air(エア出口2)
outlet 2)
(user
air)
(ユーザエア)
EE interface
EEインタフェース
(RIX8,ROX8)
(RIX8, ROX8)
B-83754EN/01
(Air
outlet 1)
(エア出口1)
(user
air)
(ユーザエア)
(Air
inlet 2)
(エア入口2)
(user
air)
(ユーザエア)
(Air
inlet 1)
(エア入口1)
(ユーザエア)
(user
air)
機構部内ケーブル仕様
:A05B-1226-H201
Spec.
of mechanical unit
cable : A05B-1226-H201
J1J1分線盤
connector panel
(Air inlet)
(for
solenoid
(エア入口)
(電磁弁用)
valve)
(エア入口)
(Air
inlet)
(ユーザエア)
(user
air)
J3J3分線盤
connector panel
(Air
outlet)
(エア出口)
(user
air)
(ユーザエア)
RO1
RO2
RO3
RO5
RO4
RO6
EE
interface
EEインタフェース
(RIX8,ROX2)
(RIX8, ROX2)
機構部内ケーブル仕様
:A05B-1226-H202
Spec.
of mechanical unit
cable : A05B-1226-H202
J1分線盤 panel
J1 connector
J3分線盤 panel
J3 connector
User
cable (signal usable
ユーザケーブル
to(力センサ・立体センサ対応信号線)
3D Laser Vision sensor
and
force sensor) interface
インタフェース
Ethernet
cable
イーサネットケーブル
Ethernet
cable
interface
インタフェース
イーサネットケーブル
interfacei
インタフェース
(Air
outlet)
(エア出口)
(ユーザエア)
(user
air)
Camera
cable
カメラケーブル
interface
インタフェース
RO2
RO1
(Air
inlet)
(エア入口)
(ユーザエア)
(user
air)
RO3
RO4
(Air
inlet)
RO6
(エア入口)
RO5
(for
solenoid
(電磁弁用)
valve)
EEインタフェース
EE
interface
(RIX8, ROX2)
(RIX8,ROX2)
3D
Laser Vision sensor
3次元センサケーブル
インタフェース
cable
interface
力センサケーブル
Force sensor
インタフェース
cable interface
Camera
cable
カメラケーブル
インタフェース
interface
ユーザケーブル
User
cable (signal us able
(力センサ・立体センサ対応信号線)
to
3D Laser Vision sensor
インタフェース
and
force sensor) interface
Force
sensor, 3D Laser Vision
力センサ、3次元センサケーブル
インタフェース
sensor
cable interface
Spec.
of mechanical unit
cable : A05B-1226-H203
機構部内ケーブル仕様
:A05B-1226-H203
Fig. 5.3 (b) Interface for option cable
- 30 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83754EN/01
1
EE interface (RI/RO) (Option)
Fig. 5.3 (c) and (d) show the pin layout for the EE interface (RI/RO).
EEインタフェース(RI/RO) (出力側)
EE interface (RI/RO) (Output)
15
9
RO5
20
4 RI4
3 RI3
2
XPPABN
8 RI8
7 RI7
14 RO4
13 RO3
12
0V(A2)
19 0V(A1)
18 RO8
24 24VF(A4) 23 24VF(A3) 22
RI2
1
6 RI6
RO2
11
17 RO7
24VF(A2) 21
RI1
5 RI5
RO1
10
16 RO6
24VF(A1)
エンド
End
エフェクタ
effector
XHBK
XHBK: Hand
:ハンド破断検出信号
XHBK
broken
XPPABN
pressure abnormal
XPPABN:: Pneumatic
空気圧異常信号
Outside
FANUC
お客様にてご用意ください。
delivery scope
制御装置
Controller
Fig. 5.3 (c) Pin layout for EE interface (RI/RO) RI/ROX8 (Option)
EEインタフェース(RI/RO)
(出力側)
EE
interface (RI/RO) (Output)
10
16
XHBK
4
9
15
20
RI4
XPPABN
3
8
14
24VF(A4) 19
RI3
RI8
0V(A2)
24VF(A3)
2
7
13
18
RI2
RI7
0V(A1)
24VF(A2)
1
6
12
17
RI1
RI6
5
RO8
11
24VF(A1)
End
エンド
effector
エフェクタ
RI5
RO7
XHBKXHBK
: Hand:ハンド破断検出信号
broken
Outside FANUC
お客様にてご用意ください。
delivery
scope
XPPABN
: Pneumatic
pressure abnormal
XPPABN:
空気圧異常信号
Controller
制御装置
Fig. 5.3 (d) Pin layout for EE interface (RI/RO) RIX8 /ROX2 (Option)
CAUTION
To wire the peripheral device to the EE interface, refer to the ELECTRICAL
CONNECTIONS Chapter of the CONTROLLER MAINTENANCE MANUAL.
- 31 -
5.PIPING AND WIRING TO THE END EFFECTOR
2
B-83754EN/01
User cable (signal usable to force sensor and 3D Laser Vision sensor) cable (ASi) Interface (Option)
Fig. 5.3 (e) shows the pin layout for the Eternet cable interface.
User cable (signal usable to force sensor and 3D Laser
ユーザケーブル(力センサ・立体センサ対応信号線)インタフェース
Vision sensor) cable interface
(output side) (J3 connector panel side)
(出力側)(J3分線盤側)
A63L-0002-0072#20SN
11
12
13
14
15
16
17
18
19
20
S11
S12
S13
S14
5
6
7
8
9
10
DRAIN
S5
S6
S7
S8
S9
S10
1
2
3
4
S1
S2
S3
S4
Endエンド
effector
エフェクタ
etc.
など
}
Outside
FANUC delivery
お客様にてご用意ください。
scope
User cable (signal usable to force sensor and 3D Laser
ユーザケーブル(力センサ・立体センサ対応信号線)インタフェース
Vision sensor) cable interface
(input side) (J1 connector panel side)
(入力側)(J1分線盤側)
MS3102A20-27PY
J
I
H
S8
K
N
G
S10
S9
S14
S7
M
F
A
S1
L
S12
S11
S13
E
S6
B
S2
D
S4
C
S3
S5
0.2mm2 8 pcs
0.2mm×8本
2
}
Outside
FANUC delivery scope
お客様にてご用意ください。
Fig. 5.3 (e) Pin layout for User cable
(signal usable to force sensor and 3D Laser Vision sensor) cable (ASi) interface (Option)
3
Camera cable Interface (CAM)(Option)
Fig. 5.3 (f) shows the pin layout for the camera cable interface.
Camera cable interface
カメラケーブルインタフェース
(output side)
(J3 connector panel side)
(出力側)(J3分線盤側)
A
1
0V
VD
B
2
5
HD
12V
C LEDGND(VD,TRG) 3
TRG
6 GND(HD) 7
D LED+
4 GND (VIDEO)
VIDEO
Camera,
light
カメラ、照明
etc.
Fig. 5.3 (f) Pin layout for Eternet (ES) cable interface (Option)
- 32 -
など
5.PIPING AND WIRING TO THE END EFFECTOR
B-83754EN/01
4
3D Laser Vision sensor cable (3DL) and force sensor cable (FS) Interface (EN)(Option)
Fig. 5.3 (g) shows the pin layout for the 3D Laser Vision sensor cable and force sensor cable
interface.
3D
Laser Vison sensor cable interface
立体センサケーブルインタフェース
(output(出力側)(J3分線盤側)
side) (J3 connector panel side)
7
8 24V(3DL) 9 24V(3DL) 1 0V(3DL)
DRAIN(A) 12 LON2
10 LON1
2 0V(3DL)
6 (LED+D) 11 (LED+A)
3 (LED-)
5 (LED+C) 4 (LED+C)
Sensor
センサ類
etc.など
Force sensor cable interface
力センサケーブルインタフェース
(output (出力側)(J3分線盤側)
side) (J3 connector panel side)
4
5
6
24V(FS)
1
2
3
0V (FS)
TX2
TX1
Fig. 5.3 (g) Pin layout for 3D Laser Vision sensor cable (3DL) and force sensor cable (FS) interface (Option)
5
Eternet cable Interface (EN)(Option)
Fig. 5.3 (h) shows the pin layout for the Eternet cable interface.
Ethernet cable interface
イーサネットケーブルインタフェース
(output side)
(J3 connector panel side)
(出力側)(J3分線盤側)
2
1
RXD+
TXD+
3
4
Sensor
センサ類
etc.など
TXDRXD+
}
Outside
FANUC delivery scope
お客様にてご用意ください。
Ethernet cable interface
イーサネットケーブルインタフェース
(input side)
(J1 connector panel side)
(入力側)(J1分線盤側)
3
4
TXDRXD-
2
1
RXD+
TXD+
}
Outside FANUC delivery scope
お客様にてご用意ください。
Fig. 5.3 (h) Pin layout for Eternet (EN) cable interface (Option)
- 33 -
5.PIPING AND WIRING TO THE END EFFECTOR
B-83754EN/01
Connector specifications
Table 5.3 (a) Connector specifications (User side)
Input side
Output side
(J1 connector panel)
(J3 connector panel)
Cable
name
EE
(RI/ROx8)
EE
(RIX8,
ROX2)
ASi
CAM
FS
3DL
EN
Connector :
Connector & cable (2m) :
Connector :
Connector & cable (2m) :
────
────
A05B-1226-K003
A05B-1226-K001
A05B-1226-K004
A05B-1226-K002
Connector :
A05B-1226-K006
Connector: A05B-1226-K005
Metal cap for connector:
A05B-1226-K061 (set for J1 &J3)
Camera cable (2m) :
A05B-1226-K041
Camera cable (2m, with LED) : A05B-1226-K046
────
Metal cap for connector :
A05B-1226-K062 (set for J1&J3)
Force sensor cable (2m) :
A05B-1226-K051
Metal cap for connector :
A05B-1226-K063 (set for J1&J3)
3DL sensor cable (2m) :
A05B-1226-K056
Metal cap for connector :
A05B-1226-K063 (set for J1&J3)
Metal cap for connector:
────
A05B-1226-K064 (set for J1&J3)
Cable name
EE (RI/ROx8)
EE(RIX8,ROX2)
ASi
Table 5.3 (b) Connector specifications
Input side
Output side
(J1 connector panel)
(J3 connector panel)
───
A63L-0002-0210#25WR24S
───
A63L-0001-0509#200S
MS3102A20-27PY
A63L-0002-0072#20SN
Maker/dealer
Hirose Electric Co. Ltd.
