< 1-axis SERVO POSITIONER
MECHANICAL UNIT
MAINTENANCE MANUAL
B-82545EN/04
•
Original Instructions
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and
understand the content.
• No part of this manual may be reproduced in any form.
• All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as “impossible”.
B-82545EN/04
PREFACE
This manual describes maintenance and connection work for the servo positioner. Before replacing parts,
check the specifications of the mechanical unit.
Model name
Mechanical unit specification No.
Remarks
1-Axis Servo Positioner
1-Axis Servo Positioner
1-Axis Servo Positioner
1-Axis Servo Positioner
A05B-1220-J101
A05B-1220-J102
A05B-1220-J103
A05B-1220-J104
300kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
(1)
TYPE
NO.
DATE
No.
CONTENTS
LETTERS
(1)
MODEL
1-Axis Servo Positioner
1-Axis Servo Positioner
1-Axis Servo Positioner
1-Axis Servo Positioner
(2)
WEIGHT
(5) kg
(3)
(4)
(2)
TYPE
A05B-1220-J101
A05B-1220-J102
A05B-1220-J103
A05B-1220-J104
(3)
No.
(4)
DATE
PRINT SERIAL
NO.
PRINT
PRODUCTION
YEAR AND
MONTH
(5)
WEIGHT kg
85
280
85
130
NOTE
The following abbreviations are used herein.
300kg payload (Hollow type) : 300kg payload 1-axis servo positioner (Hollow type)
300kg/500kg payload (Hollow type) : 300kg/500kg payload 1-axis servo positioner
(Hollow type)
1000kg/1500kg payload (Hollow type) : 1000kg/1500kg payload 1-axis servo
positioner (Hollow type)
1000kg/1500kg payload (Compact type) : 1000kg/1500kg payload 1-axis servo
positioner (Compact type)
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B-82545EN/04
Specification (1/3)
Item
Model
Specifications
300kg payload 1-axis servo positioner (Hollow type)
Motion range
Maximum operation speed (*1)
Max. load capacity (*2)
Allowable load moment
740°(-370°～ +370°) 12.9 rad(-6.46 rad～ +6.46 rad)
Continuous rotation is available.
160°/sec 2.79 rad/sec
130°/sec 2.27 rad/sec
300 kg
500 kg
36 kgf･m 353 N･m
60 kgf･m 588 N･m
Allowable bending moment
Allowable load inertia
Drive method
Weight
Follower unit (option) weight (*3)
Installation environment
250 kgf･m 2450 N･m
2
2
2,350 kgf･cm･s 230 kg･m
3,673 kgf･cm･s2 360 kg･m2
Electric servo drive by AC servo motor
About 85 kg
About 47 kg-(Follower unit (insulated flange)
About 16 kg-(Follower unit (non-insulated flange)
Ambient temperature 0 - 45°C Ambient humidity (*4)
Normally:
75%RH or less
:
Short time 95%RH or less(within 1 month)
(No dew or frost allowed)
Vibration :
0.5G or less
Free of corrosive gases (*5)
(*1) It does not arrive at each axial maximum speed at the short movement distance.
(*2) 300kg payload 1-axis servo positioner (Hollow type) does not support 500kg. Refer to Section 2.2 of
CONNECTION about changing method of payload specifications.
(*3) Two follower units (A05B-1220-J151,A05B-1220-J152) are prepared as option.
(*4) When robot is used in low temperature environment that is near to 0ºC, or robot is not operated for a long
time in the environment that is less than 0ºC in a holiday or the night, because viscous resistance of the
drive train is so big that may cause occurrence of collision detect alarm (SRVO –050) etc. In this case, we
recommend performing the warm up operation for several minutes.
(*5) Contact the service representative, if the robot is to be used in an environment or a place subjected to
severe vibrations, heavy dust, cutting oil splash and or other foreign substances.
Specification (2/3)
Item
Model
Motion range
Maximum operation speed (*1)
Max. load capacity (*2)
Allowable load moment
Specifications
300kg/500kg payload 1-axis servo positioner (Hollow type)
740°(-370°～ +370°) 12.9 rad(-6.46 rad～ +6.46 rad)
Continuous rotation is available.
160°/sec 2.79 rad/sec
130°/sec 2.27 rad/sec
300 kg
500 kg
36 kgf･m 353 N･m
60 kgf･m 588 N･m
Allowable bending moment
Allowable load inertia
Drive method
Weight
Follower unit (option) weight (*3)
Installation environment
400 kgf･m 3,920 N･m
2
2
2,350 kgf･cm･s 230 kg･m
3,673 kgf･cm･s2 360 kg･m2
Electric servo drive by AC servo motor
About 88 kg
About 47 kg-(Follower unit (insulated flange)
About 16 kg-(Follower unit (non-insulated flange)
Ambient temperature 0 - 45°C Ambient humidity
Normally:
75%RH or less
:
Short time 95%RH or less (within 1 month)
(No dew or frost allowed)
Vibration :
0.5G or less
Free of corrosive gases (*4)
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B-82545EN/04
(*1) It does not arrive at each axial maximum speed at the short movement distance.
(*2) Refer to Section 2.2 of CONNECTION about changing method of payload specifications.
(*3) Two follower units (A05B-1220-J151,A05B-1220-J152) are prepared as option.
(*4) When robot is used in low temperature environment that is near to 0ºC, or robot is not operated for a long
time in the environment that is less than 0ºC in a holiday or the night, because viscous resistance of the
drive train is so big that may cause occurrence of collision detect alarm (SRVO –050) etc. In this case, we
recommend performing the warm up operation for several minutes.
(*5) Contact the service representative, if the robot is to be used in an environment or a place subjected to
severe vibrations, heavy dust, cutting oil splash and or other foreign substances.
Specification (3/3)
Item
Specifications
1000kg/1500kg payload 1-axis servo positioner (Hollow type)
1000kg/1500kg payload 1-axis servo positioner (Compact type)
Model
Motion range
Maximum operation speed (*1)
Max. load capacity (*2)
Allowable load moment
Allowable bending moment
Allowable load inertia
740°(-370°～ +370°) 12.9 rad(-6.45 rad～ +6.45 rad)
Continuous rotation is available.
120°/sec 2.09 rad/sec
90°/sec 1.57 rad/sec
1000 kg
1,500 kg
160 kgf･m 1,568 N･m
200 kgf･m 1,960 N･m
2100 kgf･m 20,580 N･m (*6)
2,100 kgf･m 20,580 N･m (*6)
720 kgf･m 7,056 N･m (*7)
720 kgf･m 7,056 N･m (*7)
2
2
7,000 kgf･cm･s2 686 kg･m2
4,700 kgf･cm･s 460 kg･m
Drive method
Electric servo drive by AC servo motor
About 280 kg (1000kg/1500kg payload (Hollow type))
Weight
About130 kg (1000kg/1500kg payload (Compact type))
About 47 kg-(Follower unit (insulated flange)
Follower unit (option) weight (*3)
About 16 kg-(Follower unit (non-insulated flange)
Ambient temperature 0 - 45°C Ambient humidity (*4)
Normally:
75%RH or less
:
Short time 95%RH or less (within 1 month)
Installation environment
(No dew or frost allowed)
Vibration :
0.5G or less
Free of corrosive gases (*5)
(*1) It does not arrive at each axial maximum speed at the short movement distance.
(*2) Refer to Section 2.2 of CONNECTION about changing method of payload specifications.
(*3) Two follower units (A05B-1220-J151,A05B-1220-J152) are prepared as option.
(*4) When robot is used in low temperature environment that is near to 0ºC, or robot is not operated for a long
time in the environment that is less than 0ºC in a holiday or the night, because viscous resistance of the
drive train is so big that may cause occurrence of collision detect alarm (SRVO –050) etc. In this case, we
recommend performing the warm up operation for several minutes.
(*5) Contact the service representative, if the robot is to be used in an environment or a place subjected to
severe vibrations, heavy dust, cutting oil splash and or other foreign substances.
(*6) 1000kg/1500kg payload 1-axis servo positioner (Hollow type)
(*7) 1000kg/1500kg payload 1-axis servo positioner (Compact type)
Dust-proof/drip performance
Normal specification
MECHANICAL UNIT
IP54
CAUTION
Definition of IP 54
5=Dust-tight
4=Protection from water immersion
Performance of resistant chemicals and resistant solvents
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B-82545EN/04
(1) The positioner (including severe dust/liquid protection model) cannot be used with the following
liquids because there is fear that rubber parts (packing, oil seal, O-ring etc.) will corrode.
(a) Organic solvents
(b) Coolant including chlorine / gasoline
(c) Aminergic detergent
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, which will harm NBR
(2) When the positioner work in the environment, using water or liquid, complete draining of base must be
done. Incomplete draining of base will make the positioner break down.
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B-82545EN/04
RELATED MANUALS
For the FANUC Robot series, the following manuals are available:
Safety handbook B-80687EN
All persons who use the FANUC Robot and system
designer must read and understand thoroughly this
handbook
R-J3iB Mate
Setup and Operations manual
controller
LR ARC TOOL
B-82094EN
LR HANDLING TOOL
B-81524EN
Maintenance manual
B-81525EN
B-81525EN-1(For Europe)
Intended readers:
All persons who use FANUC Robot, system designer
Topics:
Safety items for robot system design, operation, maintenance
Intended readers:
Operator, programmer, maintenance person, system designer
Topics:
Robot functions, operations, programming, setup, interfaces,
alarms Use: Robot operation, teaching, system design
Intended readers:
Maintenance person, system designer
Topics:
Installation, connection to peripheral equipment, maintenance
Use: Installation, start-up, connection, maintenance
Intended readers:
Operator, programmer, maintenance person, system designer
Topics:
Robot functions, operations, programming, setup, interfaces,
alarms
Use:
Robot operation, teaching, system design
Intended readers:
Maintenance person, system designer
Topics:
Installation, connection to peripheral equipment, maintenance
Use: Installation, start-up, connection, maintenance
Intended readers:
Operator, programmer, maintenance person, system designer
Topics:
Robot functions, operations, programming, setup, interfaces,
alarms
Use:
Robot operation, teaching, system design
Intended readers: Maintenance person, system designer
Topics:
Installation, connection to peripheral equipment, maintenance
Use: Installation, start-up, connection, maintenance
Intended readers:
Operator, programmer, maintenance person, system designer
Topics:
Robot functions, operations, programming, setup, interfaces,
alarms
Use:
Robot operation, teaching, system design
R-J3iB controller
Setup and Operations manual
SPOT TOOL
B-81464EN-1
HANDLING TOOL
B-81464EN-2
ARC TOOL
B-81464EN-3
Maintenance manual
B-81465EN
B-81465EN-1(For Europe)
R-30iA Mate
controller
Operator’s Manual
LR HANDLING TOOL
B-83134EN-1
LR ARC TOOL
B-83134EN-2
ALARM CODE LIST
B-83124EN-6
Maintenance Manual
B-82725EN
B-82725EN-1(For Europe)
B-82725EN-2(For RIA)
Setup and Operations manual
SPOT TOOL+
B-83124EN-1
HANDLING TOOL
B-83124EN-2
ARC TOOL
B-83124EN-3
ALARM CODE LIST
B-83124EN-6
Maintenance manual
Intended readers: Maintenance person, system designer
B-82595EN
Topics:
B-82595EN-1(For Europe) Installation, connection to peripheral equipment, maintenance
B-82595EN-2
Use: Installation, start-up, connection, maintenance
(For RIA)
(For Europe)
For the robot mechanical unit, refer to the manual of each robot.
R-30iA controller
Robot
mechanical unit
p-5
B-82545EN/04
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
WORKING PERSON
The personnel can be classified as follows.
Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel
Programmer or teaching operator:
• Operates the robot
• Teaches robot inside the safety fence
Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)
-
An operator cannot work inside the safety fence.
A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc..
To work inside the fence, the person must be trained on proper robot operation.
-
During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following safety
precautions.
-
Use adequate clothing or uniforms during system operation
Wear safety shoes
Use helmet
2
WORKING PERSON SAFETY
Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating
space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure operator
safety.
(1) Have the robot system operators attend the training courses held by FANUC.
FANUC provides various training courses. Contact our sales office for details.
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SAFETY PRECAUTIONS
B-82545EN/04
(2) Even when the robot and positioner are stationary, it is possible that the robot is still ready to move
state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure
operator 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 operator can enter the work area without passing through
the gate. Equip the gate with an interlock that stops the robot when the gate is opened.
At this time, the positioner as well as the robot must be located within the fence completely.
The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the
controller stops the robot in an emergency. For connection, see Fig.1.2(a).
(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such
as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that
stops the robot and positioner when an operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator in charge can turn on the power of
the robot.
The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a
padlock.
(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.
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SAFETY PRECAUTIONS
B-82545EN/04
Dual chain
（Note）
Panel board
In case of R-30iA , R-J3iB
Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2
are provided on the operation box or on the terminal block
of the printed circuit board.
EAS1
EAS11
EAS2
In case of R-30iA Mate , R-J3iB Mate
Terminals EAS1,EAS11,EAS2,EAS21 are provided
on the emergency stop board or connector panel.
(in case of Open air type)
EAS21
Termianls FENCE1,FENCE2 are provided
on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1
FENCE2
Fig. 2 (a) Safety fence and gate
2.1
OPERATOR SAFETY
The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.
(1) When the robot and positioner do not need to operate, turn off the power of the robot controller or
press the emergency stop button before work.
(2) The operator must operate the robot system outside the work area of the robot or positioner.
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the
work area unexpectedly and also to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's reach.
The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection,
the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram
below for connection.
Dual chain
External stop button
Panel board
EES1
EES11
EES2
EES21
Single chain
External stop button
（Note）
Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
In case of R-30iA , R-J3iB
EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
In case of R-30iA Mate , R-J3iB Mate
EES1,EES11,EES2,EES21 are on the emergency stop board
or connector panel (in case of Open air type).
EMGIN1,EMGIN2 are on the emergency stop board.
Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2
Fig.2.1 (b) Connection Diagram for External Emergency Stop Button
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SAFETY PRECAUTIONS
2.2
B-82545EN/04
SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the
safety of the teach pendant operator especially.
(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating
condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other
conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on
the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
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 for detail of
stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand
that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety
fence. (In case of R-30iA Mate Controller standard specification, there is no mode switch. The automatic operation
mode and the teach mode is selected by teach pendant enable switch.)
Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY for
detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the mode switch setting status.
(a)
Automatic operation mode: The DEADMAN switch is disabled.
(b)
Teach mode: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iA/ R-30iA Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to
its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly,
the robot stops immediately.
The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should
make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.
The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity
of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the
teach pendant enable switch and the remote condition on the software.
In case of R-30iA Controller or CE or RIA specification of R-30iA Mate Controller
Mode
AUTO
mode
Teach pendant
enable switch
On
Off
Software
remote
condition
Teach pendant
Operator panel
Peripheral device
Local
Remote
Local
Remote
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
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SAFETY PRECAUTIONS
B-82545EN/04
Mode
Teach pendant
enable switch
Software
remote
condition
Local
Remote
Local
Off
Remote
T1,T2 mode:DEADMAN switch is effective.
On
T1, T2
mode
Teach pendant
Operator panel
Peripheral device
Allowed to start
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
In case of standard specification of R-30iA Mate Controller
Teach pendant enable switch
Software remote condition
Teach pendant
Peripheral device
On
Off
Ignored
Local
Remote
Allowed to start
Not allowed
Not allowed
Not allowed
Not allowed
Allowed to start
(5) (Only when R-30iA Controller or CE or RIA specification of R-30iA Mate controller is selected.) To
start the system using the operator’s panel, make certain that nobody is the robot work area and that
there are no abnormal conditions in the robot work area.
(6) When a program is completed, be sure to carry out a test run according to the procedure below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test run above, execute it in the
automatic operation mode.
(7) While operating the system in the automatic operation mode, the teach pendant operator should leave
the robot work area.
2.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance personnel, pay utmost attention to the following.
(1) Except when specifically necessary, turn off the power of the controller while carrying out
maintenance. Lock the power switch, if necessary, so that no other person can turn it on.
(2) When disconnecting the pneumatic system, be sure to reduce the supply pressure.
(3) Before the start of teaching, check that the robot and positioner and its peripheral devices are all in the
normal operating condition.
(4) When performing maintenance within the work area of the robot or positioner with the power on,
maintenance personnel needs to indicate that maintenance is in progress and exercise caution to
prevent anyone from starting the robot accidentally.
(5) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers
are working nearby, make certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such
as belt conveyor, pay careful attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system stand beside the operator's panel and
observe the work being performed. If any danger arises, the worker should be ready to press the
EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent foreign matter from entering the
system.
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SAFETY PRECAUTIONS
B-82545EN/04
(10) When handling each unit or printed circuit board in the controller during inspection, turn off the power
of the controller and also turn off the circuit breaker to protect against electric shock.
(11) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other
parts of non-specified ratings. They may cause a fire or result in damage to the components in the
controller.
3
3.1
SAFETY OF THE TOOLS AND PERIPHERAL
DEVICES
PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program
to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) In a system in which the robot or positioner operates in sync with peripheral devices, exercise caution
against mutual interference.
(4) The interlock between the robot and peripheral devices is necessary to check the states of all devices in
the system using the robot or positioner, so that the robot and positioner can be stopped as needed.
3.2
PRECAUTIONS FOR MECHANISM
(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does
not strike against its peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
•
Use mechanical unit cable that have required user interface.
•
Don’t add user cable or hose to inside of mechanical unit.
•
Please do not obstruct the movement of the mechanical unit cable when cables are added to
outside of mechanical unit.
•
In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.
•
Please do not interfere with the other parts of mechanical unit when install equipments in the
robot.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid
the system construction that power-off stop would be operated routinely. (Refer to bad case example.)
Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or
cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of
stop type.)
(Bad case example)
•
Whenever poor product is generated, a line stops by emergency stop.
•
When alteration was necessary, safety switch is operated by opening safety fence and power-off
stop is executed for the robot during operation.
•
An operator pushes the emergency stop button frequently, and a line stops.
•
An area sensor or a mat switch connected to safety signal operate routinely and power-off stop is
executed for the robot.
s-6
B-82545EN/04
(6)
SAFETY PRECAUTIONS
Robot stops urgently when collision detection alarm (SV050) etc. occurs. The frequent urgent stop
by alarm causes the trouble of the robot, too. So remove the causes of the alarm.
