Home

HS-G SERIES INSTALLATION & MAINTENANCE GUIDE

1. Remove the lockout bar provided on the robot controller Step 2 Step 4 Padlock the lockout bar eee Step 3 Put the lockout bar on the upper side of the power switch D 18 Chapter 2 Customizing Your Robot 2 1 What Is Customization You may customize your robot by modifying or setting the following Software motion limits for defining the motion space Mechanical ends for defining the restricted space Control set of motion optimization Robot installation conditions You are recommended to define new motion space and restricted space in order to prevent interference with other devices or entanglement of the hand s wiring and piping WARNING Always set the software motion limits and mechanical ends so that the motion space will be within the restricted space Otherwise the robot will bump the mechanical stops causing serious accidents 2 2 Modifying Software Motion Limits to Define New Motion Space 2 2 1 What Is a Software Motion Limit A limit to the operation range of the robot defined by software is called a software motion limit Software motion limits become valid after CAL of the robot has been completed and the robot has entered the range set by the limits A mechanical motion limit is called a mechanical end and set by a mechanical stop To prevent the robot from striking against a mechanical stop each sof
2. 90 degrees Unless otherwise specified corners should be chamfered to C 0 3 to C 0 5 Recommended material S45C 28 Preparing mechanical stops 3 Axis Mechanical stops 2 C05 Material S45C Surface treatment Electroless nickel plating Dimensions Robot type HS HSS G HM HMS 40 G 10 kg payload 17 HM HMS 4A G 20 kg payload 20 Unit mm Two mechanical stop bolts per collar M5x18 plated hex socket head bolt strength class 10 9 29 2 3 3 Changing the Mechanical Ends According to the procedures given below set two mechanical stop bolts to the 1st axis a mechanical stop plate to the 2nd axis and a mechanical stop collar and two mechanical stop bolts to the 3rd axis After that change the software motion limits and RANG values refer to Sections 2 3 3 through 2 3 5 1 Changing the Ist axis mechanical ends Step 1 Move the 1st axis of the robot to bring the 1st arm stopper inside the restricted range that is to be set 1st arm stopper Mechanical stop bolt preset in No 1 position lt HS HSS G series gt 30 Step 2 In addition to the current mechanical stop bolt preset in No 1 position mount two mechanical stop bolts refer to Section 2 3 2 to the desired mechanical end positions Bolt specifications Hex socket head M8x16 SCM435 JIS G4105 HRC34 to 44 Tightening torque 19 1 9 Nm Caution Do not move the 1st axis beyond points A and A at the
3. 5 1 Battery Replacement Replace the two types of backup batteries listed below and inspect the timing belts on the 3rd and 4th axes every two years NCaution 1 The battery used in this device may present a risk of fire or chemical burn if mistreated Do not recharge disassemble heat above 100 C 212 F or incinerate 2 Dispose of used battery promptly Keep away from children Do not disassemble and do not dispose of in fire Types of Backup Batteries Back up the position data Encoder backup battery of the servomotor In the robot unit encoder Section 3 5 2 Back up programs Memory backup battery parameters and CAL data In the robot Section controller 3 5 3 The position data of the encoder contained in the servomotor is stored in the internal memory of the encoder Programs parameters CAL data etc are stored in the internal memory of the robot controller The backup battery for each memory retains the above data while the power to the robot controller is turned OFF However these batteries have a limited lifetime and must therefore be replaced regularly Caution Without replacing the backup batteries important robot specific data stored in each memory will be lost Check Items ower Timing belts on No lack of teeth or C ontact our Robot ples ie and 4th Visually excessive wear Service Section 66 3 5 2 Replacing the Encoder Backup Battery Replace the encoder backup ba
4. A 51 2A Perormine CALS Elia ceattes ath E ON EE E AE EE E AE E A E 53 2 5 Setting Control Set of Motion Optimization iscsceicg caswcdiacdsasuceassekbaseeensasevhoreereseenece EEA A EEE Faso 59 2 6 Setting Robot Installation Conditions sossuina aanotenneud Mautner a eee eee eee eens 59 Chapter 3 Maintenance and Ms pection iicisssscccsscissocssscecscasesviacsecesstessaeciessecseaswsviacsncesesiasquoue cdedessesusassoadeaspendbawesate ddsdebuste 60 3 1 Maintenance amp Inspection Intervals and Purposes cccccesssesesseesessssessssesssssssssssssssssesssssssssssssssaeeeeeesaaaas 60 3 1 1 Precautions for installation and maintenance of robots for clean room USE cc ceeecccccccceeeceeeeeeeeeeeeeeeeeeeees 60 De Daily TAS 1S CLO 10S sacs saeco cease ae ae a ea a ats eet eek eee 62 Dials CHECK MCS asenaan a N aa bac aanednes A 62 2a Quarterly INSPeCUOOS naasna n aude ee dente aaa a dane eee de ets 64 Ior Check kers and 1 DM CAO Msas oudeusniand nme ttunensed A a 64 3 3 2 Cleaning the Cooling Fan Filters in the Robot Controller ccccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeesseeeess 64 SA WSemilycatly IMS PCC ONS uzica aa a a et aad wen oem ea A ee Adena ane 65 Seal BRC AO cinch seret Mase sacdine a te chlin tod ee MSy uniaats MiaaAde Voahag i PeddeMi nets caita SMa veon teeta ued 65 Soe SIC MIM All MSE COONS sass iets cabs cttacs ones tes senaae sees abedeseac a a taser icc anatase daemons ees 66 3 Battery Repl
5. HSS G gt 35 b Changing the upper mechanical end Caution Never remove the upper mechanical end stopper preset at the factory Secure a mechanical stop collar you have prepared to the desired position of the 3rd axis shaft with two bolts Step 1 Tightening torque recommended 8 8 1 7 Nm At the lower section of the 3rd axis shaft is an upper mechanical end stopper that is preset at the factory for the maximum stroke If the stroke is 200 mm in the standard type of robots for example the z axis may move up to the position 246 mm above the floor To change from 246 mm to 100 mm set a mechanical stop collar 146 mm below the top of the upper mechanical stopper preset Use vernier calipers when measuring the distance iai srana udi 3rd axis BA shaft er ig Mechanical stop Can move up to this i collar to be prepared pan position before _ by the customer Sarl chan ge la c Floor Can move up to this position after change Upper mechanical end stopper preset at the factory lt Example of HSS G gt 36 Two bolts M5x18 to be prepared by the customer E Dust proof splash proof type and cleanroom type of HS HSS G series robots Changing the upper and lower mechanical ends a Changing the lower mechanical end Caution Never remove the lower mechanical end stopper preset at the factory Step 17 Loosen the clamp band at the bottom of the upper bello
6. Modifying Software Motion Limits to Define New Motion Space cccccccccccccccccceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 20 2 2 1 WhatIsaSottware Motion Limit oireeni E A E 20 2 2 2 Software Motion Limits Factory defaults oo cccccccsccccecececececeececeeeeeeeeccceeeeeeceeeeaeeeeeeeeeeeeeeeeeeeeeeeeess 21 2 25 hanging Soltware Moton Limits asec e RR 23 2 2 4 Precautions When Changing the Software Motion Limits 00 0 cccccccccccssscceccceecceecceeeceeeeeeeceeeeeeeeeeseeeeeeees 24 2 2 5 Procedure for Changing the Software Motion Limits cc cccccccssccsecccccececeecceceeeeeeeeeeeeeeeeeeeeeseeeeseseeseeess 24 2 3 Changing Mechanical Ends to Define New Restricted Spaerne rae iar EEEa 2 Zouk Whatisa Mechanical End Chante cs nctisedensdenaeseosengectndoncwenoclennsen E E teeta 21 25 2 Preparino mechanical Stops sauet E E E E A 21 2 5 5 Chaneme the Mechanical Ends seoir a seaweed ee 30 2 3 4 Setting the software motion limits and origin coordinates RANG ccccccccccccccceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 43 2 3 5 Changing Software Motion Limits and RANG Values ccccccccccccscsecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeesseeeeeeess 46 ZA Pernormmna CALSE T saga sesaeac easaaa ise aiea aaa da aeseansins aaa dane eee aaa seaad dw oaseaaees cade ase eed ee 50 Die i meh VG oe 1a Eo Od DE i T eminem Ome nme me CoCo ene me me NE ere ee ere ee Ree eee ee ere ace 50 2A Preparation tor CALSE T oerni O O aaa pale
7. into contact with nut end A and then rotate the flange so that the setscrew becomes aligned with the flat section of the T axis shaft 4 Gradually tighten the setscrew until it comes into contact with the flat section of the T axis shaft and the flange can be rotated without looseness Then torque the setscrew to 1 6 0 3 Nm 5 Tighten the fixing bolt M5x16 to 8 8 0 9 Nm for securing the flange Fixing bolt M5x16 Setscrew Flange Kit M4x6 Flange Flat section of T axis shaft Installing the Flange Kit HS HSS G 1 6 Engineering design Notes for Robot Hands Refer to the GENERAL INFORMATION ABOUT ROBOT for HS G SERIES Chapter 3 section 3 5 Precautions When Designing the End effectors 1 7 Moving Each Axis with Motor Power OFF in Emergency Stop This section describes how to move each axis with the motor power being OFF when the robot is in an emergency stop Note that moving the 3rd Z and 4th T axes requires releasing their brakes beforehand Warning Performing the brake release operation drops the Z axis Make sure beforehand that the release operation will not cause bodily injuries or equipment damages Moving the axes in an emergency stop How to move the axes Move the robot arm by hand For robot units except UL Listed ones 1 Reset the emergency stop state as follows If the emergency stop has been triggered by the teach pendant or mini pendant turn the Emergency stop button on
8. rst ENC set F19 F11 F12 Em al M Space RANG Brake lj ZBal caLser F3 Press F3 Brake 53 Step 4 5 The Brake release setting window appears as shown below Step 6 Confirm that there is no danger even if the arm falls as a result of the brake being released Then press OK 54 Step 7 The system message appears asking you whether you want to change the brake settings System Message es jy Press OK Step 8 The system message appears informing that the brake is released Press OK Step 9 Press the axis to be CALSET against the mechanical end in the CALSET position by hand 55 Step 10 Press F6 CALSET The Set CALSET window appears as shown below Step 11 1 Press the axis number to be CALSET to turn it on green For other axes that are not to be CALSET turn it off black Set CALSET Press OK 56 cp Do you want to carry out CALSET e Caution The robot reference position will be changed Cancel OK ENC set Jc Cancel OK Es e UU Press OK The system message appears informing that CALSET is successfully completed Step 13 Press OK Step 144 Press the ROBOT STOP button The robot brake becomes activated Step 15 Turn the ROBOT STOP button to cancel robot stop Step 161 Press the MOTOR key to turn the motor ON Caution A motor lock overload error may occur just after the power to the motor