Fujikura.Ltd,
Japan Aviation Electronics
Industry, Ltd. etc
NOTE
For details, such as the dimensions, of the parts listed above, refer to the related
catalogs offered by the respective manufactures, or contact your local FANUC
representative.
User side cable specification
Cable name
EE
(RI/ROX8)
EE
(RIX8,ROX2)
Table 5.3 (c) User cable specifications
Specifications
Remarks
A05B-1226-K001
A05B-1226-K002
Between J3 arm and hand
length 2000mm
A05B-1226-K041
CAM
FS
3DL
A05B-1226-K046
A05B-1226-K051
A05B-1226-K056
- 34 -
Between J3 arm and hand
length 2000mm
with LED
Between J3 arm and hand
length 2000mm
6.AXIS LIMIT SETUP
B-83754EN/01
6
AXIS LIMIT SETUP
When axis limits are defined, the motion range of the robot can be changed from the standard value. The
motion range of the robot axes can be restricted because of:
Used motion range limitations
Tools and peripheral equipment interfere each other in some areas.
Length of the cable or hose attached to the application is limited.
Two methods are provided not to exceed the motion range of the robot:
Axis limit software settings (All axes)
Axis limit adjustable mechanical stopper (J1-axis (option))
WARNING
1 Changing the motion range of any axis affects the operation range of the robot.
To avoid troubles, carefully consider the possible effect of the change to the
movable range of each axis in advance. Otherwise, it is likely that an unexpected
condition occurs; for example, an alarm may occur when the robot tries to reach
a previously taught position.
2 For the J1 axis, do not count merely on software-based limits to the movable
range when changing the movable range of the robot. When changing the
movable range, use mechanical stoppers together to avoid damaging peripheral
equipment and human injuries. In this case, make the software-based limits
match the limits based on the mechanical stoppers.
3 Adjustable mechanical stoppers (J1 axis) are damaged in any collision to stop
the robot. Once a stopper is subjected to a collision, it can no longer assure its
original strength and, therefore, might not stop the robot. When this happens,
replace the mechanical stopper with a new one.
- 35 -
6.AXIS LIMIT SETUP
6.1
B-83754EN/01
SOFTWARE SETTING
Upper and lower limits for the motion range of an axis can be changed by software. The limits can be set
for all axes. The robot stops the motion if the robot reaches to the limits.
Setting procedure
1
2
3
4
Press the [MENU] key to display the screen menu.
Press [0 NEXT] and press [6 SYSTEM].
Press F1 ([TYPE]).
Select [Axis Limits]. The following screen will be displayed.
System Axis Limits
Group1
AXIS
GROUP
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
1
LOWER
-180.00
-100.00
-149.00
-200.00
-145.00
-270.00
0.00
0.00
0.00
JOINT 100%
1/16
UPPER
180.00
deg
140.00
deg
320.00
deg
200.00
deg
145.00
deg
270.00
deg
0.00
mm
0.00
mm
0.00
mm
[ TYPE]
WARNING
1 The setting value of 0.00 indicates that the robot does not have the axis.
2 Do not depend on J1-axis limit software settings to control the motion range of
your robot. Use the axis limit switches or adjustable mechanical stopper also;
otherwise injury to personnel or damage to equipment could occur.
5
Move the cursor to the desired axis range and type the new value using the numeric keys on the
teach pendant.
System Axis Limits
Group1
AXIS
GROUP
2
1
LOWER
-100.0
JOINT 100%
1/16
UPPER
140.00
deg
[ TYPE]
6
7
Perform the setting for all axes.
Cycle the power of the controller in the cold start mode so the new settings are enabled.
WARNING
You must cycle the power of the controller to enable the new setting. If you fail to
do so, the robot will not work normally, and it may injure personnel or damage
the equipment.
- 36 -
6.AXIS LIMIT SETUP
B-83754EN/01
6.2
ADJUSTABLE MECHANICAL STOPPER SETTING
(OPTION)
For the J1 axis, it is possible to re-position mechanical stoppers.
Change the position of the mechanical stoppers according to the desired movable range.
An adjustable mechanical stopper is damaged by a collision. Please replace it with a new one when this
occurs. An exchange method and the part are the same as a J1 axis mechanical stopper. Refer to section
3.3.
Item
J1 axis adjustable
mechanical stopper
Movable range
Upper limit
Lower limit
Settable in steps of 15 degrees in a range of +15 to +165 degrees
Settable in steps of 15 degrees in the range of -165 to -15 degrees
CAUTION
If the newly set operation range does not include 0, you must change it by zero
degree mastering so that 0 is included.
J1 AXIS STROKE MODIFICATION
A stroke modification can be performed at an arbitrary position in steps of 15 within the range -165 to
+165.
ロボット正面
Front of robot
ロボット正面
Front of robot
+150°
±165°
-150°
+135°
-135°
-120°
+120°
-105°
+105°
-90°
+90°
+75°
-75°
-60°
+60°
+45°
+30°
-45°
-30°
+15°
0°
0°
Fig. 6.2 (a) Mechanical stopper and motion limit of J1-axis (1/2)
- 37 -
-15°
6.AXIS LIMIT SETUP
B-83754EN/01
Front of robot
ロボット正面
-回転
Minus
+回転
Plus
-回転規制ストッパ
For minis limit
+回転規制ストッパ
For plus limit
Motion
limit
動作範囲
Stopper
J1ストッパ
Fig. 6.2 (b) Mechanical stopper and motion limit of J1-axis (2/2)
- 38 -
7.CHECKS AND MAINTENANCE
B-83754EN/01
7
CHECKS AND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures
presented in this chapter.
(See the APPENDIX A PERIODIC MAINTENANCE TABLE.)
NOTE
The periodic maintenance procedures described in this chapter assume that the
FANUC robot is used for up to 3840 hours a year. In cases where robot use
exceeds 3840 hours/year, adjust the given maintenance frequencies
accordingly. The ratio of actual operating time/year vs. the 3840 hours/year
should be used to calculate the new (higher) frequencies. For example, when
using the robot 7680 hours a year, the maintenance frequency should be
doubled – i.e. the time interval should be divided by 2.
7.1
PERIODIC MAINTENANCE
7.1.1
Daily Checks
Clean each part, and visually check component parts for damage before daily system operation. Check the
following items when necessary.
Check items
Oil seepage
Air control set
Vibration, abnormal
noises
Repeatability
Peripheral devices for
proper operation
Brakes for each axis
Warnings
Check points and management
Check to see if there is oil on the sealed part of each joint. If there is an oil seepage,
clean it.
⇒”7.2.1 Confirmation of Oil Seepage”
( When air control set is used)
⇒”7.2.2 Confirmation of the Air Control Set”
Check whether vibration or abnormal noises occur.
When vibration or abnormal noises occur, perform measures referring to the following
section:
⇒”9.1 TROUBLESHOOOTING”(symptom：Vibration, Noise)
Check to see that the taught positions of the robot have not deviated from the previous
taught positions. When displacement occurs, perform the measures as described in the
following section:
⇒”9.1 TROUBLESHOOOTING”(symptom：Displacement)
Check whether the peripheral devices operate properly according to commands from the
robot and the peripheral devices.
Check that the end effector drops within 5 mm when servo power is turned off.
If the end effector (hand) drops, perform the measures as described in the following
section:
⇒”9.1 TROUBLESHOOOTING”(symptom：Dropping axis)
Check whether unexpected warnings occur in the alarm screen on the teach pendant. If
unexpected warnings occur, perform the measures as described in the following manual:
⇒”R-30iB/R-30iB Mate CONTROLLER OPERATOR’S MANUAL (Alarm Code
List)(B-83284EN-1)”
- 39 -
7.CHECKS AND MAINTENANCE
7.1.2
B-83754EN/01
Periodic Check and Maintenance
Check the following items at the intervals recommended below based on the total operating time or the
accumulated operating time, whichever comes first. (○ : Item needs to be performed.)
Check and maintenance
intervals
(Operating time,
Accumulated operating
time)
1
3
1
month months year
320h
960h
3840h
○
○
1st
check
○
○
Check for water
○
Only
1st
check
○
○
Only
1st
check
○
○
Only
1st
check
○
Only
1st
check
○
Check points, management and
maintenance method
Periodic
maintenance
table No.
2
3
4
years years years
7680h 11520h 15360h
Cleaning the
controller
ventilation
system
Check for
external
damage or
peeling paint
Only
○
Check and
maintenance
item
Check for
damages
to the teach
pendant cable, the
operation box
connection cable
or the robot
connection cable
Check for
damage to the
end effector
(hand) cable
Check the
connection of
each axis motor
and other
exposed
connectors
Retightening the
end effector
mounting bolts
Confirm the controller ventilation system is not
dusty. If dust has accumulated, remove it.
