Manual Mecanico M900 513o4a

FANUC Robot M-900iA/350 FANUC Robot M-900iA/260L MECHANICAL MANUAL

MAINTENANCE MANUAL MARMI935009041E REV. D This publication contains proprietary information of FANUC Robotics America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics America, Inc. FANUC Robotics America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 48309–3253

B-82135EN/05

Before using the Robot, be sure to read the “FANUC Robot Safety Manual (B-80687EN)” and understand the content. This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.

• No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please FANUC for advice. In this manual, we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as “impossible”.

The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics America, Inc, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics’ products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL programming language, INSIGHT vision equipment, and special tools. FANUC Robotics recommends that only persons who have been trained in one or more approved FANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC Robotics’ products and/or systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.

! WARNING This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the , at his own expense, will be required to take whatever measure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at its headquarters in Rochester Hills, Michigan. For additional information FANUC Robotics America, Inc. Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucrobotics.com Send your comments and suggestions about this manual to: [email protected]

Copyright 2008 by FANUC Robotics America, Inc. All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, ed, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics America, Inc. AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL, KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks, PalletTool, SOCKETS, SOFT PARTS SpotTool, TorchMate, and YagTool are ed Trademarks of FANUC Robotics. FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir AccuCal AccuChop AccuFlow AccuPath AccuSeal ARC Mate ARC Mate Sr.  ARC Mate System 1 ARC Mate System 2 ARC Mate System 3 ARC Mate System 4 ARC Mate System 5 ARCWorks Pro AssistTool AutoNormal AutoT BellTool BODYWorks Cal Mate Cell Finder Center Finder Clean Wall CollisionGuard DispenseTool F-100 F-200i FabTool FANUC LASER DRILL Flexibell FlexTool HandlingTool HandlingWorks INSIGHT INSIGHT II IntelliTrak Integrated Process Solution Intelligent Assist Device IPC -Integrated Pump Control IPD Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD Integral Servo Dispenser Laser Mate System 3 Laser Mate System 4 LaserPro LaserTool LR Tool MIG Eye MotionParts NoBots Paint Stick PaintPro PaintTool 100 PAINTWorks PAINTWorks II PAINTWorks III PalletMate PalletMate PC PalletTool PC PayloadID RecipTool RemovalTool Robo Chop Robo Spray S-420i S-430i ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM RJ3 Controller SYSTEM R-J3iB Controller T Mate TurboMove TorchMate visLOC visPRO-3D visTRAC WebServer WebTP YagTool  FANUC LTD 2008

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No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice.

Conventions

This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text.

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WARNING

Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

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CAUTION

Information appearing under CAUTION concerns the protection of equipment, software, and data. It is boxed to set it apart from other text.

NOTE Information appearing next to NOTE concerns related information or useful hints.

Safety FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can best be determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotic systems. According to the industry standard ANSI/RIA R15-06, the owner or is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the system-including the design, implementation, and debugging of application programs-must be familiar with the recommended programming procedures for your application and robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:

• The safety of people and equipment • Use of safety enhancing devices • Techniques for safe teaching and manual operation of the robot(s) • Techniques for safe automatic operation of the robot(s) • Regular scheduled inspection of the robot and workcell • Proper maintenance of the robot

Keeping People and Equipment Safe The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:

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Safety • People • External devices • Robot(s) • Tooling • Workpiece

Using Safety Enhancing Devices Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices:

• Safety fences, barriers, or chains • Light curtains • Interlocks • Pressure mats • Floor markings • Warning lights • Mechanical stops • EMERGENCY STOP buttons • DEAN switches

Setting Up a Safe Workcell A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety.

• Sponsor your personnel for training in approved FANUC Robotics training course(s) related to your application. Never permit untrained personnel to operate the robots.

• Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot.

• Use anti-tie-down logic to prevent the operator from bying safety measures. • Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell.

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Safety • Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that extend this range.

• Position all controllers outside the robot work envelope. • Never rely on software or firmware based controllers as the primary safety element unless they comply with applicable current robot safety standards.

• Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell.

• Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end-use application.

• Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope.

• Install special guarding that prevents the operator from reaching into restricted areas of the work envelope.

• Use interlocks. • Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety.

• Periodically check the safety ts or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot.

• Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro-magnetic interference (EMI), radio frequency interference (RFI), and electro-static discharge (ESD).

• Make provisions for power lockout/tagout at the controller. • Eliminate pinch points . Pinch points are areas where personnel could get trapped between a moving robot and other equipment.

• Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely.

• Program the robot to load and unload material safely. • If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons.

• If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.

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Safety

Staying Safe While Teaching or Manually Operating the Robot Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules:

• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.

• Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment.

• Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range.

• The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department.

• FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEAN switch. Only the person with the teach pendant should be in the work envelope. Warning Never by, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

• Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked.

• Isolate the robot from all remote control signals that can cause motion while data is being taught. • Test any program being run for the first time in the following manner: Warning Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury. — Using a low motion speed, single step the program for at least one full cycle. — Using a low motion speed, test run the program continuously for at least one full cycle. — Using the programmed speed, test run the program continuously for at least one full cycle.

• Make sure all personnel are outside the work envelope before running production.

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Safety

Staying Safe During Automatic Operation Advise all personnel who operate the robot during production to observe the following rules:

• Make sure all safety provisions are present and active. • Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts.

• Understand the complete task the robot is programmed to perform before initiating automatic operation.

• Make sure all personnel are outside the work envelope before operating the robot. • Never enter or allow others to enter the work envelope during automatic operation of the robot. • Know the location and status of all switches, sensors, and control signals that could cause the robot to move.

• Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency.

• Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue activity.

• If the robot is running in a pattern, do not assume it will continue to run in the same pattern. • Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller , teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection When inspecting the robot, be sure to

• Turn off power at the controller. • Lock out and tag out the power source at the controller according to the policies of your plant. • Turn off the compressed air source and relieve the air pressure. • If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator .

• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.

• If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency.

• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not ed or resting on a hard stop. the arm on a solid before you release the brake.

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Safety

Staying Safe During Maintenance When performing maintenance on your robot system, observe the following rules:

• Never enter the work envelope while the robot or a program is in operation. • Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist.

• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.

• Consider all or any overlapping work envelopes of ading robots when standing in a work envelope.

• Test the teach pendant for proper operation before entering the work envelope. • If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEAN switch, and turn the teach pendant on. Be prepared to release the DEAN switch to turn off servo power to the robot immediately.

• Whenever possible, perform maintenance with the power turned off. Before you open the controller front or enter the work envelope, turn off and lock out the 3-phase power source at the controller.

• Be aware that an applicator bell cup can continue to spin at a very high speed even if the robot is idle. Use protective gloves or disable bearing air and turbine air before servicing these items.

• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not ed or resting on a hard stop. the arm on a solid before you release the brake. Warning Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a power source. Be extremely careful to avoid electrical shock.HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.

• Release or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines.

• Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person.

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Safety • Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked.

• Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel. Warning Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction.

• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not ed or resting on a hard stop. the arm on a solid before you release the brake.

• When replacing or installing components, make sure dirt and debris do not enter the system. • Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses.

• Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.

Programming Safety Precautions Implement the following programming safety measures to prevent damage to machine tools and other external devices.

• Back-check limit switches in the workcell to make sure they do not fail. • Implement “failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails.

• Use handshaking protocol to synchronize robot and external device operations. • Program the robot to check the condition of all external devices during an operating cycle.

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Safety

Mechanical Safety Precautions Implement the following mechanical safety measures to prevent damage to machine tools and other external devices.

• Make sure the workcell is clean and free of oil, water, and debris. • Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE Observe the following operating and programming guidelines to prevent damage to the robot.

Operating Safety Precautions The following measures are designed to prevent damage to the robot during operation.

• Use a low override speed to increase your control over the robot when jogging the robot. • Visualize the movement the robot will make before you press the jog keys on the teach pendant. • Make sure the work envelope is clean and free of oil, water, or debris. • Use circuit breakers to guard against electrical overload.

Programming Safety Precautions The following safety measures are designed to prevent damage to the robot during programming:

• Establish interference zones to prevent collisions when two or more robots share a work area. • Make sure that the program ends with the robot near or at the home position. • Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage.

• In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials. Note Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. If you have questions, see your supervisor.

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Safety

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personal also must work inside the paint booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor. Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high-voltage electrostatic tools. Paint robots are operated in three modes:

• Teach or manual mode • Automatic mode, including automatic and exercise operation • Diagnostic mode During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control (M), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or M. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals.

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Safety This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features:

• Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are.

• Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are.

• EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E-STOP buttons.

• An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. • A DEAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEAN switch is released during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E-STOP other robots. Warning An EMERGENCY STOP will occur if the DEAN switch is released on a byed robot.

• Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. Limit switches and hardstops also limit travel by the major axes.

• EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SCC is in teach mode.When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings.

• System status is monitored by computer. Severe conditions result in automatic system shutdown.

Staying Safe While Operating the Paint Robot When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. Warning Observe all safety rules and guidelines to avoid injury.

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Safety Warning Never by, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. Warning Enclosures shall not be opened unless the area is know to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time.

• Know the work area of the entire paint station (workcell). • Know the work envelope of the robot and hood/deck and door opening devices. • Be aware of overlapping work envelopes of adjacent robots. • Know where all red, mushroom-shaped EMERGENCY STOP buttons are located. • Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move.

• Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor.

• Become familiar with the complete task the robot will perform BEFORE starting automatic mode. • Make sure all personnel are outside the paint booth before you turn on power to the robot servo system.

• Never enter the work envelope or paint booth before you turn off power to the robot servo system. • Never enter the work envelope during automatic operation unless a safe area has been designated. • Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.

• Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled.

• Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object.

• Be aware of signals and/or operations that could result in the triggering of guns or bells. • Be aware of all safety precautions when dispensing of paint is required. • Follow the procedures described in this manual.

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Safety

Special Precautions for Combustible Dusts (powder paint) When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot.

• Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust can not enter the robot.

• A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. Do not energize the robot until you have performed the following steps. 1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust. 2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken. 3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust. 4. When the dust has been removed, the covers must be replaced immediately. 5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now be energized.

Staying Safe While Operating Paint Application Equipment When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems. Warning When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials , and NFPA 70 National Electrical Code .

• Grounding : All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms.

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Safety • High Voltage : High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process.

• Avoid any accumulation of combustible vapors or coating matter. • Follow all manufacturer recommended cleaning procedures. • Make sure all interlocks are operational. • No smoking. • Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material.

• Disable all air and paint pressure to bell. • that the lines are not under pressure.

Staying Safe During Maintenance When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot.

• Paint robots operate in a potentially explosive environment. Use caution when working with electric tools.

• When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area.

• For some maintenance procedures, station a second person at the control within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards.

• Be sure all covers and inspection plates are in good repair and in place. • Always return the robot to the ‘‘home’’ position before you disarm it. • Never use machine power to aid in removing any component from the robot. • During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems.

• Whenever possible, turn off the main electrical disconnect before you clean the robot. • When using vinyl resin observe the following: — Wear eye protection and protective gloves during application and removal — Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation. — If there is with the skin, wash with water.

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Safety — Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

• When using paint remover observe the following: — Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning. — Adequate ventilation is required. Overexposure could cause drowsiness. — If there is with the skin or eyes, rinse with water for at least 15 minutes. Then, seek medical attention as soon as possible. — Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

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B-82135EN/05

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SAFETY PRECAUTIONS

SAFETY PRECAUTIONS For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell.

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SAFETY PRECAUTIONS

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B-82135EN/05

OPERATOR SAFETY Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure operator safety. 1. Have the robot system operators attend the training courses held by FANUC. FANUC provides various training courses. our sales office for details. 2. Even when the robot is stationary, it is possible that the robot is still ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. 3. Install a safety fence with a gate so that no operator can enter the work area without ing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened. The controller is designed to receive this interlock signal. When the gate is opened and this signal received, the controller stops the robot in an emergency. For connection, see Fig.1.1. 4. Provide the peripheral devices with appropriate grounding (Class 1, Class 2, or Class 3). 5. Try to install the peripheral devices outside the work area. 6. Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand. 7. Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when an operator enters the work area. 8. If necessary, install a safety lock so that no one except the operator in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock. 9. When adjusting each peripheral device independently, be sure to turn off the power of the robot.

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SAFETY PRECAUTIONS

Fig. 1.1 (a) Safety Fence and Safety gate (For R-J3iB CONTROLLER)

Fig. 1.1 (b) Safety Fence and Safety (For R-30iA CONTROLLER)

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SAFETY PRECAUTIONS

1.1.1

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Operator Safety The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. 1. If it is not necessary for the robot to operate, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. 2. Operate the robot system at a location outside the work area. 3. Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. 4. Install an EMERGENCY STOP button within the operator’s reach. The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

Fig. 1.1.1 (a) Connection Diagram for External Emergency Stop Switch (For R-J3iB CONTROLLER)

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SAFETY PRECAUTIONS

Fig. 1.1.1 (b) Connection Diagram for External Emergency Stop Switch (For R-30iA CONTROLLER)

1.1.2

Safety of the Teach Pendant Operator While teaching the robot, it is necessary for the operator to enter the work area of the robot. It is particularly necessary to ensure the safety of the teach pendant operator. 1. Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. 2. Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating condition. 3. When entering the robot work area and teaching the robot, be sure to check the location and condition of the safety devices (such as the EMERGENCY STOP button and the dean’s switch on the teach pendant). The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a dean’s switch in addition to the EMERGENCY STOP button. The functions of each switch are as follows. EMERGENCY STOP button Dean’s switch When the enable switch is on

: : :

Pressing this button stops the robot in an emergency, irrespective to the condition of the teach pendant enable switch. The function depends on the state of the teach pendant enable switch. Releasing the finger from the dean’s switch stops the robot in an emergency.

When the enable switch is off-The dean’s switch is ineffective

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NOTE The dean’s switch is provided so that the robot operation can be stopped simply by releasing finger from the teach pendant in case of emergency. 4. The teach pendant operator should pay careful attention so that no other workers enter the robot work area.

NOTE In addition to the above, the teach pendant enable switch and the dean’s switch also have the following function. By pressing the dean’s switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to the controller is invalidated. In this case, it is possible for an operator to enter the fence during teach operation without pressing the EMERGENCY STOP button. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the dean’s switch indicates the start of teaching. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching. 5. When entering the robot work area, the teach pendant operator should enable the teach pendant whenever he or she enters the robot work area. In particular, while the teach pendant enable switch is off, make certain that no start command is sent to the robot from any operator’s other than the teach pendant. The teach pendant, operator , and peripheral device interface send each robot start signal. However, the validity of each signal changes as follows depending on the ON/OFF switch on the Teach pendant and the three modes switch on the Operator’s and Remote condition on the software. Operator’s three modes switch T1/T2 AUTO (Except RIA) AUTO AUTO

Teach pendant ON/OFF switch

Software remote condition

Teach pendant

Operator’s

Peripheral devices

On

Independent

Allowed to start

Not allowed

Not allowed

Off Off

Remote OFF Remote ON

Not allowed Not allowed

Allowed to start Not allowed

Not allowed Allowed to start

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SAFETY PRECAUTIONS

NOTE When starting the system using the teach pendant in the RIA specification, the three modes switch should be T1/T2. 6. To start the system using the operator’s box, make certain that nobody is in the robot work area and that there are no abnormal conditions in the robot work area. 7. When a program is completed, be sure to carry out a test run according to the procedure below. 1. Run the program for at least one operation cycle in the single step mode at low speed. 2. Run the program for at least one operation cycle in the continuous operation mode at low speed. 3. Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. 4. Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. 5. After checking the completeness of the program through the test run above, execute it in the automatic operation mode. 8. While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

1.1.3

Safety During Maintenance For the safety of maintenance personnel, pay utmost attention to the following. 1. Except when specifically necessary, turn off the power of the controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on. 2. When disconnecting the pneumatic system, be sure to reduce the supply pressure. 3. Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition. 4. If it is necessary to enter the robot work area for maintenance when the power is turned on, the worker should indicate that the machine is being serviced and make certain that no one starts the robot unexpectedly. 5. Do not operate the robot in the automatic mode while anybody is in the robot work area. 6. When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. 7. When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion. 8. If necessary, have a worker who is familiar with the robot system stand beside the operator’s and observe the work being s-7

SAFETY PRECAUTIONS

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performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. 9. When replacing or reinstalling components, take care to prevent foreign matter from entering the system. 10. When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock. 11. When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of nonspecified ratings. They may cause a fire or result in damage to the components in the controller.

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1.2

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1

Precautions in Programming 1. Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. 2. Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. 3. For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other. 4. Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.2.2

Precautions for Mechanism 1. Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust. 2. Employ a limit switch or mechanical stopper to limit the robot motion so that the robot does not encounter its peripheral devices or tools.

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1.3

SAFETY OF THE ROBOT MECHANISM

1.3.1

Precautions in Operation

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1. When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality. 2. Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

1.3.2

Precautions in Programming 1. When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. 2. Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.3.3

Precautions for Mechanisms 1. Keep the work area of the robot clean, and operate the robot in an environment free of grease, water, and dust.

1.3.4

Procedure to move arm without drive power in emergency or abnormal situations 1. For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit can be used to move the robot axes without drive power. Please order following unit and cable. Name Brake release unit Robot connection cable Power cable

Specification A05B-2450-J350 (Input voltage AC100-115V single phase) A05B-2450-J351 (Input voltage AC200-240V single phase) A05B-2450-J360 (5m) A05B-2450-J361 (10m) A05B-2525-J010 (5m) (AC100-150V type) A05B-2525-J011 (10m) (AC100-150V type) A05B-2450-J364 (5m) (AC100-200V type) A05B-2450-J365 (10m) (AC100-200V type)

2. Please make sure that adequate numbers of brake release units are available and readily accessible for robot system before installation. 3. Regarding how to use brake release unit, please refer to Robot controller maintenance manual. s-10

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SAFETY PRECAUTIONS

NOTE Robot systems installed without adequate number of brake release units or similar means are neither in compliance with EN ISO 10218-1 nor with the Machinery Directive and therefore cannot bear the CE marking. CAUTION Robot arm would fall down by releasing its brake because of gravity. Therefore, it is strongly recommended to take adequate measures such as hanging Robot arm by a crane before releasing a brake.

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SAFETY PRECAUTIONS

In case of releasing J2-axis motor brake

Fall down

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In case of releasing J3-axis motor brake

Fall down

Fall down

Method of ing robot arm Using M10 tap and eyebolt （sling １pcs）

Using M12 tap and eyebolt (sling 2pcs)

(*)This figure is example of floor mount. The direction of fall is different according to the installation angle,so please robot appropriately in consideration of the influence of gravity.

Fig. 1.3.4 Releasing J2 and J3 motor brake and measures

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1.4

SAFETY OF THE END EFFECTOR

1.4.1

Precautions in Programming 1. To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. 2. Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

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1.5

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SAFETY IN MAINTENANCE 1. Never enter the robot work area while the robot is operating. Turn off the power before entering the robot work area for inspection and maintenance. 2. If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operator’s box. 3. When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts in the pneumatic system, be sure to reduce the pressure in the piping to zero by turning the pressure control on the air regulator. 4. When handling each unit or printed circuit board in the controller during inspection, turn off the power of the controller and turn off the circuit breaker to protect against electric shock. 5. When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of nonspecified ratings. They may cause a fire or result in damage to the components in the controller. 6. Before restarting the robot, be sure to check that no one is in the robot work area and that the robot and its peripheral devices are all in the normal operating state.

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1.6

WARNING LABEL (1) Greasing and degreasing label

Fig. 1.6 (a) Greasing and Degreasing Label

Description When greasing and degreasing, observe the instructions indicated on this label. 1. When greasing, be sure to keep the grease outlet open. 2. Use a manual pump to grease. 3. Be sure to use specified grease.

CAUTION See section I.3.1 REPLACING GREASE OF THE DRIVE MECHANISM for explanations about specified greases, the amount of grease to be supplied, and the locations of grease and degrease outlets for individual models.

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(2) Step-on prohibitive label

Fig. 1.6 (b) Step-on Prohibitive Label

Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller and you may get hurt if you lose your footing as well. (3) High-temperature warning label

Fig. 1.6 (c) High-temperature warning label

Description Be cautious about a section where this label is affixed, as the section generates heat. If you have to inevitably touch such a section when it is hot, use a protective provision such as heat resistant gloves.

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SAFETY PRECAUTIONS

(4) Transportation label

Fig. 1.6 (d) Transportation label

Description When transporting the robot, observe the instructions indicated on this label. 1. Using a forklift • Use a forklift having a load capacity of 3,000 kg or greater. • Keep the total weight of the robot to be transported to within 1,000 kg, because the withstand load of the forklift bracket (option) is 13,720 N (1,400 kgf). 2. Using a crane • Use a crane having a load capacity of 3,000 kg or greater. • Use at least four slings each having a withstand load of 9,800 N (1,000 kgf) or greater. • Use at least four eyebolts each having a withstand load of 6,174 N (630 kgf) or greater.

CAUTION See section II.3.1 TRANSPORTATION for explanations about the posture a specific model should take when it is transported.

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(5) Motion range, Max. payload label When CE specification is specified, following label is added.

+180DEG -180DEG

0DEG

44

3246

J5-axis rotation center

Motion range of J5-axis rotation center

844

2650

MAX. PAYLOAD : 350kg Fig. 1.6(e) Motion range, max. payload label

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(6) Transportation prohibitive label (When transportation equipment option is specified.)

アイボルトを横引 しないこと Do not pull eyebolt sideways

輸送部材に衝撃を 与えないこと Do not have impact on this part

輸送部材にチェーン などを掛けないこと Do not chain, pry, or strap on this part

Fig. 1.6 (f) Transportation prohibitive label

Description Keep the following in mind when transporting the robot. 1. Do not pull eyebolts sideways. 2. Prevent the forks of the forklift from having impact on transport equipment. 3. Do not thread a chain or the like through a transport equipment.

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PREFACE

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PREFACE This manual explains the maintenance and connection procedures for the following robots: Model name FANUC Robot M-900iA/350 FANUC Robot M-900iA/260L FANUC Robot M-900iA/350 FANUC Robot M-900iA/260L

Mechanical unit specification No.

Maximum load

A05B-1327-B201

350kg

A05B-1327-B203

260kg

A05B-1327-B501

350kg

A05B-1327-B503

260kg

Controller

R-J3iB

R-30iA

CAUTION Note that the models for the R-J3iB controller and those for the R-30iA controller partly differ in the specifications of mechanical unit cables and motors. The label stating the mechanical unit specification number is affixed in the position shown below. Before reading this manual, determine the specification number of the mechanical unit.

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PREFACE

TABLE 1 No.

B-82135EN/05

(1)

CONTENTS

LETTERS

FANUC Robot M-900iA/350 FANUC Robot M-900iA/260L FANUC Robot M-900iA/350 FANUC Robot M-900iA/260L

(2)

(3)

(4)

(5)

TYPE

No.

DATE

A05B-1327-B201

PRINT SEAL NO.

