FANUC Robot ARC Mate 100iC FANUC Robot ARC Mate 100iCe FANUC Robot M-10iA FANUC Robot M-10iAe
MECHANICAL UNIT MAINTENANCE MANUAL MARMCM10A04081E REV. E This publication contains proprietary information of FANUC Robotics America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics America Corporation. FANUC Robotics America Corporation 3900 W. Hamlin Road Rochester Hills, Michigan 48309–3253
B-82755EN/05
This manual can be used with controllers labeled R-30iA or R-J3 iC. If you you have a controller labeled R-J3iC, you should read R-30 iA as R-J3iC throughout this manual.
Copyrights and Trademarks This new publication contains proprietary information of FANUC Robotics America Corporation Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics America Corporation. The descriptions and specifications contained in this manual were in effect at the time this manual was approved approved for printing. FANUC Robotics Robotics America Corporation, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics' products and/or systems. systems. Such systems consist of robots, extended axes, robot 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 systems and their respective components. components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.
WARNING This equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at the company's world headquarters in Rochester Hills, Michigan. For additional information information contact contact FANUC Robotics America Corporation Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucrobotics.com For customer assistance, including Technical Support, Service, Parts & Part Repair, and Marketing Requests, contact the Customer Resource Center, 24 hours a day, at 1-800-47-ROBOT 1-800-47-ROBOT (1-800-477-6268). International customers customers should call 011-1-248-377-7159. Send your comments and suggestions about this manual to: product.documentation@fanucrobotics. product.documentati
[email protected] com
Copyright ©2011 by FANUC Robotics America Corporation All Rights Reserved The information illustrated or contained herein is not to be reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics America Corporation. AccuStat®, ArcTool®, i RVision®, RVision®, KAREL®, PaintTool®, PalletTool®, SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered Trademarks of FANUC Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names: AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™, AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™, ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™, ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™, AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™, Center Finder™, Clean Wall™, DualARM™, LR Tool™, MIG Eye™, MotionParts™, MotionParts™, MultiARM™, NoBots™, Paint Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks II™, PAINTWorks III™, PalletMate™, PalletMate PC™, PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™, Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™, SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3 Controller™, SYSTEM R-J3 iB Controller™, SYSTEM R-J3 iC Controller™, SYSTEM R-30 iA Controller™,TCP Mate™, TorchMate™, TripleARM™, TripleARM™, TurboMove™, visLOC™, visPRO-3D™, visTRAC™, WebServer™, WebTP™, and YagTool™.
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©FANUC CORPORATION CORPORATION 2011 No part of this manual may be reproduced reproduced in any form. form. All specifications specifications and designs are subject to change without notice. notice.
Patents One or more of the following U.S. patents might be related to the FANUC Robotics products described in this manual.
FANUC Robotics America Corporation Patent List 4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,378,190 6,385,508 6,425,177 6,477,913 6,490,369 6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,399,363
4,942,539 4,984,745 5,331,264 5,367,944 5,696,687 5,737,218 5,987,726 6,059,092 6,204,620 6,243,621 6,356,807 6,360,143 6,518,980 6,540,104 6,705,361 6,726,773 7,211,978 7,266,422
FANUC CORPORATION Patent List 4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,329,469 5,333,242 5,337,148 5,371,452 5,375,480 5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,812,408 5,841,257 5,845,053 5,872,894 5,887,122 5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,680,461 6,696,810 6,728,417 6,763,284 6,772,493 6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,501,778 7,502,504 7,508,155 7,512,459 7,525,273
4,732,526 4,742,207 4,934,504 4,956,594 5,004,968 5,006,035 5,107,716 5,111,019 5,267,483 5,274,360 5,325,467 5,327,057 5,418,441 5,432,316 5,461,478 5,463,297 5,486,679 5,489,758 5,532,924 5,548,194 5,572,103 5,581,167 5,624,588 5,630,955 5,668,628 5,687,295 5,727,132 5,742,138 5,783,922 5,799,135 5,911,892 5,912,540 5,988,850 6,023,044 6,114,824 6,124,693 6,177,650 6,180,898 6,226,181 6,236,011 6,298,283 6,321,139 6,377,869 6,382,012 6,434,448 6,445,979 6,654,666 6,665,588 6,845,296 6,853,881 6,970,802 7,038,165 7,149,602 7,131,848 7,177,439 7,181,294 7,315,650 7,324,873 7,373,220 7,376,488 7,486,816 7,495,192 7,526,121
Conventions WARNING Information appearing under the "WARNING" caption concerns the protection of personnel. It is boxed and bolded bolded to set it apart from from the surrounding surrounding text.
CAUTION Information appearing under the "CAUTION" caption concerns the protection of equipment, software, and data. It is boxed and bolded to set it apart from the surrounding text.
Note Information appearing next to NOTE concerns related information or useful hints.
O r i g i n al al I n s t r u c t i o n s
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content.
No part of this manual may be reproduced in any form.
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All specifications and designs are subject to change without notice.
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The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as ”impossible”.
B-82755EN/05
PREFACE
PREFACE This manual explains the maintenance procedures for the mechanical units of the following robots: Model name
Mechanical uni t specification No.
FANUC Robot ARC Mate 100 iC (With all axes brakes)
A05B-1221-B201
FANUC Robot M-10 A i A (With all axes brakes)
A05B-1221-B202
FANUC Robot ARC Mate 100 iC/6L (With all axes brakes)
A05B-1221-B301
FANUC Robot M-10 A/6L i A/6L (With all axes brakes)
A05B-1221-B302
FANUC Robot ARC Mate 100 iC/10S (With all axes brakes) FANUC Robot M-10 A/10S i A/10S (With all axes brakes) FANUC Robot ARC Mate 100 iCe (NOTE) (With J2 and J3-axis brakes) FANUC Robot M-10 Ae i Ae (NOTE) (With J2 and J3-axis brakes) FANUC Robot ARC Mate 100 iCe/6L (NOTE) (With J2 and J3-axis brakes) FANUC Robot M-10 Ae/6L i Ae/6L (NOTE) (With J2 and J3-axis brakes)
A05B-1221-B401 A05B-1221-B402 A05B-1221-B501 A05B-1221-B502
Maximum load
3kg or 6kg or 10kg 3kg or 6kg or 10kg 3kg or 6kg 3kg or 6kg
A05B-1221-B601 3kg or 6kg or 10kg A05B-1221-B602 A05B-1221-B451
3kg or 6kg or 10kg
A05B-1221-B452
3kg or 6kg or 10kg
A05B-1221-B551
3kg or 6kg
A05B-1221-B552
3kg or 6kg
NOTE These robot can not support Wall & Angle mount. 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.
p-1
PREFACE
B-82755EN/05
(2)
(1)
TYPE NO. DATE
(2) (3) (4)
WEIGHT (5)
kg
DETAIL A
TYPE
TYPE NO. NO. DATE DAT DA DATE TEE
(1) (1) (2) (2)
(3) (3) ( 4 ) (4)
WEIGHT WEIGHT ( )5 kg (5) ｋｇ
A TABLE 1
CONTENTS
Position of label label indicating mechanical mechanical unit specification specification number
(1)
(2)
(3)
(4)
Model name
TYPE
No.
DATE
FANUC Robot ARC
A05B-1221-B201
Mate 100 iC
A05B-1221-B401
FANUC Robot
A05B-1221-B202
i A M-10 A
A05B-1221-B402
FANUC Robot ARC
A05B-1221-B301
Mate 100 iC/6L
A05B-1221-B501
FANUC Robot
A05B-1221-B302
i A/6L M-10 A/6L
A05B-1221-B502
FANUC Robot ARC LETTERS
Mate 100 iC/10S FANUC Robot M-10 A/10S i A/10S FANUC Robot ARC Mate 100 iCe FANUC Robot M-10 Ae i Ae FANUC Robot ARC Mate 100 iCe/6L FANUC Robot M-10 Ae/6L i Ae/6L
(5) WEIGHT kg (Without control ler) 130 130 135 135
PRINT A05B-1221-B601
PRINT
PRODUCTION
SERIAL NO.
YEAR AND
A05B-1221-B602
MONTH
130 130
A05B-1221-B451
130
A05B-1221-B452
130
A05B-1221-B551
135
A05B-1221-B552
135
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B-82755EN/05
PREFACE
RELATED MANUALS For the FANUC Robot series, the following manuals are available: Safety handbook B-80687EN All persons who use the FANUC Robot and and system designer must read and understand thoroughly this handbook R-30 A i A Operator’s Manual controller HANDLING TOOL B-83124EN-2 ARC TOOL B-83124EN-3 DISPENSE TOOL B-83124EN-4 ALARM CODE LIST B-83124EN-6
R-30 A i A Mate controller
Intended readers: Operator, programmer, maintenance person, system designer Topics: Robot functions, operations, programming, setup, interfaces, alarms Use: Robot operation, teaching, system design
Maintenance Manual B-82595EN B-82595EN-1 (For Europe) B-82595EN-2 (For RIA)
Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equipment, maintenance Use: Installation, start-up, connection, maintenance
Operator’s Manual LR HANDLING TOOL B-82724EN-1 LR ARC TOOL B-82724EN-2 ALARM CODE LIST B-83124EN-6
Intended readers: Operator, programmer, maintenance person, system designer Topics: Robot functions, operations, programming, setup, interfaces, alarms Use: Robot operation, teaching, system design
Maintenance Manual B-82725EN B-82725EN-1 (For Europe) B-82725EN-2 (For RIA) FANUC Robot ARC Mate 100iC, M-10 A i A Mechanical unit
Intended readers: All persons who use FANUC Robot, system designer designer Topics: Safety items for robot system design, operation, maintenance
Operator’s manual B-82754EN
Intended readers: Maintenance person, system designer Topics: Installation, connection to peripheral equipment, maintenance Use: Installation, start-up, connection, maintenance Intended readers: System designer, Maintenance person Topics: Installation, connection to the controller, maintenance Use: Installation, start-up, connection, maintenance
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SAFETY PRECAUTIONS
Safety FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific specific safety aspects of your company company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace. The appropriate level of safety for your application and installation can be best determined by safety system system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotics systems. According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, operation, maintenance, and service. Additionally, Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to r ecognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and and robot installation. installation. Ensure that the robot being being used is appropriate appropriate for the application. Robots used in classified (hazardous) locations must be certified for this use. FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use use the robotics system be trained in 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 your application and robot robot installation. The following guidelines are provided to emphasize the importance of safety in the workplace.
CONSIDERI CONSIDERING NG SAFETY FOR YOUR ROBOT INSTALL ATION Safety is essential whenever whenever robots are used. Keep in mind the following 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
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Safety
Keeping People and Equipment Safe The safety of people is always of of primary importance in any situation. situation. However, equipment must be kept safe, too. too. When prioritizing how to apply safety to your your robotic system, consider the following:
People
External devices
Robot(s)
Tooling
Workpiece
Using Safety Enhancing Devices Always give appropriate appropriate attention to the work work area that surrounds the robot. robot. The safety of the work area can be enhanced by the installation of some or all of the following devices:
Safety fences, barriers, or chains
Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches
Setti Setti ng Up a Safe Safe Workc ell A safe workcell is essential to protect people and equipment. 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.
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Sponsor your personnel for training in approved FANUC Robotics training course(s) related to your application. application. Never permit untrained personnel personnel to operate the robots. robots. Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot. Use anti–tie–down logic to prevent the operator from bypassing safety measures. Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell. Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the the area defined by the maximum
Safety
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 controllers as the primary safety 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 whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end–use application. Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope. Install special guarding that prevents the operator from reaching into restricted areas of the work envelope. Use interlocks. Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety. Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange flange and tooling. If the tooling strikes an object, object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot. Make sure all external devices ar e 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 points are areas where personnel personnel could get trapped between a moving robot and other other equipment. Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely. Program the robot to load and unload material safely. If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons. If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.
Staying Safe While Teaching or Manually Operating the Robot Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules:
Never wear watches, rings, neckties, scarves, or loose loose clothing that could could get caught in moving machinery.
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Safety
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 hazardous conditions exist. exist. The work envelope is the the area defined by the maximum motion range of the robot. robot. These include tooling tooling attached to the wrist flange that extends this range. The area near the robot must be clean and free of oil, 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. operations. However, if you must enter the work work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation, proper operation, and place place the robot in teach mode. Take the teach pendant with you, turn turn it on, and be prepared to release release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.
WARNING Never Never bypass , strap, or otherwi se deactiv deactiv ate a safety device, such as a limit sw itc h, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death. 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 Stay outs ide the robot work envelope envelope whenever whenever a program is b eing run. Failure Failure to d o so can result in injury.
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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.
Safety
Staying Staying Safe Safe During A utom atic Operation 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. area. The workcell includes the 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 enter the work envelope during 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. devices. Be prepared to press these buttons buttons in an emergency. Never assume that a program is complete if the the robot is not moving. moving. The robot could be waiting for an input signal signal that will permit it to continue its activity. 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 or break its motion, with your your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.
Staying Staying Safe Safe During Inspectio n When inspecting the robot, be sure to
Turn off power at the controller. Lock out and tag out the power source at the controller according to the policies of your plant. Turn off the compressed air source and relieve the air pressure. If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel. Never wear watches, rings, neckties, scarves, or loose loose clothing that could 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, button, in an emergency. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support support 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 while the robot or a program is in in operation. Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions conditions exist. Never wear watches, rings, neckties, scarves, or loose loose clothing that could could get caught in moving machinery. Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope. Test the teach pendant for proper operation before entering the work envelope. If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control control of the robot. Be sure to take the teach pendant with you, press press the DEADMAN switch, switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power power to the robot immediately. Whenever possible, perform perform maintenance with the power turned turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3–phase power source at the controller. Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
WARNING Lethal v oltage is present in t he con tro ller WHENEV WHENEVER ER IT IS IS CONNE CONNECTE CTED D to a pow er source. Be extr extr emely careful to avoid electri cal shoc k. HIGH HIGH VOLTAGE VOLTAGE IS PRESE PRESENT NT at the input s ide whenever the contro ller is co nnected to a power source. Turning Turning t he disconnect or c ircuit breaker breaker to the OFF OFF position removes power from the output side of the device only.
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Release or block all stored energy. energy. Before working on the pneumatic pneumatic system, shut off the system air supply and purge the air lines. Isolate the robot from all remote remote control signals. If maintenance must be done when when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be be held by this person. Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving 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.
Safety
WARNING Do not try to remove any mechanical mechanical component from the robot before thoroughly reading reading and understanding the proc edures edures in the appropriate manual. manual. Doing so can result in serious personal injury and component destructi on.
Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support support before you release the brake. When replacing or installing components, make sure dirt and debris do not enter the system. Use only specified parts for for replacement. To avoid fires and damage 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 ar e operating normally.
KEEPING MACHINE TOOLS TOOLS AND EXTERNAL DEVICES DEVICES SAFE Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these these measures are outlined below. below. Make sure you know all associated measures for safe use of such devices.
Programming Safety Safety Precaution Precaution s Implement the following programming safety measures to prevent damage to machine tools and other external devices.
Back–check limit switches in the workcell to make sure they do not fail. Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails. Use handshaking protocol to synchronize robot and external device operations. Program the robot to check the condition of all external devices during an operating cycle.
Mechanical Safety Precautions Implement the following mechanical safety measures to prevent damage to machine tools and other external devices.
Make sure the workcell is clean and free of oil, water, and debris. Use software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.
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KEEPING THE ROBOT ROBOT SA FE 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 Safety Precaution Precaution s 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.
methods and safety practices described in this manual NOTE: Any deviation from the methods must conform to the approved approved standards of your company. If you have questions, see your supervisor.
ADDITIONAL A DDITIONAL SAFETY SA FETY CONSIDERATIONS FOR PAINT ROB OT INSTALLATIONS Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration calibration or while teaching new paths to a robot. Maintenance personnel also must work work inside the paint booth booth periodically. Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment equipment usually is provided by the paint shop supervisor. supervisor.
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Safety
Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness awareness of the system and its capabilities. capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.
CAUTION Ensure that all ground cables remain conn ected. Never Never operate the paint robot with ground prov isions dis connected. Otherwise, Otherwise, you could injure personnel personnel or damage damage equipment. Paint robots are operated in three modes:
Teach or manual mode
Automatic mode, including automatic and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant. In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain remain outside of the booth or or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP. In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds. When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.
Paint Paint System Safety Featur Featur es Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. capabilities. To minimize the risk of injury injury when working near robots robots and related equipment, personnel must comply strictly with the procedures in the manuals. This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system. The paint system includes the following safety features:
Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. paint. Your booth might might have other kinds of indicators. indicators. Learn what these are.
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Safety
Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might might have other kinds of indicators. indicators. Learn what these are.
EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E–STOP buttons.
An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres.
A DEADMAN switch is located located on each teach pendant. When this switch is is held in, and the teach pendant is on, power power is applied to the robot servo servo system. If the engaged DEADMAN switch is released or pressed harder during robot operation, power is removed from the servo system, system, all axis brakes are applied, and the the robot comes to an EMERGENCY STOP. Safety interlocks within within the system might also E–STOP other robots.
WARNING An EMERGENCY STOP w il l o cc ur if th e DEADMAN DEA DMAN s wi tc h i s rel eased on a by pas sed robot.
Overtravel by robot axes is prevented prevented by software limits. limits. All of the major and minor axes are governed by software limits. limits. Limit switches and hardstops 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, booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic automatic or manual mode. For some systems, signals to to these switches are inactive when the switch on the SOC is in teach mode. When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings. System status is monitored monitored by computer. Severe conditions result in 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 Observe all safety rules and g uidelines to avoid injury.
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Safety
WARNING Never Never bypass , strap, or otherwi se deacti deacti vate a safety device, such as a limit s wit ch, for any operational convenience. Deacti Deacti vating a safety device is know n to have have resulted in serious i njury and death.
WARNING Enclosures shall not be opened opened unless t he area area is known to be nonhazardous nonhazardous o r all power has been been removed from devices withi n the enclosure. Power Power shall not be restored after after the enclosure has been opened opened until all combustib le dusts have been removed from th e interio r of the enclo enclo sur e and the enclos ure purged. Refer Refer to th e Purge Purge chapter for t he required purge tim e.
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 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 turn off power to the robot servo system. Never enter the work envelope during during automatic operation operation unless a safe area has been designated. Never wear watches, rings, neckties, scarves, or loose loose clothing that could could get caught in moving machinery. Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic 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 Special Precaution Precaution s f or Combus tible Dusts (Powder (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. 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 Staying Safe Safe While Operating Operating Paint Paint Appli cation Equipm ent 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 When work ing w ith electrostatic paint equipment, follow all national national and local co des as well as all all safety guidelines within you r organization. organization. Also reference the following standards: NFPA NFPA 33 Standards Standards for Spray Spray App lication Using Flammable Flammable or Combus tibl e Materials, Materials, and NFPA 70 National National Electri cal Code.
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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 Grounding is defined as the the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms. High Voltage : High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process.
Avoid any accumulation of combustible vapors or coating matter.
Follow all manufacturer recommended cleaning procedures.
Make sure all interlocks are operational.
Safety
No smoking. Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material.
Disable all air and paint pressure to bell.
Verify that the lines are not under pressure.
Staying Safe During Maintenance When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety safety rules that apply to all robot robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot.
Paint robots operate in a potentially potentially explosive environment. 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. technician. All personnel not participating participating in the maintenance must stay out of the area. For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. button. This person must understand 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 removing any component from the robot. robot. During robot operations, operations, be aware of the robot’s movements. 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 ventilation is required. Overexposure could cause cause drowsiness or skin and eye irritation. If there is contact with the skin, wash with water. Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
When using paint remover observe the following:
-
Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.
-
Adequate ventilation ventilation is required. Overexposure could cause cause drowsiness.
-
Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then seek medical attention attention as soon as possible.
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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. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.
1
WORKING PERSON
The personnel can be classified as follows.
Operator: Turns robot controller power ON/OFF Starts robot program from operator’s panel • •
Programmer or teaching operator: Operates the robot Teaches robot inside the safety fence • •
Maintenance engineer: Operates the robot Teaches robot inside the safety fence Maintenance (adjustment, replacement) • • •
-
An operator cannot work inside the safety fence. A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc.. To work inside the fence, the person must be trained on proper robot operation.
-
During the operation, programming, and maintenance of your robotic system, the programmer, teaching operator, and maintenance engineer should take additional care of their safety by using the following safety precautions. -
Use adequate clothing or uniforms during system operation Wear safety shoes Use helmet
2
WORKING PERSON SAFETY
Working person safety is the primary safety consideration. Because it is very very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working working person safety. (1) Have the robot system working persons attend the training courses held by FANUC. FANUC provides provides various training courses. Contact our sales office for details.
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(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened. The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop type). For connection, see Fig.2 (a) and Fig.2 (b).
(4) Provide the peripheral peripheral devices with appropriate grounding grounding (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral devices devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools tools such as a hand. (7) Install a mat switch or photoelectric photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a working person enters the work area. (8) If necessary, install a safety lock so that no one except except the working person person in charge can turn on the power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.
(9) When adjusting each peripheral device independently, independently, be sure to turn off off the power of the robot. robot.
RMP Motor power/brake/signal EARTH
Safety fence
Interlocking device and safety plug that are activated if the gate is opened.
Fig.2 (a) Safety Fence and Safety Gate
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Dual chain （Note）
Panel board
In case of R-30iA Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2 are provided on the operation box or on the terminal block of the printed circuit board.
EAS1 EAS11 EAS2
In case of R-30iA Mate Terminals EAS1,EAS11,EAS2,EAS21 are provided on the emergency stop board or connector panel. (in case of Open air type)
EAS21
Termianls FENCE1,FENCE2 are provided on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1 FENCE2 Fig.2 (b) Connect Connect ion Diagram for Safety Fence Fence
2.1
OPERATOR SAFETY SA FETY
The operator is a person who operates operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If you do not have to operate the robot, robot, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any any worker other than the operator from entering the work area unexpectedly and to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operator’s reach. The robot controller is designed to be connected to an external external EMERGENCY EMERGENCY STOP button. With this connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop type) when the external EMERGENCY EMERGENCY STOP button is pressed. See the diagram below for connection. Dual chain External stop button Panel board EES1 EES11 EES2 EES21
Single chain External stop button
（Note） Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2. In case of R-30iA EES1,EES11,EES2,EES21 EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board. In case of R-30iA Mate EES1,EES11,EES2,EES21 EES1,EES11,EES2,EES21 are on the emergency stop board or connector panel (in case of Open air type),. EMGIN1,EMGIN2 are on the emergency stop board. Refer to the maintenance manual of the controller for details.
Panel board EMGIN1 EMGIN2
Fig.2.1 Connection Diagram for External Emergency Stop Button
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2.2
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SAFETY OF THE PROGRAMMER
While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the safety of the teach pendant operator especially. (1) Unless it is specifically necessary to enter the robot work area, carry carry out all tasks outside the area. (2) Before teaching the robot, check that the the robot and its peripheral peripheral devices are all in the normal operating condition. (3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area. (4) The programmer programmer must be extremely careful not to let anyone else enter the robot work work area. Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot stops as Emergency stop or Control stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence. (In case of R-30i A A Mate Controller standard specification, there there is no mode switch. The automatic operation mode and the teach mode is selected by teach pendant enable switch.) Our teach pendant is provided with a DEADMAN switch as well well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop type) when pressed. (2) DEADMAN switch: Functions differently depending on the mode switch setting status. (a) Automatic operation mode: T he DEADMAN switch is disabled. (b) Teach mode: Servo power is turned turned off when the operator releases the the DEADMAN DEADMAN switch or when when the operator presses the switch strongly. Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or presses the pendant strongly strongly in case of emergency. emergency. The R-30 A/ A Mate employs a 3-position i A/ R-30i A DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN DEADMAN switch or presses the switch switch strongly, the robot stops immediately. The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely. The teach pendant, operator panel, and peripheral peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software. In case of R-30i A A Con tr ol ler or CE or RIA sp ecifi eci fi catio cat io n o f R-30i A A Mate Co nt ro ll er Mode
AUTO mode
Teach Teach pend ant enable switch On Off
Software remote condition
Teach Teach pendant
Operator panel
Peripheral device
Local Remote Local Remote
Not allowed Not allowed Not allowed Not allowed
Not allowed Not allowed Allowed to start Not allowed
Not allowed Not allowed Not allowed Allowed to start
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Mode
Teach Teach pend ant enable switch On
T1, T2 mode
Off
Software remote condition
Teach Teach pendant
Operator panel
Peripheral device
Local Remote Local Remote
Allowed to start Allowed to start Not allowed Not allowed
Not allowed Not allowed Not allowed Not allowed
Not allowed Not allowed Not allowed Not allowed
In case of standard specification of R-30i A A Mate Co nt ro ll er Teach Teach pendant enable swi tch
Softw are remote cond iti on
Teach Teach pendant
Peripheral device
On Off
Ignored Local Remote
Allowed to start Not allowed Not allowed
Not allowed Not allowed Allowed to start
(5) (Only when R-30 iA Controller or CE or RIA specification of R-30 iA Mate controller is selected.) To start the system using the operator’s panel, make certain that nobody is the robot work area and that there are no abnormal conditions in the robot work area. (6) When a program program is completed, completed, be sure to carry out out a test run run according to the procedure below. (a) Run the program for for at least one operation cycle in the single step mode at low speed. (b) Run the program for for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for for one operation cycle in the continuous continuous operation mode mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode. (7) While operating the system in the automatic operation mode, the teach pendant pendant operator should leave the robot work area.
2.3
SAFETY OF THE MAINTENANCE ENGINEER
For the safety of maintenance engineer, pay utmost attention to the following. (1) During operation, never enter the the robot robot work area. (2) 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. (3) If it becomes becomes necessary to enter the robot robot operation range range while the power is on, press the emergency emergency stop button on the operator panel, or the teach pendant before entering entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly. (4) When disconnecting the pneumatic system, be sure to reduce the supply pressure. (5) Before the start of teaching, check that the robot and its peripheral peripheral devices are all in the normal operating condition. (6) Do not operate the robot in the automatic mode mode while anybody is in the robot work area. (7) When it is necessary necessary to maintain the the robot alongside a wall or instrument, or when when multiple workers are working nearby, make certain that their escape path is not obstructed. (8) 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. (9) If necessary, have a worker worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time. (10) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. s-7
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(11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock. (12) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses fuses or other parts of non-specified non-specified ratings. They may cause a fire or result in damage to the components in the controller. (13) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal.
3
SAFETY OF THE TOOLS TOOLS A ND PERIPH PERIPHERAL ERAL DEVICES
3.1
PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other other sensor to detect a dangerous dangerous condition and, if necessary, 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 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 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 the robot and its peripheral devices so that the robot robot can detect the states of all devices in the system and can be stopped according to the states.
3.2
PRECAUTIONS FOR MECHANISM
(1) Keep the component component cells of of the robot robot system clean, and and operate the robot in an environment free of grease, water, and dust. (2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid. (3) Employ a limit limit switch or mechanical stopper to limit the robot motion so that the robot or cable does not strike against its peripheral devices or tools. (4) Observe the following precautions precautions about the mechanical unit cables. When theses attentions are not not kept, unexpected troubles might occur. Use mechanical unit cable that have required user interface. Don’t add user cable or hose to inside of mechanical unit. Please do not obstruct the movement of the mechanical unit cable when cables are added to outside of mechanical unit. In the case of the model model that a cable is exposed, Please do not perform remodeling (Adding a protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable. Please do not interfere with the other parts of mechanical unit when install equipments equipments in the robot. (5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid avoid the system construction that power-off stop would be operated routinely. (Refer to bad case example.) Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY for detail of stop type.) (Bad case example) Whenever poor product is generated, a line stops by emergency stop. When alteration was necessary, safety switch is operated by opening safety fence and power-off stop is executed for the robot during operation. An operator pushes the emergency stop button frequently, and a line stops. • • •
•
•
• •
•
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An area sensor or a mat switch connected connected to safety signal operate routinely and power-off stop is executed for the robot. (6) Robot stops urgently when collision detection alarm (SV050) etc. occurs. The The frequent urgent stop by alarm causes the trouble of the robot, too. So remove the causes of the alarm. •
4
SAFETY OF THE ROBOT MECHANISM
4.1
PRECAUTIONS IN OPERATION
(1) When operating the robot robot in the jog mode, 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 advance what motion motion the robot robot will perform in the jog mode.