9. switch will cause the 3rd axis to lower by the hand s weight Brake release switch for the 3rd axis Step 5T Move the 3rd axis shaft to the desired position where you want to set the mechanical end 3rd axis shaft Step 6 Release the brake release switch The brake comes on 34 E Standard type of HS HSS G series Changing the upper and lower mechanical ends a Changing the lower mechanical end Caution Never remove the lower mechanical end stopper preset at the factory Step 4 Secure a mechanical stop collar you have prepared to the desired position of the 3rd axis shaft with two bolts Tightening torque recommended 8 8 1 7 Nm At the top of the 3rd axis shaft is a lower mechanical end stopper that is preset at the factory for the maximum stroke If the stroke is 200 mm in the standard type of robots for example the z axis may move down to the position 46 mm above the floor To change from 46 mm to 100 mm set a mechanical stop collar 54 mm below the bottom of the lower mechanical stopper preset Use vernier calipers when measuring the distance Lower mechanical end stopper preset at the factory Mechanical stop collar to be prepared by the customer 3rd axis shaft Two bolts M5x18 to be prepared by the customer Can move down to this position after change Can move down to this position before change apa pewen p Floor lt Example of
10. the at the factory customer Floor lt Example of HSS G W gt 41 Step 4 Dust proof splash proof type Pull the bellows up to the original position and tighten 12 bolts removed in Step 1 with a hexagonal wrench Tightening torque recommended 1 6 0 3 Nm Cleanroom type Pull the bellows up to the original position and tighten the clamp band loosened in Step 1 with a flat screwdriver Tightening torque recommended 2 0 0 4 Nm Dust proof splash proof type Cleanroom type 42 2 3 4 Setting the software motion limits and origin coordinates RANG The table below lists the origin coordinates RANG and software motion limits that should be apply for each of 1st axis J1 mechanical stop positions If you add or change a mechanical stop position you need to change the and software motion limits and RANG to values listed below 1 Location of Mechanical Stops Software Motion Limits and RANG HS HSS E ese Note Values in parentheses apply to the HSS 4545 E Bolt No a No 2 No 3 No 4 No 5 No 6 No 7 No 8 No 9 No 10 No 11 Parameters parren E alale 1 1 1 152 122 92 62 32 2 158 128 98 68 38 8 m alela O Pamm e i i E a ea a Example 1 If you add a mechanical stop into No 2 position without removing the stop from No 1 position Change the software motion limit to 125 and RANG1 to 128 Example 2 If you add a mechanical stop into No 9 position without rem
11. 5 Ibs prepare a crane and forklift with a hoisting load of 0 2 ton or more 2 The overhead mounting job must be handled by at least two persons including a qualified operator for sling crane and forklift operation 3 Be sure to put on a helmet safety shoes and gloves Step 4 When unpacked the overhead mount robot unit is fastened with rope as shown below Make sure that the robot s 2nd axis arm cannot rotate Caution NEVER remove the 2nd axis arm fixing rope until the installation of the robot unit is completed This is to prevent the robot arm from rotating unexpectedly due to gravity 2nd axis arm fixing rope Step 2 As illustrated below wind the belt sling around the robot base two turns and make a knot on the side opposite to the power connector lt HSS G gt Step 3 Load the eyes of the belt sling on the hook of the crane Wire Belt sling lt Example of HSS G series gt Step 4 Remove the four bolts and release the robot unit from the pallet Caution When worker A is removing those bolts worker B should support the robot unit as shown below to prevent it from overturning Step 5 While keeping the robot posture slowly hoist the robot unit with the crane Caution Before starting this job make the work floor clear of obstacles Step 6 If the crane hoists the robot unit until it may be turned upside down stop the crane and have two workers turn the robot unit
12. DENSO ROBOT Horizontal articulated HS G SERIES INSTALLATION amp MAINTENANCE GUIDE Copyright DENSO WAVE INCORPORATED 2005 2010 All rights reserved No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher Specifications are subject to change without prior notice All products and company names mentioned are trademarks or registered trademarks of their respective holders Preface Thank you for purchasing this high speed high accuracy assembly robot Before operating your robot read this manual carefully to safely get the maximum benefit from your robot in your assembling operations Robot series and or models covered by this manual Model Note 1 Series Overall arm length HS 4535 G HS 4545 G HSS 4545 G HS 4555 G HSS 4555 G HS G Small sized horizontal articulated NOTE 1 Model names listed above apply to the models of robot systems The model names of robot units are followed by M If the robot system model is HS 4 E for example the robot unit model is HS 4 E GM the robot unit of E to G series Important To ensure operator safety be sure to read the precautions and instructions in SAFETY PRECAUTIONS How the documentation set is organized The documentation set consists of the following books If you are unfamiliar with this robot and option s please read all books and understand them fully before operating your
13. I V Local data v5 65776 100121 CEA Program CJE Source file O Executable file Map file w Cl variable w l Tool Work f Area V Parameter Arm parameters C 1 0 parameters Oe Program Parameters VSA Configuration H Cancel Controller CIS Controller 10 6 233 7 G3 Program JCS Source file OO Executable file Map file a variable w l Tool Work f Area Ja Log C Parameter Upon completion of transfer of the CALSET related arm data restart the robot controller 81 Horizontal Articulated Robot HS G SERIES INSTALLATION amp MAINTENANCE GUIDE First Edition July 2005 Sixth Edition April 2009 Seventh Edition March 2010 DENSO WAVE INCORPORATED 32M C The purpose of this manual is to provide accurate information in the handling and operating of the robot Please feel free to send your comments regarding any errors or omissions you may have found or any suggestions you may have for generally improving the manual In no event will DENSO WAVE INCORPORATED be liable for any direct or indirect damages resulting from the application of the information in this manual
14. LSET 1 CALSET of a Single Axis CALSETing a specified single axis only is called single axis CALSET Perform single axis CALSET if the motor of an axis is replaced so that the axis must be CALSET or if some axes cannot be moved to the CALSET positions mechanical stop positions at any given time because of interference between the robot unit and its surrounding facilities In the procedure below releasing the brake is required only for the 3rd and 4th axes Caution for performing single axis CALSET in HS G series The CALSET position of the 3rd axis is related with that of the 4th axis 1 Before performing the 3rd axis 4th axis CALSET move the 4th axis 3rd axis to the CALSET position 2 When performing the 3rd axis 4th axis CALSET perform the 4th axis 3rd axis CALSET at the same time Step 41 Move the axis to be CALSET to the mechanical end position E Brake releasing on UL Listed robot units On the UL Listed robot units press the brake release switch to release the brake and move the axis to the mechanical end in the CALSET position by hand After that skip to Step 10 Step 2 On the top screen of the teach pendant press F2 Arm Step 3 Press the SHIFT key and F12 Maint The Maintenance Functions Arm window appears as shown below 2 ss Jit wotelf x Maintenance Functions Arm aa A M Space RANG Brake dj ZBal CALSET F1 F2 F3 F4 CF6 o o 2 ENC inf ENC
15. Robot Position window press F12 Maint The Maintenance Functions Arm window appears as shown below mse Joint wotelf im Maintenance Functions Arm Wada 4 M Space RANG Brake Ad j ZBal CALSET F1 F2 F3 F4 CF6 s o 2 ENC inf ENC rst ENC set F19 F11 F12 m al M space RANG Brake Adj ZBa caLser F1 Press F1 M Space 46 Step 5 Step 6 Step 7 Step 8 Step 9 The Motion Space Software motion limit window appears as shown below W Y HS 45352 Joint wotolf n Motion Space Software motion limit 155 000 Software motion limit J2 145 000 Software motion limit J3 mm 246 000 Software motion limit J4 e 000 Software motion limit J5 mm 360 000 000 F5 Change the selection go Software motion limit J1 In the Motion Space Software motion limit window select the positive direction software motion limit of the target axis with the jog dial or cursor keys Press F5 Change The numeric keypad appears Using the numeric keys enter the positive direction software motion limit value then press OK The screen returns to the Motion Space Software motion limit window Press OK The screen returns to the Maintenance Functions Arm window 47 Changing the RANG Values Step 10 In the Maintenance Functions Arm window press F2 RANG The RANG window appears as shown bel
16. U Mil ate cat cccccl shits e ct A R al Sats Sas Ma ok he Stacia 10 LZA rounding he Robot Wit chee cess ccte a texte e sede E A O e 11 13 Installing tbe Roboti ontfoll ereas iea an a E O 11 1 4 Electrical Wiring and Air Piping of the Robot Unit cee eeceeeeeseeseeesesseeeeesseeeeeeeesseeeeeeesseseeeeeeeeeeeeeentaas 12 1 4 1 Notes for Wiring and Piping Through a Hollow in the Z axis Shaft cccccccssccccccccceeseseesssssnseeeeeeeeeeeeees 12 1 4 2 Reference Drawings for Stays that Clamp Wiring and Piping ccccccccccccccccccccceeseeeeeeeeeeeeeeesseeeeeseeeeeeeeeess 13 1 4 3 Prohibition Against Use of Mechanical End Bolts and Mechanical Stoppers for Wiring or Piping 14 Aa AP IDI SOL SOULCS A eseina a dM cetadinten okt at cess ceddies Ment seceed 15 1 lnstallino the Flange Kit Opuom ireas Ea outdated E a a staarenaednehehs 16 1 6 Engineering design Notes for Robot Hands 00000nonsnssnnesenseeneeseessnsnnssnsssssssssssssessssessssssssessssssesssssssssssssesssss 16 1 7 Moving Each Axis with Motor Power OFF in Emergency Stop cccccccsesesessessessessesesesessessseeeeeeeeeeeeseeeeees 17 1S Lockme Ourthe PO wero wc iis saci secre sce a deat Ne na cone aciie he Gee cee eee a tan 18 Chapter2 Customizing Your Rootsis avsivessssassassonsdcsvessencadcnvacdasesnatenscabsoosbeseddavonsescsunaeuscassacsocssenenassoascuscosenasseses 19 Zod Whal SC UStOnm ZAtlO ly vesae e a a a a 19 2 2
17. ace mic nt orar A E at eee 66 3 5 2 Replacing the Encoder Backup Battery cccccccccccccccscccecceceeceeeceeeecceeeeeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeess 67 3 0 0 Replacing the Memory Backup Battery lt geticicen ids sccpla tenet dep ae os cade e incite My cade EE RO 71 LIA soetuine the Next Battery Replacement Date isctascsi avhecadadteacgelas bacnsndetacwsiavlbacasndon sl au ceuhstasceiasievcdetacatlaiiescene 71 30 gt DUPPIES TOm Vi aiMlCN AN CC i dassrahorehaedonaasnacirtane deotardbetoruhar deneasneuninne seuleaive iinet nun asso a a 72 3 7 Replacine Puses and Output ICS erine a E a n eden 72 38 Checkime the Odometer and Trip Meter 2sc se e ve seesess saccades cdecesh nace oa Eai NES KEEA ATE AANEEN 73 3 8 1 Displaying the Odometer and Trip Meter sacsss 3shcsdecdean seat eeiccdcateedsaa baci iadees sak nd ee PAs 73 ISZ Resenine the Trip Merio Zero eoira A canes a A A 75 3 9 Checking the Controller ON Time and the Robot Running Time and Resetting Their User Counters 76 3 9 1 Displaying the Controller ON time and the Robot Running Time ccc cccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeess 76 3 9 2 Resetting the User Counters of the Controller ON Time and the Robot Running Time eccceees 78 510 Using the nitiali zation BLO ppy DISE steak eet ES EE EES E eae eee Oa 80 Chapter 1 Installing Robot Components 1 1 Preparing a Proper Environment for Installation Before installing the rob