4
SAFETY OF THE ROBOT MECHANISM
4.1
PRECAUTIONS IN OPERATION
(1) When operating the robot or positioner in the jog mode, keep an appropriate speed so that the operator
can take a responsive action in any eventuality.
(2) Before pressing the jog key, be sure to understand in advance how the robot or positioner operates by
the key.
(3) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
・ Use mechanical unit cable that have required user interface.
・ Don’t add user cable or hose to inside of mechanical unit.
・ Please do not obstruct the movement of the mechanical unit cable when cables are added to outside of
mechanical unit.
・ In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a protective
cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable.
・ Please do not interfere with the other parts of mechanical unit when install equipments in the robot.
4.2
PRECAUTIONS IN OPERATION
(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify a certain work origin in a motion program for the robot or positioner and make sure
that the motion program starts from and ends at the origin. This makes it clear at a glance whether the
robot has completed work.
4.3
PRECAUTIONS FOR MECHANISMS
(1) Clean the inside of the work area of the robot or positioner to eliminate the effect of oil, water, and
dust.
5
SAFETY OF THE END EFFECTOR
5.1
Precautions in Programming
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay
after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the
end effector.
s-7
SAFETY PRECAUTIONS
6
B-82545EN/04
STOP TYPE OF ROBOT
The following three robot stop types exist:
Power-Off Stop (Category 0 following IEC 60204-1)
Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
An alarm is generated and servo power is turned off.
The robot operation is stopped immediately. Execution of the program is paused.
Controlled stop (Category 1 following IEC 60204-1)
The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
An alarm is generated and servo power is turned off.
Hold (Category 2 following IEC 60204-1)
The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.
When the E-Stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or
Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is
different according to the controller type or option configuration.
There are the following 3 Stop patterns.
Stop
pattern
A
B
C
P-Stop:
C-Stop:
-:
Mode
AUTO
T1
T2
AUTO
T1
T2
AUTO
T1
T2
E-Stop
button
External
E-Stop
FENCE open
SVOFF input
Servo
disconnect
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
C-Stop
P-Stop
C-Stop
-
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
C-Stop
C-Stop
C-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
P-Stop
C-Stop
P-Stop
P-Stop
Power-Off stop
Controlled stop
Not stop
s-8
SAFETY PRECAUTIONS
B-82545EN/04
The following table indicates the Stop pattern according to the controller type or option configuration.
R-30iA
Standard
RIA type
(Dual)
R-30iA Mate
RIA
Standard
type
Option
Standard
(Single)
Standard
Stop type set (Stop pattern C)
(A05B-2500-J570)
B (*)
A
A
A
A (**)
A
A
N/A
N/A
C
C
N/A
C
C
CE type
CE
type
(*) R-30iA standard (single) does not have servo disconnect.
(**) R-30iA Mate Standard does not have servo disconnect, and the stop type of SVOFF input is
Power-Off stop.
The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer
to "Software version" in operator's manual of controller for the detail of software version screen.
"Stop type set (Stop pattern C)" option
"Stop type set (Stop pattern C)"(A05B-2500-J570) is an optional function. When this option is loaded, the
stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the
stop type is Power-Off stop which is the normal operation of the system.
Alarm
SRVO-001 Operator panel E-stop
SRVO-002 Teach pendant E-stop
SRVO-007 External emergency stops
SRVO-194 Servo disconnect
SRVO-218 Ext.E-stop/Servo Disconnect
SRVO-408 DCS SSO Ext Emergency Stop
SRVO-409 DCS SSO Servo Disconnect
Condition
Operator panel E-stop is pressed.
Teach pendant E-stop is pressed.
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA controller)
Servo disconnect input (SD4-SD41, SD5-SD51) is open.
(R-30iA controller)
External emergency stop input (EES1-EES11, EES2-EES21) is
open. (R-30iA Mate controller)
In DCS Safe I/O connect function, SSO[3] is OFF.
In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows:
In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems
where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.
The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the operator's
manual of a particular robot model for the data of stopping distance and stopping time.
This function is available only in CE or RIA type hardware.
When this option is loaded, this function cannot be disabled.
The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for the
whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.
s-9
SAFETY PRECAUTIONS
7
B-82545EN/04
WARNING LABEL
(1) Greasing and degreasing label
Fig. 7 (a) Greasing and Degreasing Label
Description
When greasing and degreasing, observe the instructions indicated on this label.
1)
2)
3)
When greasing, be sure to keep the grease outlet open.
Use a manual pump to grease.
Be sure to use a specified grease.
CAUTION
See section I 3.1 ″ GREASE REPLACEMENT for explanations about specified
greases, the amount of grease to be supplied, and the locations of grease and
degrease outlets for individual models.
(2) Step-on prohibitive label
Fig. 7 (b) Step-on Prohibitive Label
Description
Do not step on or climb the robot or controller as it may adversely affect the robot and positioner and you
may get hurt if you lose your footing as well.
s-10
SAFETY PRECAUTIONS
B-82545EN/04
(3) High-temperature warning label
Fig. 7 (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 such as heat-resistant gloves.
(4) Transportation label
>200kg
>200kg
>150kg
Fig. 7 (d) Transportation label (300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Description
When transporting the positioner, observe the instruction on the transportation label. The above label
includes the following instructions.
1)
Using a crane
•
Use a crane having a load capacity of 1960 N (200 kg) or greater.
•
Use one sling having a withstand load of 1960 N (200 kgf) or greater.
•
Use two eyebolts with a withstand load of 1470 N (150 kgf) or greater. (The eyebolts are
attached during shipment.)
s-11
SAFETY PRECAUTIONS
B-82545EN/04
>600kg
>600kg
>450kg
Fig. 7 (e) Transportation label (1000kg/1500kg payload (Hollow type))
Description
When transporting the positioner, observe the instruction on the transportation label. The above label
includes the following instructions.
1)
Using a crane
•
Use a crane having a load capacity of 5880 N (600 kg) or greater.
•
Use one sling having a withstand load of 5880 N (600 kgf) or greater.
•
Use two eyebolts with a withstand load of 4410 N (450 kgf) or greater. (The eyebolts are
attached during shipment.)
>400kg
>400kg
>220kg
Fig. 7 (f) Transportation label (1000kg/1500kg payload (Compact type))
Description
When transporting the positioner, observe the instruction on the transportation label. The above label
includes the following instructions.
1)
Using a crane
•
Use a crane having a load capacity of 3920 N (400 kg) or greater.
•
Use one sling having a withstand load of 3920 N (400 kgf) or greater.
•
Use two eyebolts with a withstand load of 2156 N (220 kgf) or greater. (The eyebolts are
attached during shipment.)
s-12
TABLE OF CONTENTS
B-82545EN/04
TABLE OF CONTENTS
PREFACE ....................................................................................................p-1
SAFETY PRECAUTIONS............................................................................s-1
I. MAINTENANCE
1
CONFIGURATION .................................................................................. 3
2
PREVENTIVE MAINTENANCE............................................................... 4
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
PERIODIC MAINTENANCE .................................................................... 8
3.1
3.2
3.3
4
GREASE REPLACEMENT ............................................................................ 8
PROCEDURE FOR RELEASING THE GREASE REMAINING PREESSURE
..................................................................................................................... 10
BATTERY REPLACEMENT ........................................................................ 10
TROUBLESHOOTING .......................................................................... 12
4.1
4.2
4.3
4.4
5
DAILY INSPECTION ..................................................................................... 4
First 1-month (960 hours) checks .................................................................. 5
First 3-MONTH CHECKS (960 hours) ........................................................... 6
3-MONTH CHECKS (960 hours) ................................................................... 6
1-YEAR CHECKS (3,840 hours).................................................................... 6
1.5-YEAR CHECKS (5,760 hours)................................................................. 6
3-YEAR CHECKS (11,520 hours).................................................................. 6
MAINTENANCE TOOLS ............................................................................... 6
GENERAL ................................................................................................... 12
PROBLEMS AND CAUSES......................................................................... 12
BACKLASH MEASUREMENT..................................................................... 18
COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 20
ADJUSTMENTS.................................................................................... 21
5.1
5.2
REFERENCE POSITION AND MOVING RANGE....................................... 21
MASTERING ............................................................................................... 22
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
6
COMPONENT REPLACEMENT AND ADJUSTMENTS....................... 42
6.1
6.2
6.3
7
Resetting Alarms and Preparing for Mastering ......................................................23
Fixture Position Master ..........................................................................................23
Zero Position Mastering .........................................................................................31
Quick Mastering .....................................................................................................34
Single Axis Mastering ............................................................................................36
Mastering Data Entry .............................................................................................39
Confirming Mastering ............................................................................................41
REPLACING THE MOTOR ......................................................................... 42
REPLACING THE REDUCER ..................................................................... 46
SEALANT APPLICATION
(1000kg/1500kg payload (Hollow
type))
(1000kg/1500kg payload (Compact type))............................... 48
PIPING AND WIRING ........................................................................... 51
c-1
TABLE OF CONTENTS
7.1
8
B-82545EN/04
CABLING (WHEN THE HARTING CONNECTOR OPTION IS SELECTED)51
CABLE REPLACEMENT ...................................................................... 52
8.1
REPLACING CABLES................................................................................. 52
II. CONNECTION
1
POSITIONER OUTLINE DRAWING ..................................................... 59
1.1
2
OUTLINE DRAWING AND OPERATION AREA DIAGRAM ........................ 59
MOUNTING DEVICES ON THE POSITIONER ..................................... 62
2.1
2.2
POSITIONER LOAD CONDITION............................................................... 62
CHANGING METHOD OF PAYLOAD SPECIFICATION............................. 66
2.2.1
2.2.2
3
Method of executing KAREL program by using “Call program”..........................67
Method of executing KAREL program directly.....................................................69
TRANSPORTATION AND INSTALLATION ......................................... 72
3.1
3.2
3.3
3.4
3.5
3.6
TRANSPORTATION.................................................................................... 72
STORING THE POSITIONER ..................................................................... 74
INSTALLATION ........................................................................................... 74
MAINTENANCE CLEARANCE.................................................................... 88
ASSEMBLING THE POSITIONER FOR INSTALLATION ........................... 90
INSTALLATION CONDITIONS.................................................................... 90
APPENDIX
A
SPARE PARTS LISTS .......................................................................... 93
B
CONNECTION DIAGRAMS .................................................................. 95
C
PERIODIC INSPECTION TABLE.......................................................... 98
D
STRENGTH OF BOLT AND BOLT TORQUE LIST............................ 100
c-2
I. MAINTENANCE
MAINTENANCE
B-82545EN/04
1
1.CONFIGURATION
CONFIGURATION
Fig. 1 shows the configuration of the mechanical unit.
The axis drive mechanism is configured in such a way that the flange base is rotated by reducing the rotation
speed of an AC servo motor with a reducer.
The flange base is supported on the base through the reducer.
Flange
Reducer
Base
Motor
Fig. 1 Mechanical unit configuration
Refer to Appendix A about the major mechanical unit components.
-3-
2.PREVENTIVE MAINTENANCE
2
MAINTENANCE
B-82545EN/04
PREVENTIVE MAINTENANCE
Daily inspection, periodic inspection, and periodic maintenance can keep the performance of the positioner
stable for a long period of time.
NOTE
The annual operating time of the 1-axis servo positioner is assumed 3,840 hours.
When using the positioner beyond this annual operating time, correct the
maintenance frequency in this chapter, which is determined on assumption that
the positioner is used for 3,840 hours per year, and perform maintenance as
appropriate.
2.1
DAILY INSPECTION
Clean and maintain each robot component during everyday system operations. At the same time, check the
components to see if there is a crack or break in them. Also, check and maintain the following items as
required.
a)
Item
1
Before automatic operation
Check items
Oil exudation
Check points
Check there is oil exudation on sealed part of each joint parts.
If there is oil exudation, clean it.
NOTE
1 Oil exudation may be attached (Slightly a loot oil stick) to outside of lip depend on
the movement condition or environment of the circumference. If this oil contents
change to a state of dew, it may fail depend on the movement.
You can prevent oil accumulation by wiping the oil contents which is under of oil
seal of Fig.2.1 (a) before operating robot.
2 Also, motors may become the high temperature and the internal pressure of oil
bath may rise by frequent repetition movement and use in the high temperature
environment. In these cases, you can return internal pressure by releasing oil out
let just after operation of robot. (When opening oil outlet, pay attention oil is not
scattered.)
Fig.2.1 (a) Check point of oil seal
-4-
MAINTENANCE
B-82545EN/04
Item
Check items
1
Air pressure
2
Lubricator oil mist
quantity
3
4
5
Lubricator oil level
Leakage from hose
Drain
2.PREVENTIVE MAINTENANCE
Check points
Check air pressure using the pressure gauge on the air regulator as shown in
Fig.2.1 (b). If it does not meet the specified pressure of 0.49 to 0.69 MPa (5-7
kgf/cm2), adjust it using the regulator pressure-setting handle.
Check the drop quantity during wrist or hand motion. If it does not meet the
specified value(1 drop/10-20 sec), adjust it using the lubricator control knob. Under
normal usage, the lubricator becomes empty in about 10 to 20 days under normal
operation.
Check to see that the lubricator level is within the specified level.
Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.
Check drain and release it. When quantity of the drain is remarkable, examine the
setting of the air dryer to the air supply side.
Oil inlet
Adjusting knob
Lubricator
mist amount check
Lubricator
Filter
Regulator
pressure
setting handle
Pressure gauge
Fig. 2.1 (b) Three-piece pneumatic option
b) After automatic operation
Item
Check items
Check points
1
Vibration, abnormal
noises, and motor
heating
Changing repeatability
Check whether the robot moves along and about the axes smoothly without
unusual vibration or sounds. Also, check whether the temperatures of the motors
are excessively high.
Check to see that the stop positions of the robot have not deviated from the
previous stop positions.
Check whether the peripheral devices operate properly according to commands
from the robot.
Check that the end effector drops within 5 mm when the power is off.
2
3
4
2.2
Peripheral devices for
proper operation
Brakes for each axis
First 1-month (960 hours) checks
Check the following items once every one-month (320 hours). Additional inspection areas and times should
be added to the table according to the robot’s working conditions, environment, etc. Then every 3 months
thereafter. (See the Section 2.4.)
Item
1
Check items
Ventilation portion of
controller
Check points
If the ventilation portion of the controller is dusty, turn off power and clean the unit.
-5-
2.PREVENTIVE MAINTENANCE
2.3
MAINTENANCE
B-82545EN/04
First 3-MONTH CHECKS (960 hours)
Check the following items at the first quarterly inspection, then every year thereafter.(See the Section 2.5.)
No.
Inspection item
1
2
Loose connector
Loose bolt
3
Debris removal
2.4
Inspection procedure
Check that the motor connectors or other connectors are not loose.
Check that the cover retaining bolts or external bolts are not loose. In
particular, check the following three points.
1 axis positioner, Follower unit base fixing bolts
Bolts fixing jigs to the flange surface
motor cover retaining bolts
Remove any spatter, debris, and dust from the mechanical unit.
3-MONTH CHECKS (960 hours)
Check the following item once every 3 months (960 hours).
Item
1
2.5
Check items
Check points
Ventilation portion of controller
(See Section 2.2.)
1-YEAR CHECKS (3,840 hours)
Check the following items once every year (3,840 hours).
No.
1
2
3
2.6
Inspection item
Loose connector
Loose bolt
Debris removal
Inspection procedure
See Section 2.3.
See Section 2.3.
See Section 2.3.
1.5-YEAR CHECKS (5,760 hours)
Check the following item once every 1.5 year (5,760 hours).
No.
1
2.7
Inspection item
Battery replacement
Inspection procedure
Replace the battery in the mechanical unit. (See Section 3.3.)
3-YEAR CHECKS (11,520 hours)
Check the following item once every 3 year (11,520 hours).
No.
1
2.8
Inspection item
Grease replacement
Inspection procedure
See Section 3.1.
MAINTENANCE TOOLS
You should have the following instruments and tools ready for maintenance.
a)
Measuring instruments
-6-
MAINTENANCE
B-82545EN/04
Instrument
Dial gauge
Calipers
b)
Condition
Use
1/100mm
150mm
Tools
Phillips screwdrivers
Flat-blade screwdrivers
Box wrenches
Allen wrenches
Torque wrench
Long T wrenches
Adjustable wrenches
Pliers
Long-nose pliers
Cutting pliers
Both-ended wrench
Grease gun
C-ring pliers
Flashlight
Seal tape
LOCTITE 242, 262, 675
Sling
Gear puller
Separator
2.PREVENTIVE MAINTENANCE
For positioning precision and backlash measurement
(large, medium, and small sizes)
(large, medium, and small sizes)
7 mm wide across wrenches flats (For grease nipple)
Dihedral width 2.5, 3, 5, 6, 8, 10, 12, 14, 17 (For replacing part)
(M5, M6)
(medium and small sizes)
-7-
3.PERIODIC MAINTENANCE
MAINTENANCE
B-82545EN/04
3
PERIODIC MAINTENANCE
3.1
GREASE REPLACEMENT
The grease for the reducers needs to be replaced every three years or 11,520 hours in the procedure shown
below. For greasing points, see Figs. 3.1 (a) to (c).
<1> Remove the seal bolts and plugs of the grease outlets shown in Figs. 3.1(a) to (c).
<2> Attach the grease nipple supplied with the positioner.
<3> Apply the grease specified in Table 3.1(a) to (c) until the old grease is replaced and the new grease is
output from the grease outlets. Use grease outlet 1 shown in Figs. 3.1 (a) to (c). Only when grease
outlet 1 cannot be used due to the installation state of the jig, use grease outlet 2. At this time, confirm
that the same amount of the old grease as that of applied grease has been output to prevent the grease
bath from overflowing.
<4> After applying grease, release the remaining pressure in the grease bath as instructed by the procedure
in Section 3.2.
CAUTION
When reusing a grease nipple once used, wind sealing tape around the screw.
Table 3.1 (a) Grease to be replaced at regular intervals of three years (11,520 hours)
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Specified grease
Amount of grease to
Positioner posture when
Gun tip pressure
be applied
greased
Kyodo Yushi
Reducer
VIGOGREASE RE0
About 980 ml
(Specification: A98L-0040-0174)
0.1 MPa or less
(NOTE)
Grease outlet 1 is used : 0°
Grease outlet 2 is used : free
NOTE When using a hand pump, apply grease approximately once per two seconds.