4.2
PRECAUTIONS IN PROGRAMMING
(1) When the work 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.
4.3
PRECAUTIONS FOR MECHANISMS
(1) Keep the work areas of the robot clean, and and operate the robot in an environment free of grease, water, and dust.
4.4
PROCEDURE TO MOVE ARM A RM WITHOUT DRIVE POWER IN EMERGENCY EMERGENCY OR ABNORMAL AB NORMAL SITUATIONS
(1) For emergency or abnormal situations (e.g. persons persons trapped in or by the robot), brake release unit 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 AC100-115V single phase) A05B-2450-J351 (Input voltage AC200-240V AC200-240V single phase) A05B-2525-J047 (5m) A05B-2525-J048 (10m) A05B-2525-J010 (5m) (AC100-115V (AC100-115V Power Power plug) (*) A05B-2525-J011 (10m) (AC100-115V (AC100-115V Power Power plug) (*) A05B-2450-J364 (5m) (No (No power plug) A05B-2450-J365 (10m) (No (No power plug)
(*) These do not support CE marking.
(2) Please make sure sure that adequate numbers of brake release units units are available and readily accessible for robot system before installation. (3) Regarding how to use brake brake release unit, please refer to Robot controller maintenance manual. s-9
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CAUTION Robot systems installed without adequate number of brake release units or similar means are neither in compliance with EN ISO 10218-1 nor with the Machinery Directive and therefore cannot bear the CE marking. WARNING Robot arm would fall down by releasing its brake because of gravity. Therefore, it is strongly recommended to take adequate measures such as hanging Robot arm by a crane before releasing a brake. In case case of relea eleasi sing ng J2-a J2-axi xiss moto motorr brak brake e
Fall down
In case case of rele releas asin ingg J3-ax 3-axis is moto motorr brak brake e
Fall down
Fall down
Method of supporting robot arm
Sling
(*)This figure is example of floor mount. The direction of fall is different according to the installation angle,so please support robot appropriately in consideration of the influence of gravity.
Fig.4.4 Releasing Releasing J2 and J3 moto r br ake and measures
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5
SAFETY SA FETY OF THE END EFFECTOR EFFECTOR
5.1
PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control. (2) Provide the end effector with a limit switch, and control the robot robot system by monitoring monitoring the state of the end effector.
6
STOP TYPE OF ROBOT
The following three robot stop types exist:
Power-Off Sto p (Categor (Categor y 0 fo llo wing wi ng IEC 6020 602044-1) 1) Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is moving, and the motion path of the deceleration is uncontrolled. The following processing is performed at Power-Off stop. An alarm is generated and servo power is turned off. The robot operation is stopped immediately. Execution of the program is paused.
Contr oll ed sto p (Categor (Categor y 1 follo wing wi ng IEC 6020 602044-1) 1) The robot is decelerated until it stops, and servo power is turned off. The following processing is performed at Controlled stop. The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the program is paused. An alarm is generated and servo power is turned off.
Hold (Category (Category 2 fol low ing IEC 6020 602044-1) 1) The robot is decelerated until it stops, and servo power remains on. The following processing is performed at Hold. The robot operation is decelerated until it stops. Execution of the program is paused.
WARNING The stopping distance and stopping time of Controlled stop are longer than the stopping distance and stopping stopping time of Power-Off stop. A risk r isk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when Controlled stop is used. When the E-Stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is different according to the controller type or option configuration.
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SAFETY PRECAUTIONS
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There are the following 3 Stop patterns. Stop pattern
E-Stop button
External E-Stop
FENCE o pe pen
SVOFF i np np ut ut
Servo disconnect
A
AUTO T1 T2
P-Stop P-Stop P-Stop
P-Stop P-Stop P-Stop
C-Stop -
C-Stop C-Stop C-Stop
P-Stop P-Stop P-Stop
B
AUTO T1 T2
P-Stop P-Stop P-Stop
P-Stop P-Stop P-Stop P-Stop
P-Stop -
P-Stop P-Stop P-Stop
P-Stop P-Stop P-Stop
C
AUTO T1 T2
C-Stop P-Stop P-Stop
C-Stop P-Stop P-Stop P-Stop
C-Stop -
C-Stop C-Stop C-Stop
C-Stop P-Stop P-Stop
P-Stop: C-Stop: -:
Mode
Power-Off stop Controlled stop Not stop
The following table indicates the Stop pattern according to the controller type or option configuration. R-30i A A
R-30i A A Mate
Option
Standard (Single)
Standard (Dual)
RIA t y p e
CE t y p e
St an d ar d
RIA type
CE type
Standard Stop type set (Stop pattern C) (A05B-2500-J570)
B (*)
A
A
A
A (**)
A
A
N/A
N/A
C
C
N/A
C
C
(*) R-30 A i A standard (single) does not have servo disconnect. (**) R-30 A i A Mate Standard does not have servo disconnect, and the stop type of SVOFF input is Power-Off stop. The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer "Software version" in operator's manual of controller for the detail of software version screen.
" Stop type set (Stop (Stop pattern C)" C)" opt ion "Stop type set (Stop pattern C)"(A05B-2500-J570) C)"(A05B-2500-J570) is an optional function. When this option is loaded, the stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is the normal operation of the system. Alar m
Con di ti on
SRVO-001 Operator panel E-stop SRVO-002 Teach pendant E-stop SRVO-007 External emergency stops
Operator panel E-stop is pressed. Teach pendant E-stop is pressed. External emergency stop input (EES1-EES11, EES2-EES21) is open. (R-30i A A controller)
SRVO-194 Servo disconnect
Servo disconnect input (SD4-SD41, SD5-SD51) is open. (R-30 A i A controller)
SRVO-218 Ext.E-stop/Servo Disconnect
External emergency stop input (EES1-EES11, EES2-EES21) is open. (R-30i A A Mate controller)
SRVO-408 DCS SSO Ext Emergency Stop SRVO-409 DCS SSO Servo Disconnect
In DCS DCS Safe I/O connect function, function, SSO[3] SSO[3] is OFF. OFF. In DCS Safe I/O connect function, SSO[4] is OFF.
Controlled stop is different from Power-Off stop as follows: In Controlled stop, the robot is stopped on the program path. This function is effective for a system where the robot can interfere with other devices if it deviates from the program path. In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized. s-12
SAFETY PRECAUTIONS
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-
The stopping distance and stopping time of Controlled stop is longer longer than the stopping distance and stopping time of Power-Off stop, depending on the robot model and axis. Please refer the operator's manual of a particular robot model for the data of stopping distance and stopping time.
This function is available only in CE or RIA type hardware. When this option is loaded, this function can not be disabled. The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.
WARNING The stopping distance and stopping time of Controlled stop are longer than the stopping distance and stopping stopping time of Power-Off stop. A risk r isk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when this option is loaded.
7
WARNIN WARNING G LABEL LA BEL
(1) Greasing and degreasing label
Fig.7 (a) (a) Greasing Greasing and degr easing 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 2.2 Replacing the Grease and Oil of the Drive Mechanism (3 years (11,520 hours) checks) for f or 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.7 (b) Step-on Prohib iti ve Label
Description Do not step on or climb the robot or controller as i t 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.7 (c) High-Temperature 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
300kg 250kg×2
150kg×2
Fig.7 (d) Transportation label
Description When transporting the robot, observe the instructions indicated on this label. 1) Using a crane Use a crane having a load capacity of 300 kg or greater. Use at least two slings each having a withstand load of 2450 2450 N (250 kgf) or or greater. In this case, please intersect and hang two Slings. Use at least two M10 eyebolts each having a withstand load of of 1470 1470 N (150 kgf) or greater. greater. • •
•
NOTE See section 1.1 TRANSPORTATION of operator’s manual for explanations about the posture a specific model should take when it is transported.
(5) Transportation prohibitive label (When transport equipment option A05B-1221-H072 is specified.)
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.7 (e) Transportation prohibitive label
Description Keep the following in mind when transporting the robot. (1) Prevent the forks of the forklift from having impact on transport equipment (2) Do not thread a chain or the like through transport equipment. equipment. s-15
SAFETY PRECAUTIONS
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(6) High current attention label 接触注意 溶接中、内部は高電流が流れます。
DO NOT ACCESS DURING ENERGIZED HIGH CURRENT INSIDE Fig.7 (f) High current attention Label
Description Do not access during energized high current inside.
(7) Range of motion and payload mark label Below label is added when CE specification is specified. -170 deg
(-180 deg) 0 deg
+170 deg
(+180 deg) J5 axis rotation center Motion range of J5 axis rotation center
A
B
C
ARC Mate 100iC, M-10iA ARC Mate 100iCe,M-10iAe ARC Mate 100iC/6L, M-10iA/6L ARC Mate 100iCe/6L,M-10iAe/6L AR ARC Mate 100iC/10S, M-10iA/10S
D A (mm)
B (mm)
C (mm)
D (mm)
MAX. PAYLOAD (kg)
1720
784
1120
1420
10
1933
996
1333
1632
6
1398
474
798
1098
10
Fig.7 (g) Range of motion and payload mark label
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TABLE OF CONTENTS
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TABLE OF CONTENTS PREFACE ........................... ......................................... ............................ ........................... ........................... ............................ ..................p-1 ....p-1 SAFETY PRECAUTIONS ......................... ....................................... ........................... ........................... ........................s ..........s-1 -1 1
CHECKS A ND MAINTENANCE MAINTENA NCE ......................... ...................................... .......................... ....................... ..........1 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10
2
DAILY CHECKS CHECKS ....................... .................................. ...................... ....................... ....................... ...................... ...................... ............. .. 1 FIRST 1-MONTH (320 HOURS) CHECKS............ CHECKS ......................... ........................... ........................... ............. 4 FIRST 3-MONTH (960 HOURS) CHECKS............ CHECKS ......................... ........................... ........................... ............. 5 3-MONTH 3-MONTH (960 HOURS) HOURS) CHECKS CHECKS ...................... ................................. ....................... ....................... .................. ....... 9 1-YEAR (3,840 HOURS) CHECKS.......................... CHECKS............. .......................... .......................... ......................... ............ 9 1.5-YEAR CHECKS (5,760 hours)...................... hours)......... ........................... ........................... .......................... ............... 10 2-YEAR CHECKS (7,680 hours)........................ hours)........... ........................... ........................... .......................... ............... .. 10 3-YEAR (11,520 HOURS) CHECKS........................ CHECKS........... ........................... ........................... ...................... ......... 10 4-year 4-year (13,820 (13,820 hours) hours) checks checks ....................... .................................. ....................... ....................... ...................... ............. .. 10 MAINTENAN MAINTENANCE CE TOOLS ..................... ................................. ....................... ...................... ...................... ...................... ........... 10
PERIODIC MAINTENANCE MAINTENA NCE ......................... ...................................... ........................... ........................... ............... 15 2.1 2.2
Replacing the Batteries (1 Year (3,840 Hours) or (1.5 Year (5,760 Hours) Checks) Checks) ....................... .................................. ...................... ....................... ....................... ...................... ...................... ....................... .............. 15 REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM (3 YEARS (11,520 (11,520 HOURS) HOURS) CHECKS) CHECKS) ...................... ................................. ...................... ....................... ............... ... 17 2.2.1 2.2.2 2.2.3 2.2.4
3
TROUBLESHOOTING TROUBL ESHOOTING .......................... ....................................... ........................... ........................... ..................... ........30 30 3.1 3.2 3.3
4
Grease replacement procedure for the reducer (J1 to J3-axis) ...............................24 Oil replacement procedure for the gearbox (J4 to J6-axis) ....................................24 Procedure for releasing remaining pressure from the grease bath (J1 to J3-axis) ..27 Procedure for releasing oil (J4 to J6-axis) ........................................................... ..............................................................28 ...28
GENERAL GENERAL ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ........... 30 FAILURES, CAUSES AND MEASURES............ MEASURES ......................... .......................... .......................... ............... .. 30 BACKLASH MEASUREMENT....... MEASUREMENT.................... .......................... .......................... .......................... ....................... .......... 38
COMPONENT REPLA CEMENT .......................... ...................................... ......................... ..................... ........43 43 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8
FIGURE FIGURE OF DRIVE MECHANISM MECHANISM ..................... ................................ ...................... ...................... ................... ........ 44 REPLACING REPLACING THE J1-AXIS J1-AXIS MOTOR M1 ..................... ................................ ...................... ..................... .......... 46 REPLACING THE J1-AXIS REDUCER ......................... ............ .......................... .......................... ................. .... 48 REPLACING REPLACING THE J2-AXIS J2-AXIS MOTOR M2 ..................... ................................ ...................... ..................... .......... 52 REPLACING THE J2-AXIS REDUCER ......................... ............ .......................... .......................... ................. .... 53 REPLACING REPLACING THE J3-AXIS J3-AXIS MOTOR M3 ..................... ................................ ...................... ..................... .......... 56 NOTES OF ATTACHING J3-AXIS MOTOR TO REDUCER....................... REDUCER......... ................ 58 REPLACING THE J3-AXIS REDUCER ......................... ............ .......................... .......................... ................. .... 63 4.8.1
4.9 4.10
J3-axis reducer mounting phase auto adjusting function........................................66
REPLACING THE J4-AXIS MOTOR M4 (ARC Mate 100iC, M-10 A, i A, ARC Mate 100iC/6L, M-10i A/6L) A/6L) ..................... ............... ...... 66 REPLACING THE J4-AXIS MOTOR M4 (ARC Mate 100iC/10S, M-10 A/10S) i A/10S) ........................... ............. ........................... .......................... ................... ...... 68 c-1
TABLE OF CONTENTS 4.11
4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23
5
REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iC, M-10 A, i A, ARC Mate 100iC/6L, M-10i A/6L, A/6L, ARC Mate 100iCe, M-10 Ae, i Ae, ARC Mate 100iCe/6L, M-10 Ae/6L) i Ae/6L) .......................... ............. ................... ...... 69 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iC/10S, M-10 A/10S) i A/10S) ........................... ............. ........................... .......................... ................... ...... 72 REPLACING REPLACING THE J5-AXIS J5-AXIS MOTOR M5 ..................... ................................ ...................... ..................... .......... 75 REPLACING REPLACING THE J6-AXIS J6-AXIS MOTOR M6 ..................... ................................ ...................... ..................... .......... 77 REPLACING REPLACING WRIST WRIST UNIT ..................... ................................. ....................... ...................... ....................... ................... ....... 79 REPLACING REPLACING THE J2 COVER (OPTION) (OPTION) ..................... ................................ ...................... .................... ......... 82 REPLACING REPLACING THE J4 COVER (OPTION) (OPTION) ..................... ................................ ...................... .................... ......... 84 NOTES FOR ASSEMBLING CABLES WITH M/H CONDUIT................ ...... 85 REPLACING M/H CONDUIT (OPTION) ......................... ............ .......................... .......................... ................ ... 86 NOTES FOR ASSEMBLING CABLES WITH NO DUST M/H CONDUIT .... 88 REPLACING NO DUST M/H CONDUIT (OPTION) .......................... ............ ......................... ........... 93 REPLACING REPLACING FLUORIC FLUORIC RESIN RESIN RING ....................... .................................. ...................... ...................... ............. 97 SEALANT APPLICATION..................... APPLICATION......... ......................... .......................... .......................... .......................... ................ ... 97
CAB L E REPLACEMENT REPLA CEMENT ......................... ...................................... .......................... .......................... ................... ......99 99 5.1 5.2 5.3
6
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CABLE WIRING........................ WIRING........... .......................... ......................... ......................... .......................... .......................... ............... 100 CABLE CABLE DRESSING DRESSING ...................... ................................. ...................... ...................... ...................... ...................... ................. ...... 101 REPLACING REPLACING CABLES CABLES........... ....................... ....................... ...................... ...................... ...................... ...................... ............. 110
MASTERING MA STERING ........................... ........................................ ........................... ........................... ........................... .................... ......119 119 6.1 6.2 6.3 6.4 6.5
GENERAL GENERAL ...................... .................................. ....................... ...................... ....................... ....................... ...................... .................. ....... 119 REGISTER OF MASTERING POSTURE........... POSTURE ......................... ........................... ......................... ............ 121 RESETTING ALARMS AND PREPARING FOR MASTERING ................. ................ . 122 FIXTURE FIXTURE POSITION POSITION MASTER MASTER ...................... ................................. ...................... ...................... ..................... .......... 123 CHECKING CHECKING THE MASTERING MASTERING ...................... ................................. ...................... ...................... ..................... .......... 130
A
SPARE PARTS PA RTS LIST .............................. ............................................ ........................... ........................... ................. ... 133
B
CIRCUIT DIAGRAM DIAGRA M ......................... ....................................... ........................... ........................... ........................ ..........137 137
C
PERIODIC MAINTENANCE MAINTENA NCE TABL TA BL E .......................... ....................................... ......................... ............142 142
D
MOUNTING BOL T TORQUE L IST .......................... ....................................... .......................... ............... 145
E
INSULATION INSULA TION A BOUT ARC WELDING ROBOT............................... ROBOT................................. .. 146 E.1 E.2
ABSTRACT................... ........................... ABSTRACT................................ ........................... .......................... .......................... ........................ ........... 146 INSULATION AT THE WRIST............. WRIST .......................... .......................... .......................... .......................... ............... .. 146
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1.CHECKS AND MAINTENANCE
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1
CHECK CHECK S AND A ND MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter (See the APPENDIX C PERIODIC MAINTENANCE TABLE.). TABLE.).
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.
1.1
DAILY CHECKS
Clean each part, and visually check component parts for damage before daily system operation. Check the following items as the occasion demands. (1) Before turning on power Item 1
Check items Oil exudation
Check poi nts Check there is oil exudation on sealed part of each joint parts. (Note 1)
Note 1) 1) About exudation of oil Check Check it ems -
-
Check there is exudation of oil on sealed part of each joint parts. Oil exudation exudation may may be attached (Slightly a loot oil stick) to outside of lip depend on the movement condition or environment of the circumference. If this oil contents change to a state of dew, it may fail depend on the movement. You can prevent oil spot from falling down by wiping the oil contents which is accumulated to under part of oil seal before operation. Also, motors motors may may become become the high high temperature temperature and the internal internal pressure pressure of grease bath or or oil oil bath may rise by frequent repetition movement and use in the high temperature environment. In these cases, you can return internal pressure by releasing grease out let or oil outlet just after operation of robot. (When opening grease outlet or oil outlet, refer to Section 2.2 and pay attention grease or oil is not scattered.)
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1.CHECKS AND MAINTENANCE
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Oil seal (J1)
Detail A
C
B
Oil seal (J2)
Detail B Oil seal (J3)
A
Detail C
Fig.1.1 (a) (a) Check Check parts of main axis
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1.CHECKS AND MAINTENANCE
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Oil seal (J6)
Detail F Oil seal (J5)
F E Detail E
Oil seal (J4)
D
Detail D Fig.1.1 (b) Check parts of wrist axis
Check method - Insert waste to clearance of each joint which which have oil seal and wipe oil. In this time, pay attention not to press edge of oil seal with waste.
Oil seal
Cleaning area
Pay attention not to press edge of oil seal with waste. Fig.1.1 (c) Cleanin Cleanin g metho d
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1.CHECKS AND MAINTENANCE
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When air control set is combined Item
Check items
Check poin ts
1
Air pressure
2
Lubricator oil mist quantity
3 4
Lubricator oil level Leakage from hose
5
Drain
Check air pressure using the pressure gauge on the air regulator as shown in Fig.1.1 (d). If it does not meet the specified pressure of 0.49 2 to 0.69 MPa (5-7 kgf/cm ), adjust it using the regulator pressure-setting handle. Check the drop quantity during wrist or hand motion. If it does not meet the specified value (1 drop/10-20 sec), adjust it using the lubricator control knob. Under normal usage, the lubricator becomes empty in about 10 to 20 days under normal operation. Check to see that the lubricator level is within the specified level. Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required. Check drain and release it. When quantity of the drain is remarkable, examine the setting of the air dryer to the air supply side.
Lubricator Oil inlet
Adjusting knob
Lubricator mist amount check
Lubricator Filter
Regulator pressure setting handle
Pressure gauge
Fig.1.1 (d) Air contr ol set
(2) After automatic operation Item
Check items
1
Vibration, abnormal noises, and motor heating
2 3 4
1.2
Changing repeatability Peripheral devices for proper operation Brakes for each axis
Check poin ts Check whether the robot moves along and about the axes smoothly without unusual vibration or sounds. Also, check whether the temperatures of the motors are excessively high. Check to see that the stop positions of the robot have not deviated from the previous stop positions. Check whether the peripheral devices operate properly according to commands from the robot. Check that the end effector drops within 5 mm when the power is cut.
FIRST 1-MONTH (320 HOURS) CHECKS
Check the following items once every one-month (320 hours). Additional inspection areas and times should be added to the table according to the robot’s working conditions, environment, etc. Then every 3 months thereafter. (See the Section 1.4.)
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1.CHECKS AND MAINTENANCE
B-82755EN/05
Item
Check items
Check poin ts
1
Check the oil gauge of J4/J5/J6-axis gearbox
2
Confirm the broken of fluoric resin ring
3
Ventilation portion of controller
OK
Please confirm whether the amount of oil of the oil gauge has come above the center. Please replenish it in case of the shortage. When the oil gauge part does not have air moiety, there is it, but this is not abnormality. When oil does not enter, the red index moiety of the oil gauge shows the reflected heat of the light, and the outline of the index moiety is seen clearly. When oil enters, it does not show this reflected heat, and the outline of the index is not clear. Moreover, please exchange oil when oil discolors due to deterioration and the character of the oil gauge cannot be read. Confirm fluoric resin ring is not broken. If it is broken, replace it to new one. See Section 1.3. (Note 4) Check whether the cable connected to the teach pendant and robot is unevenly twisted.
OK
OK
NG (Exchange oil)
Fig.1.2 The extent of oil deterioration
1.3
FIRST 3-MONTH (960 HOURS) CHECKS
Check the following items at the first quarterly inspection, then every year thereafter. (See the Section .1.4.) Item
Check items
1
Mechanical unit cable and welding cable
2
Retightening external main bolts
3
Check the mechanical stopper and adjustable mechanical stopper Cleaning and checking each part
4 5 6
Check the end effector (hand) cable, etc. Controller cable and robot connecting cable
Check poi nts Check whether the jackets of the mechanical unit cables and welding are damaged. Also, check whether the cables are excessively bent or unevenly twisted. Check that the connectors of the motors and connector panels are securely engaged. (NOTE1) Further, tighten the end-effecter mounting bolts and external main bolts. (NOTE2) Check the looseness of mounting bolts of mechanical stopper and adjustable mechanical stopper. (NOTE3) Clean each part (remove chips, etc.) and check component parts for cracks and flaws. (NOTE4) Confirm whether there is wound in the cable Check whether the cable connected to the teach pendant and robot is unevenly twisted.
Note 1) 1) Inspecti Inspecti on poi nts and ch eck items of t he mechanical mechanical unit cables and and connectors -5-
1.CHECKS AND MAINTENANCE
B-82755EN/05
Inspection Inspection points of the mechanical mechanical unit cables cables Check the cable for damage that has been exposed. Clean it when the spatter adheres.
Fig.1.3 (a) Inspection points of the mechanical unit cables
Inspection Inspection poi nts of the connectors -
Power/brake connectors of the motor exposed externally Robot connection cables, earth terminal and user cables
Check Check it ems -
Circular connector: Square connector: Earth terminal:
Check the connector for looseness by turning it manually. Check the connector for disengagement of its lever. Check the connector for looseness.
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1.CHECKS AND MAINTENANCE
B-82755EN/05
Remove this cover and check here.
Fig.1.3 Fig.1.3 (b) (b) Inspection poin ts of connectors
Note 2) 2) Point Point s t o be retigh tened -
The end effecter mounting bolts, robot installation bolts, and bolts to be removed for inspection need to be retightened. The bolts exposed to the outside of the robot need to be retightened. For the tightening torque, see the recommended bolt tightening torque shown in the Appendix. A loose prevention prevention agent (adhesive) is applied applied to some some bolts. If the bolts are tightened tightened with greater than the recommended recommended torque, the loose prevention agent may be removed. So, follow the recommended tightening torque when retightening them.
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1.CHECKS AND MAINTENANCE
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Note 3) 3) Check Check of mechanical sto pper and adjustable mechanical sto pper. -
Check the looseness of stopper mounting bolts. If they are are loose, they are needed to be retightened.
J3-axis mechanical stopper B Spec Bolt : A97L-0218-0742#M10X20 (Tightening torque 50Nm) Stopper: A290-7221-X324
J3-axis mechanical stopper
J2-axis mechanical stopper A
J1-axis mechanical stopper B (When mechanical stopper is specified) J2-axis mechanical stopper B Spec Stopper : A290-7215-X A290-7215-X323 323 (2) Spec Bolt : A6-BA-16X20 (Tighthening torque 56Nm) (Tightening torque 56Nm)
J1-axis mechanical stopper A (When mechanical stopper is specified) Spec: Bolt : A6-BA-8X12 (2) (Tightening torque 37.2Nm) Stopper : A290-7221-X361 A290-7221-X361
Fig.1.3 (c) Check of mechanical stopper and adjustable mechanical stopper
Note 4) Cleanin Cleanin g -
-
-
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. → Vicinity of M/H conduit If chipping or spatters are attached to fluoric resin ring, it may shorten life of conduit. → Vicinity of the welding torch and wrist flange → The insulation failure occurs when the spatter has collected around the wrist flange or welding torch, and there is a possibility of damaging the robot mechanism by the welding current. (See Appendix E) Check items 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. Confirm if Fluoric resin ring ring is broken, broken, if it was broken, broken, replace it to new one. one. Two years are aims in an exchange period. If you operate robot with the state that hard mine dust is attached to rotated part, exchange period may shortens. Check the reducer or grease bath /oil bath for an oil leak. If oil can be found a day after wiping oil, an oil leak may be caused. →
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1.CHECKS AND MAINTENANCE
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Fluoric resin ring (Spec:A290-7221-X571)
Fig.1.3 (d) Cleaning points
1.4
3-MONTH (960 HOURS) CHECKS
Check the following items once every one-month (320 hours). Item
Check items
1
Check the oil gauge of J4/J5/J6-axis gearbox Confirm the broken of fluoric resin ring
2
3
1.5
Ventilation portion of controller
Check poi nts (See Section 1.2). Confirm fluoric resin ring is not broken. If it is broken, replace it to new one. See Section 1.3. (Note 4) (See Section 1.2.)
1-YEAR (3,840 HOURS) CHECKS
Check the following items once every year (3,840 hours). Item
Check items
1
Mechanical unit cable and welding cable Retightening external main bolts Check the mechanical stopper and adjustable mechanical stopper Cleaning and checking each part Check the end effector (hand) cable, etc
2 3
4 5
Check poi nts (See Section 1.3.) (See Section 1.3.) (See Section 1.3.)
(See Section 1.3). (See Section 1.3.)