PRINT PRODUCTION YEAR AND MONTH

WEIGHT (Without controller) 1720kg

A05B-1327-B203

1800kg

A05B-1327-B501

1720kg

A05B-1327-B503

1800kg

Position of label indicating mechanical unit specification number

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PREFACE

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Specifications ITEM Type Controlled axes Installation (NOTE) Motion range J1-axis Motion range J2-axis Motion range J3-axis Motion range J4-axis Motion range J5-axis Motion range J6-axis Max. Motion speed J1-axis Max. Motion speed J2-axis Max. Motion speed J3-axis Max. Motion speed J4-axis Max. Motion speed J5-axis Max. Motion speed J6-axis Max. Load capacity at wrist Max. Load capacity at J3 arm Max. Load capacity at J2 arm Allowable load moment at wrist J4-axis Allowable load moment at wrist J5-axis Allowable load moment at wrist J6-axis Allowable load inertia at wrist J4-axis Allowable load inertia at wrist J5-axis Allowable load inertia at wrist J6-axis Drive method Repeatability Weight Acoustic noise level (NOTE2) Installation environment

M-900iA/350

M-900iA/260L

Articulated Type 6 axes (J1, J2, J3, J4, J5, J6) Floor mount, Upside-down (Angle mount) 360° (6.28rad) 360° (6.28rad) 150° (2.62rad) 150° (2.62rad) 223.4° (3.90rad) 211.28° (3.69rad) 720° (12.57rad) 720° (12.57rad) 250° (4.36rad) 250° (4.36rad) 720° (12.57rad) 720° (12.57rad) 100°/s (1.75rad/s) 100°/s (1.75rad/s) 95°/s (1.66rad/s) 105°/s (1.83rad/s) 95°/s (1.66rad/s) 95°/s (1.66rad/s) 105°/s (1.83rad/s) 120°/s (2.09rad/s) 105°/s (1.83rad/s) 120°/s (2.09rad/s) 170°/s (2.97rad/s) 200°/s (3.49rad/s) 350kg 260kg 25kg 25kg 550kg 550kg 1960N.m (200kgf.m) 1666N.m (170kgf.m) 1960N.m (200kgf.m) 1666N.m (170kgf.m) 891.8N.m (91kgf.m) 715.4N.m (73kgf.m) 235.2kg.m2 (2400kgf.cm.s2) 188.2kg.m2 (1920kgf.cm.s2) 2 2 313.6kg.m2 (3200kgf.cm.s2) 392kg.m (4000kgf.cm.s ) 2 2 235.2kg.m (2400kgf.cm.s ) 188.2kg.m2 (1920kgf.cm.s2) 2 2 313.6kg.m2 (3200kgf.cm.s2) 392kg.m (4000kgf.cm.s ) 2 2 156.8kg.m (1600kgf.cm.s ) 117.6kg.m2 (1200kgf.cm.s2) 2 2 225.4kg.m2 (2300kgf.cm.s2) 352.8kg.m (3600kgf.cm.s ) Electric servo drive by AC servo motor +/- 0.3mm Approx.1720kg Approx. 1800kg 76.3dB Ambient temperature: 0 - 45°C Normally: Ambient humidity 75%RH or less No dew, nor frost allowed. Short time (within one month): Max 95%RH Height: Up to 1,000 meters above the sea level requires no particular provision for attitude. Vibration: 0.5 (4.9m/s2) or less

NOTE 1 The operation range of the J1-axis and J2-axis are limited to the installation condition. 2 This value is equivalent continuous A-weighted sound pressure level, which applied with ISO11201 (EN31201). This value is measured with the following conditions. - Maximum load and speed - Operating mode is AUTO p-3

PREFACE

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RELATED MANUALS For the FANUC Robot series, the following manuals are available: Safety handbook B-80687EN

Intended readers: All persons who use FANUC Robot, system designer All persons who use the FANUC Robot and system Topics: designer must read and understand thoroughly this Safety items for robot system design, operation, handbook maintenance R-J3iB Operator’s manual Intended readers: SPOT TOOL Operator, programmer, maintenance person, controller B-81464EN-1 system designer HANDLING TOOL Topics: B-81464EN-2 Robot functions, operations, programming, SEALING TOOL setup, interfaces, alarms B-81464EN-4 Use: Robot operation, teaching, system design R-J3iB Maintenance manual Intended readers: B-81465EN Maintenance person, system designer controller B-81465EN-1 Topics: (For Europe) Installation, connection to peripheral equipment, maintenance Use: Installation, start-up, connection, maintenance R-30iA Operator’s manual Intended readers: SPOT TOOL+ Operator, programmer, maintenance person, controller B-82594EN-1 system designer HANDLING TOOL Topics: B-82594EN-2 Robot functions, operations, programming, DISPENSE TOOL setup, interfaces, alarms B-82594EN-4 Use: SERVO GUN FUNCTION Robot operation, teaching, system design B-82634EN R-30iA Maintenance manual Intended readers: B-82595EN Maintenance person, system designer controller B-82595EN-1 Topics: (For Europe) Installation, start-up, connection, maintenance B-82595EN-2 Use: (For RIA) Installation, start-up, connection, maintenance Mechanical Maintenance manual Intended readers: unit FANUC Robot M-900iA/350 Maintenance person, system designer Topics: FANUC Robot M-900iA/260L Installation, connection to the controller, B-82135EN maintenance Use: Installation, start-up, connection, maintenance

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TABLE OF CONTENTS

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TABLE OF CONTENTS SAFETY PRECAUTIONS............................................................................s-1 PREFACE ....................................................................................................p-1 MAINTENANCE 1

CONFIGURATION .................................................................................. 3 1.1 1.2 1.3 1.4 1.5

2

PREVENTIVE MAINTENANCE............................................................... 9 2.1 2.2 2.3 2.4 2.5 2.6

3

J1-AXIS DRIVE MECHANISM....................................................................... 4 J2/J3-AXIS DRIVE MECHANISM .................................................................. 5 J4-AXIS DRIVE MECHANISM....................................................................... 6 J5/J6-AXIS DRIVE MECHANISM .................................................................. 7 MAJOR COMPONENT SPECIFICATI ONS .................................................. 8 DAILY CHECKS .......................................................................................... 10 3-MONTH CHECKS (960 hours) ................................................................. 12 1-YEAR CHECKS (3,840 hours).................................................................. 15 1.5-YEAR CHECKS (5,760 hours)............................................................... 16 3-YEAR CHECKS (11,520 hours)................................................................ 17 MAINTENANCE TOOLS ............................................................................. 18

PERIODIC MAINTENANCE .................................................................. 23 3.1

REPLACING GREASE OF THE DRIVE MECHANISM ............................... 24 3.1.1

Grease Replacement Procedure for the J1-Axis/J2- Axis/J3-Axis and J4-Axis Gear Box ......................................................................................................................26

3.2 3.3

4

Grease Replacement Procedure for the Wrist.........................................................26

3.1.3

Procedure for Releasing the Grease Residual Pressure ..........................................27

GREASING POINTS ................................................................................... 29 REPLACING THE BATTERIES ................................................................... 30

TROUBLESHOOTING .......................................................................... 31 4.1 4.2 4.3 4.4

5

3.1.2

OVERVIEW ................................................................................................. 32 FAILURE AND CAUSE................................................................................ 33 BACKLASH MEASUREMENT..................................................................... 40 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 43

ADJUSTMENTS.................................................................................... 44 5.1

AXIS LIMITS SETUP ................................................................................... 45 5.1.1

Zero Point Position and Motion Limit ...................................................................46 c-1

TABLE OF CONTENTS

5.2 5.3

6

6.6 6.7

5.1.3

Hard Stopper and Limit Switch Setting..................................................................51

ADJUSTING LIMIT SWITCH (OPTION) ...................................................... 57 MASTERING ............................................................................................... 60 5.3.1

General ...................................................................................................................60

5.3.2

Resetting Alarms and Preparing for Mastering ......................................................61

5.3.3

Mastering to a Fixture (Master Position Master) ...................................................62

5.3.4

Zero Degree Mastering...........................................................................................67

5.3.5

Quick Mastering .....................................................................................................69

5.3.6

Single Axis Mastering ............................................................................................71

5.3.7

Mastering Data Entry .............................................................................................74

NOTE FOR PART REPLACEMENT............................................................ 77 REPLACING J1-AXIS MOTOR (M1) AND REDUCER ................................ 78 REPLACING J2-AXIS MOTOR (M2) AND REDUCER ................................ 85 REPLACING J3-AXIS MOTOR (M3) AND REDUCER ................................ 90 REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6), WRIST UNIT AND J4 AXIS REDUCER............................................................................. 95 SEALANT APPLICATION............................................................................ 98 REPLACING MOTOR COVERS (OPTION) ................................................ 99 PIPING DIAGRAM..................................................................................... 101 WIRING DIAGRAM.................................................................................... 102

REPLACING CABLES ........................................................................ 105 8.1 8.2 8.3

9

Software Setting .....................................................................................................50

PIPING AND WIRING ......................................................................... 100 7.1 7.2

8

5.1.2

REPLACING PARTS ............................................................................ 76 6.1 6.2 6.3 6.4 6.5

7

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CABLE FORMING ..................................................................................... 107 CABLE REPLACEMENT ........................................................................... 112 LIMIT SWITCH REPLACEMENT (OPTION) ............................................. 120

SEVERE DUST/LIQUID PROTECTION OPTION ............................... 124 9.1

9.2

OVERVIEW ............................................................................................... 125 9.1.1

Severe Dust/Liquid Protection Characteristics.....................................................125

9.1.2

Configuration of the Severe Dust/Liquid Protection Option................................126

9.1.3

Notes on Specifying Severe Dust/Liquid Protection Option................................127

REPLACING COMPONENTS OF THE SEVERE DUST/LIQUID PROTECTION OPTION ............................................................................ 128 9.2.1

Replacing Motor Covers ......................................................................................128

9.2.2

Replacing Cable Covers .......................................................................................130 c-2

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9.2.3

Replacing the Battery and Battery Box Cover .....................................................132

CONNECTION 1

ROBOT INTERFERENCE AREA........................................................ 137 1.1 1.2

2

MECHANICAL COUPLING TO THE ROBOT..................................... 144 2.1 2.2 2.3 2.4 2.5 2.6

2.7 2.8

3

External Dimensions.................................................................................. 138 Operation Area .......................................................................................... 140 WRIST LOAD CONDITIONS ..................................................................... 145 LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM ................... 148 MECHANICAL COUPLING OF END EFFECTOR TO WRIST .................. 149 EQUIPMENT MOUNTING FACE .............................................................. 150 OPERATION PERFORMANCE SCREENS............................................... 151 INERTIA LOAD SETTINGS ....................................................................... 154 2.6.1

Setting...................................................................................................................155

2.6.2

Checking the Settings...........................................................................................156

AIR SUPPLY (OPTION) ............................................................................ 158 INTERFACE FOR OPTION CABLE (OPTION) ......................................... 159

TRANSPORTATION AND INSTALLATION ....................................... 176 3.1

TRANSPORTATION.................................................................................. 177 3.1.1

3.2 3.3 3.4 3.5 3.6

Transportation with an End Effector Attached.....................................................184

INSTALLATION ......................................................................................... 185 MAINTENANCE AREA .............................................................................. 189 AIR PIPING (OPTION) .............................................................................. 190 INSTALLATION SPECIFICATIONS .......................................................... 192 STORAGE ................................................................................................. 193

APPENDIX A

SPARE PARTS LIST .......................................................................... 197

B

CIRCUIT DIAGRAM ............................................................................ 201

C

PERIODIC MAINTENANCE TABLE ................................................... 206

D

MOUNTING BOLT TORQUE LIST ..................................................... 208

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1

MAINTENANCE

1.CONFIGURATION

CONFIGURATION The configuration of the mechanical unit is shown in Fig. 1.

Fig. 1 Mechanical unit configuration

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1.CONFIGURATION

1.1

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J1-AXIS DRIVE MECHANISM Fig. 1.1 shows the J1-axis drive mechanism. The rotation of the J1-axis motor (M1) fastened to the table is input to the reducer through the center gear, and the output rotates the table.

Fig. 1.1 J1-axis drive mechanism

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1.2

MAINTENANCE

1.CONFIGURATION

J2/J3-AXIS DRIVE MECHANISM Fig. 1.2 shows the J2/J3-axis drive mechanism. Rotation of the J2-axis motor (M2) is directly fed to the reducer, and the output moves the J2-axis arm. Rotation of the J3-axis motor (M3) is directly fed to the reducer, and the output moves the J3-axis arm via the Link1 and Link2.

Fig. 1.2 J2/J3-axis drive mechanism

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1.CONFIGURATION

1.3

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J4-AXIS DRIVE MECHANISM Fig. 1.3 shows the J4-axis drive mechanism. Rotation of the J4-axis motor (M4) is fed to the reducer via the gear and drive shaft, and the output rotates the J4-axis (all of the wrist unit).

Fig. 1.3 J4-axis drive mechanism

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1.4

MAINTENANCE

1.CONFIGURATION

J5/J6-AXIS DRIVE MECHANISM Fig. 1.4 shows the J5-axis/J6-axis drive mechanism. The rotation of the J5-axis motor (M5) is input to the reducer via the gear and drive shaft, and the output moves the J5-axis. The rotation of the J6-axis motor (M6) is input to the reducer via the gear and drive shaft, and the output rotates the J6-axis (wrist flange).

Fig. 1.4 J5/J6-axis drive mechanism

NOTE All motors incorporate a brake that is applied when not energized. These brakes are active at power-off and emergency stop.

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1.CONFIGURATION

1.5

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MAJOR COMPONENT SPECIFICATI ONS Table 1.5 (a) Motor Motor Specifications M1

A06B-0268-B605#S000

M2, M3

A06B-0272-B605#S000

M4, M5, M6

A06B-0238-B605#S000

Model (α30/4000is) αiS30/4000 (α40/4000is) αiS40/4000 (α12/4000is) αiS12/4000

Axis J1 J2, J3 J4, J5, J6

Table 1.5 (b) Reducer (M-900iA/350) Axis

Specifications

J1 J2 J3 J4

A97L-0218-0347#500C-30 A97L-0218-0348#550F-253 A97L-0218-0348#550F-253 A97L-0218-0349#160E-57

Table 1.5 (c) Reducer (M-900iA/260L) Axis

Specifications

J1 J2 J3 J4

A97L-0218-0347#500C-30 A97L-0218-0348#550F-227 A97L-0218-0348#550F-267 A97L-0218-0349#160E-57

Table 1.5 (d) Wrist Unit Model Name M-900iA/350 M-900iA/260L

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Specifications A290-7327-T501 A290-7327-T503

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2

MAINTENANCE

2.PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter.

NOTE The periodic maintenance procedures described in this chapter assume that the FANUC robot is used for up to 3840 hours a year. When using the robot beyond this total operating time, correct the maintenance frequencies shown in this chapter by calculation in proportion to the difference between the actual operating time and 3840 hours/year.

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2.PREVENTIVE MAINTENANCE

2.1

MAINTENANCE

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DAILY CHECKS Clean each part, and visually check component parts for damage before daily system operation. Check the following items as the occasion demands. 1. Before turning on power When air control set is combined Item

Check items

1

Air pressure

2

Oiler oil mist quantity

3

Oiler oil level

4

Leakage from hose

Check points Check air pressure using the pressure gauge on the air regulator as shown in Fig. 2.1. If it does not meet the specified pressure of 0.49 to 0.69 MPa (5-7kgf/cm2), adjust it using the regulator pressure setting handle. Check the drop quantity during wrist or hand motion. If it does not meet the specified value (1 drop/10-20 sec), adjust it using the oiler control knob. Under normal usage, the oiler becomes empty in about 10 to 20 days under normal operation. Check to see that the oiler level is within the specified level shown in Fig. 2.1. Check the ts, tubes, etc. for leaks. Repair leaks, or replace parts, as required.

1 2

Oil inlet Adjusting knob

3 4

Lubricator mist amount check 7 Lubricator Fig. 2.1 Air control set (option)

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5 6

Pressure gauge Regulator pressure handle Filter

setting

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2.PREVENTIVE MAINTENANCE

2. After automatic operation Item

Check items

1

Vibration, abnormal noises, and motor heating

2

Changing repeatability

3

Peripheral devices for proper operation

4

Brakes for each axis

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Check points Check whether the robot moves along and about the axes smoothly without unusual vibration or sounds. Also, check whether the temperatures of the motors are excessively high. Check to see that the stop positions of the robot have not deviated from the previous stop positions. Check whether the peripheral devices operate properly according to commands from the robot. Check that the end effector drops within 0.2 mm when the power is cut.

2.PREVENTIVE MAINTENANCE

2.2

MAINTENANCE

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3-MONTH CHECKS (960 hours) 1. Check the following items once every about three months (or 960 hours operating). Additional inspection areas and times should be added to the table according to the robot’s working conditions, environment, etc. Item

Check items

1

Control unit cable

2

Ventilation portion of control unit

Check points Check whether the cable connected to the teach pendant is unevenly twisted. If the ventilation portion of the control unit is dusty, turn off power and clean the unit.

2. First quarterly inspection Check the following items at the first quarterly inspection, then every year thereafter. Item 1

2

3

Check items

Check points

Cables used in mechanical unit

Check whether the jackets of the mechanical unit cables are damaged. Also, check whether the cables are excessively bent or unevenly twisted. Check that the connectors of the motors and connector s are securely engaged. See Section 7.2. (NOTE 1) Cleaning and checking Clean each part (remove chips, etc.) and each part check component parts for cracks and flaws. (NOTE 2) Further tightening Further, tighten the end effector mounting external main bolts bolts and external main bolts. (NOTE 3)

NOTE 1) Inspection points and check items of the mechanical unit cables and connectors Inspection points of the mechanical unit cables Fixed part cables likely to interfere with the J1, J2, and J3 movable parts and peripheral devices For the J1-axis, inspect the cables from above the J2 base and from the side by removing the metal plate on the side of the J1 base. Check items For cables with a cable cover, open the cover before making the check. Check the cables for a sheath break and wear. If wires of the cable appear, replace it.

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MAINTENANCE

2.PREVENTIVE MAINTENANCE

Fig. 2.2 (a) Check items of Mechanical unit cable

Inspection points of the connectors - Power/brake connectors of the motor exposed externally - Robot connection cables and cables, earth terminal Check items - Circular connector: Check the connector for looseness by turning it manually. - Square connector: Check the connector for disengagement of its lever. - Earth terminal: Check the connector for looseness.

Fig. 2.2 (b) Check items of connector

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2.PREVENTIVE MAINTENANCE

MAINTENANCE

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NOTE 2) Cleaning - Necessary cleaning points, dust on the flat part, sedimentation of spatters Clean sediments periodically. In particular, clean the following points carefully. Vicinity of the wrist axis and oil seal If chippings or spatters are attached to the oil seal, an oil leak may be caused. -

Check if the vicinity of the necessary inspection points, wrist part, and J3 arm significantly wears due to rubbing against the welding cable or hand cable. Check if there is a trace of a collision around the gun or hand. Check the reducer or grease bath for an oil leak.

If oil can be found a day after wiping oil, an oil leak may be caused.

Fig. 2.2 (c) Cleaning part

NOTE 3) Points to be retightened -

The end effector mounting bolts, robot installation bolts, and bolts to be removed for inspection need to be retightened. The bolts exposed to the outside of the robot need to be retightened.

For the tightening torque, see the recommended bolt tightening torque shown in the Appendix. A loose prevention agent (adhesive) is applied to some bolts. If the bolts are tightened with greater than the recommended torque, the loose prevention agent may be removed. So, follow the recommended tightening torque when retightening them.

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MAINTENANCE

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2.3

2.PREVENTIVE MAINTENANCE

1-YEAR CHECKS (3,840 hours) Check the following items once every about year (or 3,840 hours operating). Item 1 2 3

Check items Cables used in mechanical unit Cleaning each parts and inspection Tightness of major external bolts

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Check points (See Section 2.2.) (See Section 2.2.) (See Section 2.2.)

2.PREVENTIVE MAINTENANCE

2.4

MAINTENANCE

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1.5-YEAR CHECKS (5,760 hours) Check the following item once every 1.5-year. Item 1

Check items Battery

Check points Replace battery in the mechanical unit. Refer to Section 3.3.

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MAINTENANCE

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2.5

2.PREVENTIVE MAINTENANCE

3-YEAR CHECKS (11,520 hours) Check the following items once every about 3 years (or 11,520 hours operating). Item 1

Check items

Check points

Refer to Section 3.1. Replacing grease of each axis, reducer and gear box

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2.PREVENTIVE MAINTENANCE

2.6

MAINTENANCE

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MAINTENANCE TOOLS The following tools and instruments are required for the maintenance procedures contained in this manual. 1. Measuring instruments Instruments Dial gauge accuracy Slide calipers Push/pull tension gauge

Accuracy/Capacity 1/100 mm accuracy 150 mm capacity 98N (10 kgf) accuracy

Applications Measurement of positioning and backlash Measurement of backlash

2. Tools Cross-point (+) screwdrivers sizes Conventional (-) screwdrivers sizes Box screw drivers Hexagonal wrench key sets (metric) Adjustable wrenches Pliers Cutting pliers Cutting nippers Double hexagon offset wrench Grease gun Pliers for C-retaining ring Torque wrench Gear puller Spanner T-shaped hexagonal wrench

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: Large, medium, and small

: Large, medium, and small : M6 : M3 - M20 : Medium and small sizes

: 30x32mm or 32x36mm (Thickness: 14 mm or less for stopping J41 gear rotation) : M8 (Length: 270 mm or more. Used for wrist axis motor connection) M12 (Length: 300 mm or more. Used for J2 and J3 axis motor connection)

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MAINTENANCE

2.PREVENTIVE MAINTENANCE

3. Special Tools A290-7324-X921 2PCS (Guide pin (M12) for J1/J2/J3-axis reducer replacement) See Fig.2.6 (a). A290-7324-X922 (Spring pin striking tool for J1-axis reducer replacement) See Fig.2.6 (b)) A290-7324-X923 2PCS (Guide pin (M16) for J1/J2/J3-axis reducer replacement) See Fig.2.6 (c). A290-7324-X924 (For bearing installation in the J1-axis input gear) See Fig. 2.6 (d). A290-7321-X947 (For bearing installation in gear J41) See Fig. 2.6 (e). A290-7327-X924 (For oil seal installation in the J2/J3-axis reducer) See Fig. 2.6 (f). A290-7327-X910 (Robot hanging tool for J1-axis reducer replacement) See Fig. 2.6(g). 4. Options (For securing the arm during J2 or J3-axis motor replacement) For changing the J2-axis operating range: A05B-1327-J032 For changing the J3-axis operating range: A05B-1327-J033

Fig. 2.6 (a) Guide pin (M12) for J1/J2/J3-axis reducer replacement

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2.PREVENTIVE MAINTENANCE

MAINTENANCE

Fig. 2.6 (b) Spring pin striking tool for J1-axis reducer replacement

Fig. 2.6 (c) Guide pin (M16) for J1/J2/J3-axis reducer replacement

Fig. 2.6 (d) For bearing installation in the J1-axis input gear

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MAINTENANCE

2.PREVENTIVE MAINTENANCE

Fig. 2.6 (e) For installing bearing on gear J41

Fig. 2.6 (f) For installing oil seal to the J2/J3-axis reducer

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2.PREVENTIVE MAINTENANCE

MAINTENANCE

Fig. 2.6 (g) Robot hanging tool for J1-axis reducer replacement

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3

MAINTENANCE

PERIODIC MAINTENANCE

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3.PERIODIC MAINTENANCE

3.PERIODIC MAINTENANCE

3.1

MAINTENANCE

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REPLACING GREASE OF THE DRIVE MECHANISM Replace the grease of the reducers of J1, J2, and J3 axes, and the J4-axis gear box, and the wrist, every three years or 11,520 hours by using the following procedures.

Table 3.1 (a) Grease for 3-year periodical replacement Quantity Models Supply position

M-900iA/350 M-900iA/260L

J1-axis reducer J2-axis reducer J3-axis reducer J4-axis gear box Wrist

Gun tip pressure

7000g (8000ml) 3000g (3400ml) 2700g (3100ml) 1900g (2200ml) 5000g (5750ml)

Grease name Kyodo yushi

0.15MPa or less (NOTE)

VIGOGREASE RE0 Spec. ; A98L-0040-0174

NOTE When using a hand pump, apply grease approximately once per 1.5 seconds. For grease replacement or replenishment, use the attitudes indicated below. Table 3.1 (b) Attitudes for greasing Supply position J1-axis reducer J2-axis reducer J3-axis reducer J4-axis gear box Wrist

Attitude J1

J2

J3

Arbitrary

Arbitrary 0° 0° Arbitrary

J4

J5

J6

Arbitrary

Arbitrary

Arbitrary

0°

0°

0°

J4

J5

J6

Arbitrary

Arbitrary

Arbitrary

0°

0°

Arbitrary 0° 0° 0°

For ceiling-hung installation, see Table 3.1 (c). Table 3.1 (c) Attitudes for greasing (for ceiling-hung installation) Supply position J1-axis reducer J2-axis reducer J3-axis reducer J4-axis gear box Wrist

Attitude J1

J2

J3

Arbitrary -75°

Arbitrary

Arbitrary

+76° -96° 0°

Arbitrary

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180° or

-180°

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MAINTENANCE

Fig. 3.1 (a) Replacing grease of J1/J2-axis reducer

Fig. 3.1 (b) Replacing grease of J3-axis gear box

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3.PERIODIC MAINTENANCE

3.PERIODIC MAINTENANCE

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Fig. 3.1 (c) Replacing grease of wrist

3.1.1

Grease Replacement Procedure for the J1-Axis/J2Axis/J3-Axis and J4-Axis Gear Box 1. 2. 3. 4.

Move the robot to the greasing attitude described in Section 3.1. Turn off the power. Remove the seal bolt from the grease outlet. Supply new grease until new grease is output from the grease outlet. 5. After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 3.1.3.

3.1.2

Grease Replacement Procedure for the Wrist 1. 2. 3. 4.

Move the robot to the greasing attitude described in Section 3.1. Turn off the power. Remove the seal bolt from wrist grease outlet 1 and 2. Supply new grease through the wrist grease inlet until new grease is output from wrist grease outlet 1. 5. Attach the seal bolt onto wrist grease outlet 1. When reusing the seal bolt, be sure to seal the seal bolt with seal tape. 6. Remove the seal bolt from wrist grease outlet 2. - 26 -

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3.PERIODIC MAINTENANCE

7. Supply new grease through the wrist grease inlet until new grease is output from wrist grease outlet 2. 8. After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 3.1.3.

CAUTION If greasing is performed incorrectly, the internal pressure of the grease bath may suddenly increase, possibly causing damage to the seal, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, observe the following cautions. 1. Before starting to grease, open the grease outlet (remove the plug or bolt from the grease outlet). 2. Supply grease slowly without applying excessive force, using a manual pump. 3. Whenever possible, avoid using a compressed-air pump, powered by the factory air supply. Even when using Table 3.1(a) or less during application of grease. 4. Use grease only of the specified type. Grease of a type other than that specified may damage the reducer or lead to other problems. 5. After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 3.1.3. 6. To prevent accidents caused by slipping, completely remove any excess grease from the floor or robot.