Table 3.1 (b) Grease to be replaced at regular intervals of three years (11,520 hours)
(1000kg/1500kg payload (Hollow type))
Specified grease
Amount of grease to
Positioner posture when
Gun tip pressure
be applied
greased
Kyodo Yushi
Reducer
VIGOGREASE RE0
About 5500 ml
(Specification: A98L-0040-0174)
0.15 MPa or less
(NOTE)
Grease outlet 1 is used : 0°
Grease outlet 2 is used : free
NOTE When using a hand pump, apply grease approximately twice per three seconds.
Table 3.1 (c) Grease to be replaced at regular intervals of three years (11,520 hours)
(1000kg/1500kg payload (Compact type))
Specified grease
Amount of grease to
Positioner posture when
Gun tip pressure
be applied
greased
Kyodo Yushi
Reducer
VIGOGREASE RE0
About 1193 ml
(Specification: A98L-0040-0174)
0.15 MPa or less
(NOTE)
NOTE When using a hand pump, apply grease approximately twice per three seconds.
-8-
free
MAINTENANCE
B-82545EN/04
Seal
bolt M12X15
排 脂 口 2 シ ー ル ボ ル
for grease outlet 2
3.PERIODIC MAINTENANCE
Taper plug Rc1/8
for grease outlet 1
排 脂 口 1 シ ー ル ボ ル ト
ト
Taper plug Rc1/8
for
grease
給 脂
口
埋 inlet
栓
Fig. 3.1 (a) Grease inlet and outlet
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Seal
bolt シールボルト
M12X15
排脂口2
for grease outlet 2
Seal bolt M12X15
for grease outlet 1
排脂口1 シールボルト
Taper
Rc1/8
給脂口plug
埋栓
for grease inlet
Fig. 3.1 (b) Grease inlet and outlet (1000kg/1500kg payload (Hollow type))
Taper plug Rc1/8
for grease inlet
A
75°
A
Taper plug Rc1/8
for grease outlet
SECTION A-A
Fig. 3.1 (c) Grease inlet and outlet (1000kg/1500kg payload (Compact type))
-9-
3.PERIODIC MAINTENANCE
1
2
3
4
5
6
3.2
MAINTENANCE
B-82545EN/04
CAUTION
If you grease incorrectly, the pressure in the grease bath will increase, leading to a
broken seal, which will eventually cause grease leakage or malfunction.
When greasing, be sure to follow the cautions stated below.
Before starting greasing, open the grease outlets (remove bolts and the like from
the grease outlets).
Supply grease slowly, using a manual pump. (once per two seconds)
Avoid using a pneumatic pump driven from a factory pneumatic line as much as
possible.
Even when using Table 3.1 (a) to (c) or less during application of grease.
Be sure to use the specified grease. Otherwise, damage to reducers or a similar
abnormality may occur.
After applying grease, release the remaining pressure within the grease bath as
described in the procedure in Section 3.2.
Wipe off any grease from the floor and positioner completely, so no one will slip on
it.
PROCEDURE FOR RELEASING THE GREASE
REMAINING PREESSURE
After applying grease, to release remaining pressure from the grease bath, perform a repetitive operation
with a motion angle of at least 60 degrees and OVR100% for 10 minutes or more while leaving the grease
inlets and outlets open.
Under the grease inlets and outlets, attach bags for collecting grease so that grease does not spatter when it
comes out of the inlets or outlets.
If the above operation cannot be performed due to the environment of the positioner, prolong the operating
time so that an equivalent operation can be performed. (If only a motion angle of 30 degrees can be set,
perform an operation for 20 minutes or more.) After completion of the operation, attach the plugs and seal
bolts to the grease inlets and outlets. When reusing the taper plugs and seal bolts, be sure to seal them with
seal tape.
3.3
BATTERY REPLACEMENT
A backup battery is used to keep the reference-position data for the positioner.
The battery needs to be replaced at regular intervals of one year and half. Follow this procedure for battery
replacement.
This section describes the battery replacement procedure to follow when the HARTING connector option is
selected. Replace the battery on the controller side when the HARTING connector option is not selected.
1)
Keep the power turned on.
Press the EMERGENCY STOP button of the robot to keep robot and positioner from moving.
CAUTION
Be sure to turn on the power. If the battery is replaced when the power is off, the
current position information is lost, so that mastering becomes necessary.
2)
3)
4)
Uncap the battery case.
Take out the battery from the battery case.
Insert a new battery into the battery case while paying attention to the polarity of the battery.
- 10 -
MAINTENANCE
B-82545EN/04
5)
3.PERIODIC MAINTENANCE
Cap the battery case.
Fig. 3.3 (a) Battery replacement 1
(300kg load capacity (Hollow type)) , (300kg/500kg load capacity (Hollow type))
, (1000kg/1500kg payload (Hollow type))
Fig. 3.3 (b) Battery replacement 1
(1000kg/1500kg payload (Compact type))
Cap
Battery case
Battery specifications: A98L-0031-0005
(1.5V size-D 4 pcs)
Fig. 3.3 (c) Battery replacement 2
- 11 -
4.TROUBLESHOOTING
MAINTENANCE
4
TROUBLESHOOTING
4.1
GENERAL
B-82545EN/04
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems
may become further complicated, if they are not corrected properly. Therefore, it is necessary to keep an
accurate record of problems and to take proper corrective actions.
4.2
PROBLEMS AND CAUSES
Table 4.2 (a) shows the main mechanical unit problems and their causes. If a cause of remedy is unclear,
please contact your FANUC service representative.
Symptom
Vibration
noise
Description
Table 4.2 (a) Problems and causes
Cause
-The base lifts off the floor plate
as the positioner operates.
-There is a gap between the
base and floor plate.
-A base retaining bolt is loose.
-The rack or floor vibrates
during operation of the
positioner.
-Vibration becomes more
serious when the positioner
adopts a specific posture.
-If the operating speed of the
positioner is reduced, vibration
stops.
-Vibration is most noticeable
when the positioner is
accelerating.
[Base fastening]
-It is likely that the positioner
base is not securely fastened to
the floor plate.
-Probable causes are a loose
bolt, an insufficient degree of
surface flatness, or foreign
material caught.
-If the positioner is not securely
fastened to the floor plate, the
base lifts the floor plate as the
positioner operates, allowing
the base and floor plates to
strike each other, which, in turn,
leads to vibration.
[Rack or floor]
-It is likely that the rack or floor
is not sufficiently rigid.
-If the rack or floor is not
sufficiently rigid, reaction from
the positioner deforms the rack
or floor, leading to vibration.
[Overload]
-It is likely that the load on the
positioner is greater than the
maximum rating.
-It is likely that the positioner
control program is too
demanding for the positioner
hardware.
-It is likely that the
ACCELERATION value is
excessive.
- 12 -
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 matter
between the base and floor
plate, remove it.
-Reinforce the rack or floor to
make it more rigid.
-If it is impossible to reinforce
the rack or floor, modify the
robot control program; doing so
might reduce the amount of
vibration.
-Check the maximum load that
the positioner can handle once
more. If the positioner is found
to be overloaded, reduce the
load, or modify the positioner
control program.
-Vibration in a specific portion
can be reduced by modifying
the robot control program while
slowing the positioner and
reducing its acceleration (to
minimize the influence on the
entire cycle time).
MAINTENANCE
B-82545EN/04
Symptom
Vibration
noise
(Continued)
Description
Cause
-Vibration was first noticed after
the positioner collided with an
object or the positioner was
overloaded for a long period.
-The grease has not been
exchanged for a long period.
[Broken gear, bearing, or
reducer]
- It is likely that collision or
overload applied an excessive
force on the drive mechanism,
thus damaging the geartooth
surface or rolling surface of a
bearing, or reducer.
- It is likely that prolonged use of
the positioner while overloaded
caused fretting of the gear tooth
surface or rolling surface of a
bearing, or reducer due to
resulting metal fatigue.
- It is likely that foreign matter
caught in a gear, bearing, or
within a reducer caused
damage on the gear tooth
surface or rolling surface of the
bearing, or reducer.
- It is likely that, because the
grease has not been changed
for a long period, fretting
occurred on the gear tooth
surface or rolling surface of a
bearing, or reducer due to metal
fatigue.
These factors all generate
cyclic vibration and noise.
- 13 -
4.TROUBLESHOOTING
Measure
-Remove the motor, and
replace the gear , the bearing,
and the reducer. For the spec.
of parts and the method of
replacement, contact FANUC.
-Using the positioner within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
4.TROUBLESHOOTING
Symptom
Vibration
Noise
(Continued)
MAINTENANCE
Description
Cause
-The cause of problem cannot
be identified from examination
of the floor, rack, or mechanical
section.
[Controller, cable, and motor]
-If a failure occurs in a controller
circuit, preventing control
commands from being supplied
to the motor normally, or
preventing motor information
from being sent to the controller
normally, vibration might occur.
-If the pulsecoder develops a
fault, vibration might occur
because
information about the motor
position cannot be transferred
to the controller accurately.
-If the motor becomes
defective, vibration might occur
because the motor cannot
deliver its rated performance.
-If a connection cable between
them has an intermittent break,
vibration might occur.
-If the power cable has an
intermittent break, vibration
might occur.
-If the power source voltage
drops below the rating, vibration
might occur.
-If a robot control parameter is
set to an invalid value, vibration
might occur.
-There is some relationship
between the vibration of the
positioner and the operation of
a machine near the positioner.
[Noise from a nearby machine]
-If the positioner is not
grounded properly, electrical
noise is induced on the
grounding wire, preventing
commands from being
transferred accurately, thus
leading to vibration.
-If the positioner is grounded at
an unsuitable point, its
grounding potential becomes
unstable, and noise is likely to
be induced on the grounding
line, thus leading to vibration.
-There may be an unusual
sound when using other than
the specified grease.
-Even for the specified grease,
there may be an unusual
sound during operation at low
speed immediately after
replacement or after a long
period of time.
-There is an unusual sound
after replacement of grease.
-There is an unusual sound
after a long period of time.
-There is an unusual sound
during operation at low speed.
- 14 -
B-82545EN/04
Measure
-Refer to the Controller
Maintenance Manual for
troubleshooting related to the
controller and amplifier.
-Replace the pulsecoder for the
motor, and check whether the
vibration still occurs.
-Also, replace the motor, and
check whether vibration still
occurs. For the method of
replacement, contact FANUC.
-Check that the positioner is
supplied with the rated voltage.
-Check whether the sheath of
the power cord is damaged. If
so, replace the power cord, and
check whether vibration still
occurs.
-Check whether the sheath of
the cable connecting the
mechanical section and
controller is damaged. If so,
replace the connection cable,
and check whether vibration still
occurs.
-Check that the positioner
control parameter is set to a
valid value. If it is set to an
invalid value, correct it. Contact
FANUC for further information if
necessary.
-Connect the grounding wire
firmly to ensure a reliable
ground potential and prevent
extraneous electrical noise.
-Use the specified grease.
-When there is an unusual
sound even for specified
grease, perform operation for
one or two days on an
experiment. Generally, a usual
sound will disappear.
MAINTENANCE
B-82545EN/04
Symptom
Rattling
4.TROUBLESHOOTING
Description
Cause
Measure
-While the positioner is not
supplied with power, pushing it
with the hand causes part of the
mechanical unit to wobble.
-There is a gap on the mounting
surface of the mechanical unit.
[Mechanical section coupling
bolt]
-It is likely that overloading or a
collision has loosened a
mounting bolt in the positioner
mechanical section.
-Backlash is greater than the
tolerance stated in the
applicable maintenance
manual.
(See Table 4.3 (b) and (c).)
[Increase in backlash]
-It is likely that excessive force
applied to the drive mechanism,
due to a collision or
overloading, has broken a gear
or the inside of the reducer,
resulting in an increase in the
amount of backlash.
-It is likely that prolonged use in
overload conditions has caused
the tooth surfaces of a gear and
the reducer to wear out,
resulting in an increase in the
amount of backlash.
-It is likely that prolonged use
without changing the grease
has caused the tooth surfaces
of a gear and the inside of the
reducer to wear out, resulting in
an increase in the amount of
backlash.
-Check that the following bolts
are tight. If any of these bolts is
loose, apply LOCTITE and
tighten it to the appropriate
torque.
-Motor retaining bolt
-Reducer retaining bolt
-Reducer shaft retaining bolt
-Base retaining bolt
-End effecter retaining bolt
-Remove the motor, and check
whether any of its gears are
broken. If any gear is broken,
replace it.
-Check whether any other gear
of the drive mechanism is
damage. If there is no damage
gear, replace the reducer.
-If the reducer is broken, or if a
gear tooth is missing, replace
the relevant component. Also,
remove all the grease from the
gear box and wash the inside of
the gear box.
-After replacing the gear or
reducer, add an appropriate
amount of grease.
-Using the positioner within its
maximum rating prevents
problems with the drive
mechanism.
-Regularly changing the grease
with a specified type can help
prevent problems.
- 15 -
4.TROUBLESHOOTING
Symptom
Motor
overheating
MAINTENANCE
Description
Cause
-The ambient temperature of
the installation location
increases, causing
the motor to overheat.
-After a cover was attached to
the motor, the motor
overheated.
-After the robot control program
or the load was changed, the
motor
overheated.
[Ambient temperature]
-It is likely that a rise in the
ambient temperature or
attaching the motor cover
prevented the motor from
releasing heat efficiently, thus
leading to overheating.
[Operating condition]
-It is likely that the positioner
was operated with the
maximum average current
exceeded.
-After a control parameter was
changed, the motor
overheated.
[Parameter]
-If data input for a workpiece is
invalid, the positioner cannot be
accelerated or decelerated
normally, so the average
current increases, leading to
overheating.
[Mechanical section problems]
-It is likely that problems
occurred in the mechanical unit
drive mechanism, thus placing
an excessive load on the motor.
[Motor problems]
-It is likely that a failure of the
motor brake resulted in the
motor running with the brake
applied, thus placing an
excessive load on the motor.
-It is likely that a failure of the
motor prevented it from
delivering its rated
performance, thus causing an
excessive current to flow
through the motor.
-Symptom other than stated
above
- 16 -
B-82545EN/04
Measure
-The teach pendant can be
used to monitor the average
current. Check the average
current when the robot control
program is running. The
allowable average current is
specified for the positioner
according to its ambient
temperature. Contact FANUC
for further information.
-Relaxing the positioner control
program and conditions can
reduce the average current,
thus preventing overheating.
-Reducing the ambient
temperature is the most
effective means of preventing
overheating.
-Having the surroundings of the
motor well ventilated enables
the motor to release heat
efficiently, thus preventing
overheating. Using a fan to
direct air at the motor is also
effective.
-If there is a source of heat near
the motor, it is advisable to
install shielding to protect the
motor from heat radiation.
-Input an appropriate parameter
as described in CONTROLLER
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.
MAINTENANCE
B-82545EN/04
Symptom
Description
Grease
leakage
-Grease is leaking from the
mechanical unit.
Axis rotation
-An axis rotates because the
brake does not function.
-An axis rotates gradually when
it should be at rest.
Displaceme
nt
-The positioner operates at a
point other than the taught
position.
-The repeatability is not within
the tolerance.
-Displacement occurs only in a
specific peripheral unit.
4.TROUBLESHOOTING
Cause
Measure
[Poor sealing]
-Probable causes are a crack in
the casting, a broken O-ring, a
damaged oil seal, or a loose
seal bolt.
-A crack in a casting can occur
due to excessive force that
might be caused in collision.
-An O-ring can be damaged if it
is trapped or cut during
disassembling or
re-assembling.
-An oil seal might be damaged if
extraneous dust scratches the
lip of the oil seal.
-A loose seal bolt and grease
nipple might allow grease to
leak along the threads.
[Brake drive relay and motor]
-It is likely that brake drive relay
contacts are stuck to each other
to keep the brake current
flowing, thus preventing the
brake from operating when the
motor is deenergized.
-It is likely that the brake shoe
has worn out or the brake main
body is damaged, preventing
the brake from operating
efficiently.
-It is likely that oil or grease has
entered the motor, causing the
brake to slip.
[Mechanical section problems]
-If the repeatability is unstable,
probable causes are a failure in
the drive mechanism or a loose
bolt.
-If the repeatability becomes
stable it is likely that a collision
imposed an excessive load,
leading to slipping on the base
surface or the mating surface of
an arm or reducer.
-It is likely that the pulsecoder is
abnormal.
[Peripheral unit displacement]
-It is likely that an external force
was applied to the peripheral
unit, thus shifting its position
relative to the positioner.
-If a crack develops in the
casting, sealant can be used as
a quick-fix to prevent further
grease leakage. However, the
component should be replaced
as soon as possible, because
the crack might extend.
-O-rings are used in the
locations listed below.
-Motor coupling section
-Reducer (case and shaft)
coupling section
-Oil seals are used in the
locations stated below.
-Inside the reducer
-Seal bolts and nipples are used
in the locations stated below.
-Grease drain inlet and outlet
-Check whether the brake drive
relay contacts are stuck to each
other. If they are found to be
stuck, replace the relay.
-If the brake shoe is worn out, if
the brake main body is
damaged, or if oil or grease has
entered the motor, replace the
motor.
- 17 -
-If the repeatability is unstable,
repair the mechanical section
by referring to the above
descriptions of vibration, noise,
and rattling.
-If the repeatability is stable,
correct the taught program.
Variation will not occur unless
another collision occurs.
-If the pulsecoder is abnormal,
replace the motor or the
pulsecoder.
-Correct the setting of the
peripheral unit position.
-Correct the taught program.
4.TROUBLESHOOTING
MAINTENANCE
B-82545EN/04
Symptom
Description
Cause
Measure
Displaceme
nt
-Displacement occurred after a
parameter was changed.
BZAL alarm
occurred
-BZAL is displayed on the
controller screen
-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.
Troubles
related to
arc welding
-Starting of an arc is not good.
-An arc is unstable.
-Beads are irregular.
[Parameter]
-It is likely that the mastering
data was rewritten in such a
way that
the positioner origin was
shifted.
-The voltage of the memory
backup battery may be low.
-The pulsecoder cable may be
defected.
-The welding ground cable may
be loosened or broken(NOTE).
-Tighten the connection part of
the ground cable.