Check whether the robot has external damage or
peeling paint due to the interference with the
peripheral devices. If an interference occurs,
eliminate the cause. Also, if the external damage is
serious, and causes a problem in which the robot
will not operate, replace the damaged parts.
Check whether the robot is subjected to water or
cutting oils. If water is found, remove the cause and
wipe off the liquid.
Check whether the cable connected to the teach
pendant, operation box and robot are unevenly
twisted or damaged. If damage is found, replace
the damaged cables.
Check whether the end effector cables are
unevenly twisted or damaged. If damage is found,
replace the damaged cables.
Check the connection of each axis motor and other
exposed connectors.
⇒”7.2.3 Check the mechanical unit
connectors”
Retighten the end effector mounting bolts.
Refer to the following section for tightening torque
information:
⇒”4.1 END EFFECTOR INSTALLATION TO
WRIST”
- 40 -
18
1
2
17
3
4
5
7.CHECKS AND MAINTENANCE
B-83754EN/01
Check and maintenance
intervals
(Operating time,
Accumulated operating
time)
1
3
1
month months year
320h
960h
3840h
○
Check and
maintenance
item
○
Retightening the
external main
bolts
1st
check
○
Check the
mechanical
stopper and the
adjustable
mechanical
stopper
Clean spatters,
sawdust and
dust
Only
1st
check
○
Periodic
maintenance
table No.
2
3
4
years years years
7680h 11520h 15360h
Only
○
Check points, management and
maintenance method
○
Only
1st
check
○
○
○
○
○
Replacing the
mechanical unit
batteries
Replacing the
grease of J1 to
J3- axis
reducers
Supplying
grease l to J4 to
J6- axis
reducers
Replacing the
mechanical unit
cable
Replacing the
controller
batteries
Retighten the robot installation bolts, bolts to be
removed for inspection, and bolts exposed to the
outside. Refer to the recommended bolt tightening
torque guidelines in “Appendix B, STRENGTH OF
BOLT AND BOLT TORQUE LIST” An adhesive to
prevent bolts from
loosening is applied to some bolts. If the bolts are
tightened with greater than the recommended
torque, the adhesive might be removed.
Therefore, follow the recommended bolt tightening
torque guidelines when retightening the bolts.
⇒“Appendix B, STRENGTH OF BOLT AND
BOLT TORQUE LIST”
Check that there is no evidence of a collision on the
mechanical stopper, the adjustable mechanical
stopper, and check the looseness of the stopper
mounting bolts.
⇒”7.2.4 Check of Fixed Mechanical Stopper
and Adjustable Mechanical Stopper”
Check that spatters, sawdust, or dust does not exist
on the robot main body. If dust has accumulated,
remove it.
Especially, clean the robot movable parts well (each
joint, around the welding torch, conduit part, wrist
axis hollow part and the cable protection sheath).
The insulation failure occurs when the spatter has
collected around the wrist flange or welding torch,
and there is a possibility of damaging the robot
mechanism by the welding current. (See Appendix C)
Replace the mechanical unit batteries
⇒”7.3.1 Replacing the batteries”
Replace the grease and oil of each axis reducer and
gearbox
⇒”7.3.2 Replacing the Grease of the J1 to J3
axis Reducers”
Supply grease l to J4 to J6- axis reducers
⇒”7.3.3 Supping the Grease to the J4 to J6
axis Reducers”
Replace the mechanical unit cable
Contact your local FANUC representative for
information regarding replacing the cable.
Replace the controller batteries
⇒Chapter 7 Replacing batteries of R-30iB
CONTROLLER MAINTENANCE MANUAL
(B-83195EN) or R-30iB Mate CONTROLLER
MAINTENANCE MANUAL (B-83525EN)”
- 41 -
6
7
8
9
10 to 12
13 to 15
16
19
7.CHECKS AND MAINTENANCE
B-83754EN/01
7.2
CHECK POINTS
7.2.1
Confirmation of Oil Seepage
Check items
Check whether there is oil on the sealed part of each joint. If there is oil seepage, clean each part.
Fig. 7.2.1 Check parts for oil seepage
Management

Oil might accumulate on the outside of the seal lip depending on the movement condition or
environment of the axis. If the oil changes to a state of liquid, the oil might fall depending on the
axis movement. To prevent oil spots, be sure to wipe away any accumulated oil under the axis
components before you operate the robot.

If oil seepage does occur, please consider replacing the grease and the oil altogether. This
replacement can potentially reduce the oil seepage condition.

Also, motors might become hot and the internal pressure of the grease bath or oil bath might rise by
frequent repetitive movement and use in high temperature environments. In these cases, normal
internal pressure can be achieved by venting the grease outlet. (When opening the grease outlet,
refer to Subsection 7.3.2 and ensure that grease is not expelled onto the machine or tooling.)
WARNING
Grease may come out suddenly when opening the grease outlet. Attach bags for
collecting grease.

If you must wipe oil frequently, and opening the grease outlet does not stop the seepage, perform the
measures below.
⇒”9.1 TROUBLESHOOOTING”(symptom：Grease leakage)
- 42 -
7.CHECKS AND MAINTENANCE
B-83754EN/01
7.2.2
Item
Confirmation of the Air Control Set
Check items
1
Air pressure
2
Leakage from hose
3
Drain
Check points
Check air pressure using the pressure gauge on the air control set as shown in
Fig.7.2.2. If it does not meet the specified pressure of 0.49MPa (5 kg/cm2), adjust it
using the regulator pressure setting handle.
Check the joints, tubes, etc. for leaks.
Repair leaks, or replace parts, as required.
Check drain and release it. When quantity of the drain is remarkable, examine the
setting of the air dryer to the air supply side.
Pressure
Adjusting Knob
2-6.5×16.5
Length round hole
Rc1/4
AIR OUTLET
Pressure gauge
Rc1/4
AIR SUPPLY
Fig. 7.2.2 Air control set (option)
- 43 -
7.CHECKS AND MAINTENANCE
7.2.3
B-83754EN/01
Check the Mechanical Unit Connectors
Inspection points of the connectors

Robot connection cables, earth terminal and user cables
Check items

Circular connector: Check the connector for tightness by turning it by hand.

Square connector: Check the connector for engagement of its lever.

Earth terminal:
Check the connector for tightness.
Remove
this cover
このカバーを外して
and
check
here.
点検する事
Fig. 7.2.3 Connector Inspection points
- 44 -
7.CHECKS AND MAINTENANCE
B-83754EN/01
7.2.4



Check of Fixed Mechanical Stopper and Adjustable
Mechanical Stopper
Check that there is no evidence of a collision on the fixed mechanical stopper and the adjustable
mechanical stopper. If there is evidence of a collision on the stopper, replace it with a new one.
Check the tightness of the stopper mounting bolts. If they are loose, retighten them.
Be sure to check the tightness of the mounting bolts of the J1-axis swing stopper.
Refer to Section 6.2 for details regarding the adjustable mechanical stopper.
J3-axis
J3軸機械式ストッパ
(プラス側) stopper
mechanical
(plus side)
J1-axis
mechanical
stopper
J1軸機械式ストッパ
・A290-7226-X206
A290-7226-X206
・ボルト
M12X40
Bolt
M12X40
1 pc1個
(締付けトルク
129Nm)
(Tightening
torque
129Nm)
J3-axis
J3軸機械式ストッパ
mechanical
stopper
(マイナス側)
(minus
side)
断面A-A
A-A
Section
A
J2-axis
J2軸機械式ストッパ
mechanical
stopper
(マイナス側)
(minus
side)
When
J1-axis mechanical
J1軸機械式ストッパ選択時
stopper
is specified
A05B-1226-H051
A A05B-1226-H051
・A290-7226-X207
・ボルト M12X20 2個
A290-7226-X207
(締付けトルク
Bolt
M12X20 294Nm)
pcs
(Tightening torque 94Nm)
J2-axis
J2軸機械式ストッパ
mechanical
stopper
(プラス側)
(plus
side)
Fig. 7.2.4 Check of fixed mechanical stopper and adjustable mechanical stopper
7.3
MAINTENANCE
7.3.1
Replacing the Batteries (1.5 year checks)
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced
every year. Also, use the following procedure to replace the batteries when the backup battery voltage
drop alarm occurs.
Procedure of replacing the battery
1
2
3
Move the robot to the posture to remove the battery part cover.
Keep the power on. Press the EMERGENCY STOP button to stop the robot motion.
Remove the hexagon stainless bolts (M5X14), then remove the cover and the gasket. If the cover
could not be removed, insert a straight-head screwdriver into the arrow part, then remove it.
CAUTION
Be sure to keep controller power turned on. Replacing the batteries with the
power turned off causes all current position data to be lost. Therefore, mastering
will be required again.
4
5
6
7
Remove the battery case cap. (Fig. 7.3.1)
Take out the old batteries from the battery case. In this time, battery can be taken out by pulling the
stick of the center of the battery box.
Insert new batteries into the battery case. Pay attention to the direction of batteries.
Close the battery case cap.
- 45 -
7.CHECKS AND MAINTENANCE
8
B-83754EN/01
Replace hexagon bolts by new article when they are removed. When reusing hexagon bolts, be sure
to wind it with seal tape. Gaskets can be reused.