3.1.3

Procedure for Releasing the Grease Residual Pressure Release the residual pressure as described below. Attach the recovery bag under the grease inlet and outlet to prevent drained grease from splattering.

Exchange position J1-axis reducer J2-axis reducer J3-axis reducer J4-axis gear box

Wrist

Operation angle 80° or more 90° or more 70° or more J4=60° or more J5=120° or more J6=60° or more J4=60° or more J5=120° or more J6=60° or more

OVR

Operation time

Release position

50% 50% 50%

20minutes 20minutes 20minutes

A A A

100%

20minutes

B

100%

10minutes

C

For A: Make a run with the grease inlet and outlet open. For B: Make a run with only the grease outlet open. For C: Make a run with all of the grease inlets and outlets in the following figure open. - 27 -

3.PERIODIC MAINTENANCE

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Fig. 3.1.3 Positions to be released when the wrist residual pressure is released

When the above operation is impossible due to ambient conditions, perform the program operation for a time equivalent to the above. (When the maximum allowable axis angle is half the specified angle, run the program for twice the specified time.) Upon completion of the above operation, attach the grease nipple or the seal bolt to each the grease inlet and outlet. When reusing the grease nipple and the seal bolt, be sure to seal it with seal tape.

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3.2

3.PERIODIC MAINTENANCE

MAINTENANCE

GREASING POINTS Fig. 3.2 shows the greasing points. If the robot is installed in a severe environment, apply grease whenever necessary. If water splashes on the robot, apply grease immediately. Table 3.2 (b) shows the substitute table grease. Apply grease every three years or 11,520 hours. Table 3.2 (a) Greasing points Greasing Grease points Bearing at J2/J3-axis connection

SHELL ALVANIA GREASE S2 (Spec.: A97L-0001-0179#2)

Amount

Way

20 ml each (2 locations)

Apply grease from the grease nipple.

Table 3.2 (b) Substitutes for ALVANIA GREASE S2 MOBIL OIL ESSO STANDARD NIPPON OIL NIPPON OIL IDEMITSU KOHSAN COSMO OIL

MOBILACKS GREASE NO.2 VICON NO.2 MULTINOC 2 EPNOC AP-2 EPONEX GREASE NO.2 DYNAMAX NO.2

Fig. 3.2 Greasing Points

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3.PERIODIC MAINTENANCE

3.3

MAINTENANCE

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REPLACING THE BATTERIES The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every 1.5 year. Also, use the following procedure to replace when the backup battery voltage drop alarm occurs. 1. Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.

NOTE Replacing the batteries with the power supply turned off causes all current position data to be lost. Therefore, mastering will be required again. 2. Remove the battery case cap. 3. Take out the old batteries from the battery case. 4. Insert new batteries into the battery case. Pay attention to the direction of batteries. 5. Close the battery case cap.

Fig. 3.3 Replacing Batteries

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4

MAINTENANCE

TROUBLESHOOTING

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4.TROUBLESHOOTING

4.TROUBLESHOOTING

4.1

MAINTENANCE

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OVERVIEW The cause of a failure in the mechanical unit may be difficult to localize, because failures can arise from many interrelated factors. If you fail to take the correct measures, the failure may be aggravated. Therefore, it is necessary to analyze the symptoms of the failure precisely so that the true cause can be found.

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4.2

4.TROUBLESHOOTING

FAILURE AND CAUSE Table 4.2 lists the major failures that may occur in the mechanical unit and their probable causes. If you cannot pinpoint a failure cause or which measures to apply, FANUC.

Table 4.2 Failures and Causes Symptom Description Vibration Noise

- As the robot operates, its base plate lifts off the floor plate. - There is a gap between the base plate and the floor plate.

- The J1 base lifts off the base plate as the robot operates. - There is a gap between the J1 base and base plate. - A J1 base retaining bolt is loose.

- Apply epoxy to the floor surface and reinstall the plate.

- Vibration becomes more serious when the robot adopts a specific posture. - If the operating speed of the robot is reduced, vibration stops. - Vibration is most noticeable when the robot is accelerating. - Vibration occurs when two or more axes operate at the same time.

Cause [Base plate and floor plate fastening]- It is likely that the base plate is not securely fastened to the floor plate because of poor welding. - If the base plate is not securely fastened to the floor plate, it lifts as the robot operates, allowing the base and floor plates to strike each other, which, in turn, leads to vibration. [J1 base fastening] - It is likely that the robot J1 base is not securely fastened to the base plate. - Probable causes are a loose bolt, an insufficient degree of surface flatness, or foreign material caught between the base plate and floor plate. - If the robot is not securely fastened to the base plate, the J1 base lifts the base plate as the robot operates, allowing the base and floor plates to strike each other, which, in turn, leads to vibration. [Rack or floor] - It is likely that the rack or floor is not sufficiently rigid. - If the rack or floor is not sufficiently rigid, reaction from the robot deforms the rack or floor, leading to vibration. [Overload] - It is likely that the load on the robot is greater than the maximum rating. - It is likely that the robot control program is too demanding for the robot hardware. - It is likely that the ACCELERATION value is excessive.

- 33 -

Measure - Re-weld the base plate to the floor plate. - If the weld is not strong enough, increase its width and length.

- If a bolt is loose, apply Loctite and tighten it to the appropriate torque. - Adjust the base plate surface flatness to within the specified tolerance. - If there is any foreign matter between the J1 base and base plate, remove it. - As the robot operates, the rack or floor on which the robot is mounted vibrates.

- Reinforce the rack or floor to make it more rigid. - If it is impossible to reinforce the rack or floor, modify the robot control program; doing so might reduce the amount of vibration. - Check the maximum load that the robot can handle once more. If the robot is found to be overloaded, reduce the load, or modify the robot control program. - Vibration in a specific portion can be reduced by modifying the robot control program while slowing the robot and reducing its acceleration (to minimize the influence on the entire cycle time).

4.TROUBLESHOOTING Symptom Vibration Noise (Continued)

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Description

Cause

Measure

- Vibration was first noticed after the robot collided with an object or the robot was overloaded for a long period. - The grease of the vibrating axis has not been exchanged for a long period.

[Broken gear, bearing, or reducer] - It is likely that collision or overload applied an excessive force on the drive mechanism, thus damaging the gear tooth surface or rolling surface of a bearing, or reducer. - It is likely that prolonged use of the robot while overloaded caused fretting of the gear tooth surface or rolling surface of a bearing, or reducer due to resulting metal fatigue. - It is likely that foreign matter caught in a gear, bearing, or within a reducer caused damage on the gear tooth surface or rolling surface of the bearing, or reducer. - It is likely that, because the grease has not been changed for a long period, fretting occurred on the gear tooth surface or rolling surface of a bearing, or reducer due to metal fatigue. These factors all generate cyclic vibration and noise.

- Operate one axis at a time to determine which axis is vibrating. - Remove the motor, and replace the gear, the bearing, and the reducer. For the spec. of parts and the method of replacement, FANUC. - Using the robot within its maximum rating prevents problems with the drive mechanism. - Regularly changing the grease with a specified type can help prevent problems.

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MAINTENANCE

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Symptom Vibration Noise (Continued)

4.TROUBLESHOOTING

Description

Cause

Measure

- The cause of problem cannot be identified from examination of the floor, rack, or mechanical section.

[Controller, cable, and motor] - If a failure occurs in a controller circuit, preventing control commands from being supplied to the motor normally, or preventing motor information from being sent to the controller normally, vibration might occur. - If the pulse coder develops a fault, vibration might occur because information about the motor position cannot be transferred to the controller accurately. - If the motor becomes defective, vibration might occur because the motor cannot deliver its rated performance. - If a power line in a movable cable of the mechanical section has an intermittent break, vibration might occur because the motor cannot accurately respond to commands. - If a pulse coder wire in a movable part of the mechanical section has an intermittent break, vibration might occur because commands cannot be sent to the motor accurately. - If a connection cable between them has an intermittent break, vibration might occur. - If the power source voltage drops below the rating, vibration might occur. - If a robot control parameter is set to an invalid value, vibration might occur. [Noise from a nearby machine] - If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. - If the robot is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration.

- Refer to the Controller Maintenance Manual for troubleshooting related to the controller and amplifier. - Replace the pulse coder for the motor of the axis that is vibrating and check whether the vibration still occurs. - Also, replace the motor of the axis that is vibrating, and check whether vibration still occurs. - Check that the robot is supplied with the rated voltage. - Check whether the sheath of the power cord is damaged. If so, replace the power cord, and check whether vibration still occurs. - Check whether the sheath of the cable connecting the mechanical section and controller is damaged. If so, replace the connection cable, and check whether vibration still occurs. - If vibration occurs only when the robot assumes a specific posture, it is likely that a cable in the mechanical unit is broken. - Shake the movable part cable while the robot is at rest, and check whether an alarm occurs. If an alarm or any other abnormal condition occurs, replace the mechanical unit cable. - Check that the robot control parameter is set to a valid value. If it is set to an invalid value, correct it. FANUC for further information if necessary.

- There is some relationship between the vibration of the robot and the operation of a machine near the robot.

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- Connect the grounding wire firmly to ensure a reliable ground potential and prevent extraneous electrical noise.

4.TROUBLESHOOTING Symptom

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Description

Cause

Measure

Vibration Noise (Continued)

- There is an unusual sound after replacement of grease. - There is an unusual sound after a long period. - There is an unusual sound during operation at low speed.

- Use the specified grease. - When there is an unusual sound even for specified grease, perform operation for one or two days on an experiment. Generally, a usual sound will disappear.

Rattling

- While the robot is not supplied with power, pushing it with the hand causes part of the mechanical unit to wobble. - There is a gap on the mounting face of the mechanical unit.

- There may be an unusual sound when using other than the specified grease. - Even for the specified grease, there may be an unusual sound during operation at low speed immediately after replacement or after a long period. [Mechanical section coupling bolt] - It is likely that overloading or a collision has loosened a mounting bolt in the robot mechanical section.

- Backlash is greater than the tolerance stated in the applicable maintenance manual. (See Table. 4.3 (b))

[Increase in backlash] - It is likely that excessive force applied to the drive mechanism, due to a collision or overloading, has broken a gear or the inside of the reducer, resulting in an increase in the amount of backlash. - It is likely that prolonged use without changing the grease has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase for backlash.

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Check that the following bolts for each axis are tight. If any of these bolts is loose, apply Loctite and tighten it to the appropriate torque. - Motor retaining bolt - Reducer retaining bolt - Reducer shaft retaining bolt - Base retaining bolt - Arm retaining bolt - Casting retaining bolt - End effector retaining bolt - Operate one axis at a time to determine which axis has the increased backlash. - Remove the motor, and check whether any of its gears are broken. If any gear is broken, replace it. - Check whether any other gear of the drive mechanism is damage. If there is no damage gear, replace the reducer. - If the reducer is broken, or if a gear tooth is missing, replace the relevant component. Also, remove all the grease from the gear box and wash the inside of the gear box. - After replacing the gear or reducer, add an appropriate amount of grease. - Using the robot within its maximum rating prevents problems with the drive mechanism. - Regularly changing the grease with a specified type can help prevent problems.

MAINTENANCE

B-82135EN/05

Symptom Motor Overheating

Description

Cause

- The ambient temperature of the installation location increases, causing the motor to overheat. - After a cover was attached to the motor, the motor overheated. - After the robot control program or the load was changed, the motor overheated.

[Ambient temperature] - It is likely that a rise in the ambient temperature or attaching the motor cover prevented the motor from releasing heat efficiently, thus leading to overheating. [Operating condition] - It is likely that the robot was operated with the maximum average current exceeded.

- After a control parameter was changed, the motor overheated.

[Parameter] - If data input for a workpiece is invalid, the robot cannot be accelerated or decelerated normally, so the average current increases, leading to overheating. [Mechanical section problems] - It is likely that problems occurred in the mechanical unit drive mechanism, thus placing an excessive load on the motor. [Motor problems] - It is likely that a failure of the motor brake resulted in the motor running with the brake applied, thus placing an excessive load on the motor. - It is likely that a failure of the motor prevented it from delivering its rated performance, thus causing an excessive current to flow through the motor.

- Symptom other than stated above

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4.TROUBLESHOOTING Measure The teach pendant can be used to monitor the average current. Check the average current when the robot control program is running. The allowable average current is specified for the robot according to its ambient temperature. FANUC for further information. - Relaxing the robot control program and conditions can reduce the average current, thus preventing overheating. - Reducing the ambient temperature is the most effective means of preventing overheating. - Having the surroundings of the motor well ventilated enables the motor to release heat efficiently, thus preventing overheating. Using a fan to direct air at the motor is also effective. - If there is a source of heat near the motor, it is advisable to install shielding to protect the motor from heat radiation. - Input an appropriate parameter as described in the controller operator’s manual.

Repair the mechanical unit while referring to the above descriptions of vibration, noise, and rattling. - Check that, when the servo system is energized, the brake is released. - If the brake remains applied to the motor all the time, replace the motor. - If the average current falls after the motor is replaced, it indicates that the first motor was faulty.

4.TROUBLESHOOTING Symptom

MAINTENANCE

Description

Cause

Measure - If a crack develops in the casting, sealant can be used as a quick-fix to prevent further grease leakage. However, the component should be replaced as soon as possible, because the crack might extend. - O-rings are used in the locations listed below. - Motor coupling section - Reducer (case and shaft) coupling section - Wrist coupling section - J3 arm coupling section - Inside the wrist - Oil seals are used in the locations stated below. - Inside the reducer - Inside the wrist - Seal bolts are used in the locations stated below. - Grease drain outlet - Replace the grease nipple. - Check whether the brake drive relay s are stuck to each other. If they are found to be stuck, replace the relay. - If the brake shoe is worn out, if the brake main body is damaged, or if oil or grease has entered the motor, replace the motor.

Grease Leakage

- Grease is leaking from the mechanical unit.

[Poor sealing] - Probable causes are a crack in the casting, a broken O-ring, a damaged oil seal, or a loose seal bolt. - A crack in a casting can occur due to excessive force that might be caused in collision. - An O-ring can be damaged if it is trapped or cut during disassembling or re-assembling. - An oil seal might be damaged if extraneous dust scratches the lip of the oil seal. - A loose seal bolt or a plug might allow grease to leak along the threads. - Problems with the grease nipple or threads.

Dropping axis

- An axis drops because the brake does not function. - An axis drops gradually when it should be at rest.

[Brake drive relay and motor] - It is likely that brake drive relay s are stuck to each other to keep the brake current flowing, thus preventing the brake from operating when the motor is deenergized. - It is likely that the brake shoe has worn out or the brake main body is damaged, preventing the brake from operating efficiently. - It is likely that oil or grease has entered the motor, causing the brake to slip.

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Symptom Displacement

Description - The robot operates at a point other than the taught position. - The repeatability is not within the tolerance.

- Displacement occurs only in a specific peripheral unit.

- Displacement occurred after a parameter was changed.

BZAL alarm occurred

- BZAL is displayed on the controller screen.

4.TROUBLESHOOTING

Cause

Measure

[Mechanical section problems] - If the repeatability is unstable, probable causes are a failure in the drive mechanism or a loose bolt. - If the repeatability becomes stable, it is likely that a collision imposed an excessive load, leading to slipping on the base surface or the mating surface of an arm or reducer. - It is likely that the pulse coder is abnormal. [Peripheral unit displacement] - It is likely that an external force was applied to the peripheral unit, thus shifting its position relative to the robot. [Parameter] -It is likely that the mastering data was rewritten in such a way that the robot origin was shifted. - It is likely that the voltage of the memory backup battery is low. - It is likely that the pulse coder cable is defected.

- If the repeatability is unstable, repair the mechanical section by referring to the above descriptions of vibration, noise, and rattling. - If the repeatability is stable, correct the taught program. Variation will not occur unless another collision occurs. - If the pulse coder is abnormal, replace the motor or the pulse coder.

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- Correct the setting of the peripheral unit position. - Correct the taught program.

- Re-enter the previous mastering data, which is known to be correct. - If correct mastering data is unavailable, perform mastering again. - Replace the battery. - Replace the cable.

4.TROUBLESHOOTING

4.3

MAINTENANCE

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BACKLASH MEASUREMENT

Measurement method 1. Maintain the robot in a specified posture. (See Table. 4.3 (a) and Fig. 4.3 (b).) 2. Apply positive and negative loads to each axis as shown in Fig.4.3 (a). 3. Remove the loads and measure the displacement. Measure backlash by applying positive and negative loads to each axis three times. Average the values measured in the last two measurements for each axis, and use the averages as a measured backlash for the respective axes.

Stop position 0

+10kg

Firtst step (Do not measure)

-10kg

+10kg L1

-10kg 0kg

L2

0kg

+10kg 0kg L3

-10kg 0kg

Second step (B2 =L 1+ L2)

Third step (B3=L 3+ L4)

L4

Fig. 4.3 (a) Backlash Measurement Method

Backlash B is calculated using the following expression: B=

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B2 + B3 2

4.TROUBLESHOOTING

MAINTENANCE

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Measurement posture and position Table 4.3 (a) Backlash Measurement Posture Posture

Measured axis

J1-axis

J2-axis

J3-axis

J4-axis

J5-axis

J6-axis

J1-axis

Any angle

75°

0°

0°

0°

90°

J2-axis

Any angle

0°

0°

-90°

90°

0°

J3-axis

Any angle

42°

-90°

-90°

90°

90°

J4-axis J5-axis

Any angle

42°

-90°

-90°

90°

90°

Any angle

0°

0°

-90°

90°

90°

J6-axis

Any angle

0°

0°

0°

-90°

90°

When measuring backlash, press the dial indicator to the center of the test work at right angles.

Loading position

Loading position

《１》　Ｊ１-axis measurement posture

When measurring backlash, press the dial indicator to the center of the test work at right angles.

Loading position 《２》　Ｊ２-axis measurement posture

《３》　Ｊ３-axis measurement posture

Fig. 4.3 (b) Backlash Measurement Posture (1/2)

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When measuring backlash, press the dial indicator to the center of the test work at right angles.

4.TROUBLESHOOTING

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Loading position 《４》　Ｊ４-axis measurment posture

When measuring backlash, press the dial indicator to the center of the test work at right angles.

Loading position When measuring backlash, press the dial indicator to the center of the test work at right angles.

Loading position When measuring backlash press the dial indicator to the center of the test work at right angles.

《５》　Ｊ５-axis measurement posture

《６》　Ｊ６-axis measurment posture

Fig. 4.3 (c) Backlash Measurement Posture (2/2)

Permissible backlash values Table 4.3 (b) Permissible Backlash Value (M-900iA/350) J1-axis

J2-axis

J3-axis

J4-axis

J5-axis

J6-axis

Angle conversion (arc-min)

2.16

2.00

2.00

2.24

2.55

4.94

Displacement conversion (mm)

1.99

0.73

0.73

0.35

0.39

0.40

Distance between the rotation center and dial indicator (mm)

3165

1250

1250

530

530

277

J1-axis

J2-axis

J3-axis

J4-axis

J5-axis

J6-axis

Angle conversion (arc-min)

2.16

2.00

2.00

2.24

2.55

4.94

Displacement conversion (mm)

2.35

0.73

0.99

0.42

0.48

0.46

Distance between the rotation center and dial indicator (mm)

3735

1250

1705

645

645

321

Table 4.3 (c) Permissible Backlash Value (M-900iA/260L)

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4.4

MAINTENANCE

4.TROUBLESHOOTING

COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS Adjustments are needed after a component is replaced. The following table lists components and the adjustment items that must be made after their replacement. After replacing a component, make necessary adjustments according to this table. Component replacement or function change Cable replacement Change to J1-axis stroke Battery replacement (The battery should be replaced once 1.5 years.)

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Adjustment item (a) Cable dressing (b) Quick mastering (a) Change to stopper position (b) Change to parameter Replace the battery with the power kept on. No adjustment is needed.

5.ADJUSTMENTS

5

MAINTENANCE

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ADJUSTMENTS Each part of the mechanical unit is carefully adjusted at the factory before shipment. Therefore, it is usually unnecessary for the customer to make adjustments at the time of delivery. However, after a long period of use or after parts are replaced, adjustments may be required.

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5.1

MAINTENANCE

5.ADJUSTMENTS

AXIS LIMITS SETUP Axis limits define the motion range of the robot. The operating range of the robot axes can be restricted because of: - Work area limitations - Tooling and fixture interference points - Cable and hose lengths There are three methods used to prevent the robot from going beyond the necessary motion range. These are - Axis limit software settings (All axes) - Axis limit hardstops ((J1, J2, J3-axis) optional) - Axis limit switches ((J1, J2, J3-axis) optional)

CAUTION 1 Changing the movable range of any axis affects the operation range of the robot. To avoid trouble, carefully consider a possible effect of the change to the movable range of each axis in advance. Otherwise, it is likely that an unexpected condition occurs; for example, an alarm may occur in a previous taught position. 2 For the J1, J2, and J3 axes, do not count merely on software-based limits to the movable range when changing the movable range of the robot. Use mechanical stoppers together so that damage to peripheral equipment and injuries to human bodies can be avoided. In this case, make the software-specified limits match the limits based on the mechanical stoppers. 3 Mechanical stoppers are physical obstacles. The robot cannot move beyond them. For the J1, J2, and J3 axes, it is possible to re-position the mechanical stoppers. For J5-axis, the mechanical stoppers are fixed. For the J4 and J6 axes, only software-specified limits are available. 4 For changing J2 and J3 axes interference angles, only mechanical stoppers are available; a software specified movable range cannot be changed. 5 Movable mechanical stoppers (J1, J2, and J3 axes) are deformed in a collision to stop the robot. Once a stopper is subject to a collision, it can no longer assure its original strength and, therefore, may not stop the robot. When this happens, replace it with a new one.

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5.ADJUSTMENTS

MAINTENANCE

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Upper Limits Displays the upper limits of each axis, or the axis limits in a positive direction.

Lower Limits Displays the lower limits of each axis, or the axis limits in a negative direction.

5.1.1

Zero Point Position and Motion Limit Zero point and software motion limit are provided for each controlled axis. Exceeding the software motion limit of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit for each axis. The robot cannot exceed the software motion limit unless there is a failure of the system causing loss of zero point position or there is a system error. Fig. 5.1.1 (a) - Fig. 5.1.1 (g) show the zero point and motion limit, LS detection position, and mechanical stopper position of each axis.

Fig. 5.1.1 (a) J1-axis

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MAINTENANCE

Fig. 5.1.1 (b) J2-axis

Fig. 5.1.1 (c) J3-axis

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5.ADJUSTMENTS

MAINTENANCE

Fig. 5.1.1 (d) J2/J3-axis interference angle

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MAINTENANCE

Fig. 5.1.1 (e) J4-axis

Fig. 5.1.1 (f) J5-axis

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5.ADJUSTMENTS

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Fig. 5.1.1 (g) J6-axis

5.1.2

Software Setting Axis limit software settings are upper and lower motion degree limitations. The limits can be set for all robot axes and will stop robot motion if the robot is calibrated.

Procedure Setting Up Axis Limits Step 1. 2. 3. 4.

Press MENUS. Select SYSTEM. Press F1, [TYPE]. Select Axis Limits. You will see a screen similar to the following.

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5.ADJUSTMENTS

NOTE 0 indicates the robot does not have these axes. 5. Move the cursor to the axis limit you want to set.

WARNING Do not depend on J1, J2, and J3 axis limit software settings to control the motion range of your robot. Use the axis limit switches or hardstops also; otherwise, injury to personnel or damage to equipment could occur. 6. Type the new value using the numeric keys on the teach pendant. 7. Repeat Steps 5 through 6 until you are finished setting the axis limits.

WARNING You must turn off the controller and then turn it back on to use the new information; otherwise, injury to personnel or damage to equipment could occur. 8. Turn off the controller and then turn it back on again in cold start mode so the new information can be used.

5.1.3

Hard Stopper and Limit Switch Setting For the J1-axis, J2-axis and J3-axis, it is possible to re-position mechanical stoppers. Change the position of the mechanical stoppers according to the desired movable range. The limit switch-based movable range can be changed by changing the dog positions. The dog for the J1 axis is placed in the same position as the mechanical stopper. Item

J1-axis mechanical stopper, limit switch J2-axis mechanical stopper

Upper limit Lower limit Space between the upper and lower limits Upper limit

Lower limit

Space between the upper and lower limits

M-900iA/350

M-900iA/260L

Settable in steps of 7.5° degrees in a range of -135° to +180° degrees Settable in steps of 7.5° degrees in the range of -180° to +135° degrees A space of 45° degrees or more is required.

Settable in steps of 15° degrees in the range of -60° to +60° degrees. A mechanical stopper is also provided at the upper limit +75° degrees of the standard movable range. Settable in steps of 15° degrees in the range of -60° to +60° degrees. A mechanical stopper is also provided at the lower limit -75° degrees of the standard movable range. A space of 15° degrees or more is required.