-Replace the ground cable.
NOTE
Arc welding troubles may be caused by a welding unit such as a welding power
supply or torch. When a trouble occurs, see the manual of each unit to find the
cause.
4.3
BACKLASH MEASUREMENT
Measurement method
1.
2.
3.
Maintain the positioner in a specified posture. (See Fig. 4.3 (a))
Apply positive and negative loads to each axis as shown in Fig. 4.3 (a).
Remove the loads and measure the displacement.
Apply positive and negative loads three times and then remove the loads. Calculate the average of the
displacements in the second and third measurements as the backlash.
Stop position
0
+10kgf
Firtst step
(Do not measure)
-10kgf
+10kgf
L1
-10kgf
0kgf
Second step
(B2 =L1+ L2)
f
L2
+10kgf
0kgf
L3
-10kgf
Third step
(B3=L3+ L4)
0kgf
L4
Fig. 4.3 (a) Backlash Measurement Method
- 18 -
MAINTENANCE
B-82545EN/04
4.TROUBLESHOOTING
Backlash B is calculated using the following expression:
B2 + B3
B=
2
Table 4.3 (a) Backlash measurement posture and measurement position
Measured posture
Measurement position (mm)
0°
See fig 4.3 (b)
Table 4.3 (b) Backlash allowable rattling of each axis
(300kg payload (hollow type)), (300kg/500kg payload (Hollow type)),
Angle conversion (arc-min)
Displacement conversion (mm)
Distance from rotation center to measurement position (mm)
2.5
0.127
175
Table 4.3 (c) Backlash allowable rattling of each axis
(1000kg/1500kg payload (Hollow type))
Angle conversion (arc-min)
Displacement conversion (mm)
Distance from rotation center to measurement position (mm)
2.5
0.164
225
Table 4.3 (d) Backlash allowable rattling of each axis
(1000kg/1500kg payload (Compact type))
Angle conversion (arc-min)
Displacement conversion (mm)
Distance from rotation center to measurement position (mm)
2.5
0.109
150
NOTE
The displacement conversion value indicates play in the direction of rotation from
the center of the axis at the distance shown in brackets.
- 19 -
4.TROUBLESHOOTING
MAINTENANCE
B-82545EN/04
(*)
Backlash
measurement position
Install the fixture like this.
(*)
350mm : 300kg payload (Hollow type), 300kg/500kg payload (Hollow type)
450mm : 1000kg/1500kg payload (Hollow type)
300mm : 1000kg/1500kg payload (Compact type)
Fig. 4.3 (b) Backlash measurement position
4.4
COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS
Adjustments are needed after a component is replaced.
The following table lists components and the adjustment items that must be made after their replacement.
After replacing a component, make necessary adjustments according to this table.
Component replacement or function change
Adjustment item
Cable replacement
Battery replacement
(The battery should be replaced once 1.5 years.)
Quick mastering
Replace the battery with the power kept on.
No adjustment is needed.
- 20 -
MAINTENANCE
B-82545EN/04
5
5.ADJUSTMENTS
ADJUSTMENTS
Each part of the mechanical units of a positioner is set to the best condition before the positioner is shipped
to the customer. The customer does not need to make adjustments on the positioner when it is delivered.
If a mechanical unit of the positioner has a large backlash because of a long-term use or component
replacement, make adjustments according to this section.
5.1
REFERENCE POSITION AND MOVING RANGE
Zero point and software motion limits are provided for 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 positioner cannot exceed the software motion limit unless there is a failure of the system
causing loss of zero point position or there is a system error.
Fig. 5.1 (a) shows the zero point and motion limit (stroke).
Fig. 5.1 (b) shows the motion direction (+/−).
+370°
0°
-370°
(NOTE) There is not a mechanical stopper.
Fig. 5.1 (a) Axis swiveling
- 21 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
+
740°
(±370°)
-
Fig. 5.1 (b) Axis motion direction
5.2
MASTERING
Mastering method
There are following five methods of mastering.
Table 5.2 Mastering methods
Fixture position mastering
Zero-position mastering (witness
mark mastering)
Quick mastering
Single axis mastering
Mastering data entry
This is performed using a mastering fixture before the machine is shipped
from the factory.
This is performed with all axes set at the 0-degree position. A zero-position
mark (witness mark) is attached to each positioner axis. This mastering is
performed with all axes aligned to their respective witness marks.
This is performed at a user-specified position. The corresponding count value
is obtained from the rotation speed of the pulsecoder connected to the
relevant motor and the rotation angel within one rotation. Quick mastering
uses the fact that the absolute value of a rotation angel within one rotation will
not be lost.
This is performed for one axis at a time. The mastering position for each axis
can be specified by the user. This is useful in performing mastering on a
specific axis.
Mastering data is entered directly.
Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an
operation is which the controller reads the current pulse count value to sense the current position of the
positioner.
If the backup batteries for the pulsecoder go dead during cable replacement, quick mastering can be
performed, resetting the positioner exactly to its initial position by calibration.
If replacement of the motors, reducers, or other parts causes mechanical changes in the phases of the
pulsecoder, quick mastering cannot be performed. In this case, perform fixture position mastering for
accurate position calibration.
- 22 -
MAINTENANCE
B-82545EN/04
5.ADJUSTMENTS
CAUTION
If mastering is performed incorrectly, the positioner may behave unexpectedly.
This is very dangerous. Therefore, the positioning screen is designed to appear
only when the $MASTER_ENB system variable is 1 or 2. After performing
positioning, press F5 [DONE] on the positioning screen. The $MASTER_ENB
system variable is reset to 0 automatically, thus hiding the positioning screen.
NOTE
It is recommended that you back up the current mastering data before performing
mastering.
5.2.1
Resetting Alarms and Preparing for Mastering
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.
Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse not established”
Procedure
1
Display the positioning menu by following steps 1 to 6.
1
Press the screen selection key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press F1 [TYPE], and select [SYSTEM Variable] from the menu.
4
Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER].
5
Press F1 [TYPE], and select [Master/Cal] from the menu.
6
Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
1
Press the screen selection key.
2
Press [0 NEXT] and Select [6 SYSTEM].
3
Press F1 [TYPE], and select [Master/Cal] from the menu.
4
Place the cursor on F3 RES_PCA, then press F4 [TRUE].
5
Turn off the controller power and on again.
3
To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 3.
1
When the controller power is turned on again, the message “Servo 075 Pulse not established”
appears again.
2
Move the axis for which the message mentioned above has appeared till alarm disappears when
press [FAULT RESET] in either direction.
5.2.2
Fixture Position Master
Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the
predetermined fixture position.
Fixture position mastering is accurate because a dedicated mastering fixture is used. Fixture position
mastering is not required in daily operations because it is factory-performed.
When mastering the positioner, arrange the positioner to meet the following conditions.
- Make the positioner mounting base horizontal.
(Set the positioner mounting surface so that the levelness of the entire surface is 1 mm or less.)
- Remove the hand and other parts form the wrist.
- Set the positioner in the condition protected from an external force.
- 23 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
CAUTION
Be extremely careful in moving the positioner during mastering because an axis
movement range is not checked.
Assembling mastering fixtures
Attach the mastering fixture to the positioner as shown in Fig. 5.2.2 (a) to (h).
Remove the seal from the mastering fixture attaching surface.
Be sure to restore the original condition after completion of mastering.
Pin D
A290-7220-X956
Bolt
M10X20(2pcs)
Mastering fixture B
A290-7220-X952
Pin C
A290-7220-X955
Bolt
M5X16
Clamp
A290-7022-X954
Mastering fixture A
A290-7220-X951
Dial gauge
Bolt
M8X20(2pcs)
Pin B
A290-7220-X953
Pin A
A290-7220-X954
Fig. 5.2.2 (a) Attaching the mastering fixture to the 1-axis positioner
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
- 24 -
MAINTENANCE
B-82545EN/04
5.ADJUSTMENTS
Fig. 5.2.2 (b) Attaching the mastering fixture to the 1-axis positioner
(300kg payload (hollow type)) , (300kg/500kg payload (Hollow type))
Bolt
M5X16
Mastering fixture A
A290-7220-X957
Pin A
A290-7220-X953
Clamp
A290-7022-X954
Pin B
A290-7220-X954
Bolt
M8X20(2pcs)
Fig. 5.2.2 (c) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Hollow type))
- 25 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
Mastering fixture B
A290-7220-X958
Bolt
M16X30(2pcs)
Pin D
A290-7220-X956
Pin C
A290-7220-X955
Fig. 5.2.2 (d) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Hollow type))
The direction
of pin O6
The direction
of pin O10
Fig. 5.2.2 (e) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Hollow type))
- 26 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
Clamp
A290-7022-X954
Mastering fixture A
A290-7220-X961
Bolt
M5X16
Dial gauge
Bolt
M8X20 (2 pcs)
Pin B
A290-7220-X954
Pin A
A290-7220-X953
Fig. 5.2.2 (f) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Compact type))
Mastering fixture B
A290-7220-X962
Bolt
M12X30 (2pcs)
Pin C
A290-7220-X955
Pin D
A290-7220-X956
Fig. 5.2.2 (g) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Compact type))
- 27 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
The direction of
pin O6
The direction of
pin O10
Fig. 5.2.2 (h) Attaching the mastering fixture to the 1-axis positioner (1000kg/1500kg payload (Compact type))
Mastering
1
2
3
4
Press MENUS.
Press NEXT and select SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Calibrate key select? [NO]
[ TYPE ]
5
YES
NO
Release brake control, and jog the positioner into a posture for mastering.
See fig. 5.2.2 (i) to (k) for the mastering posture.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.(∗)SSV_OFF_ALL: FALSE
$PARAM_GROUP.(∗)SSV_OFF_ENB[*]: FALSE
(for all axes)
After changing the system variables, turn off the controller power and on again.
[*] is the axis number of the positioner.
Slowly move the positioner by axial feed so that the values of dial indicators shown in Fig. 5.2.2 (a),
(c) and (f) are 3 mm.
- 28 -
6
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data :
<
0.0000> <
90.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
[ TYPE ] LOAD RES_PCA
7
DONE
Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be performed
Alternatively, turn off the controller power and on again. Turning on the controller power on always
causes positioning to be performed.
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
Quick master ? [NO]
[ TYPE ]
8
9
YES
NONE
After positioning is completed, press F5 [DONE].
Restore brake control.
Reset system variables $PARAM_GROUP.$SV_OFF_ALL and
$PARAM_GROUP.$SV_OFF_ENB to their original values, and turn the power off and then back on.
- 29 -
5.ADJUSTMENTS
10
MAINTENANCE
B-82545EN/04
After mastering, update the mastering data listed in the factory-supplied data sheet with new mastering
data ($DMR_GROUP.$MASTER_COUN [*]).
([*] is the axis number of the positioner.).
Mastering position :0°
Fig. 5.2.2 (i) Mastering position
(300kg payload (Hollow type)), (300kg/500kg payload (Hollow type))
Mastering position : 0°
Fig. 5.2.2 (j) Mastering position (1000kg/1500kg payload (Hollow type)
- 30 -
MAINTENANCE
B-82545EN/04
5.ADJUSTMENTS
Mastering position
:0°
Fig. 5.2.2 (k) Mastering position (1000kg/1500kg payload (Compact type)
5.2.3
Zero Position Mastering
Zero-position mastering is performed with axes set at the 0-degree position. A zero-position mark (witness
mark) is attached to each positioner axis. This mastering is performed with all axes set at the 0-degree
position using their respective witness marks.
Zero-position mastering involves a visual check. It cannot be so accurate. It should be used only as a
quick-fix method.
Procedure Mastering to Zero Degrees
Step
1
2
3
4
Press MENUS.
Select NEXT and press SYSTEM.
Press F1, [TYPE].
Select Master/Cal.
- 31 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Calibrate zero position master key select? [NO]
[ TYPE ]
5
YES
NO
Release brake control, and jog the robot into a posture for mastering. See Fig. 5.2.3 (a) to (c) for the
mastering posture.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SSV_OFF_ALL: FALSE
$PARAM GROUP.SSV OFF ENB[*]: FALSE
(for all axes)
After changing the system variables, turn off the controller power and on again.
([*] is the axis number of the positioner.)
6
Select Zero Position Master.
AUTO
SYSTEM
Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0>
[ TYPE ] LOAD RES_PCA
- 32 -
DONE
7
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
Press F4, YES. Mastering will be performed automatically.
Alternatively, turn the power off and then back on. Mastering is performed.
When the power is turned off and then back on, mastering is always performed.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000>
Quick master?
[NO]
[ TYPE ]
8
9
YES
NO
After calibration is completed, press F5[DONE].
Reset the brake control release settings to the original state. Set system variables $PARAM_GROUP,
$SV_OFF_ALL, and $SV_OFF_ENB to their original values, then turn off then back on the power.
A
Detail A
Fig. 5.2.3 (a) Marking of the zero-degree for each axis (witness mark)
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
- 33 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
B
Detail B
Fig. 5.2.3 (b) Marking of the zero-degree for each axis (witness mark) (1000kg/1500kg payload (Hollow type))
A
Detail A
Fig. 5.2.3 (c) Marking of the zero-degree for each axis (witness mark) (1000kg/1500kg payload (Compact type))
5.2.4
Quick Mastering
Quick mastering is performed at a user-specified position. The corresponding count value is obtained from
the rotation speed of the pulsecoder connected to the relevant motor and the rotation angle within one
rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not
be lost.
Quick mastering is factory-performed at the zero-degree position. Do not change the setting unless there is
a problem.
If it is impossible to set the positioner at the position mentioned above, it is necessary to re-set the quick
mastering reference position using the following method. (It would be convenient to set up a marker that
can work in place of the position mark.)
- 34 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
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.
3 This operation cannot be performed if mastering data is lost as a result of
mechanical disassembly or maintenance. In this case, perform zero position
mastering or fixture position mastering to recover the mastering data.
Procedure Recording the Quick Master Reference Position
Step
1
2
Select SYSTEM.
Select Master/Cal.
AUTO
SYSTEM Master/Cal
G2
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
3
4
LOAD
RES_PCA
DONE
Release brake control, and jog the positioner to the quick mastering reference position.
Move the cursor to SET QUICK MASTER REF and press ENTER. Press F4, YES.
Set quick master ref? [NO]
- 35 -
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
Procedure Quick Mastering
Step
1
Display the Master/Cal screen
AUTO
SYSTEM Master/Cal
JOINT
1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Not Mastered!
Quick master? [NO]
[ TYPE ]
2
4
5
6
7
YES
NO
Release brake control, and jog the positioner to the quick mastering reference position.
3
Move the cursor to QUICK MASTER and press ENTER. Press F4, YES. Quick mastering data
is memorized.
Move the cursor to CALIBRATE and press ENTER. Calibration is executed. Calibration is executed
by power on again.
After completing the calibration, press F5, DONE.
Restore brake control.
Reset system variables $PARAM_GROUP.$SV_OFF_ALL and
$PARAM_GROUP.$SV_OFF_ENB to their original values, and turn the power off and then back on.
After mastering, update the mastering data listed in the factory-supplied data sheet with new mastering
data ($DMR_GROUP[*].$MASTER_COUN ).
([*] is the group number of the positioner.)
5.2.5
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.
- 36 -
MAINTENANCE
B-82545EN/04
Item
Current position
(Actual axis)
Mastering position (MSTR POS)
SEL
ST
5.ADJUSTMENTS
Table 5.2.5 Items Set in Single Axis Mastering
Description
The current position of the robot is displayed for each axis in degree units.
A mastering position is specified for an axis to be subjected to single axis mastering.
It would be convenient to set to it to the 0° position.
This item is set to 1 for an axis to be subjected to single axis mastering.
Usually, it is 0.
This item indicates whether single axis mastering has been completed for the
corresponding axis. It cannot be changed directly by the user. The value of the item
is reflected in $EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis mastering is necessary.
1 : Mastering data has been lost.
(Mastering has been performed only for the other interactive axes.)
Single axis mastering is necessary.
2 : Mastering has been completed.
Procedure Mastering a Single Axis
Step
1.
2.
Select SYSTEM.
Select Master/Cal.
3.
Select 4, Single Axis Master. You will see a screen similar to the following.
- 37 -
5.ADJUSTMENTS
4.
MAINTENANCE
B-82545EN/04
5.
6.
Move the cursor to the SEL column for the unmastered axis and press the numeric key “1”. Setting
of SEL is available for one or more axes.
Turn off brake control as required, and then jog the robot to the mastering position.
Enter axis data for the mastering position.
7.
Press F5 [EXEC]. Mastering is performed. Therefore, SEL is reset to 0, and ST is re-set to 2 or 1.
GROUP
EXEC
F5
SINGLE AXIS MASTER
ACTUAL POS
J1 25.255
J2 25.550
J3 -50.000
J4 12.500
J5
0.000
J6
0.000
E1
0.000
E2
0.000
E3
0.000
(MSTR POS)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
(0.000)
JOINT 30%
1/9
(SEL) [ST]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
GROUP
8.
9.
EXEC
When single axis mastering is completed, press the previous page key to resume the previous
screen.
Select [6 CALIBRATE], then press F4 [YES]. Positioning is performed. Alternatively, turn off the
- 38 -
MAINTENANCE
B-82545EN/04
5.ADJUSTMENTS
controller power and on again. Positioning is performed.
10. After positioning is completed, press F5 [DONE].
11.
Return brake control to original setting, and turn off the controller power and on again.
5.2.6
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
Step
1
2
Select [6 SYSTEM] and press ENTER.
Select [Variable]. The system variable screen appears.
3
Change the mastering data.
The mastering data is saved to the $DMR_GRP(∗).$MASTER_COUN system variable.(∗ is the axis
number of the positioner.)
4
Select $DMR_GRP. (* is the group number of the positioner.)
- 39 -
5.ADJUSTMENTS
MAINTENANCE
G2
SYSTEM
ｼｽﾃﾑ
ﾍﾝｽｳVariables
B-82545EN/04
ｶｸｼﾞｸ
JOINT
$DMR_GRP[2]
1/25
1 $MASTER_DONE
TRUE
2 $OT_MINUS
[9] of BOOLEAN
3 $OT_PLUS
[9] of BOOLEAN
4 $MASTER_COUN
[9] of INTEGER
5 $REF_DONE
FALSE
6 $REF_POS
[9] of REAL
7 $REF_COUNT
[9] of INTEGER
8 $BCKLSH_SIGN
[9] of BOOLEAN
9 $EACHMST_DON
[9] of INTEGER
10 $SPC_COUNT
[9] of INTEGER
[ TYPE
ｶﾞﾒﾝ ]
5
TRUE
FALSE
Select $MASTER_COUN, and enter the mastering data you have recorded.