Gasket
ガスケット
A290-7226-X318
A290-7226-X318
Cover
カバー
A
Hexagon
bolt
六角ステンレスボルト
M5X14(6)(6)
M5X14
Spec.:
A97L-0318-0450#051410S
Arrow
矢印部
part
Detail A
詳細
A
Battery
case
バッテリケース
Battery
spec. :A98L-0031-0005
バッテリ仕様:A98L-0031-0005
(単一アルカリ電池
4本)
(D batery
4 pcs)
Fig. 7.3.1 Replacing the battery
- 46 -
Case
cap
ケースキャップ
7.CHECKS AND MAINTENANCE
B-83754EN/01
7.3.2
Replacing the Grease of the J1 to J3 Axis Reducers
(3 years (11520 hours) checks)
According to Table 7.3.2 (a) and (b), replace the grease of the reducers of J1, J2, and J3 axes at the
intervals based on every 3 years or 11520 hours, whichever comes first.
天吊設置のmount
場合
Upside-down
-90º
wall
mount
-90°
壁掛
け設
置の場合
+90º
壁掛wall
け設mount
置の場合
+90°
Fig. 7.3.2(a) Installation method
Table 7.3.2 (a) Grease name and amount to be replaced at regular intervals of three years (11520 hours)
Grease supplying
Gun tip pressure
Amount of grease to be applied
Specified grease
position
J1-axis reducer
790g(870ml)
J2-axis reducer
300g(330ml)
J3-axis reducer
170g(190ml)
0.1MPa or less
(NOTE)
Kyodo Yushi
VIGOGREASE RE0
(Specification: A98L-0040-0174)
NOTE
When a manual pump is used for greasing or oiling, the standard rate is one
pumping cycles per two seconds.
- 47 -
7.CHECKS AND MAINTENANCE
B-83754EN/01
For grease replacement or replenishment, use the postures indicated in Table 7.3.2 (b).
For angle mount robots, consider the relative angle from the posture of a floor mount robot.
Table 7.3.2 (b) Grease supplying posture (J1, J2, J3-axis reducer)
Posture
Grease supplying position
J1
J2
J3
J4
J1-axis reducer
grease supplying
posture
J2-axis reducer
grease supplying
posture
J3-axis reducer
grease supplying
posture
1
2
3
4
5
6
J5
J6
Arbitrary
Arbitrary
Floor mount
Upside-down mount
Wall mount -90º
Wall mount +90º
Floor mount)
Upside-down mount
Wall mount -90º
Wall mount +90º
Floor mount
Upside-down mount
Wall mount -90º
Wall mount +90º
Arbitrary
Arbitrary
0
-90º
90º
-90º
0
0
0
0
Arbitrary
Arbitrary
Arbitrary
0
180
0
0
Move the robot to the greasing posture described in Table.7.3.2 (b).
Turn off the controller power.
Remove the hexagon bolt from grease outlet. (Fig.7.3.2(b))
Remove the taper plug from grease inlet and attach grease nipple.
Keep greasing until the new grease pushes out the old grease and comes out from each grease outlet.
Release remaining pressure using the procedure given in Subsection 7.3.2.1. In case of Upside-down
mount, pull out about 130ml grease to make space of grease bath.
J3-axis
reducer grease inlet
J3軸減速機給脂口
Taper
plug 1/8
テーパプラグ
R1/4
J3-axis reducer
grease outlet
J3軸減速機排脂口
Hexagon bolt 六角ボルト
M8X10 M8X10
J2-axis reducer
grease
inlet
J2軸減速機給脂口
Taper
plug 1/8
テーパプラグ
R1/8
J2-axis reducer grease outlet
J2軸減速機排脂口
Hexagon bolt M8X10
六角ボルト M8X10
J1-axis reducer
grease inlet
J1軸減速機給脂口
テーパプラグ
R1/8
Taper plug 1/8
J1-axis
reducer grease outlet
J1軸減速機排脂口
六角ボルトbolt
M8X10
Hexagon
M8X10
Fig. 7.3.2 (b) Greasing point of J1 to J3-axis reducer
Table 7.3.2 (c) Specification of hexagon bolts and taper plugs
Parts name
Specification
Hexagon bolt
Taper plug
(M8X10)
(R1/8)
A97L-0318-0410#081010S
A97L-0001-0436#2-1D
- 48 -
7.CHECKS AND MAINTENANCE
B-83754EN/01
1
2
3
4
5
6
CAUTION
Failure to follow proper greasing procedures may cause a sudden increase of
the grease bath internal pressure and damage to the seal. This, could lead to
grease leakage and abnormal operation. When greasing, observe the following
cautions.
Before starting to grease, open the seal bolt of the grease outlet.
Supply grease slowly, using a manual pump. (once per two seconds)
Whenever possible, avoid using an air pump, which is powered by the factory air
supply.
If the use of an air pump is unavoidable, supply grease with the pump at a
pressure lower than or equal to the gun tip pressure (see Table 7.3.2 (a)).
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 greasing, release remaining pressure from the grease bath using the
procedure given in Subsection 7.3.2.1, and then close the grease outlet.
To prevent an accident such as a fall or fire, remove all the excess grease from
the floor and robot.
7.3.2.1
Procedure for releasing remaining pressure from the grease
bath (J1 to J3-axis)
After applying grease, operate the robot more than 10 minutes as instructed below with one of the taper
plugs and hexagon bolts of the grease inlet and outlet which is in high position uncapped to release the
remaining pressure within the grease bath.
Attach a recovery bag below the grease inlet and outlet to prevent output grease from splattering.
Operating axis
Grease
replacement part
J1-axis
J1-axis reducer
Axis angle of
60 or more
OVR 100
J2-axis reducer
Arbitrary
J3-axis reducer
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
Arbitrary
Axis angle of
60 or more
OVR 100
Arbitrary
Arbitrary
Axis angle of
60 or more
OVR 100
Arbitrary
If the above operation cannot be performed due to the environment of the robot, prolong the operating
time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 30
degrees, perform the twice operation for 20 minutes or more.) When you supply grease or oil to multiple
axes, you can run the multiple axes at the same time. After completion of the operation, attach the taper
plug and seal bolts to the grease inlets and outlets. When reusing the seal bolts, be sure to seal them
with seal tape.
After replacing grease, the internal pressure of the grease bath may rise if the robot is operated again
under frequent inversion movement or a high temperature environment. In these cases, you can return to
normal internal pressure by releasing the grease outlet just after robot operation. (When opening grease
outlet, be sure that grease or oil is not spattered.)
- 49 -
7.CHECKS AND MAINTENANCE
7.3.3
B-83754EN/01
Grease Supplying Procedure for J4 to J6-axis Reducer
(4 years (15360 hours) periodical check)
Supply the grease of the J4,J5,J6-axis reducers every four years or 15360 hours by using the following
procedures. For the grease name and quantity, see the Table 7.3.3 (a).
Table 7.3.3 (a) Grease for 4-year (15360 hours) periodical greasing
Greasing points
Greasing amount
Specified grease
2.7ｇ(3ml)
J4-axis reducer
Harmonic grease 4BNo.2
2.7ｇ(3ml)
J5 -axis reducer
Spec: A98L-0040-0230
2.7ｇ(3ml)
J6-axis reducer
For grease replacement, use the arbitrary postures.
CAUTION
The following maintenance kits are prepared for the greasing.
-Greasing kit:
A05B-1226-K031
(This a set of greasing syringe and grease in tube. (80g))
-Grease in tube: A05B-1139-K022 (grease in tube. (80g))
CAUTION
Failure to follow proper lubrication procedures may cause a sudden increase of
the grease bath internal pressure and damage to the seal. This could lead to
grease leakage and abnormal operation. When greasing, observe the following
cautions.
1 Use specified grease. Use of non-approved grease may damage the reducer or
lead to other problems. Do no use Harmonic grease SK-3
2 To prevent an accident such as a fall or fire, remove all the excess grease from
the floor and robot.
3 When you use the grease greasing kit, massage the grease tube by hand to
soften the grease before you fill a necessary amount in the injection syringe.
Please install the nozzle in the point of the injection syringe. Remove the nozzle
and replace the cap when you are finished using the injection syringe.
- 50 -
7.CHECKS AND MAINTENANCE
B-83754EN/01
1
2
3
4
Turn off controller power.
Remove the hexagon bolts of the grease inlet.
Supply a regulated amount of grease by using the injection syringe. Please note that grease might
come out immediately after the grease has been supplied, or during the greasing. Even in this case,
please do not supply grease beyond the regulated amount specified.
Replace the hexagon bolts with new ones. When reusing the hexagon bolt, be sure to seal it with seal
tape.
J6-axis
reducer grease inlet
J6軸減速機給脂口
Hexagon
bolt M5X10
六角ボルト
M5X10
J5-axis
reducer grease inlet
J5軸減速機給脂口
Hexagon
bolt M5X10
六角ボルト
M5X10
J4-axis reducer
grease inlet
J4軸減速機給脂口
Hexagon
bolt M8X10M8X10
六角ボルト
Fig. 7.3.3 Greasing point of J4,J5,J6-axis reducers
Parts name
Table 7.3.3 (b) Spec. of the Hexagon bolts
Specification
Hexagon bolt (M5X10)
Hexagon bolt (M8X10)
7.4
A97L-0318-0410#051010S
A97L-0318-0410#081010S
STORAGE
When storing the robot, place it on a level surface with the same posture for transportation. (See Section
1.1.)
- 51 -
8.MASTERING
8
B-83754EN/01
MASTERING
Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute
Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for
obtaining the pulse count value; corresponding to the zero position.
8.1
OVERVIEW
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 is required under the following conditions:

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 die. Replace
the batteries in the controller and mechanical units periodically. An alarm will
alert you when battery voltage is low.