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5.ADJUSTMENTS

MAINTENANCE

Item J2-axis limit switch

Upper limit Lower limit

J3-axis (J2+J3) mechanical stopper

Space between the upper and lower limits Upper limit

Lower limit

J3-axis (J2+J3) limit switch

Space between the upper and lower limits Upper limit Lower limit

Space between the upper and lower limits

M-900iA/350

B-82135EN/05

M-900iA/260L

Settable in steps of 15° degrees in the range of -60° to +60° degrees. Also settable to the upper limit +75° degrees of the standard movable range. Settable in steps of 15° degrees in the range of -60° to +60° degrees. Also settable to the lower limit -75° degrees of the standard movable range. A space of 15° degrees or more is required.

Settable in steps of 15° degrees in the range of -120° to +75° degrees. A mechanical stopper is also provided at the upper limit +90° degrees of the standard movable range. Settable in steps of 15° degrees in the Settable in steps of 15° degrees in the range of -120° to +75° degrees. A range of -120° to +75° degrees. A mechanical stopper is also provided mechanical stopper is also provided at the lower limit -121.3° degrees of at the lower limit -133.4° degrees of the standard movable range. the standard movable range. A space of 15° degrees or more is required.

Settable in steps of 15° degrees in the range of -120° to +75° degrees. Also settable to the upper limit +90° degrees of the standard movable range. Settable in steps of 15° degrees in the Settable in steps of 15° degrees in the range of -120° to +75° degrees. A range of -120° to +75° degrees. Also mechanical stopper is also provided settable to the lower limit - 133.4° at the lower limit -121.3° degrees of degrees of the standard movable the standard movable range. range. A space of 15° degrees or more is required.

NOTE If the newly set operation range does not include 0°, it is necessary to change it by zero degree mastering so that 0° is included.

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MAINTENANCE

Fig. 5.1.3 (a) Mechanical stopper change of J1-axis (option)

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5.ADJUSTMENTS

5.ADJUSTMENTS

MAINTENANCE

Fig. 5.1.3 (b) Mechanical stopper change of J2-axis (option)

Fig. 5.1.3 (c) Mechanical stopper change of J3-axis (option)

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Fig. 5.1.3 (d) J1-axis dog (option) change

Fig. 5.1.3 (e) J2-axis dog (option) change

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5.ADJUSTMENTS

MAINTENANCE

Fig. 5.1.3 (f) J3-axis dog (option) change

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5.2

5.ADJUSTMENTS

MAINTENANCE

ADJUSTING LIMIT SWITCH (OPTION) Axis limit switches are overtravel switches that, when tripped, cut power to the servo motors and an operation is stopped. Overtravel switches for J1-axis, J2-axis and J3-axis and J2/J3 interference angle are optional. 1. Set the $MOR_GRP.$CAL_DONE system parameter to FALSE. This disables the motion limit specified by the software. As a result, the operator can rotate the robot by a jog feed which goes beyond the motion limit. 2. Loosen the following bolts. Bolts secure the J1-axis: Bolts secure the J2-axis: Bolts secure the J3-axis: Bolt secure the J2/J3 interference angle:

two M8 x 12 two M4 x 25 two M12 x 20 two M6 x 10 two M12 x 20 two M6 x 10 four M4 x 6

3. Move the limit switch so that the robot activates it at about 0.5 degrees before the stroke end. Step on the dog, and position the limit switch in such a place that only one of the step-on allowance indication lines at the tip of the switch is hidden. 4. When the limit switch operates and detects overtravel (OT), the robot stops, and an error message, “OVERTRAVEL”, is displayed. To restart the robot, hold on the SHIFT key and press the RESET key. Then, while holding on the SHIFT key, move the adjusting axis off the OT limit switch by jogging in t mode. 5. Check that the robot also activates the limit switch when the robot is approx. 0.5 degrees from the opposite stroke end in the same way as above. If the limit switch does not operate at the position, adjust the position of the switch again. 6. Set the $MOR_GRP.$CAL_DONE system parameter to TRUE. 7. Turn off the power, and then turn it on again to restart the controller.

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5.ADJUSTMENTS

MAINTENANCE

Fig. 5.2 (a) Adjusting J1-axis limit switch (option)

Fig. 5.2 (b) Adjusting J2-axis limit switch (option)

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MAINTENANCE

Fig. 5.2 (c) Adjusting J3-axis limit switch (option)

Fig. 5.2 (d) Adjusting J2/J3-axis limit switch (option)

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5.ADJUSTMENTS

5.ADJUSTMENTS

5.3

MAINTENANCE

B-82135EN/05

MASTERING Mastering is an operation performed to associate the angle of each robot axis with the pulse count value supplied from the absolute pulse coder connected to the corresponding axis motor. To be specific, mastering is an operation for obtaining the pulse count value corresponding to the zero position.

5.3.1

General The current position of the robot is determined according to the pulse count value supplied from the pulse coder on each axis. Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However, mastering becomes necessary after: -

Motor replacement Pulse coder replacement Reducer replacement Cable replacement Batteries for pulse count backup in the mechanical unit have gone dead.

CAUTION Robot data (including mastering data) and pulse coder data are backed up by their respective backup batteries. Data will be lost if the batteries go dead. Replace the batteries in the control and mechanical units periodically. An alarm will be issued to warn the of a low battery voltage.

Mastering method Table 5.3.1 Types of Mastering Fixture position mastering Zero-position mastering (eye mark mastering) Quick mastering

Single-axis mastering Mastering data entry

This is performed using a mastering fixture before the machine is shipped from the factory. This is performed with all axes set at the 0-degree position. A zero-position mark (eye mark) is attached to each robot axis. This mastering is performed with all axes aligned to their respective eye marks. This is performed at a -specified position. The corresponding count value is obtained from the rotation speed of the pulse coder connected to the relevant motor and the rotation angle within one rotation. Simplified mastering uses the fact that the absolute value of a rotation angle within one rotation will not be lost. This is performed for one axis at a time. The mastering position for each axis can be specified by the . This is useful in performing mastering on a specific axis. Mastering data is entered directly.

Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an operation in which the control unit reads the current pulse count value to sense the current position of the robot. - 60 -

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5.ADJUSTMENTS

CAUTION If mastering is performed incorrectly, the robot may behave unexpectedly. This is very dangerous. Therefore, the positioning screen is designed to appear only when the $MASTER_ENB system variable is 1 or 2. After performing positioning, press F5 [DONE] on the positioning screen. The $MASTER_ENB system variable is reset to 0 automatically, thus hiding the positioning screen. It is recommended that you back up the current mastering data before performing mastering. NOTE It is recommended that you back up the current mastering data before performing mastering.

5.3.2

Resetting Alarms and Preparing for Mastering Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and display the positioning menu.

Alarm displayed “Servo 062 BZAL” or “Servo 075 Pulse mismatch”

Procedure Preparing the Robot for Mastering Step 1. Display the positioning menu by following Steps 1 to Steps 6. 1. Press the screen selection key. 2. Press [0 NEXT] and select [6 SYSTEM]. 3. Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4. Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER]. 5. Press F1 [TYPE], and select [Master/Cal] from the menu. 6. Select the desired mastering type from the [Master/Cal] menu. 2. To reset the “Servo 062 BZAL” alarm, follow Steps 1 to 5. 1. Press the screen selection key. 2. Press [0 NEXT] and select [6 SYSTEM]. 3. Press F1 [TYPE], and select [Master/Cal] from the menu. 4. Press the F3 RES_PCA, then press F4 [TRUE]. 5. Switch the controller power off and on again. 3. To reset the “Servo 075 Pulse mismatch” alarm, follow Steps 1 to 3. 1. When the controller power is switched on again, the message “Servo 075 Pulse mismatch” appears again. 2. Rotate the axis for which the message mentioned above has appeared through 10 in either direction. 3. Press [FAULT RESET]. The alarm is reset. - 61 -

5.ADJUSTMENTS

5.3.3

MAINTENANCE

B-82135EN/05

Mastering to a Fixture (Master Position Master) Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering fixture is used. Fixture position mastering is factory performed. It is unnecessary to perform it in daily operations. When mastering the robot, arrange the robot to meet the following conditions. -

Make the robot mounting base horizontal. (Set the robot mounting face so that the levelness of the entire surface is 1 mm or less.) Remove the hand and other parts from the wrist. Set the robot in the condition protected from an external force.

1. Assembling the fixture base Assemble the fixture base as shown in Fig. 5.3.3 (a). See 2) for the mount of the dial gauges.

Fig. 5.3.3 (a) Assembling fixture base

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MAINTENANCE

5.ADJUSTMENTS

2. Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M5 bolt as shown in Fig. 5.3.3 (b). (Do not tighten the bolt too strongly or the dial indicator will be broken.)

Fig. 5.3.3 (b) Mounting dial indicator

3. Mount the fixture on the J1-axis base with bolts as shown in Fig. 5.3.3 (c).

Fig. 5.3.3 (c) Mounting fixture base

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4. Mount the fixture to the wrist flange as shown in Fig. 5.3.3 (d).

Fig. 5.3.3 (d) Mounting fixture to wrist

Mastering 1. 2. 3. 4.

Press MENUS. Press NEXT and select SYSTEM. Press F1, [TYPE]. Select Master/Cal.

5. Release brake control, and jog the robot into a posture for mastering. See the Fig. 5.3.3 (e) for the mastering posture. - 64 -

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MAINTENANCE

5.ADJUSTMENTS

NOTE Brake control can be released by setting the system variables as follows: $PARAM_GROUP.SV_OFF_ALL: FALSE $PARAM GROUP.SV_ OFF_ ENB[*]: FALSE (For all axes) After changing the system variables, switch the control unit power off and on again. 6. Select Fixture Position Master. 7. Press F4, YES. Mastering will be performed automatically. Alternatively, switch the power off and on again. Switching the power on always causes positioning to be performed. 8. After positioning is completed, press F5 [DONE].

CAUTION No check is made on the axis movable range during mastering. Be very careful when running the robot. Continuing axis movement may result in the mechanical stopper being bumped.

Fig. 5.3.3(e) Mastering attitude (M-900iA/350)

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5.ADJUSTMENTS

MAINTENANCE

Fig. 5.3.3 (f) Mastering attitude (M-900iA/260L)

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5.3.4

5.ADJUSTMENTS

Zero Degree Mastering Zero-position mastering (eye mark mastering) is performed with all axes set at the 0-degree position. A zero-position mark (eye mark) is attached to each robot axis. This mastering is performed with all axes set at the 0-degree position using their respective eye marks. Zero-position mastering involves a visual check. It cannot be so accurate. It should be used only as a quick-fix method.

Procedure Mastering to Zero Degrees Step 1. 2. 3. 4.

Press MENUS. Select NEXT and press SYSTEM. Press F1, [TYPE]. Select Master/Cal.

5. Release brake control, and jog the robot into a posture for mastering.

NOTE Brake control can be released by setting the system variables as follows: $PARAM_GROUP.SV_OFF_ALL: FALSE $PARAM GROUP.SV_ OFF ENB[*]: FALSE (for all axes) After changing the system variables, switch the control unit power off and on again. 6. Select Zero Position Master. 7. Press F4, YES. Mastering will be performed automatically. Alternatively, switch the power off and on again. Switching the power on always causes positioning to be performed.

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5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

Table 5.3.4 Attitude with position marks aligned Axis Position J1-axis J2-axis J3-axis J4-axis J5-axis J6-axis

Fig. 5.3.4 (a) Zero degree position arrow mark for each axis

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0 deg 0 deg 0 deg 0 deg 0 deg 0 deg

MAINTENANCE

B-82135EN/05

5.3.5

5.ADJUSTMENTS

Quick Mastering Quick mastering is performed at a -specified position. The corresponding count value is obtained from the rotation speed of the pulse coder connected to the relevant motor and the rotation angle within one rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will not be lost. Quick mastering is factory-performed at the position indicated in Table. 5.3.4 Do not change the setting unless there is any problem. If it is impossible to set the robot at the position mentioned above, it is necessary to re-set the simplified mastering reference position using the following method. (It would be convenient to set up a marker that can work in place of the eye mark.)

CAUTION 1. Quick mastering can be used, if the pulse count value is lost, for example, because a low voltage has been detected on the backup battery for the pulse counter. 2. Quick mastering cannot be used, after the pulse coder is replaced or after the mastering data is lost from the robot control unit.

Procedure Recording the Quick Master Reference Position Step 1. Select SYSTEM. 2. Select Master/Cal.

3. Release brake control, and jog the robot to the quick mastering reference position. 4. Move the cursor to SET QUICK MASTER REF and press ENTER. Press F4, YES.

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5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

CAUTION If the robot has lost mastery due to mechanical disassembly or repair, you cannot perform this procedure. In this case, master to a fixture or master to zero degrees to restore robot mastery.

Procedure Quick Mastering Step 1. Display the Master/Cal screen.

2. Release brake control, and jog the robot to the quick mastering reference position.

3. Move the cursor to QUICK MASTER and press ENTER. Press F4, YES. Quick mastering data is memorized. 4. Move the cursor to CALIBRATE and press ENTER. Calibration is executed. Calibration is executed by power on again. 5. After completing the calibration, press F5 Done.

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MAINTENANCE

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5.3.6

5.ADJUSTMENTS

Single Axis Mastering Single axis mastering is performed for one axis at a time. The mastering position for each axis can be specified by the . Single axis mastering can be used, if mastering data for a specific axis is lost, for example, because a low voltage has been detected on the pulse counter backup battery or because the pulse coder has been replaced.

Table 5.3.6 Items Set in Single Axis Mastering Item Description Current position (Actual axis) Mastering position (Matra pos)

SEL

ST

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The current position of the robot is displayed for each axis in degree units. A mastering position is specified for an axis to be subjected to single axis mastering. It would be convenient to set to it to the 0° position. This item is set to 1 for an axis to be subjected to single axis mastering. Usually, it is 0. This item indicates whether single axis mastering has been completed for the corresponding axis. It cannot be changed directly by the . The value of the item is reflected in $EACHMST_DON (1 to 9). 0 : Mastering data has been lost. Single axis mastering is necessary. 1 : Mastering data has been lost. (Mastering has been performed only for the other interactive axes.) Single axis mastering is necessary. 2 : Mastering has been completed.

5.ADJUSTMENTS

MAINTENANCE

B-82135EN/05

Procedure Mastering a Single Axis Step 1. Select SYSTEM. 2. Select Master/Cal.

3. Select 4, Single Axis Master. You will see a screen similar to the following.

4. Move the cursor to the SEL column for the unmastered axis and press the numeric key “1”. Setting of SEL is available for one or more axes. 5. Turn off brake control as required, and then jog the robot to the mastering position. 6. Enter axis data for the mastering position.

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MAINTENANCE

5.ADJUSTMENTS

7. Press F5 [EXEC]. Mastering is performed. Therefore, SEL is reset to 0, and ST is re-set to 2 or 1.

8. When single axis mastering is completed, press the previous page key to resume the previous screen.

9. Select [6 CALIBRATE], then press F4 [YES]. Positioning is performed. Alternatively, switch the power off and on again. Positioning is performed. 10. After positioning is completed, press F5 [DONE].

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5.ADJUSTMENTS

5.3.7

MAINTENANCE

B-82135EN/05

Mastering Data Entry This function enables mastering data values to be assigned directly to a system variable. It can be used if mastering data has been lost but the pulse count is preserved.

Mastering data entry method Step 1. Press MENUS, then press NEXT and select SYSTEM. 2. Press F1, [TYPE]. Select [Variables]. The system variable screen appears.

3. Change the mastering data. The mastering data is saved to the $DMR_GRP.$MASTER_COUN system variable.

4. Select $DMR_GRP.

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MAINTENANCE

5.ADJUSTMENTS

5. Select $MASTER_COUN, and enter the mastering data you have recorded.

6. Press the PREV key. 7. Set $MASTER_DONE to TRUE.

8. Display the positioning screen, and select [6 CALIBRATE], then press F4 [YES]. 9. After completing calibration, press F5 [DONE].

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6.REPLACING PARTS

6

MAINTENANCE

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REPLACING PARTS This section describes the replacement procedures for the major components of the mechanical section. When replacing mechanical components, be sure to follow the respective procedures. See Section 8 for how to replace the cables and limit switches.

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6.1

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

NOTE FOR PART REPLACEMENT Once motors, reducers, and gears are replaced, mastering becomes necessary. Perform mastering according to Section 5.3 after any of these components are replaced. Be very careful when carrying and assembling the heavy components listed below.

Table 6.1 Weight of the main parts Component Servo motors

Reducers

Weight (approximate) M1 M2, M3 M4, M5, M6 J1-axis J2-axis J3-axis J4-axis

30kg 35kg 15kg 160kg 95kg 95kg 30kg 90kg 150kg

J2-axis table J2-axis arm Link J3-axis arm

M-900iA/350 M-900iA/260L

115kg 85kg 105kg 110kg

M-900iA/350

365kg

Wrist unit J3-axis casing-wrist unit J2-axis arm-wrist unit J2-axis base-wrist unit

M-900iA/260L

385kg

M-900iA/350

515kg

M-900iA/260L

535kg

M-900iA/350 M-900iA/260L

1195kg 1215kg 180kg

Controller

Remarks

J1 motor is not included.

Link is not included. J1 motor and J2 table are not included.

In case of reusing sealbolts for M-900iA, observe following notes strictly. (If possible, change them to new sealbolts) 1. Apply LOCTITE No.242 to the reusing sealbolts. (However, seal tape needs to be wound around the seal bolts used as a plug.) 2. Notice the following note. - Remove excessive bits of sealant on the sealbolt.

NOTE When applying Loctite to the important bolt tightening points, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient effects cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps.

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6.REPLACING PARTS

6.2

MAINTENANCE

B-82135EN/05

REPLACING J1-AXIS MOTOR (M1) AND REDUCER

1) Replacing J1-axis motor (M1) Remove 1. Turn off the power. 2. Remove the pulse coder connector cover (2). (The cover turns together with the bolt, possibly causing damage to the connector. Hold the cover to prevent it from turning.) 3. Remove three connectors of the motor (1). 4. Remove four motor mounting bolts (4) and then remove the washers (5). 5. Pull out the motor (1) from the 2 base vertically, while being careful not to scratch the surface of the gear (7) teeth. 6. Remove the bolt (12) and washer (11) from the shaft of the motor (1). 7. Pull off the gear (7) with bearing (9), C ring (8,10) from the shaft of the motor (1). 8. Remove the nut (6) from the shaft. Assembling 1. Polish the flange surface of the motor (1) using an oil stone. 2. Mount the nut (6) on the shaft of the motor (1). 3. Attach the gear (7) with bearing (9), C ring (8, 10) to the shaft of the motor (1). Note) Before attaching the gear (7) to the motor (1), attach the bearing (9) and the C rings (8, 10) to the gear (7) by using the fixture (A290-7324-X924). (See Fig. 6.2 (b)) 4. Mount the bolt (12) and the washer (11) on the motor (1). 5. Mount the motor (1) on the 2 base vertically, while being careful not to scratch the surface of the gear (7) teeth. When mounting, make sure that the O-ring (13) is in the prescribed place. 6. Attach the four motor mounting bolts (4) and washers (5). 7. Attach the three connectors to the motor (1). 8. Attach the pulse coder connector cover (2). 9. Perform mastering. (See the Section 5.3 for mastering.)

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6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

1

Name MOTOR

Specifications A06B-0268-B605#S000

Q’ty 1

Loctite

2

COVER

A290-7324-X101

3

BOLT

A6-BA-8X12

1

4

BOLT

A6-BA-12X30

4

5

WASHER

A97L-0001-0823#M12H

4

6

NUT

A290-7324-X151

1 LT242

7

J1 GEAR1

A290-7327-X221

1

8

C RING

A6-CJR-45

1

9

J1 BEARING A97L-0001-0195#09D000A 1

1

10

C RING

A6-CJR-45

1

11

WASHER

A97L-0001-0823#M8H

1

12

BOLT

A6-BA-8X20

1 LT242

13

O RING

JB-OR1A-G125

1

Torque N-m (kgf-m)

1

Fig. 6.2 (a) Replacing J1-axis motor (M1)

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118(12)

27.5(2.8)

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Fig. 6.2 (b) Bearing Presser

2) Replacing J1-axis reducer Remove

WARNING The special tools listed below are required to replace the J1-axis reducer. Be sure to prepare the special tools. Name

Specifications

Guide pin Punch Guide pin Adapter Bolt Nut Eyebolt

A290-7324-X921 A290-7324-X922 A290-7324-X923 A290-7327-X910 A6-BA-16x35 A6-N1-20S JB-BEY-20

Q’ty 2 1 2 2 12 4 4

1. Remove loads such as the hand and workpiece from the wrist. 2. Ensure that the robot assumes the attitude as J1-axis = 0°, J2-axis = -75°, J3-axis = +9°, J4-axis = option, J5-axis = 0°, J6-axis = option, then turn off the power. 3. Remove the J1 motor (2) according to the previous item. 4. Detach the cable for connection between the control unit and the robot, and remove the connector from the back of the J1 base (18), then detach the connector. - 80 -

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MAINTENANCE

6.REPLACING PARTS

5. Remove the cable clamp in the J1 base (18) and the cable clamp on the table (6) so that the cable is disconnected from the J1 unit when the unit above the J2-axis base (1) is lifted up. 6. According to Fig. 6.2 (f) and (f), install the hanging fixtures onto the robot to enable the robot to be hung. 7. Remove the J2-axis base (1) fixing bolt and remove the unit above the J2-axis base (1) from the table (6) by lifting it up with a crane, with due attention to the cable. 8. Remove the cable fixing bolt (7) and the washer (8) and then remove the table (6) and the J1 gear 2 (11) (with the bearing (10)). 9. Remove the reducer mounting bolt (13) and washer (14), then remove the reducer (16) from the J1 base (18). The J1-axis reducer and J1 base are positioned with the spring pin (15). So, remove the J1-axis reducer by using the J1-axis reducer removal tap. Assembling 1. Polish the mounting face of the J1 base reducer with an oilstone. 2. After attaching the O-ring (17) to the reducer (16), mount the reducer onto the J1 base by using the guide pin (A290-7324-X921), and position the reducer by striking the spring pin (15) with the punch (A290-7324-X922). Then, fasten the reducer with the reducer mounting bolt (13) (Apply LT262 and specify the torque.) and washer (14). 3. Apply a sealing agent to the shaft surface of the reducer according to Section 6.6, “SEALANT APPLICATION” and Fig. 6.2 (e). 4. Attach the O-ring (12). Before attachment, replace the O-ring with a new one. 5. Attach the J1 gear 2 (11) (with the bearing (10)). 6. Attach the table (6) and fix it with the table mounting bolt (7) (with LT262 applied and the torque specified) and washer (8). At this time, make sure that the oil seal (9) is placed in the specified position and the lip does not curl up. 7. Place the unit above the J2-axis base onto the table (6) using the guide pin (A290-7324-X923) with due attention to the cables. Then, secure J2-axis base with the bolt. See Fig. 6.2 (d) for the locations where to insert the guide pins. 8. Lay the cables neatly and secure the cable clamp in the J1 base (18) and the cable clamp on the table (6). 9. Attach the connector to the connector on the back of the J1 base (18) and secure it on the robot. 10. Fasten the J1 motor (2) according to the previous item. 11. Connect the cable for connection between the control unit and the robot. 12. Apply grease (See Section 3.1, “REPLACING GREASE OF THE DRIVE MECHANISM”). 13. Perform mastering (See Section 5.3, “MASTERING”).

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6.REPLACING PARTS

MAINTENANCE

Name 1

Specifications

B-82135EN/05

Q’ty

Loctite

J2 BASE

A290-7327-X301

2

MOTOR

Fig.6.2(a)

1

3

BOLT

Fig.6.2(a)

4

4

WASHER

Fig.6.2(a)

4

5

O-RING

Fig.6.2(a)

1

6

TABLE

A290-7327-X202

1

7

BOLT

A6-BA-16X85

19

8

WASHER

A97L-0001-0823#M16H

19

9

Torque N-m(kgf-m)

1

OIL SEAL

A98L-0040-0047#13516514

1

10

J1 BEARING2

A97L-0001-0192#3200000

1

11

J1 GEAR2

A290-7327-X222

1

12

O-RING

A290-7327-X206

1

13

BOLT

A6-BA-12X95

24

14

WASHER

A97L-0001-0823#M12H

24

15

SPRING PIN

A6-PS-12X30

2

16

REDUCER

A97L-0218-0347#500C-30

1

17

O-RING

JB-OR1A-G460

1

18

J1 BASE

A290-7327-X201

1

LT262

LT262

Fig. 6.2 (c) Replacing J1-axis reducer

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318.5 (32.5)

128.4 (13.1)

B-82135EN/05

MAINTENANCE

Fig. 6.2 (d) Insert location of the guide pins and the spring pins

Fig. 6.2 (e) Replacing J1-axis reducer

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6.REPLACING PARTS

6.REPLACING PARTS

MAINTENANCE

Fig. 6.2 (f) Replacing J1-axis reducer (for M-900iA/350)

Fig. 6.2 (g) Replacing J1-axis reducer (for M-900iA/260L)

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6.3

MAINTENANCE

6.REPLACING PARTS

REPLACING J2-AXIS MOTOR (M2) AND REDUCER

1) Replacing the J2-axis motor (M2) Remove 1. Place the robot in the posture shown in Fig. 6.3 (b), and hoist it using a sling.