G2
SYSTEM
ｼｽﾃﾑ
ﾍﾝｽｳVariables
JOINT
ｶｸｼﾞｸ
$DMR_GRP[2].$MASTER_COUN
1
[1]
95678329
2
[2]
10223045
0
3
[3]
0
4
[4]
0
5
[5]
0
6
[6]
0
7
[7]
0
8
[8]
0
9
[9]
0
[ TYPE
ｶﾞﾒﾝ ]
6
7
1%
Press the previous page key.
Set $MASTER_DONE to TRUE.
- 40 -
1%
1/9
5.ADJUSTMENTS
MAINTENANCE
B-82545EN/04
G2
SYSTEM
Variables
ｼｽﾃﾑ ﾍﾝｽｳ
$DMR_GRP[2]
1/25
1 $MASTER_DONE
TRUE
2 $OT_MINUS
[9] of BOOLEAN
3 $OT_PLUS
[9] of BOOLEAN
4 $MASTER_COUN
[9] of INTEGER
5 $REF_DONE
FALSE
6 $REF_POS
[9] of REAL
7 $REF_COUNT
[9] of INTEGER
8 $BCKLSH_SIGN
[9] of BOOLEAN
9 $EACHMST_DON
10 $SPC_COUNT
2)
TRUE
FALSE
Press F1 [TYPE] and select CALIBRATE.
select [6 CALIBRATE], then press F4 [YES].
After completing positioning, press F5 [DONE].
5.2.7
1)
[9] of INTEGER
[9] of INTEGER
[ TYPE
ｶﾞﾒﾝ ]
8
9
10
1%
JOINT
ｶｸｼﾞｸ
Confirming Mastering
Confirming that mastering was performed normally
Usually, positioning is performed automatically when the power is turned on. To confirm that
mastering was performed normally, check that the current-position display matches the actual position
of the positioner, using this procedure.
a) Replay the taught operation of the positioner to set zero degrees, and visually check that the
zero-degree position marks shown in Subsection 5.2.3 are aligned.
b) Replay a specific portion of the program, and check that the positioner has moved to the taught
position.
Possible alarms in positioning
The following paragraphs describe alarms that may occur in positioning and explain how to handle
them.
a) BZAL alarm
This alarm is raised if the voltage of the pulsecoder backup battery becomes 0V when the
controller power is off. Mastering must be performed again because the counter has already lost
data.
b) BLAL alarm
This alarm indicates that the voltage of the pulsecoder backup battery is too low to run the
pulsecoder. If this alarm is issued, replace the backup battery soon while keeping the power on,
and check whether the current-position data is correct, using a method described in item (1).
c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and SPHAL alarms
If any of these alarms is issued, contact your FANUC service representative. A motor may have
to be replaced.
- 41 -
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
6
MAINTENANCE
B-82545EN/04
COMPONENT REPLACEMENT AND
ADJUSTMENTS
Once motors, reducers, and gears are replaced, mastering becomes necessary, Perform mastering according
to Chapter 5 of MAINTENANCE after any of these components is replaced.
NOTE
Be very careful when dismounting and mounting the heavy components that are
listed below.
Component
Weight (about)
Load capacity
Motor
10kg
Motor
Reducer
22kg
20kg
Reducer
Reducer
Flange
91kg
45kg
16kg
Flange
Flange
28kg
9kg
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps.
Be sure to wipe the excess LOCTITE after tightening bolt.
6.1
REPLACING THE MOTOR
In the case of 300kg payload (Hollow type) , 300kg/500kg payload (Hollow
type)
1
2
3
4
5
6
7
8
Set dial gauges and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the four M8×12 bolts and remove the motor cover.
(Only when the motor cover option is selected)
After removing the battery box fixing plate while referencing Fig. 6.1 (b), remove the four M6×10
bolts and remove the connector box.
(Only when the HARTING connector option is selected)
Remove the motor connector.
Remove the four M8×20 motor mounting bolts, washer, and remove the motor.
Attach the input gear to a new motor, and reverse the removal steps to mount the motor. Replace the
O-rings with new ones, and put the new O-rings in place. See Fig. 6.1 (a) for the tightening torque and
LOCTITE application.
Supply the grease bath with the specified grease as described in Section 3.1.
- 42 -
B-82545EN/04
9
MAINTENANCE
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
Perform single axis mastering while referencing Chapter 5.
Washer
Bolt
M8X20,4pcs
Nut
LOCTITE 242
Tightening Torque 16.7Nm
Motor cover
(When Motor cover option is specified.)
Motor
C ring
O ring
Washer
Bearing
Bolt
M8X12,4pcs
(When Harting connector option or
Motor cover option is specified.)
Input Gear
Connector box
(Harting connector option is specified.)
Plate for fixtation of Battery Box
(When Harting connector option is specified.)
Fig. 6.1 (a) Replacing the motor
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Part name
Replacing parts (300kg payload (Hollow type))
Specification
O-ring
Motor
Bearing
Oil seal
JB-OR1A-G105
A06B-0235-B605#S000
A97L-0001-0195#06Z000A
A98L-0040-0047#07010014
Replacing parts (300kg/500kg payload (Hollow type))
Part name
Specification
O-ring
Motor
Bearing
Oil seal
JB-OR1A-G105
A06B-0235-B605#S000
A97L-0218-0903#6306R
A98L-0040-0047#07010014
Battery box
Bolt
M6X10,4pcs
Battery box
mounting plate
Fig. 6.1 (b) Removing the connector box (when the HARTING connector option is selected)
- 43 -
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
MAINTENANCE
B-82545EN/04
In the case of 1000kg/1500kg payload (Hollow type)
1
2
3
4
5
6
7
8
9
Set dial gauges and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the four M8×12 bolts and remove the motor cover.
(Only when the motor cover option is selected)
After removing the battery box fixing plate while referencing Fig. 6.1 (b), remove the four M6×10
bolts and remove the connector box.
(Only when the HARTING connector option is selected)
Remove the motor connector.
Remove the four M12×30 motor mounting bolts, washer, and remove the motor.
Attach the input gear to a new motor, and reverse the removal steps to mount the motor. Replace the
O-rings with new ones, and put the new O-rings in place. See Fig. 6.1 (c) for the tightening torque and
LOCTITE application.
Supply the grease bath with the specified grease as described in Section 3.1.
Perform single axis mastering while referencing Chapter 5.
Nut
LOCTITE
242
ナット
Tightening
Torque 3.2N.m
ロックタイト242塗布
Draw
bolt
ドローボルト
LOCTITE
242
ロックタイト242塗布
締付トルク 118N.m
Tightening
Torque 118N.m
Washer
ワッシャ
CCリング
ring
締付トルク3.2N.m
OOリング
ring
アルバニヤグリースS2を塗布
Alvania
grease S2
ワッシャ,4個
Washer
4pcs
ボルト
Bolt
M12×30.4pcs
M12X30,4本
Motor
モータ
Motor cover
モータカバー
(Motor
cover option is
(モータカバーオプション選択時)
selected.)
Bearing
ベアリング
Input
インプットギヤ
gear
Bolt
ボルト
Connector box
M8×12.4pcs
(Harting connector optionM8X12,4本
(ハーテイングコネクタオプション又は
is setected.)
(Harting connector option or
モータカバーオプション選択時)
分線箱
motor cover option is selected.)
(ハーテイングコネクタオプション選択時)
Plate
for fixation of Battery Box
バッテリボックス固定用プレート
(ハーテイングコネクタオプション選択時)
(Harting
connector option
is setected.)
Fig. 6.1 (c) Replacing the motor (1000kg/1500kg payload (Hollow type))
Replacing parts (1000kg/1500kg payload (Hollow type))
Part name
Specification
O-ring
Motor
Bearing
Oil seal
JB-OR1A-G125
A06B-0265-B605#S000
A97L-0001-0196#09Z000A
A98L-0040-0047#13016014
- 44 -
B-82545EN/04
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
MAINTENANCE
In the case of 1000 kg/1500kg payload (Compact type)
1
2
3
4
5
6
7
8
Set dial gauges and prepare for single axis mastering after replacement.
Turn off the controller power.
Remove the four M8×12 bolts and remove the motor cover.
(Only when the motor cover option is selected)
Remove the motor connector.
Remove the four M12×30 motor mounting bolts, washer, and remove the motor.
Attach the input gear to a new motor, and reverse the removal steps to mount the motor. Replace the
O-rings with new ones, and put the new O-rings in place. See Fig. 6.1 (d) for the tightening torque and
LOCTITE application.
Supply the grease bath with the specified grease as described in Section 3.1.
Perform single axis mastering while referencing Chapter 5.
O ring
Bolt M5X25
Appy LOCTITE 242.
Tightening torque : 3.2Nm
Input gear
Draw nut
Appy LOCTITE 242.
Tightening torque : 118Nm
Motor cover
(When motor cover option is specified.)
Motor
Bolt
M12X30, 4pcs
Washer 4pcs
Bolt
M8X12, 4pcs
(When motor cover option is specified.)
Connector box
(When harting connector option is specified.)
Fig. 6.1 (d) Replacing the motor (1000kg/1500kg payload (Compact type))
Replacing parts (1000kg/1500kg payload (Compact type))
Part name
Specification
O-ring
Motor
Seal bolt (for motor mounting 4pcs)
JB-OR1A-G125
A06B-0265-B605#S000
A97L-0218-0423#122210
NOTE
Replace the bearing or oil seal only when it is broken.
- 45 -
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
6.2
MAINTENANCE
B-82545EN/04
REPLACING THE REDUCER
In the case of 300kg payload (Hollow type) , 300kg/500kg payload (Hollow
type)
1
2
3
4
5
6
7
8
9
Remove the motor as Section 6.1.
Remove the covers, bolts, insulators A and B, collar, flange, and insulator in that order.
Pull the pipe out of the reducer.
Remove the 11 M10×45 bolts with washers that fasten the reducer on the base, and remove the
reducer.
Remove the gear.
Reverse the removal steps to mount a new reducer. Replace the O-rings with new ones, and put the
new O-rings in place. Be careful not to damage the oil seal.
See Fig. 6.2 (a) for the tightening torque and LOCTITE application.
Install the motor as Section 6.1.
Supply the grease bath with the specified grease as described in Section 3.1.
Perform single axis mastering while referencing Chapter 5.
Bolt
M10X45,11pcs
Apply LOCTITE 262.
Tightening torque 73.5Nm
O ring
Apply Shell Alvania
grease S2.
Washer
Reducer
Flange
Washer plate, 3pcs
Bolt M12X35
(300kg payload (Hollow type) :, 9pcs
300kg/500kg payload (Hollow type) : 12pcs)
Apply LOCTITE 262.
Tightening torque 128.4Nm
Cover, 3pcs
Insulator B
Insulator A, 3pcs
Gear
Base
Collar
O ring
Apply Shell Alvania (300kg payload (Hollow type) :, 9pcs
300kg/500kg payload (Hollow type) : 12pcs)
grease S2.
Insert after the insulator A.
Pipe
Insulator C
Fig. 6.2 (a) Replacing the reducer (300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
Replacing parts (300kg payload (Hollow type))
Part name
Specification
O-ring (pipe)
O-ring (reducer)
Reducer
Input gear
Center gear
JB-OR1A-G95
A98L-0040-0041#173
A97L-0218-0805#37
A290-7220-X111
A290-7216-X212
Replacing parts (300kg/500kg payload (Hollow type))
Part name
Specification
O-ring (pipe)
O-ring (reducer)
Reducer
Input gear
Center gear
JB-OR1A-G95
A98L-0040-0041#173
A97L-0218-0891#37
A290-7220-Z111
A290-7216-X212
- 46 -
B-82545EN/04
MAINTENANCE
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
In the case of 1000 kg/1500kg payload (Hollow type)
1
2
3
4
5
6
7
8
Remove the motor as described in Section 6.1.
Remove the covers, bolts, washers, insulators A and B, flanges, insulators C in that order.
Remove the 15 bolts (M16×50) that fix the reducer and base and then remove the reducer and the
components ahead of it.
Remove the 16 bolts (M12×85) and washers that secure the reducer and adapter and remove the
reducer from the adapter.
Apply sealant to a new reducer as described in Section 6.3 and assemble these components in the
reverse order. Replace the O-rings with new ones and put them in place. Be careful not to damage the
oil seal. For the tightening torque and the application of LOCTITE, see Fig. 6.2 (b).
Mount the motor as described in Section 6.1.
Supply the grease bath with the specified grease as described in Section 3.1.
Perform single axis mastering as described in Chapter 5.
Bolt
M16X50,15 pcs
LOCTITE 262Nm
Tightening torque 318.5Nm
Bolt
M12X85,16 pcs
LOCTITE 262
Tightening torque 128.4Nm
Washer,15 pcs
Washer,16 pcs
Reducer
Insulator B,18 pcs
(Insert after the insulator A.)
O ring
Apply Alvania grease S2
Insulator A,18 pcs
Pipe
Insulator C
Adapter
Flange
Washer ,18 pcs
Bolt
M12X35,18 pcs
LOCTITE 262
Tightening torque 128.4Nm
Cover,18 pcs
Base
Fig. 6.2 (b) Replacing the reducer (1000kg/1500kg payload (Hollow type))
Replacing parts (1000kg/1500kg payload (Hollow type))
Part name
Specification
O-ring (pipe)
O-ring (reducer)
Reducer
JB-OR1A-G125
A98L-0040-0041#281
A97L-0218-0819
In the case of 1000 kg/1500kg payload (Compact type)
1
2
3
4
Set dial gauges, and prepare for single axis mastering after replacement.
Remove flange mounting bolts M10×22(24 pcs) , M12×22(9 pcs) to flange and remove flange.
Remove reducer mounting bolts M12×50(16 pcs) and washers (16 pcs) to base and remove reducer.
Apply sealant to a new reducer as described in Section 6.3 and assemble these components in the reverse
order. Replace the O-rings with new ones and put them in place. Be careful not to damage the oil seal. For
the tightening torque and the application of LOCTITE, see Fig. 6.2 (c).
5 Supply the grease bath with the specified grease as described in Section 3.1.
6 Perform single axis mastering as described in Chapter 5.
- 47 -
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
MAINTENANCE
B-82545EN/04
Flange
Bolt
M12X22, 9pcs
Apply LOCTITE 262.
Tightening torque : 128.4Nm
Bolt
M12X50, 16pcs
Apply LOCTITE 262.
Tightening torque : 128.4Nm
O ring
Appy SHELL ALVANIA GREASE S2.
Washer 16pcs
Base
Reducer
Bolt
M10X22, 24pcs
Apply LOCTITE 262.
Tightening torque : 73.5Nm
Fig. 6.2 (c) Replacing the reducer (1000kg/1500kg payload (Compact type))
Replacing parts (1000kg/1500kg payload (Compact type))
Part name
Specification
O-ring (pipe)
Reducer (reducer)
6.3
JB-OR1A-G270
A97L-0218-0889#171
SEALANT APPLICATION
(1000kg/1500kg payload (Hollow type))
(1000kg/1500kg payload (Compact type))
Washing and degreasing the surfaces to be sealed
1
2
3
4
After dismounting the reducer from the member which installed the reducer, apply releasant
(LOCTITE Gasket Remover etc.) to the arm’s surface from which the reducer was dismounted, then
wait until the sealant (LOCTITE 518) becomes softened (for about 10 minutes). Remove the softened
sealant from the surface using a spatula.
Blow air onto the surface to be sealed to remove dust from the tapped holes.
Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a
cloth dampened with oil and grease remover. Do not spray oil and grease remover directly onto the
surface.
Polish the arm’s surface to be sealed with an oil stone, and degrease it with removal and cleaner again.
CAUTION
Oil may drip from the inside of the reducer. After degreasing, make sure that no oil
is dripping.
Applying sealant
5
Make sure that the reducer and the member which installed the reducer are dry (with no oil and grease
remover remaining). If they are still wet with oil and grease remover, wipe them dry. Always use a new
surface of a cloth so that the grease once wiped up with the cloth will not get on the degreased surface.
Make sure that no ingredient of oil and grease remover is left in the threaded holes or on any other
portion. If ingredient is left, it may prevent stiffening of sealant.
- 48 -
MAINTENANCE
B-82545EN/04
6
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
Apply sealant (LOCTITE 518) to the surfaces.
CAUTION
The portions to which sealant is to be applied vary from one axis to another. See
descriptions about reducer replacement for the relevant axes for details.
Assembling
7
8
9
To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as
quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was
wiped off, apply again.
After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get
closer.
After attaching the reducer, wipe off any excessive sealant that comes out from the sealed section with
a cloth or spatula. Do not use oil and grease remover.
CAUTION
Do not grease or move the reducer before the sealant sets, as it may allow grease
to leak. Before greasing or moving, wait for about at least four hour after the
reducer is mounted.
APPLY SEALANT (LOCTITE 518) TO THE
PART.
Fig. 6.3 (a) Applying sealant to the reducer (1000kg/1500kg payload (Hollow type))
- 49 -
6.COMPONENT REPLACEMENT AND ADJUSTMENTS
MAINTENANCE
B-82545EN/04
LOCTITE 518 applying area
Take special care and check
that there are no gaps of
sealant around these parts.
Fig. 6.3 (b) Applying sealant to the reducer (1000kg/1500kg payload (Compact type))
- 50 -
B-82545EN/04
7
7.1
MAINTENANCE
7.PIPING AND WIRING
PIPING AND WIRING
CABLING (WHEN THE HARTING CONNECTOR OPTION IS
SELECTED)
Fig. 7.1 shows the cabling in the mechanical unit when the HARTING connector option is selected. (There
are no cables in the mechanical unit when the HARTING connector option is not selected.)
K101
Pulsecoder cable
K102
Motor cable
Fig. 7.1 Wiring in the mechanical unit
- 51 -
8.CABLE REPLACEMENT
8
MAINTENANCE
B-82545EN/04
CABLE REPLACEMENT
If a cable is broken or damaged, replace it according to the procedure described in this chapter.