Types of Mastering
Table 8.1 describes the following mastering methods.
Table 8.1 Type of mastering
Fixture position
mastering
Zero-position mastering
(witness mark
mastering)
Quick mastering
Quick mastering for
single axis
Single axis mastering
Mastering data entry
Mastering performed before shipping using the mastering fixture. .
Mastering performed with all axes set at the 0-degree position. A zero-position mark
(witness mark) is attached to each robot axis. This mastering is performed with all axes
aligned to their respective witness marks.
Mastering performed at a user-specified position. The corresponding count value is
obtained from the rotation speed of the Pulsecoder connected to the relevant motor and
the rotation angle within one rotation. Quick mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost. (All axes at the same time)
Mastering performed at a user-specified position for one axis. The corresponding count
value is obtained from the rotation speed of the Pulsecoder connected to the relevant
motor and the rotation angle within one rotation. Quick mastering uses the fact that the
absolute value of a rotation angle within one rotation will not be lost.
Mastering performed for one axis at a time. The mastering position for each axis can be
specified by the user. This is useful when performing mastering on a specific axis.
Enter the Mastering data directly.
Once mastering is performed, you must carry out positioning (calibration). Positioning is an operation in
which the controller reads the pulse count value to sense the current position of the robot.
This section describes zero-position mastering, quick mastering, single-axis mastering, and mastering data
entry. For more detailed mastering (fixture position mastering), contact your local FANUC
representative.
- 52 -
8.MASTERING
B-83754EN/01
CAUTION
1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. For this reason, the Master/Cal screen is designed to appear
only when the $MASTER_ENB system variable is 1 or 2. After performing
positioning, press F5, ([DONE]) on the Master/Cal screen. The $MASTER_ENB
system variable is reset to 0 automatically, and the Master/Cal screen will
disappear.
2 It is recommended that the current mastering data be backed up before
mastering is performed. Use mastering data of without additional axis to with
additional axis and opposite can not be done.
3 When the motion range is mechanically 360 degrees or more, turning any of the
axes (J1-axis and J4-axis) to which the cables are connected one turn in the
correct mastering position will damage the cables in the mechanical unit.. If the
correct rotation position is not clear because the axis is moved too much during
mastering, remove the connector panel or cover, check the states of the internal
cables, and perform mastering in the correct position. For the checking
procedure, see Fig. 8.1 (a) and 8.1 (b).
Gasket
ガスケット
A290-7226-X209
A290-7226-X209
J1
connector panel
J1分線盤
Hexagon bolt
ボルト
M5X14
(9)
M5X14 (9)
Spec.:
A97L-0318-0450#051410S
Check
that the cables are
J1=0vの時
ケーブルが捻れていないことを
not
twisted with the
確認してください。
J1 axis placed in 0º
Fig. 8.1 (a) Confirming the state of cable (J1-axis)
- 53 -
8.MASTERING
B-83754EN/01
六角ステンレスボルト
Hexagon
bolt
M5X14(6)
(6)
M5X14
Spec.:
A97L-0318-0450#051410S
Check
that the cables are
J4=0°の時
not
twisted with the
ケーブルが捻れていないことを
確認してください。
J4
axis placed in 0º
Gasket
ガスケット
A290-7226-X424
A290-7226-X424
Fig. 8.1 (b) Confirming the state of cable (J4-axis)
8.2
RESETTING ALARMS AND PREPARING FOR
MASTERING
Before performing mastering because a motor is replaced, you must 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 the steps 1 to 6.
1
Press the [MENU] key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press the F1 ([TYPE]), and select [Variable] from the menu.
4
Place the cursor on $MASTER_ENB, then key in “1” and press the [ENTER] key.
5
Press the 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 [MENU] key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press the F1 ([TYPE]), and select [Master/Cal] from the menu.
4
Place the cursor on the F3 ([RES_PCA]), then press the F4 ([YES]).
5
Cycle power of the controller.
3
To reset the “Servo 075 Pulse not established” alarm, follow the steps 1 to 2.
1
After cycle power of the controller, 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.
- 54 -
8.MASTERING
B-83754EN/01
8.3
ZERO POSITION MASTERING
Zero-position mastering (witness mark mastering) is performed with all axes set at the 0-degree position.
A zero-position mark (witness mark) is attached to each robot axis (Fig. 8.3). This mastering is performed
with all axes set at the 0-degree position using their respective witness marks.
Zero-position mastering involves a visual check. It cannot be so accurate. It should be used only as a
quick-fix method.
Procedure of Zero-position Mastering
1
2
3
4
Press the [MENU] key to display the screen menu.
Select [0 NEXT] and press [6 SYSTEM].
Press F1 [TYPE].
Select [Master/Cal].
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
5
LOAD
RES_PCA
DONE
Release brake control, and jog the robot into a posture for mastering.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM_GROUP.SV_OFF_ENB[*]: FALSE (for all axes)
After changing the system variables, turn off the controller power and on again.
6
Select [Zero Position Master]. Press F4 [YES].
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <12200039> <2000319>
[ TYPE ] LOAD RES_PCA
DONE
- 55 -
8.MASTERING
7
B-83754EN/01
Select [6 CALIBRATE] and press F4 [YES]. Mastering will be performed automatically.
Alternatively, turn off the controller power and on again. Turning on the power always causes
positioning to be performed.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
8
After positioning is completed, press F5 [DONE].
DONE
F5
9
Return brake control to original setting, and cycle power of the controller.
Table 8.3 Posture with position marks (witness mark) aligned
Axis
Position
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
0 deg
0 deg
0 deg (NOTE) When J2-axis is 0 deg.
0 deg
0 deg
0 deg
- 56 -
8.MASTERING
B-83754EN/01
J5
Detail
詳細 EE
J3
D
C
J4
Detail
詳細 C
C
J2
詳細 DD
Detail
DetailBB
詳細
B
J1
A
DetailAA
詳細
Fig. 8.3 Zero-position mark (witness mark) for each axis
- 57 -
E
8.MASTERING
8.4
B-83754EN/01
QUICK MASTERING
Quick mastering is performed at a user-specified position. The pulse 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 8.3. Do not change the setting
unless there is any problem.
If setting the robot at the position mentioned above is impossible, you must re-set the quick mastering
reference position using the following method. (It would be convenient to set up a marker that can work
in place of the witness mark.)
CAUTION
1 Quick mastering can be used, if the pulse count value is lost, for example,
because a low voltage has been detected on the backup battery for the pulse
counter.
2 Quick mastering cannot be used, after the Pulsecoder is replaced or after the
mastering data is lost from the robot controller.
Procedure Recording the Quick Mastering Reference Position
1
2
Select SYSTEM.
Select Master/Cal. Master/Cal screen will be displayed.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
3
4
LOAD
RES_PCA
DONE
Release brake control, and jog the robot to the quick mastering reference position.
Select [5 SINGLE AXIS MASTER] and press F4 [YES]. Quick mastering reference position will be
set.
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
CAUTION
If the robot has lost mastering data due to mechanical disassembly or repair, you
cannot perform this procedure. In this case, perform Fixture position mastering
or zero –position mastering is required to restore mastering data.
- 58 -
8.MASTERING
B-83754EN/01
Procedure of Quick Mastering
1
Display the Master/Cal screen.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Not Mastered!
Quick master? [NO]
2
3
Release brake control, and jog the robot to the quick mastering reference position.
Select [3 QUICK MASTER] and press F4 [YES]. Quick mastering reference position will be set.
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
4
5
Select [7 CALIBRATE] and press [ENTER] key. Calibration is executed. Calibration is executed by
cycling power.
After completing the calibration, press F5 [Done].
DONE
F5
6
Return brake control to original setting, and cycle power of the controller.
- 59 -
8.MASTERING
8.5
B-83754EN/01
QUICK MASTERING FOR SINGLE AXIS
Quick mastering is performed at a user-specified position for one axis. The pulse count value is obtained
from the rotation times of the Pulsecoder connected to the relevant motor and the rotation angle within
one rotation. Quick mastering uses the character that the absolute value of a rotation angle within one
rotation will not be lost.
Quick mastering is factory-performed at the position indicated in Table 8.3. If possible, do not change the
setting.
If setting the robot at the position mentioned above is impossible, you must re-set the quick mastering
reference position using the following method. (It would be convenient to set up a marker that can work
in place of the witness mark.)
CAUTION
1 Quick mastering can be used, if the pulse count value is lost, for example,
because a low voltage has been detected on the backup battery for the pulse
counter.
2 Quick mastering cannot be used, after the Pulsecoder is replaced or after the
mastering data is lost from the robot controller.
Procedure Recording the Quick Mastering Reference Position
1
2
Select [6 SYSTEM].
Select [Master/Cal]. The positioning screen will be displayed.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
3
4
LOAD
RES_PCA
DONE
Release brake control, and jog the robot to the quick mastering reference position.
Select [6 SET QUICK MASTER REF] and press F4 [YES]. Quick mastering reference position will
be set.
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
CAUTION
If the robot has lost mastering data due to mechanical disassembly or repair, you
cannot perform this procedure. In this case, perform Fixture position mastering
or zero –position mastering is required to restore mastering data.
- 60 -
8.MASTERING
B-83754EN/01
Procedure of Quick Mastering for single axis
1
Display the Master/Cal screen.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Not Mastered!
Quick master? [NO]
2
Select [4 QUICK MASTER FOR SINGLE AXIS]. You will see the quick master for single axis
screen.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
(
0.000)
(
0.000)
(
0.000)
J OINT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
3
Move the cursor to the [SEL] column for the unmastered axis and press the numeric key [1].