18. adosteseanusssacuasnshooasnsscpesdautawsussdevassensatecconsudseadestodeaunneesdustuakesssususessdautucn a i How the documentation Set 18 orsanized oooi castdsuustcdnesvedsscenssacedsuets duvaviceseed dawtiweveusd dead dusdieseveuseudsassesvscawarssucesdic il HOW this DOOK IS OP SANIZEO sei dissvisscesevetcsetauecsecasvsdenenvedesevetsaweduaueusasvedevouvecesessevedideuteseeusasuelecauseisssetaedddectesetusareetdncasveeenes iii SAFETY PRECAUTIONS Chapter 1 Installing Robot Components sisisscicsscssccciedesaatnccedssdsesucdasncsededeaseasncccasedsesscdasnensauadecsaccctesdaccsceatauaueteassoceustedeees 1 1 1 Preparing a Proper Environment for Installation seess0 00 4sncseeesss vices sdacdeceads sade dines eeade vices sdaadeceadeseseeseeeadens eee adoass Lobb Ambient Temperature and Hvar yscioes cic a a a A aortas ad kena eee ena l hn NiD OI are ne e E E E E e EE 1 1 1 3 Connecting the Robot Unit and Robot Controller 2 0 00 ccccccccssseeseeeeeeeeeeeeceaceeeeeeeceeeeeeeeeceeeeeeeeeeeeeeeees l 1 1 4 Installation Environment of the Robot Unit 2 0 cccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeees 2 L2 Moonin aAhe RODO UN enian a een ne ne a Eee ah aaer eee een ane meee een eee een anes 4 12 1 Transporting the FloomMount Types acna sa es ag aga gol as al eco 4 1 2 2 Transporting the Overhead Mount Type HSS G Series 0 cccccccccccccccseceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeesesesseeeeeees 6 123 SC CUI Che Ropo
19. al stop collars you prepare Caution The 3rd axis Z axis has a brake The brake releasing operations differ between the UL Listed robot units and other ones Releasing brake on robot units except UL Listed ones 1 Use a brake release command with the teach pendant or mini pendant 2 In direct teaching mode press the brake release switch provided on the top of the 2nd arm This procedure is used in the procedure given below Releasing brake on UL Listed robot units Press the brake release switch when the controller power is ON Note The UL Listed robot units cannot release the brake with the teach pendant or mini pendant or support the direct teaching mode E Preparation common to the HS HSS G series Step 1 Prepare a pair of mechanical stop collars and two mechanical stop bolts To be prepared by the customer Refer to Section 2 3 2 Step 2 l Turn the controller power ON Step 3 For UL Listed robot units skip to Step 4 For other ones perform this step Place the robot controller in direct teaching mode as follows On the teach pendant set the mode switch to the MANUAL position and make sure that the motor is off Then press F2 Arm F6 Aux F3 Direct OK 33 Step 4 Hold down the brake release switch for the 3rd axis Only while the switch is held down the brake is released Caution Be careful with the robot motion when pressing the brake release switch Releasing the brake with the
20. and ends respectively Do not remove the mechanical stop bolt preset in No 1 position Doing so may damage wirings inside the robot unit lt HS HSS G series gt No 1 1 No 1 Nos 1 through 11 Stop positions Connector side Mechanical Ends at Bolt Positions Values in parentheses apply to the HSS 4545 G Positive Negative Positive Negative direction direction direction direction Began Ja ea B 128 124 B 128 124 08 04 142 1460 D 6e name D onz cne r N S Sr 34 82 86 E 82 86 38 34 8 4 52 56 F 52 56 8 4 NOTE Software motion limits should be 2 to 3 inside the mechanical end positions 31 2 Changing the 2nd axis mechanical ends You may change the 2nd axis mechanical ends to arbitrary positions by using a mechanical stop plate you prepare Step 4 Prepare a mechanical stop plate To be prepared by the customer Refer to Section 2 3 2 Step 2 Remove the two stopper bolts Stopper bolts lt HS HSS G gt Step 3 Secure the mechanical stop plate you have prepared in Step 1 with two stopper bolts removed in Step 2 Tightening torque 9 8 1 9 Nm Mechanical stop plate lt Example of HS G gt 32 3 Changing the 3rd Z axis mechanical ends HS HSS G series You can change the 3rd axis mechanical ends to arbitrary positions by using a pair of mechanic
21. aster Control Parameters of the Payload Center of Gravity and Control Set of Motion Optimization 2 6 Setting Robot Installation Conditions Depending on whether the robot is floor mounted or overhead mounted the optimum operating conditions differ However as for horizontal articulated type the HS G series floor mount type and HSS G series overhead mount type the installation conditions are preset at the factory You do not need to change the factory default of the installation settings 59 Chapter 3 Maintenance and Inspection 3 1 Maintenance amp Inspection Intervals and Purposes The table below lists the intervals and purposes of maintenance amp inspection required for your robot Maintenance amp Inspection Intervals and Purposes pe mera vooo Daily before Inspection jobs specified To use your robot safely starting in Section 3 2 operations Quarterly Inspection jobs specified To maintain the precision of the robot and to prevent in Section 3 3 failures caused by overheat of the robot controller Semiyearly Inspection jobs specified To check the rotary sections and slideways of the in Section 3 4 robot and its controller for wear preventing seizure breakage and other serious failures that could result from wear 4 Biennial Replacement of backup To retain the position data stored in the electronic batteries and inspection absolute encoders built in the robot unit and the of timing belts specifi
22. atment Galvanizing HS HSS G series 1 4 3 Prohibition Against Use of Mechanical End Bolts and Mechanical Stoppers for Wiring or Piping Never remove the 1st or 2nd axis mechanical end bolts or 3rd axis mechanical stoppers shown below or use them for securing a stay that clamps wiring or piping Doing so may result in the following problems The CALSET initial position will be deviated when CALSET is performed software limits will become invalid the robot arm will fail to run as programmed the robot arm will interfere with its peripheral devices and so on SS Z 2nd axis mechanical 3rd axis mechanical 1st axis mechanical end bolt stoppers end bolt For HS G series 1 4 4 Piping of Source Air The robot unit is equipped with four air pipes two of 4 mm and two of 6 mm in diameter for controlling hands The maximum of the source air pressure is listed below Apply dry air to the robot unit Apply dry air Air piping joint PT 1 8 Air piping joint PT 1 4 Air Piping of the Robot Unit HS HSS G 1 5 Installing the Flange Kit Option The flange kit consists of a flange fixing bolt M5x16 and setscrew M4x6 Install the flange to the T axis shaft according to the procedure below 1 Wipe off oil from the circumference of the T axis shaft which the flange should be fitted on 2 Loosen the setscrew of the flange so that the flange can be fitted on the T axis 3 Push the flange until it comes
23. djustment easy 4 Position related data in some programs made before CALSET may vary somewhat after CALSET NOTE When CALSETing the 4th axis of the dust amp splash proof type or cleanroom type you need to pull down the lower bellows for setting the CALSET bolt 51 What is a CALSET position The limit position of an axis to be CALSET is called a CALSET position Each axis has a mechanical end in each of the positive and negative directions The CALSET to be carried out before shipment uses mechanical ends shown below as CALSET positions 1 CALSET position HS HSS G series Mounting CALSET bolts on the 4th axis To CALSET the 4th axis you need to mount two CALSET bolts on the axis As illustrated below the CALSET bolts are built in the robot unit so remove them and set them up into the specified positions After completion of CALSET put them back into place Turning end in the positive direction counterclockwise end when viewed from the top Cc 2 2nd axis Turning end in the negative direction clockwise end when viewed from the top Upper end in the positive direction Turning end in the positive direction counterclockwise end when viewed from the top CALSET bolts 2 bolts for 4th axis J1 stopper bolt Do not remove this stopper bolt External appearance CALSET Bolt built in the robot unit Les 4th axis T CALSET Positions at Shipment HS HSS G series 52 2 43 Performing CA
24. e space is maintained for safe teaching maintenance and inspection 3 3 3 4 3 5 3 6 3 7 3 8 Control devices outside the robot s restricted space Positioning of gauges Protection of electrical wiring and hydraulic pneumatic piping Grounding resistance Positioning of emergency stop switches Positioning of operating status indicators The robot controller teach pendant and mini pendant should be installed outside the robot s restricted space and in a place where you can observe all of the robots movements and operate the robot easily Pressure gauges oil pressure gauges and other gauges should be installed in an easy to check location If there is any possibility of the electrical wiring or hydraulic pneumatic piping being damaged protect them with a cover or similar item The protective grounding resistance of the robot power supply should not be more than 1000 Emergency stop switches should be provided in a position where they can be reached easily should it be necessary to stop the robot immediately 1 The emergency stop switches should be red 2 Emergency stop switches should be designed so that they will not be released after pressed automatically or mistakenly by any other person 3 Emergency stop switches should be separate from the power switch Operating status indicators should be positioned in such a way where workers can easily see whether the robot is on a temporary ha
25. echanical end by hand Step 3 Press F2 Arm on the top screen of the teach pendant The Current Robot Position window appears as shown below Step 5 In the Current Robot Position window check the value in each of J1 through J4 boxes that appears when each axis is in contact with the mechanical end in Step 4 The value is RANG value to be newly set Mechanical End Positions and Software Motion Limits to be Set J1 through J3 set each software motion limit as follows 1st axis J1 3 inside from the mechanical end 2nd axis J2 2 0 inside from the mechanical end 3rd axis J3 4 mm inside from the mechanical end CAUTION If the software motion limits are set to less than the values specified above the robot arm may bump against the mechanical stops before it stops by software 45 2 3 5 Changing Software Motion Limits and RANG Values The procedure below describes how to change positive direction mechanical ends as an example If you change the positive direction mechanical ends you need to change the preset positive direction software motion limits PLIMs and RANG in succession according to Steps 1 through 15 given below Changing Positive Direction Software Motion Limits PLIMs Step 1 l Set the power switch of the robot controller to ON Step 2 l Set the mode selector switch of the teach pendant to MANUAL Step 3 Press F2 Arm on the top screen The Current Robot Position window appears Step 4 In the Current
26. ed robot specific data programs parameters etc In Section 3 5 stored in the internal memory of the robot controller To maintain the precision of the robot motion N Caution Before performing maintenance and inspection jobs read the SAFETY PRECAUTIONS 4 Precautions while Robot is Running and 5 Daily and Periodical Inspections 3 1 1 Precautions for installation and maintenance of robots for clean room use Notes in handling the cleanroom type When carrying out maintenance or inspection jobs of the cleanroom type of robots in your cleanroom be sure to follow your dust proof job rules If you remove the covers from the robot controller or robot unit even the cleanroom type may scatter worn belt dust piping grease dust or dirt accumulating inside Jobs requiring special care m CALSET m Cleaning of cooling fan filters in the robot controller m Replacement of encoder backup batteries m Replacement of controller memory backup batteries m Inspection of timing belts m Replacement of controller fuses m Replacement of controller output ICs m Greasing 60 CAUTION When transporting or maintaining the cleanroom type of robot units take care not to apply an impact or shock to the cover section specified below An impact or shock applied to the cover section or the resulting deformed cover section may deteriorate the cleanliness performance No impact or shock is allowed on this cover section 61 3 2 Daily I