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1.CHECKS AND MAINTENANCE Item
B-82755EN/05
Check items
Check poi nts
6
Battery (except ARC Mate 100iCe, M-10 Ae, i Ae, ARC Mate 100iCe/6L, M-10 Ae/6L) i Ae/6L)
Replace battery in the mechanical unit.
7
Controller cable and robot connecting cable
(See Section 1.3.)
1.6
(See Section 2.1.)
1.5-YEAR 1.5-YEAR CHECKS CHECKS (5,760 (5,760 ho ur s)
Check the following item once every 1.5 year (5,760 hours). Item
Check items
Check poi nts
Battery (ARC Mate 100iCe, M-10 Ae, i Ae, ARC Mate 100iCe/6L, M-10 Ae/6L) i Ae/6L)
1
1.7
Replace battery in the mechanical unit. (See Section 7.2.1)
2-YEAR 2-YEAR CHECKS CHECKS (7,680 (7,680 hour ho ur s)
Check the following item once every 2 years (7,860 hours). Item
Check items
Check poi nts
Replacing M/H conduit /No dust M/H conduit
1
1.8
Replace M/H conduit. (See Section 4.19)
3-YEAR (11,520 HOURS) CHECKS
Check the following items once every 3 years (11,520 hours). Item
Check items
1
Replacing grease and oil of each axis reducer and gearbox
1.9
Check poi nts Replace grease and oil of reducer and gearbox. See Section 2.2.
4-year 4-year (13,8 (13,820 20 hour s) checks ch ecks
Check the following items once every 4 years (13,820 hours). Item 1
Check items
Check poi nts
Replace the mechanical unit cable
1.10
Replace mechanical unit cable. (See Chapter 5.)
MAINTENANCE TOOLS
You should have the following instruments and tools ready for maintenance. a)
Measuring instruments Instrument
Condition
Dial gauge Calipers
1/100mm 150mm
Use For positioning precision and backlash measurement
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1.CHECKS AND MAINTENANCE
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b)
Tools Name
Phillips screwdrivers Flat-blade screwdrivers Box wrenches Hexagonal wrench sets Torque wrench Long T wrenches Adjustable wrenches Pliers Long-nose pliers Cutting pliers Both-ended wrench Grease gun C-ring pliers Press-fit fixture for J1-axis oil seal J6 motor wiring detaching tool Adaptor for J5/J6 axis oiling Mounting fixture for J3-axis motor Mounting fixture for J3-axis motor
Mounting fixture for input gear of J3-axis motor Mounting fixture for input gear of J3-axis motor Mounting fixture for input gear of J3-axis motor Flashlight LOCTITE 242,262,518,7649 Three bond Oil injection gun Oil injection nipple with valve Oil tray with valve
Remarks (Large, medium, and small sizes) (Large, medium, and small sizes) Width across flats 7, 10 Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts) Width across flats 2.5, 3, 4, 5, 6, 8, 10, 17 (for replacing parts) Width across flats 2.5, 3, 4, 5, 6, 8, 10, 12 (for replacing parts) (Medium and small sizes)
See Fig.4.3 (d) A290-7221-X971 A290-7221-X591 A290-7221-Z972 (Fig.1.10 (a)) (For robot which is made before March, 2010) A290-7221-Z974 (Fig.1.10 (b)) (For ARC Mate 100iC, M-10 A, A/6L i A, ARC Mate 100iC/6L,M-10i A/6L which is made after March, 2010) A290-7221-X973 (Fig.1.10 (c)) (c)) (For ARC Mate 100iC, M-10 A, A/6L i A, ARC Mate 100iC/6L,M-10i A/6L which is made before June, 2009) A290-7221-X974 (Fig.1.10 (d)) (d)) (For ARC Mate 100iC, M-10 A, A/6L i A, ARC Mate 100iC/6L,M-10i A/6L which is made after July, 2009 and before March, 2010) A290-7221-X976 (Fig.1.10 (e)) (e)) (For ARC Mate 100iC/10S,M-10 A/10S) i A/10S)
A05B-1221-K005 A05B-1221-K006 A05B-1221-K007
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1.CHECKS AND MAINTENANCE
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0.3
(
)
3 0 °
DETAIL A 2 5.5
10
2 4.5
A 6
6
O
0 5 0 . 0 0 -
注） NOTE)
6 . 6
O
バリ無き事。 1)NO BURR.
O
0 5 0 . 0 0 -
3 0 . 3 C 0 . C
C 0 . 3 3
8 . 2
O
全周糸面取り。 2)ALL EDGES SOULD BE CHAMFERED C0.2～C0.5.
DETAIL 詳細
Fig.1.10 Fig.1.10 (a) Mounting fixt ure f or J3-axis moto r A290-7221 A290-7221-Z9 -Z972 72
12(二面幅) WIDTH ACROSS FLAT
M10 (ピッチ1.5) PITCH ° 1 3 5
A
6
1 3 35 °
3.5
2
1 . 0 0 -
1 . 0 0 +
2 . 6 2 . 9 1 7 O O
4 . 8
O
. 2 . 0 2 0 C R
O
R
4 0 . 4
19
A
14 断面 A-A
注） NOTE) バリ無き事。 1)NO BURR.
SECTION 断面
全周糸面取り。 2)ALL EDGES SOULD BE CHAMFERED C0.2～C0.5.
Fig.1.10 Fig.1.10 (b) Mountin g f ixtu re for J3-axis J3-axis motor A290-72 A290-722121-Z97 Z974 4
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1.CHECKS AND MAINTENANCE
B-82755EN/05 6 6
4 - R
1
5 1
(
G
)
2 6
0.01
r
94
P
45
Ｇ
R 3
n
7 9
O
A
0. 01 01 P
0 0 1
SECTION B-B O
1 0 . 0 0 +
R E L I E F
5 1 . 3 1
6 0 8 3
5 4
R
64
P Q 1 1 0 . 0 . 0 0
O
1 1
B
3
R
0 9
0 8
O O
B ° 5 4
1 0 . 0 0 +
0 8 2 7
G
O O
5 0 . C
5 0 .
2 - R 1
G
Q
8 5
A
n a
0 1 2
SECTION A-A
62
90
15
4-M6 THRU. EQ.SP. THRU. EQ.SP. RELIEF SECTION
注） NOTE) 全周糸面取りの事。 ALL EDGES SHOULD BE CHAMFERED C0.1～C0.5.
貫通 周上等配 逃げ 断面
Fig.1.10 Fig.1.10 (c) Moun Moun ting fixt ure fo r in put gear of J3-axis mot or A290-722 A290-7221-X 1-X973 973 6.5
6.5
4 - R 1
(
5 1
G
)
2 6
90
P 94
r
45
0.01
A
G
7
9 n
0 .0 1 P
0 1 0 . 0 0 +
5 1 . 3 1
6 8
2 3
O O
0 2 0 . 0 0 +
10
R 3
RELIEF
0 1 0 . 0 0 +
G
0 8 2 7
G
2 2
3 R
RELIEF
P Q 1 1 0 . 0 . 0 0
n a
64
R
5 0 . C
. 0 5
8 5
0 9
0 8
O O
O
5 4
O
2 1
2 - R 1
G
Q
A
O
( 62 )
1 2 0
SECTION A-A
注） NOTE)
THRU. 貫通 EQ.SP. 周上等配 RELIEF 逃げ SECTION 断面
全周糸面取りの事。 ALL EDGES SHOULD BE CHAMFERED C0.1～C0.5.
Fig.1.10 Fig.1.10 (d) Mounting fixt ure for inpu t gear of J3-axis J3-axis mo tor A290-72 A290-722121-X97 X974 4
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1.CHECKS AND MAINTENANCE
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6.5
4 - R
6.5
1
5 1
G
(
)
5 6
90
P 97
r
45
0.01
A
G
7
9 n
0 .0 1 P
0 1 0 . 0 0 +
2 5 3 . 6 1
6 8
2 3
O O
0 2 0 . 0 0 +
G
10
R 3
G
RELIEF
0 1 0 . 0 0 +
0 8 2 7
2 2
3 R
RELIEF
67
P Q 1 1 0 . 0 . 0 0
n a
5 0 . C
8 R
5 0 .
5
0 9
0 8
O O
O
5 4
O
2 1
2 - R 1
G
Q
A
O
( 65 )
1 2 0
SECTION A-A THRU. 貫通 EQ.SP. 周上等配 RELIEF 逃げ SECTION 断面
注） NOTE) 全周糸面取りの事。 ALL EDGES SHOULD BE CHAMFERED C0.1～C0.5.
Fig.1.10 Fig.1.10 (e) Mountin g fi xtur e for i nput gear of J3-axis mot or A290-722 A290-7221-X 1-X976 976
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( 15 )
2.PERIODIC MAINTENANCE
B-82755EN/05
2
PERIODIC MAINTENANCE
Optimum performance of the robot can be maintained by performing the periodic maintenance procedures presented in this chapter. (See the APPENDIX C PERIODIC MAINTENANCE TABLE.)
2.1
Replacing Replaci ng the th e Batteri es (1 Yea Yearr (3,840 (3,840 Hou Hours rs)) or (1.5 (1.5 Yea Yearr (5,7 (5,760 60 Hours ) Checks )
The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every 1 year in case of ARC Mate 100 iC, M-10iA, ARC Mate 100 iC/6L, M-10iA/6L ARC Mate 100iC/10S, M-10iA/10S and 1.5 year in case of ARC Mate 100 iCe, M-10iAe, ARC Mate 100 iCe/6L, M-10iAe/6L. Also, use the following procedure to replace when the backup battery voltage drop alarm occurs.
Procedure of replacing th e battery battery 1
Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion.
CAUTION Be sure to keep the controller power on. Replacing the batteries with the power supply turned off causes all current position data to be lost. Therefore, mastering will be required again. 2 3 4 5
Remove the battery case cap. (Fig. 2.1 (a) - (c)) Take out the old batteries from the battery battery case. In this time, battery can be taken out by pulling the stick of the center of the battery box. Insert new batteries into the battery case. Pay attention to the direction of batteries. Close the battery case cap.
CAUTION When using a robot with the severe dust/liquid protection option, remove the cover from the battery case as shown in Fig. 2.1 (b) to replace the battery. After replacing the battery, reinstall the cover. In this time, please be sure to replace packing to new one for effects of severe dust/liquid protection.
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2.PERIODIC MAINTENANCE
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Battery can be taken out by pulling this stick.
Battery case
Case cap Battery spec:A98L-0031spec:A98L-0031-0027 0027 (C battery 4pcs)
Fig.2.1 (a) (a) Replacin Replacin g th e battery
Battery cover mounting bolt M5X10 (4pcs) Battery cover Packing for battery cover A290-7221-Z236
Case cap Battery case
Battery spec:A98L-0031-0027 (C battery 4pcs)
Fig.2.1 (b) Replacing the battery (When severe dust/liquid protection option is specified)
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2.PERIODIC MAINTENANCE
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Battery case
Battery spec:A98L-0031-0005 (D battery 4 pcs)
Case cap
Fig.2.2.1 Fig.2.2.1 (c) Replacing Replacing the batt ery (ARC Mate 100iCe, M-10i Ae, Ae, ARC Mate 100iCe/6L, M-10i Ae/6L) Ae/6L)
2.2
REPLACING REPLA CING THE THE GREASE AND A ND OIL OF THE DRIVE MECHANISM (3 YEARS (11,520 HOURS) CHECKS)
Replace the grease of the reducers of J1, J2, and J3 axes and oil of the J4/J5/J6-axis gearbox in cycle that is shorter among every three years and 11,520 hours by using the following procedures. See table 2.2 (a) for the grease name and the quantity for J1 to J3 axis. See table 2.2 (b) for the oil name and the quantity for J4 to J6 axis. Table 2.2 2.2 (a) Grease name name and amount to b e replaced at regul ar int ervals of t hree years (11,5 (11,520 20 hours) Greasin Greasing g points
Amount of grease grease to be applied applied
Gun tip pressure pressure
J1-axis reducer J2-axis reducer J3-axis reducer
785g(872ml) 300g(333ml) 167g(186ml)
0.1MPa or less (NOTE 1)
Specified Specified grease grease Kyodo Yushi VIGOGREASE RE0 (Specification: A98L-0040-0174)
Table 2.2 2.2 (b) (b) Oil name and and amoun t of st andard to b e replaced at regular regular i ntervals of t hree years years (11,520 hours) Oiling points
Amo un t o f o il to be ap pl ied (NOTE 2)
J4-axis gearbox
408g(480ml)
J5/J6-axis gearbox
340g(400ml)
Gun tip pressure 0.1MPa or less (NOTE 1)
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Specified Specified oil Nippon Oil Corporation BONNOC AX68 (Specification: A98L-0040-0233)
2.PERIODIC MAINTENANCE
B-82755EN/05
NOTE When using a hand pump, apply grease approximately once per two seconds. It is not a regulated amount injection. Be sure to confirm the amount of oil with the oil gauge. Please supplyl oil until oil level is 3/4 or more ot the total height.
Please supply oil until oil level is 3/4 or more ot the total height.
Please pay attention to the p osture of robot when the oig gauge is comfirmed referring to subection 7.2.2.
Please pay attention to the posture of robot when the oig gauge is comfirmed referring to subection 7.2.2.
In case of rising sun flag type oil gauge
In case of "H-L" type oil gauge
Fig.2.2 (a) Oil gauge
For grease and oil replacement or replenishment, use the postures indicated below. Consider relative angle of from posture of floor mount when robot is angle mount. There is no brake for wrist axes of RC Mate 100 iCe, M-10iAe, ARC Mate 100 iCe/ 6L, M-10 iAe/6L, so be careful not to drop the axes.
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2.PERIODIC MAINTENANCE
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Table 2.2 (c) Postures for greasing and oiling (Floor mount) Supply position J1-axis reducer J2-axis reducer
Posture J1
J2
J3
J4
J5
J6
Arbitrary
Arbitrary 0°
Arbitrary
Arbitrary
Arbitrary
Arbitrary
0° Arbitrary
0° 180° 18° 18° 90° -30° 0°
-40° 90° 0° -70° 0°
0°
20° to 90°
90°
Arbitrary
J3-axis reducer J4-axis gearbox Wrist (using oil pump) Wrist (not using oil pump) Wrist (Replenishment) Wrist (Oil discharge) Wrist (confirm oiling) Wrist (Release remaining pressure)
Table 2.2 (d) Postures for greasing and oiling (Upside-down mount) Supply position J1-axis reducer J2-axis reducer
Posture J1
J2
J3
J4
J5
J6
Arbitrary
Arbitrary -90°
Arbitrary
Arbitrary
Arbitrary
Arbitrary
0° Arbitrary
180°
J3-axis reducer J4-axis gearbox Wrist (using oil pump)
0° -18°
140°
Wrist (not using oil pump)
-18°
-90°
Wrist (Replenishment)
-90°
0°
Wrist (Oil discharge)
30°
110°
Wrist (confirm oiling)
180°
0°
20° to 90°
90°
Wrist (Release remaining pressure)
0°
Arbitrary
Table 2.2 (e) Postures for greasing and and oilin g (-90 (-90 wall mount) Supply position J1-axis reducer J2-axis reducer J3-axis reducer J4-axis gearbox
Posture J1
J2
J3
J4
J5
J6
Arbitrary
Arbitrary 90°
Arbitrary
Arbitrary
Arbitrary
Arbitrary
0° Arbitrary
0° 90°
Wrist (using oil pump)
-72°
-40°
Wrist (not using oil pump)
-72°
90°
0°
0°
Wrist (Oil discharge)
-210°
-70°
Wrist (confirm oiling)
-90°
0°
0° to 70°
90°
Wrist (Replenishment)
Wrist (Release remaining pressure)
- 19 -
0°
Arbitrary
2.PERIODIC MAINTENANCE Table 2.2 (f) Supply position J1-axis reducer J2-axis reducer J3-axis reducer J4-axis gearbox
B-82755EN/05
Postures for greasing greasing and oil ing (+90 (+90 wall mount) Posture J1
J2
J3
J4
J5
J6
Arbitrary
Arbitrary -90°
Arbitrary
Arbitrary
Arbitrary
Arbitrary
0° Arbitrary
0° -90°
Wrist (using oil pump)
108°
-40°
Wrist (not using oil pump)
108°
90°
Wrist (Replenishment)
180°
0°
Wrist (Oil discharge)
150°
-70°
Wrist (confirm oiling)
90°
0°
110° to 180°
90°
Wrist (Release remaining pressure)
0°
Arbitrary
Upside-down mount
-90°wall mount
+90°wall mount
Fig.2.2 (b) Installation method
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2.PERIODIC MAINTENANCE
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Oil gauge for J4-axis gearbox
A
J4-axis gearbox oil inlet taper plug R1/8
VIEW A
J1-axis reducer grease outlet seal bolt M8X10
Fig.2.2 Fig.2.2 (c) (c) greasing greasing po int of reducer and oil suppl ying po ints of gearbox (1) (1) (ARC Mate 100iC,M-10i A,ARC A,ARC Mate 100iC/6L,M-10i A/6L,A A/6L,A RC Mate 100iCe, M-10i Ae, Ae, ARC Mate 100iCe/6L, M-10i Ae/6L) Ae/6L) Oil gauge for J5/J6-axis gearbox J2-axis reducer grease inlet taper plug R1/8 VIEW B
J5/J6-axis gearbox first oil inlet (when oil pump is used) Extra low bolt M6X8 & seal washer
J5/J6-axis gearbox oil outlet Extra low bolt M8X8 & seal washer
J3-axis reducer grease inlet seal bolt M6X8 or bolt M6X10 ＆ seal washer J3-axis reducer grease outlet seal bolt M8X10 Refer to the note of lower right.
J5/J6-axis gearbox ventilator hole when replacing oil Extra low bolt M5X8 ＆seal washer J5/J6-axis gearbox second oil inlet (When oil pump is not used) Extra low bolt M6X8 &seal washer
B
J2-axis reducer grease outlet seal bolt M8X10 Note) Thre is a case that position of J3-axis grease outlet is figure below depending on the time of shippment.
J1-axis reducer grease inlet taper plug R1/8
J3-axis reducer grease outlet seal bolt M8X10
Fig.2.2 Fig.2.2 (d) (d) Greasing Greasing point of reducer and o il sup plying points of gearbox (2) ARC Mate 100iC,M-10i A,ARC A,ARC Mate 100iC/6L,M-10i A/6L,A A/6L,A RC Mate 100iCe, M-10i Ae, Ae, ARC Mate 100iCe/6L, M-10i Ae/6L) Ae/6L)
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2.PERIODIC MAINTENANCE
B-82755EN/05
J4-axis gearbox oil outlet taper plug R1/8 or seal bolt M8X10 Fig.2.2 Fig.2.2 (e) (e) greasing greasing p oint of reducer and o il su pplying points of g earbox earbox (3) (ARC Mate 100iC,M-10i A,ARC A,ARC Mate 100iC/6L,M-10i A/6L,A A/6L,A RC Mate 100iCe, M-10i Ae, Ae, ARC Mate 100iCe/6L, M-10i Ae/6L) Ae/6L)
Oil gauge for J4-axis gear box
A
A
J4-axis gearbox oil inlet taper plug R1/8 J4-axis gearbox ventilator hole taper plug R1/8
SECTION A-A
J1-axis reducer grease outlet seal bolt M8X10
Fig.2.2 Fig.2.2.1 .1 (f) (f) greasing point of reducer and o il su pplying points of gearbox (1) (ARC Mate 100iC/10S,M-10i A/10S) A/10S)
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2.PERIODIC MAINTENANCE
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J5/J6-axis gearbox oil outlet Extra low bolt M8X8 & seal washer
J2-axis reducer grease inlet taper plug R1/8 VIEW B
J3-axis reducer grease inlet bolt M6X10 ＆ seal washer
J5/J6-axis gearbox first oil inlet (when oil pump is used) Extra low bolt M6X8 & seal washer
Oil gauge for J5/J6-axis gearbox
J5/J6-axis gearbox ventilator hole when replacing oil Extra low bolt M5X8 ＆seal washer
B
J5/J6-axis gearbox second oil inlet (When oil pump is not used) Extra low bolt M6X8 &seal washer J3-axis reducer grease outlet seal bolt M8X10
J2-axis reducer grease outlet seal bolt M8X10
J1-axis reducer grease inlet taper plug R1/8 Fig.2.2 Fig.2.2.1 .1 (g) (g) greasing point of reducer and oi l supp lying points of gearbox (2) (ARC Mate 100iC/10S,M-10i A/10S) A/10S)
J4-axis gearbox oil outlet seal bolt M8X10 Fig.2.2 Fig.2.2.1 .1 (h) (h) greasing point of reducer and oi l supp lying points of gearbox (3) (ARC Mate 100iC/10S,M-10i A/10S) A/10S)
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2.PERIODIC MAINTENANCE
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Table 2.2 Specification of seal bolts, taper plug and seal washer Parts name
2.2.1
Specificati on
Seal bolt (M6X8) Seal bolt (M8X10) taper plug (R1/8) seal washer (M5) seal washer (M6)
A97L-0218-0417#060808 A97L-0218-0417#081010 A97L-0001-0436#1-1D A30L-0001-0048#5M A30L-0001-0048#6M
seal washer
A30L-0001-0048#8M
(M8)
Grease Grease replacement replacement pro cedure for the reduc er (J1 to J3-axis) J3-axis) 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 seal bolt from the grease outlet). 2 Supply grease slowly, using a manual pump. 3 Whenever possible, possible, avoid avoid using an air pump, which is powered by the factory air supply. If the use of an air pump is unavoidable, supply grease with the pump at a pressure lower than or equal to the gun tip pressure (see Table 2.2 (a)). 4 Use grease grease only of the specified type. type. Grease of a type other than that specified may damage the reducer or lead to other problems. 5 After greasing, release remaining remaining pressure from the grease bath bath using the procedure given in Subsection 2.2.3, and then close the grease outlet. 6 To prevent accidents caused caused by slipping, completely completely remove any excess excess grease from the floor or robot.
Grease Grease replacement pr ocedure oc edure of t he J1, J2, J3-axis J3-axis r educer 1 2 3 4 5 6
Move the robot to the greasing posture described in Table.2.2 (c) to (f). Turn off the controller power. Remove the taper plug or seal bolt bolt from grease outlet. (Fig.2.2 (c) to 2.2 (h)) Remove the taper plug or seal bolt from grease inlet and attach grease nipple. Keep greasing greasing until until the new grease pushes pushes out the old grease and comes out from from each grease outlet outlet Release remaining pressure using the procedure given in Subsection 2.2.3.
2.2.2
Oil replacement replacement p roc edure for the gearbo gearbo x (J4 to J6-axis) J6-axis)
NOTE Operation with oil shortage may cause severe damage to gears. Please make sure the gearbox is always filled with correct amount of oil. 1 2 3
In case of J4-axis, move the the robot to the oil-replacing posture posture described in Table 2.2 (c) to (f). In case of J5/J6-axis, move the robot to the posture of wrist (oil discharge). Turn off the controller power. Put the collection bottle under the oil outlet. (In case of J4-axis gearbox) Remove any peripheral equipment, which has been mounted at the J4 oil outlet. In case of ARC Mate 100iC/10S,M-10iA/10S, remove ventilator hole, too. And remove J4 connector plate - 24 -
2.PERIODIC MAINTENANCE
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4
mounting bolts so that you cans see plug of oil inlet. In this time, pay attention not to cut nylon band which is attached to mechanical unit cable. There is a case to have to take connector of user side and air joint off for move the connector panel. Afterwards remove the taper plug of oil inlet and outlet. (In case of J5/J6-axis gearbox) Remove the extra low bolt M8 ×8 and seal washer.(See Fig.2.2 (c) to (e)) Install the taper plug plug or or extra low bolt and seal washer in the oil outlet after all oil is exhausted. exhausted. In case of ARC Mate 100 iC/10S,M-10iA/10S, attach taper plug of ventilator hole, too (In case of J4-axis gearbox) Firstly, supply oil of 150ml, attach taper plug of oil inlet, in case of ARC Mate 100iC/10S,M-10iA/10S, attach taper plug of ventilator hole, too, make the robot to J3-axis 0 º, remove seal bolt of J4-axis oil outlet, furthermore add oil of 330ml. When the adapter for oiling (A290-7221-X591) is used, oiling is easy. Install it as shown in Fig.2.2.2 (b) when you use the oiling adapter. The amounts of oiling are about as many as two adapters. It takes about five minutes to oil as many as one cup. Attach seal bolt of J4-axis oil outlet after supplying oil. (In case of J5/J6-axis gearbox) 1) When oil pump is used Oil from the J5/J6 axis gearbox first oil inlet (M6) of Fig. 2.2 (d) when you use the oil pump. At this time, make robot to the posture of wrist (using oil pump). In addition, oil after opening the oil outlet of the J6 axis crossing roller ring. At this time, stop the M8 oil out once after it puts it from the M8 oil discharge entrance to going out, make to the posture of wrist (Replenishment). This time, and add oil from the second oil inlet (M5) with the syringe etc. Stop it because oil comes out from the oil inlet by about 15ml. Make robot to the posture of wrist (confirm oiling) at the end and confirm the amount of the oil gauge. 2) When oil pump is not used Remove the extra low bolt and seal washer of oil inlet and ventilator hole of Fig.2.2 (d), move the robot posture of wrist (not using oil pump) and add oil. When the adapter for oiling (A290-7221-X591) is used, oiling is easy. Install it to second oil inlet as shown in Fig.2.2.2 (b) and add oil when you use the oiling adapter. The amounts of oiling are about as many as two adapters. It takes about five minutes to oil as many as one cup. When oil come ventilator hole, remove adapter and move the robot to the posture of wrist (confirm oiling) and check oil gauge referring to Fig.2.2.2 (c). In case oil level is insufficient, please fine-tune it by replenishing it i t with a syringe. Then turn J4-axis 90 °and put it back and confirm height of oil level is 3/4 or more. When oil amount is insufficient, make robot to the posture of wrist w rist (Replenishment) this time, and add oil from the second oil inlet (M5) with the syringe etc. Stop it because oil comes out from the oil inlet by about 15ml and close the oil inlet. Make robot to the posture of wrist (confirm oiling) at the end and confirm the amount of the oil gauge. 3) When using oil gun Attach oil injection nipple with valve (A05B-1221-K002) to J5/J6-axis gearbox first oil inlet of Fig.2.2 (d),(g). Attach oil tray with valve (A05B-1221-K003) to J5/J6-axis gearbox oil outlet (J6-axis cross roller part). Confirm valve of oil inlet and oil outlet are open referring to Fig.2.2.2 (d). Supply oil to J5/J6-axis gearbox first oil inlet till oil is come out come from oil outlet by oil injection gun (A05B-1221-K005). When oil appears from oil outlet, stop supplying oil and close the valve of oil injection nipple. After that, close the valve of oil tray, remove tray and close the oil outlet. Then remove oil injection nipple and close the oil inlet. Make robot to the posture of wrist (Replenishment) this time, and add oil from the second oil inlet (M5) with the syringe etc. Stop it because oil comes out from the oil inlet by about 15ml and close the oil inlet. Finally make robot to the posture of wrist (confirm oiling) at the end and confirm the amount of the oil gauge. Then turn J4-axis 90 °and put it back and confirm height of oil level is 3/4 or more. If oil is sufficient replenish oil with sponge and adjust it. - 25 -
2.PERIODIC MAINTENANCE
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CAUTION If supplying oil forcibly when valve is closed, internal pressure of oil bath rise abnormally and cause oil leak from seal part or oil seal falling out. Be careful 5
Release remaining pressure using the procedure given in Subsection 2.2.4. If equipment is installed to this surface, remove it.