WARNING When its J2-axis motor is removed, its weight, can cause the J2-axis arm to move extensively unless the robot is in a specified attitude, resulting in a very dangerous situation. If it is impossible to keep the robot in a specified attitude when its J2-axis motor is replaced, fasten the arm so firmly that it will not move. An optional stopper for operation range modification can be used to fasten the J2-axis arm. Before starting to replace the motor, install the stopper and jog-feed the arm to get it sufficiently close to the stopper. 2. Turn off the power. 3. Remove the four pulse coder connector cover (2). (The cover turns together with the bolt, possibly causing damage to the connector. Hold the cover to prevent it from turning.) 4. Detach the three connectors from the J2-axis motor (1). 5. Remove the four motor mounting seal bolts (4) and washers (5). 6. Pull out the J2-axis motor (1) horizontally, while being careful not to damage the surface of the gear teeth. 7. Remove the bolt (9) and washer (8), then dismount the input gear (7), nut (6). Assembling 1. Polish the flange surface of the J2-axis motor (1) using an oil stone. 2. Mount the nut (6). 3. Mount and fasten the input gear (7) with bolt (8) and washer (9). 4. Mount the J2-axis motor (1) horizontally, while being careful not to damage the surface of the gear teeth. Replace the O-ring (10) with a new one, and put the new O-ring in place. 5. Attach the four motor mounting seal bolts (4) and washers (5). 6. Attach the three connectors to the J2-axis motor (1). 7. Attach the pulse coder connector cover (2) 8. Apply grease. 9. Perform mastering. - 85 -

6.REPLACING PARTS

MAINTENANCE

Name

Specifications

B-82135EN/05

Q’ty

1

MOTOR

A06B-0272-B605#S000

1

2

COVER

A290-7324-X101

1

3

BOLT

A6-BA-8X12

1

4

BOLT

A6-BA-12X25

4

5

WASHER

A97L-0001-0823#M12H M-900iA/350

6

NUT M-900iA/260L

Loctite

Torque N-m (kgf-m)

4

It is included in the spec. of INPUT GEAR A97L-0218-0363#253 It is included in the spec. of INPUT GEAR A97L-0218-0363#227

M-900iA/350

A97L-0218-0363#253

M-900iA/260L

A97L-0218-0363#227

1 LT242

7

INPUT GEAR

8

WASHER

A30L-0001-0048#8M

1

9

BOLT

A6-BA-8X70

1 LT242

10

O-RING

JB-OR1A-G125

1

1

Fig. 6.3 (a) Replacing J2-axis motor (M2)

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118 (12)

27.5 (2.8)

MAINTENANCE

B-82135EN/05

6.REPLACING PARTS

Fig.6.3 (b) J2-axis motor (M2) and reducer replacing posture

2) Replacing J2-axis reducer Disassembling 1. Detach all devices of the wrist flange and place the arm in the posture shown in Fig. 6.3 (b) and hoist it using a sling. 2. Switch off the power. 3. Detach all of the cables connected to the motor for J2-axis. 4. Remove the J2 motor (1) according to the procedure described in the previous item. 5. Remove only three sets of bolt (6) and washer (7) that are separated each other and then insert the guide pins (A290-7324-X923) instead. After inserting the guide pins, remove the remaining bolts (6) and washers (7). 6. Remove the bolt (8) and washer (9) and remove the bracket (11). Since the bracket (11) and J2-axis base (16) are positioned by the - 87 -

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

spring pin (10), remove them using the bracket extract threaded holes. 7. Remove the cap (20), grease nipple (19), and pipe (18) from the reducer (14). 8. Remove only three sets of bolt (12) and washer (13) that are separated each other and insert the guide pins (A290-7324-X921) instead. After inserting the guide pins, remove the remaining bolts (12) and washers (13). 9. Remove the reducer (14). Assembling 1. Attach the oil seal (5) to a new reducer (14) using the punching fixture (A290-7324-X924) and then polish the surface on which the reducer (14) is mounted with oil stone. 2. Attach the O-ring (15) to the reducer (14), lift it up with a crane, mount it on the J2 base (16) with the guide pins (A290-7824-X921), and fix it with the bolts (12) (with LT262 applied and the torque specified) and washers (13). At this time, first insert bolts (12) and washers (13) into the holes in which no guide pins (A290-7324-X921) are set (A290-7324-X921) and tighten them. Next, remove the guide pins, insert the bolts (12) and washers (13) instead, and tighten them. 3. Attach the pipe (18) to the reducer (14) and then attach the grease nipple (19) and cap (20). 4. Attach the bracket (11) to the reducer (14) with the guide pins (A290-7824-X923) and secure it with the bolts (6) (with LT262 applied and the torque specified) and washers (7). At this time, first insert bolts (6) and washers (7) into the holes in which no guide pins (A290-7324-X923) are set and tighten them. Next, remove the guide pins, insert the bolts (6) and washers (7) instead, and tighten them. 5. Adjust the phases of the bracket (11) and J2-axis base (16) with the crane and make positioning by hitting the spring pin (10) with the punching (A290-7324-X922). Perform tightening with the bolt (8) (Applying LT262 and specifying the torque) and washer (9). 6. Mount the J2-axis motor (1) as described above. 7. Connect the cables leading to the J2-axis motor (1) and optional cables. 8. Apply grease. 9. Perform mastering.

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6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Name 1 MOTOR

Specifications

Q’ty

Fig.6.3(a)

Loctite

2 BOLT

Fig.6.3(a)

4

3 WASHER

Fig.6.3(a)

4

4 O-RING

Fig.6.3(a)

1

5 OIL SEAL

A98L-0040-0185

6 BOLT

A6-BA-16X50

19 LT262

7 WASHER

A97L-0001-0823#M16H

19

1

8 BOLT

A6-BA-16X40

12 LT262

9 WASHER

A97L-0001-0823#M16H

12

10 SPRING PIN

A6-PS-12X30

11 BRACKET

A290-7327-X306

12 BOLT

A6-BA-12X65

30 LT262

13 WASHER

A97L-0001-0823#M12H

30

14 REDUCER

Torque N-m (kgf-m)

1

319 (32.5) 319 (32.5)

2 1

M-900iA/350

A97L-0218-0348#550F-253

M-900iA/260L

A97L-0218-0348#550F-227

1

15 O-RING

JB-OR1A-G340

16 J2 BASE

A290-7327-X301

1 1

17 J2 ARM

A290-7327-X315

1

18 PIPE

A290-7327-X346

1

19 GREASE NIPPLE

A97L-0218-0013#A610

1

20 CAP

A290-7120-X219

1

Fig. 6.3 (c) Replacing J2-axis reducer

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128 (13.1)

6.REPLACING PARTS

6.4

MAINTENANCE

B-82135EN/05

REPLACING J3-AXIS MOTOR (M3) AND REDUCER

1) Replacing J3-axis motor Disassembling 1. Ensure that the robot assumes the attitude shown in Fig. 6.4 (b) and hang the robot with a sling.

WARNING It is very dangerous to remove J3-axis motor when the robot is not set in the specified posture. This is because the J3-axis arm may be greatly moved by gravity. If the robot cannot be set in the specified posture during replacement of the J3-axis motor, be sure to fix the arm securely. An optional stopper for operation range modification can be used to fasten the J3-axis arm. Before starting to remove the motor, install the stopper, and jog-feed the arm to get it sufficiently close to the stopper. 2. Turn off the power supply. 3. Remove the pulse coder connector cover (2). (At this time, hold the cover so that it does not rotate. Otherwise, it rotates together with the bolt, breaking the connector.) 4. Detach the three connectors from the J3-axis motor (1). 5. Remove the four motor mounting seal bolts (4) and washers (5). 6. Pull out the J3-axis motor (1) horizontally, while being careful not to damage the surface of the gear teeth. 7. Remove the bolt (9) and washer (8), then dismount the input gear (7), nut (6). Assembling 1. Polish the flange surface of the J3-axis motor (1) using an oil stone. 2. Mount the nut (6). 3. Mount the input gear (7) and fasten with bolt (9) and washer (8). 4. Mount the J3-axis motor (1) horizontally, while being careful not to damage the surface of the gear teeth. Replace the O-ring (10) with a new one, and put the new O-ring in place. 5. Attach the four motor mounting bolts (4) and washers (5). 6. Attach the three connectors to the J3-axis motor (1). 7. Attach the pulse coder connector cover (2). 8. Apply grease. 9. Perform mastering.

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6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Name

Specifications

Q’ty

1

MOTOR

A06B-0272-B605#S000

1

2

COVER

A290-7324-X101

1

3

BOLT

A6-BA-8X12

1

4

BOLT

A6-BA-12X25

4

5

WASHER

A97L-0001-0823#M12H M-900iA/350

6

NUT M-900iA/260L

Loctite

Torque N-m (kgf-m)

4

It is included in the spec. of INPUT GEAR A97L-0218-0363#253 It is included in the spec. of INPUT GEAR A97L-0218-0363#267

1 LT242

7

INPUT GEAR

M-900iA/350

A97L-0218-0363#253

M-900iA/260L

A97L-0218-0363#267

8

WASHER

A30L-0001-0048#8M

1

9

BOLT

A6-BA-8X70

1 LT242

10

O-RING

JB-OR1A-G125

1

1

Fig. 6.4 (a) Replacing J3-axis motor (M3)

- 91 -

118 (12)

27.5 (2.8)

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

Fig. 6.4 (b) Changing posture of the J3-axis motor (M3) and reducer

2) Replacing J3-axis reducer Disassembling 1. Detach all devices of the wrist flange and control the attitude as shown in Fig. 6.4 (b), then attach the sling to hang the unit. 2. Turn off the power supply. 3. Detach all cables leading to the J3-axis motor. 4. Remove the J3-axis motor (1) as described above. 5. Remove only three sets of bolt (6) and washer (7) that are separated each other and insert the guide pins (A290-7324-X923) instead. After inserting the guide pins, remove the remaining bolts (6) and washers (7). 6. Remove the bolts (8) and washers (9) and remove the bracket (11). Since the bracket (11) and J2-axis base (16) are positioned by the spring pin (10), remove them using the bracket extract threaded holes. 7. Remove the cap (20), grease nipple (19), and pipe (18) from the reducer (14). 8. Remove only three sets of bolt (12) and washer (18) that are separated each other and insert the guide pins (A290-7324-X921) instead. After inserting the guide pins, remove the remaining bolts (12) and washers (13). 9. Remove the reducer (14). - 92 -

B-82135EN/05

MAINTENANCE

6.REPLACING PARTS

Assembling 1. Attach the oil seal (5) to a new reducer (14) using the punching fixture (A290-7324-X924) and then polish the surface on which the reducer (14) is mounted with oil stone. 2. Attach the new O-ring (15) to the reducer (14), lift it up with a crane, mount it on the J2 base (16) with the guide pins (A290-7824-X921), and fix it with the bolts (12) (with LT262 applied and the torque specified) and washers (13). At this time, first insert bolts (12) and washers (13) into the holes in which no guide pins (A290-7324-X921) are set and tighten them. Next, remove the guide pins, insert the bolts (12) and washers (13) instead, and tighten them. 3. Attach the pipe (18) to the reducer (14) and then attach the grease nipple (19) and cap (20). 4. Attach the bracket (11) to the reducer (14) with the guide pins (A290-7324-X923) and secure it with the bolts (6) (with LT262 applied and the torque specified) and washers (7). At this time, first insert bolts (6) and washers (7) into the holes in which no guide pins (A290-7324-X923) are set and tighten them. Next, remove the guide pins, insert the bolts (12) and washers (13) instead, and tighten them. 5. Adjust the phases of the bracket (11) and J2-axis base (16) with the crane and make positioning by hitting the spring pin (10) with the punching (A290-7324-X922). Perform tightening with the bolt (8) (Applying LT262 and specifying the torque) and washer (9). 6. Mount the J3-axis motor (1) as described above. 7. Attach the cables leading to the J3-axis motor (1) and optional cables. 8. Apply grease. 9. Perform mastering.

- 93 -

6.REPLACING PARTS

MAINTENANCE

Name 1 MOTOR 2 BOLT

Specifications

B-82135EN/05

Q’ty

Fig 6.4(a)

4

3 WASHER 4 O-RING

Fig 6.4(a)

4

Fig 6.4(a)

1

5 OIL SEAL 6 BOLT

A98L-0040-0185

1

A6-BA-16X50

19 LT262

A97L-0001-0823#M16H

19

A6-BA-16X40

12 LT262

9 WASHER 10 SPRING PIN

A97L-0001-0823#M16H

12

11 BRACKET 12 BOLT

A290-7327-X306 A6-BA-12X65

30 LT262

13 WASHER

A97L-0001-0823#M12H

30

14 REDUCER 15 O-RING 16 J2 BASE

A6-PS-12X30

M-900iA/350

Torque N-m (kgf-m)

1

Fig 6.4(a)

7 WASHER 8 BOLT

Loctite

319 (32.5) 319 (32.5)

2 1

A97L-0218-0348#550F-253

M-900iA/260L A97L-0218-0348#550F-267 JB-OR1A-G340 A290-7327-X301

1 1 1

17 LINK

A290-7327-X317

1

18 PIPE

A290-7327-X346

1

19 GREASE NIPPLE

A97L-0218-0013#A610

1

20 CAP

A290-7120-X219

1

Fig. 6.4 (c) Replacing the J3-axis reducer

- 94 -

128 (13.1)

B-82135EN/05

6.5

MAINTENANCE

6.REPLACING PARTS

REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6), WRIST UNIT AND J4 AXIS REDUCER

1) Replacing the Wrist Axis Motors (M4, M5, and M6) The following describes the procedure for replacing wrist axis motors. For convenience, the procedure is provided for each of three motors, but use only the procedure for the motor to be replaced. Disassembling 1. Place the wrist in a posture in which no load is applied to the wrist axis. 2. Switch off the power. 3. Detach the three connectors from the motor (8) for J4-axis, the motor (15) for J5-axis and the motor (1) for J6-axis. 4. Remove the motor mounting bolts (2) and washers (3). 5. Pull out the motor (8), (15) and (1), while being careful not to damage the surface of the gear teeth. 6. In case of J4-axis motor (8), remove the nut (13) and washer (12), and dismount the gear J41 (11) (with bearing (10) and C ring (9)). In case of J5-axis motor (15) remove the nut (18) and washer (17), and dismount the gear J42 (16). In case of J6-axis, motor (1) remove the nut (6) and washer (5) and dismount the gear J43 (4). Assembling 1. Polish the flange surface of the motor (8), (15) and (1) using an oil stone. 2. In case of J4 motor (8), mount gear J41 (11) (with bearing (10) and C ring (9)) with the washer (12) and nut (13). Note) Before attaching the gear J41 (11) to the motor (8), use the fixture A290-7321-X947 to attach the bearing (10) and Cring (9) to the gear J41 (11). In case of J5-axis motor, fasten the gear J42 (16) with the washer (17) and nut (18). In case of J6-axis, motor (1) fasten the gear J43 (4) with the washer (5) and nut (6). 3. Mount the motor (8), (15) and (1), while being careful not to damage the surface of the gear teeth. When mounting, make sure that the O-ring (14), (19) and (7) is in the prescribed place. Also, be sure to orient the motor (1) correctly. 4. Attach the motor mounting bolts (2) and washers (3). 5. Attach the three connectors to the motor (8), (15) and (1). 6. Apply grease. 7. Perform mastering.

NOTE - When tightening the nut (15), hold the gear (13) with a 30x32mm or 32x36mm spanner (Thickness is 14mm or less). - To install a motor, an M8 T-shaped hexagonal wrench not shorter than 270mm is required. - 95 -

6.REPLACING PARTS

MAINTENANCE

Name

Specifications

B-82135EN/05

Q’ty

1

MOTOR

A06B-0238-B605#S000

2

BOLT

A6-BA-8X20

9

3

WASHER

A97L-0001-0823#M8H

9

Loctite

Torque N-m (kgf-m)

1

4

GEAR J61

A290-7327-X425

1

5

WASHER

A6-WB-10S

1

6

NUT

A6-N1-10X1.25S-M-N1

1 LT242

7

O-RING

JB-OR1A-G105

1

8

MOTOR

A06B-0238-B605#S000

1

9

C-RING

A6-CJR-30

1

10

BEARING

A97L-0218-0428#0600000

1

11

GEAR J41

12

WASHER

A6-WB-10S

13

NUT

A6-N1-10X1.25S-M-N1

1 LT242

14

O-RING

JB-OR1A-G105

1

15

MOTOR

A06B-0238-B605#S000

M-900iA/350

A290-7324-X421

M-900iA/260L

A290-7324-Y421

16.7 (1.7)

1 1 16.7 (1.7)

1

M-900iA/350

A290-7324-X423

M-900iA/260L

A290-7324-Y423

16

GEAR J51

1

17

WASHER

A6-WB-10S

18

NUT

A6-N1-10X1.25S-M-N1

1 LT242

19

O-RING

JB-OR1A-G105

1

1

Fig. 6.5 (a) Replacing the Wrist Axis Motors (M4, M5, M6)

- 96 -

16.7 (1.7)

6.REPLACING PARTS

MAINTENANCE

B-82135EN/05

2) Replacing the wrist unit and J4-axis reducer Disassembling 1. Unload the wrist by removing the hand and any workpiece. 2. Remove the wrist unit mounting bolt (2) and washer (3), and then dismount the wrist unit. 3. Remove the reducer mounting bolt (5) and washer (6), and then dismount the reducer (7) from the J3 arm (9). Assembling 1. Install the O-ring (8) onto the reducer (7). 2. Mount the reducer (7) to the J3 arm (9) and fasten with the reducer mounting bolt (5) and washer (6). 3. Install the new O-ring (4) in the groove of the end face of the reducer. 4. Fasten the wrist unit with the wrist unit mounting bolt (2) and washer (3). 5. Apply grease. 6. Perform mastering.

Name 1

WRIST ASSY

2

BOLT

3 4

Specifications M-900iA/350

A290-7327-T501

M-900iA/260L

A290-7327-T503

Q’ty

Loctite

Torque N-m (kgf-m)

LT262

73.5 (7.5)

LT262

128.4 (13.1)

1

A6-BA-10X35

20

WASHER

A97L-0001-0823#M10H

20

O-RING

JB-OR1A-G135

5

BOLT

A6-BA-12X45

12

6

WASHER

A97L-0001-0823#M12H

12

7

REDUCER

A97L-0218-0349#160E-57

1

8

O-RING

A98L-0040-0041#271

1

9

J3 ARM

1

M-900iA/350

A290-7327-X402

M-900iA/260L

A290-7327-Y402

1

Fig. 6.5 (b) Replacing the Wrist Unit and J4 Axis Reducer

- 97 -

6.REPLACING PARTS

6.6

MAINTENANCE

B-82135EN/05

SEALANT APPLICATION

Washing and degreasing the surfaces to be sealed 1. After dismounting the reducer from the arm, apply releasant (Loctite Gasket Remover) to the arm’s surface from which the reducer was dismounted, then wait until the sealant (Loctite 518) becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a spatula. 2. Blow air onto the surface to be sealed to remove dust from the tapped holes. 3. Sufficiently degrease the reducer’s surface to be sealed and the arm’s surface to be sealed, using a cloth dampened with alcohol. 4. Polish the arm’s surface to be sealed with an oil stone, and degrease it with alcohol again.

CAUTION Oil may drip from the inside of the reducer. After degreasing, make sure that no oil is dripping.

Applying sealant 5. Make sure that the reducer and the arm are dry (with no alcohol remaining). If they are still wet with alcohol, wipe them dry. 6. Apply sealant (Loctite 518) to the surfaces.

CAUTION The portions to which sealant is to be applied vary from one axis to another. See descriptions about reducer replacement for the relevant axes for details.

Assembling 7. To prevent dust from sticking to the portions to which sealant was applied, mount the reducer as quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was wiped off, apply again. 8. After mounting the reducer, fasten it with bolts and washers quickly so that the mated surfaces get closer.

CAUTION Do not grease the reducer before the sealant sets, as it may allow grease to leak. Before greasing, wait for about at least one hour after the reducer is mounted.

- 98 -

B-82135EN/05

6.7

MAINTENANCE

6.REPLACING PARTS

REPLACING MOTOR COVERS (OPTION)

Replacing the J4-/J5-/J6-axis motor cover 1. Remove the four M6x10 bolts and washers that fasten the motor cover, and remove the two M12x20 bolts and washers that fasten the plate, and then remove the motor cover. 2. To mount the motor covers, reverse the above mounting procedure steps. In this case, however, first attach the bolts, but keep them loose so that the motor covers can be put in correct place; After the motor covers are positioned properly, tighten the bolts.

Fig. 6.7 Replacing the J4-/J5-/J6-axis motor covers

- 99 -

7.PIPING AND WIRING

7

MAINTENANCE

PIPING AND WIRING

- 100 -

B-82135EN/05

MAINTENANCE

B-82135EN/05

7.1

7.PIPING AND WIRING

PIPING DIAGRAM Fig. 7.1 shows the piping diagram of the mechanical unit.

Fig. 7.1 Piping diagram

- 101 -

7.PIPING AND WIRING

7.2

MAINTENANCE

B-82135EN/05

WIRING DIAGRAM Fig 7.2 (a) shows the wiring diagram of the mechanical unit.

K111 K114 K112 K131 K132 K133 K135 K136 K137 K138 K139 K140

(R-J3iB) or K115 (R-30iA) (M1 to M6 pulse coder, End effector (RDI/RDO) or (RI/RO) (R-J3iB) or K116 (R-30iA) (M1to M6 pulse coder, End effector (RDI/RDO) or (RI/RO): SDLP designated) (M1 to M6 power, brake) ( cable (signal)) ( cable (power)) (Devicenet (signal)) (I/O unit model B) (Load axis (pulse coder)) (Load axis (power brake)) (J1/J2/J3OT) (Devicenet (power supply)) (J2/J3 interference angle OT)

*SDLP：SEVERE DUST&LIQUID PROTECTION

Fig. 7.2 (a) Wiring diagram

- 102 -

B-82135EN/05

MAINTENANCE

Fig. 7.2 (b) Wiring block diagram

- 103 -

7.PIPING AND WIRING

7.PIPING AND WIRING

MAINTENANCE

Fig. 7.2 (c) Connector locations

- 104 -

B-82135EN/05

B-82135EN/05

8

8.REPLACING CABLES

MAINTENANCE

REPLACING CABLES Replace the cables every about four years (or 15,360 hours operating). When the cable is broken or damaged, or shows signs of wear, replace it according to this chapter.

Precaution to be observed when handling the pulse coder cable The pulse coder cable is provided with a marking tie, as shown below, to warn against disconnecting the cable during transportation, installation, or maintenance. If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not disconnect the cable except when replacement of the cable is necessary. The J1-axis, J2-axis and J3-axis motors are provided with a pulse coder connector cover, as shown in Fig. 8 (b), to protect the connectors. Before removing the connectors for cable replacement or other purposes, remove the covers. In this case, turning the bolt may also turn the cover, possibly causing damage to the connector. When removing the cover, hold it to prevent it from turning.

Fig. 8 (a) Marking tie

- 105 -

8.REPLACING CABLES

MAINTENANCE

Fig. 8 (b) Pulse coder connector cover

- 106 -

B-82135EN/05

MAINTENANCE

B-82135EN/05

8.1

8.REPLACING CABLES

CABLE FORMING When replacing cables, clamp the cable at the position specified in Table 8.1 (a) to Table 8.1 (c) using a clamp or a nylon band. Otherwise, cables are loosened or forcedly pulled to cause their disconnection. Refer to the figures in Section 8.2 for the cable clamp position not listed in the Table.

- 107 -

8.REPLACING CABLES

MAINTENANCE

B-82135EN/05

Table 8.1 (a) CABLE CLAMP

Cable clamping position

Mark

GB1

BATTERY BACKUP DON'T

M1P K111

DISCONNECT コネクタ取外不可

M2P

BATTERY BACKUP DON'T

M2P K111

DISCONNECT コネクタ取外不可

DON'T DISCONNECT コネクタ取外不可

RP1 BATTERY BACKUP

J123OT

K111 (R-J3iB) or K115 (R-30iA)

M3P

BATTERY BACKUP

M3P K111

Cable No.