27. emergency stop ES o Note 2 The normal operation of the cooling fan is as shown on the next page 62 jad pru gt O lt x Air inlet Normal Operation of Cooling Fan Example of HS G 63 3 3 Quarterly Inspections 3 3 1 Check Items and Lubrication Check the items listed below every three months Quarterly Inspections Table ower Robot base Measure the No looseness Tighten the bolts to the specified torque mounting bolts tightening a torque with a Specified torque torque wrench 70 14 Nm Cooling fan filters OFF Visually No dust or dirt Clean the cooling fan in the robot filters Refer to Section controller 3 3 2 3 3 2 Cleaning the Cooling Fan Filters in the Robot Controller For the cleaning procedures of the air intake filter refer to the RC7M CONTROLLER MANUAL Section 6 4 Cleaning the Air Intake Filter 64 3 4 Semiyearly Inspections 3 4 1 Lubrication Apply the specified grease to the whole Z axis shaft as shown below every six months Lubrication Points and Lubricants HS HSS G series ee Lubricant so toni anne A Pageant Epinoc AP 1 PPY the grease to the whole Z axis lt Example of HS G gt NOTE When applying grease to the dust amp splash proof type or cleanroom type you need to pull up and down the upper and lower bellows on the Z axis shaft respectively Refer to Changing the 3rd Z axis mechanical end 65 3 5 Biennial Inspections 3
28. emory backup battery for instance use the arm data held in the initialization floppy disk for recovery Loading the arm data held in the initialization floppy disk into the WINCAPSIII project Start WINCAPSIII log on as a Programmer and create a project suitable for your robot model Choose Tool Arm parameters to display the Arm Parameter window Press Load and select the arm data WAM held in the floppy disk to load Arm Parameter Save the ARM Parameter Load the 4RM Parameter to current project 80 Step 2 Step 3 Configuring communication options for transfer of arm data from WINCAPSIII to the robot controller Choose Tool Option Communication tab Select Data send setting CALSET data and press OK Option setting General Editor communication Arm Monitor sampling tine A Robotik i Programi T Others Data send option 100 msec 100 msec 100 msec Note During ordinary operations the Data send setting CALSET data should be deselected If it is selected creating a new project and transferring arm parameters overwrites the CALSET related data in the robot controller with the transferred data causing errors in teaching positions Transferring arm data to the robot controller Choose Connect Transfer data to display the Transfer data window Select Parameters Arm parameters and Configuration CALSET then press Send Transfer data WINCAPS II
29. en reset to zero 19 3 9 Checking the Controller ON Time and the Robot Running 3 9 1 Time and Resetting Their User Counters You may check the robot controller ON time and the robot running time in the Total hours window of the teach pendant The Total hours window shows the following items Total operation Shows the grand total of the robot controller ON time counted after the controller leaves the factory Total running Shows the grand total of the robot running time counted after the robot leaves the factory Cumu operation Shows the total of the robot controller ON time counted after you reset the user counter to zero Cumu running Shows the total of the robot running time counted after you reset the user counter to zero Operation Shows the ON time of the robot controller counted after it is turned ON this time Running Shows the running time of the robot counted after the robot controller is turned ON this time Displaying the Controller ON time and the Robot Running Time Display the Maintenance window as shown below Access F6 Set F6 Maint from the top screen 2 a mam Join wotel 2m Maintenance c e 2 a 2 Total h Yersion Date Battery Odometer F1 F2 F3 F4 F5 Clr Data F7 Cancel Close this window A al Total h Version Date Battery Odoneter F1 Press F1 Total h 76 Step 2 The Total hours window appears as shown below Tota
30. he place of installation and to the content of the work Be sure to consult the opinions of related workers engineers at the equipment manufacturer and that of a labor safety consultant when creating these working regulations 4 2 Display of operation To prevent anyone other than the worker from accessing the start panel switch or the changeover switch by accident during operation display something to indicate it is in operation on the operation panel or teach pendant Take any other steps as appropriate such as locking the cover 4 3 Ensuring safety of When performing jobs within the robot s restricted space take workers performing any of the following steps to ensure that robot operation can be jobs within the robot s stopped immediately upon a malfunction restricted space 1 Ensure an overseer is placed in a position outside the robot s restricted space and one in which he she can see all robot movements and that he she is devoted solely to that task An emergency stop device should be activated immediately upon a malfunction Do not permit anyone other than the worker engaged for that job to enter the robot s restricted space 2 Ensure a worker within the robot s restricted space carries the portable emergency stop switch so he she can press it the emergency button on the teach pendant immediately if it should be necessary to do so 4 4 Inspections before Before starting work such as teaching inspect the followi
31. ife will become short 69 Step 8 Install the cover to the robot unit NOTE On the dust amp splash proof type or cleanroom type the cover has a packing for sealing Take care not to lose or pinch it Tightening toque Hex socket head bolt M3x8 1 6 0 3 Nem lt HS HSS G gt 70 3 5 3 3 5 4 Replacing the Memory Backup Battery For the replacing procedures of the memory backup battery refer to the RC M CONTROLLER MANUAL Section 6 5 Replacing the Memory Backup battery Setting the Next Battery Replacement Date After replacing the memory backup battery set the next battery replacement date from the teach pendant according to the following procedure NOTE This procedure cannot be performed with the operating panel NOTE Check that the system clock of the robot controller shows the correct date beforehand If it is incorrect the next replacement date will also become incorrect Step 1 l Step 2 Step Step 4 Step 5 On the top screen of the teach pendant press F6 Set The Settings Main window appears Press F6 Maint in the Settings Main window The Maintenance menu appears Press F4 Battery in the Maintenance menu The Next Battery Replacement Date window appears In the top of the window the current setting is displayed The date entry areas show the default replacement date that is two years later the current data at which you open this window assuming that the battery ser
32. ing items Odometer Shows the total distance of each axis traversed after the robot leaves the factory You cannot reset the odometer Trip meter Shows the distance of each axis traversed after you reset the trip meter to zero You can reset the trip meter by pressing F6 Reset in the Odometer window and following the guidance shown on the screen 3 8 1 Displaying the Odometer and Trip Meter Step 1 Turn the robot controller ON Step 2 On the teach pendant set the mode switch to the MANUAL position Step 3 On the top screen press F6 Set The Settings Main window appears as shown below M 2 a mrm sont woro x Settings Main o a e el 4 Load Log Mem Info Set Com Maint F1 F2 F3 F4 F5 CF6 B Options Save SaveFile CF7 CF8 CF9 Cancel Close this window aei Press F6 Maint 73 Step 4 The Maintenance menu appears as shown below Maintenance c e g Press F5 Odometer Step 5 The Odometer window appears as shown below Odometer In the above Odometer window the J1 J2 and J4 are expressed in number of revolutions and J3 in meter 74 3 8 2 Resetting the Trip Meter to Zero Step 1 Display the Odometer window as shown below Access F6 Set F6 Maint F5 Odometer from the top screen Odometer Press F6 Reset Step 2 The following message appears Odometer System Message Press the OK button The trip meter has be
33. intenance of the RC M controller It also describes interfacing with external devices system and user input output signals and I O circuits ERROR CODE TABLES List error codes that will appear on the teach pendant or mini pendant if an error occurs in the robot system These tables also provide detailed description and recovery ways OPTIONS MANUAL Describes the specifications installation and use of optional devices For the extension board conveyer tracking board refer to the OPTIONS MANUAL SUPPLEMENT How this book is organized This book is just one part of the robot documentation set This book consists of SAFETY PRECAUTIONS chapters one through three SAFETY PRECAUTIONS Defines safety terms and related symbols and provides precautions that should be observed Be sure to read this section before operating your robot Chapter 1 Installing Robot Components Provides information about physical site planning installation procedures and engineering design notes for hands Chapter 2 Customizing Your Robot Describes how to customize your robot defining the software motion space and restricted space CALSETing and setting control set of motion optimization Chapter 3 Maintenance and Inspection Describes the regular maintenance and inspections necessary for maintaining the performance and functions of your robot SAFETY PRECAUTIONS SAFETY PRECAUTIONS Be sure to observe all of the following safety precauti
34. ip this step These dowel pins can minimize the risk of misalignment that could be caused by replacement of the robot unit during maintenance or due to vibration 4 Put the robot unit on the robot mount following the transport instructions given in Section 1 2 1 Transporting the Floor Mount Type or Section 1 2 2 Transporting the Overhead Mount Type 5 Secure the robot unit with four bolts and plain washers Fixing bolts M10 x 30 mm JIS strength class 12 9 For HS HSS G series Tightening torque 70 14 Nm For HS HSS G series Reference hole 2 p6H718 0 Diamond shaped pin For HS HSS G series Bolt Positions for Securing the Robot Unit 1 2 4 Grounding the Robot Unit Ground the grounding terminal of the robot unit using a wire of 5 5 mm or more Caution Use a dedicated grounding wire and grounding electrode Do not share them with other power facilities or welding machines Grounding terminal M5 Functional ground Wire of 5 5 mm min HS HSS G Grounding the Robot Unit 1 3 Installing the Robot Controller For the installing procedures of the robot controller refer to the RC7M CONTROLLER MANUAL Section 6 2 Installing the Robot Controller 11 1 4 Electrical Wiring and Air Piping of the Robot Unit Make electrical wiring and air piping for the hand or tool to be attached to the arm end referring to the ei