Cautions in handling the pulsecoder cable
When transporting, installing, or maintaining the positioner, do not detach the pulsecoder cables carelessly.
The cables are provided with the marking tie shown below. If you detached any cable with the marking tie,
you need to perform mastering for the robot.
Do not detach any connector unless you replace a motor, pulsecoder, reducer, or cable.
BATTERY BACKUP
DON'T
DISCONNECT
コネクタ取外不可
Fig. 8 Wire mark
If there is a break in or any other damage to a cable, replace the cable according to the procedure described
in this chapter. If the connector of a pulsecoder cable (K101) is detached, the data about the absolute
position of the positioner is lost. Once any of these cables is replaced, perform quick mastering while
referencing Section 5.2. If the data is lost because of a break in a cable, also perform quick mastering to
calibrate the positioner into the previous absolute position.
8.1
REPLACING CABLES
When the HARTING connector option is not selected, turn off the power to the controller, directly remove
the motor connector, and replace the cables. When the HARTING connector option is selected, use the
procedure below to replace the cables.
In the case of 300kg payload (Hollow type) ,
300kg/500kg payload (Hollow type),
1000kg/1500kg payload (Hollow type)
1
2
3
4
5
6
Make sure that the quick mastering reference point is set with reference to Subsection 5.2.4.
Turn off the controller power.
Remove the motor cover while referencing Chapter 6.
Remove the four M6X10 bolts from the battery box fixing plate, and remove the plate together with
the battery. Take care not to break the battery connection cable by excessively pulling it.
Remove the three M8X12 bolts that fasten the connector box, and remove the connector box.
Remove the motor connector and the cable.
- 52 -
MAINTENANCE
B-82545EN/04
7
8
9
10
11
8.CABLE REPLACEMENT
Detach the cables from the connector box. The K101 cable can be detached from the connector box by
removing the four M4X8 bolts, and the K102 cable can be detached by removing the four M3X8 bolts,
housing, and insert.
Remove the battery connection cable.
Remove the ground wire.
Reverse the removal steps to install new cables. Take care not to cause the cables to be caught and cut
in metal plates while installing them. Also, take care not to break the cables by pulling them.
Perform quick mastering. (See Chapter 5).
Motor cover
Bolt
M8X12,4pcs
Fig.8.1 (a) Replacing cables 1
300kg payload (Hollow type) , 300kg/500kg payload (Hollow type) , 1000kg/1500kg payload (Hollow type)
Battery box
Bolt
M6X10,4pcs
Battery box
mounting plate
Fig. 8.1 (b) Replacing cables 2
300kg payload (Hollow type) , 300kg/500kg payload (Hollow type) , 1000kg/1500kg payload (Hollow type)
- 53 -
8.CABLE REPLACEMENT
MAINTENANCE
B-82545EN/04
Connector
for cable K102
Connector
for cable K101
Connector box
Bolt
Bolt
M4X8(4pcs) M3X8(4pcs)
Bolt
M8X12(3pcs)
Fig. 8.1 (c) Replacing cables 3
300kg payload (Hollow type) , 300kg/500kg payload (Hollow type) , 1000kg/1500kg payload (Hollow type)
In the case of 1000kg/1500kg payload (Compact type)
1
2
3
4
5
6
7
8
9
10
Make sure that the quick mastering reference point is set with reference to Subsection 5.2.4.
Turn off the controller power.
Remove the motor cover while referencing Chapter 6.
Remove the two M6X10 bolts from the battery box fixing plate, and remove the plate together with the
battery. Take care not to break the battery connection cable by excessively pulling it.
Remove the motor connector and the cable.
Detach the cables from the connector box. The K101 cable can be detached from the connector box by
removing the four M4X8 bolts, and the K102 cable can be detached by removing the four M3X8 bolts,
housing, and insert.
Remove the battery connection cable.
Remove the ground wire.
Reverse the removal steps to install new cables. Take care not to cause the cables to be caught and cut
in metal plates while installing them. Also, take care not to break the cables by pulling them.
Perform quick mastering. (See Chapter 5).
- 54 -
B-82545EN/04
MAINTENANCE
8.CABLE REPLACEMENT
Bolt
M8X12,4pcs
Motor cover
Bolt
M4X8,4pcs
Connector of
cable K101
Connector box
Connector of
cable K102
Bolt
M4X8,4pcs
Fig. 8.1 (d) Replacing cables 1
1000kg/1500kg payload (Compact type)
Battery box
Bolt
M6X10,2pcs
Battery box
mounting plate
Fig. 8.1 (e) Replacing cables 2
1000kg/1500kg payload (Compact type)
- 55 -
II. CONNECTION
CONNECTION
B-82545EN/04
1
1.POSITIONER OUTLINE DRAWING
POSITIONER OUTLINE DRAWING
When installing peripheral equipment, be careful not to cause interference with the positioner body. For
installation, see Section 3.3 of CONNECTION and use through holes provided on the base.
1.1
OUTLINE DRAWING AND OPERATION AREA DIAGRAM
Figs. 1.1 (a) to (e) show the outer dimensions and the operation area of the positioner and follower unit.
Motor cover option
2-φ10 H8 +0.022
0
Through
for mastering
3-φ10 H8 +0.022
0
Through
380
374
0
30
φ
12-M10
Through
Equally spaced
360
φ350
15°
185
φ11
Depth3 H7
6
f
sha
ow
Holl
+0.03
5
0
65
tφ
φ
27
0
143
207
Harting connector option
409
183
Fig. 1.1 (a) Outline of 1 axis positioner
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
- 59 -
1.POSITIONER OUTLINE DRAWING
CONNECTION
B-82545EN/04
582
573
12-M16
Depth 25
Equally spaced
32
0
6-M12
Depth 20
Equally spaced
485
O 260
0
O 450
O
Motor cover option
2-O10H8+0.022
0
Depth 8
O
260
1
Dep 60 H7
th 8
w
llo
Ho
d
er
et
m
a
i
O
0
12
+0.0
40
0
329.5
259
654
293.5
Harting connector option
Fig. 1.1 (b) Outline of 1 axis positioner (1000kg/1500kg payload (Hollow type))
12-M12
Through
Motor cover option
2-O10H8 +0.002
0
Depth 8
399.5
O
27
10-M12
Depth 12
Equally spaced
0
300
Harting connector option
400.5
30
O1
141.5
170.5
255
503
Fig. 1.1 (c) Outline of 1 axis positioner (1000kg/1500kg payload (Compact type))
- 60 -
1.POSITIONER OUTLINE DRAWING
CONNECTION
B-82545EN/04
343
12-M10
Through
Equally spaced
O 350
15°
ed
360
4Th O
rou 10
gh H 8
+0
Eq
uq 0 .022
lly
sp
ac
185
O 11
Dept 3 H7
h6
30
0
O
w
llo
Ho
O
+0.035
0
2 70
am
di
169
er
et
118
O
205
65
231
Fig. 1.1 (d) Outline of follower unit (insulated flange)
144.5
2-O10H7 +0.015
0
O
0
13
0 H7
O 10
35
+0.0
0
185
Hollow d
iameter
O 65
O 170
10-M12
Through
83
310
Fig. 1.1 (e) Outline of follower unit (non-insulated flange)
- 61 -
2.MOUNTING DEVICES ON THE POSITIONER
2
CONNECTION
B-82545EN/04
MOUNTING DEVICES ON THE POSITIONER
NOTE
Wipe oil off the flange surface before mounting the unit. Otherwise, the unit may
be misaligned.
2.1
POSITIONER LOAD CONDITION
Payload（kg)
Fig. 2.1 (a) to (d) show the positioner load conditions.
Use the positioner so that the load condition falls within the range in the table and the allowable load inertia
and allowable load moment in the table are satisfied.
300
250
200
150
120
300
Payload vs Payload C.G
Displacement (mm)
240
180
144
120
Fig. 2.1 (a) Positioner allowable load condition (300kg load capacity)
300kg payload (Hollow type) , 300kg/500kg payload (Hollow type)
300kg pay load capacity
36 kgf.m (353 N.m)
Allowable load moment (Mr)
250kgf.m (2,450 N.m)
2,350 kgf.cm.s2(240kg.m2)
Allowable bending moment (Mb)
Allowable load inertia (J)
- 62 -
B-82545EN/04
2.MOUNTING DEVICES ON THE POSITIONER
CONNECTION
Payload（kg)
500
400
300
200
Payload vs Payload C.G
Displacement (mm)
300
200
150
120
Fig. 2.1 (b) Positioner allowable load condition (500kg payload capacity)
300kg payload (Hollow type) , 300kg/500kg payload (Hollow type)
500kg payload capacity
60 kgf.m (588 N.m)
Allowable load moment (Mr)
400kgf.m (3,920 N.m)
3,673 kgf.cm.s2(360kg.m2)
Allowable bending moment (Mb)
Allowable load inertia (J)
- 63 -
2.MOUNTING DEVICES ON THE POSITIONER
CONNECTION
Payload（kg)
1000
800
700
600
500
Payload vs Payload C.G
Displacement (mm)
320
267
229
200
160
Fig. 2.1 (c) Positioner allowable load condition (1000kg payload capacity)
1000kg/1500kg payload (Hollow type),1000kg/1500kg payload (Compact type)
1000kg payload capacity
160 kgf.m (1,568 N.m)
Allowable load moment (Mr)
2,100kgf.m (20,580 N.m)
4,700 kgf.cm.s2(461kg.m2)
Allowable bending moment (Mb)
Allowable load inertia (J)
- 64 -
B-82545EN/04
B-82545EN/04
CONNECTION
2.MOUNTING DEVICES ON THE POSITIONER
1500
1400
1300
1200
Payload（kg)
1100
Payload vs Payload C.G
Displacement (mm)
182
167
154
143
133
Fig. 2.1 (d) Positioner allowable load condition (1500kg payload capacity)
1000kg/1500kg payload (Hollow type),1000kg/1500kg payload (Compact type)
1500kg payload capacity
200 kgf.m (1,960 N.m)
Allowable load moment (Mr)
2,100kgf.m (20,580 N.m)
7,000 kgf.cm.s2(686kg.m2)
Allowable bending moment (Mb)
Allowable load inertia (J)
- 65 -
2.MOUNTING DEVICES ON THE POSITIONER
2.2
CONNECTION
B-82545EN/04
CHANGING METHOD OF PAYLOAD SPECIFICATION
About Max payload shift function
In Positioner, the best two servo motion parameters are prepared. The best addition and subtraction velocity
operation can be achieved by setting the parameter matched to the payload specification. The parameter is
changed by executing the following KAREL programs (It is abbreviated as KAREL for Changing method
of payload specification thereafter.)
1000kg/1500kg payload (Hollow type) (A05B-1220-J102)
P1HSET10.PC:
P1HSET15.PC:
1000kg payload specification
1500kg payload specification
300kg/500kg payload (Hollow type) (A05B-1220-J103)
P1HSET03.PC:
P1HSET05.PC:
300kg payload specification
500kg payload specification
1000kg/1500kg payload (Compact type) (A05B-1220-J104)
P1CSET10.PC:
1000kg payload specification
P1CSET15.PC:
1500kg payload specification
It explains the procedure as an example of 1000kg/1500kg payload (Hollow type) (A05B-1220-J102)at the
following.
Positioner is set to specified payload specification by customer when it is shipped.
CAUTION
When positioner over payload specification of set, (Refer to specification table in
PREFACE and Section 2.1.of CONNECTION), set in appropriate payload
specification. If the positioner is operated with wrong setting, the function and the
lifetime of the robot would deteriorate.
Method of shifting
There are the following two in the method of executing KAREL for changing method of payload
specification. Please use it properly according to the purpose.
1) Method of executing KAREL program by using “Call program” → Refer to Subsection 2.2.1.
•
The KAREL program is set in the program call instruction of the TP program and the parameter is set
by specifying with the argument that shows the group number, and executing it. The parameter of
1-axis positioner of a specific group can be switched in this method.
Instruction that calls
program
2)
•
•
Example of program：
１：
CALL P1HSET10(１)
Group number
specification for
argument
Method of executing KAREL program directly → Refer to Subsection 2.2.2.
Select and execute the KAREL program in program select screen.
Two or more 1-axis positioner exists in the multi group system, and it is possible to change in this
method bringing the parameter of two or more 1-axis positioner together to set the parameter for the
same load as them.
- 66 -
2.MOUNTING DEVICES ON THE POSITIONER
CONNECTION
B-82545EN/04
NOTE
1.
2.
Execute KAREL for Changing method of payload specification in the state of cold start mode.
Be careful that the tracks and the cycle time of an existing instruction program change if KAREL for
changing method of payload specification is executed. It depends as follows, and it explains the
method of executing KAREL for Changing method of payload specification.
2.2.1
∗
Method of executing KAREL program by using “Call program”
The following procedures assume the thing of changing 1-axis positioner of the first group to the
1000kg payload specification.
Execution procedure
1
Call the system variable screen.
MENU key
2
3
4
→
Select “System” and press F1 key(screen)
→
Select “System variables”
Set system variables $KAREL_ENB to 1.
Open TP program edit screen.
Select “call program” from among the program instruction
F1 key (INST) →Select “CALL” →Select “CALL program”
Then, the following screens are displayed.
SYST-039 Operation
PROGRAM list
1 A1
2 HOME_IO
3 P1HSET10
4 P1HSET15
A1
Mode
T2
Selected
JOINT 10 %
5
6
7
8
1/2
1:
[ End ]
CALL . . .
Select item
PROGRAM
5
MACRO
KAREL
STRINGS
Press F3 key (KAREL). Then, select KAREL P1HSET10 of 1000kg payload specification from
among that because it becomes the following screens.
- 67 -
2.MOUNTING DEVICES ON THE POSITIONER
SYST-039 Operation
KAREL list
1 GEMDATA
2 GET_HOME
3 P1HSET10
4 P1HSET15
A1
Mode
CONNECTION
B-82545EN/04
T2
5
6
7
8
Selected
JOINT 10 %
MEM_PORT
PSCOLD
1/2
1:
[ End ]
CALL . . .
Select item
PROGRAM
6
MACRO
KAREL
STRINGS
Press F4 key (select). Choose “CONSTANT” from there. Then, it becomes the following screens.
SYST-039
A1
A1
Operation Mode
LINE 0
T2
Selected
T2 ABORTED
JOINT
10%
1/2
1:
[ End ]
CALL P1HSET10 ( Constant )
[ CHOICE ]
7
The group number (It is 1 here) is put with the cursor in “Constant”.
SYST-039
A1
A1
Operation Mode
LINE 0
1:
[ End ]
CALL P1HSET10 ( 1)
POINT
T2
Selected
T2 ABORTED
JOINT
10%
1/2
TOUCHUP>
- 68 -
CONNECTION
B-82545EN/04
8
2.MOUNTING DEVICES ON THE POSITIONER
Execute this program.
Push FWD key while pushing SHIFT key.
Then, the following screens are displayed. This shows the thing that KAREL P1HSET10.PC of
1000kg payload specification is executed.
This means specification is
SERVO-333
A1
USER
Power
off to
LINE 0
reset
T2 ABORTED
JOINT
10%
changed to payload 1000kg
specification.
1000kg
parameter set . ( GP :
1)
－－－－－－－－ WARNING －－－－－－－－－－
－ Path and Cycle Time is Changed ！！ －
－－－－－－－－－－－－－－－－－－－－－－－－－
Please
power
off
Please turn off the controller
power and turn it on.
9
Turn on the controller power again.
The change of the parameter ends above.
2.2.2
Method of executing KAREL program directly
Use scene
For instance, it is assumed that the following multi group systems exist.
1st group:
1-axis positioner
2nd group:
1-axis positioner
When the method of the explanation in this chapter is used to do 1-axis positioner of the 1st group and 2nd
group here to 1000kg payload specification, it is possible to set the 1st group and 2nd group to the parameter
of an acceptable 1000kg payload specification at the same time.
NOTE
If you want to 1-axis positioner of 1st group to 1000kg payload specification and 1-axis positioner of 2nd
group to 1500kg payload specification, Method of this chapter cannot be used.
In that case, please make two programs as follows, and do the parameter change by the method of Chapter 1.
1
2
Turn on the controller power again after executing the program 1.
Turn on the controller power again after executing the program 2.
- 69 -
2.MOUNTING DEVICES ON THE POSITIONER
CONNECTION
Example of program
1st group is Max
payload 1000kg
specification
Program 1:
1:
B-82545EN/04
call P1HSET10(１)
Program 2:
1:
call P1HSET15(２)
2nd group is Max
payload 1500kg
specification
Execution procedure
1
Call the system variable screen.
MENU key
2
3
→
Press F1 key (screen) after selecting “system”→
Select system variables
Set system variables $KAREL_ENB to 1.
Call program select screen and select “
program select key→ select KAREL by F1 key （type）
Then, three KAREL programs are displayed as follows.
A1
Select
T2 ABORTED
G1
JOINT
10%
710186 bytes free
1/7
No .
Program name
Comment
1 GEMDATE
PC [ GEM Vars
]
2 GET_HOME
PC [ Get Home Pos
]
3 P1HSET10
PC [ 1000kg payload
]
4 P1HSET15
PC [ 1500kg payload
]
5 MEM_PORT
PC [
]
6 PSCOLD
PC [
]
[ TYPE ]
4
LINE 0
CREATE
DELETE
MONITOR
[ ATTR ] >
Match the cursor to the KAREL program of the load that wants to be set, and push the ENTER key. It
is time when it selected P1HSET10.PC that is KAREL of 1000kg payload specification as follows.
The selected program name is displayed to two places as follows.
P1HSET10
Select
Selected program name is
shown.
LINE 0
T2 ABORTED
G1
JOINT
10%
710186 bytes free
3/7
No .
Program name
Comment
1 GEMDATE
PC [ GEM Vars
]
2 GET_HOME
PC [ Get Home Pos
]
3 P1HSET10
PC [ 1000kg payload
]
4 P1HSET15
PC [ 1500kg payload
]
5 MEM_PORT
PC [
]
6 PSCOLD
PC [
]
P1HSET10 is selected
[ TYPE ] CREATE DELETE
- 70 -
MONITOR
[ ATTR ] >
CONNECTION
B-82545EN/04
5
2.MOUNTING DEVICES ON THE POSITIONER
Execute the program.
Push FWD key while pushing SHIFT key.
Then, the following screens are displayed. This is case of executing KAREL P1HSET10.PC of Max
payload 1000kg specification.