+6V 0V M1P

+

Mark

DO N'T

M4P K111

DISCONNECT コネクタ取外不可

BATTERY BACKUP DO N'T

M5P K111

DISCO NNECT コネクタ取外不可

BATTERY BACKUP DO N'T

M6P K111

DISCONNECT コネクタ取外不可

M4P M5P M6P

EE K111

-

+

EE +6V 0V M1P

GB1

BATTERY BACKUP DON'T

M1 P K114

DISCONNECT コネクタ取外不可

M2P

BATTERY BACKUP DON'T

M2P K114

DISCONNECT コネクタ取外不可

M3P

BATTERY BACKUP DON'T DISCONNECT

M3P K114

コネクタ取外不可

RP1 BATTERY BACKUP DO N'T

J123OT

M4P K114

DISCONNECT コネクタ取外不可

BATTERY BACKUP DO N'T

M5P K114

DISCO NNECT コネクタ取外不可

BATTERY BACKUP DO N'T

M6P K114

DISCONNECT コネクタ取外不可

M4P M5P M6P

EE K114

EE

- 108 -

K114 (R-J3iB) or K116 (R-30iA)

8.REPLACING CABLES

MAINTENANCE

B-82135EN/05

Table 8.1 (b) CABLE CLAMP

Mark

Cable clamping position

Mark

M6M M6BK

M6M K112

M6BK

RM2

M5M K112

M5BK

M4M K112

M4BK

RM1

Cable No.

M3M K112

M3BK

M5M K112 M5BK M4M M4BK M3M M3BK M2M M2BK

M2M K112

M2BK

M1M M1BK

M1M K1 12

M1BK

AS1

AS2 K131

AS-K131

AP1

AP1 K132 AP-K132

DS3

DS1

DS3 K133

DS1-K133

DS3

DS2

I/O

I/O I/O-K135

- 109 -

K135

8.REPLACING CABLES

MAINTENANCE

B-82135EN/05

Table 8.1 (c) CABLE CLAMP

Mark

Cable clamping position

Mark

ARP1

Cable No.

ARP2 K136 +6V 0V

ARP-K136 + -

ARM1

ARM2 ARM-K137

IFOT

COM

NC

IFOTK138

NC

J3OTK138

COM

J123OT J2OTK138

J3 NC J3COM J2 NC J2COM

J123OT

J1OTK138

COM

NC

J1 NC J2COM

DP3

DP1

DP3

DP1-K139

DP2

- 110 -

DP2

K138

B-82135EN/05

8.REPLACING CABLES

MAINTENANCE

Table 8.1 (d) CABLE CLAMP

Mark

Cable clamping position

Mark

Cable No.

3DV

CAM-K143

- 111 -

COM NC IFOT

K142 K142

3DV-K142

CAM

IFOT

COM NC

K140

K140

K143

8.REPLACING CABLES

8.2

MAINTENANCE

B-82135EN/05

CABLE REPLACEMENT This section describes a procedure for periodically replacing all the (full-option) mechanical unit cables. If you need to replace a specific cable (because, for example, it is damaged), do so by referencing this section. See Section 7.2 for the configuration of the mechanical unit cables. Cable replacement makes it necessary to perform mastering. Before attempting replacement, therefore, see Section 5.3.

Replacement procedure 1. Place all the robot axes in their 0-degree position, then set the control unit power switch to off. 2. Detach, from the connector on the rear of the J1-axis base, the cable leading to the control unit. Remove the connector from the J1 base, and then detach all the cable tubes from the connector . When detaching a RM, RP, AS, AP, ARP, ARM, DP connector, leave its housing on the connector ; remove the inserts together with the cable. If the housing is left on the cable, the cable cannot be pulled out through the J1 axis piping (Fig. 8.2 (a)). 3. When the robot has J1-axis limit switches (option), remove the limit switch for the J1-axis from the plate of the J1-axis base, and remove the terminal in the switch, then pull out the cable from the cast through hole (Fig. 8.2 (b)). 4. Remove all connectors from the J1-axis through J6-axis motors. For the precautions that must be taken, see “Precaution to be observed when handling the pulse coder cable” at the beginning of Chapter 8. 5. When the robot has the J2-axis, J3-axis, and interference angle limit switches (option), remove the limit switches from the mounting plate and remove the terminals in the J2-axis and J3-axis limit switches (Fig. 8.2(c)). 6. When the robot has the DS/DP cable (option), remove the cable from the J2-axis base connector (Fig. 8.2(d)). 7. Run the J2-axis and J3-axis motor and pulse coder cables, J2-axis and J3-axis limit switch cables (option), and J2-axis DS/DP cables (option) into the J2 base. 8. Remove the connector on the back of the J3-axis casing (Fig. 8.2(e)). 9. Remove the lower plate 1 of the J3-axis casing (Fig. 8.2(e)). 10. Remove the plate 2 that covers the cable on the J2-axis arm (Fig. 8.2(e)). 11. Remove the heat-shrink tubing that covers connectors and remove the interference angle limit switch cable and the J1-axis, J2-axis, and J3-axis limit switch cable connectors (Fig.8.2(c)). 12. Remove the plate 3 that secures the cable on the back of the J2-axis arm (Fig. 8.2(e)). 13. Remove the plate 4 that secures the cable on the top of the J2-axis base (Fig. 8.2(f)). 14. Remove the plate 5 on the J2-axis base (Fig. 8.2(f)). - 112 -

B-82135EN/05

MAINTENANCE

8.REPLACING CABLES

15. Remove the bolts that secure the plate 6 in the J1-axis base, take out the plate, and remove the bolts of the plate that secures the cable (Fig. 8.2(g)). 16. Pull out the cable upward from the pipe of the J1-axis. This completes cable unit detachment from the robot. 17. When replacing a part of the cables, remove the clamp and cover from the cable unit. Next, cut the cable tie securing the cables, and then detach the desired cable(s) (Fig. 8.2 (h)). Install the cable according to the procedure below. 1. Before connecting the cable to the robot, fasten the cable at the marked position with a cable tie, and install the clamp and cable cover (Fig. 8.2 (h)). 2. Run the cable from the top of the J2-axis base to the back of J1-axis base through the J1-axis pipe. 3. Secure the clamp on the plate 6 within the J1-axis base. Securely bind the cable with the thick cable tie (T120I) attached to the clamp and fix the plate on the J1-axis base (Fig.8.2 (g)). 4. Install the upper plate 5 of the J2-axis base (Fig. 8.2(f)). 5. Install the upper plate 4 of the J2-axis base, that fixes cables (Fig. 8.2(f)). 6. Install the upper plate 3 of the J2-axis base, that fixes cables (Fig. 8.2(e)). 7. Install the lower plate 1 of the J3-axis casing (Fig. 8.2(e)). 8. Install the connector on the back of J3-axis casing (Fig.8.2 (e)). 9. When the robot has the interference angle limit switch (option), mount it on the mounting plate, run the cable through the casting hole, connect it to the J1-axis, J2-axis, and J3-axis limit switch cables with connectors, and cover the connector part with heat-shrink tubing (Fig. 8.2(c)). 10. Lay the cables straight in the J2-axis arm to relieve mechanical strain. 11. Install the plate 2 that covers the cable on the back of the J2-axis arm (Fig. 8.2(e)). 12. Connect all connectors to the J1-axis, J2-axis, and J3-axis motors. Attach the pulse coder connector covers to the J1-axis, J2-axis, and J3-axis motors. For notes on this step, refer to “Notes on Using Pulse Coder Cables” at the beginning in Chapter 8. In addition, secure the J3-axis motor cable with a cable tie considering the routing in the J2 base to prevent interference during J3 linking. 13. When the robot has the DS/DP cable (option), secure the connector on the connector and secure the connector on the side of the J2 base (Fig. 8.2(d)). 14. When the robot has the J1-axis, J2-axis, and J3-axis limit switches (option), connect the cable to the limit switch terminal of each axis and mount the limit switch on the mounting plate (Figs. 8.2(b) and (c)). - 113 -

8.REPLACING CABLES

MAINTENANCE

B-82135EN/05

15. Connect the cable and tube to the connector on the back of the J1-axis base. Connect the ground terminal to the J1-axis base, connect battery terminal to the back of the battery box. Secure the connector on the J1-axis base and connect the cable for connection with the control unit to the connector (Fig. 8.2(a)). 16. Turn on the power. If an alarm is issued at this time, release it according to Section 5.3. 17. Perform mastering.

Fig. 8.2 (a) Replacing the cable

- 114 -

B-82135EN/05

MAINTENANCE

Fig. 8.2 (b) Replacing the cable

- 115 -

8.REPLACING CABLES

8.REPLACING CABLES

MAINTENANCE

Fig. 8.2 (c) Replacing the cable

- 116 -

B-82135EN/05

B-82135EN/05

MAINTENANCE

Fig. 8.2 (d) Replacing the cable

Fig. 8.2 (e) Replacing the cable

- 117 -

8.REPLACING CABLES

8.REPLACING CABLES

MAINTENANCE

Fig. 8.2 (f) Replacing the cable

Fig. 8.2 (g) Replacing the cable

- 118 -

B-82135EN/05

B-82135EN/05

MAINTENANCE

Fig. 8.2 (h) Replacing the cable

- 119 -

8.REPLACING CABLES

8.REPLACING CABLES

8.3

MAINTENANCE

B-82135EN/05

LIMIT SWITCH REPLACEMENT (OPTION) This section explains how to replace limit switches. See the cable replacement procedure for an explanation of how to detach the limit switch cables.

CAUTION 1 Before limit switch replacement, turn off the power to the control unit. 2 After a limit switch is installed, be sure to adjust the limit switch. 1. J1-axis limit switch replacement 1. Remove the limit switch from the plate on the J1-axis base. 2. Cut the cable tie, and detach the cable from the plate. 3. Remove the terminal in the switch, and remove the limit switch from the cable. 4. Attach a new limit switch to the cable. 5. Install the limit switch on the plate. 6. Fasten the cable to the plate with a cable tie. 2. J2-axis limit switch replacement 1. Cut the cable tie used to prevent the limit switch cable from slackening. 2. Remove the two plates used to fasten the limit switch to the robot. 3. Remove the limit switch from the plate. 4. Remove the terminal in the switch, and then remove the limit switch from the cable. 5. Attach a new limit switch to the cable. 6. Install the limit switch on the plate. 7. Install the two plates used for securing the limit switch on the robot, on the robot. 8. Secure the limit switch cable with a cable tie on the robot to prevent slack.

CAUTION 1 If the cable slackens, it may with robot components, causing a break. Exercise care to prevent the slackening cable being with robot components. 2 At some sections on the cable where the clearance between the cable and the casting is small, sponge covers are wound for protection. When securing the cable, make sure that the sponge covers are placed near the casting. 9. Adjust limit switches. 3. Interference limit switch replacement - 120 -

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MAINTENANCE

8.REPLACING CABLES

1. Remove the cover plate and cut the cable tie for preventing the limit switch cable from slacking. 2. Remove the nylon clip. 3. Remove the limit switch from the plate. 4. Remove the heat-shrink tubing, remove the connector for connection with the J1-axis, J2-axis, and J3-axis limit switch cables, and then remove the limit switch. 5. Install a new limit switch on the plate. 6. Connect the cable to the J1-axis, J2-axis, and J3-axis limit switch cable connectors through the casting hole and cover the connectors with heat-shrink tubing. 7. Secure the cable with the nylon clip. 8. Secure the limit switch cable with a cable tie on the robot to prevent slack.

CAUTION 1 If the cable slackens, it may with robot components, causing a break. Exercise care to prevent the slackening cable being with robot components. 2 At some sections on the cable where the clearance between the cable and the casting is small, sponge covers are wound for protection. When securing the cable, make sure that the sponge covers are placed near the casting. 9. Fasten the cover plate. 10. Adjust limit switches.

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8.REPLACING CABLES

MAINTENANCE

Fig. 8.3 (a) Replacing the J1-axis limit switch

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MAINTENANCE

8.REPLACING CABLES

Fig. 8.3 (b) Replacing the J2/J3-axis interference angle limit switch

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9.SEVERE DUST/LIQUID PROTECTION OPTION

9

MAINTENANCE

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SEVERE DUST/LIQUID PROTECTION OPTION

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9.1

9.SEVERE DUST/LIQUID PROTECTION OPTION

MAINTENANCE

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OVERVIEW The package is intended to improve the Severe dust/Liquid protection characteristics of the robot so that it can be used in a severe environment. It is also intended to improve the rust resistance of the robot so that it can be used for a longer time.

9.1.1

Model

Severe dust/liquid protection specification

M-900iA/350,260L

A05B-1327-J801

Severe Dust/Liquid Protection Characteristics The following table lists the IEC529-based Severe dust/Liquid protection characteristics of the M-900iA.

J3-axis arm and wrist section Driving unit of the body Main body

Standard

Severe dust/liquid protection package

IP67 IP66 IP54

IP67 IP66 IP56

Fig. 9.1.1 Severe dust/Liquid protection characteristics of the M-900iA

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9.SEVERE DUST/LIQUID PROTECTION OPTION

9.1.2

MAINTENANCE

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Configuration of the Severe Dust/Liquid Protection Option The following table lists the major differences between the M-900iA/350, 260L standard specification and severe dust/liquid protection package. Standard specification Whole mechanical unit

Bolts

Bolts Black steel bolt Black washer

Cover

J3-axis connector EE, I/O connector

Non-waterproof connector

Dust-proof/drip-proof enhancement package Main body

J3-axis arm and wrist section

FR coating bolt FR coating bolt Black chrome plated washer Black chrome plated washer Stainless bolt Stainless bolt Black steel bolt J1-axis motor cover J2-axis motor cover J3-axis motor cover J4, 5, 6-axis motor cover Battery box cover Mechanical unit cable cover (for all exposed cable sections) Waterproof connector

Fig. 9.1.2 Configuration of the Severe dust/Liquid protection option

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9.1.3

MAINTENANCE

9.SEVERE DUST/LIQUID PROTECTION OPTION

Notes on Specifying Severe Dust/Liquid Protection Option 1. The liquids below cannot be applied because they may cause deterioration or corrosion of the rubber parts (such as packings, oil seals, and O-rings) used in the robot. 1. Organic solvent 2. Chlorine- or gasoline-based cutting fluid. 3. Amine-based cleaning fluid 4. Liquid or solution that includes a corrosive such as an acid or alkali or causes rust 5. Some other liquid or solution to which nitrile rubber (NBR) does not have resistance 2. When the robot is used in an environment where a liquid such as water is dashed over the robot, great attention should be given to drainage under the J1-axis base. A failure may be caused if the J1-axis base is kept immersed in water due to poor drainage.

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9.SEVERE DUST/LIQUID PROTECTION OPTION

MAINTENANCE

9.2

REPLACING COMPONENTS OF THE SEVERE DUST/LIQUID PROTECTION OPTION

9.2.1

Replacing Motor Covers

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Replacing the J1-axis motor cover 1. Remove the bolt (5) that fixes the motor cover (1) to the motor body and then remove the motor cover. 2. To attach the motor cover, reverse the above procedure.

Replacing the J2- or J3-axis motor cover 1. Remove the bolt (5) that fixes the motor cover (2) to the motor body, remove the bolt (6) that fixes the motor cover to the bracket, and then remove the motor cover. 2. To attach the motor cover, reverse the above procedure.

Replacing the J4-, J5-, or J6-axis motor cover 1. Remove the washer (9) and bolt (8) that fix the motor cover (3) to the J3 casing and plate (4) and then remove the motor cover. 2. Remove the bolt (7) that fixes the plate (4) to the J3 casing and then remove the plate. 3. To attach the motor cover, reverse the above procedure.

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9.SEVERE DUST/LIQUID PROTECTION OPTION

MAINTENANCE

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3 9 8

4 7

1 5

6

6

5

5 2 2

Name

Specification

Q’ty

1

MOTOR COVER

A290-7327-X601

1

2

MOTOR COVER

A290-7327-X602

1

3

MOTOR COVER

A290-7327-X603

1

4

PLATE

A290-7327-X604

1

5

BOLT

A6-BA-8X12SUS

4

6

BOLT

A6-BA-12X16SUS

2

7

BOLT

A6-BA-12X20SUS

2

8

BOLT

A6-BA-6X10SUS

6

9

WASHER

A6-WM-6S

6

Fig. 9.2.1 The exchange of the motor cover

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9.SEVERE DUST/LIQUID PROTECTION OPTION

9.2.2

MAINTENANCE

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Replacing Cable Covers In the severe dust/liquid protection option, the cable cover is put on exposed cables. When replacing the cables or cable covers, put the covers as described in Fig. 9.2.2.

NOTE Arrange the wrinkles at the end of the cable cover and fix the end to the connector or cable with a cable tie. NOTE When the cable cover is put, the side with the Velcro strap must face downward or the covering side (male side) must lie on the covered side correctly to prevent water from entering the inside of the cover or being left in the cover.

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MAINTENANCE

Fig. 9.2.2 Attachment of cable covers

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9.SEVERE DUST/LIQUID PROTECTION OPTION

9.SEVERE DUST/LIQUID PROTECTION OPTION

9.2.3

MAINTENANCE

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Replacing the Battery and Battery Box Cover

Replacing the battery 1. Remove the six SUS bolts (M4 x 10) and remove the plate of the battery box cover. 2. Replace the battery as described in Section 3.3. 3. Install the plate with the six SUS bolts (M4 x 10).

Replacing the battery box cover NOTE When the battery box cover is replaced, the power must be kept on as in the replacement of the battery because the battery box needs to be opened. If the battery is replaced when the power is off, mastering becomes necessary because current position information is lost. Press the emergency stop button to prevent danger during the work. 1. Remove the six SUS bolts (M4 x 10) and then remove the plate of the battery box cover. 2. Remove the lid of the battery box and then take the battery out of the box. 3. Remove the four flat head screws (M4 x 12) that fix the battery box and battery box cover together to the J1-axis connector and then remove the battery box and battery box cover. 4. Remove the battery cable terminal on the rear face of the battery box and replace the battery box cover. 5. Attach the battery box and battery box cover by reversing the above procedure.

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MAINTENANCE

Fig. 9.2.3 Replacement of the battery box cover

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9.SEVERE DUST/LIQUID PROTECTION OPTION

CONNECTION

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1

CONNECTION

1.ROBOT INTERFERENCE AREA

ROBOT INTERFERENCE AREA

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1.ROBOT INTERFERENCE AREA

1.1

CONNECTION

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External Dimensions Fig. 1 shows the external dimensions of the robot. When installing peripheral devices, be careful to clear away any objects that are in the robot’s motion path in normal operation. Fig. 1.1 (a) to Fig. 1.2 (a) show the operation range of the robot.

Fig. 1.1 (a) Mechanical unit operation area (M-900iA/350)

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CONNECTION

1.ROBOT INTERFERENCE AREA

Fig. 1.1 (b) Mechanical unit operation area (M-900iA/260L)

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1.ROBOT INTERFERENCE AREA

1.2

CONNECTION

Operation Area

Fig. 1.2 (a) Mechanical unit operation area (1/2) (M-900iA/350)

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CONNECTION

1.ROBOT INTERFERENCE AREA

Fig. 1.2 (a) Mechanical unit operation area (2/2) (M-900iA/350)

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1.ROBOT INTERFERENCE AREA

CONNECTION

Fig. 1.2 (b) Mechanical unit operation area (1/2) (M-900iA/260L)

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CONNECTION

1.ROBOT INTERFERENCE AREA

Fig. 1.2 (b) Mechanical unit operation area (2/2) (M-900iA/260L)

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2.MECHANICAL COUPLING TO THE ROBOT

2

CONNECTION

MECHANICAL COUPLING TO THE ROBOT

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2.1

CONNECTION

2.MECHANICAL COUPLING TO THE ROBOT

WRIST LOAD CONDITIONS Fig. 2.1 (a), (b) contains diagrams that show the wrist load limits. Apply a load within the region indicated in the graph. Apply the conditions of the allowable load moment and the allowable load inertia.

Fig. 2.1 (a) Wrist Load Diagram (M-900iA/350)

NOTE The FANUC and special flange options cannot be selected.

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2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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Fig. 2.1 (b) Wrist Load Diagram (M-900iA/260L)

NOTE The FANUC and special flange options cannot be selected.

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CONNECTION

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M-900iA/350

M-900iA/260L

350kg

260kg

1960N・m (200kgf・m) 1960N・m (200kgf・m) 891.8N・m (91kgf・m)

1666N・m (170kgf・m) 1666N・m (170kgf・m) 715.4N・m (73kgf・m)

Standard inertia mode

235.2kg・m2 (2400kgf・cm・s2)

188.2kg・m (1920kgf・cm・s2)

High inertia mode

392kg・m2 (4000kgf・cm・s2)

313.6kg・m (3200kgf・cm・s2)

Standard inertia mode

235.2kg・m2 (2400kgf・cm・s2)

188.2kg・m (1920kgf・cm・s2)

High inertia mode

392kg・m2 (4000kgf・cm・s2)

313.6kg・m (3200kgf・cm・s2)

Standard inertia mode

156.8kg・m2 (1600kgf・cm・s2)

117.6kg・m (1200kgf・cm・s2)

High inertia mode

352.8kg・m2 (3600kgf・cm・s2)

225.4kg・m (2300kgf・cm・s2)

Item Load capacity

At wrist J4

Allowable load moment at wrist

J5 J6

J4

Allowable load inertia at wrist

J5

J6

2.MECHANICAL COUPLING TO THE ROBOT

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2

2

2

2

2

2

2.MECHANICAL COUPLING TO THE ROBOT

2.2

CONNECTION

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LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM Following shows J2-axis base and J3-axis arm load conditions. Table 2.2 Installation conditions of loads to be added Installation site Loads Condition J2-axis base

550kg

J3-axis arm

25kg

The center of gravity must lie within a radius of 500 mm from the rotation center of the J1 axis. J3 axis arm 25kg See Fig. 2.2 for the positional condition of the center of gravity.

Fig. 2.2 Load Conditions on J2-Axis Base and J3-Axis Arm

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MECHANICAL COUPLING OF END EFFECTOR TO WRIST Fig. 2.3 (a) and (b) are the diagrams for installing end effectors on the wrist. To fasten the end effector, first position it with two pin holes at [D] using fitting [B] or [C], then lock it using screws at [E]. Select screws and positioning pins of a length that matches the depth of the tapped and pin holes. Fasten the bolt for fixing the end effector with following torque: 128.4 ± 6.4 Nm (1310 ± 65kg fcm) R

2-O12 H7 depth12 O200 Equally spaced [D]

21 7 5.

6-M12 depth 20 O200 Equally spaced [E]

8

A

200u0.05

0°

[C]

O 250 h8

145

[B] +0.040 0

0 -0.072

O 125 H7

145

60°

8

A

270

SECTION A-A 165

130

Fig. 2.3 (a) End effector mounting face (ISO flange)

R

2-O12 H7 depth 12 O200 Equally spaced [D]

21 5.7

6-M12 depth 12 O 200 Equally spaced [E]

8

A

[C] 0 -0.072

200 u0.05

0°

[B] +0.040 0

145

° 60

8

145

O 125 H7 O 250 h8

2.3

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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A

295

SECTION A-A 165

130

Fig. 2.3 (b) End effector mounting face (Insulated flange)

NOTE The FANUC and special flange options cannot be selected.

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2.MECHANICAL COUPLING TO THE ROBOT

2.4

CONNECTION

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EQUIPMENT MOUNTING FACE As shown in Fig. 2.4 tapped holes are provided to install equipment to the robot.

CAUTION Never perform additional machining operation such as drilling or tapping on the robot body. This can seriously affect the safety and function of the robot. NOTE Note that the use of any threaded holes not shown in the following figure could injure personnel or damage equipment.

Fig. 2.4 Equipment mounting faces

- 150 -

CONNECTION

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2.5

2.MECHANICAL COUPLING TO THE ROBOT

OPERATION PERFORMANCE SCREENS The operation performance screens include the MOTION PERFORMANCE screen, MOTION PAYLOAD SET screen, and MOTION ARMLOAD SET screen. These screens are used to specify payload information and equipment information on the robot. 1. 2. 3. 4.

Click the [MENUS] key to display the screen menu. Select “6 SYSTEM” from the next page. Click F1 ([TYPE]). Select “MOTION”. The MOTION PERFORMANCE screen appears.

5. Ten different pieces of payload information can be set using condition No.1 to 10 on this screen. Place the cursor on one of the numbers, and click F3 (DETAIL). The MOTION PAYLOAD SET screen appears.

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2.MECHANICAL COUPLING TO THE ROBOT

Center of robot flange

CONNECTION

X X

y

Z xg (cm)

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Iy (kgf・cm・s 2)

mass m(kg) Center of gravity

Center of gravity

Iz (kgf・cm・s2 ) yg (cm) 2

Ix (kgf・cm・s )

zg (cm)

Fig. 2.5 Standard tool coordinate

6. Set the payload, gravity center position, and inertia around the gravity center on the MOTION PAYLOAD SET screen. The X, Y, and Z directions displayed on this screen correspond to the respective standard tool coordinates (with no tool coordinate system set up). When values are entered, the following message appears: “Path and Cycletime will change. Set it?” Respond to the message with F4 ([YES]) or F5 ([NO]). 7. Clicking F3 ([NUMBER]) will bring you to the MOTION PAYLOAD SET screen for another condition number. For a multigroup system, clicking F2 ([GROUP]) will bring you to the MOTION PAYLOAD SET screen for another group. 8. Click the previous page key to return to the MOTION PERFORMANCE screen. Click F5 ([SETIND]), and enter the desired payload setting condition number. 9. On the MOTION PERFORMANCE screen, click F4 ([ARMLOAD]) to display the MOTION ARMLOAD SET screen.