35. is turned ON In this case try to turn ON the power to the motor several times or release the brake move the axis a little in the opposite direction of the mechanical end and turn ON the power to the motor again Step 12 The system message appears asking whether you want to carry out CALSET w Y ts a5950e Joint moro a2 57 Step 147 Move the CALSET axis in the opposite direction from the mechanical end by manual operation from the teach pendant The single axis CALSET of the specified axis is completed 2 CALSET of All Axes The CALSET of all axes is called all axis CALSET The procedure is the same as that for single axis CALSET except that you should select all axes in Step 11 For detailed procedure see 1 CALSET of a Single Axis 58 2 5 Setting Control Set of Motion Optimization The optimum speed or acceleration will vary depending upon the payload and center of gravity of the hand and or workpiece that are to be set at the end of the robot flange Set the payload and center of gravity position of the hand or workpiece and the control set of motion optimization according to the payload and the robot posture The mass of payload is a total mass of a hand and workpiece expressed in gram For further information see the PROGRAMMER S MANUAL I Section 4 7 Setting the Master Control Parameters in User Preferences For the setting procedure refer to the SETTING UP MANUAL Section 2 9 Setting the M
36. ively prepared for your robot 2 After finishing teaching or making any changes always save the programs and data onto floppy disks Making back ups will help you recover if data stored in the robot controller is lost due to the expired life of the back up battery 3 Write the names of each of the floppy disks used for storing task programs to prevent incorrect disks from loading into the robot controller Store the floppy disks where they will not be exposed to dust humidity and magnetic field which could corrupt the disks or data stored on them T Safety Codes The safety standards relating to robot systems are listed below As well as observing the safety precautions given in this manual ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system Standards Title ANSI RIA R15 06 1999 Industrial Robots and Robot Systems Safety Requirements ANSI UL1740 1998 Safety for Robots and Robotic Equipment CAN CSA 2434 03 Industrial Robots and Robot Systems General Safety Requirements ISO10218 1 2006 Robots for industrial environments Safety requirements Part 1 Robot NFPA 79 2002 Electrical Standard for Industrial Machinery 8 Battery Recycling DENSO Robot uses lithium batteries Discard batteries according to your local and national recycling RA eS Ete as el ic EU Contents PRCT ACC sosessiencphcsostaueasnsccatessavenesnascac
37. l operation Total running Cumu operation Cumu running Operation Running Total hours pH OH OM OH D HOM HIM OH M Shows the grand total of the robot controller ON time counted after the controller leaves the factory Shows the grand total of the robot running time counted after the robot leaves the factory Shows the total of the robot controller ON time counted after you reset the user counter to zero Shows the total of the robot running time counted after you reset the user counter to zero Shows the ON time of the robot controller counted after it is turned ON this time Shows the running time of the robot counted after the robot controller is turned ON this time 3 9 2 Resetting the User Counters of the Controller ON Time and the Robot Running Time Step 1 Display the Total hours window as shown below Access F6 Set F6 Maint F1 Total h from the top screen To reset the user counter of the controller ON time Cumu operation for example press F4 Cumu o Step 2 The following system message appears Press the OK button 78 Step 3 The user counter of the controller ON time has been reset to zero as shown below 79 3 10 Using the Initialization Floppy Disk Step 1 The initialization floppy disk WAM holds arm data exclusively prepared for your robot lf CALSET related data in the robot controller is lost due to exhaustion of the m
38. lt or on an emergency or abnormal stop Note The UL Listed robot units have motor ON lamps on their robot arms SAFETY PRECAUTIONS 3 9 Setting up a safety A safety fence should be set up so that no one can easily enter fence the robot s restricted space 1 The fence should be constructed so that it cannot be easily moved or removed 2 The fence should be constructed so that it cannot be easily damaged or deformed through external force 3 Establish the exit entrance to the fence Construct the fence so that no one can easily get past it by climbing over the fence 4 The fence should be constructed to ensure that it is not possible for hands or any other parts of the body to get through it 5 Take any one of the following protections for the entrance exit of the fence 1 Place a door rope or chain across the entrance exit of 09 d the fence and fit it with an interlock that ensures the XS y emergency stop device operates automatically if it is opened or removed 2 Post a warning notice at the entrance exit of the fence stating In operation Entry forbidden or Work in progress Do not operate and ensure that workers follow these instructions at all times When making a test run before setting up the fence place an overseer in a position outside the robot s restricted space and one in which he she can see all of the robot s movements The overseer should prevent workers from entering the robot s re
39. ndicating a malfunction on the robot or related equipment are lit Check that the display lamp indicating automatic operation is lit during automatic operation Steps to be taken when a malfunction occurs Stop the robot s operation by activating the emergency stop device when it is necessary to enter the safeguarded space with a safety fence to perform emergency maintenance in the case of malfunction of the robots or related equipment Take any necessary steps such as posting a notice on the start switch to indicate work is in progress to prevent anyone from accessing the robot Do not perform repairs outside of the designated range Under no circumstances should the interlock mechanism be removed When opening the robot controller s cover for battery replacement or any other reasons always turn the robot controller power off and disconnect the power cable Use only spare tools specified in this manual 5 Daily and Periodical 1 Be sure to perform daily and periodical inspections Before In tion starting jobs always check that there is no problem with the ll robot and related equipment If any problems are found take any necessary measures to correct them 2 When carrying out periodical inspections or any repairs maintain records and keep them for at least 3 years 6 Management of 1 Carefully handle and store the Initial settings floppy disks packaged with the robot which store special data Floppy Disks exclus
40. ng commencing work items carry out any repairs immediately upon detection of a such as teaching malfunction and perform any other necessary measures 1 Check for any damage to the sheath or cover of the external wiring or to the external devices 2 Check that the robot is functioning normally or not any unusual noise or vibration during operation 3 Check the functioning of the emergency stop device 4 Check there is no leakage of air or oil from any pipes 5 Check there are no obstructive objects in or near the robot s restricted space SAFETY PRECAUTIONS 4 5 Release of residual air pressure 4 6 Precautions for test runs 4 7 Precautions for automatic operation 4 8 Precautions in repairs Before disassembling or replacing pneumatic parts first release any residual air pressure in the drive cylinder Whenever possible have the worker stay outside of the robot s restricted space when performing test runs 1 At start up 4 Stay out of the safeguarded space with a safety fence when starting the robot in particular take extra caution in Internal automatic operation Before starting the robot check the following items as well as setting the signals to be used and perform signaling practice with all related workers 1 Check that there is no one inside the safeguarded space with a safety fence 2 Check that the teach pendant and tools are in their designated places 3 Check that no lamps i
41. nspections 3 2 1 Check Items Before starting operations check the items listed below every day Daily Inspections Table Controller eee What to do no ene SORUP How toatecke cron MR Connectors CN1 to Engage the CN10 on the robot No looseness parts properly controller and their ore wisually disengagement or dirt and clean mating parts them Cables connected to CN1 to CN10 on the OFF Visually Free of damage or Repair or robot controller and gouges replace robot s external cables LCD on the teach Repair or Pilot lamps on the robot O Visually Should light Repair or controller replace Cooling fan in the robot Visually Repair or N soriroler ON Note 2 Should work properly replace EMERGENCY STOP button on the teach pendant or the mini pendant Press the The robot should EMERGENCY STOP come to an button emergency stop Repair or replace Brake release switch FF Check for looseness Tighten up Bellows on the z axis inaucetaud of dust amp splash proof OFF Visually No breakage a Sif type or cleanroom type pal Motor ON lamp on the l It should light when Inspect and UL Listed robot units ON visual the motor is ON Note 1 Some repair and replacement operations shown in What to do column may involve special jobs Contact our Robot Service Section Operate the safety The robot should Poaceand 7 Safety door ON door switch and open come to an PRSA ap repair the switch wiring door
42. o Hass Jint noto r R Change Limit Motion Space Software motion limit 155 Software motion limit J1 aes Software motion limit J2 7 a oj Software motion limit J3 mm Software motion limit J4 af f Software motion limit J5 mm Es al 0K Take in new entry Cancel Discard new entry gt ef ff J Step 7 The new value will be set on the line of the item selected in the Motion Space window If two or more items must be changed repeat Steps 6 and 7 Step 9 Turn the robot controller off Caution Restarting the controller makes the new motion space settings software motion limits effective Step 8 l Press OK in the Motion Space window 2 3 Changing Mechanical Ends to Define New Restricted Space 2 3 1 What is a Mechanical End Change In the case of the HS G series you may change mechanical ends on the 1st through 3rd Z axes When the robot leaves the factory the mechanical ends are set at points 2 to 3 outside the default software motion limits Refer to Section 2 2 2 Software Motion Limits Factory defaults Adding mechanical stops to change mechanical ends is called Mechanical end change Note Once you have changed mechanical ends be sure to change the software motion limits 2 3 2 Preparing mechanical stops To change mechanical ends you need to prepare mechanical stops for each of the 1st through 3rd axes as specified below For the 1st axi
43. ons Strict observance of these warning and caution indications are a MUST for preventing accidents which could result in bodily injury and substantial property damage Make sure you fully understand all definitions of these terms and related symbols given below before you proceed to the text itself A N WARNING Alerts you to those conditions which could result in serious bodily injury or death if the instructions are not followed correctly A N CAUTION Alerts you to those conditions which could result in minor bodily injury or substantial property damage if the instructions are not followed correctly Terminology and Definitions Maximum space Refers to the space which can be swept by the moving parts of the robot as defined by the manufacturer plus the space which can be swept by the end effector and the workpiece Quoted from the ISO 10218 1 2006 Restricted space Refers to the portion of the maximum space restricted by limiting devices i e mechanical stops that establish limits which will not be exceeded Quoted from the ISO 10218 1 2006 Motion space Refers to the portion of the restricted space to which a robot is restricted by software motion limits The maximum distance that the robot end effector and workpiece can travel after the software motion limits are set defines the boundaries of the motion space of the robot The motion space is DENSO WAVE proprietary terminology Operating space Refers to the