This means 1st group is
changed
to
Max
payload
SERVO-333
P1HSET10
USER
Power
off to
LINE 0
reset
T2 ABORTED
JOINT
10%
1000kg specification.
This means 2nd group is
changed to Max payload
1000kg specification.
1000kg
parameter set . ( GP :
1)
1000kg
parameter set . ( GP :
2)
－－－－－－－－ WARNING －－－－－－－－－－
－ Path and Cycle Time is Changed ！！ －
－－－－－－－－－－－－－－－－－－－－－－－－－
Please
Please turn off the power
supply and turn it on.
6
Turn on the controller power again.
The change of the parameter ends above.
- 71 -
power
off
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
3
TRANSPORTATION AND INSTALLATION
3.1
TRANSPORTATION
The positioner can be transported by suspending it. For the 300 kg payload (Hollow type) or 300
kg/500kg payload (Hollow type), thread a rope through the M10 eyebolts. For the 1000 kg/1500kg
payload (Hollow type), thread a rope through the M16 eyebolts. For the 1000 kg/1500kg payload
(Compact type), thread a rope through the M12 eyebolts. (See Figs. 3.1 (a) to (c).) After installation,
remove transport equipment. In case of 1000 kg/1500kg payload (Compact type), a metal plate for
prevention of fall is attached when Harting option is selected, so remove it after installation.
CAUTION
When transporting a positioner, be careful not to damage a motor connector with a
sling for lifting the positioner.
CAUTION
When an end effector and peripherals are installed on a positioner, the center of
gravity of the positioner changes and the positioner might become unstable while
being transported.
If the positioner becomes unstable, remove the tooling and place the positioner
into the transportation position. This will position the unit center of gravity
correctly. It is recommended to transport the end effector and peripherals
separately from the positioner.
Do not pull the eyebolt horizontally.
Do not thread a chain or the like through the transport member.
Before moving the positioner by using transport equipment, check and tighten any
loose bolts.
- 72 -
CONNECTION
B-82545EN/04
3.TRANSPORTATION AND INSTALLATION
NOTE)
1.Weight of positioner : 85kg
2 Eyebolt complied with JIS B 1168.
3 Eyebolt 1pcs
4 When you transport positoner , take out all works.
Crane capacity min : 200kg (1960N) or greater
Sling capacity min : 200kg (1960N) or greater
Positioner posture
for transportation : Arbitrary
>200kg (1960N)
Transport
equipment
>200kg (1960N)
>150kg (1470N)
Fig. 3.1 (a) Carrying the positioner with a crane
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
NOTE)
1.Weight of positioner : 280kg
2 Eyebolt complied with JIS B 1168.
3 Eyebolt 1pcs
4 When you transport positoner , take out all works.
Crane capacity min : 600kg (5800N) or greater
Sling capacity min : 600kg (5800N) or greater
Positioner posture
for transportation : Arbitrary
>600kg (5880N)
Transport
equipment
>600kg (5880N)
>450kg (4410N)
Fig. 3.1 (b) Carrying the positioner with a crane (1000kg/1500kg payload (Hollow type))
- 73 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
NOTE)
1.Weight of positioner : 130kg
2 Eyebolt complied with JIS B 1168.
3 Eyebolt 1pcs
4 When you transport positoner , take out all works.
Crane capacity min : 400kg (3920N) or greater
Sling capacity min : 400kg (3920N) or greater
Positioner posture
for transportation : Arbitrary
>400kg
Transport
equipment
>400kg
>220kg
Fig. 3.1 (c) Transportation using a crane (1000kg/1500kg payload (Compact type))
CAUTION
When harting option (A05B-1220-J116) is not selected for 1000kg/1500kg payload
(Compact type) Install transport equipment option (A05B-1220-J103) to prevent
positioner from overturning.
3.2
STORING THE POSITIONER
When storing the positioner, keep it in the posture with the following NOTES.
NOTE
Before storing a positioner for a long term, take measures for securing the
positioner to prevent it from falling.
NOTE
The flange surface is likely to rust, so apply antirust oil to the flange surface to
save it for a long period of time.
3.3
INSTALLATION
(1) Before installation
Wipe oil off the flange because it is factory-oiled.
There is no insulated flange for 1000kg/1500kg payload (Compact type) (Spec : A05B-1220-J104)
and follower unit (non-insulated flange) (Spec : A05B-1220-J152), so it is necessary to prepare the
- 74 -
CONNECTION
B-82545EN/04
3.TRANSPORTATION AND INSTALLATION
structure for insulation by customer. Examine it referring to Fig.3.3 (a). Please pay attention not to do
conduction with a bolt fixing an insulation plate enough.
Washer for prevention
the cave-in of the bolt
Flange
Make clearlance.
Insulated plate
(bakelite etc.)
Fig. 3.3 (a) Structure for insulation
Fig. 3.3 (b) to (f) shows the dimensions of the base of the positioner main body and the follower unit.
182
182
A
51
143
47
A
2-O10H8 +0.022
0
貫通
THROUGH
29
47
6-O14
貫通
THROUGH
O 28
O 14
25 5
207
202
SECTION A-A
Fig. 3.3 (b) Dimensions of the base of the positioner main body
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
- 75 -
3.TRANSPORTATION AND INSTALLATION
297.5
CONNECTION
B-82545EN/04
297.5
B
4-O24
貫通
THROUGH
2-O10H8 +0.022
0
貫通
THROUGH
32
132
259
200
B
5
O 42
O 24
20
SECTION B-B
329.5
324.5
Fig. 3.3 (c) Dimensions of the base of the positioner main body (1000kg/1500kg payload (Hollow type))
220
6-O24
貫通
THROUGH
220
C
2-O10H8 +0.022
0
貫通
THROUGH
74.25
78
35.25
397.5
141.5
C
O 24
40
SECTION C-C
255
248
Fig. 3.3 (d) Dimensions of the base of the positioner main body (1000kg/1500kg payload (Compact type))
- 76 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
D
D
31
0
2-O10H8 +0.022
貫通
116
56
169
56
6-O18
貫通
M12ボルト使用 GTワッシャ使用
Use M12 bolts. Use GT Washer.
O 18
25
SECTION D-D
87
87
118
113
Fig. 3.3 (e) Dimensions of the base of the positioner follower unit (insulated flange)
155
155
123.5
78.5
123.5
20
41.5
83
25
12.5
E
12.5
25
E
20
40
32
40
SECTION E-E
Fig. 3.3 (f) Dimensions of the base of the positioner follower unit (non-insulated flange)
- 77 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
Fig. 3.3 (g) shows an example of installing the 300kg payload (Hollow type) or 300kg/500kg payload
(Hollow type) positioner and the follower unit (insulated flange). In this example, the sole plate is fixed
with four M20 chemical anchors (in strength category 4.8), and the positioner base is fastened to the sole
plate with six M12×40 bolts (in strength category 12.9). The follower unit base is fastened with six
M12×70 bolts (in strength category 12.9) and six GT washers.
When compatibility must be maintained in teaching the positioner mechanical unit replacement, use the
mounting surface.
NOTE
The customer shall arrange for the positioning pin, anchor bolts, and sole plate.
29 47
47
56
350
56 31
350
4-Φ24 THROUGH
FRONT
FRONT
413
(MOUNTING FACE)
174
(MOUNTING FACE)
409
900
364
318
50
INSTALLATION BOARD
(MOUNTING FACE)
(MOUNTING FACE)
(MOUNTING FACE)
POSITIONER MOUNTING BOLT
M12X40(6pcs)
STRENGTH CLASSIFICATION:12.9
TIGHTTENING TORQUE:110 Nm
200
CHEMICAL ANCHOR
M20(4PCS)
STRENGTH CLASSIFICATION:4.8
TIGHTENING TORQUE:186.2 Nm
50
FOLLOWER UNIT BASE
FOLLOWER UNIT BASE MOUNTING BOLT
M12×70(6PCS)
STRENGTH CLASSIFICATION:12.9
TIGHTENING TORQUE:128.4 Nm
GT WASHER (6PCS)(NOTE 2)
32
2400
POSITIONER BASE
Fig. 3.3 (g) Example of installing the positioner
(300kg payload (Hollow shaft)), (300kg/500kg payload (Hollow shaft)) and follower unit (insulated flange)
NOTE
- Install the positioner and follower unit so that their axial centers are aligned. For
the installation, follow the guidelines provided by the contractor and use a level or
three-dimensional measuring instrument to ensure that the positioner and follower
unit are centered.
The allowable moment for the reducer is 2,450 N . m (250 kgf . m). Install the
reducer so as not to exceed the allowable moment by placing the reducer
off-center.
- Be sure to use the supplied GT washers for the installation of the follower unit.
- 78 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
Fig. 3.3 (h) shows an example of installing the 300kg payload (Hollow type) or 300kg/500kg payload
(Hollow type) positioner and the follower unit (non-insulated flange). In this example, the sole plate is fixed
with four M20 chemical anchors (in strength category 4.8), and the positioner base is fastened to the sole
plate with six M12×40 bolts six M12×50or (in strength category 12.9). The follower unit base is fastened
with two M20×50 bolts (in strength category 12.9).
When compatibility must be maintained in teaching the positioner mechanical unit replacement, use the
mounting surface.
NOTE
The customer shall arrange for the positioning pin, anchor bolts, and sole plate.
350
29 47
47
308.5
350
4-Φ24 through
Front
Front
247
(Mounting face)
409
900
364
318
50
Installation board
(Mounting face)
(Mounting face)
2400
50
Follower unit base
Positioner base
Positioner mounting bolt
M12X40(6 pcs) (*1) or
M12X50(6 pcs) (*2)
Strength classification : 12.9
Tightening toruqe : 110 Nm
200
32
Chemical anchor
M20(4 pcs)
Strength classification:4.8
Tightening torque:186.2 Nm
Follower unit mouting bolt
M20×50(2 pcs)
Strength classification : 12.9
Tightening torque : 530 Nm
(*1) 300kg payload (Hollow type)
(*2) 300kg/500kg payload (Hollow type)
Fig. 3.3 (h) Example of installing the positioner
(300kg payload (Hollow shaft)),(300kg/500kg payload (Hollow shaft)) and follower unit
(non-insulated flange)
NOTE
- When the follower unit is installed in the customer site, the axial centers of the
positioner and follower unit must be aligned. For the installation, follow the
guidance provided by the contractor and use a level or three-dimensional
measuring instrument to ensure that the positioner and follower unit are centered.
The allowable moment for the reducer is 20,580 N×m (2100 kgf×m). Install the
follower unit so that the allowable moment is not exceeded because it is placed
off-center.
- 79 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
Fig. 3.3 (i) shows an example of installing the 1000kg/1500kg payload capacity type positioner and
follower unit (insulated flange).
In this example, the sole plate is fixed with four M20 chemical anchors (in strength category 4.8), and the
positioner base is fastened to the sole plate with four M20×40 bolts (in strength category 12.9). The
follower unit base is fastened to the sole plate with six M12×70 bolts (in strength category 12.9).
When compatibility must be maintained in teaching the positioner mechanical unit replacement, use the
mounting surface.
NOTE
The customer shall arrange for the positioning pin, anchor bolts, and sole plate.
32 100 100
56
(Mounting face)
56 31 319
4-Φ24 through
230
50
Installation board
(Mounting face)
174
Front
Front
595
900
(Mounting face)
(Mounting face)
(Mounting face)
2400
50
Follower unit base
Positioner base
Positioner mounting bolt
M20X40(4 pcs)
Strength classification : 12.9
Tightening toruqe : 450 Nm
Follower unit mouting bolt
M12×70(6 pcs)
Strength classification : 12.9
Tightening torque : 110 Nm
GT washer (6 pcs)(Note 2)
200
32
Chemical anchor
M20(4 pcs)
Strength classification:4.8
Tightening torque:186.2 Nm
Fig. 3.3 (i) Example of installing the positioner
(When using 1000kg/1500kg payload (Hollow shaft) and follower unit (insulated flange)
NOTE
- Install the positioner and follower unit so that their axial centers are aligned. For
the installation, follow the guidelines provided by the contractor and use a level or
three-dimensional measuring instrument to ensure that the positioner and follower
unit are centered.
The allowable moment for the reducer is 2,0580 N . m (2100 kgf . m). Install the
reducer so as not to exceed the allowable moment by placing the reducer
off-center.
- Be sure to use the supplied GT washers for the installation of the follower unit.
- 80 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
Refer to Table 3.3 (a) about size of bolt, number, and tightening torque.
Table 3.3 (a) Base mounting bolts of positioner and follower unit
Model
Mounting
bolt
Q’ty
Tightening
torque [Nm]
300kg
300kg/500kg
1000kg/1500kg
payload
payload
payload
1000kg/1500kg
Follower unit
Follower unit
（non-insulated
（insulated flange）
flange）
(Compact type)
(Hollow type)
(Hollow type)
(Hollow type)
M12
M12
M20
M20
M12
M20
6
6
4
4
4
2
110
110
450
530
110
530
payload
NOTE
When 1-axis servo positioner or .follower unit (with insulated flange) only is used
on wall mount. We recommend to use 2 parallel pins to pin holes.
Matching the center of 1-axis positioner and follower unit
Example of matching the center is shown below. Match the center of 1-axis positioner and follower unit
referring to below.
When the parallel degree of hardness and the installation side of a footstool installing 1 axis positioner and
follower unit is bad, 1 axis positioner and follower unit give off vibration and allophone at the time of
driving, and it becomes the cause that you invite damage for the early stage.
1
2
3
4
5
6
Install 1-axis positioner and follower unit to common footstool and perform leveling.
Insert fixture which you can confirm hollow hole of follower unit. (See Fig.3.3 (j))
Rotate the positioner and confirm that a change of laser floodlight equal to or less than 0.5mm at 1m
Set a projection of the light device to flange surface of drive side so that it is vertical to flange and it is
near rotation center.
Rotate the positioner and adjust the position of follower side so that match the position of rotation
center of light of projection of the light device and rotation center of follower side. If laser light
penetrate fixture for matching position, you can confirm matching position is performed.
Move the position of fixture to the depth of hollow hole to adjust the degree of leaning .
And adjust it to match the center.
- 81 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
A
Follower unit
B-82545EN/04
A
1-axis positioner
Laser light
Mounting fixure
(follower unit side)
Mounting fixture
(positioner side)
A laser floodlight
Section A-A
Fig.3.3 (j) Example of matching the center of 1-axis positioner and follower unit
- 82 -
B-82545EN/04
3.TRANSPORTATION AND INSTALLATION
CONNECTION
Assemble fixture of positioner side referring to Fig.3.3 (k).
Screw
M4X8 (3)
Bolt
M4X20 (3)
Laser floodlight
Holder
A290-7220-X971
Adapter
A290-7220-X972 (for 300kg payload (Hollow type) or 300kg/500kg payload (Hollow type))
A290-7220-X973 (for 1000kg/1500kg payload (Hollow type)
A290-7220-X974 (for 1000kg/1500kg payload (Compact type)
Fig.3.3 (k) Installation of fixture of positioner side
Fig.3.3 (l) to (o) shows example of fixture for matching the center. Fixture (positioner side) is installed to a
projection of the light device by insertion. Fixture (follower unit side) is installed to pipe by insertion.
64.5
3-O6 THRU
EQ.SP
14
(9 ) 5
+0.1
0
3-M4 THRU
A
貫通
周上等配
断面
13.7
+0.1
0
(5 )
THRU
EQ.SP
SECTION
( 34 )
20
9
62
14
14
17
SECTION A-A
Fig.3.3 (l) Holder (Spec: A290-7220-X971)
- 83 -
A
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
A
10
THRU
EQ.SP
SECTION
-0.15
-0.20
O 113
O 40
3-M4 THRU
EQ.SP
貫通
周上等配
断面
SECTION A-A
A
Fig.3.3 (m) Adapter for 300kg payload (Hollow type),300kg/500kg payload (Hollow type)
(Spec:A290-7220-X972)
B
10
O 40
-0.15
O 160 -0.20
3-M4 THRU
EQ.SP
THRU
EQ.SP
SECTION
貫通
周上等配
断面
SECTION B-B
B
Fig.3.3 (n) Adapter for 1000kg/1500kg payload (Hollow type) (Spec:A290-7220-X973)
10
THRU
EQ.SP
SECTION
-0.15
-0.20
A
O 100
O 40
3-M4 THRU
EQ.SP
貫通
周上等配
断面
SECTION A-A
A
Fig.3.3 (o) Adapter for 1000kg/1500kg payload (Compact type) (Spec:A290-7220-X974)
- 84 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
20
.2 0
-0 0.25
-
A
O
65
B
C
O2
SECTION
断面
a O 0.03 B
A
n 0.05 C
SECTION A-A
Fig.3.3 (p) Adapter for follower unit (insulated flange) (Spec:A290-7220-X975)
20
.20
-0 0 .2 5
-
A
O
67
C
B
SECTION
O2
断面
a O 0.03 B
A
n 0.05 C
SECTION A-A
Fig.3.3 (q) Adapter for follower unit (non-insulated flange) (Spec:A290-7220-X976)
Laser floodlight is assumed below.
KOCHI TOYONAKA GIKEN CO.LTD TYPE : GLM-A2 or GLM-A3
Refer to Fig.3.3 (r) about permissible angle of inclination of 1-axis positioner and follower unit.
If angle of inclination is more than it , it cause reduction life of 1-axis servo positioner and follower unit.
ang
le o
f in
clin
ati
on
Permissible angle of inclination : 4min (0.067°)
Fig.3.3 (r) Permissible angle of inclination of positioner and follower unit
- 85 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
When inserting fixture to follower unit (non-insulated flange), Insert fixture after removing sleeve of he
side where flange does not come with referring to 3.3 (s).
Remove this sleeve
and insert fixture.
Fig.3.3 (s) Removing the sleeve of follower unit (non-insulated flange)
Fig. 3.3 (t) and Table 3.3 (b) to (e) explain what load is put on the base when the positioner is at a rest,
accelerating or decelerating, and at a Power-Off stop.