Bolt M6X10 J4 connector panel
Bolt M6X10 J4 connector panel
ARC Mate 100 iC/10S , M-10iA/10S
ARC Mate 100 iC , M-10iA ARC Mate 100 iC/6L , M-10iA/6L ARC Mate 100 iCe , M-10iAe ARC Mate 100 iCe/6L , M-10iAe/6L
Fig.2.2.2 Fig.2.2.2 (a) (a) Replacing Replacing oil of J4-axis gearbo x
Remove this bolt.
J4-axis gearbox
In case of J5/J6-axis Fig.2.2.2 Fig.2.2.2 (b) Oiling adapter
Please supply oil until oil level is 3/4 or more of the total height.
In case of rising sun flag type oil gauge
Please supply oil until oil level is 3/4 or more of the total height.
In case of "H-L" type oil gauge
Fig.2.2.2 Fig.2.2.2 (c) (c) Standard of oil gauge
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2.PERIODIC MAINTENANCE
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Oil tray with valve A05B-1221-K007
White line Oil injection nipple with valve A05B-1221-K006 Valve is open
Valve is closed
Oil injection gun A05B-1221-K005
Fig.2.2.2 Fig.2.2.2 (d) (d) Oiling b y oil g un
2.2.3
Procedure for r eleasing eleasing remaining p ressur e from the grease bath (J1 to J3-axis) J3-axis)
After applying grease, operate the robot as instructed below with the taper plug and seal bolt of the grease inlet and outlet uncapped to release the remaining pressure within the grease bath. In case of J2-axis, there are two seal bolts for grease outlet, so uncap both of them. Attach a recovery bag below the grease inlet and outlet to prevent output grease from splattering. Operating axis Grease replacement part
J1-axis J1-axis
J1-axis reducer
Axis angle of 60° or more OVR 100%
J2-axis reducer
J3-axis reducer
Arbitrary
J2-axis
J3-axis J3-axis
J4-axis
J5-axis
J6-axis J6-axis
Arbitrary Axis angle of 60° or more OVR 100%
Arbitrary
Arbitrary Axis angle of 60° or more OVR 100%
Arbitrary
If the above operation cannot be performed due to the environment of the robot, prolong the operating time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 30 - 27 -
2.PERIODIC MAINTENANCE
B-82755EN/05
degrees, perform the twice operation for 20 minutes or more.) After completion of the operation, operation, attach the taper plug and seal bolts to the grease inlets and outlets. When reusing the taper plug and seal bolts, be sure to seal them with seal tape. After replacing grease or oil, grease bath or oil bath may rise if robot is operated again under frequent inversion movement or high temperature environment. In these cases, you can return internal pressure by releasing grease out let or oil outlet just after operation of robot. (When opening grease outlet or oil outlet, refer to Section 2.2 and pay attention grease or oil is not scattered.)
2.2.4
Procedure for releasing releasing oil (J4 to J6-axis) J6-axis)
After replacing oil, please do the following operation to adjust the amount of oil properly.
In case of J 4-axis 4-axis gearbox Confirm that oil level seen in oil gauge is as per Fig.2.2.2 (c). If confirmed then please operate robot J4 axis during 10 minutes, at 100% override, making 90 degrees motion (or more). Keep oil inlet and oil outlet closed during this operation. When completed, move the robot posture so that J4-gearbox oil outlet is right above. (In case of floor mount, J3=0 °.) Remaining pressure release at once if upper side of oil inlet/outlet is opened. When removing oil outlet, please work while covering the oil outlet in wastes so that oil may protrude. After operation, confirm whether the oil side of the oil gauge has come above the 3/4 or more of the total height, add oil from the J4 axis gearbox oil inlet with the syringe etc. when oil is a little. In addition, attach taper plug of the oil inlet. Wipe the oil that adheres to the surface of the robot off when confirming it and close the oil inlet/outlet completely.
In case of J5/J6-axis gearbox Confirm that oil level seen in oil gauge is as per Fig.2.2.2 (c). If confirmed then please jog robot to the posture of wrist (Release remaining pressure). Attach extra low bolt and seal washer of the oil inlet but keep it loose. Operate robot J5 and J6 axis during 10 minutes, at 100% override, making 90 degrees motion (or more) on both axis. When completed, please jog to the posture of wrist (Replenishment). Remaining pressure release at once if second oil inlet (M5) is opened. Confirm that oil level seen in oil gauge is above 3/4 or more of total height. At this time, please rotate the J4 axis in the direction of +/-, and confirm the thing that the amount of oil doesn't decrease. Move robot to the posture of wrist (Replenishment) again and add oil from the second oil inlet (M5) with the syringe etc. when decreasing after operation, attach taper plug of the oil inlet. Wipe the oil that adheres to the surface of the robot off when confirming it and close the first oil inlet completely. Be sure to wind seal tape to thread part when taper plug is reused. When tightening bolts of oil inlet and oil outlet, confirm seal washer is attached before tightening bolts. Be sure to wind seal tape to thread part when seal tape is reused. If the above operation cannot be performed due to the environment of the robot, prolong the operating time so that an equivalent operation can be performed. (When the maximum allowable axis angle is 45 degrees, perform the twice operation for 20 minutes or more.) After completion of the operation, attach the taper plug to the oil inlets. After replacing grease or oil, grease bath or oil bath may rise if robot id operated again under frequent inversion movement or high temperature environment. In these cases, you can return internal pressure by releasing grease out let or oil outlet just after operation of robot. (When opening grease outlet or oil outlet, refer to Section 2.2 and pay attention grease or oil is not scattered.)
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2.PERIODIC MAINTENANCE
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CAUTION When reusing seal bolt and taper plug, be sure to seal t thread part with seal tape. As for the seal washer, n one side, rubber sticks sticks to the entire and the other side, rubber sticks to only around hole and rubber sticks is incomplete state, Attach later face to bolt side. Confirm seal washer by viewing. If it is damaged obviously, replace it to new one. See Table 2.2 about specification of seal bolts and seal washer.
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3.TROUBLESHOOTING
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3
TROUBLESHOOTING
3.1
GENERAL
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems may become further complicated, if they are not corrected properly. Therefore, it is necessary to keep an accurate record of problems and to take proper corrective actions.
3.2
FAILURES, CAUSES AND MEASURES
Table 3.2 (a) 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, contact FANUC. Table 3.2 (a) (a) Failu Failu res, causes and measures Symptom Vibration Noise
Descriptio n
Cause
-The J1 base lifts off the floor plate as the robot operates. -There is a gap between the J1 base and floor plate. -A J1 base-retaining bolt is loose.
[J1 base fastening] -It is likely that the robot J1 base is not securely fastened to the floor plate. -Probable causes are a loose bolt, an insufficient degree of surface flatness, or foreign material caught between the J1 base and floor plate. -If the robot is not securely fastened to the floor plate, the J1 base lifts the floor plate as the robot operates, allowing the base and floor plates to strike each other, which, in turn, leads to vibration. -The rack or floor plate [Rack or floor] -It is likely that the rack or floor vibrates during operation of the robot. 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] -Vibration becomes more serious when the robot adopts -It is likely that the load on the robot is greater than the a specific posture. -If the operating speed of the maximum rating. robot is reduced, vibration -It is likely that the robot control stops. program is too demanding for -Vibration is most noticeable the robot hardware. when the robot is accelerating. -It is likely that the -Vibration occurs when two or ACCELERATION ACCELERATION value is more axes operate at the excessive. same time.
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Measure Measure -If a bolt is loose, apply LOCTITE and tighten it to the appropriate torque. -Adjust the floor plate surface flatness to within the specified tolerance. -If there is any foreign matter between the J1 base and floor plate, remove it.
-Reinforce the rack or floor to make it more rigid. -If it is impossible to reinforce the rack or floor, modify the robot control program; doing so might reduce the amount of vibration. -Check the maximum load that the robot can handle once more. If the robot is found to be overloaded, reduce the load, or modify the robot control program. -Vibration in a specific portion can be reduced by modifying the robot control program while slowing the robot and reducing its acceleration (to minimize the influence on the entire cycle time).
B-82755EN/05
Symptom Vibration Noise (Continued)
3.TROUBLESHOOTING Descriptio n
Cause
Measure 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 geartooth surface or rolling surface of a bearing, or reducer. - It is likely that prolonged use of the robot while overloaded caused fretting of the gear tooth surface or rolling surface of a bearing, or reducer due to resulting metal fatigue. - It is likely that foreign 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.
-Operate one axis at a time to determine which axis is vibrating. -Confirm the oil side of the oil gauge of J4-J6 axis. Replenish oil when the oil side has not reached above the half. -Remove the motor, and replace the gear, the bearing, and the reducer. For the spec. of parts and the method of replacement, contact FANUC. -Using the robot within its maximum rating prevents problems with the drive mechanism. -Regularly changing the grease with a specified type can help prevent problems.
These factors all generate cyclic vibration and noise.
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3.TROUBLESHOOTING Symptom Vibration Noise (Continued)
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Descriptio n
Cause
Measure 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 Pulsecoder develops a fault, vibration might occur because Information about the motor position cannot be transferred to the controller accurately. -If the motor becomes defective, vibration might occur because the motor cannot deliver its rated performance. -If a power line in a movable cable of the mechanical section has an intermittent break, vibration might occur because the motor cannot accurately respond to commands. -If a Pulsecoder wire in a movable part of the mechanical section has an intermittent break, vibration might occur because commands cannot be sent to the motor accurately. -If a connection cable between them has an intermittent break, vibration might occur. -If the power cable has an intermittent break, vibration might occur. -If the power source voltage drops below the rating, vibration might occur. -If a robot control parameter is set to an invalid value, vibration might occur.
-Refer to the controller Maintenance Manual for troubleshooting related to the controller and amplifier. -Replace the Pulsecoder for the motor of the axis that is vibrating and check whether the vibration still occurs. -Also, replace the motor of the axis that is vibrating, and check whether vibration still occurs. For the method of replacement, contact FANUC. -Check that the robot is supplied with the rated voltage. -Check whether the sheath of the power cord is damaged. If so, replace the power cord, and check whether vibration still occurs. -Check whether the sheath of the cable connecting the mechanical section and controller is damaged. If so, replace the connection cable, and check whether vibration still occurs. -If vibration occurs only when the robot assumes a specific posture, it is likely that a cable in the mechanical unit is broken. -Shake the movable part cable while the robot is at rest, and check whether an alarm occurs. If an alarm or any other abnormal condition occurs, replace the mechanical unit cable. -Check that the robot control parameter is set to a valid value. If it is set to an invalid value, correct it. Contact FANUC for further information if necessary.
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Symptom Vibration Noise (Continued)
3.TROUBLESHOOTING Descriptio n -There is some relationship between the vibration of the robot and the operation of a machine near the robot.
-There is an unusual sound after replacement of grease. -There is an unusual sound after a long period. -There is an unusual sound during operation at low speed.
-There is an unusual sound when operating right immediately the replacing part, grease or oil.
Cause [Noise from a nearby machine] -If the robot is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. -If the robot is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration. -There may be an unusual sound when using other than the specified grease. -Even for the specified grease, there may be an unusual sound during operation at low speed immediately after replacement or after a long period. -There is a possibility of grease or oil has not been exchanged accurately. The amount of grease or oil may be insufficient.
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Measure Measure -Connect the grounding wire firmly to ensure a reliable ground potential and prevent extraneous electrical noise.
-Use the specified grease. -When there is an unusual sound even for specified grease, perform operation for one or two days on an experiment. Generally, a usual sound will disappear. -Stop the robot, and confirm the damage situation at once. -Replenish grease or oil when they are insufficient.
3.TROUBLESHOOTING Symptom Rattling
B-82755EN/05
Descriptio n
Cause
-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.
[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 Section 3.3/)
[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 has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash. -It is likely that prolonged use without changing the grease has caused the tooth surfaces of a gear and the inside of the reducer to wear out, resulting in an increase in the amount of backlash.
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Measure Measure -Check that the following bolts for each axis are tight. If any of these bolts is loose, apply LOCTITE and tighten it to the appropriate torque. -Motor retaining bolt -Reducer retaining bolt -Reducer shaft retaining bolt -Base retaining bolt -Arm retaining bolt -Casting retaining bolt -End effecter retaining bolt -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 or oil from the gearbox and wash the inside of the gearbox. -After replacing the gear or reducer, add an appropriate amount of grease or oil. -Using the robot within its maximum rating prevents problems with the drive mechanism. -Regularly applying the grease or oil with a specified type can help prevent problems.
B-82755EN/05
Symptom Motor overheating
3.TROUBLESHOOTING Descriptio n
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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Measure 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. Contact FANUC for further information. -Relaxing the robot control program and conditions can reduce the average current, thus preventing overheating. -Reducing the ambient temperature is the most effective means of preventing overheating. -Having the surroundings of the motor well ventilated enables the motor to release heat efficiently, thus preventing overheating. Using a fan to direct air at the motor is also effective. -If there is a source of heat near the motor, it is advisable to install shielding to protect the motor from heat radiation. -Input an appropriate parameter as described in CONTROLLER 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.
3.TROUBLESHOOTING Symptom Grease oil leakage
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Descriptio n
Cause
Measure Measure
-Grease or oil is leaking from
[Poor sealing]
-If a crack develops in the
the mechanical unit.
-Probable causes are a crack in
casting, sealant can be used as
the casting, a broken O-ring, a
a quick-fix to prevent further
damaged oil seal, or a loose
grease or oil leakage. However,
seal bolt.
the component should be
-A crack in a casting can occur
replaced as soon as possible,
due to excessive force that
because the crack might
might be caused in collision.
extend.
-An O-ring can be damaged if it
-O-rings are used in the
is trapped or cut during
locations listed below.
disassembling or
-Motor coupling section
re-assembling.
-Reducer (case and shaft)
-An oil seal might be damaged if
coupling section
extraneous dust scratches the
-Connection part of the wrist
lip of the oil seal.
-J3 arm coupling section
-A loose seal bolt might allow
-Inside the wrist
grease to leak along the
-Oil seals are used in the
threads.
locations stated below. -Inside the reducer -Inside the wrist -Seal bolts are used in the locations stated below. -Grease inlet/outlet -Oil inlet/outlet -For fix of cover
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Symptom
3.TROUBLESHOOTING Descriptio n
Dropping axis -An axis drops because the
Cause
Measure Measure
[Brake drive relay and motor]
-Check whether the brake drive
brake does not function.
-It is likely that brake drive relay
relay contacts are stuck to each
-An axis drops gradually when
contacts are stuck to each other
other. If they are found to be
it should be at rest.
to keep the brake current
stuck, replace the relay.
flowing, thus preventing the
-If the brake shoe is worn out, if
brake from operating when the
the brake main body is
motor is reenergized.
damaged, or if oil or grease has
-It is likely that the brake shoe
entered the motor, replace the
has worn out or the brake main
motor.
body is damaged, preventing
- J4-axis cable has movable
the brake from operating
part .So if robot exceeds stroke
efficiently.
limit, load depends on cable and
-It is likely that oil or grease has
it may cause damage of cables .
entered the motor, causing the
If robot exceeds stroke limit,
brake to slip.
remove plate of back of J4,
- In case of ARC Mate 100iCe ,
return axis to motion range
M-10iAe, ARC Mate 100iCe/6L,
during checking condition of
M-10iAe/6L
cables. If nylon band is cut,
brake is not
installed for J1/J4/J5/J6-axes. In
attach new articles. If you
case of J4/J5/J6-axes If you
operate robot with nylon band is
turn off the controller power at
cut, it cause damage of cables.
wait position, robot may move
(See Section 6.1).
greatly by weight or exceeds stroke limit depend on the posture of robot or wrist load condition. Adjust the wait position so that axis does not move greatly when controller power is turned off.
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3.TROUBLESHOOTING Symptom
B-82755EN/05
Descriptio n
Cause
Measure Measure
Displacement -The robot operates at a point
[Mechanical section problems]
-If the repeatability is unstable,
other than the taught position.
-If the repeatability is unstable,
repair the mechanical section by
-The repeatability is not within
probable causes are a failure in
referring to the above
the tolerance.
the drive mechanism or a loose
descriptions of vibration, noise,
bolt.
and rattling.
-If the repeatability becomes
-If the repeatability is stable,
stable, it is likely that a collision
correct the taught program.
imposed an excessive load,
Variation will not occur unless
leading to slipping on the base
another collision occurs.
surface or the mating surface of
-If the Pulsecoder is abnormal,
an arm or reducer.
replace the motor or the
-It is likely that the Pulsecoder is
Pulsecoder.
-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
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 Pulsecoder cable is defected.
-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.
Table 3.2 3.2 (b) (b) Allow able drop s At power off At Power-Off stop
5mm 5mm
NOTE Each value indicates the amount by which an end effector mounting face may fall.
3.3
BA CKLASH CKL ASH MEASUREME MEASUREMENT NT
Measurement Measurement m ethod 1 2 3
Maintain the robot in a specified posture. (See Fig. 3.3 (b) to (d).) Apply positive and negative loads to each axis as shown in Fig.3.3 (a). 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.
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B-82755EN/05
3.TROUBLESHOOTING
Stop position 0 +10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis)
First step (Do not measure)
-10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis) +10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis) -10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis) 0kg L2
L1
Second step (B2 =L 1+ L2)
0kg
+10kgf (J1 to J3-axis) + 3kgf (J4 to J6-axis)
-10kgf (J1 to J3-axis) - 3kgf (J4 to J6-axis)
Third step (B3=L 3+ L 4)
0kg L3
0kg L4
Fig.3.3 (a) (a) Backlash measurement meth od
Backlash B is calculated using the following expression:
B=
B2
+
B3
2
1629 : ARC Mate 100 iC, M-10iA ARC Mate 100iCe, M-10iAe 1300 : ARC Mate 100 iC/10S,M-10 iA/10S
1760
56
Loading position
Loading positon
Measured position
ARC Mate 100iC, M-10iA ARC Mate 100iC/10S, M-10iA/10S ARC Mate 100iCe, M-10iAe
J1 Arbitrary J2 80° J3 0° J4 0° J5 0° J6 ±90°
Measured position
ARC Mate 100iC/ 6L, M-10iA/6L ARC Mate 100iCe/6L, M-10iAe/6L
Fig.3.3 (b) (b) Backlash measured po stur e (1/3) (1/3)
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3.TROUBLESHOOTING
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Measured position
Loading positon
600 : ARC Mate 100iC, M-10iA ARC Mate 100iCe, M-10iAe ARC Mate 100iC/6L, M-10iA/6L ARC Mate 100iCe/6L, M-10iAe/6L 400 : ARC Mate 100iC/10S, M-10iA/10S
J1 Arbitrary J2 0° J3 82° J4 0° J5 0° J6 Arbitrary
5 0 0
Measured position
Loading position
5 0 0
Measured position J1 J2 J3 J4 J5 J6
Loading position ARC Mate 100iC, M-10iA ARC Mate 100iCe, M-10iAe
Arbitrary 40° -105° -90° 90° 0°
J1 J2 J3 J4 J5 J6
Arbitrary 15° -100° -90° 90° 0°
ARC Mate 100iC/6L, M-10iA/6L ARC Mate 100iCe/6L, M-10iAe/6L
5 0 0
J1 J2 J3 J4 J5 J6
Measured position
Arbitrary 40° -105° -90° 90° 0°
Loading position ARC Mate 100iC/10S, M-10iA/10S
Fig.3.3 (c) (c) Backlash measured po sture (2/3) (2/3)
- 40 -
B-82755EN/05
3.TROUBLESHOOTING
mounting position of magnet stand
Magnet stand Dial gauge Loading position (Loading should be alingned with the center of J5/J6-axes to avoid the effect of J5/J6 backlash.)
109
J1 Arbitrary J2 40° J3 -90° J4 -90° J5 90° J6 0°
115 Loading position (Loading position should be loaded in the direction of the rotation of J6-axis.)
Loading position (Loading position should be aligned with the center of J6-axis to avoid the effect of J6 backlash.)
5 4
Magnet stand Dial gauge Mounting position of magnet stand
Dial gauge
Mounting position of magnet stand Magnet stand
J1 J2 J3 J4 J5 J6
Arbitrary 0° 0° -90° 90° 0°
J1 J2 J3 J4 J5 J6
Arbitrary 0° 0° 0° 90° 0°
Fig.3.3 (d) (d) Backlash measured po stur e (3/3) (3/3)
- 41 -
3.TROUBLESHOOTING
B-82755EN/05
Table.3.3 (a) Permissible backlash value (ARC Mate 100iC, ARC Mate 100iCe) Angle conversion (arc-min) Displacement conversion (mm) Distance between the rotation center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50 1.23
2.50 0.33
2.50 0.31
3.00 0.10
3.00 0.04
5.00 0.17
1629
600
500
109
45
115.
Table.3.3 Table.3.3 (b) Permissib le b acklash value (M-10 (M-10i A, A, M-10i Ae) Ae) Angle conversion (arc-min) Displacement conversion (mm) Distance between the rotation center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50 1.23
2.50 0.33
2.50 0.31
4.00 0.13
4.00 0.05
6.00 0.20
1629
600
500
109
45
115
Table.3.3 (c) Permissible backlash value (ARC Mate 100iC/6L, ARC Mate 100iCe/6L) Angle conversion (arc-min) Displacement conversion (mm) Distance between the rotation center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50 1.27
2.50 0.33
2.50 0.31
3.00 0.10
3.00 0.04
5.00 0.17
1760
600
500
109
45
115
i A/6L, M-10 Ae/6L) i Ae/6L) Table.3.3 Table.3.3 (d) Permissib le b acklash value (M-10 (M-10 A/6L,
Angle conversion (arc-min) Displacement conversion (mm Distance between the rotation center and dial gauge (mm)
J1-axis
J2-axis
J3-axis
J4-axis
J5-axis
J6-axis
2.50 1.27
2.50 0.33
2.50 0.31
4.00 0.13
4.00 0.05
6.00 0.20
1760
600
500
109
45
115
Table.3.3 (e) Permissible backlash value (ARC Mate 100iC/10S) Angle conversion (arc-min) Displacement conversion (mm Distance between the rotation center and dial gauge (mm)
J1-a J1-axis xis
J2-a J2-axis xis
J3J3-ax axis is
J4-a J4-axis xis
J5-a J5-axis xis
J6J6-ax axis is
2.50 0.94
2.50 0.29
2.50 0.36
3.00 0.10
3.00 0.04
5.00 0.17
1300
400
500
109
45
115.5
Table.3.3 Table.3.3 (f) Permissibl e backlash value Angle conversion (arc-min) Displacement conversion (mm Distance between the rotation center and dial gauge (mm)
(M-10 (M-10i A/10S) A/10S)
J1J1-axis
J2J2-axis
J3 J3-axis
J4 J4-axis xis
J5J5-axis
J6 J6-axis
2.50 0.94
2.50 0.29
2.50 0.36
4.00 0.13
4.00 0.05
6.00 0.20
1300
400
500
109
45
115.5
NOTE When measuring backlash under circumstances where the distance between the rotation center and the dial gauge is different from those in t he above table, make angle and displacement conversions according to the table.
- 42 -
4.COMPONENT REPLACEMENT
B-82755EN/05
4
COMPONENT COMPONENT REPLACEMENT REPLA CEMENT
Once motors, reducers, gearbox and wrist unit are replaced, mastering becomes necessary, perform mastering according to Section 6 after any of these components is replaced.
NOTE Be very careful when dismounting and mounting the heavy components that are listed below. Component
Model
Weight Weight
ARC Mate 100iC, M-10 A i A ARC Mate 100iC/10S, M-10 A/10S i A/10S ARC Mate 100iCe, M-10i Ae Ae ARC Mate 100iC/6L, M-10 A/6L, i A/6L, ARC Mate 100iCe/6L, M-10 Ae/6L i Ae/6L ARC Mate 100iC, M-10 A, i A, ARC Mate 100iC/10S, M-10 A/10S, i A/10S, ARC Mate 100iCe, M-10i Ae Ae ARC Mate 100iC/6L, M-10 A/6L, i A/6L, ARC Mate 100iCe/6L, M-10 Ae/6L i Ae/6L
12.5 kg
All components from J2 arm to wrist unit (See Fig. 4.5 (b))
ARC Mate 100iC, M-10 A i A ARC Mate 100iC/10S, M-10 A/10S i A/10S ARC Mate 100iCe, M-10i Ae Ae
54 kg
All components from J2 arm to wrist unit (See Fig. 4.5 (b)) All components from J2 base to wrist unit (See Fig. 4.3 (b))
ARC Mate 100iC/6L, M-10 A/6L, i A/6L, ARC Mate 100iCe/6L, M-10 Ae/6L i Ae/6L ARC Mate 100iC, M-10 A i A ARC Mate 100iC/10S, M-10 A/10S i A/10S ARC Mate 100iCe, M-10i Ae Ae ARC Mate 100iC/6L, M-10 A/6L, i A/6L, ARC Mate 100iCe/6L, M-10 Ae/6L i Ae/6L
55.5 kg
J3 arm (See Fig. 4.11 (b), Fig.4.12 (a)) J3 arm (See Fig. 4.11 (a)) All components from J3-axis reducer to wrist wrist unit (See Fig. 4.11 (b), Fig.4.12 (b)) All components from J3-axis reducer to wrist wrist unit (See Fig. 4.11 (b))
All components from J2 base to wrist unit (See Fig. 4.3 (b)) Wrist unit (See Fig. 4.13 (a))
All models
14 kg 28 kg
29.5 kg
94.5 kg
96 kg 6kg
NOTE When applying LOCTITE to the important bolt tightening points, make sure that it is applied to the entire longitudinal portion in the engaging section of the female threads. If it is applied to the male threads, the bolts may be loosened because sufficient adhesion cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps. Be sure to wipe the excess LOCTITE after tightening screw. NOTE 1 Description of [LT242] means LOCTITE 242. 2 Description of [LT262] means LOCTITE 262. 3 Description of [LT518] means LOCTITE 518. 4 Description of [LT675] means LOCTITE 675.
- 43 -
4.COMPONENT REPLACEMENT
4.1
B-82755EN/05
FIGURE OF DRIVE MECHANISM
The drive mechanisms of each axis are shown in the following.
AC servo motor for J1-axis (M1)
J1-axis reducer
Gear Fig.4.1 (a) (a) Drive mechanism of J1-axis J1-axis
J2 arm J2-axis reducer
Input gear
J2 base AC servo motor for J2-axis (M2)
Fig.4.1 (b) (b) Drive mechanism of J 2-axis 2-axis
- 44 -
4.COMPONENT REPLACEMENT
B-82755EN/05
J3-axis reducer Input gear J2 arm
AC servo motor for J3-axis (M3) Fig.4.1 (c) (c) Drive mechanism of J3-axis J3-axis
Gear
Gear
AC servo motor for J4-axis (M4)
Fig.4.1 (d) (d) Drive mechanism of J 4-axis 4-axis
- 45 -
4.COMPONENT REPLACEMENT
B-82755EN/05
AC servo motor for J5-axis(M5) Gear
Gear Hollow flange
Fig.4.1 (e) (e) Drive mechanism of J5-axis J5-axis AC servo motor for J6-axis(M6)
Drive shaft
Gear Gear
Gear
Gear
Hollow flange
Fig.4.1 (f) (f) Drive mechanism of J 6-axis 6-axis
4.2 1 2 3 4
5 6 7 8 9 10 11
REPLACING REPLA CING THE J1-AXIS MOTOR MOTOR M1 Set dial gauges at J1-axis, and prepare for single axis mastering after replacement. Turn off the controller power. Remove the J1-axis motor connector. Remove the motor mounting bolts (1). Dismount the motor from the J2 base. When dismounting the motor, be careful of the grease that may drop from the motor if the robot is suspended from a ceiling or mounted on a wall. Remove the M10 hexagonal nut (5) from the motor shaft, and pull out the gear (3). Attach the gear to a new motor (2). Attach an M10 spring washer (4), (4), apply LOCTITE 242 242 to the M10 threaded n of the nut (5), and tighten the M10 nut with a specified torque of [20 Nm]. Replace the O ring (6) with a new one and put it into the J2 base where the J1-axis motor is to be mounted, and fasten them with bolt (1). Attach the cable connector to the J1-axis motor. According to Section 2.2, supply the J1-axis grease grease bath with the specified grease grease if grease is overflowed. Perform single axis mastering referring to Section 8.5 of of operator’s operator’s manual. manual.