44. ore change Restricted range Positive directi Negative direction ee a software motion limit Other device S ayers a 1st axis 155 Changing Software Motion Limits 23 2 2 4 Precautions When Changing the Software Motion Limits 1 Confirm the motion space of the robot unit in the actual working environment 2 When setting the software motion limits be careful with the units 3 Specifying too small motion space may cause the robot unit to seem immovable 2 2 5 Procedure for Changing the Software Motion Limits Described below is the procedure for changing the software motion limits Step 1 Turn the power switch of the robot controller ON Step 2 l Set the mode selector switch of the teach pendant to MANUAL Step 3 Press F2 Arm on the top screen of the teach pendant The Current Robot Position window appears as shown in Step 4 24 Step 4 Press the SHIFT key and then press F12 Maint Step 5 Current Robot Position 9 00 F12 The Maintenance Functions Arm window will appear In the Maintenance Functions Arm window press F1 M Space The Motion Space window will appear as shown below Select the item to be modified then press F5 Change Motion Space Software motion limit 155 000 145 000 246 000 360 000 360 000 ooa 25 Step 6f The numeric keypad will appear as shown below Enter a desired value using the numeric keys then press OK M g c
45. ot unit and robot controller confirm that the operating environment is in conformity with each item of SAFETY PRECAUTIONS Installation Precautions Also take proper measures to protect the components from vibration In an inappropriate environment the robot will not operate to its full capacity or performance components may not last long and unexpected failure may result 1 1 1 Ambient Temperature and Humidity Keep the ambient temperature between 0 C and 40 C during operation Keep the ambient humidity at 90 or below to prevent dew condensation 1 1 2 Vibration Do not install the robot in an environment where it will be exposed to excessive vibration or impact 1 1 3 Connecting the Robot Unit and Robot Controller Before delivery the robot unit and the robot controller are adjusted to each other as a set When two or more robots are to be used use the robots and robot controllers that have been adjusted to each other as a set Caution The robot unit and robot controller in a set are given the same serial number 1 1 4 Installation Environment of the Robot Unit The table below lists the installation requirements for the robot unit Prepare a highly rigid mount as shown on the next page Caution Do not electric weld the equipment including the robot A large current may flow through the motor encoder or robot controller resulting in a failure If electric welding is required remove the robot unit and the robot cont
46. ount with heavy equipment Some mounts may produce a resonance sound howling If this sound is loud increase the rigidity of the mount or slightly modify the robot speed Robot Mount Sample for Floor mount Type Mounting face 350 x 350 x 20 square steel pipe NCaution 1 When the robot operates at high speed the top plate structure undergoes large reaction forces The robot mount must be vibration proof so that the top plate will not vibrate due to reaction forces Also it must be designed to be separated from other top plate structures in the equipment Some mounts may produce a resonance sound howling If this sound is loud increase the rigidity of the mount or slightly modify the robot speed Robot Mount Sample for Overhead mount Type 1 2 Mounting the Robot Unit Caution 1 Before handling or installing the robot unit be sure to read SAFETY PRECAUTIONS Installation Precautions 2 The grease is applied to the shaft and rack of the Z axis for lubrication and rust proof Do no touch or wipe the shaft and rack so as to keep rust proof 1 2 1 Transporting the Floor Mount Type This section gives the typical installation procedure assuming that you have set up the robot mount bed and prepared robot mounting bolt holes in it If you have not done it yet first read Section 1 2 3 Securing the Robot Unit Caution 1 The installation jobs should be handled by at least two persons Robot unit weigh
47. oving the stop from No 1 position Change the software motion limit to 65 Example 3 If you add a mechanical stop into Nos 3 and 10 positions each removing the stop from No 1 position Change the and software motion limits to 95 and 95 respectively and RANG1 98 43 Checking the set RANG values After mounting mechanical stop parts check the RANG values according to the procedure below The RANG values that you check here should be entered to the 1st through 3rd axes in the procedures given in Section 2 3 4 Changing Positive Direction Software Motion Limits PLIMs and RANG values and Section 2 3 5 Changing Negative Direction Software Motion Limits NLIMs As long as you use the permanent mechanical end this checking job is not required Once you remove the permanent mechanical end however it is necessary to set the RANG values and software motion limits Step 1 l Turn the power switch of the robot controller ON Step 27 Set the mode selector switch of the teach pendant to MANUAL W 2 m es Jint woro z Current Robot Position fete Gu N gt gt gt gt gt o o Cancel Close this window a Step 4 If you have changed the 1st and 3rd axis mechanical ends bring those axes into contact with their new positive direction mechanical ends by hand If you have changed the 2nd axis mechanical end bring the axis into contact with the new negative direction m
48. ow 158 00000 147 00000 249 00000 167 62640 Q 00000 west Select the RANG of the target axis then press F5 Change Step 11 The numeric keypad appears Step 12 Using the numeric keys enter RANG values and then press OK The screen returns to the RANG window 48 Step 13 Press OK The screen returns to the Maintenance Functions Arm window Step 14 l Set the power switch of the robot controller to OFF Performing CALSET Step 151 Perform CALSET for the target axis Refer to Section 2 4 3 Performing CALSET Caution After CALSET is completed move the 1st axis over the full stroke in the manual mode speed 10 or less to confirm that the positive direction and negative direction software motion limits function properly If they are valid the axis stops just before the mechanical end and ERROR6071 appears In the following cases reset the bolt positions the positive direction software motion limits the RANG values and the negative direction software motion limits to the original settings and repeat the procedure from the beginning 1 The software motion limits do not function when any of those axes is near a mechanical end and any other error 6111 6121 or 6171 occurs 2 A software motion limit error ERROR6071 occurs although none of those axes is near a mechanical end 49 2 4 Performing CALSET 2 4 1 What Is CALSET Calibrating the relationship between
49. portion of the restricted space that is actually used while performing all motions commanded by the task program Quoted from the ISO 10218 1 2006 Task program Refers to a set of instructions for motion and auxiliary functions that define the specific intended task of the robot system Quoted from the ISO 10218 1 2006 1 Introduction 2 Warning Labels Label 1 DENSO Label 4 Label 3 Sr Label 2 Example Location of labels Warning label A Ai BRORNG THURRAAICASS Risk of injury Do not enter restricted space Unfallgefahr Nicht die Sperrzone betreten SEA FH GS TS AB SS Yo EA EA Bae ole HEN Maer Label 1 lt Except HM gt N WARNING P LATE Moving robot can cause serious injury Durch Roboterbewegungen k nnen Verletzungen verursacht werden 2 ARM t F9 TEMAS Bo lt HM gt A WARNING SM gt P L xe tA wy Label 2 Part No 410985 406 Moving robot can cause serious injury Durch Roboterbewegungen k nnen Verletzungen verursacht werden 2 ARM 34 F79 HEME IE Z WARNING Risk of electrical shock Do not open controller cover when power is on Do not touch inside within 3 minutes of turning off power and disconnecting cable Label 3 Z WARNING Risk of injury Do not turn on power when someone is inside safety fence Locko
50. position related information recognized by the robot controller and the actual position of the robot unit is called CALSET CALSET must be performed when any motor is replaced or when any encoder backup battery goes dead so that the position related data retained in the encoder is lost as a result After CALSET is completed the calibrated data of the robot unit will be stored in the robot controller This data is called CALSET data which differs on each robot This robot has been CALSET before delivery and the CALSET data is stored in the floppy disks that come with the robot unit Therefore even if the memory backup battery in the robot controller dies so that the CALSET data is lost you do not need to CALSET the robot Just reload the CALSET data from the floppy disks 50 2 4 2 Preparation for CALSET Press each of the 1st to 4th axes against the associated mechanical ends by hand to get the actual positions CALSET requires some space for bringing each axis into contact with the mechanical end Caution 1 When CALSETing move the axis to be CALSET in the vicinity of the mechanical end release the brake and bring the axis into contact with the mechanical end 2 After CALSET confirm in the manual mode that each axis stops at the software motion limit before coming into contact with the mechanical end 3 In automatic operation start to run the robot at low speed Ensuring safety gradually increase the speed It makes a
51. r Nicht den Sicherheitsbereich des Roboters betreten 5a Pei7t Us oe HS AIH ol SA7 B A ANHEE RBENRERPUEN Post a notice showing axes names and moving directions in a visible location on the robot unit The posted moving directions should match the actual directions No posting or wrong direction posting may result in bodily injuries or property damages due to incorrect operation SAFETY PRECAUTIONS 4 Precautions AN Touching the robot while it is in while Robot is Warning operation can lead to serious WARNING Running injury Please ensure the fol lowing conditions are maintained and that the cautions listed from Section 4 1 and onwards are followed when any work is_ being TROEN WWARBANCASE performed Risk of injury Do not enter restricted space Untallgefahr Nicht die Sperrzone betreten B59 Pot GE 7H Ast AA Yo EAH LA AMEER AREA A AR el Mah Do not enter the robot s restricted space when the robot is in operation or when the motor power is on As a precaution against malfunction ensure that an emergency stop device is activated to cut the power to the robot motor upon entry into the robot s restricted space When it is necessary to enter the robot s restricted space to perform teaching or maintenance work while the robot is running ensure that the steps described in Section 4 3 Ensuring safety of workers performing jobs within the robot s restricted space are taken 4 1 Crea