Fig. 3.3 (t) Load and moment applied to the base
State
At rest
Accelerating or
decelerating
At a Power-Off stop
Table 3.3 (b) Load and moment applied to the base 300kg payload
(300kg payload (hollow type)) , (300kg/500kg payload (Hollow type))
MV
FV
MH
[Kg・m]
(N・m)
[Kg・m]
(N・m)
[Kg]
(N)
FH
[Kg]
(N)
36
353
385
3773
0
0
0
0
200
1961
411
4024
24
236
26
251
334
3276
432
4230
44
430
47
457
- 86 -
3.TRANSPORTATION AND INSTALLATION
CONNECTION
B-82545EN/04
State
At rest
Accelerating or
decelerating
At a Power-Off stop
Table 3.3 (c) Load and moment applied to the base 500kg payload
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type))
MV
FV
MH
[Kg・m]
(N・m)
[Kg・m]
(N・m)
[Kg]
(N)
FH
[Kg]
(N)
60
588
585
5733
0
0
0
0
227
2221
613
6005
17
165
28
272
439
4300
648
6352
38
376
63
619
Table 3.3 (d) Load and moment applied to the base 1000kg payload
(1000kg/1500kg payload (Hollow type) , (1000kg/1500kg payload (Compact type)
MV
FV
MH
FH
State
[Kg・m]
(N・m)
[Kg・m]
(N・m)
[Kg]
(N)
[Kg]
At rest
Accelerating or
decelerating
At a Power-Off stop
1568
1280
12544
0
0
0
0
407
3989
1365
13377
193
1891
85
833
741
7262
1481
14514
455
4459
201
1970
Table 3.3 (e) Load and moment applied to the base 1500kg payload
(1000kg/1500kg payload (Hollow type) , (1000kg/1500kg payload (Compact type)
MV
FV
MH
FH
State
[Kg・m]
(N・m)
[Kg・m]
(N・m)
[Kg]
(N)
[Kg]
At rest
Accelerating or
decelerating
At a Power-Off stop
(N)
160
(N)
200
1960
1585
15533
0
0
0
0
384
3760
1638
16057
15
143
53
524
700
6858
1731
16961
40
391
146
1428
- 87 -
3.TRANSPORTATION AND INSTALLATION
3.4
CONNECTION
MAINTENANCE CLEARANCE
Fig. 3.4 (a) and (b) show the layout of maintenance clearances.
600
450
450
500
Fig. 3.4 (a) Maintenance clearance layout
(300kg payload (Hollow type)) , (300kg/500kg payload (Hollow type)) ,
(1000kg/1500kg load capacity (Compact type))
- 88 -
B-82545EN/04
B-82545EN/04
CONNECTION
3.TRANSPORTATION AND INSTALLATION
800
570
570
500
Fig. 3.4 (b) Maintenance clearance layout (1000kg/1500kg payload (Hollow type))
- 89 -
3.TRANSPORTATION AND INSTALLATION
3.5
CONNECTION
B-82545EN/04
ASSEMBLING THE POSITIONER FOR INSTALLATION
The robot connection cables are detached from the mechanical unit when the robot is shipped (the cables are
connected on the controller side). When the HARTING connector option is not selected, directly connect
the cable for direct motor connection to the motor connector.
When the HARTING connector option is selected, connect the cables shown in Fig. 3.5 to the connector
box of the mechanical unit. During the connection, take care not to pull the HARTING connector cable.
In connecting cables between the robot controller and the positioner body, the customer needs to obtain
cable ducts or the like.
J7P
Connect the pulsecoder cable from the
controller.
J7M
Connect the power cable from the controller
Fig. 3.5 Cable connection panel for the positioner mechanical unit
3.6
INSTALLATION CONDITIONS
Refer to Specification of [PREFACE] about installation conditions.
- 90 -
APPENDIX
A
A.SPARE PARTS LISTS
APPENDIX
B-82545EN/04
SPARE PARTS LISTS
Cable No.
Table A (a) Cables (When the HARTING connector option is selected.)
Specifications
Remarks
Load capacity
K101
A660-8016-T096
Pulsecoder
K102
A660-8016-T097
Motor power, brake
K101
K102
K101
K102
A660-8016-T241
A660-8016-T243
A660-8017-T441
A660-8017-T442
Pulsecoder
Motor power, brake
Pulsecoder
Motor power, brake
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
1000kg/1500kg payload (Compact type)
Table A (b) Motor
Model
αiS8/4000
Specifications
A06B-0235-B605#S000
Load capacity
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
αiS22/4000
A06B-0265-B605#S000
Table A (c) Reducer
Weight
Specifications
A97L-0218-0805#37
A97L-0218-0819
A97L-0218-0891#37
A97L-0218-0889#171
20kg
91kg
20kg
45kg
Load capacity
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
300kg/500kg payload (Compact type)
1000kg/1500kg payload (Compact type)
Table A (d) Gear
Name
Specifications
Load capacity
A290-7216-X212
Center gear
A290-7220-X111
A290-7220-X151
A290-7220-Z111
Input gear
Input gear
Input gear
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
300kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
300kg/500kg payload (Hollow type)
Table A (e) Insulator , collar
Q’ty Use position
Model
Specifications
Name
A290-7220-X325
A98L-0040-0211#121512
A290-7220-X326
A98L-0040-0211#121512
A98L-0040-0222#30152
A290-7220-X144
A290-7220-Z325
A98L-0040-0211#121512
A290-7220-Z326
Insulator
Collar
Cover
Insulator A
Insulator B
Cover
Insulator
Collar
Cover
3
9
3
18
18
18
3
12
3
- 93 -
Flange
Flange
Flange
Flange
Flange
Flange
Flange
Flange
Flange
300kg payload (Hollow type)
300kg payload (Hollow type)
300kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
300kg/500kg payload (Hollow type)
300kg/500kg payload (Hollow type)
300kg/500kg payload (Hollow type)
A.SPARE PARTS LISTS
APPENDIX
B-82545EN/04
Table A (f) Bearing
Specifications
Load capacity
A97L-0001-0192#1600000
A97L-0001-0195#06Z000A
A97L-0001-0196#09Z000A
A97L-0218-0903#6306R
300kg/500kg payload (Hollow type)
300kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
300kg/500kg payload (Hollow type)
Table A (g) O ring
Use position
Specifications
JB-OR1A-G105
Motor
JB-OR1A-G95
Pipe
A98L-0040-0041#173
Reducer
JB-OR1A-G125
Motor, pipe
A98L-0040-0041#281
JB-OR1A-G270
Reducer
Reducer
Load capacity
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
Table A (h) Oil seal
Use position
Specifications
A98L-0040-0047#07010014
Pipe
A98L-0040-0047#13016014
Pipe
Load capacity
300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
1000kg/1500kg payload (Hollow type)
Table A (i) Grease
Name
Specifications
Load capacity
VIGOGREASE RE0 300kg payload (Hollow type)
300kg/500kg payload (Hollow type)
1000kg/1500kg payload (Compact type)
1000kg/1500kg payload (Hollow type)
A98L-0040-0174#1kg
A98L-0040-0174#4.9kg
Table A (j) Grease nipple
Specifications
Name
A98L-0218-0013#A110
Grease nipple (1/8)
Table A (k) Seal bolt
Parts name
Seal bolt
Taper plug
Specifications
A97L-0218-0417#121515
A97L-0001-0436#2-1D
Use position
Outlet 2 (300kg payload (Hollow type))
(300kg/500kg payload (Hollow type))
Outlet 1,2 (1000kg/1500kg payload (Hollow type))
Outlet 1 (300kg payload (Hollow type))
(300kg/500kg payload (Hollow type))
Inlet, Outlet (1000kg/1500kg payload (Compact type))
NOTE
For the locations of outlet 1 and 2, see I.MAINTENANCE 3.1.
Specifications
A98L-0031-0005
Table A (l) Battery
Name
1.5V, size D
- 94 -
Q’ty
4 pcs
B-82545EN/04
B
APPENDIX
B.CONNECTION DIAGRAMS
CONNECTION DIAGRAMS
Fig. B shows the circuit in the mechanical unit when the HARTING connector option is selected. When the
option is not selected, a direct connection is established from the motor.
- 95 -
B.CONNECTION DIAGRAMS
APPENDIX
B-82545EN/04
CONNECTOR PANEL
M7M
M TYPE
Han 15D
(2.5SQ 10A)
C1
C2
C3
C4
C5
B1 BK(J1)
B2 BKC(J1)
B3
B4
B5
G Ｇ
A1
A2
A3
A4
A5
K102
J1U1
J1V1
J1W1
J1G1
A66L-0001-0401#10
(1.25SQ*10C)Φ11.8
M7P
21
22
23
24
Han 24DD
(2.5SQ 10A)
M TYPE
17
18
19
20
13
14
15
16
6V
BT1
9 5V(A1)
10
11
12
5
6
7
8
0V(A1)
1
2
3 PRQJ1
4 XPRQJ1
K101
+
BATTERY
0V
BT1
-
Fig. B Connection diagram
- 96 -
A66L-0001-0464#1
(0.2SQ*4P)Φ6.7
B.CONNECTION DIAGRAMS
APPENDIX
B-82545EN/04
MOTOR (αiS8/4000) (*1)
(αiS22/4000) (*2)
J1
A63L-0001-0648#810SL3SJ
A63L-0001-0653#04A
M1 BK
A
BK(J1)
A63L-0001-0881#1810S
A63L-0001-0881#10C
M1 M
A J1U1
B
A63L-0001-0848#A10SL1
A63L-0001-0850
10SL-3P(1.25SQ 13A)
B BKC(J1)
C
18-10P
C J1W1
D J1G
J1V1
M1 P
8 5V(A1)
9
10 0V(A1)
10SL1(0.3SQ 3A)
4
5
6
7
6V(BT1)
XPRQJ1
PRQJ1
OV(BT1)
1
2
3
FG
(*1) 300kg payload 1-axis Servo Positioner (Hollow type) or
300kg/500kg payload 1-axis Servo Positioner (Hollow type)
(*2) 1000kg/1500kg payload 1-axis Servo Positioner (Hollow type) or
1000kg/1500kg payload 1-axis Servo Positioner (Compact type)
1-axis Servo Positioner
:MOVABLE
- 97 -
C.PERIODIC INSPECTION TABLE
C
APPENDIX
B-82545EN/04
PERIODIC INSPECTION TABLE
FANUC 1-AXIS SERVO POSITIONER
Working Check
time
time (H)
Item
Check the mechanical cable.
7680
8640
○
○
○
○
○
○
○
○
○
―
○
○
○
0.2H
―
○
○
○
4 bolt.
0.5H
―
○
○
○
5 Remove spatter and dust etc.
1.0H
―
○
○
○
6 Replacing battery. NOTE2)
0.1H
―
0.3H
980ml
1.0H
5500ml
0.3H
1193ml
Tighten the loosened flange
Tighten the cover and main
7
8
9
Replacing grease of reducer.
300kg payload (Hollow type)
300kg/500kg payload
(Hollow type) NOTE3)
Replacing grease of reducer.
1000kg/1500kg payload
(Hollow type) NOTE3)
Replacing grease of reducer.
1000kg/1500kg payload
(Compact type) NOTE3)
Check the robot cable, teach
pendant cable and robot
connecting cable
Cleaning the ventilator.
NOTE4)
10 Replacing battery NOTE5)
9600 10560
●
○
0.2H
0.2H
○
6720
0.2H
3 mounting bolts.
○
5760
○
Check the motor connector
○
2
years
―
2 (tightness).
Mechanical unit
Grease First
3
6
9
amount check months months months 1 year
320
960 1920 2880 3840 4800
0.2H
1 (damaged or twisted) NOTE1)
Controller
PERIODIC INSPECTION TABLE
○
○
○
○
○
○
○
○
○
○
○
0.1H
NOTE1) Check this when Harting connector option is selected.
The cycle of replacing is necessary to be shortened. Refer to MAINTENANCE 8 in replacing the cable.
NOTE2) Refer to the manual MAINTENANCE 3.3.
NOTE3) Refer to Fig. 3.1 (a) and (b) of the Section 3.1 in MAINTENANCE.
NOTE4) Clean the positioner properly in case of using the positioner under much dust existing.
NOTE5) Refer to the controller maintenance manual.
●:
requires order of parts
○: does not require order of parts
- 98 -
C.PERIODIC INSPECTION TABLE
APPENDIX
B-82545EN/04
3
years
4
years
5
years
6
years
7
years
8
years
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Items
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
1
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
●
●
●
●
●
●
●
●
●
○
○
○
○
○
○
○
○
○
○
○
○
●
○
○
●
○
6
7
○
○
Overhaul
○
○
○
○
○
○
8
○
○
○
9
10
- 99 -
D.STRENGTH OF BOLT AND BOLT TORQUE LIST
D
APPENDIX
B-82545EN/04
STRENGTH OF BOLT AND BOLT TORQUE LIST
NOTE
When applying LOCTITE to the important bolt tightening points, make sure that it
is applied to the entire longitudinal portion in the engaging section of the female
threads. If it is applied to the male threads, the bolts may be loosened because
sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps
and wipe oil off the engaging section. Make sure that there is no solvent in the
taps. Be sure to wipe the excess LOCTITE after tightening bolt.
Use bolt which strengths are below.
But if it is specified in text, obey it.
Hexagon socket head bolt made by steel
Size is M22 or less : Tensile strength 1200N/mm2 or more
Size is M24 or more : Tensile strength 1000N/mm2 or more
All size of bolt of the plating : Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc)
Tensile strength 400N/mm2 or more
If no tightening torque is specified for a bolt, tighten it according to this table.
Recommended bolt tightening torques
Nominal
diameter
M3
M4
M5
M6
M8
M10
M12
(M14)
M16
(M18)
M20
(M22)
M24
(M27)
M30
M36
Hexagon socket head
bolt
(Steel)
Tightening torque
Upper limit Lower limit
1.8
1.3
4.0
2.8
7.9
5.6
14
9.6
32
23
66
46
110
78
180
130
270
190
380
260
530
370
730
510
930
650
1400
960
1800
1300
3200
2300
Unit: Nm
Hexagon socket head
button bolt
Hexagon bolt
Hexagon socket head
Hexagon socket head
(steel)
flush bolt
bolt (stainless)
Low-head bolt
(steel)
Tightening torque
Tightening torque
Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
――――
――――
―――
0.76
0.53 ――――
1.8
1.3
1.8
1.3
1.7
1.2
3.4
2.5
4.0
2.8
3.2
2.3
5.8
4.1
7.9
5.6
5.5
3.8
14
9.8
14
9.6
13
9.3
27
19
32
23
26
19
――――
――――
48
33
45
31
――――
――――
76
53
73
51
――――
――――
120
82
98
69
――――
――――
160
110
140
96
――――
――――
230
160
190
130
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
――――
- 100 -
INDEX
B-82545EN/04
INDEX
<Number>
<O>
1.5-YEAR CHECKS (5,760 hours)..................................6
1-YEAR CHECKS (3,840 hours).....................................6
3-MONTH CHECKS (960 hours)....................................6
3-YEAR CHECKS (11,520 hours)...................................6
OUTLINE DRAWING AND OPERATION AREA
DIAGRAM.................................................................59
<P>
PERIODIC INSPECTION TABLE ...............................98
PERIODIC MAINTENANCE .........................................8
PIPING AND WIRING .................................................51
POSITIONER LOAD CONDITION .............................62
POSITIONER OUTLINE DRAWING ..........................59
PREFACE .................................................................... p-1
PREVENTIVE MAINTENANCE ...................................4
PROBLEMS AND CAUSES.........................................12
PROCEDURE FOR RELEASING THE GREASE
REMAINING PREESSURE ......................................10
<A>
ADJUSTMENTS ...........................................................21
ASSEMBLING THE POSITIONER FOR
INSTALLATION .......................................................90
<B>
BACKLASH MEASUREMENT ...................................18
BATTERY REPLACEMENT .......................................10
<C>
<Q>
CABLE REPLACEMENT.............................................52
CABLING (WHEN THE HARTING CONNECTOR
OPTION IS SELECTED)...........................................51
CHANGING METHOD OF PAYLOAD
SPECIFICATION.......................................................66
COMPONENT REPLACEMENT AND
ADJUSTMENT ITEMS .............................................20
COMPONENT REPLACEMENT AND
ADJUSTMENTS........................................................42
CONFIGURATION .........................................................3
Confirming Mastering ....................................................41
CONNECTION DIAGRAMS........................................95
Quick Mastering.............................................................34
<R>
REFERENCE POSITION AND MOVING RANGE ....21
REPLACING CABLES .................................................52
REPLACING THE MOTOR .........................................42
REPLACING THE REDUCER .....................................46
Resetting Alarms and Preparing for Mastering ..............23
<S>
SAFETY PRECAUTIONS ........................................... s-1
SEALANT APPLICATION
(1000kg/1500kg payload (Hollow type))
(1000kg/1500kg payload (Compact type)).................48
Single Axis Mastering....................................................36
SPARE PARTS LISTS ..................................................93
STORING THE POSITIONER......................................74
STRENGTH OF BOLT AND BOLT TORQUE LIST 100
<D>
DAILY INSPECTION .....................................................4
<F>
First 1-month (960 hours) checks.....................................5
First 3-MONTH CHECKS (960 hours)............................6
Fixture Position Master ..................................................23
<T>
<G>
TRANSPORTATION ....................................................72
TRANSPORTATION AND INSTALLATION.............72
TROUBLESHOOTING .................................................12
GENERAL .....................................................................12
GREASE REPLACEMENT ............................................8
<I>
<Z>
INSTALLATION...........................................................74
INSTALLATION CONDITIONS..................................90
Zero Position Mastering.................................................31
<M>
MAINTENANCE CLEARANCE..................................88
MAINTENANCE TOOLS...............................................6
MASTERING ................................................................22
Mastering Data Entry .....................................................39
Method of executing KAREL program by using “Call
program”.....................................................................67
Method of executing KAREL program directly.............69
MOUNTING DEVICES ON THE POSITIONER .........62
i-1
REVISION RECORD
B-82545EN/04
REVISION RECORD
Edition
Date
04
Dec., 2011
03
Oct., 2010
02
01
July, 2007
May, 2007
Contents
•
•
•
•
•
•
•
Addition of note about installation
Correction of mistakes
Addition of 300kg/500kg payload (Hollow type)
Addition of1000kg/1500kg payload (Compact type)
Change 1000kg load capacity to of1000kg/1500kg payload (Hollow type)
Correction of mistakes
Addition of 1000kg load capacity
r-1
B-82545EN/04
* B - 8 2 5 4 5 E N /
0 4 *