Setting of [SEL] is available for one or more axes.
SINGLE AXIS MASTER
J5
J6
ACTUAL POS
0.000
0.000
AUTO
(MSTR POS)
0.000)
(
(
0.000)
JOINT 10%
1/9
(SEL) [ST]
(0)
[2]
(0)
[0]
EXEC
4
5
6
7
Turn off brake control, then jog the robot to the quick mastering reference position.
Press F5 [EXEC]. Mastering is performed. So, [SEL] is reset to 0, and [ST] is re-set to 2.
Select [7 CALIBRATE] and press [ENTER] key. Calibration is executed. Calibration is executed
by cycling power.
After completing the calibration, press F5 Done.
DONE
F5
8
Return brake control to original setting, and cycle power of the controller.
- 61 -
8.MASTERING
8.6
B-83754EN/01
SINGLE AXIS MASTERING
Single axis mastering is performed for one axis at a time. The mastering position for each axis can be
specified by the user.
Single axis mastering can be used, if mastering data for a specific axis is lost, for example, because a low
voltage has been detected on the pulse counter backup battery or because the Pulsecoder has been
replaced.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
(
0.000)
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
(
0.000)
(
0.000)
(
0.000)
J OINT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
Table 8.6 Items set in single axis mastering
Description
Item
Current position
(ACTUAL AXIS)
Mastering position
(MSTR POS)
SEL
ST
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 if it is set to 0 degree position.
This item is set to 1 for an axis to be subjected to single axis mastering. Usually, it is 0.
This item indicates whether single axis mastering has been completed for the corresponding
axis. It cannot be changed directly by the user.
The value of the item is reflected in $EACHMST_DON (1 to 9).
0 :Mastering data has been lost. Single axis mastering is necessary.
1 :Mastering data has been lost. (Mastering has been performed only for the other interactive
axes.) Single axis mastering is necessary.
2 :Mastering has been completed.
Procedure of Single axis mastering
1
2
Select [6 SYSTEM].
Select [Master/Cal].
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
LOAD
RES_PCA
- 62 -
DONE
8.MASTERING
B-83754EN/01
3
Select [4 SINGLE AXIS MASTER]. You will see a screen similar to the following.
SINGLE AXIS MASTER
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
AUTO
(MSTR POS)
0.000)
(
(
0.000)
0.000)
(
0.000)
(
0.000)
(
(
0.000)
(
0.000)
(
0.000)
(
0.000)
JO INT 10%
1/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
4
5
6
7
For the axis to which to perform single axis mastering, set (SEL) to “1.” Setting of [SEL] is
available for one or more axes.
Turn off brake control, then jog the robot to the mastering position.
Enter axis data for the mastering position.
Press F5 [EXEC]. Mastering is performed. So, [SEL] is reset to 0, and [ST] is re-set to 2 or 1.
SINGLE AXIS MASTER
AUTO
EXEC
F5
J1
J2
J3
J4
J5
J6
E1
E2
E3
ACTUAL POS
0.000
0.000
0.000
0.000
0.000
90.000
0.000
0.000
0.000
(MSTR POS)
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
(
(
0.000)
(
0.000)
(
0.000)
JOINT 10%
6/9
(SEL)
[ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(1)
[0]
(0)
[0]
(0)
[0]
(0)
[0]
EXEC
8
When single axis mastering is completed, press the [PREV] key to resume the previous screen.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
9
10
LOAD
RES_PCA
DONE
Select [7 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].
DONE
F5
11
Return brake control to original setting, and cycle power of the controller.
- 63 -
8.MASTERING
8.7
B-83754EN/01
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 the [MENU] key, then press [0 NEXT] and select [6 SYSTEM].
Press F1 [TYPE]. Select [Variables]. The system variable screen appears.
SYSTEM Variables
1
2
3
4
5
6
$AAVM_GRP
$AAVM_WRK
$ABSPOS_GRP
$ACC_MAXLMT
$ACC_MINLMT
$ACC_PRE_EXE
[ TYPE ]
3
AUTO
Change the mastering data.
system variable.
JOINT 10%
1/669
AAVM_GRP_T
AAVM_WRK_T
ABSPOS_GRP_T
0
0
0
DETAIL
The mastering data is saved to the $DMR_GRP.$MASTER_COUN
SYSTEM Variables
135
136
AUTO
$DMR_GRP
$DMSW_CFG
JOINT 10%
1/669
DMR_GRP_T
DMSW_CFG_T
[ TYPE ]
4
Select $DMR_GRP.
SYSTEM Variables
$DMR_GRP
1
[1]
[ TYPE ]
AUTO
JOINT 10%
1/1
DMR_GRP_T
DETAIL
SYSTEM Variables
$DMR_GRP
1
2
3
4
5
6
AUTO
$MASTER_DONE
$OT_MINUS
$OT_PLUS
$NASTER_COUN
$REF_DONE
$REF_POS
[ TYPE ]
FALSE
[9] of BOO LEAN
[9] of BO OLEAN
[9] of INTEGER
FALSE
[9] of REAL
TRUE
- 64 -
J OINT 10%
1/29
FALSE
8.MASTERING
B-83754EN/01
5
Select $MASTER_COUN, and enter the mastering data you have recorded.
SYSTEM Variables
AUTO
$DMR_GRP[1].$MASTER_CO UN
1
[1]
95678329
2
[2]
10223045
3
[3]
3020442
4
[4]
30405503
5
[5]
20497709
6
[6]
2039490
7
[7]
0
8
[8]
0
9
[9]
0
J OINT 10%
1/9
[ TYPE ]
6
7
Press [PREV] key.
Set $MASTER_DONE to TRUE.
SYSTEM Variables
$DMR_GRP
1
2
AUTO
$MASTER_DONE
$OT_MINUS
TRUE
[9] of BOO LEAN
[ TYPE ]
8
9
JOINT 10%
1/29
TRUE
FALSE
Display the positioning screen, and select [7 CALIBRATE], then press F4 [YES].
After completing positioning, press F5 [DONE].
DONE
F5
- 65 -
8.MASTERING
8.8
1
2
B-83754EN/01
VERIFYING MASTERING
How to verify that the robot is mastered properly:
Usually, positioning is performed automatically when the power is turned on. To check whether
mastering has been performed correctly, examine if the current displayed position meets the actual
robot position by using 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 (0 rad) positions. Check that the zero-degree position
marks indicated in Section 8.3 of OPERATOR’S MANUAL are aligned. There is no need to
use a visual aid.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described in 8.2. Alternatively, the mastering data in system
variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation
error or some other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value of
the system variable on the data sheet.
Alarm type displayed during mastering and their solution method:
(1) BZAL alarm
This alarm is displayed if the Pulsecoder's backup battery voltage decreases to 0 V while the
power to the controller is disconnected. Furthermore, if the Pulsecoder connector is removed
for cable replacement, etc. this alarm is displayed as the voltage decreases to 0. Confirm if the
alarm will disappear by performing a pulse reset (See Section 8.2.). Then, cycle power of the
controller to check if the alarm disappears or not.
The battery may be drained if the alarm is still displayed. Perform a pulse reset, and turn off
and on the controller power after replacing the battery. Note that, if this alarm is displayed, all
the original data held by the Pulsecoder will be lost. Mastering is required.
(2) BLAL alarm
This alarm is displayed if the voltage of the Pulsecoder's backup battery has fallen to a level
where backup is no longer possible. If this alarm is displayed, replace the battery with a new
one immediately while keeping the power turned on. Check whether the current position data is
valid, using the procedure described in 1.
(3) Alarm notification like CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and
SPHAL may have trouble with Pulsecoder, contact your local FANUC representative.
- 66 -
9.TROUBLESHOOTING
B-83754EN/01
9
TROUBLESHOOTING
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, you must keep an accurate
record of problems and take proper corrective actions.
9.1
TROUBLESHOOTING
Table 9.1 shows the major troubleshooting that may occur in the mechanical unit and their probable causes.
If you cannot pinpoint a failure cause or which measures to take, contact your local FANUC representative.
Symptom
Vibration
Noise
-
-
-
-
-
-
-
Table 9.1 Troubleshooting
Description
Cause
[J1 base fastening]
The J1 base lifts off the
It is likely that the robot J1 base is
floor plate as the robot
not securely fastened to the floor
operates.
plate.
There is a gap between the
Probable causes are a loose bolt,
J1 base and floor plate.
an insufficient degree of surface
A J1 base retaining bolt is
flatness, or foreign material caught
loose.
between the J1 base 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, which, in turn, leads to
vibration.
[Rack or floor]
The rack or floor plate
It is likely that the rack or floor is
vibrates during operation of not rigid enough.
the robot.
If they are not rigid enough,
counterforce deforms the rack or
floor, and responsible for the
vibration.
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.
[Overload]
It is likely that the load on the robot
is greater than the maximum
rating.
It is likely that the robot control
program is too demanding for the
robot hardware.
It is likely that the
ACCELERATION value is
excessive.
- 67 -
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 reinforcing the rack
or floor is impossible,
modify the robot
control program;
doing so might reduce
the 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).
9.TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
B-83754EN/01
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 replaced for a
long period.
-
There is some relationship
between the vibration of
the robot and the operation
of a machine near the
robot.
-
There is an abnormal noise
after replacing grease.
There is an abnormal noise
after a long time.
There is an abnormal noise
during operation at low
speed.
-
Cause
[Broken gear, bearing, or reducer]
It is likely that collision or overload
applied an excessive force on the
drive mechanism, thus damaging
the gear tooth surface or rolling
surface of a bearing, or reducer.