52. robot and option s GENERAL INFORMATION ABOUT ROBOT Provides the packing list of the robot and outlines of the robot system robot unit and robot controller INSTALLATION amp MAINTENANCE GUIDE this book Provides instructions for installing the robot components and customizing your robot and maintenance amp inspection procedures STARTUP HANDBOOK Introduces you to the DENSO robot system and guides you through connecting the robot unit and controller with each other running the robot with the teach pendant and making and verifying a program This manual is a comprehensive guide to starting up your robot system SETTING UP MANUAL Describes how to set up or teach your robot with the teach pendant or mini pendant For the panel designer functions refer to the Panel Designer User s Manual SUPPLEMENT WINCAPSIIT GUIDE Provides instructions on how to use the programming support tool WINCAPSIII which runs on the PC connected to the robot controller for developing and managing programs PROGRAMMER S MANUAL I Program Design and Commands Describes the PAC programming language program development and command specifications in PAC This manual consists of two parts Part 1 provides the basic programming knowledge and Part 2 details of individual commands PROGRAMMER S MANUAL II PAC Library Describes the program libraries that come with WINCAPSIII as standard RC7M CONTROLLER MANUAL Provides the specifications installation and ma
53. roller from the equipment beforehand Installation Requirements for the Robot Unit tem fC onments and Conaltions Floor mount or overhead mount Only for HSS G l During operation 0 to 40 C Ambient temperature During storage and transportation 10 to 60 C During operation 90 or less No dew condensation allowed Humidity During storage and transportation 75 or less No dew condensation allowed a During operation 4 9 m s 0 5G or less Vibration During storage and transportation 29 4 m s 3G or less Altitude During operation 1 000 m or less Refer to the SAFETY PRECAUTIONS 3 1 Insuring the proper environment installation environment Safe installation e Sufficient service space must be available for inspection and disassembly e Keep wiring space at least 190 mm for Standard type at least 230 mm for Working space etc Dust proof splash proof type behind the robot and fasten the wiring to the mounting face or beam so that the weight of the cables will not be directly applied to the connectors Groundina conditions Functional ground i See the figure given on page 11 0 1 500 20 or more 1000 or less 100 x 100 pipe 500 or more NCaution 1 When the robot operates at high speed the robot mount undergoes large reaction forces The mount must be rigid enough so that it will not vibrate or be displaced due to reaction forces It is also advisable to mechanically join the robot m
54. s Two mechanical stop bolts M8x16 plated hex socket head bolt strength class 10 9 For the 2nd axis Mechanical stop plate For the 3rd axis A pair of mechanical stop collars and two mechanical stop bolts per collar M5x18 plated hex socket head bolt strength class 10 9 Determine the desired travel range and prepare those mechanical stops if necessary Preparing mechanical stops 1 Axis Mechanical stops 1st axis Two mechanical stop bolts M8x16 plated hex socket head bolt strength class 10 9 lt Bolt specifications M8x16 SCM435 JIS G4105 HRC34 44 gt NOTE On the robot units manufactured after the middle of 2006 the bolt holes are spot faced This manual describes the robot units with the spot faced bolt holes On the robot units without spot facing use two M8x12 bolts 2 Preparing mechanical stops 2 Axis Mechanical stops 2n d axis Mechanical stop plate Mel eae R5 6 5 dia 11 dia spot faced 2 holes 5 deep Negative direction Positive direction 75 7 72 8 Values in parentheses apply to the HSS 4545 G For and inthe above drawing enter your desired values which are added 5 degrees to the travel range If using an original 2nd axis stopper bolt enter 150 degrees 146 degrees for HSS 4545 G for or B This reference drawing shows a motion change sample of 90 degrees in the negative direction In this case change the software motion limits to 145 degrees and
55. stricted space and be devoted solely to that task 3 10 Setting the robot s The area required for the robot to work is called the robot s motion space operating space If the robot s motion space is greater than the operating space it is recommended that you set a smaller motion space to prevent the robot from interfering or disrupting other equipment Refer to the INSTALLATION amp MAINTENANCE GUIDE Chapter 2 3 11 No robot modification allowed 3 12 Cleaning of tools 3 13 Lighting 3 14 Protection from objects thrown by the end effector 3 15 Affixing the warning label 3 16 Posting the moving directions of all axes Never modify the robot unit robot controller teach pendant or other devices If your robot uses welding guns paint spray nozzles or other end effectors requiring cleaning it is recommended that the cleaning process be carried out automatically Sufficient illumination should be assured for safe robot operation If there is any risk of workers being injured in the event that the object being held by the end effector is dropped or thrown by the end effector consider the size weight temperature and chemical nature of the object and take appropriate safeguards to ensure safety Place the warning label packaged with the robot on the exit entrance of the safety fence or in a position WARN N G where it is easy to see TROENSI o Risk iT Do not enter safety fence area Unfallgefah
56. t Approx 25 kg 55 Ibs 2 Be sure to put on a helmet safety shoes and gloves Step 4 Disconnect the motor cable encoder cable air pipes hand and tools from the robot unit if mounted Illustration HS G Disconnect the motor cable encoder cable and others Step 2 Turn the 2nd axis until it comes into contact with the mechanical end in order to keep the safe position Then remove the four bolts and release the robot unit from the pallet Caution When worker A is removing those bolts worker B should support the 1st axis arm to prevent the robot unit from overturning Turn until it comes into contact with the mechanical end LOCC Pallet HS G Step 3 Hold the robot unit as shown below This job should be handled by two workers Caution 1 Do not hold the robot at sections other than those specified below The plastic cover could easily break 2 Before starting transportation make sure that there are no obstacles in the path to the mounting bed Worker A Worker B HS G Step 4 Put the robot unit on the mount bed and secure it with four bolts temporarily Step 5 Fix the robot unit referring to Section 1 2 3 Securing the Robot Unit Tightening torque 70 14 Nm For HS G series 1 2 2 Transporting the Overhead Mount Type HSS G series This section gives the typical installation procedure of the robot unit Caution 1 Since the robot unit weighs approx 25 kg 5
57. tal processing or other conductive material flying about 3 there are any acidic alkaline or other corrosive material 4 there is a mist 5 there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise E For dust amp splash proof The dust amp splash proof type has an IP54 equivalent structure type but it has not been designed to withstand explosions The HM HS G W and the wrist of the VM VS G W are an IP65 equivalent dust and splash proof structure Note that the robot controller is not a dust or splash proof structure Therefore when using the robot controller in an environment exposed to mist put it in an optional protective box The dust amp splash proof type should not be installed in any environment where 1 there are any flammable gases or liquids 2 there are any acidic alkaline or other corrosive material 3 there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise 4 it may likely be submerged in fluid 5 there are any grinding or machining chips or shavings 6 any machining oil not specified in this manual is in use or Note Yushiron Oil No 4C non soluble is specified 7 there is sulfuric cutting or grinding oil mist 3 2 Service space The robot and peripheral equipment should be installed so that sufficient servic
58. tandard type Dust proof splash proof type 2 Robot type HSS 45451 HSS 45452 HSS 45453 HSS 45451 HSS 45452 HSS 45453 G G G G W G W G W Positive l direction 1st axis l Negative 1520 direction direction 2nd axis Negative 4440 direction Positive 431 mm 431 mm 431 mm 471 mm 471 mm 471 mm direction 3rd axis Negative 581mm 631mm 751mm 621mm 671mm 791 mm direction Positive 360 direction Negative 360 direction 21 HSS 4555 G Overhead mount type Overall arm length 550 mm Standard type Dust proof splash proof type Robot type HSS HSS ae HSS o HSS 45551 HSS 45552 HSS 45553 G W G W EIS W Positive 1550 direction 1st axis Fg 1550 Fg direction 2nd axis or 445 or direction 3rd axis T egalive 581mm 631mm 751mm 621mm 671mm 791mm direction Positive 360 direction 4th axis Negative 360 direction 22 2 2 3 Changing Software Motion Limits If the robot interferes with other devices or the air piping and wiring of the hand become taut as the robot arm moves then change the software motion limits to make the motion space smaller as shown below Caution When changing software motion limits always take into account that the robot arm will motion within the range specified by the initial software motion limits SOftware motion limit Motion range after change Mechanical end Motion range bef
59. the pendant clockwise if it has been triggered by the equipment restore the emergency stop switch to the short circuited state 3rd axis Z axis Release the brakes with either of the following procedures and then move the target axis by hand Use the brake command with the teach pendant or mini pendant Access F2 Arm F12 Maint F3 Brake on the teach pendant Enter the direct mode with the teach pendant and press the brake release switch Access F2 Arm F6 Aux F3 Direct on the teach pendant Note 1 For detailed procedures refer to the SETTING UP MANUAL Chapter 5 Commands Assigned to Function Keys of the Teach Pendant and Chapter 6 Using the Mini Pendant Note 2 On robot units except UL Listed ones the brake release switch is enabled only in direct teaching mode 4th axis T axis For UL Listed robot units When the controller power is ON move the axis by hand while holding down the brake release switch Note On UL Listed robot units the teach pendant or mini pendant cannot release the brakes and the direct teaching mode is not supported 2nd axis OU 3rd axis 4th axis T axis 1 8 Locking Out the Power Switch Lock out the power switch during maintenance and inspection jobs using a commercially available padlock according to the following procedure Step 11 Check that the power switch of the robot controller is turned OFF Power OFF
60. the upper mechanical end stopper preset at the factory Step 4 Dust proof splash proof type Remove 12 bolts M3 on the top of the lower bellows with a hexagonal wrench Cleanroom type Loosen the clamp band at the top of the lower bellows with a flat screwdriver ee nee EE oe Lower bellows Dust proof splash proof type Cleanroom type Step 21 Pull down the bellows Upper mechanical end stopper preset at the factory Upper mechanical end stopper preset at the factory Dust proof splash proof type Cleanroom type 40 Step 3 Secure a mechanical stop collar you have prepared to the desired position of the 3rd axis shaft with two bolts Tightening torque recommended 8 8 1 7 Nm At the lower section of the 3rd axis shaft is an upper mechanical end stopper that is preset at the factory for the maximum stroke If the stroke is 200 mm in the dust amp splash proof type of robots for example the z axis may move up to the position 206 mm above the floor To change from 206 mm to 100 mm set a mechanical stop collar 106 mm below the top of the upper mechanical stopper preset Use vernier calipers when measuring the distance 3rd axis shaft es a aaa Can move up to this position before Donen change Mechanical stop Can move up to this collar to be position after change prepared by the customer Upper mechanical Two bolts M5x18 to end stopper preset be prepared by