- 46 -
4.COMPONENT REPLACEMENT
B-82755EN/05
NOTE If there is a danger that the t he J1-axis section may fall, for example, because the robot is installed except floor f loor mount, fix the J1-axis section during replacement work, for example, by pushing the J1-axis mechanical stopper against the J1-axis section. 1
2
3 4 5
6
Fig.4.2 Replacing th e J1-axis J1-axis moto r Parts name 1
BOLT
2
MOTOR
3
GEAR WASHER (Attached to motor) NUT (Attached to motor) O RING
4 5 6
Specificati on
Q’ty
A6-BA-8X20 A06B-0235-B605 (*1) (*1) A06B-0235-B005#S000 A06B-0235-B005#S000 (*2) A290-7215-X211
1
A6-WB-10S
1
A6-N1-10S JB-OR1A-G105 JB-OR1A-G10 5
1 1
Locki ng
Torque (N-m) (N-m)
4
1
LT242
20
(*1) ARC Mate 100 iC, M-10iA, ARC Mate 100 iC/6L, M-10 iA/6L, ARC Mate 100 iC/10S, M-10iA/10S (*2) ARC Mate 100 iCe, M-10iAe, ARC Mate 100 iCe/6L, M-10 iAe/6L
- 47 -
4.COMPONENT REPLACEMENT
4.3 1 2 3
4 5 6 7 8
9 10 11 12 13
14 15 16 17 18
B-82755EN/05
REPLACING REPLA CING THE THE J1-AXIS J1-A XIS REDUCER REDUCER Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore J2 to J6 axes. ( It is set in 0°for all axes when robot is shipped.) Set dial gauges at J1-axis, and prepare for single axis mastering after replacement. Put the robot in such a position that the J2 base and the portions above it can be suspended with a crane or the like (hereafter abbreviated as a crane), and then turn off the controller power. (See Fig. 4.3 (a)) While referencing referencing Section 5.3, pull out the cables cables below the J2 base from from the J1-axis hollow hollow pipe section toward the upper portion of the J2 base. While referencing Section 4.2, remove the J1-axis motor from the J2 base. As shown in Fig. 4.3 (c), remove remove the bolts bolts (3) that fasten the J2 base to the J1-axis reducer. While referencing Section 4.3 (b), hoist the J2 base and portions above it slowly. As shown in Fig. 4.3 (c), remove the O ring (5), bearing, bearing, and gear. Bearing rarely left in J2 base. It is not necessary to remove bearing in this case, when bearing does not rotate smoothly, break oil seal (12) and remove both oil seal and bearing then replace them to new article. Remove the bolts bolts (7) that fasten fasten the J1-axis reducer reducer to the J1 base, and and dismount dismount the reducer. reducer. Disconnect the pipe. Replace the O ring (10) with a new one and fit it with the pipe correctly. Replace the O ring (11) with a new one one and attach it to a new reducer, reducer, and fasten the reducer to J1 base with (7) bolts (by applying LOCTITE 262 and tightening with a torque of [129 Nm]). Mount the center gear, bearing (with LOCTITE 675 applied to its outer ring), and O ring (5) to the reducer. When bearing is broken in this process, replace bearing to new one. When replacing oil seal (12), press-fit it by using fixture in Fig.4.3 (d). Fasten the J2 base to the reducer with bolts (3) (by applying LOCTITE 262 and tightening with a torque of [73.5 Nm]). Nm]). Be careful not to let the pipe damage the oil seal. According to Section 4.2, mount the J1-axis motor on the J2 base. According to Section 5.3, mount the cables. According to Section 2.2, supply the J1-axis grease bath with the specified grease. Perform quick quick mastering, then perform single axis mastering mastering to J1-axis referring to Section 8.4 and 8.5 of operator’s manual.
NOTE 1 Reducer and gear of upper upper of reducer are can be installed only in combination below. (1) Spec of reducer: A97L-0218-0822#33 A97L-0218-0822#33 Gear: A290-7215-X212 (2) Spec of reducer: A97L-0218-0885#33 A97L-0218-0885#33 Gear: A290-7221-Z212 See Fig.4.3 (a) when distinguishing it. 2 When the influence of the damaged pieces pieces generated generated from broken reducer reducer is concerned about, exchange gear (A290-7215-X211) of J1-axis motor shaft, gear (A290-7215-X212) on J1-axis reducer and bearing (A97L-0001-0192#1400000).
- 48 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Old spec. A97L-0218-
#33 New spec. A97L-0218-
#33
Bearing size becomes 6813 from 6814. Inside diameter shrinks.
Spur gear becomes two steps from one step.
Contents for change of J1center gear New spec. A290-
Old spec. A29040.8
45.3
5 6
0 7
O
O
Dimension is changed. There is no compatibility. Fig.4.3 (a) Distinc tio n of new and o ld redu cer and gear
- 49 -
4.COMPONENT REPLACEMENT
B-82755EN/05
A M10 Eyebolt
VIEW A
Mounting position of eyebolt
Fig.4.3 (b) Slin Slin g the J2 base uni t
5 6
3 2 1
4
8 7
11 9
10 Fig.4.3 (c) (c) Replacing th e J1-axis J1-axis r educer Parts name 1 2 3 4 5 6
BOLT MOTOR BOLT O RING O RING GEAR
7
BEARING BOLT
8
J1 REDUCER
9 10
PIPE O RING
Specificati ons A6-BA-8X20 A06B-0235-B605 A06B-0235-B605 A6-BA-10X50 JB-OR1A-G105 A290-7207-X342 A290-7215-X212 (*1) (*1) A290-7221-Z212 (*2) A97L-0001-0192#1400000 A6-BA-12X80 A97L-0218-0822#33 (*1) (*1) A97L-0218-0885#33 (*2) (*2) A290-7215-X215 JB-OR1A-G65
- 50 -
Q’ty 4 1 7 1 1
Locki ng
Torque
(N-m) (N-m)
LT262
73.5
LT262
129
1 2 6 1 1 1
4.COMPONENT REPLACEMENT
B-82755EN/05
Parts name 11 12
Specificati ons
O RING OIL SEAL
Q’ty
A98L-0001-0347#S150 A98L-0040-0047#06009008 A98L-0040-0047#0600900 8
Locki ng
Torque
(N-m) (N-m)
1 1
(*1) Old spec: robot shipped before March, 2010. (*2) New spec: robot shipped after April, 2010.
J2 base 12 Bearing Fig.4.3 (d) (d) Replacing t he J1-axis J1-axis r educer 29 7 12
A
1 . 0 3 ± 4 8 7 5 . 9 O O 8
1 C 2 . 3 . 0 0
0 - 6 2 8 O
O
1 C
C 0 . 5
C 1
5 5 0 . 0 . C C
A
SECTION A-A
Fig.4.3 (e) Example of press-fit f ixtu re for oi l seal
- 51 -
O
4.COMPONENT REPLACEMENT
4.4 1 2
B-82755EN/05
REPLACING REPLA CING THE J2-AXIS MOTOR MOTOR M2 Set dial gauges at J2-axis, and prepare for single axis mastering after replacement. Push the J2-axis section against the mechanical stopper, or fix it in such a way that it will not swivel when the motor is dismounted, for example, by placing it in the direction of gravity.
NOTE If the J2-axis section is not pushed against the stopper correctly, or it i s not placed in the direction of gravity, there is a danger that t he J2-axis section will swivel when the J2-axis motor is removed. 3 4 5 6
Turn off the controller power. Remove the J2-axis motor connector. Remove the motor mounting bolts (1), and dismount the motor from the J2 base. Remove the bolt (5) that fastens the input gear (4), and dismount the input gear (4). Also, remove the draw nut from the motor shaft. Apply LOCTITE 242 to the threaded portion of a draw nut (3) and tighten the draw nut to shaft of new motor with a torque of [16.7 Nm]. Put the input gear (4) over over the draw nut (3), apply LOCTITE 242 to the M6 threaded portion of the draw nut (3), and tighten the bolt (5) with a torque of [6.8 Nm]. Replace the O ring (6) with a new one and and put it into the J2 base portion where the motor is to be mounted, and fasten the motor to the J2 base with bolts (1). Do not force in the motor. Otherwise, the input gear may not settle in the correct place, possibly causing vibration (if the input gear is engaged correctly, the motor will be mounted smoothly). Attach the cable connector to the J2-axis motor. According to Section 2.2, supply the J2-axis grease bath with the specified grease. Perform single axis mastering referring to Section 8.5 of operator’s manual.
7 8 9
10 11 12
5
4
2
3
1
6
Fig.4.4 Replacing J2-axis moto r Parts name 1 2 3 4 5 6
BOLT MOTOR DRAW NUT INPUT GEAR BOLT O RING
Specificati ons A6-BA-8X20 A06B-0235-B605 A290-7221-X321 A290-7221-X311 A6-BA-5X45 JB-OR1A-G105 JB-OR1A-G10 5
Q’ty 4 1 1 1 1 1
- 52 -
Locki ng
Torque (N-m) (N-m)
LT242
16.7
LT242
6.8
4.COMPONENT REPLACEMENT
B-82755EN/05
4.5
REPLACING REPLA CING THE THE J2-AXIS J2-A XIS REDUCER REDUCER
1 2
Set dial gauges at J2-axis, and prepare for single axis mastering after replacement. Put the robot in such a posture that the J2 arm and the components components on it can be suspended with a crane. 3 Turn off the controller power. 4 Suspend the J2 arm and the components on on it as shown Fig. 4.5 (a) and (b) with a crane so that they will not drop when the J2 arm is dismounted. (If there is the fixture shown in Fig. 4.5 (b), work improves. The material must be SS400 or or an equivalent. equivalent. Use the eyebolts eyebolts delivered with the J2 base when robot is shipped.) 5 Remove the J2-axis J2-axis motor motor as described in Section 4.4 (If the the reducer reducer is replaced while the motor is still mounted, the input gear may be damaged.) 6 As shown in Fig. 4.5 (c), remove remove the bolts (1) that fasten the reducer reducer (3) to J2 base, and and remove remove bolts bolts (2) that fasten the reducer (3) to J2 arm .Be careful not to allow an excessive load to be put on the cables (because the cables are left attached when the reducer is dismounted). 7 Replace the O ring (4) with a new one and attach it to a new reducer, insert it into the J2 arm, and fasten them with bolts (2) (by applying LOCTITE 262 and tightening with a torque of [15.6 Nm]). Nm]). 8 Degrease both both the J2 base and the J2-axis reducer reducer surfaces that are to meet meet each other, and as shown in Fig. 4.5 (d), apply sealant (LOCTITE 518) to the J2-axis reducer on which the J2 base is to be mounted. 9 Mount the reducer to the J2 arm with bolts (1) (by applying LOCTITE 262 262 and tightening with a torque of [73.5 Nm]). 10 Mount the J2-axis motor as described in Section 4.4. 11 According to Section 2.2, supply the J2-axis grease bath with the specified grease. 12 Perform single axis mastering referring to Section 8.5 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange input gear (A290-7221-X311) of J2-axis motor shaft.
- 53 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Wind sling to ruggedness part of tip of wrist.
Wind sling so that sling goes around J3-axis reducer.
Fig.4.5 (a) (a) Slin Slin g th e J2 and J3 arms 140 45
2-M10 THRU 7
0 0 7 5
4-O7 THRU 130 M10 eyebolts (2pcs)
Fig.4.5 (b) Sling th e J2 and J3 arms (When (When fix ture is used)
- 54 -
4.COMPONENT REPLACEMENT
B-82755EN/05
4
シール剤塗布面 SEALANT APPLYING SURFACE
3 2
1
Fig.4.5 (c) (c) Replacing th e J2-axis J2-axis r educer Parts name 1 2
BOLT BOLT
3
J2 REDUCER
4
O RING
(*1) (*2)
Specificatio ns A6-BA-10X20 A6-BA-6X30 A97L-0218-0886#127(*1) A97L-0218-0886#127(* 1) A97L-0218-0886#93 (*2) (*2) JB-OR1A-G130
Q’ty 9 16 1
Locki ng LT262 LT262
1
Except ARC Mate 100iC/10S,M-10iA/6S ARC Mate 100iC/10S,M-10iA/6S
Fig.4.5 (d) applying sealant to th e J2-axis J2-axis reducer
NOTE Refer to Section 4.23 about applying sealant (LOCTITE 518).
- 55 -
Torque (N-m) (N-m) 73.5 15.6
4.COMPONENT REPLACEMENT
4.6
B-82755EN/05
REPLACING REPLA CING THE J3-AXIS MOTOR MOTOR M3
NOTE Fixtures are necessary for replacing J3-axis motor and reducer. See Fig.1.10 (a) to (e). 1 2 3 4 5 6 7 8 9
10
11 12 13 14
Set dial gauges at J3-axis, and prepare for single axis mastering after replacement. Place the robot in the posture J2=0 º. At this chance, confirm J1 base is fixed to prevent from falling. Suspend the J3 arm and the components components on it as shown Fig. 4.6 (a) with a crane so that they will not drop when the J2 arm is dismounted Turn off the controller power. Remove the connector of a cable leading to the J3-axis motor. Remove the bolts bolts (1) that fasten the J3-axis motor to the J3 casing, and dismount the motor motor and packing (7). Remove the bolt bolt (6) from the motor motor shaft, and dismount the input input gear (5) and draw nut nut (4). (4). Apply LOCTITE 242 to the threaded portion of draw nut (4) and tighten it to the new motor with a torque of [3.1 Nm]. Put the input gear gear (5) over the draw nut (4), (4), apply LOCTITE 242 242 to the M5 threaded portion of the draw nut (4), and tighten the t he bolt (6) with a torque of [3.4 Nm]. In this time, be sure to attach key (3), too. Refer to section 4.8 about mounting input gear to J3-axis motor. motor into the reducer. Keep the J3-axis degrease outlet on Attach new packing new packing (7), and insert the motor the J2 arm side open (see Fig. 2.2 (c)), and look into the outlet to make sure that the input gear has settled in the correct correct place. place. Even one tooth tooth of of a shift in engagement can cause vibration. vibration. (If the input gear (5) is engaged correctly, the motor can get in the reducer smoothly.) In this case, if robot is shipped before March, 2010, please confirm whether attaching the motor to the reducer is appropriate referring to paragraph 4.8. Please confirm whether the flange of the motor floats, and install it with the phase that spur gears form a line like figure 4.6 (c) up and down. Fasten the motor to the the J3-axis reducer with bolts (1). Be sure to use use a new packing packing to prevent grease leakage. Refer to section 4.8 about mounting J3-axis motor to reducer. Attach the cable connector to the J3-axis motor. According to Section 2.2, supply the J3-axis grease bath with the specified grease. Perform single axis mastering referring to Section 8.5 of operator’s manual.
Wind sling to ruggedness part of tip of wrist.
J2=0°
Fig.4.6 (a) (a) Sling t he J3 arm
- 56 -
4.COMPONENT REPLACEMENT
B-82755EN/05
1
2
5
6
3
7
4
Fig.4.6 (b) Replacing Replacing the J3-axis motor Parts name 1 2
4
BOLT MOTOR KEY (Attached to motor) DRAW NUT
5
INPUT GEAR
6 7
BOLT PACKING
3
Specificati ons
Q’ty
A6-BA-6X14 A06B-0212-B605#S000 A06B-0212-B605#S000
4 1
JB-HGKYA-4X13
1
A290-7221-X421 A290-7221-X411 (*1) (*1) A290-7221-Z411 (*2) A290-7221-Z415 (*3) A6-BA-4X55 A98L-0040-0042#03
1
Locki ng
Torque (N-m) (N-m)
LT242
3.1
LT242
3.4
1 1 1
(*1) Old spec robot ARC Mate 100 iC, M-10iA, ARC Mate 100 iC/6L, M-10iA6L shipped before March, 2010. (*2) New spec: robot ARC Mate 100 iC, M-10iA, ARC Mate 100 iC/6L, M-10iA6L shipped after April, 2010 or ARC Mate 100 iCe, M-10iAe, ARC Mate 100 iCe/6L, M-10iAe6L. (*3) ARC Mate 100 iC/10S, M-10iA/10S
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4.COMPONENT REPLACEMENT
B-82755EN/05
The old and new reducer is incompatible. See Fig.4.6 (c) when distinguish it.
New spec. A290-7221-
Old spec. A290-7221 3
Chamfering size is different. 6 . 4 8
6 . 1 8
Fig.4.6 Fig.4.6 (c) (c) Distinction of new and old input gear gear
Assmeble motor so that spur gear form a line with this phase.
Fig.4.6 (d) Phase for mounting J3-axis motor to reducer (Only for robot which is shipped before March, 2010)
4.7
NOTES OF ATTACHING J3-AXIS MOTOR TO REDUCER
1) Procedure of J 3 Motor Input Gear Gear Alig nment 1 2 3
Apply LOCTITE LOCTITE 242 242 to thread the Draw Nut (A290-7221-X421) and mount it to the motor motor shaft by using torque wrench with regulated torque set at 3.1Nm. Attach the woodruff key to motor shaft, confirm confirm there is no dust on taper shaft of motor motor and insert input gear to motor shaft. Mount fixture to motor as Fig.4.7 (a) for centering.
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4.COMPONENT REPLACEMENT
B-82755EN/05
4
5
Apply LOCTITE 242 to thread and tighten bolt (M4 ×55) with regulated torque 3.4Nm while supporting input gear with spanner wrench preventing the input gear from rotating.(to prevent motor brake slips) If you hear the ratchet sound of the torque wrench then, turn the torque wrench until the next ratchet sound or until the bolt head is completely past the motor input gear. This completes setting of the input gear on the motor taper shaft. Remove the Fixture from the Motor Shaft. Ｂｏｌｔ A6-BA-4X55 Tightening torque 3.4 Nm
Fixture A290-7221-X973 A290-7221-X973
LOCTITE Insert spanner not to rotate the motor shaft
J3-axis motor input gear
Fixture(*) Fixture(*)
J3-axis motor Draw nut A290-7221-X421 A290-7221-X421 Tightening torque 3.1 Nm LOCTITE 242
Fixture A290-7221-X974 or A290-7221-X976
J3-axis motor
Ｂｏｌｔ A6-BA-4X55 Tightening torque 3.4 Nm LOCTITE
Fixture(*) Insert spanner not to rotate the motor shaft
J3-axis motor input gear
Fixture(*) J3-axis motor
Draw nut A290-7221-X421 A290-7221-X421 Tightening torque 3.1 Nm LOCTITE 242
J3-axis motor
(*) Specification of fixture is differ depend on robot. i A,ARC Mate 100 i A/6L which is made before March,2010. 1. ARC Mate 100iC,M-10 A,ARC 100iC/6L, M-10 A/6L March,2010.
A290-7221-X973 A290-7221-X973 i A,ARC Mate 100 i A/6L which is made after April,2010 2. ARC Mate 100iC,M-10 A,ARC 100iC/6L, M-10 A/6L April,2010 or i Ae,ARC Mate 100 i Ae/6L ARC Mate 100 100iCe,M-10 Ae,ARC 100iCe/6L,M-10 Ae/6L
A290-7221-X974 A290-7221-X974 (Use them them after connecting them.) i A/10S 3. ARC Mate 100iC/10S,M-10 A/10S
A290-7221-X976 A290-7221-X976 (Use them after after connecting them.) them.) Fig.4.7 (a) Attachin g J2-axis and J3-axis motor to redu cer
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4.COMPONENT REPLACEMENT
B-82755EN/05
There are 3 cases about method of installing J3-axis motor to reducer depend on the shipment time of robot. 1
Robot which is made before June, 2009 J3-axis reducer grease outlet is made in J3-axis rotation center of J2 arm. Mount J3-axis motor referring to procedure 2) of this Section.
J3-axis reducer grease outlet Seal bolt A97L-0218-0417#081010
Fig.4.7 (b) Robot wh ich i s made before June, 2009 2009
2
Robot which is made after July, 2009 and before March, 2010 J3-axis reducer grease outlet is at the position upper than J3-axis rotation center of J2 arm. Seal bolt is attached to tap for mounting fixture. Mount J3-axis motor referring to procedure 3) of this Section.
J3-axis reducer grease outlet Seal bolt A97L-0218-0417#081010
Seal bolt A97L-0218-0417#101212 (Note： This is not J3-axis reducer grease outlet.)
Fig.4.7 (c) (c) Robot w hich is made after Ju ly, 2009 and befor e March, March, 2010
3
Robot which is made after April, 2010 No fixture is needed while mounting J3-axis motor to reducer. reducer. - 60 -
4.COMPONENT REPLACEMENT
B-82755EN/05
2) Procedure of J 3-axis 3-axis Reducer Alig nment (Robo (Robo t wh ich is m ade befor befor e June, 200 2009) 9) 1
2
Mount J3-axis motor motor that is aligned to J3 casing after attaching packing to motor flange referring to previous section. Confirm that the Motor Flange is not floating from the attaching surface of the J3 casing from the three sight direction of Fig.4.7 (e). If there is clearance between motor and J3 casing, input gear is not aligned, insert it again. If you confirm there is no gap, work is completion. Insert the Fixture (A290-7221-Z972) into the J3 grease outlet as Fig.4.7 (f) until it touches touches the face of the bolt. You can judge that it is the good condition in case that the male screw part is not sticking out of the surface of the counter bore. If input gear is not aligned, the male screw part is sticking out of the surface of the counterbored hole(2mm) as Fig.4.7 (f). If the centering is good, the top of the Fixture (A290-7221-Z972) can enter into the hexagon socket on the bolt head.
Spur gear Motor shaft + Input gear
RV reducer
(a) Wrong fitting case
(b) Correct fitting
Fig.4.7 (d) Attaching J3-axis motor to reducer
Confirm there is no clearance in this face. Fig.4.7 Fig.4.7 (e) (e) Confirmin Confirmin g th e mounting of J3-axis J3-axis motor
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4.COMPONENT REPLACEMENT
B-82755EN/05
Centering fixture A290-7221-Z972 1.5～2.0mm
Centering is performed
Centering is not performed
Fig.4.7 (f) Conf Conf irmi ng th e gap of the core of J3-axis moto r (1/2) (1/2)
3) Procedure of J 3-axis 3-axis Reducer Alig nment (Robo (Robo t w hic h is made after Jul y, 2009 2009 and befo re Marc March, h, 2010 2010)) 1 2
3
4
Remove seal bolt of J3-axis rotation center of J2 arm in Fig.4.7 (c), mount mount fixture (A290-7221-Z974) and tighten it well. Attach J3-axis J3-axis motor which gear is attached to J3 casing. Attach it so that motor flange surface is mounted to J3 casing without clearance. (If centering is performed, it is hard to pull out motor. So try to pull out to confirm it.) Look the center of fixture fixture which is attached to J2 arm with flashlight and confirm bolt of center gear is center of fixture. If centering of input gear is performed, center of bolt of input gear accords in center of hole of fixture. Confirm it referring to Fig.4.7 (g). If centering is not performed, motor is not mounted to J3 casing. If it is confirmed, confirmed, attach seal bolt. If seal bolt is reused, be sure to wind it with seal tape.
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4.COMPONENT REPLACEMENT
B-82755EN/05 If centering is performed, center of bolt of input gear accords in center of hole of fixture.
If centering is not performed, center of bolt of input gear does not accord in center of hole of fixture.
The part which slips off
The part which slips off
Detail A
Detail A
Detail A
Centering fixture A290-7221-Z974
A Fig.4.7 (g) Confi Confi rmin g the adhering of J3-axis motor (2/2) (2/2)
4.8
REPLACING REPLA CING THE THE J3-AXIS J3-A XIS REDUCER REDUCER
NOTE Fixtures are necessary for replacing J3-axis motor and reducer. See Fig.1.10 (a) to (e). 1 2
3 4
5 6 7 8 9
Set dial gauges at J3-axis, and prepare for single axis mastering after replacement. Put the robot in such a posture that that the J3-axis section and the components on it can be suspended with a crane, (If there is the fixture shown in Fig. 4.5 (b), work improves. improves. The material must must be SS400 or an equivalent. Use the eyebolts delivered with the J2 base.) Turn off the controller power. While referencing Section 5.3, remove the cable from from the the J2 arm section. Suspend Suspend the J3-axis section and the components on it with a crane so that they will not drop when the reducer is dismounted from the J2 arm. This supporting method is common to replacing J2-axis reducer so reference to section 4.5 for more details. Be careful not to allow an excessive load to be put on the cable assembly (because the cables are left attached when the reducer is dismounted). While referencing Section 4.6, dismount the J3-axis motor from the J3 arm unit. Remove bolts (3) that fasten the J3-axis reducer to the J3 arm dismount the J3 arm that reducer attaches from the J2 arm. Remove bolt (1) that fasten J3-axis reducer reducer to J3 casing. In addition, remove J3-axis reducer reducer from J3 casing. Remove O ring (5) and and attach new O ring (5) to the reducer installation part of J2 arm. Suspend the J3-axis section and the components on it with a crane, and fasten the J2 arm and and J3-axis J3-axis reducer with bolts (3) (by applying LOCTITE 262 and tightening with a torque of [9.0 Nm]). Please install it so that the phase of the spur gears form a line like figure 4.6 (c) up and down.
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4.COMPONENT REPLACEMENT 10
B-82755EN/05
Degrease both the J3-axis reducer reducer and the J3 casing surfaces that are to meet each other, other, and as shown in Fig. 4.8 (c), apply sealant (LOCTITE 518) to the J3-axis reducer surface on which the J3 casing is to be mounted. While referencing Section 4.6, mount mount the J3-axis motor motor on the J3 arm unit. In this case, if robot is shipped before March, 2010, please confirm whether attaching the motor to the reducer is appropriate referring to paragraph 4.8. While referencing Section 5.3, 5.3, dress dress the cable into the previous form. According to Section 2.2, supply the J3-axis grease bath with the specified grease. Perform single axis mastering referring to Section 8.5 of operator’s manual. Confirm software version and cope as needed.
11
12 13 14 15
The shipment time of robot Before March, 2010.
Software version
Cope when replacing J3-axis J3-axis reducer
V7.30P-27 or earlier V7.40P-06 or earlier V7.30P-28 or later V7.40P-07 or later
J3-axis reducer mounting phase auto adjusting function is not needed.
All
J3-axis reducer mounting phase auto adjusting adjusting function is not needed.
After April, 2010
Be sure to perform J3-axis reducer mounting phase auto adjusting function referring to subsection 4.7.1.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange input gear of J3-axis motor shaft. At this time, confirm there is no clearance between input gear and J2 arm referring to Section 4.8.
3
1
2
シール剤塗布面 SEALANT APPLYING SURFACE
4 5
Fig.4.8 (a) (a) Replacin Replacin g th e J3 –axis reducer Parts name 1 2 3
BOLT ADAPTER BOLT
4
J3 REDUCER
5
O RING
Specificatio ns
Q’ty
A6-BA-8X25 A290-7221-X422 A6-BA-5X20 A97L-0218-0824#150 (*1) (*1) A97L-0218-0887#150 (*2) (*2) A97L-0218-0887#108 (*3) (*3) JB-OR1A-G130 JB-OR1A-G13 0
8 1 12
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1 1
Locki ng
Torque (N-m) (N-m)
LT262
37.2
LT262
9.0
4.COMPONENT REPLACEMENT
B-82755EN/05
(*1) (*2) (*3)
Old spec:： ARC Mate 100 iC,M-10iA,ARC Mate 100 iC/6L,M-10iA/6L which are shipped before March, 2010 New spec： ARC Mate 100 100iC,M-10iA,ARC Mate 100 iC/6L,M-10iA/6L which are shipped after April, 2010 or ARC Mate 100 iCe,M-10iAe,ARC Mate 100 iCe/6L, M-10iAe/6L. ARC Mate 100iC/10S,M-10iA/10S
The old and new reducer is incompatible. See Fig.4.8 (b) when distinguish it.