10. Specify the weight of the load on the J2 axis base and J3 axis arm as follows: ARM LOAD AXIS #1 [kg]: - 152 -

Weight of the load on the J2 axis base

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CONNECTION

ARM LOAD AXIS #3 [kg]:

2.MECHANICAL COUPLING TO THE ROBOT

Weight of the load on the J3 axis arm

The following message appears: “Path and Cycletime will change. Set it?” Respond to the message with F4 ([YES]) or F5 ([NO]). Once the arm payload is set up, the settings are completed by switching the power off and on again.

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2.MECHANICAL COUPLING TO THE ROBOT

2.6

CONNECTION

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INERTIA LOAD SETTINGS For the M-900iA/350 and 260L, there are two parameter settings depending on the magnitude of load inertia. (By default, the parameter settings for the standard inertia mode are made.)

350

Standard inertia mode 235.2kg･m2 (2400kgf･cm･s2)

260L

188.2kg･m (1920kgf･cm･s2)

313.6kg･m (3200kgf･cm･s2)

350

235.2kg･m2 (2400kgf･cm･s2)

392kg･m (4000kgf･cm･s2)

260L

188.2kg･m (1920kgf･cm･s2)

350 260L

J4-axis

Wrist unit allowable load inertia

2

J5-axis

J6-axis

High inertia mode 2 392kg･m (4000kgf･cm･s2) 2

2

2

313.6kg･m (3200kgf･cm･s2)

2

156.8kg･m (1600kgf･cm･s2)

2

352.8kg･m (3600kgf･cm･s2)

117.6kg･m2 (1200kgf･cm･s2)

225.4kg･m (2300kgf･cm･s2)

2

2

CAUTION When a workpiece with inertia exceeding the allowable inertia for the standard inertia mode is used in the standard inertia mode, components of the mechanical unit may be degraded earlier. Software system

Software version

Mechanical unit

V6.10P (7D80) V6.20P (7D81) V6.30P (7D82)

92 or earlier 44 or earlier 41 or earlier

All models

V7.10P (7DA0)

All versions

When M-900iA/350 insulated flange or M-900iA/260L is selected.

Since the high inertia mode is not ed, make use within the allowable range of the standard inertial mode. Software system

Software version

V6.10P (7D80) V6.20P (7D81) V6.30P (7D82)

94 or earlier 46 or earlier 44 or earlier

Mechanical unit

All models

Following the setting method described in Section 2.6.1, make parameter settings depending on the load. (By default, the parameter settings for the standard inertia mode are made.)

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CONNECTION

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Software system

2.MECHANICAL COUPLING TO THE ROBOT

Software version

V6.10P (7D80) V6.20P (7D81) V6.30P (7D82)

95 or earlier 47 or earlier 45 or earlier

V7.10P (7DA0)

All versions

V7.20P (7DA1)

All versions

V7.30P (7DA2)

All versions

Mechanical unit

All models When M-900iA/350 standard flange is selected. When M-900iA/350 standard flange or M-900iA/260L is selected. M-900iA/350 standard flange or solution arm is attached or M-900iA/260L is selected

Parameters are set automatically based on the load settings made in Section 2.5.

NOTE With version 19 or later, the settings can also be used when a solution arm is mounted. CAUTION Set the load inertia correctly as described in Section 2.5. When a workpiece with inertia exceeding the allowable inertia for the standard inertia mode is used in the standard inertia mode, components of the mechanical unit may be degraded earlier.

2.6.1

Setting In the M-900iA/350, when the software edition is: V6.10P (7D80) and the versions is 93 or 94 V6.20P (7D81) and the versions is 45 or 46 V6.30P (7D82) and the versions is any of 42 to 44 Follow the procedure below to change settings manually. To make parameter settings, execute the factory-stored setting program, PAYLD350.PC. This program sets parameters based on the magnitude of the currently used load inertia of the load settings made in Section 2.5. Call the setting program within the operation program. In particular, when changing the load setting with the PAYLOAD SET command, execute this program. [Example of the operation program] 1: PAYLOAD SET [1] 2: CALL PAYLD350 (i) Enter the robot group number in input parameter i of PAYLD350. If input parameter i is not specified, set group 1. - 155 -

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

Exception processing In the following cases, exception processing is performed and a message describing exception processing appears on the screen without changing the parameter. 1. When the load setting condition number (1 to 10) on the operation performance screen is not selected [ screen display] Payload number 0 is invalid. (GP: x) When this message appears, select a load setting condition on the operation performance screen or set the load setting condition with the PAYLOAD SET command. 2. When the group specified by input parameter i of PAYLD350 is not present [ screen display] Incorrect group number When this message appears, specify a correct group number. 3. When the group specified by input parameter i of PAYLD350 is not M-900iA/350 [ screen display] This group is not M-900iA/350 When this message appears, specify a correct group number.

2.6.2

Checking the Settings Settings can be checked on the screen. To display the screen, press the screen selection key and select “9 ”. [ screen display] For the standard inertia load setting: Standard payload set. (GP: x, Payload: y) For the high inertia load setting: High payload set. (GP: x, Payload: y) “x” indicates the group name for which the parameter was set and “y” indicates the load setting number used for evaluation. To check only the current settings without switching the parameter, enter the value obtained by adding 100 to the group number in input parameter i of PAYLD350 and then perform execution. The current parameter settings of the group are displayed on the screen.

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CONNECTION

2.MECHANICAL COUPLING TO THE ROBOT

[ screen display] For the standard inertia load setting: Standard payload type now (GP: x) For the high inertia load setting: High payload type now (GP: x) “x” indicates the group number for which the parameter was checked.

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2.MECHANICAL COUPLING TO THE ROBOT

2.7

CONNECTION

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AIR SUPPLY (OPTION) There is an air-pressure supply opening on the side of the J1-axis base and the front of J3-axis casting. The connector is a Rc1/2 female (ISO). As couplings are not supplied, it will be necessary to prepare couplings, which suit to the hose size.

Fig. 2.7 Air-pressure supply connection (option)

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2.8

CONNECTION

2.MECHANICAL COUPLING TO THE ROBOT

INTERFACE FOR OPTION CABLE (OPTION) Fig. 2.8 (a) to (d) show the position of the end effector interface. End effector interface (RDI/RDO or RI/RO), I/O Unit-MODEL B interface, cable (signal lines, power lines) and device net cable (signal lines, power lines), camera cable and 3DV sensor cable are prepared as options.

Fig. 2.8 (a) Interface for Optional cable (Option)

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2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

J3-axis casing connector (output) End effector interface (RDI/RDO) or (RI/RO)

B-82135EN/05

J1-axis connector (input)

cable (signal) interface (Air supply)

cable (power) interface

cable(power) interface

cable (signal) interface

(Air supply)

VIEW A

VIEW B

VIEW C

With cable(signal/power) J3-axis casing connector (output)

J2-axis base connecotr (output)

J1-axis connector (input) Devicenet cable (power) interface

End effector interface (RDI/RDO) or (RI/RO)

Devicenet cable (signal) interface Devicenet cable (power) interface

Devicenet cable (signal) interface

(Air supply)

(Air supply)

Devicenet cable (signal) interface

Deviecnet cable (power) interface

VIEW A

VIEW D

VIEW C

With devicenet cable (power/signal) J3-axis casing connector (output)

I/OユニットMODEL B インタフェース

J1-axis connector (input)

End effector interface (RDI/RDO) or (RI/RO)

cable (power) interface

I/O UNIT MODEL B interface cable (powerl) interface

(Air supply)

(Air supply)

VIEW A

VIEW B

VIEW C

With I/O unit model B and cable(power)

J3-axis casing connector (output)

J1-axis connector (input)

Additional axis motor (power,brake) interface Additional axis motor (pulse coder) interface

End effector interface (RDI/RDO) or (RI/RO)

（Air supply)

Additional axis motor (power,brake) interface

Additional axis motor (pulse coder) interface (Air supply)

VIEW A

VIEW B

VIEW C

With additional axis motor cable (pulse coder/power,brake)

Fig. 2.8 (b) Interface for Optional cable 1

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2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

J3-axis casing connector (output) End effector interface (RDI/RDO) or (RI/RO)

J1-axis base connector (input) 3DV sensor interface

cable (signal) interface

(Air supply)

cable (signal) interface

(Air supply)

3DV sensor interface

Camera cable interface

Camera cable interface

VIEW A

VIEW B

VIEW C

With cable(signal),camera cable and 3DV sensor

J3-axis casing connector (output)

J1-axis base connector (input) cable (signal) interface

cable (power) interface

(Air supply)

Additional axis motor (pulse coder) interface

Camera cable interface

(Air supply)

Additional axis motor (pulse coder) interface

Additional axis motor (power,brake) interface Camera cable interface

Additional axis motor (power,brake) interface

VIEW A

VIEW B

VIEW C

With cable(signal),camera cable and additional axis motor cable (pulse coder/power,brake) ,without EE

J3-axis casing connector (output)

Camera cable interface

J1-axis base connector (input)

cable (signal) interface

End effector interface (RI/RO)

(Air supply)

cable (signal) interface

VIEW A

(Air supply)

Camera cable interface

VIEW B

VIEW C

With cable(signal) and camera cable (*) This interface does't correspond to R-J3iB controller.

Fig. 2.8 (c) Interface for Optional cable 2

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2.MECHANICAL COUPLING TO THE ROBOT

J3-axis casing connector e (output) End effector interface (RDI/RDO) or (RI/RO)

CONNECTION

B-82135EN/05

J1-axis base connector (input)

cable(power) interface (Air supply)

cable (signal) interface

cable (power) interface cable (signal) interface

(Air supply)

VIEW A

VIEW B

VIEW C

With cable(signal/power) J3-axis casing connector e (output)

J1-axis base connector (input)

Additional axis motor (power,brake) interface Additional axis motor (pulse coder) interface

End effector interface (RDI/RDO) or (RI/RO)

（Air supply)

Additional axis motor (power,brake) interface

Additional axis motor (pulse coder) interface (Air supply)

VIEW A

VIEW B

VIEW C

With additional axis motor cable (pulse coder/power,brake) J3-axis casing connector e (output)

J1-axis base connector (input)

J2-axis base connector (output)

(Air supply)

End effector interface (RDI/RDO) or (RI/RO)

Devicenet cable (power) interface Devicenet cable (power) interface

Devicenet cable (signal) interface

Devicenet cable (signal) interface

(Air supply)

Devicenet cable (power) interface

Devicenet cable (signal) interface

VIEW A

VIEW C

Withd devicenet cable (signa/power)

Fig. 2.8 (d) Interface for Optional cable 3

- 162 -

VIEW D

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

1. End effector interface (RDI/RDO or RI/RO) (option) Fig. 2.8 (e), (f), (g), (h) show pin layout for end effector interface (RDI/RDO or RI/RO).

WARNING The RDO signal for the R-J3iB controller and the RO signal for the R-30iA controller are incompatible with each other because different output formats are used. For details, refer to the maintenance manuals for the controllers. End effector interface(RDI/RDO) (output side) EE 1 RDO1 5 RDO5 10 RDI2

2 RDO2

6 RDO6

11 RDI3

3 RDO3

7 XHBK

12 RDI4

4 RDO4 8 0V

9 RDI1

14 15 XPPABN RDI5 16 17 18 19 20 RDI6 +24V +24V +24V +24V 21 22 23 24 RDI7 RDO7 RDO8

13 RDI8

XHBK

Controller

End effector

Prepared by

:Hand broken

XPPABN:Pneumatic pressure abnormal

Fig. 2.8 (e) Pin layout for end effector interface (RDI/RDO) (option) (For R-J3iB controller)

End effector interface(RI/RO) (output side) EE 1 RO1 5 RO5 10 RI2

2 RO2 6 RO6

11 RI3

3 RO3 7 XHBK

8 0V

9 RI1

14 15 XPPABN RI5 16 17 18 19 20 RI6 +24V +24V +24V +24V 21 22 23 24 RI7 0V RO7 RO8

Controller

12 RI4

4 RO4

End effector

13 RI8

XHBK

Prepared by

:Hand broken

XPPABN:Pneumatic pressure abnormal

Fig. 2.8 (f) Pin layout for end effector interface (RDI/RDO) (option) (For R-30iA controller)

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2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

End effector interface (RDI/RDO) (Output) Han24DD(HARTING) 21 22 23 24

RDO7 RDO8 RDI7

17 18 19 20

+24V +24V +24V +24V

13 14 15 16

RDI8 XPPABN RDI5 RDI6

9 10 11 12

RDI1 RDI2 RDI3 RDI4

5 6 7 8

RDO5 RDO6 XHBK 0V

1 2 3 4

RDO1 RDO2 RDO3 RDO4

End effector

XHBK : Hand broken

Please prepare for .

XPPABN : Pneumatic pressure abnormal

Controller Fig. 2.8 (g) Pin layout for end effector interface (RDI/RDO) (When the severe dust/liquid protection package is selected) (Option) (For R-J3iB controller)

End effector interface (RI/RO) (Output) Han24DD(HARTING) 21 22 23 24

RO7 RDO8 0V RI7

17 18 19 20

+24V +24V +24V +24V

13 14 15 16

RI8 XPPABN RI5 RI6

9 10 11 12

RI1 RI2 RI3 RI4

5 6 7 8

RO5 RO6 XHBK 0V

1 2 3 4

RO1 RO2 RO3 RO4

End effector

XHBK : Hand broken XPPABN : Pneumatic pressure abnormal

Please prepare for .

Controller Fig. 2.8 (h) Pin layout for end effector interface (RI/RO) (When the severe dust/liquid protection package is selected) (Option) (For R-30iA controller)

- 164 -

B-82135EN/05

CONNECTION

2.MECHANICAL COUPLING TO THE ROBOT

2. 2. I/O Unit-MODEL B interface (option) Fig.2.8 (i) show pin layout for I/O Unit-MODEL B interface.

Fig. 2.8 (i) Pin layout for I/O Unit-MODEL B interface (option)

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2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

3. cable (signal line) Interface (option) Fig. 2.8 (j) shows pin layout for cable (signal line) interface. The connector has a code pin for preventing improper insertion. For cables prepared by , use this code pin.

1

Prepared by

4

2

A first pin

5

3

Code pin Fig. 2.8 (j) Pin layout for cable (signal line) interface and code pin layout (option)

- 166 -

cable (signal cable) interface code pin position inlet cable (signal cable) interface code pin position outlet

B-82135EN/05

CONNECTION

2.MECHANICAL COUPLING TO THE ROBOT

4. cable (power line) Interface (option) Fig. 2.8 (k) shows pin layout for cable (power line) interface. The connector has a code pin for preventing improper insertion. For cables prepared by , use this code pin.

1

Prepared by

4

2

A first pin

5

3

Code pin Fig. 2.8 (k) Pin layout for cable (power line) interface and code pin layout (option)

- 167 -

cable (signal cable) interface code pin position inlet cable (signal cable) interface code pin position outlet

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

5. DeviceNet cable (signal line) interface (option) Fig. 2.8 (l) shows pin layout for DeviceNet cable (signal line) interface.

Fig. 2.8 (l) Pin layout for DeviceNet cable (signal line) interface (option)

6. DeviceNet cable (power line) interface (option) Fig. 2.8 (m) shows pin layout for DeviceNet cable (power line) interface.

Fig. 2.8 (m) Pin layout for DeviceNet cable (power line) interface (option)

- 168 -

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

7. Additional axis motor cable (pulse coder cable) interface (optional) Fig. 2.8 (n) shows the pin layout of the additional axis motor cable (pulse coder cable) interface. The connector has a code pin for preventing improper insertion.

Additional axis motor cable (pulsecoder) interface (outlet)

FEMALE TYPE Han24DD (HARTING) 17 18 19 20

21 22 23 24

13 14 15 16

9 +5V(A1) 10 +5V(A2) 11 12 +6V(BT1)

5 6 7 8

1 2 3 0V(BT1) 4

0V(A1) 0V(A2)

Additional axis motor

SPD1 XSPD1 PRQJ1 XPRQJ1

Additional axis motor cable (pulsecoder) interface (inlet)

MALE TYPE Han24DD (HARTING)

Controller 1 2 3 4

SPD1 XSPD1 PRQJ1 XPRQJ1

5 6 7 8

0V(A1) 0V(A2)

9 +5V(A1) 13 10 +5V(A2) 14 11 15 16 12

17 18 19 20

+6V(BT1)

21 22 23 24

0V(BT1)

Battery box

Code pin First pin

First pin

Code pin Additional axis motor cable (pulsecoder) interface code pin position (inlet)

Additional axis motor cable (pulsecoder) interface code pin position (outlet)

Fig. 2.8 (n) Pin Layout of the Additional Axis Motor Cable (Pulse Coder Cable) Interface and Layout Position of the Code Pin (Optional)

- 169 -

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

8. Additional axis motor cable (power and brake cables) interface (optional) Fig. 2.8 (o) shows the pin layout of the additional axis motor cable (power and brake cables) interface. The connector has a code pin for preventing improper insertion.

Additional axis motor cable (pulsecoder) interface (outlet)

FEMALE TYPE Han24DD (HARTING) 21 22 23 24

17 18 19 20

13 14 15 16

9 +5V(A1) 10 +5V(A2) 11 12 +6V(BT1)

5 6 7 8

1 2 3 0V(BT1) 4

0V(A1) 0V(A2)

Additional axis motor

SPD1 XSPD1 PRQJ1 XPRQJ1

Additional axis motor cable (pulsecoder) interface (inlet)

MALE TYPE Han24DD (HARTING)

Controller 1 2 3 4

SPD1 XSPD1 PRQJ1 XPRQJ1

5 6 7 8

0V(A1) 0V(A2)

9 +5V(A1) 13 10 +5V(A2) 14 11 15 16 12

17 18 19 20

+6V(BT1)

21 22 23 24

0V(BT1)

Battery box

Code pin First pin

First pin

Code pin Additional axis motor cable (pulsecoder) interface code pin position (inlet)

Additional axis motor cable (pulsecoder) interface code pin position (outlet)

Fig. 2.8 (o) Pin Layout of the Additional Axis Motor Cable (Power and Brake Cables) Interface and Layout Position of the Code Pin (Optional)

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2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

Connector Specifications Table 2.8 (a) Connector specifications (Mechanical unit side) Cable Input side (J1-axis base) RDO/RDO or RI/RO I/O

Output side (J3-axis casing)

───

JMWR2524F

───

JMWR2516F

AS (Signal)

Housing Insert Code pin

09 30 006 0301 09 16 024 3001(Han 24DD M) 09 15 000 6103 09 30 000 9901

Housing Insert Code pin

09 30 006 0301 09 16 024 3101(Han 24DD F) 09 15 000 6203 09 30 000 9901

AP (Power)

Housing Insert Code pin

09 20 010 0301 09 21 015 3001(Han 15D M) 09 15 000 6101 09 30 000 9901

Housing Insert Code pin

09 20 010 0301 09 21 015 3101(Han 15D F) 09 15 000 6201 09 30 000 9901

Housing Insert Guide pin Bush

09 30 006 0301 09 16 024 3101(Han 24DD F) 09 15 000 6204 09 33 000 9908 09 33 000 9909

RDI/RDO or RI/RO When the severe dust/liquid protection package is selected

───

- 171 -

Manu. Fujikura Ltd

Harting

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

Table 2.8 (b) Connector specifications ( side) Cable Input side (J1-axis base) RDI/RDO or RI/RO

────

I/O

────

Hood Select one

AS (Signal)

Insert Select one Clamp Select one

AP (Power)

Hood Select one Insert Select one

Clamp Select one Code pin

B-82135EN/05

Output side (J3-axis casing) JMSP2524M Straight (Appendix) (FANUC specification: A63L-0001-0234#S2524M) JMLP2524M Angle JMSP2516M Straight (Appendix) JMLP2516M Angle

09 30 006 1540 Side entry 1541 0542 0543 1440 Top entry 1441 0442 0443 09 16 024 3101(Han 24DD F) 09 15 000 6204 AWG 26-22 6203 AWG 20 6205 AWG 18 6202 AWG 18 6201 AWG 16 6206 AWG 14 09 00 000 5083 5086 5090 5094

Hood

← The same

Insert

09 16 024 3001(Han 24DD M) 09 15 000 6104 AWG 26-22 6103 AWG 20 6105 AWG 18 6102 AWG 18 6101 AWG 16 6106 AWG 14



Clamp

← The same

Hood

← The same

Insert

09 21 015 3001(Han 15D M) 09 15 000 6104 AWG 26-22 6103 AWG 20 6105 AWG 18 6102 AWG 18 6101 AWG 16 6106 AWG 14

Manu.

Fujikura Ltd

Harting

etc 09 20 010 1541 Side entry 0540 0541 1440 Top entry 0440 0441 09 21 015 3101(Han 15D F) 09 15 000 6204 AWG 26-22 6203 AWG 20 6205 AWG 18 6202 AWG 18 6201 AWG 16 6206 AWG 14



09 00 000 5083 5086 5090 5094

Clamp

← The same

etc 09 30 000 9901

Code pin

- 172 -

09 30 000 9901

Harting

CONNECTION

B-82135EN/05

Table 2.8 (b) Connector specifications ( side) (continued) Cable Input side (J1 base)

Hood

RDI/RDO or RI/RO Severe dust/liquid protection cables which are corresponded is specified

Insert

────

Clamp

Guide pin Bush

2.MECHANICAL COUPLING TO THE ROBOT

Output side (J3 casing) 09 30 006 1540 Side entry 1541 0542 0543 1440(Appendix) Top entry (FANUC specification: A63L-0001-0453#06B1440) 1441 0442 0443 09 16 024 3001(Han 24DD M) (Appendix) (FANUC specification: A63L-0001-0453#24DDM) 09 15 000 6104(Appendix) AWG 26-22 (FANUC specification: A63L-0001-0453#CA6140) 6103 AWG 20 6105 AWG 18 6102 AWG 18 6101 AWG 16 6106 AWG 14 09 00 000 5083(Appendix) 5086 5090 5094 etc 09 33 000 9908(Appendix) (FANUC specification: A63L-0001-0453#A-9908) 09 33 000 9909(Appendix) (FANUC specification: A63L-0001-0453#A-9909)

Manu.

Harting

NOTE For details, such as the dimensions, of the parts listed above, refer to the related catalogs offered by the respective manufacturers, or FANUC.

- 173 -

2.MECHANICAL COUPLING TO THE ROBOT

CONNECTION

B-82135EN/05

Table 2.8 (c) Connector specifications (DeviceNet cable) (Mechanical unit side) Cable Input side (J1-axis base) Output side Manu. (J2-axis Manu. base) DS (Signal line)

84854-9101

DP (Power line)

Housing Insert

MOLEX 84854-9100 JAPAN CO., LTD. 09 30 006 0301(Han 6E) 09 32 010 3001(Han 10EE M) 09 33 000 6104

Harting

84854-9102

Output side (J3-axis casing)

Manu.

MOLEX 84854-9100 JAPAN CO., LTD.

MOLEX JAPAN CO., LTD.

MOLEX 84854-9102 JAPAN CO., LTD.

MOLEX JAPAN CO., LTD.

Table 2.8 (d) Connector specifications (DeviceNet cable, on the equipment side) Cable Input side (J1-axis base) Output side Manu. Manu. (J2-axis base)

Output side (J3-axis casing)

Manu.

DS (Signal line)

MINI connector for use on the device net 5-pin FEMALE CM03A-R5P-P-2

Fujikura MINI connector for Fujikura use on the device Ltd Ltd net, 5-pin male CM03A-R5P-P-2

MINI connector for Fujikura use on the device Ltd net, 5-pin male CM03A-R5P-P-2

DP (Power line)

Hood

Harting

MINI connector for Fujikura use on the device Ltd net, 4-pin male CM03A-PR4S-P-2

MINI connector for Fujikura use on the device Ltd net, 4-pin male CM03A-PR4S-P-2

09 30 006 1540(Han 6E) Side entry 1541 Select 0542 one 0543 1440 Top entry 1441 0442 0443 Insert

09 32 010 3101(Han 10EE F)

09 33 000 6220 6214 6205 6204 6202 6207

AWG20 AWG18 AWG18 AWG16 AWG14 AWG12

Clamp 09 00 000 5083 5086 Select 5090 one 5094 etc

- 174 -

CONNECTION

B-82135EN/05

2.MECHANICAL COUPLING TO THE ROBOT

Table 2.8 (e) Connector specifications (Additional axis motor cable, Mechanical unit side) Cable Input side (J1-axis base) Output side (J3-axis casing) ARP (Pulse code line)

Housing Insert Code pin

09 30 006 0301 09 16 024 3001(Han 24DD M) 09 15 000 6103 09 30 000 9901

Housing Insert Code pin

09 30 006 0301 09 16 024 3101(Han 24DD F) 09 15 000 6203 09 30 000 9901

ARM (Power brake line)

Housing Insert Code pin

09 20 010 0301 09 21 015 3001(Han 15D M) 09 15 000 6101 09 30 000 9901

Housing Insert Code pin

09 20 010 0301 09 21 015 3101(Han 15D F) 09 15 000 6201 09 30 000 9901

- 175 -

Manu.