61. ther of examples 1 and 2 below 1 Using a hollow provided in the Z axis shaft Robot model HS HSS G series Hollow diameter in the Z axis shaft 014 2 Securing a stay to the robot unit for clamping wiring and piping Wiring and piping through a hollow 14 dia in the Z axis shaft Stay Secured with two M3 bolts Wiring and Piping Image HS G series 1 4 1 Notes for Wiring and Piping Through a Hollow in the Z axis Shaft The Z axis shaft has a hollow through which you may make wiring and piping from the hand control signal connector CN21 or air piping joints on the top of the 2nd arm In this wiring and piping check that 1 When the robot is in motion the wiring and piping do not become taut or interfere with other sections 2 During up or down movement of the Z axis the wiring and piping inside the hollow do not become taut or interfere with other sections 1 4 2 Reference Drawings for Stays that Clamp Wiring and Piping When mounting a stay that clamps wiring and piping to the robot unit be sure to secure it with at least two screws using the four existing internal threads provided in the underside of the second arm Referring to the drawing given below set up a stay Existing internal thread positions Internal threads M3 6 mm deep Second arm First arm 1st axis Internal threads M3 6 mm deep Viewed from A Reference drawing for a stay Material SPCC t2 0 Surface tre
62. tion of working When entering the robot s restricted space to perform teaching regulations and or maintenance inspections set working regulations for the assuring worker following items and ensure workers adhere to them adherence 1 Operating procedures required to run the robot 2 Robot speed when performing teaching 3 Signaling methods to be used when more than one worker is to perform work 4 Steps that must be taken by the worker in the event of a malfunction according to the contents of the malfunction 5 The necessary steps for checking release and safety of the malfunction status in order to restart the robot after robot movement has been stopped due to activation of the emergency stop device 6 Apart from the above any steps below necessary to prevent danger from unexpected robot movement or malfunction of the robot 1 Display of the control panel See Section 4 2 on the next page 2 Assuring the safety of workers performing jobs within the robot s restricted space See Section 4 3 on the next page 3 Maintaining worker position and stance Position and stance that enables the worker to confirm normal robot operation and to take immediate refuge if a malfunction occurs 4 Implementation of measures for noise prevention 5 Signaling methods for workers of related equipment 6 Types of malfunctions and how to distinguish them Please ensure working regulations are appropriate to the robot type t
63. ttery according to the procedure given below Step 4 Prepare two new backup batteries for replacement Step 2 Turn the controller power OFF Power switch Step 3 Remove the cover from the robot unit Four hex socket head bolts M3x8 lt HS HSS G gt NOTE On the dust amp splash proof type or cleanroom type the cover has a packing for sealing Take care not to lose it 67 Step 4 Disconnect the old battery 1st one from the battery board and then remove it from the holder Battery board Connector Old backup battery Holder 1st one lt HS HSS G gt Step 5 Connect a new battery 1st one to the battery board from which you have disconnected the old one in Step 4 and then load it into the holder New backup battery 1st one lt HS HSS G gt NOTE Do not disconnect both of the current batteries at the same time Doing so will lose the encoder positional data 68 Step 6 Disconnect the remaining old battery 2nd one from the battery board and then remove it from the holder Connector Battery board Old backup battery 2nd one Holder lt HS HSS G gt Step 7 Connect a new battery 2nd one to the battery board from which you have disconnected the old one in Step 6 and then load it into the holder New backup battery 2nd one lt HS HSS G gt NOTE Be sure to replace both of two batteries with new ones at one time Otherwise the battery service l
64. tware motion limit is set slightly in front of the mechanical end as shown below If the robot reaches a software motion limit during manual or automatic operation an error message will be displayed error code starting from 607x where x represents the axis number and the robot will come to a stop The power to the motor will be also turned OFF if the robot is in automatic operation Each of all axes is assigned a software motion limit in both the positive and negative direction of the operation range The software motion limit in the positive direction is called the positive direction software motion limit and that in the negative direction is called the negative direction software motion limit Software motion limit Mechanical end Motion range l NLIM Negative direction Restricted range software motion limit PLIM Positive direction software motion limit Software Motion Limits and Mechanical Ends 20 2 2 2 Software Motion Limits Factory defaults The table below lists the factory defaults of software motion limits 1 HS G series Floor mount type Standard type OUSE prop peer aner Cleanroom type Robot type type l direction 1st axis A Negative 1550 direction l direction 2nd axis l Negative 1450 direction l direction 3rd axis Neda Ne 46 mm 4mm 6mm 114 mm 6mm 114 mm direction direction 4th axis Negative 360 direction 2 HSS 4545 G Overhead mount type Overall arm length 450 mm tom S
65. upside down as shown below Step 7 While having two workers keep the robot unit in the upside down position slowly hoist the robot unit with the crane so that the robot base comes into contact with the robot installation face of the overhead mount frame Secure the robot unit with four mounting bolts temporarily lt HSS G gt Step 8 Firmly secure the robot unit referring to Section 1 2 3 Securing the Robot Unit lt For HSS G Series gt Tightening torque 70 14 Nm lt HSS G gt Step 9 After completing bolting unhook the belt sling from the crane and then remove the 2nd axis arm fixing rope Caution Store the 2nd axis arm fixing rope for future removal of the robot unit 1 2 3 Securing the Robot Unit 1 According to the dimensions specified in the figure below drill four robot fixing holes and two dowel pin holes in the robot mount where the robot unit is to be anchored Drilling in the robot mount Drilling in the robot mount For HS HSS G series Four robot fixing holes M10 bolt holes a minimum of 20 mm deep Two holes for For diamond shaped pin 4H7 dia hole a minimum of 10 mm deep BOWEHpIiS For internally threaded 6H7 dia hole a minimum of 10 mm deep positioning pin 2 Drive a diamond shaped pin into the hole HS HSS G 4H7 dia so that the pin becomes oriented as shown below 3 Drive an internally threaded positioning pin into the hole HS HSS G 6H7 dia Caution Never sk
66. ut and tagout power before servicing Label 4 This section provides safety precautions to be observed for the robot system The installation shall be made by qualified personal and should confirm to all national and local codes The robot unit and controller have warning labels These labels alert the user to the danger of the areas on which they are pasted Be sure to observe the instructions printed on those labels Instructions printed on the label Risk of injury Never enter the restricted space For UL Listed robot units only Risk of injury This label alerts the user that pressing the brake release switch could drop the arm Risk of electrical shock Never open the controller cover when the power is on Never touch the inside of the controller for at least 3 minutes even after turning the power off and disconnecting the power cable Risk of injury Be sure to perform before starting servicing lockout tagout Turning the power ON when a person is inside the safety fence may move the arm Causing injuries SAFETY PRECAUTIONS 3 Installation Precautions 3 1 Insuring the proper installation environment E For standard type and The standard and cleanroom types have not been designed to cleanroom type withstand explosions dust proof nor is it splash proof Therefore it should not be installed in any environment where 1 there are flammable gases or liquids 2 there are any shavings from me
67. vice life is two years Press OK NOTE If you do not want to change the replacement date press Cancel The message Are you sure you want to set the next battery replacement date appears Press OK The screen returns to the Settings Main window 71 3 6 Supplies for Maintenance The table below lists the supplies for maintenance Caution 1 The battery used in this device may present a risk of fire or chemical burn if mistreated Do not recharge disassemble heat above 100 C 212 F or incinerate 2 Dispose of used battery promptly Keep away from children Do not disassemble and do not dispose of in fire Supplies for Maintenance Epinoc Ap l E ncoder backup battery set 410679 0010 A set of two batteries HS E17500 410053 0100 For standard type of controllers FS 1705W Air filter set For global type of controllers FS 1705 IC M54522P for controller output PNP IC for output 410077 0020 IC M54564P for controller output 3 7 Replacing Fuses and Output ICs For the replacing procedures of the fuses and output ICs refer to the RC 7M CONTROLLER MANUAL Section 6 6 Replacing Fuses and Output ICs 72 3 8 Checking the Odometer and Trip Meter You may check the odometer and trip meter which count traversed distance of each axis in the Odometer window of the teach pendant The access to the Odometer window is F6 Set F6 Maint F5 Odometer The Odometer window shows the follow
68. ws with a flat screwdriver Upper bellows w N D Step 2 Pull up the bellows Lower mechanical end stopper preset at the factory 3 Step 3 Secure a mechanical stop collar you have prepared to the desired position of the 3rd axis shaft with two bolts Tightening torque recommended 8 8 1 7 Nm At the top of the 3rd axis shaft is a lower mechanical end stopper that is preset at the factory for the maximum stroke If the stroke is 200 mm in the dust amp splash proof type of robots for example the z axis may move down to the position 6 mm above the floor To change from 6 mm to 100 mm set a mechanical stop collar 94 mm below the bottom of the lower mechanical stopper preset Use vernier calipers when measuring the distance aN Lower mechanical end stopper preset at the factory O Fan i NWA AWN AEA lt s Mechanical end collar to be prepared by the customer Two bolts M5x18 to be prepared by the customer Can move down to this position after change 5 Can move down to this Kig position before change 1 ay aetetateetateta tse 7 4 l Floor lt Example of HSS G W gt 38 Step 4 Pull the bellows down to the original position and tighten the clamp band loosened in Step 1 with a flat screwdriver Tightening torque recommended 2 0 0 4 Nm 39 b Changing the upper mechanical end Caution Never remove

HS-G SERIES INSTALLATION & MAINTENANCE GUIDE

Contents

Download Pdf Manuals

Related Search

Related Contents

HS-G SERIES INSTALLATION &amp; MAINTENANCE GUIDE

Contents

Download Pdf Manuals

Related Search

Related Contents

HS-G SERIES INSTALLATION & MAINTENANCE GUIDE