Old spec. A97L-0218-
#150 New spec. A97L-021812-O5.8 Equally spaced
7 . 2
16-O5.8 Equally spaced
3
Fig.4.8 (b) Distinction of new and old J3-axis reducer
Fig.4.8 (c) Applyin g sealant to t he J3-axis J3-axis redu cer
NOTE Refer to Section 4.23 about applying sealant (LOCTITE 518). - 65 -
#150
7 . 5
4.COMPONENT REPLACEMENT
4.8.1 1 2 3
B-82755EN/05
J3-axis J3-axis reducer reducer moun ting p hase auto adjus adjus ting fu nctio n
If H839INIT program and H839RVAT program are not installed to controller, contact FANUC. Perform H839INIT program. In H839RVAT program, disturbance torque is measured with J1=J2=J4=J6=0 °, J5=-90° and J3 moves between 0° and 40 ° with override 10%. Before executing H839RVAT.TP, keep the space so at to move the robot arm without interference with peripheral. And to avoid the harmful effect by vibration of a robot hand, the position of J5 axis is set to –90º. Check the interference between a robot arm and a robot hand, too. Perform H839RVAT program.
4
NOTE The H839RVAT-related parameter is stored away by SYSMAST.SV. In addition, a value is listed in inspection certification attached at the time of shipment. After V7.30P-25, it is necessary to return backup of SYSMAST.SV at the time of the update of the software. In addition, contact FANUC about group 2 or later for robots of multiple control.
4.9 1 2 3 4 5 6 7
8 9 10 11
REPLACING REPLA CING THE J4-AXIS MOTOR MOTOR M4 (ARC Mate 100iC, M-10i A, A , ARC Mat e 100iC/6L, M-10i A/6L A /6L)) Place the robot in a posture of J3 = +180 °. Set dial gauges at J4-axis, and prepare for single axis mastering after replacement. Turn off the controller power. Remove the connector of a cable leading to the J4-axis motor. As shown in Fig. 4.9, remove remove the three bolts (1) that fasten the J4-axis motor motor to the J3 casing, and dismount the motor. Remove the bolt (6) that fastens the gear (4) (4) to the motor motor shaft, and dismount dismount the washer (5), (5), gear (4) and key (3). Mount the gear (4) to a new motor, apply LOCTITE 242 to the threaded portion of the motor shaft, and fasten them with a bolt by tightening with a torque of [1.3 Nm]. (Ensure the specified torque is achieved otherwise, the J4-axis may get out of place.) Replace the Packing (7) (7) with a new one and put it in the J3 casing portion where where the motor is to be mounted accurately, and fasten the motor to the J3 casing with bolts (1). Attach the cable connector to the J4-axis motor. According to Section 2.2, supply the J4-axis gearbox gearbox with the specified oil. Perform single axis mastering referring to Section 8.5 of operator’s manual. manual.
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4.COMPONENT REPLACEMENT
B-82755EN/05
1 2
3 4 5 6 7
Fig.4.9 Replacing th e J4-axis J4-axis moto r Parts name 1
BOLT
2
MOTOR
3 4 5 6 7
KEY GEAR WASHER BOLT PACKING
Specificatio ns A97L-0218-0612#051212 A06B-0115-B804 (*1) (*1) A06B-0115-B205#S000 A06B-0115-B205#S000 (*2) JB-HKY-3X3X20B JB-HKY-3X3X20B A290-7221-X412 A290-7210-X532 A6-BA-3X8 A98L-0040-0042#07
Q’ty
Torque
(N-m) (N-m)
4 1 1 1 1 1 1
(*1) ARC Mate 100 iC, M-10iA, ARC Mate 100 iC/6L, M-10 iA/6L (*2) ARC Mate 100 iCe, M-10iAe, ARC Mate 100 iCe/6L, M-10 iAe/6L
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Locki ng
LT675
LT242
1.3
4.COMPONENT REPLACEMENT
4.10
B-82755EN/05
REPLACING REPLA CING THE J4-AXIS MOTOR MOTOR M4 (ARC Mate 100iC/10S, M-10i A/10S) A /10S)
1 2 3 4 5
Place the robot in a posture of J3 = +180 °. Set dial gauges at J4-axis, and prepare for single axis mastering after replacement. Turn off the controller power. Remove the connector of a cable leading to the J4-axis motor. As shown in Fig. 4.10, remove the three bolts (1) that fasten the J4-axis motor to the J3 casing, and dismount the motor. 6 Remove the set screw (5) that fastens the gear (4) to the motor shaft, and dismount the gear (4) and key (3). 7 Attach key (3) and gear (4) to new motor. Apply Apply LOCTITE 242 to set screw (5) and tighten it with torque of [0.54 Nm]. (Ensure the specified torque is achieved otherwise, the J4-axis may get out of place.) 8 Replace the packing (6) with a new one and put put it in the J3 casing portion where where the motor is to be mounted accurately, and fasten the motor to the J3 casing with bolts (1). 9 Attach the cable connector to the J4-axis motor. 10 According to Section 2.2, supply the J4-axis gearbox gearbox with the specified oil. oil. 11 Perform single axis axis mastering referring to Section 8.5 of operator’s operator’s manual. manual.
1
2
3 4 5 6
Fig.4.10 Fig.4.10 Replacin Replacin g the J4-axis moto r Parts name 1 2 3 4 5 6
BOLT MOTOR KEY GEAR SET SCREW PACKING
Specificati ons A97L-0218-0612#051212 A97L-0218-0612#051212 A06B-0115-B804 JB-HKY-3X3X20B JB-HKY-3X3X20B A290-7221-Z412 A6-SAKT-3X4 A98L-0040-0042#07
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Q’ty 4 1 1 1 2 1
Locki ng
Torque
(N-m) (N-m)
LT675 LT242
0.54
4.COMPONENT REPLACEMENT
B-82755EN/05
4.11
REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iC, M-10i A, A , ARC Mat e 100iC/6L, M-10i A/6L A /6L,, ARC A RC Mate 100 iCe, M-10i Ae, A e, ARC Mat e 100iCe/6L, M-10i Ae/6L A e/6L))
Pay attention that specification of J4-axis gearbox is different by time of robot shipment Before March 2010 (Spec. of mechanical unit: A05B-1221-B201, B202, B301, B302): A05B-1221-K401 After April 2010 (Spec. of mechanical unit: A05B-1221-B401, B402, B451, B452, B501, B502, B551, B552): A05B-1221-K411 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20
21 22 23 24 25 26
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore J5 to J6 axes. (It is set in 0º for all axes when robot is shipped.) Set dial gauges at J3/J4-axes, and prepare for single axis mastering after replacement. Turn off the controller power. Pull out all oil of J4-axis gearbox referring to Section 2.2. Wrap and hang hang Sling in two places of the J3 arm referring to Fig.4.11 (a) and (b). Remove the wiring and piping between J3-axis and wrist. When When cable installed in M/H conduit or No dust M/H conduit is removed, refer to Section 4.19 or 4.22. 4.22. Referring to section 5.3,remove option cable from J4-axis connector panel. Referring to section 5.3,remove 5.3,remove J3/J4-axis motor motor connector, clamp part in J3 casing, clamp part in J3 arm and cable of J5/J6-axis motor, and pull out cable from J3 arm unit. Referring to Section 4.9, remove J4-axis motor. Remove bolt (1), cover (2) and packing (3). Remove bolt (4) and pipe B (5). Remove bolt (6), J3 arm and O ring (7). Referring to Section 4.6, remove J3-axis motor. Remove bolt (8) and J4 connector plate (9). Remove bolt (10) that fasten fasten J3 unit (13) (13) to J2 arm, and remove J3 unit unit (13) from J2 arm. Remove adapter (12). Remove bolt (14) and clamp (15). Then remove bolt bolt (16) and clamp (17). Remove bolt bolt (18) and pipe A (19). Then remove remove bolt (20), cover (21) and packing (22). Please apply parts removed to new J4 axis axis gearbox by 10 –17. Please spread LOCTITE according to the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time, replace packing (22) to new one. When installing J3 unit to J2 arm, apply LOCTITE 518 to J3-axis reducer referring to Section 4.8. Do process of 5-9 by opposite procedure. Please spread LOCTITE according to the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time, replace packing (3) and O ring (7) to new one. Referring to section 5.3,attach cables to J3 arm and J3 casing. Referring to Section 4.6 and 4.9 attach J3/J4-axis motor. In this time replace packing and seal bolt to new one. Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J4 oil outlet. According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to J4-axis gearbox with specified oil. Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J3-axis reducer reducer grease inlet. Perform quick quick mastering and perform perform single axis mastering to J3 to J4-axis referring to Section 8.4 and 8.5 of operator’s manual.
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4.COMPONENT REPLACEMENT
B-82755EN/05
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear (A290-7221-X412) of J4-axis motor shaft. In this time, confirm sitting sate of gear referring to section 4.8.
7
2
5
6
4
1
3
Fig.4.11 Fig.4.11 (a) Replacing Replacing the J4-axis gearbo x un it (1/4) (1/4) (ARC Mate 100iC, M-10i A, A, ARC Mate 100iC/6L, M-10i A/6L) A/6L) Parts name
Specificati ons
Q’ty
1 2
BOLT PLATE
A97L-0218-0502#M5X12 A97L-0218-0502#M5X12 A290-7221-X425
8 1
3 4
PACKING BOLT
1 3
5
PIPE B
6 7
BOLT O RING
A290-7221-X441 A97L-0001-0674#3X35 A290-7221-X430 or A290-7221-X433 A290-7221-X433 (*1), A290-7221-Z430 or A290-7221-Z433 A290-7221-Z433 (*2 A6-BA-6X85 A290-7221-X444
Locki ng
Torque (N-m) (N-m)
LT242
4.5
LT262
15.7
1
14 1
(*1) ARC Mate 100 iC, M-10iA (*2) ARC Mate 100 iC/6L, M-10iA/6L
7
5 6
2 1
4
3
Fig.4.11 Fig.4.11 (b) Replacing Replacing the J4-axis gearbox uni t (2/4) (2/4) (ARC Mate 100iCe, M-10i Ae, Ae, ARC Mate 100iCe/6L, M-10i Ae/6L) Ae/6L)
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4.COMPONENT REPLACEMENT
B-82755EN/05
Parts name
Specifications
Q’ty
1 2 3 4
BOLT PLATE PACKING BOLT
A6-BA-5X8 A290-7221-Z427 A290-7221-X441 A6-BA-3X30
8 1 1 3
5 6 7
DUMMY PIPE BOLT O RING
A290-7221-Z434 A6-BA-6X85 A290-7221-X444
1 14 1
Locking
Torque (N-m) (N-m) 6.8
LT262
15.7
13 11 10 8
12 9
Fig.4.11 Fig.4.11 (c) Replacin Replacin g th e J4-axis J4-axis gearbox u nit (3/4) (3/4) (ARC Mate 100iC, M-10i A, A, ARC Mate 100iC/6L, M-10i A/6L A/6L ARC Mate 100iCe, M-10i Ae, Ae, ARC Mate 100iCe/6L, M-10i Ae/6L) Ae/6L) Parts name 8
BOLT
9
CON.PLATE
10 11 12
BOLT WASHER ADAPTER
13
J3 UNIT
Specificati ons A6-BA-6X10 Specification is depend on mechanical unit cable A6-BA-8X25 A97L-0001-0823#M8H A290-7221-X422 Specification is depend on mechanical unit cable
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Q’ty
Locki ng
Torque (N-m) (N-m)
2 1 8 or 9 8 or 9 1 1
LT262
15.7
4.COMPONENT REPLACEMENT
B-82755EN/05
19 18 15 14 16 17
22
21 20 Fig.4.11 Fig.4.11 (d) Replacin Replacin g th e J4-axis J4-axis gearbox u nit (4/4) (4/4) (ARC Mate 100iC, M-10i A, A, ARC Mate 100iC/6L, M-10i A/6L) A/6L)
14 15 16 17 18 19 20
Parts name BOLT CLAMP BOLT CLAMP BOLT PIPE A BOLT
21
COVER
22
PACKING
Specificati ons A6-BA-4X5 A290-7221-X473 A6-BA-3X6 A290-7221-X474 A6-BA-4X35 A290-7221-X427 A6-BA-5X14 A290-7221-X426 or A290-7221-Y426 A290-7221-X442
Q’ty 2 1 2 1 2 1 7
Locki ng
Torque (N-m) (N-m)
LT262
15.7
1 1
The following service parts are appended to J4-axis gearbox (A05B-1221-K401, A05B-1221-K411) for maintenance. Please exchange these with the J4-axis gearbox. Parts name PACKING PACKING BOLT BOLT BOLT WASHER SEAL BOLT SEAL BOLT SEAL WASHER PACKING PACKING O RING PIN
4.12 1 2 3
Specificati ons A98L-0040-0042#03 A98L-0040-0042#07 A6-BA-8X25 A6-BA-5X14 A6-BA-6X10 A97-0001-0823#M8H A97L-0218-0502#5X10 A97L-0218-0417#081010 A30L-0001-0048#6M A290-7221-X441 A290-7221-X442 A290-7221-X444 JB-PH-H7A-5X10S45C JB-PH-H7A-5X10S45C
Q’ty 1 1 8 or 9 7 1 8 or 9 4 1 1 1 1 1 4
Used place J3-axis Motor J4-axis Motor Between J3 casing and J3-axis reducer J4-axis Motor mounting part J3 grease inlet Between J3 casing and J3-axis reducer J4-axis Motor J4 oil outlet J3 grease inlet J4-axis hollow part J4-axis Motor mounting part Between J3 arm and J3 casing Z424, Z425
REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iC/10S, M-10i A/10S) A /10S)
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual to restore J5 to J6 axes. (It is set in 0º for all axes when robot is shipped.) Set dial gauges at J3/J4-axes, and prepare for single axis mastering after replacement. Turn off the controller power. - 72 -
4.COMPONENT REPLACEMENT
B-82755EN/05
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21
22 23 24 25 26 27
Pull out all oil of J4-axis gearbox referring to Section 2.2. Wrap and hang Sling in two places of the J3 arm referring to Fig.4.12 (a). Remove the wiring and piping between J3-axis and wrist. When When cable installed in M/H conduit or No dust M/H conduit is removed, refer to Section 4.19 or 4.22. 4.22. Referring to Section 5.3,remove option cable from J4-axis connector panel. Referring to Section 5.3,remove J3/J4-axis motor motor connector, clamp part in J3 casing, clamp part in J3 arm and cable of J5/J6-axis motor, and pull out cable from J3 arm unit. Referring to Section 4.10, remove J4-axis motor. Remove bolt (1), cover (2) and packing (3). Remove bolt (4) and pipe B (5). Remove bolt (6), J3 arm and O ring ring (7). Referring to Section 4.6, remove J3-axis motor. Remove bolt (8) and J4 connector plate (9). Remove bolt (10) and plate (11). Remove bolt (13) that fasten J3 unit (12) to J2 arm, arm, and remove remove J3 unit (12) from J2 arm. Remove adapter (14). Remove bolt (16) and clamp (17). Then remove bolt bolt (18) and clamp clamp (19). Remove bolt (20) and pipe A (21). Then remove bolt (23), pin (24), cover (25) and packing (26). Please apply parts removed to new J4 axis axis gearbox by 10 –19. Please spread LOCTITE according to the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time, replace packing (28) to new one. When installing J3 unit to J2 arm, apply LOCTITE 518 to J3-axis reducer referring to Section 4.8. Do process of 5-9 by opposite procedure. Please spread LOCTITE according to the table of this paragraph, and tighten by the regulated tightening torque when you install the bolt. In this time, replace packing (3) and O ring (7) to new one. Referring to section 5.3,attach cables to J3 arm and J3 casing. Referring to Section 4.6 and 4.10 attach J3/J4-axis motor. motor. In this time replace packing and seal bolt to new one. Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J4 oil outlet. According to Section 2.2, supply grease to J3-axis reducer with specified grease and supply oil to J4-axis gearbox with specified oil. Attach seal bolt, which is attached to the J4-axis gearbox for maintenance to J3-axis reducer reducer grease inlet. Perform quick quick mastering and perform single axis mastering to J3 to J4-axis referring to Section 8.4 and 8.5 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear (A290-7221-Z412) of J4-axis motor shaft. 7
6 5
2 1
4
3
Fig.4.12 Fig.4.12 (a) Replacing Replacing the J4-axis g earbox u nit (ARC (ARC Mate 100 100iC/10S, M-10i A/10S) A/10S)
- 73 -
(1/3)
4.COMPONENT REPLACEMENT Parts name
B-82755EN/05
Specificatio ns
1 2 3 4
BOLT PLATE PACKING BOLT
A97L-0218-0502#M5X12 A97L-0218-0502#M5X12 A290-7221-X425 A290-7221-X441 A97L-0001-0674#3X35 A97L-0001-0674#3X35
5 6 7
PIPE B BOLT O RING
A290-7221-X430 A6-BA-6X85 A290-7221-X444
Q’ty 8 1 1 3 1 14 1
Locki ng
Torque (N-m) (N-m)
LT242
4.5
LT262
15.7
12
10
11
15
14
13 8 9
8 9 10 11 12 13 14 15
Fig.4.12 Fig.4.12 (b) Replacing the J4-axis g earbox u nit (ARC (ARC Mate 100 100iC/10S, M-10i A/10S) A/10S)
(2/3)
Parts name
Torque (N-m) (N-m)
BOLT PLATE BOLT PLATE J3 UNIT BOLT WASHER ADAPTER
Specificati ons A6-BA-6X10 A290-7221-Z471 A6-BA-6X10 A290-7221-Z472 A290-7221-T413 A6-BA-8X25 A97L-0001-0823#M8H A290-7221-X422
- 74 -
Q’ty 2 1 1 1 1 9 9 1
Locki ng
LT262
37.2
4.COMPONENT REPLACEMENT
B-82755EN/05
22 21
20 17
16 18 19
26 24 25 23
Fig.4.12 Fig.4.12 (c) Replacin Replacin g th e J4-axis J4-axis gearbox u nit (ARC (ARC Mate Mate 100iC/10S, M-10i A/10S) A/10S) (3/3) Par ts ts n am am e 16 17 18 19 20 21 22 23 24 25 26
BOLT CLAMP BOLT CLAMP BOLT PIPE A PIN BOLT PIN COVER PACKING
Sp ec ec if if ic ic at at io io ns ns
Q’ ty ty
A6-BA-4X5 A290-7221-X473 A6-BA-3X6 A290-7221-X474 A6-BA-4X35 A290-7221-X427 JB-PH-H7A-5X10S45C JB-PH-H7A-5X10S45C A6-BA-5X14 JB-PH-H7A-5X10S45C JB-PH-H7A-5X10S45C A290-7221-Z424 A290-7221-X442
2 1 2 1 2 1 2 7 2 1 1
L oc oc ki ki ng ng
LT262
To rq rq ue ue (N-m )
15.7
The following service parts are appended to J4-axis gearbox (A05B-1221-K413) for maintenance. Please exchange these with the J4-axis gearbox. Parts name PACKING PACKING BOLT BOLT WASHER SEAL BOLT SEAL BOLT SEAL BOLT PACKING PACKING O RING PIN
4.13
Specificati ons A98L-0040-0042#03 A98L-0040-0042#07 A6-BA-8X25 A6-BA-5X14 A97L-0001-0823#M8H A97L-0218-0502#5X10 A97L-0218-0417#081010 A97L-0218-0417#060808 A290-7221-X441 A290-7221-Z442 A290-7221-X444 JB-PH-H7A-5X10S45C JB-PH-H7A-5X10S45C
Q’ty 1 1 9 7 9 4 1 1 1 1 1 4
Used place J3-axis Motor J4-axis Motor Between J3 casing and J3-axis reducer J4-axis Motor mounting part Between J3 casing and J3-axis reducer J4-axis Motor J4 oil outlet J3 grease inlet J4-axis hollow part J4-axis Motor mounting part Between J3 arm and J3 casing Z424, Z425
REPLACING REPLA CING THE J5-AXIS MOTOR MOTOR M5
NOTE Please exchange it by one when you exchange both J5 and the J6 axis motors. Otherwise, the balance of pressure collapses, and oil spouts. Moreover, please open neither oiling entrance nor the oil discharge entrance. - 75 -
4.COMPONENT REPLACEMENT 1
B-82755EN/05
Place the robot in a posture of J3 = -90 °. If it is impossible to make the posture in the on-site environment, put the collection bottle under the robot. Set dial gauges at J5-axis, and prepare for single axis mastering after replacement. Turn off the controller power. Remove seal bolt (1) and J5 motor cover (2). In case of M-10iA or M-10iA/6L or M-10iA/10S, replace packing (3). (Remove adhesive tape completely.) Remove bolt (4) and duct cover (5). Remove cable of motor. Remove nylon bands of Pulsecoder line. Remove seal bolt (6) and plate cover 1 (7). In case of M-10 iA or M-10 iA/6L or M-10 iA/10S, replace packing (8). (Remove adhesive tape completely.) Remove bolt (9) and motor that gears attaches. Replace motor new one and assemble it by opposite opposite procedure. Refer to Fig.4.13 (b) when motor motor (10) is assembled. Please wrap the seal tape when you recycle seal bolt (1), (6). Replace packing (3), (8) and O ring (16) to new article. Attach nylon band of Pulsecoder line. According to Section 2.2, supply the J5/J6-axis gearbox gearbox with the specified oil. Perform single axis mastering referring to Section 8.5 of operator’s manual.
2 3 4 5 6 7 8 9 10 11 12
13 14 15
1
2
10 9 8
3
12 14
5
7
11 13
4
6
15 16
Fig.4.13 Fig.4.13 Replacin Replacin g the J5-axis moto r
1 2 3 4 5
Parts name name SEAL BOLT J5M COVER PACKING (*1) BOLT DUCT COVER
Specif pecifica icatio tions ns A97L-0218-0736#050808 A290-7221-X509 A290-7221-X579 A6-BA-5X45 A290-7221-X506
- 76 -
Numbe umber 4 1 1 2 1
Locki Locking ng
LT262
Torque orque (N-m) 4.5
9.0
4.COMPONENT REPLACEMENT
B-82755EN/05
Parts name name SEAL BOLT PLATE COVER 1 PACKING (*1) BOLT
6 7 8 9 10
MOTOR
11 12 13 14 15 16
SPACER KEY GEAR J6-1 WASHER BOLT O RING
Specif pecifica icatio tions ns A97L-0218-0736#050808 A290-7221-X561 A290-7221-X581 A6-BA-5X12 A06B-0115-B855#0048 A06B-0115-B855#0048 (*2) A06B-0115-B205#S000 A06B-0115-B205#S000 (*3) A290-7221-X529 JB-HKY-3X3X8A JB-HKY-3X3X8A A290-7221-X511 A290-7210-X532 A97L-0218-0514#M3X8 A97L-0218-0514#M3X 8 A98L-0001-0347#S39
Numbe umber 2 1 1 3
Locki Locking ng
Torque orque (N-m) 4.5
1 1 1 1 1 1 1
LT675
LT242
1.0
(*1) In case of M-10 iA, M-10iA/6L, M-10iA/10S (*2) ARC Mate 100 iC, M-10iA, ARC Mate 100 iC/6L, M-10iA/6L, ARC Mate 100 iC/10S, M-10iA/10S (*3) ARC Mate 100 iCe, M-10iAe, ARC Mate 100 iCe/6L, M-10 iAe/6L Fix the motor while gently pressing the motor against the direction of the arrow. However, be careful not to press it strongly.
Gear A290-7221-X591
J5-axis motor
Fig.4.13 Fig.4.13 (b) Note Note of assembl ing J5-axis J5-axis mo tor
4.14
REPLACING REPLA CING THE J6-AXIS MOTOR MOTOR M6
NOTE Please exchange it by one when you exchange both J5 and the J6 axis motors. Otherwise, the balance of pressure collapses, and oil spouts. Moreover, please open neither oiling entrance nor the oil discharge entrance. 1 2 3 4 5 6 7 8 9 10
Place the robot in a posture of J3 = -90 °.If it is impossible to make the posture in the on-site environment, put the collection bottle under the robot. Set dial gauges at J6-axis, and prepare for single axis mastering after replacement. Turn off the controller power. Remove seal bolt (1) and plate cover 2 (2). In case of M-10iA, M-10iA/6L,and M-10 iA/10S replace packing (3). (Remove adhesive tape completely.) Remove seal bolt (4) and J6 motor cover (5). In case of M-10iA or M-10 iA/6L, M-10iA/10S replace packing (6). (Remove adhesive tape completely.) Remove cables of motor. Remove bolt (7) and motor (8) that gears attaches. Replace motor new one and assemble it by opposite opposite procedure. Refer to Fig.4.14 (c) when motor (10) is assembled. Please wrap the the seal tape when you recycle seal bolt (1), (4). Replace O ring - 77 -
4.COMPONENT REPLACEMENT
B-82755EN/05
(14) to new one, too. Please put O ring in the ditch surely. Confirm the gear passes O ring and the gear has not come in contact with O ring. Apply LOCTITE 675 to key. According to Section 2.2, supply the J5/J6-axis gearbox gearbox with the specified oil. Perform single axis mastering referring to Section 8.5 of operator’s manual.
11 12
1 2
3
Fig.4.14 Fig.4.14 (a) Replacin Replacin g t he J6-axis mo tor (1/2) (1/2)
8
7
6 5
14
4
9
10 11 12
13
Fig.4.14 Fig.4.14 (b) Replacing the J6-axis mo tor (2/2) (2/2) Parts name name 1 2
SEAL BOLT PLATE COVER 2
Specif pecifica icatio tions ns A97L-0218-0736#050808 A290-7221-X562
- 78 -
Numbe umberr 4 1
Locki Locking ng
Torque orque (N-m) 4.5
4.COMPONENT REPLACEMENT
B-82755EN/05
Parts name name 3 4 5 6 7
PACKING SEAL BOLT J6M COVER PACKING BOLT
8
MOTOR
9 10 11 12 13 14
SPACER GEAR J6-1 KEY BOLT WASHER O RING
Specif pecifica icatio tions ns A290-7221-X582 A97L-0218-0735#040808 A290-7221-X505 A290-7221-X575 A6-BA-5X12 A06B-0115-B855#0048 (*2) (*2) A06B-0115-B205#S000 (*3) A290-7221-X529 A290-7221-X521 JB-HKY-3X3X8A JB-HKY-3X3X8A A97L-0218-0514#M3X8 A97L-0218-0514#M3X 8 A290-7210-X532 A98L-0001-0347#S39
Numbe umberr
Locki Locking ng
1 4 1 1 3
Torque orque (N-m) 4.5
1 1 1 1 1 1 1
LT675 LT242
1.0
(*1) In case of M-10 iA, M-10iA/6L, M-10iA/10S (*2) ARC Mate 100 iC, M-10iA, ARC Mate 100 iC/6L, M-10iA/6L, ARC Mate 100 iC/10S, M-10iA/10S (*3) ARC Mate 100 iCe, M-10iAe, ARC Mate 100 iCe/6L, M-10 iAe/6L
Fix the motor while gently pressing the motor m otor against the direction of the arrow. However, be careful not to press it strongly.