Prolonged overloaded use may
cause fretting fatigue on gear tooth
surface or rolling surface of
bearing and reducer.
It is likely that foreign material
caught in a gear, bearing, or inside
the reducer has 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 inside
the reducer has caused 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 by neglect
greasing.
Above causes will generate cyclical
vibration and noise.
[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 abnormal noise
when using other than the
specified grease.
Even for the specified grease,
there may be an abnormal noise
during operation at low speed
immediately after replacement or
after a long time.
- 68 -
Measure
-
-
-
-
Operate each axis at
individually to judge
which axis has been
vibrating.
Remove the motor,
and replace the gear,
the bearing, and the
reducer. For the
specification of parts
and the procedure of
replacement, contact
your local FANUC
representative.
Using the robot within
its maximum rating
prevents problems
with the drive
mechanism.
Specific type and
period of grease
change will prevent
troubles.
-
Connect the
grounding wire firmly
to ensure a reliable
ground potential and
prevent extraneous
electrical noise.
-
Use the specified
grease.
When there is an
abnormal noise even
for specified grease,
operate for one or two
days on an
experiment.
Generally, an
abnormal noise will
disappear.
-
9.TROUBLESHOOTING
B-83754EN/01
Symptom
Vibration
Noise
(Continued)
Rattling
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.
Pulsecoder defect may be the
cause of the vibration as the motor
cannot propagate the accurate
position to the controller.
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 unit 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 unit has an
intermittent break, vibration might
occur because commands cannot
be sent to the motor accurately.
If a connection cable between the
mechanical unit and the controller
has an intermittent break, vibration
might occur.
If the power supply cable is about
to be snapped, vibration might
occur.
If the power source voltage drops
below the rating, vibration might
occur.
It may vibrate when the invalid
robot control parameter was set.
-
While the robot is not
supplied with power,
pushing it by hand wobbles
part of the mechanical unit.
There is a gap on the
mounting face of the
mechanical unit.
[Mechanical unit mounting bolt]
It is likely that overloading or a
collision has loosened a mounting
bolt in the robot mechanical unit.
-
- 69 -
Measure
Refer to the Controller
Maintenance Manual
for troubleshooting
related to the
controller and
amplifier.
Also, replace the
motor of the axis that
is vibrating, and check
whether vibration still
occurs. For the
method of
replacement, Contact
your local FANUC
representative.
If vibration occurs only
when the robot
assumes a specific
posture, it is likely that
a mechanical unit is
broken.
Check whether the
cable jacket
connecting the
mechanical unit and
controller is damaged.
If so, replace the
connection cable, and
check whether
vibration still occurs.
Check whether the
power cable jacket is
damaged. If so,
replace the power
cable, and check
whether vibration still
occurs.
Check that the robot is
supplied with the rated
voltage.
Check that the robot
control parameter is
set to a valid value. If it
is set to an invalid
value, correct them.
Contact your local
FANUC
representative for
further information if
necessary.
Check the following
retaining bolts
tightness for each
axis. If any of these
bolts is loose, apply
LOCTITE and bolt
down with appropriate
torque.
- Motor retaining bolt
- Reducer retaining bolt
- Reducer shaft retaining
bolt
- Base retaining bolt
- Arm retaining bolt
- Casing retaining bolt
- End effector retaining bolt
-
9.TROUBLESHOOTING
Symptom
Motor
overheating
B-83754EN/01
Description
-
-
-
The motor overheated due
to the temperature in the
installation area rose.
After a cover was attached
to the motor, the motor
overheated.
After changing the Robot
control program or the load,
the motor overheat.
Cause
[Ambient temperature]
It is likely that the motor
overheated along with the ambient
temperature rose, and could not
release heat.
[Operating condition]
It is likely that the overcurrent
above the specified permissive
average current.
Measure
-
-
-
-
-
After a robot control
parameter (load setting
etc.) was changed, the
motor overheated.
-
Symptom other than stated
above
[Parameter]
If data input for a workpiece is
invalid, the robot cannot be
accelerated or decelerated
normally, so the average current
increases, leading to overheat.
[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.
- 70 -
-
-
-
-
Reducing the ambient
temperature is the
most effective means
of preventing
overheat.
If there is a source of
heat near, it is
advisable to install
shielding to protect
the motor from heat
radiation.
Relaxing the robot
control program and
load condition is
effective to reduce the
average current.
Thus, prevent
overheat.
The teach pendant
can monitor the
average current.
Check the average
current when the robot
control program
launched.
As for load setting,
Input an appropriate
parameter referring to
Section 4.3 of the
operator’s manual.
Repair the mechanical
unit while referring to
the above
descriptions of
vibration, noise, and
rattling.
Check that, when the
servo system is
energized, the brake
is released.
If the brake remains
applied to the motor all
the time, replace the
motor.
If the average current
falls after the motor is
replaced, it indicates
that the first motor was
faulty.
9.TROUBLESHOOTING
B-83754EN/01
Symptom
Grease
leakage
Dropping
axis
Description
Cause
-
Grease leaks from the
mechanical unit.
[Poor sealing]
Probable causes are a crack in the
casting, a damaged O-ring, a
damaged oil seal, or a loose seal
bolt.
The casting may crack with
excessive force caused in
collision.
An O-ring can be damaged if it is
trapped or cut during
disassembling or re-assembling.
An oil seal may be damaged if dust
scratches the lip.
A loose hexagon bolt may allow
grease to leak along the threads.
-
An axis falls because the
brake went out.
An axis falls in standstill.
[Brake drive relay and motor]
It is likely that brake drive relays
are stuck to each other and keep
the brake current flowing, thus
preventing the brake from
operating when the motor is
reenergized.
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 soak
through the motor, causing the
brake to slip.
-
- 71 -
Measure
-
If a crack develops in
the casting, sealant
can be used as a
quick-fix to prevent
further grease or oil
leakage. However, the
component should be
replaced as soon as
possible, because the
crack might enlarge.
- 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
Hexagon bolts are
used in the locations
stated below.
- Grease drain outlet
- For cover fixation
Check whether the
brake drive relays
stuck each other or
not. If they are found
to be stuck, replace
the relay.
Replace the motor
confirmed following
symptoms.
- Brake shoe is worn out
- Brake main body is
damaged
- Oil soak through the
motor
9.TROUBLESHOOTING
Symptom
Displace
ment
B-83754EN/01
Description
-
-
The robot operates at a
point other than the taught
position.
The repeatability is not
within the tolerance.
Cause
[Mechanical unit problems]
If the repeatability is unstable,
probable causes are a failure in
the drive mechanism or a loose
bolt, and so on.
If the repeatability is stable, it is
likely that collision by an excessive
load caused slip on the mounting
face of each axis arm, and
reducer.
It is likely that the Pulsecoder is
abnormal.
Measure
-
-
-
-
-
BZAL alarm
occurred
-
Displacement occurs only
in a specific peripheral
equipment.
Displacement occurred
after a parameter was
changed.
BZAL is displayed on the
teach pendant screen
[Peripheral equipment displacement]
It is likely that an external force
was applied to the peripheral
equipment, 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.
-
-
-
-
It is likely that the voltage of the
memory backup battery is low.
It is likely that the Pulsecoder
cable is defected.
- 72 -
-
-
If the repeatability is
unstable, repair the
mechanical unit 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.
Correct the setting of
the peripheral
equipment 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.
APPENDIX
B-83754EN/01
A
APPENDIX
A.PERIODIC MAINTENANCE TABLE
PERIODIC MAINTENANCE TABLE
- 75 -
A.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83754EN/01
FANUC Robot M-20iB Periodic Maintenance Table
Working time (H)
Check
time
Oil
Grease
amount
1 damage or peeling paint
0.1H
-
○
○
○
2 Check for water
0.1H
-
○
○
○
Items
Check for external
Check the end effector (hand)
First
6
9
1
3
check months months months year
960 1920 2880 3840
320
2
years
4800
5760
6720
7680
8640
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
0.1H
-
○
○
○
Check the motor connector.
(Loosening)
0.1H
-
○
○
○
5 Tighten the end effector bolt
0.1H
-
○
○
○
0.5H
-
○
○
○
0.1H
-
○
○
○
○
○
○
3 cable
4
Tighten the cover and main
6 bolt
9600 10560
Mechanical unit
Check the fixed mechanical
7 stopper and adjustable
mechanical stopper
8 Remove spatter and dust etc.
0.1H
9 Replacing battery
0.1H
-
0.5H
870ml
0.5H
330ml
0.5H
190ml
0.5H
3ml
0.5H
3ml
0.5H
3ml
Replacing grease of J1 axis
10 reducer
Replacing grease of J2 axis
11 reducer
Replacing grease of J3 axis
12 reducer
Supplying grease to J4-axis
13 reducer
Supplying grease to J5-axis
14 Reducer
Supplying grease to J6-axis
15 reducer
Replacing cable of
Controller
16 mechanical unit
Check the robot cable, teach
17 pendant cable and robot
connecting cable
Cleaning the controller
18 ventilation system
19 Replacing battery *1
4.0H
-
0.2H
-
0.2H
-
0.1H
-
●
○
○
○
*1 Refer to manual of controller.