Harting

3.TRANSPORTATION AND INSTALLATION

3

CONNECTION

B-82135EN/05

TRANSPORTATION AND INSTALLATION

- 176 -

B-82135EN/05

3.1

CONNECTION

3.TRANSPORTATION AND INSTALLATION

TRANSPORTATION CAUTION When hoisting or lowering the robot with a crane or forklift, move it slowly with great care. When placing the robot on the floor, exercise care to prevent the installation surface of the robot from striking the floor strongly. 1. Transportation using a crane the robot can be transported by lifting it. When transporting the robot, be sure to change the attitude of the robot to that shown in Fig. 3.1 (a), (b) and lift by attaching slings to the four M20 eyebolts.

CAUTION When lifting the robot, take notice so that the motor, connectors, or cables of the robot are not scratched by slings. 2. Transportation using a forklift the robots can also be transported using a forklift (refer to Fig.3.1 (c), (d)). Transport materials are available as an option.

NOTE Detach the end effectors and base plate before transporting the robot. If the robot must necessarily be transported with the base plate attached, take the following precautions: - If the end effectors and base plate are attached, the center of gravity of the entire robot changes. When lifting the robot, be extremely careful to keep the robot in balance. - The end effectors may oscillate due to, for example, vibrations during transportation, possibly overloading the robot. Fasten the end effectors securely referring to subsection 3.1.1. - If the base plate is attached, lift the base plate instead of the robot. CAUTION Use the forklift transport bracket only when carrying the robot with a forklift. Do not use the forklift transport bracket for other transport means. Do not use the transport bracket for fastening the robot. Before transporting the robot with the transport brackets, check the fastening bolts of the brackets for looseness. Tighten the loose bolts, if any. - 177 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.1 (a) Transportation using a crane (M-900iA/350)

- 178 -

B-82135EN/05

B-82135EN/05

CONNECTION

3.TRANSPORTATION AND INSTALLATION

Fig. 3.1 (b) Transportation using a crane (M-900iA/260L)

- 179 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.1 (c) Transportation using a forklift (M-900iA/350)

- 180 -

B-82135EN/05

B-82135EN/05

CONNECTION

3.TRANSPORTATION AND INSTALLATION

Fig. 3.1 (d) Transportation using a forklift (M-900iA/260L)

CAUTION Exercise care to prevent the fork of the forklift from striking transport equipments strongly.

- 181 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.1 (e) Eyebolt installation location

- 182 -

B-82135EN/05

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CONNECTION

3.TRANSPORTATION AND INSTALLATION

Fig. 3.1 (f) Transport equipment installation location

- 183 -

3.TRANSPORTATION AND INSTALLATION

3.1.1

CONNECTION

B-82135EN/05

Transportation with an End Effector Attached When transporting a robot with an end effector such as a welding gun or hand attached, secure the arm with wood. If the arm is not secured, the end effector may oscillate for a cause such as vibration during transportation, thus imposing a large impact load on the reducer of the robot and damaging the reducer at an earlier stage.

Woods

Pallet Woods

Fig. 3.1.1 Example of securing the arm during transportation when an end effector is attached

- 184 -

CONNECTION

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3.2

3.TRANSPORTATION AND INSTALLATION

INSTALLATION Fig. 3.2 (a) shows the robot base dimensions. Fig. 3.2 (b) shows actual examples of robot installations. In Fig. 3.2 (b), the floor plate is imbedded in concrete and fastened with twelve M20 (strength classification 4.8) chemical anchors. Also, fasten the base plate to the robot base using eight M20x60 bolts (strength classification 12.9). Next, position the robot, and weld the base plate to the floor plate. (Foot length is 10 to 15mm.) (The base plate is prepared as an option.) Avoid placing any object in front of the robot on the mounting face to facilitate the installation of the mastering fixture, as shown in Fig. 3.2 (a). (The shaded portion) Fig. 3.2 (c) and Table 3.2 (a), (b) show the force and moment applied to the base plate at the time of emergency stop. Table 3.2(c) indicates the coasting time and distance consumed from the pressing of the emergency stop button until the robot stops.

Fig. 3.2 (a) Dimensions of the robot base

- 185 -

3.TRANSPORTATION AND INSTALLATION

CONNECTION

B-82135EN/05

Fig. 3.2 (b) Actual installation example

NOTE The strength of the chemical anchor depends on the concrete strength. See the design guideline of the manufacturer for the execution of the chemical anchor and consider the safety ratio sufficiently before use. NOTE 1. Parts to be provided by the customer: Robot mounting bolts: Chemical anchors: Base plates: Floor plate:

M20 x 60 (strength classification 12.9 M20 (strength classification 4.8) Thickness 32t Thickness 32t

8pcs. 12pcs. 4pcs. 1pcs.

2. Installation work (welding, anchoring, etc.) is repaired by the customer. 3. If the robot is operated with any combination other than stated above, it is likely to be damaged. - 186 -

CONNECTION

B-82135EN/05

3.TRANSPORTATION AND INSTALLATION

Table 3.2 (a) Force and moment during emergency stop Model Vertical moment Force in vertical MV [kNm (kgfm)] direction FV [kN (kgf)] M-900iA/350 84.28(8600) 53.90(5500) M-900iA/260L 94.08(9600) 53.90(5500)

Horizontal moment MH [kNm (kgfm)]

Force in horizontal direction FH [kN (kgf)]

25.48(2600) 34.30(3500)

32.34(3300) 34.30(3500)

Table 3.2 (b) Force and moment applied during acceleration or deceleration Horizontal moment Model Vertical moment Force in vertical MH [kNm (kgfm)] MV [kNm (kgfm)] direction FV [kN (kgf)] M-900iA/350 34.3(3500) 35.28(3600) 9.8(1000) M-900iA/260L 34.3(3500) 33.32(3400) 11.76(1200) Table 3.2(c) Coasting time and distance when emergency stop Model J1-axis M-900iA/350 M-900iA/260L

Coasting time [msec] Coasting distance [deg] (rad) Coasting time [msec] Coasting distance [deg] (rad)

* Override : 100% * Max. payload, and max. inertia posture

- 187 -

739 36.1 (0.63) 754 33.3 (0.58)

Force in horizontal direction FH [kN (kgf)] 12.34(1300) 11.76(1200)

J2-axis

J3-axis

260 13.9 (0.24) 193 10.5 (0.18)

251 10.8 (0.19) 373 15.6 (0.27)

3.TRANSPORTATION AND INSTALLATION

CONNECTION

Fig. 3.2 (c) Force to the base plate

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B-82135EN/05

B-82135EN/05

3.3

CONNECTION

3.TRANSPORTATION AND INSTALLATION

MAINTENANCE AREA Fig. 3.3 shows the maintenance area of the mechanical unit. In mastering, it needs to take the posture in item 5.3.3 of Chapter I. Be sure to leave enough room for the robot to be mastered.

Fig. 3.3 Maintenance area

- 189 -

3.TRANSPORTATION AND INSTALLATION

3.4

CONNECTION

B-82135EN/05

AIR PIPING (OPTION) Fig. 3.4 (a) shows how to connect air hose to the robot. If the air control set is specified as an option, the air hose between the mechanical unit and the air control set is provided. Mount the air control set using the information in Fig. 3.4 (b).

Fig. 3.4 (a) Air piping Option

- 190 -

B-82135EN/05

CONNECTION

3.TRANSPORTATION AND INSTALLATION

Air control set Fill the oiler having three air components to the specified level with turbine oil #90 to #140. The machine tool builder is required to prepare mounting bolts.

Fig. 3.4 (b) Air control set Option

- 191 -

3.TRANSPORTATION AND INSTALLATION

3.5

B-82135EN/05

INSTALLATION SPECIFICATIONS

Table 3.5 Installation specifications Items Pressure Air pressure Air flow Weight of mechanical unit Allowable ambient temperature Allowable ambient humidity Atmosphere Vibration

CONNECTION

Specifications 2 0.49～0.69MPa(5～7kgf/cm ) 2 Set pressure 0.49MPa(5kgf/cm ) 3 (Note 1) Max. Peak 150Nl/min (0.15Nm /min) M-900iA/350 Approx.1720kg M-900iA/260L Approx.1800kg 0～45℃ Usual: Less than 75%RH Short period (in one month): Max. 95%RH or less (Condensation free) Free of corrosive gases. (Note 2) Less than 0.5G(4.9m/s2)

CAUTION 1. This value indicates the maximum capacity of the air control set. Adjust the air flow to be less than this value. 2. the service representative, if the robot is to be used in an environment or a place subjected to severe vibrations, heavy dust, cutting oil splash and or other foreign substances.

- 192 -

CONNECTION

B-82135EN/05

3.6

3.TRANSPORTATION AND INSTALLATION

STORAGE To store the robot, set it to the same attitude as that used for transportation. (See II- 3.1)

- 193 -

APPENDIX

A

A.SPARE PARTS LIST

APPENDIX

B-82135EN/05

SPARE PARTS LIST

Table A (a) Cables (Standard: CE) No.

Specification

Function

K111

A660-8015-T036

J1～J6 PULSECODER +EE

K115

A660-8015-T875

J1～J6 PULSECODER +EE (R-30iA)

K114

A660-8015-T144

J1～J6 PULSECODER +EE (SDLP) (R-J3iB)

K116

A660-8015-T876

J1～J6 PULSECODER +EE (SDLP) (R-30iA)

K112 Table A (b) Cables (Option cable: CE) No.

A660-8015-T037

J1～J6 POWER

Specification

Function

K131

A660-8015-T039

AS (/SIGNAL)

K132

A660-8015-T040

AP (/POWER)

K133

A660-4004-T372

DNS (SIGNAL)

K135

A05B-1327-D001

I/O

K136

A660-8015-T041

ARP

K137

A660-8015-T042

ARM

K138

A660-8015-T043

J123 OT

K139

A660-4004-T376

DNP (POWER)

K140

A05B-1327-D002

J2/J3 Interference angle OT

K142

A660-8015-T161

3DV

K143

A05B-1327-D003#A

CAMERA

Table A (c) Motor Axis J1

Specification A06B-0268-B605#S000

Remarks (Model α30/4000is) Model αiS30/4000

J2, J3

A06B-0272-B605#S000

(Model α40/4000is) Model αiS40/4000

J4, J5, J6

A06B-0238-B605#S000

(Model α12/4000is) Model αiS12/4000

- 197 -

(R-J3iB)

A.SPARE PARTS LIST

APPENDIX

Table A (d) Reducer Axis name

Specification

J1 J2 J3 J4

B-82135EN/05

Model

A97L-0218-0347#500C-30

M-900iA/350,260L

A97L-0218-0348#550F-253

M-900iA/350

A97L-0218-0348#550F-227

M-900iA/260L

A97L-0218-0348#550F-253

M-900iA/350

A97L-0218-0348#550F-267

M-900iA/260L

A97L-0218-0349#160E-57

M-900iA/350, 260L

Table A (e) Gear Name

Specification

Model

J1-axis spur gear

A290-7327-X221

M-900iA/350, 260L

J1-axis bearing 1

A97L-0001-0195#09D000A

M-900iA/350, 260L

J1-axis C-ring

A6-CJR-45

M-900iA/350,260L

J1-axis center gear

A290-7327-X222

M-900iA/350,260L

J1-axis bearing 2

A97L-0001-0192#3200000

M-900iA/350,260L

J2-axis input gear

A97L-0218-0363#253

M-900iA/350

A97L-0218-0363#227

M-900iA/260L

A97L-0218-0363#253

M-900iA/350

A97L-0218-0363#267

M-900iA/260L

A290-7324-X421

M-900iA/350

A290-7324-Y421

M-900iA/260L

J4-axis bearing

A97L-0218-0428#0600000

M-900iA/350,260L

J4-axis C-ring

A6-CJR-30

M-900iA/350,260L

J5-axis spur gear

A290-7324-X423

M-900iA/350

A290-7324-Y423

M-900iA/260L

A290-7327-X425

M-900iA/350,260L

J3-axis input gear J4-axis spur gear

J6-axis spur gear

- 198 -

B-82135EN/05

Table A (f) Other (Mechanical unit) Name

A.SPARE PARTS LIST

APPENDIX

Specification

Model

A290-7327-T501

M-900iA/350

A290-7327-T503

M-900iA/260L

Shaft assembly (link)

A290-7327-V321

M-900iA/350,260L

J3 arm assembly

A290-7327-V401

M-900iA/350

A290-7327-V403

M-900iA/260L

Wrist unit

Table A (g) Battery and grease Name

Specification

Remarks

Battery

A98L-0031-0005

1.5V, size D

Grease

A98L-0040-0174#16KG

Kyodo Yushi VIGOGREASE RE0

Grease Table A (h) O-ring Name

A97L-0001-0179#2

Shell Alvania GREASE S2

Specification

Location

O-ring

JB-OR1A-G125

J1 to J3-axis motor

O-ring

JB-OR1A-G105

J4 to J6-axis motor

O-ring

JB-OR1A-G460

O-ring

A290-7327-X206

O-ring

JB-OR1A-G340

O-ring

A98L-0040-0041#271

O-ring

JB-OR1A-G135

O-ring

JB-OR1A-G210

O-ring

JB-OR1A-G135

O-ring

JB-OR1A-G135

- 199 -

J1-axis reducer J2/J3-axis reducer J4-axis reducer

J3-axis arm assembly Wrist assembly

A.SPARE PARTS LIST

APPENDIX

Table A (i) Mechanical Stopper Name

B-82135EN/05

Specification

Collar

A290-7324-X214

Bush

A97L-0218-0484#3125

Bolt

A6-BA-24X80

Washer

A6-WM-24S

Stopper

A290-7327-X215

Plate

A290-7327-X216

Stopper J2A

A290-7324-X361

Location For J1-axi

Common plus side to the J2-axis and the J3-axis

Stopper J2B

A290-7324-X362

Common minus side to the J2-axis and the J3-axis

Stopper J3C

A290-7324-Y362

M-900iA/260L Minus side of the J3-axis Specific to the stroke end position

- 200 -

B-82135EN/05

B

APPENDIX

CIRCUIT DIAGRAM

- 201 -

B.CIRCUIT DIAGRAM

B.CIRCUIT DIAGRAM

APPENDIX

Fig. B (a) Circuit Diagram (R-J3iB controller)

- 202 -

B-82135EN/05

B-82135EN/05

APPENDIX

- 203 -

B.CIRCUIT DIAGRAM

B.CIRCUIT DIAGRAM

APPENDIX

Fig. B (b) Circuit Diagram (R-30iA controller)

- 204 -

B-82135EN/05

B-82135EN/05

APPENDIX

- 205 -

B.CIRCUIT DIAGRAM

C.PERIODIC MAINTENANCE TABLE

C

APPENDIX

B-82135EN/05

PERIODIC MAINTENANCE TABLE

FANUC Robot M-900iA/350 and 260L Periodic Maintenance Table Items

Working time (H) Check Oil First 3 6 9 1 time Grease check months months months year Amount 320 960 1920 2880 3840

5760

6720

2 years 7680

8640

9600

10560

3 12480 13440 14400 years 11520

Check the mechanical cable (damaged or twisted)

0.2H

-

○

○

○

○

Check the motor connector 2 (loosening)

0.2H

-

○

○

○

○

3

Tighten the end effector bolt

0.2H

-

○

○

○

○

4

Tighten the cover and main bolt

2.0H

-

○

○

○

○

5

Remove spatter and dust etc

1.0H

-

○

○

○

○

0.1H

-

1

6 Replacing battery

Mechanical unit

4800

*

7

Replacing grease J1-axis reducer

of

8

Replacing grease J2-axis reducer

of

Replacing grease 9 J3-axis reducer

of

10

Replacing grease J4-axis gear box

of

11

Replacing grease of wrist 5750ml * 1.0H (J5/J6) axis reducer

●

●

* 1.0H 8000ml

●

* 0.5H 3400ml

●

* 0.5H 3100ml

●

* 0.5H 2200ml

● ●

12

Greasing Points

13 14 15 Greasing to J2/J3 bearing *

0.1H

20ml

●

each

16

Control unit

17 18

Replacing cable of mechanical unit

4.0H

-

19

Check the robot cable and teach pendant cable

0.2H

-

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○

○ ○ ○ ○

20 Cleaning the ventilator

0.2H

-

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○

○ ○ ○ ○

21 Check the source voltage *

0.2H

-

○

* 0.1H

-

22 Replacing battery

○

○

*: Refer to this manual or the controller maintenance manual. ●:Requires exchange of parts ○:Does not require exchange of parts - 206 -

○

○

○

○

○

C.PERIODIC MAINTENANCE TABLE

APPENDIX

B-82135EN/05

4 16320 17280 18240 5 years 20160 21120 22080 6 years 24000 24960 25920 7 years 27840 28800 29760 8 years years 19200 23040 26880 30720 15360

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

●

●

●

● ● ● Overhaul

● ●

●

● ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○

○

○

○

○

○

●

- 207 -

○

D.MOUNTING BOLT TORQUE LIST

D

APPENDIX

B-82135EN/05

MOUNTING BOLT TORQUE LIST NOTE When applying Loctite to the important bolt tightening points, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient effects cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps.

- 208 -

APPENDIX

B-82135EN/05

D.MOUNTING BOLT TORQUE LIST

If no tightening torque is specified for a bolt, tighten it according to this table. Recommended bolt tightening torques

Nominal diameter

M3 M4 M5 M6 M8 M10 M12 (M14) M16 (M18) M20 (M22) M24 (M27) M30 M36

Hexagon socket head bolt (Steel in strength category 12.9)

Hexagon socket head bolt (stainless)

Tightening torque Upper limit Lower limit

Tightening torque Upper limit Lower limit

1.8(18) 4.0(41) 7.9(81) 14(140) 32(330) 66(670) 110(1150) 180(1850) 270(2800) 380(3900) 530(5400) 730(7450) 930(9500) 1400(14000) 1800(18500) 3200(33000)

1.3(13) 2.8(29) 5.6(57) 9.6(98) 23(230) 46(470) 78(800) 130(1300) 190(1900) 260(2700) 370(3800) 510(5200) 650(6600) 960(9800) 1300(13000) 2300(23000)

0.76(7.7) 1.8(18) 3.4(35) 5.8(60) 14(145) 27(280) 48(490) 76(780) 120 (1200) 160(1650) 230(2300) -

- 209 -

0.53(5.4) 1.3(13) 2.5(25) 4.1(42) 9.8(100) 19(195) 33(340) 53(545) 82(840) 110(1150) 160(1600) -

Unit: Nm (kgf-cm) Hexagon socket head boss bolt Hexagon socket head flush bolt (steel in strength category 12.9) Tightening torque Upper limit Lower limit 1.8(18) 4.0(41) 7.9(81) 14(140) 32(330) -

1.3(13) 2.8(29) 5.6(57) 9.6(98) 23(230) -

INDEX

B-82135EN/05

INDEX



1.5-YEAR CHECKS (5,760 hours)................................. 16

INERTIA LOAD SETTINGS....................................... 154

1-YEAR CHECKS (3,840 hours).................................... 15

INSTALLATION ......................................................... 185

3-MONTH CHECKS (960 hours)................................... 12

INSTALLATION SPECIFICATIONS ......................... 192

3-YEAR CHECKS (11,520 hours).................................. 17

INTERFACE FOR OPTION CABLE (OPTION) ........ 159



<J>

ADJUSTING LIMIT SWITCH (OPTION)..................... 57

J1-AXIS DRIVE MECHANISM ...................................... 4

ADJUSTMENTS ............................................................ 44

J2/J3-AXIS DRIVE MECHANISM ................................. 5

AIR PIPING (OPTION)................................................ 190

J4-AXIS DRIVE MECHANISM ...................................... 6

AIR SUPPLY (OPTION).............................................. 158

J5/J6-AXIS DRIVE MECHANISM ................................. 7

AXIS LIMITS SETUP .................................................... 45





LIMIT SWITCH REPLACEMENT (OPTION) ........... 120

BACKLASH MEASUREMENT .................................... 40

LOAD CONDITIONS ON J2-AXIS BASE AND J3-AXIS ARM ............................................................................. 148



<M>

CABLE FORMING ...................................................... 107 CABLE REPLACEMENT............................................ 112

MAINTENANCE AREA ............................................. 189

Checking the Settings.................................................... 156

MAINTENANCE TOOLS ............................................. 18

CIRCUIT DIAGRAM................................................... 201

MAJOR COMPONENT SPECIFICATI ONS.................. 8

COMPONENT REPLACEMENT AND ADJUSTMENT

MASTERING ................................................................. 60

ITEMS............................................................................. 43

Mastering Data Entry...................................................... 74

CONFIGURATION ..........................................................3

Mastering to a Fixture (Master Position Master) ............ 62

Configuration of the Severe Dust/Liquid Protection Option

MECHANICAL COUPLING OF END EFFECTOR TO

...................................................................................... 126

WRIST.......................................................................... 149 MECHANICAL COUPLING TO THE ROBOT.......... 144



MOUNTING BOLT TORQUE LIST ........................... 208

DAILY CHECKS............................................................ 10



<E>

NOTE FOR PART REPLACEMENT ............................ 77

EQUIPMENT MOUNTING FACE .............................. 150

Notes on Specifying Severe Dust/Liquid Protection Option

External Dimensions ..................................................... 138

...................................................................................... 127





FAILURE AND CAUSE ................................................ 33

Operation Area.............................................................. 140



OPERATION PERFORMANCE SCREENS ............... 151 OVERVIEW ............................................................ 32,125

General............................................................................ 60 Grease Replacement Procedure for the J1-Axis/J2-

Axis/J3-Axis and J4-Axis Gear Box ............................... 26

PERIODIC MAINTENANCE ........................................ 23

Grease Replacement Procedure for the Wrist.................. 26

PERIODIC MAINTENANCE TABLE ........................ 206

GREASING POINTS...................................................... 29

PIPING AND WIRING ................................................ 100



PIPING DIAGRAM...................................................... 101 PREFACE...................................................................... p-1

Hard Stopper and Limit Switch Setting........................... 51

i-1

INDEX

B-82135EN/05



PREVENTIVE MAINTENANCE ....................................9

Zero Degree Mastering ................................................... 67

Procedure for Releasing the Grease Residual Pressure ... 27

Zero Point Position and Motion Limit ............................ 46

Quick Mastering.............................................................. 69

Replacing Cable Covers ................................................ 130 REPLACING CABLES ................................................ 105 REPLACING COMPONENTS OF THE SEVERE DUST/LIQUID PROTECTION OPTION .................... 128 REPLACING GREASE OF THE DRIVE MECHANISM ........................................................................................ 24 REPLACING J1-AXIS MOTOR (M1) AND REDUCER78 REPLACING J2-AXIS MOTOR (M2) AND REDUCER85 REPLACING J3-AXIS MOTOR (M3) AND REDUCER90 Replacing Motor Covers ............................................... 128 REPLACING MOTOR COVERS (OPTION) ................ 99 REPLACING PARTS ..................................................... 76 REPLACING THE BATTERIES ................................... 30 Replacing the Battery and Battery Box Cover .............. 132 REPLACING THE WRIST AXIS MOTORS (M4, M5, AND M6), WRIST UNIT AND J4 AXIS REDUCER.... 95 Resetting Alarms and Preparing for Mastering ............... 61 ROBOT INTERFERENCE AREA ............................... 137

<S> SAFETY PRECAUTIONS ............................................ s-1 SEALANT APPLICATION............................................ 98 Setting ........................................................................... 155 Severe Dust/Liquid Protection Characteristics.............. 125 SEVERE DUST/LIQUID PROTECTION OPTION..... 124 Single Axis Mastering..................................................... 71 Software Setting .............................................................. 50 SPARE PARTS LIST.................................................... 197 STORAGE .................................................................... 193

TRANSPORTATION ................................................... 177 TRANSPORTATION AND INSTALLATION............ 176 Transportation with an End Effector Attached.............. 184 TROUBLESHOOTING .................................................. 31

<W> WIRING DIAGRAM .................................................... 102 WRIST LOAD CONDITIONS ..................................... 145

i-2

May, 2007

Jul., 2006

Sep., 2004

Date

03

02

01

Edition

04

-

Contents

Addition of the M-900iA/260L Addition of the board for the R-J3iC Addition of a model that s the R-J3iC Correction of the trouble shooting table Addition of a procedure for releasing the residual pressure of the grease bath - Correction of a description of the severe dust/liquid protection package - Addition of an alert during transport

- Change the name of controller (From R-J3iC to R-30iA) - Add the note of the transportation equipments - Change of the Section 2.2 3-month checks - Change of the installation - Correction of errors

Edition

05

Date

Dec., 2007

Contents

- Addition of a procedure to move arms in emergency or abnormal situations - Addition of notes to transportation with an end effector attached - Addition of coasting time and distance when emergency stop - Addition of sensor cables for Severe Dust/Liquid Protection Option - Correction of errors

FANUC Robot M-900iA/350/260L MECHANICAL UNIT MAINTENANCE MANUAL (B-82135EN)

Revision Record