Gear A290-7221-X521 J6-axis motor Fig.4.14 Fig.4.14 (c) Note of assembli ng J6-axis moto r
4.15 1 2 3 4 5 6 7 8 9
REPLACING REPLA CING WRIST UNIT
Place the robot in a posture of J3 = -90 ° and J4 = J5 =0°. Release all oil of J5/J6 gearbox referring to section 2.2. Make robot to the the posture posture of J3=5° and J4=±180° while being careful not to move the J5/J6-axes enough. (If J5/J6-axis are moved without oil, it causes burning of the gear.) Set dial gauges at J5/J6-axes, and prepare for single axis mastering after replacement. Turn off the controller power. Remove the J5-axis motor as described in Section 4.13. Remove seal bolt (1), (3) and wrist unit (2). In this case, it is possible to remove by evenly evenly tightening the M5 bolt in the pulling out tap two places shown in Fig.4.15 (b). Remove sealant of sealing face of of J3 arm side completely, completely, then clean them by using cleaning agent and remove grease thoroughly. Spread three bonds TB1133G (Spec: A98L-0040-0238#0.33KG) or LOCTITE 518 on the uniting side of the wrist unit and the J3 arm by the thickness of about 1mm referring to Fig.4.13 (c). In this - 79 -
4.COMPONENT REPLACEMENT
10
11 12 13 14
B-82755EN/05
time, apply three bonds to the hollow part of the counter boring, too. Remove the seal material that may be seen to the oil bath part as much as possible. (When using LOCTITE 7649 together) Five hours are usually necessary because of hardening after applying three bond 1133G or LOCTITE 518. But if LOCTITE 7649 (accelerator) is used together, it can shorten time. The method is shown below. Apply sealant (1133G) to J3 arm side (Refer to right figure of Fig.4.15 (c).), then apply LOCTITE 7649 (Refer to left figure of Fig.4.13 (c).) Insert wrist unit to J3 arm within 2 minutes, and wipe up the overflowed sealant. Apply LOCTITE 7649 to all circumference part of mating face referring to Fig.4.13 (b). After 30 minutes wipe the LOCTITE 7649 (blue) neatly and start the oiling process. Confirm there are two parallel φ5 pins for the positioning on the J3 arm. Then replace wrist unit to new one and assemble it by opposite procedure. Please wrap the seal tape when you re-use the seal bolt (1) and (3). Please do not forcibly pull with the bolt and do not not fix the wrist unit. The gear might not enter the drive shaft easily when the wrist unit is installed. And it must enter smoothly and not forcibly. For this case, the J6 axis motor is removed referring to Section 4.14, and the wrist unit is installed while rotating the drive shaft by the hand. Please fix the bolt when you confirm the installation is easily obtained neatly. Please leave the robot for five hours or more and monitor the firmness the seal sealant material. material. (Only when LOCTITE 7649 is not used.) Referring to Section 4.13, attach J5-axis motor. According to Section 2.2, supply the J5/J6-axis gearbox gearbox with the specified oil. Perform single axis mastering referring to Section 8.5 of operator’s manual.
NOTE When the influence of the damaged pieces generated from broken reducer is concerned about, exchange gear (A290-7221-X511) of J5-axis motor shaft and gear (A290-7221-X521) of J6-axis motor shaft.
O5 parallel pin
1
2 3 Fig.4.15 (a) Replacing the wrist unit
- 80 -
4.COMPONENT REPLACEMENT
B-82755EN/05
Removal tap (M5)
Applying area of LOCTITE 7649 (accelerator) (all circumference part including back side)
Fig.4.15 Fig.4.15 (b) Posit Posit ion o f removal tap o f wr ist u nit and LOCTITE LOCTITE 7649 7649 applyi ng area
) 1 1 (
( 19 )
( 18 )
Apply 1133G to this range of X507. Apply 1133G to the head of the bolt.
Wrist unit side
J3 arm side
Fig.4.15 Fig.4.15 (c) Sealant Sealant applyi ng area
- 81 -
4.COMPONENT REPLACEMENT Specifications
Parts name 1 2 3
SEAL BOLT WRIST ASSY SEAL BOLT
4.16 1 2 3 4 5 6
B-82755EN/05
A97L-0218-0423#053016 A290-7221-V504 A97L-0218-0423#052016
Numb er
Locki ng
4 1 3
REPLACING REPLA CING THE J2 COVER (OPTION (OPTION))
Remove bolt (1) and washer (2). Remove J2 cover (3). When replacing only J2 cover, omit the procedure 3 to 5. Remove bolt (5) and washer (6). Remove base support (4). Remove bolt (8) and support (7). Replace J2 cover (3) to new one, and assemble it by opposite procedure.
3
1 2
Fig.4.16 (a) Replacing J2 cover (1/3)
- 82 -
Torque (N-m) (N-m) 9.0 9.0
4.COMPONENT REPLACEMENT
B-82755EN/05
4 6 5
Fig.4.16 (b) Replacing J2 cover (2/3)
7
8
Fig.4.16 (c) Replacing J2 cover (3/3)
1 2 3 4 5 6 7 8
Parts name name BOLT WASHER J2 COVER BASE SUPPORT SEAL BOLT WASHER SUPPORT BOLT
Specif pecifica icatio tions ns A97L-0218-0502#M5X10 A6-WM-5S A290-7221-X381 A290-7221-X382 A97L-0218-0736#050808 A6-WM-6S A290-7221-X383 A6-BA-8X12
- 83 -
Numbe umber 5 5 1 1 2 2 1 1
Lockin Locking g
Torque orque
(N-m)
4.COMPONENT REPLACEMENT
4.17 1 2 3 4 5
B-82755EN/05
REPLACING REPLA CING THE J4 COVER (OPTION (OPTION))
Remove bolt (1) and washer (2). Remove J4 cover (3). When replacing only J4 cover, omit the procedure 3 and 4. Remove bolt (5) and support A (4). Remove bolt (6) and support B (7). Replace J4 cover (3) to new one, and assemble it by opposite procedure.
1 2
3
Fig.4.17 (a) Replacing J4 cover (1/2)
6
4
7
5
Fig.4.17 (b) Replacing J4 cover (2/2) Parts name name 1 2 3 4 5 6 7
BOLT WASHER J4 COVER SUPPORT A BOLT BOLT SUPPORT B
Specif pecifica icatio tions ns A97L-0218-0502#M5X10 A97L-0218-0502#M5X10 A6-WM-6S A290-7221-X481 A290-7221-X482 A6-BA-6X10 A6-BA-3X5 A290-7221-X483
- 84 -
Numbe umberr 4 4 1 1 2 2 1
Lockin Locking g
Torque orque (N-m)
4.COMPONENT REPLACEMENT
B-82755EN/05
4.18
NOTES FOR FOR ASSEMBL ING CABL CAB L ES WITH M/H M/H CONDUIT CONDUIT
1
M/H conduit is option to protect hand cable etc. You can prevent cables interference with arm directly by installing this and can postpone life of cables. Instead conduit is expendable supplies> replace it regularly. 2 The cable is clamped at a position 70mm or more away for the wrist side is recommended. recommended. A position position 30mm or more away is recommended for the J4 back side. In case of M-10 iA, adjust the length of the cable between clamping to 785±5mm. In case of M-10 iA/6L, adjust the length of the cable between clamping to 1005±5mm. Please absorb extra length to Conduit. If cables are not clamped, it cause broken of cable and conduit, be sure to clamp cables. cables. 3 The longevity of the cable improves by spreading grease on the surface of the cable in Conduit. Shell Alvania grease S2 is recommended. In this case, please use the cable with performance that can endure oil. If grease is not applied, it causes early damage of cables and conduit. Table 4.18 4.18 (a) Recommended Recommended c ables and air tub e Cable name End effector cable Signal line 3DL sensor cable Power line
Force sensor cable
3DL sensor camera cable
LED lighting cable
Maker Maker Oki cable co. Ltd Oki cable co. Ltd Oki cable co. Ltd Okano cable co. Ltd Hitachi cable co. Ltd Hitachi cable co. Ltd
Air tube
SMC
(Cable length between clamp
Spec of FANUC FANUC
Specificati ons 2
A66L-0001-0459
0.2mm
24-core Cable for moving part
A66L-0001-0464#1
0.2mm 2-core 4 pairs (8-core) Cable for moving part
A66L-0001-0401#10
1.25mm 10-core Cable for moving part
A66L-0001-0178#03P
0.3mm 2-core 3 pairs (6-core) Cable for moving part
2
2
2
2
A66L-0001-0525
0.26mm 2 0.13mm 2 0.08mm 2
4-core 2-core 2-core
Cable for moving part
A66L-0001-0143
0.2mm
6-core Cable for moving part
A97L-0218-0010
TU0604 (Outside (Outside diameter=Φ6mm diameter=Φ6mm,, Inside diameter=Φ4mm) diameter=Φ4mm)
M-10iA : 785u5mm , M-10iA/6L : 1005 u5mm
70 mm
30 mm
Nylon band Cable , air tube Rubber tube Cable clamp position
A
Greaes applying area (recommended) Cable clamp position Fig.4.18 Fig.4.18 (a) Cable Cable lengt h b etween clamps
- 85 -
4.COMPONENT REPLACEMENT 3
B-82755EN/05
Please install circumscription yen of of bunches of cables on 30mm or less as shown in figure figure so that cables should not rub at the edge of the J6 hollow flange. If filling degree is over , it causes early damage of conduit.
O
0 3 cable,air tube
Conduit Fig.4.18 Fig.4.18 (b) (b) Diameter Diameter of cable and air tu be in con duit
4 5 6
It is recommended to install protect ring ring if necessary so that neither cable nor bolt attached to the J6 hollow flange may interfere. Please roll cables in the rubber seat etc. so as not to damage surfaces surfaces of cables by the edge of the nylon band in the cable clamping part, and bind on that in the nylon band. When M/H conduit is installed, use by the range limitation limitation of J6 axis range of motion ±190° is recommended. The longevities of cables shortens when using it exceeding ±190° though it is possible to use even in range of motion more than this (maximum ±270°). Table 4.18 4.18 (b) Regular exch ange cycl e Exchange cycle J5-axis:±140° J6-axis:±190°
Cycle that is shorter among 2.4 million cycles (As one cycle every 30 seconds and four years
NOTE Please note that it is a standard at the exchange cycle when the cable wire rod and the air tube of the FANUC recommendation are used. If cable is not clamped or grease is not applied or filling degree of cable in conduit is over or robot is operated with fluoric resin ring is broken, it causes early damage of cables and conduit. (7) Please examine the structure that the cutting powder etc. Do not invade in Conduit when you specify M/H conduit and severe dust/liquid protection option simultaneously. (8) Fluoric resin ring is installed to J6 hollow part and white powder is generated to reduce friction of rotation. This is not trouble. Fluoric resin ring is expendable supply. (Spec: A290-7221-X571) Two years are aims in an exchange period. If you operate operate robot with the state that hard mine dust is attached to rotated part, exchange period may shortens. If robot is operated with fluoric resin rig is broken, it causes early damage of conduit.
4.19
REPLACING M/H CONDUIT (OPTION)
(When (When replacing unit ) 1 2 3
Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit. Remove M4×10 bolts bolts (2pcs) in Fig.4.19 Fig.4.19 (a) and remove unit of M/H conduit. conduit. Attach new M/H conduit conduit by opposite procedure. procedure. In this time, according to Fig.4.19 (a) apply LOCTITE 242 to internal thread and tighten by regulated torque. Assemble them while paying attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part. - 86 -
4.COMPONENT REPLACEMENT
B-82755EN/05
(Otherwise abnormal noise occurs.) Confirm there is a clearance between them. Pay attention that ring does not protrude from circumference of adapter, too.
Bolt M4X10(2) LT242
Fig.4.19 (a) Replacing M/H conduit (1/2)
(When (When replacing replacing o nly co nduit ) 1 2 3 4 5 6
Remove all cables, the air tubes, and the cable clamping, etc. that go in M/H conduit. Remove M4×10 bolts bolts (2pcs) in Fig.4.19 Fig.4.19 (a) and remove unit of M/H conduit. conduit. Remove set screw that fix ring. Sleeve might be attached depending on the shipping time, then remove sleeve. Remove conduit from adapter. Attach new new M/H conduit by opposite opposite procedure. procedure. In this time, according to Fig.4.19 (a), (b) apply LOCTITE 242 to internal thread and tighten by regulated torque. If you cut conduit, be sure to refer NOTE in Appendix A. Assemble them while paying attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part. (Otherwise abnormal noise occurs.) Confirm there is a clearance between them. Pay attention that ring does not protrude from circumference of adapter, too.
Sleeve A97L-0118-0735#RKS-36 (It might be attached depending on the shipping time.)
Adapter A290-7221-X631 Bolt M4X8(3) Tightening torque 4.5Nm
Plate A290-7221-X632
LT242
Ring A290-7221-X633 Set screw A6-SAKT-3X10(2) LT242
Conduit (FANUC spec： M-10iA , M-10iA/10S : A97L-0118-0734#E36-0062 M-10iA/6L : A97L-0118-0734#E36- 0084) (PMA spec：ESDT-36B)
Fig.4.19 Fig.4.19 (b) Replacing M/H condui t (2/2) (2/2)
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4.COMPONENT REPLACEMENT
4.20 1
2
3
4
B-82755EN/05
NOTES FOR FOR ASSEMBL ING CABL CAB L ES WITH NO NO DUST M/H CONDUIT
M/H conduit conduit is option to protect hand cable etc. You can prevent prevent cables cables interference with arm directly by installing this and can postpone life of cables . Instead conduit is expendable supplies> replace it regularly. Please prepare prepare rubber bush as figure figure below. Please make make thickness between wrist flange flange and and tip of rubber bush is 9mm, thickness of rubber bush is 6mm. In case of J3 casing side, please make thickness between back of J3 casing and tip of rubber bush is 11.4mm and thickness of rubber bush is 6mm.Make length of cable between rubber bush is 721 ±5mm (in case of M-10 iA) or 941 ±5mm (in case of M-10 iA/6L) and absorb extra length to Conduit. If cables are not clamped, it cause broken of cable and conduit, be sure to clamp clamp cables. The longevity longevity of the cable improves by spreading grease on the surface of the cable in Conduit. Shell Alvania grease S2 is recommended. In this case, please use the cable with performance that can endure oil. If grease is not applied, it causes early damage of cables and conduit. Confirm there is no gap in slit part of rubber bush. If there is a gap, clean degree degree turn worse. Please be careful. Table 4.20 4.20 Cable name
Maker Maker
End effector cable Signal line 3DL sensor cable Power line
Force sensor cable
3DL sensor camera cable
LED lighting cable
Air tube
Oki cable co. Ltd Oki cable co. Ltd Oki cable co. Ltd Okano cable co. Ltd Hitachi cable co. Ltd Hitachi cable co. Ltd SMC
Recommended cables and air tub e Spec of FANUC FANUC
Specificati ons 2
A66L-0001-0459
0.2mm
24-core Cable for moving part
A66L-0001-0464#1
0.2mm 2-core 4 pairs (8-core) Cable for moving part
A66L-0001-0401#10
1.25mm 10-core Cable for moving part
A66L-0001-0178#03P
0.3mm 2-core 3 pairs (6-core) Cable for moving part
2
2
2
2
A66L-0001-0525
0.26mm 2 0.13mm 2 0.08mm 2
4-core 2-core 2-core
Cable for moving part
A66L-0001-0143
0.2mm
6-core Cable for moving part
A97L-0218-0010
TU0604 (Outside (Outside diameter=Φ6mm diameter=Φ6mm,, Inside diameter=Φ4mm) diameter=Φ4mm)
Clamp length between clamp M-10iA : 721±5mm M-10iA/6L : 941±5mm 6 11.4
6 9
Rubber bush
Rubber bush
Grease applying area
Fig.4.20 Fig.4.20 (a) Cable Cable lengt h b etween clamp
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4.COMPONENT REPLACEMENT
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5
Please install circumscription yen of of bunches of cables on 30mm or less as shown in figure figure so that cables should not rub at the edge of the J6 hollow flange. If filling degree is over, it causes early damage of cables and conduit.
Conduit
O 30
Cable , air tube Fig.4.20 Fig.4.20 (b) (b) Diameter Diameter of cable and air tu be in con duit
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4.COMPONENT REPLACEMENT 6
B-82755EN/05
Refer to Fig.4.20 (c) about shape of rubber bush and structure of cables in conduit.
slit(to go through wire rod)
Shape of rubber bush of back of J3 casing side
2mm or more
7
5
Air tube (O6mm) X 4
O
4
e r o m r o
6 4
m m 2
3 4
O
O
6
O 7
O 3
EE (O8mm)
7
O
Signal line (O8mm)
Shape of rubber bush of wrist side
slit(to go through wire rod) 2mm or more
7 5
O
4
O 3
O
e r o m r o
6
3 4
Air tube (O6mm) X 4
m m 2
6 4
O
O 7
EE (O8mm)
7
O
Signal line (O8mm)
[Example of four φ6 air tube ,EE(φ8mm) and signal line (φ8mm)] ・Design rubber bush so that diameter of hole is smaller 1mm than air tube and cable sheet. ・Post air tube and wire rod in dotted line of φ36mm. ・The direction of taper is reversed in case of back of J3 casing side and wrist side. ・Secure the wall thickness more than 2mm between holes. ・Flouring rubber , the hardness between 30 to 50 is recommended.
Fig.4.20 Fig.4.20 (c) Shape Shape of r ubber b ush (example)
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4.COMPONENT REPLACEMENT
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7
Refer to Fig.4.20 (d) about structure of seal of back of J3 casing.
Example of structure of seal of back of J3 casing Base plate mounting bolt M5×25 (9pcs：Tightening torque 6.0Nm) Use belleville spring washer. Remove bolts which are attached to robot when it is shipped, and tighten base plate and plate of back together.
9
2.4±0.05
Ｒ 0 . 8 M A X
O ring G105 (JIS-B-2401,JIS-B-2406)
Plate to hold (Metal which thickness is 2T or more. SUS or plating metal is recommended.) Rubber bush (Flouring rubber The hardness between 30 to 50)
5 3 0 . 0 0 +
7 H 0 0 1 4 1
4 0 4 4
O O
O O
A Bolt for mounting plate for holding rubber bush
M4 is recommended,Bolt screw mating length 1.5d, Equally spaced (8pcs：Tightening torque 4.5Nm) 6
Base plate
(The board of aluminium alloy)
46
32.5
32.5
46
6 4
5 . 2 3
5 2
5 . 8 7
5 . 7
39
VIEW A Fig.4.20 Fig.4.20 (d) Structu re of seal of back of J3 casing
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4.COMPONENT REPLACEMENT 8
B-82755EN/05
Refer to Fig.4.20 (e) about structure of seal of wrist. If wrist is not sealed, dust come from hollow hole. Be sure to seal wrist.
*When you choose material and treatment, take rust protection into account. *When you choose rubber bush, take weatherability and medicine characteristic resistant into account.
Example of structure of seal of wrist 3
Hand base plate mounting bolt M4×10(8pcs：Tightening M4×10(8pcs：Tighte ning torque 4.5Nm) Use belleville spring washer. Refer to section 4.1 about mounting pitch.
4 5
Ｒ０．４ＭＡＸ
A board to hold (Metal which thickness is 2T or more. SUS or plating metal is recommended.) 0 4 0 3 0 . 0 0 +
O
0 4
7 H 2 6
O
4 4
O
O
Rubber bush (Flouring rubber The hardness between 30 to 50)
3
Robot wrist flange Sealant applying area （Recommended sealant:LOCTITE 518)
6
Bolt for mounting plate for holding rubber bush M4 is recommended,Bolt recommended,Bolt screw mating length 1.5d, Equally spaced (8pcs：Tightening (8pcs：Tightening torque 4.5Nm) Hand base plate (The board of aluminium alloy)
Fig.4.20 Fig.4.20 (e) Structu re of s eal of w rist (example) (example)
9
When No dust M/H conduit is installed, use by the range limitation of J6 axis range of motion motion ±190° is recommended. The longevities of cables shortens when using it exceeding ±190° though it is possible to use even in range of motion more than this (maximum ±270°). For J5-axis use it motion range in ±120°. If J5-axis move more than ±120°, it cause break of conduit, be careful.
NOTE If cable is not clamped or grease is not applied or fi lling degree of cable in conduit is over or robot is operated with fluoric f luoric resin ring is broken, it causes early damage of cables and conduit. 10 Specification is ISO class 5 (equal to clean class 100). 100).
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4.COMPONENT REPLACEMENT
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4.21
REPLACING NO DUST M/H CONDUIT (OPTION)
(When (When replacing unit ) 1 2 3
Remove all cables, the air tubes, and the cable clamping, etc. that go in No dust M/H conduit. conduit. Remove M4×10 bolts (2pcs) and M5×45 bolts bolts (2pcs) in Fig.4.21 (a) and remove unit of M/H conduit. Attach new No dust dust M/H conduit by opposite procedure. procedure. In this time, according to Fig.4.21 (a) (a) apply LOCTITE 242 to internal thread and tighten by regulated torque.
Bolt A97L-0218-0432#5X45 (2) LT262 Tightening torque 7Nm
Bolt A97L-0218-0496#M4X10SC A97L-0218-0496#M4X 10SC (2) LT242 Tightening torque 4.5Nm Fig.4.21 Fig.4.21 (a) Replacin Replacin g No dust M/H M/H cond uit (1/3) (1/3)
(When (When replacing replacing o nly co nduit ) 1 2 3 4 5 6
Remove all cables, the air tubes, and the cable clamping, etc. that go in No dust M/H conduit. conduit. Remove bolt M3×8 (8pcs), holder (2pcs), J6 adapter and packing of wrist side. Remove bolt M3×8 (8pcs), holder (2pcs), J3 adapter and packing of J3 casing side. Cut conduit referring to note of Appendix A. Polish conduit with a brush made by nylon. Attach new new No dust M/H conduit conduit by opposite procedure procedure referring to Fig.4.21 (a) to (c). (c). Replace Replace packing , seal bolt and bolts that LOCTITE is applied. Remove old packing of holder and attach new packing referring to Fig.4.21 (b). When attaching packing, put it on the oil seal inside the wrist unit and put J6 adapter on it, and fix them with bolts. Apply LOCTITE 242 and 262 to thread of bolt and tighten bolts with regulated torque.
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4.COMPONENT REPLACEMENT
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Holder A290-7221-X642 (2) Seal bolt A97L-0218-0546#030806SC (8) Tightening torque 2Nm
Holder A290-7221-X642 (2) Seal bolt A97L-0218-0546#030806SC (8) Tightening torque 2Nm
Wrist side
J3 casing side Packing B A290-7221-X642
Packing A A290-7221-Z641
Attachment packing to holder A290-7221-X642
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4.COMPONENT REPLACEMENT
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(When (When attachin attachin g No dust M/H cond uit t o whi ch is o rdered after after ship ment of robot) 1 2 3
Remove fluoric resin ring referring to Section 4.22. Remove duct cover and clean the tap hole. Remove plate cover and clean the tap hole.
Bolt A6-BA-5X45(2) Plate cover 1 A290-7221-Z561
Duct cover A290-7221-X506
Seal bolt A97L-0218-0736#050808(2) Fig.4.21 Fig.4.21 (d) Attach No dust M/H cond uit (1/4) (1/4)
4
Paste packing (A290-7221-X647) to plate cover 1 (A290-7221-X561).
Attach packing while being careful not to make clearlance between packing.
Plate cover 1 A290-7221-Z561 Packing A290-7221-X647 Fig.4.21 Fig.4.21 (e) Attach No d ust M/H M/H cond uit (2/4) (2/4)
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4.COMPONENT REPLACEMENT 5
B-82755EN/05
Fix plate cover 1 (A290-7221-Z561) with 2 seal bolts. bolts. Tightening torque is 4.5Nm. 4.5Nm. Bend packing (A290-7221-X647) to have no gap at the corner.
Casting
Packing A290-7221-X647
A Be careful not to make clearlance in conrer.
Plate Seal bolt A97L-0218-0736#050808SC(2) (Tightening torque 4.5Nm)
Casting
DETAIL A
Fig.4.21 Fig.4.21 (f) Attach No d ust M/H M/H cond uit (3/4) (3/4)
6
Fix J3 adapter (A290-7221-X643) of no dust M/H conduit to J3 arm. Bolts are 2 RF coating bolts. Tighten them with tightening torque 9Nm after applying LOCTITE 262 into taps. Fix J6 adapter (A290-7221-X641) of no dust M/H conduit to J6 housing (A290-7221-X503) pushing it to the direction of arrow D of Fig.4.21 (g). Then confirm that the gap between J5 adapter (A290-7221-X502) and J6 adapter (A290-7221-X641) is less than 2.5mm. Bolts are 2 stainless coating bolts. Washers are 2 stainless washers. Tighten them with tightening torque 4.5Nm after applying LOCTITE 242 into taps.
7
C
J3 adapter A290-7221-X643
B
B
Bolt A97L-0218-0432#5X45(2) (Tightening torque 9Nm) LT262
Bolt A97L-0218-0496#M4X10SC(2) (Tightening torque 4.5Nm) Washer A6-WM-4SUS(2)
D
C J5 adapter A290-7221-X502
J6 adapter A290-7221-X641
LT242
SECTION C-C
Fig.4.21 Fig.4.21 (g) Attach No dust M/H cond uit (3/4) (3/4)
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SECTION B-B 2.5or less
4.COMPONENT REPLACEMENT
B-82755EN/05
4.22 1 2 3 4 5 6
REPLACING REPLA CING FLUORIC RESIN RING
Remove the all cable connection of J3 casing. Remove the plated plated bolts (2pcs) as shown Fig. 4.22, then remove remove the end of M/H conduit unit from J6 hollow part. Remove the fluoric fluoric resin ring using needle-nose pliers and other tool. tool. Be careful not to hurt hurt the J6 housing. Replace the fluoric resin ring, and insert it to J6 hollow part until until the edge of of it get in groove inside inside of J6 hollow part. Correct the strained of the fluoric resin ring using the screwdriver and other tool. Attach the M/H conduit conduit unit and the cable connection of J3 casing. Assemble them while paying attention that circumference of adapter does not interfere inside of out shaft of J6 hollow part. (Otherwise abnormal noise occurs.) Confirm there is a clearance between them. In this time, note that the plated bolts are applied LOCTITE 242 to internal thread and are tightened by regulated torque. (Refer to Fig.4.22.)
Fluoric resin ring A290-7221-X571
A
Adapter A290-7221-X631
Plated bolt A97L-0218-0496#M4X10TC (2) Tightening torque 4.5Nm Applying LOCTITE 242
DETAIL A Fig.4.2 Fig.4.22 2 Replacing Replacing f luoric resin rin g
4.23
SEALA NT APPLICATION APPLICATION
Washin Washin g and degreasing degreasing the surf aces aces to be sealed sealed 1
2 3
4
After dismounting the reducer from the arm, apply releasant (LOCTITE Gasket Remover etc.) to the the arm’s surface from which the reducer was dismounted, then wait until the sealant (LOCTITE 518) becomes softened (for about 10 minutes). Remove the softened sealant from the surface using a spatula. Blow air onto the surface to be sealed to remove dust from the tapped holes. Sufficiently degrease the reducer’s surface to be be sealed and the arm’s surface surface to be sealed, using a cloth dampened with oil and grease remover. Do not spray oil and grease remover directly onto the surface. Polish the arm’s surface to be sealed with an oil stone, and degrease it with removal removal and cleaner again.
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4.COMPONENT REPLACEMENT
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CAUTION Oil may drip from the inside of the reducer. After degreasing, make sure that no oil is dripping.