*2 ●: requires order of parts
○: does not requires order of parts
- 76 -
○
○
○
○
○
○
○
○
○
A.PERIODIC MAINTENANCE TABLE
APPENDIX
B-83754EN/01
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
●
●
Overhaul
●
9
●
●
●
●
11
●
●
12
○
○
●
13
●
14
●
15
●
16
○
○
○
○
10
○
○
○
○
○
○
○
○
○
○
●
○
○
○
○
○
○
17
○
○
○
18
19
- 77 -
B.STRENGTH OF BOLT
AND BOLT TORQUE LIST
B
APPENDIX
B-83754EN/01
STRENGTH OF BOLT AND BOLT TORQUE LIST
NOTE
When applying LOCTITE to a part, spread the LOCTITE on the entire length area
of the engaging part of the female thread. If applied to the male threads, poor
adhesion can occur potentially loosening the bolt. Clean the bolts and the
threaded holes and wipe off the oil on the engaging section. Make sure that there
is no solvent left in the threaded holes. In this case, remove all the excess
LOCTITE when you are finished screwing the bolts into the threaded holes.
Adopt following strength bolts. Comply with any bolt specification instructions as specified.
Hexagon socket head bolt made by steel:
Size M22 or less:
Tensile strength 1200N/mm2 or more
Size M24 or more: Tensile strength 1000N/mm2 or more
All size plating bolt: 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
Refer to the following tables if the bolts tightening torque are not specified.
Recommended bolt tightening torques
Unit: Nm
Hexagon socket head
button bolt
Hexagon socket head
Hexagon bolt
Hexagon socket head
Hexagon socket head
bolt
(steel)
flush bolt
bolt (stainless)
Nominal
(Steel)
Low-head bolt
diameter
(steel)
Tightening torque
Tightening torque
Tightening torque
Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
――――
――――
――――
―――
M3
1.8
1.3
0.76
0.53
M4
4.0
2.8
1.8
1.3
1.8
1.3
1.7
1.2
M5
7.9
5.6
3.4
2.5
4.0
2.8
3.2
2.3
M6
14
9.6
5.8
4.1
7.9
5.6
5.5
3.8
M8
32
23
14
9.8
14
9.6
13
9.3
M10
66
46
27
19
32
23
26
19
――――
――――
M12
110
78
48
33
45
31
――――
――――
(M14)
180
130
76
53
73
51
――――
――――
M16
270
190
120
82
98
69
――――
――――
(M18)
380
260
160
110
140
96
――――
――――
M20
530
370
230
160
190
130
――――
――――
――――
――――
――――
――――
(M22)
730
510
――――
――――
――――
――――
――――
――――
M24
930
650
――――
――――
――――
――――
――――
――――
(M27)
1400
960
――――
――――
――――
――――
――――
――――
M30
1800
1300
――――
――――
――――
――――
――――
――――
M36
3200
2300
- 78 -
APPENDIX
B-83754EN/01
C
C.INSULATION ABOUT
ARC WELDING ROBOT
INSULATION ABOUT ARC WELDING
ROBOT
The arc welding robot performs welding, using a welding torch attached to its end effector mounting face
via a bracket. Because a high welding current flows through the welding torch, the insulating material
must not permit bolting directly from the welding torch bracket to mounting face plate.
If no due consideration is taken, a poor insulation caused by a pileup of spatter can allow the welding
current to leak into robot mechanical units, possibly damaging the motor or melting the mechanical unit
cable jackets.
C.1
-
-
-
INSULATION AT THE WRIST
Insulate the end effector mounting surface. Insulation material which is inserted between the end
effector mounting surface and the welding torch bracket must be different, and bolt them separately
referring to Fig. C.1.
Insert the insulating material between the torch bracket and faceplate to ensure the two are
electrically isolated. When installing the insulating material, be sure to set the crack in the torch
holder away from that of the insulating material to prevent spatter from getting in the cracks.
Allow a sufficient distance (at least 5 mm) at the insulating materials in case a pileup of spatter
should occur.
5mm5mm以上
or more
Torch
bracket
トーチブラケット
トーチ
Torch
Robot
ロボット手首
wrist
Insulation material
絶縁部材固定ボルト
mounting
bolts
Torch
bracket mounting bolts
トーチブラケット固定ボルト
Bad 悪い例
example
Insulation
絶縁部材 material
(ベークライト等)
(bakelite
etc.)
Fig. C.1
-
Insulation at the wrist
Even after the insulation is reinforced, it is likely that, if a pileup of spatter grows excessively,
current may leak. Periodically remove the spatter.
- 79 -
D.CONTROL OF MULTIPLE ROBOTS
D
APPENDIX
B-83754EN/01
CONTROL OF MULTIPLE ROBOTS
One controller can control up to four robots. Moreover, one controller can control up to eight groups, 72
axes.
NOTE
“Group” means the gathering of independent movable axes.
グループ1
Group
1
グループ3
Group
3
グループ2
Group
2
Group
4
グループ4
グループ5
Group
5
Positioner
ポジショナ
Additional
付加軸
axis
Teach
教示操作盤
pendant
Amplifier
アンプ
box
ボックス
Amplifier
アンプ
box
ボックス
アンプ
Amplifier
ボックス
box
Main
controller
メイン制御装置
Fig. D Example of Control of multiple robots
When multiple robots are controlled with one controller, select the appropriate servo card and auxiliary
axis board of controller from Table D.
Table D Servo card and auxiliary axis board when multiple robots are controlled (R-30iB, R-30iB Mate)
Number of
robots
2
3
4
(Note)
Servo card and auxiliary axis board
A05B-2600-H041
A05B-2600-H042
A05B-2600-H042
A05B-2600-H043
A05B-2600-H043
A05B-2600-H044
(12 axes) (Note )
(18 axes)
(18 axes) (Note )
(24 axes)
(24 axes) (Note )
(36 axes)
Remarks
Max. 6 auxiliary axes can be used in total of robot
1st and 2nd
Max. 6 auxiliary axes can be used in total of robot
1st , 2nd and 3rd
Max. 12 auxiliary axes can be used in total of robot
1st , 2nd, 3rd and 4th
It can be used only when auxiliary axes are not specified.
- 80 -
INDEX
B-83754EN/01
INDEX
<A>
<O>
ADJUSTABLE MECHANICAL STOPPER
SETTING (OPTION) ................................................. 37
AIR PIPING (OPTION) ................................................. 28
AIR SUPPLY (OPTION) ............................................... 27
Angle of Mounting Surface Setting.................................. 6
AXIS LIMIT SETUP ..................................................... 35
OPERATING AREA FOR INCLINATION
INSTALLATION ....................................................... 18
OVERVIEW .................................................................. 52
<P>
Periodic Check and Maintenance ................................... 40
PERIODIC MAINTENANCE ....................................... 39
PERIODIC MAINTENANCE TABLE ......................... 75
PIPING AND WIRING TO THE END
EFFECTOR ................................................................ 26
PREFACE .................................................................... p-1
Procedure for releasing remaining pressure from
the grease bath (J1 to J3-axis) .................................... 49
<B>
BASIC SPECIFICATIONS ............................................. 9
<C>
Check of Fixed Mechanical Stopper and
Adjustable Mechanical Stopper .................................. 45
CHECK POINTS ........................................................... 42
Check the Mechanical Unit Connectors ......................... 44
CHECKS AND MAINTENANCE ................................ 39
Confirmation of Oil Seepage.......................................... 42
Confirmation of the Air Control Set............................... 43
CONNECTION WITH THE CONTROLLER ................. 8
CONTROL OF MULTIPLE ROBOTS .......................... 80
<Q>
QUICK MASTERING ................................................... 58
QUICK MASTERING FOR SINGLE AXIS ................. 60
<R>
Replacing the Batteries (1.5 year checks) ...................... 45
Replacing the Grease of the J1 to J3 Axis
Reducers (3 years (11520 hours) checks) ................... 47
RESETTING ALARMS AND PREPARING
FOR MASTERING .................................................... 54
ROBOT CONFIGURATION........................................... 9
<D>
Daily Checks .................................................................. 39
<E>
END EFFECTOR INSTALLATION TO WRIST ......... 21
EQUIPMENT INSTALLATION TO THE
ROBOT ...................................................................... 21
EQUIPMENT MOUNTING FACE ............................... 22
<S>
SAFETY PRECAUTIONS ........................................... s-1
SINGLE AXIS MASTERING ....................................... 62
SOFTWARE SETTING................................................. 36
STORAGE ..................................................................... 51
STRENGTH OF BOLT AND BOLT TORQUE
LIST ........................................................................... 78
<G>
Grease Supplying Procedure for J4 to J6-axis
Reducer(4 years (15360 hours) periodical
check) ......................................................................... 50
<T>
<I>
TRANSPORTATION ...................................................... 1
TRANSPORTATION AND INSTALLATION ............... 1
TROUBLESHOOTING ................................................. 67
INSTALLATION ............................................................. 3
INSTALLATION CONDITIONS.................................... 7
Installation Method .......................................................... 4
INSULATION ABOUT ARC WELDING
ROBOT ...................................................................... 79
INTERFACE FOR OPTION CABLE (OPTION).......... 29
<V>
VERIFYING MASTERING .......................................... 66
<W>
<L>
WRIST LOAD CONDITIONS ...................................... 17
LOAD SETTING ........................................................... 24
<Z>
<M>
ZERO POINT POSITION AND MOTION
LIMIT......................................................................... 12
ZERO POSITION MASTERING .................................. 55
MAINTENANCE .......................................................... 45
MAINTENANCE AREA ................................................. 7
MASTERING ................................................................ 52
MASTERING DATA ENTRY ...................................... 64
MECHANICAL UNIT EXTERNAL
DIMENSIONS AND WORK ENVELOPE ............... 11
i-1
REVISION RECORD
B-83754EN/01
REVISION RECORD
Edition
Date
01
Feb., 2016
Contents
r-1
B-83754EN/01
* B - 8 3 7 5 4 E N / 0 1 *