Ap pl yi ng s ealant eal ant 5
6
Make sure that the reducer and the arm are are dry (with no oil and grease remover remover remaining). remaining). If they are still wet with oil and grease remover, wipe them dry. Always use a new surface of a cloth so that the grease once wiped up with the cloth will not get on the degreased surface. Make sure that no ingredient of oil and grease remover is left in the threaded holes or on any other portion. If ingredient is left, it may prevent stiffening of sealant. Apply sealant (LOCTITE 518) to the surfaces.
CAUTION The portions to which sealant is to be applied vary from one axis to another. See descriptions about reducer replacement for the relevant axes for details.
As s emb em b li ng 7
8 9
To prevent prevent dust dust from sticking to the portions portions to which sealant was applied, mount the reducer as quickly as possible after sealant application. Be careful not to touch the applied sealant. If sealant was wiped off, apply again. After mounting mounting the reducer, reducer, fasten it with bolts and and washers quickly so that the mated surfaces get closer. After attaching the reducer, wipe off any excessive sealant that comes comes out from the sealed section with a cloth or spatula. Do not use oil and grease remover.
CAUTION Do not grease or move the reducer before the sealant sets, as it may allow grease to leak. Before greasing or moving, wait for about at least four hour after the reducer is mounted.
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5.CABLE REPLACEMENT
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5
CABLE CAB LE REPLA REPLACE CEME MENT NT
Replace the welding power cables of the mechanical unit in the cycle that is shorter among every about two years and 7,680 hours operating. Replace the other cables of the robot in the cycle that is shorter among every four years and 15,360 hours operating. If a cable is broken or damaged, replace it according to the procedure described in this chapter.
Cautio Cautio ns in h andling th e Pulsecoder Pulsecoder cable When transporting, installing, or maintaining the robot, do not detach the Pulsecoder cables carelessly. The cables are provided with the marking tie shown below. If you detached any cable with the marking tie, you need to perform mastering for the robot. Do not detach any connector unless you replace a motor, Pulsecoder, reducer, gearbox or cable.
BATTERY BACKUP
DON'T DISCONNECT
コネクタ取外不可
Fig.5 Wire mark
If there is a break in or any other damage to a cable, replace the cable according to the procedure described in this chapter. If the connector of a motor cable is detached, the data about the absolute position of the robot is lost. Once any of these cables is replaced, perform quick mastering while referencing Section 8 of operator’s manual. If the data data is lost because because of a break in a cable, also perform mastering to calibrate the robot into the previous absolute position.
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5.CABLE REPLACEMENT
5.1
B-82755EN/05
CABLE CAB LE WIRING WIRING
Fig.5.1 is the routing of the robot cables. See Chapter 5 of operator’s manual for option cable interface. K101 (M1 to M6 Pulsecoder,power,brake,end Pulsecoder,power,brake,end effector (RI/RO*8)) K102 (M1 to M6 Pulsecoder,power,brake Pulsecoder,power,brake,end ,end effector (RI/RO*1)) (Non corresopondence to CE) K103 (M1 to M6 Pulsecoder,power,brake,end Pulsecoder,power,brake,end effector (RI/RO*1)) (ARC Mate 100iC , M-10iA) K111 (M1 to M6 Pulsecoder,power,brake,end Pulsecoder,power,brake,end effector (RI/RO*8) :for severe dust/liquid protection option) (M-10iA) K121 (M1 to M6 Pulsecoder,power,brake(J2/J3-axis only)) (ARC Mate 100iCe , M-10iAe) K131 (M1 to M6 Pulsecoder,power,brake,end Pulsecoder,power,brake,end effector (RI/RO*8)) K132 (M1 to M6 Pulsecoder,power,brake Pulsecoder,power,brake,end ,end effector (RI/RO*1)) (Non corresopondence to CE) K133 (M1 to M6 Pulsecoder,power,brake,end Pulsecoder,power,brake,end effector (RI/RO*1)) (ARC Mate 100iC/6L , M-10iA/6L) K141 (M1 to M6 Pulsecoder,power,brake,end Pulsecoder,power,brake,end effector (RI/RO*8) :for severe dust/liquid protection option) (M-10iA/6L) K151 (M1 to M6 Pulsecoder,power,brake(J2/J3-axis only)) (ARC Mate 100iCe/6L , M-10iAe/6L) K161 (M1 to M6 Pulsecoder,power,brake,end Pulsecoder,power,brake,end effector (RI/RO*8)) K162 (M1 to M6 Pulsecoder,power,brake Pulsecoder,power,brake,end ,end effector (RI/RO*1)) (Non corresopondence to CE) (ARC Mate 100iC/10S , M-10iA/10S) K301 Wire feeder cable K311 User cable (signal) K312 User cable (power) K315 User cable (signal usable to force sensor and 3DL sensor) K321 Welding power cable 38SQ K323 Welding power cable 60SQ K331 Earth cable for camera K351 Camera and 3DL sensor cable K701 Camera cable (non waterproof type) K702 Camera cable (waterproof type) (ARC Mate 100iC , M-10iA,ARC Mate 100iC/6L , M-10iA/6L) K314 User cable (signal line usable to the 3DL sensor and force sensor) K331 Earth cable for camera K703 Camera cable (waterproof type) (ARC Mate 100iC/10S , M-10iA/10S)
Fig.5.1 Fig.5.1 Routing Routing of th e robot
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5.CABLE REPLACEMENT
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5.2
CABLE DRESSING
After a cable is replaced individually rather than in a bundle, clamp it with nylon ties (cable ties) at the specified positions listed in Table 5.2 (a) to (f). Otherwise, the cable might sag or become too tight, leading to a break in the cable. Clamp position of Table 5.2 (a) to (g) mean position in Fig.5.2 (a), (b). Clamp position of inside J1 base
DETAIL B Clamp position of pipe of J1-axis reducer
A C
DETAIL C Clamp position of J2 base
D B SECTION A-A
DETAIL D A
G F
Clamp position of lower side of J2 arm
Clamp position of J4 connector plate
DETAIL E Clamp position of upper side of J2 arm
E
DETAIL G
DETAIL F
Fig.5.2 (a) Clamp position of motor cable (ARC Mate 100 iC, M-10i A, A, ARC Mat e 100iC/6L, M-10i A/6L A/6L , ARC Mat e 100iCe, M-10i Ae) Ae)
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5.CABLE REPLACEMENT
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Clamp position of inside J1 base
DETAIL I Clamp position of pipe of J1-axis reducer
H J
DETAIL J J
I SECTION H-H
K
Clamp position of J2 base
J
DETAIL K
H
N M L
Clamp position of lower side of J2 arm
DETAIL L
Clamp position of upper side of J2 arm
DETAIL M
DETAIL N
Clamp position of J4 connector plate
Fig.5.2 (b) Clamp posi tio n of m otor cable (ARC Mate Mate 100 100 iC/10S, M-10i A/10S) A/10S)
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5.CABLE REPLACEMENT
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Table 5.2 (a) Cable pattern diagram (1)
Cable pattern diagram
Stamp
Stamp
Cable No.
Clamp position of inside of J1 base Clamp position on pipe of J1-axis reducer Clamp position of J2 base Clamp position of lower side of J2 arm + G B 1
Clamp position of upper side of J2 arm +
-
Clamp position of J4 connector plate M 1 P
M1P
M 2 P
1 0 1 K
M2P M3P
M 3 P
M 4 P
M4P
M 5 P
M 5 M
EE
-
M 5 B K
M5P M5M M5BK
E E
M 6 P
M 6 M
M 6 B K
M3M
M 3 M
M 4 M
M 4 B K
M 1 M
M
1 B K
M 2 M
M6P M6M M6BK
M4M M4BK M1M M1BK
M2M
M 2 B K
M2BK
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K101, K131, K161
5.CABLE REPLACEMENT
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Table 5.2 (b) (b) Cable pattern diagram (2)
Stamp Cable No.
Cable pattern diagram
Stamp
Clamp position of inside of J1 base Clamp position on pipe of J1-axis reducer Clamp position of J2 base Clamp positio of lower side of J2 J 2 arm + G B 1
Clamp position of upper side of J2 arm +
-
Clamp position of J4 connector plate M 1 P
M1P
M 2 P
1 0 1 K
M2P M3P
M 3 P
M 4 P
M4P
M 5 P
M 5 M
EE
-
M 5 B K
M5P M5M M5BK
E E
M 6 P
M 6 M
M 6 B K
M3M
M 3 M
M 4 M
M 4 B K
M 1 M
M 1 B K
M 2 M
M6P M6M M6BK
M4M M4BK M1M M1BK
M2M
M 2 B K
M2BK
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K102, K132, K162
5.CABLE REPLACEMENT
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Table 5.2 (c) Cable Cable p attern diagram (3)
Cable pattern diagram
Stamp
Stamp
Cable No.
Clamp position of inside of J1 base Clamp position on pipe of J1-axis reducer Clamp position of J2 base b ase Clamp position of lower side of J2 arm + G B 1
Clamp position of upper side of J2 arm +
-
Clamp position of J4 connector plate M 1 P
M1P M2P
M 2 P
1 0 1 K
M3P
M 3 P
M 4 P
M4P
M 5 P
M 5 M
EE
-
M 5 B K
M5P M5M M5BK
E E
M 6 P
M 6 M
M 6 B K
M3M
M 3 M
M 4 M
M 4 B K
M 1 M
M
1 B K
M 2 M
M6P M6M M6BK
M4M M4BK M1M M1BK
M2M
M 2 B K
M2BK
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K103, K133
5.CABLE REPLACEMENT
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Table 5.2 (d) Cable Cable p attern d iagram (4)
Cable pattern diagram
Stamp
Stamp
Cable No.
Clamp position of inside of J1 base Clamp position on pipe of J1-axis reducer Clamp position of J2 base Clamp position of lower side of J2 arm + G B 1
Clamp position of upper side of J2 arm +
-
Clamp position of J4 connector plate M 1 P
1 0 1 K
M1P
M 2 P
M2P
M 3 P
M3P
M 4 P
M4P
M 5 P
M 5 M
EE
-
M 5 B K
M5P M5M M5BK
E E
M 6 P
M 6 M
M 6 B K
M3M
M 3 M
M 4 M
M 4 B K
M 1 M
M 1 B K
M 2 M
M6P M6M M6BK
M4M M4BK M1M M1BK
M2M
M 2 B K
M2BK
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K111, K141
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Table 5.2 (e) Cable pattern diagram (5)
Cable pattern diagram
Stamp
Stamp
Cable No.
Clamp position of inside of J1 base Clamp position on pipe of J1-axis reducer Clamp position of J2 base Clamp position of lower side of J2 arm + G B 1
Clamp position of upper side of J2 arm +
-
Clamp position of J4 connector plate p late M 1 P
M1P
M 2 P
1 0 1 K
M2P M3P
M 3 P
M 4 P
M4P
M 5 P
M 5 M
EE
-
M5P M5M
E E
M 6 P
M 6 M
M 3 M
M 4 M
M 1 M
M 2 M
M6P M6M
M3M M4M M1M
M2M
M 2 B K
M2BK
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K121, K151
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Table 5.2 (f) (f) Cable patt ern d iagram (6)
Cable pattern diagram
Stamp
Stamp
Cable No.
W/F2
K301
AS2
K311
AP2
K312
ASi2
K314
ASi2
K315
Clamp position of J4 connector plate W/F1
2 F / W
1 F / W 1 0 3 K
Clamp position of J4 connector plate AS1
1 S A 1 1 3 K
2 S A
Clamp position of J4 connector plate AP1 1 P A 2 1 3 K
2 P A
Clamp position of J4 connector plate
ASi1
2 i S A
4 1 i 1 S 3 K A
Clamp position of J4 connector plate ASi1
1 i S A 5 1 3 K
2 i S A
Clamp position of J4 connector plate Clamp position of upper side of J2 arm
K321
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Table 5.2 (g) Cable Cable p attern d iagram (7)
Cable pattern diagram
Stamp
Stamp
Cable No.
Clamp position of lower side of J2 arm Clamp position of upper side of J2 arm
Clamp position of J2 base
Clamp position of J4 connector plate
K323
K331 Clamp position of J4 connector plate SEN1
CAM1
CAM1
CAM1
2 3 0
T 1 7 N 0 E 0 S 2
3 0 3 D 1 2 2 1 1 M A C
K351
CAM2
K701
CAM2
K702
CAM2
K703
Clamp position of J4 connector plate
1 0 3 D 1 2 2 1 1 M A C
2 0 3 D 1 2 2 1 1 M A C
SEN2 1 5 3 K
2 N E S
1 0 7 K 2 M A C
Clamp position of J4 connector plate 2 0 7 K 2 M A C
Clamp position of J4 connector plate 3 0 7 K 2 M A C
Clamp positio of lower side of J2 arm
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5.CABLE REPLACEMENT
5.3 1)
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REPLACING CABLES Replacing the cable kit When you have special tool for remove connector of J6-axis, place the robot in a posture of J1 to J4 = 0° When you don’t have special tool, place the robot in a posture of J1, J2 and J4 =0° and J3=-90° (Refer to Section 4.14.) 1 2 3
4
5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24
Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is set in 0º for all axes when robot is shipped.) Before replacing cables, turn off the controller power and remove all cables between robot and controller from the robot. Cut the nylon band for the J2-/J3-axis cable protection sheet, and and remove remove the cover cover from from the cable kit. (Refer to Fig.5.3 (a)). (There is no cable protection sheet for ARC Mate 100 iCe,M-10iAe, ARC Mate 100iCe/6L,M-10iAe/6L.) Remove extra low bolt and button seal bolt, J6 motor cover and J5 motor motor cover. (Refer to Fig.5.3 (b)). In case of M-10 iA or M-10iA/6L or M-10iA/10S, replace packing. (Remove adhesive tape completely.) Remove duct cover and plate cover cover 1 (Refer to Fig.5.3 (b)). In case of M-10 iA or M-10iA/6L or M-10iA/10S, replace packing. (Remove adhesive tape completely.) Cut the nylon band of plate cover 1. 1. Remove Remove the earth terminal terminal (M3) of upper upper side of J5-axis J5-axis motor. (Refer to Fig.5.3 (b)) Remove connector of J5/J6-axis motor, when connector of J6-axis motor is removed, removed, use special tool (A290-7221-X971). If special tool cannot be prepared, remove J6-axis motor referring to Section 4.14 and remove connector. Remove earth terminal (M3) above J6-axis motor. (Refer to Fig.5.3 (c)) Remove bolt M5×12 (9pcs), cover, packing (A290-7221-X441). (Refer to Fig.5.3 (e)) (Remove adhesive tape completely.) Remove bolt M3×35 (3pcs) and pulled out pipe. (Refer to Fig.5.3 (e)) Cut the nylon band of the the back of the J6-axis motor. Remove seal bolt M6×16 (2pcs). (Refer to Fig.5.3 (e)) Remove bolt that fasten clamp (2 places) of J3 casing. Then cut nylon band. (Refer to Fig.5.3 (f)) Pull out cable that is in J3 arm to the J3 casing. When Pulsecoder cable passes between cable clamps that is read side of J6-axis motor and J3 arm base. Pass it carefully so as not to damage it by using the space referring to Fig.5.3 (d). Pull out the cable from the side of the J3 casing. In this time, if power cable and Pulsecoder cable is pulled beforehand. Work becomes easy. Remove bolt and J4 connector plate. (Refer to Fig.5.3 (g).) In this time, do not put put it into the state to hang the cable of J4 connector plate. The cable might be hurt. Remove connector and lead line of J3/J4-axis motor. In this time, do not put it into the state to hang the cable of J4 connector plate. The cable might be hurt. Remove cable cover and bolt. (Refer to Fig.5.3 (h)). Remove connector of J1/J2-axis motor. Remove M8×10 bolts (4pcs) that fasten J1 connector plate to J1 base and remove J1connector plate from J1 base (Refer to Fig.5.3 (i)). Cut the nylon band that fastens rubber boots. Remove M4×10 bolts (4pcs) that fasten connector housing and bolt M6 ×10 bolts (2pcs) that fasten support. (Refer to Fig.5.3 (i)). Remove connector connector insert from connector connector housing and remove connector insert and rubber boot from J1 connector plate. Remove the terminal from battery box. - 110 -
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25 26 27 28 29 30 31 32 33 34 35
36 37 38
39
Remove the two earth terminals secured to the J1 base. Pull out the air tube from the panel union. When option cable attached, remove them from from J1 connector plate and J1 base. Remove rubber boot from the cable. Remove the plate, which is attached to support. support. (Refer (Refer to Fig.5.3 (i)). Pull out cables. When cable pass hollow part of J1-axis reducer, be careful connector insert don’t caught in it. If cable is pulled forcibly, it causes the disconnection. Remove plate fixation M8 bolts bolts and the cable. (Refer to Fig.5.3 Fig.5.3 (k)). (k)). Replace the cable kit to new one .Do 29 to 31 by opposite procedure. procedure. Pay attention cable don’t twist in the J1 base. Do 23 to 28 by opposite procedure. Pay attention rubber boot come between J1 connector plate and connector housing. Do 16 to 22 by opposite opposite procedure. In this time, do not put it into the state to hang the cable of J4 connector plate. The cable might be hurt. Do 12 to 15 by opposite procedure. Wind the cable to J3 casing 4 times, and apply shell Alvania grease S2 referring to Fig.5.3 (f). When reuse seal bolt, be sure to seal them with seal tape. At this time, please connect it to come to the position in which the head of the nylon band is shown in Figure 5.3 (f). The cable might be hurt when differing from the shown in the figure position. Do 11 by opposite procedure. Clamp Clamp cables while pulling it to the J6 motor side at this time. If pull is insufficient, when the pipe is inserted, cable might be hurt. Do 9 to 10 by opposite procedure. In this time, be sure to replace packing to new one. Do 2 to 8 by opposite procedure. In this time, be sure to replace packing packing to new article. Install the J2-/J3-axis cable protection sheet onto the cable kit as originally done, and then secure the cover with nylon band. (Secure the nylon band to such an extent that the cable protection sheet does not get out of position when the robot operates. If the nylon band is tightened excessively, the cables in the movable section are confined and the cables can be broken at an earlier time.) Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed, removed, perform single axis mastering for the axis referring referring to Section 8.5 of operator’s manual.
2)
Replacing only motor cable 1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is set in 0°for all axes when robot is shipped.) 2 Remove cable kit from robot referring to Section (1) of Section 5.3 (1). 3 Replace motor motor cable cable to new one one and assemble it to cable kit. Clamp Clamp cables as the clamping position that the marking position shown in Figure 5.2 (a) - (f) and in Figure 5.3 (l) is corresponding. If cable is clamped in not specified position, slack and an impossible pull are caused in the cable, and it causes the cable disconnection. There are cables that don’t have marking on all position. First, set the cable with the marking position to a specified position. The cable without marking is formed along it and do so as not to twist along it. 4 Attach the cable kit onto the robot body. (See (1) of Section 5.3.) Retighten the mounting bolts. 5 Install the J2/J3-axis cable protection sheet as originally done. (Secure the nylon band to such an extent that the cable protection sheet does not get out of position when the robot operates. If the nylon band is tightened excessively, the cables in the movable section are confined and the cables can be broken at an earlier time.) (There is no cable protection sheet for ARC Mate 100iCe,M-10iAe, ARC Mate 100 iCe/6L,M-10iAe/6L.) 6 Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed, removed, perform single axis mastering for the axis referring referring to Section 8.5 of operator’s manual.
3)
Replacing only option cables (K301 etc.) (There is no option cable for ARC Mate 100 iCe,M-10iAe, ARC Mate 100 iCe/6L,M-10iAe/6L.) 1 Record the Quick Master Reference Position referring to Section 8.4 of operator’s manual. (It is set in 0°for all axes when robot is shipped.) - 111 -
5.CABLE REPLACEMENT
2 3 4 5
6
7
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Cut the nylon band that fastens J2/J3-axis cable protection sheet and and remove it from cable kit. Remove cables that is between J1 base and J4 connector plate plate from robot referring referring to (1) of of Section 5.3 and Fig.5.3 (g) to (k) Replace option cable to new one and fasten it by opposite procedure. Retighten the mounting bolts. Clamp cables as the clamping position that the marking marking position shown in Figure Figure 5.2 (a) - (f) (f) and in Figure 5.3 (l) is corresponding. If cable i s clamped in not specified position, posi tion, slack and an impossible pull are caused in the cable, and it causes the cable disconnection. There are cables that don’t have marking on all position. First, set the cable with the marking position to a specified position. The cable without marking is formed along it and do so as not to twist along it. Install the J2-/J3-axis cable protection sheet as originally done. (Secure the nylon band to such an extent that the J2/J3-axis cable protection sheet does not get out of position when the robot operates. operates. If the nylon band is tightened excessively, the cables in the the movable section are confined and the cables can be broken at an earlier time.) Perform quick mastering referring Section 8.4 of operator’s manual. If motor is removed, removed, perform single axis mastering for the axis referring referring to Section 8.5 of operator’s manual.
Cable protection sheet Cable protection sheet
J
ARC Mate 100iC , M-10iA, ARC Mate 100iC/6L , M-10iA/6L
ARC Mate 100iC/10S , M-10iA/10S
Fig.5.3 (a) Replacing cable kit (J2/J3-axis cable protection sheet)
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5.CABLE REPLACEMENT
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Bolt M5X45 (2) Tightening torque 9Nm LT262 Duct cover Cut nylon band and remove cable from clamp of the back side.
Extra low bolt M5X8 (2) Tightening torque 4.5Nm Plate cover 1
Bolt M3X6 Earth terminal
Packing (*) A290-7221-X581
Cut nylon band which fix this cable to the plate of the interior of J6-axis motor. Bolt M3X6 Packing (*) A290-7221-X582
Packing (*) A290-7221-X575
J5 motor cover
J6 motor cover Button seal bolt M4X8(4) Tightening torque 4.5Nm
Extra low seal bolt M5X8(4) Tightening torque 4.5Nm
(*) In case of M-10iA , M-10iA/6L , M-10iA/10S Fig.5.3 (b) Replacing c able kit (J3 arm part 1)
Earth terminal
Fig.5.3 (c) (c) Replacing cable ki t (J3 arm part 2)
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5.CABLE REPLACEMENT
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Cable clamp Pulsecoder cable connector
J3 arm base Fig.5.3 (d) Replacing c able kit (J3 arm part 3)
Packing A290-7221-X441 Cover Bolt M5X12(9) Apply LOCTITE 242. Tightening torque : 4.5Nm Seal bolt M6X16(2)
Bolt M3X35(3) Pipe
Fig.5.3 (e) Replacing c able kit (J3 casi ng p art 1) (ARC Mate 100iC, M-10i A, A, ARC Mat e 100iC/6L, M-10i A/6L A/6L , ARC Mat e 100iC/10S, M-10i A/10S) A/10S)
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5.CABLE REPLACEMENT
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Dummy pipe Bolt M3X30 (3) Packing A290-7221-X441 Cover Bolt M5X8 (9) Tightening torque 6.8Nm
Seal bolt M6X16 (2)
Fig.5.3 (f) Replaci Replaci ng cabl e kit (J3 casin g part 1) (ARC Mate 100 iCe, M-10i Ae, Ae, ARC Mat e 100iCe/6L, M-10 i Ae/6L Ae/6L ) Marking position
WIND THE CABLE FOUR TIMES. APPLY SHELL ALVAIA GREASE S2 AFTER ASSEBLING.
Bolt M4X5(2)
Position of the head of the nylon band
Position of the head of the nylon band Bolt M3X6(2) Apply LOCTITE 242. Clamp
Marking position
Fig.5.3 (g) Replacin Replacin g cabl e kit (J3 casin g part 2)
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5.CABLE REPLACEMENT
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Prevent the load from hanging to the cable which is connected to J4 connector plate.
Bolt M6X10
Bolt M6X10
Bolt M8X10 (2)
J4 connector panel 2
Bolt M6X10 (3)
Prevent the load from hanging to the cable which is connected to J4 connector plate.
J4 connector panel 1 J4 connector panel
ARC Mate 100 iC/10S , M-10 iA/10S
ARC Mate 100 iC , M-10iA, ARC Mate 100 iC/6L , M-10iA/6L ARC Mate 100 iCe , M-10iAe, ARC Mate 100 iCe/6L , M-10 iAe/6L
Fig.5.3 (h) Replaci Replaci ng cabl e kit (J4 connect or pl ate part)
Cable cover
Bolt M8X10(2) Bolt M6X12(2)
Fig.5.3 (i) Replaci Replaci ng cabl e kit (J2 base part)
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5.CABLE REPLACEMENT
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Option cable Rubber boot(*) Connector insert Plate J1 connector plate Bolt M8X10(4) Bolt M4X10(4) Connector housing Bolt M6X10(2)
Support Terminal of battery box
Air tube
Bolt M6X8 (2)
(*)When mechanical unit cable A05B-1221-H202, A05B-1221-H20 2, H203,H232 or H233 is selected,there selected,there is is no rubber rubber boot. Tie up with nylon band. -
-
+
+
Tightening torque 0.40Nm Battery box terminal side
Fig.5.3 (j) Replacin Replacin g cable kit (J1 connecto r plate part 1) A
TIE UP END OF RUBBER TUBE WITH NYLON BAND.
SECTION A-A
A
Fig.5.3 (k) Replacing Replacing cable kit (J1 con nector p late part 2)
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5.CABLE REPLACEMENT
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Bolt M8X10(4) Apply LOCTITE 262
Plate
Plate Bolt M8X12 (4) Apply LOCTITE 262 J
ARC ARC ARC ARC
Mate Mate Mate Mate
100iC , M-10iA, 100iC/6L , M-10iA/6L 100iCe , M-10iAe, 100iCe/6L , M-10iAe/6L
ARC Mate 100iC/10S , M-10iA/10S
Fig.5.3 (l) Replacin Replacin g cable ki t (J2 arm part)
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6
6.MASTERING
MASTERING
Mastering is an operation performed to associate the angle of each robot axis with the pulse count value supplied from the absolute Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for obtaining the pulse count value corresponding to the zero position.
6.1
GENERAL
The current position of the robot is determined according to the pulse count value supplied from the Pulsecoder on each axis. Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However, mastering becomes necessary after: Motor replacement Pulsecoder replacement Reducer replacement Cable replacement Batteries for pulse count backup in the mechanical unit have gone dead.
WARNING
Robot data (including mastering data) and Pulsecoder data are backed up by their respective respective backup backup batteries. batteries. Data will be lost if the batteries go dead. Replace the batteries in the control and mechanical units periodically. An alarm will be issued to warn the user of a low battery voltage.
Mastering Mastering m ethod There are following five methods of mastering. Table 6.1 6.1 Masterin Masterin g metho d
Fixture position mastering Zero-position mastering (witness mark mastering) Quick mastering
Single axis mastering mastering Mastering data entry
This is performed using a mastering fixture before the machine is shipped from the factory. This is performed with all axes set at the 0-degree position. A zero-position mark (witness mark) is attached to each robot axis. This mastering is performed with all axes aligned to their respective witness marks. This is performed at a user-specified position. The corresponding count value is obtained from the rotation speed of the Pulsecoder connected to the relevant motor and the rotation angle within one rotation. Quick 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 mastering position for for each axis can be specified by the user. This is useful in performing mastering on a specific axis. Mastering data is entered directly.
This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during replacement of parts. For other mastering methods, refer to OPERATOR'S MANUAL. Once mastering is performed, it is necessary to carry out positioning, or calibration. Positioning is an operation is which the controller reads the current pulse count value to sense the current position of the robot.
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6.MASTERING
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CAUTION
1 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 $MATER_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. 2 Before mastering mastering is performed, it is recommended recommended that that the current mastering mastering data be backed up. 3 When the motion range is mechanically mechanically 360 degrees degrees or more, if any of the axes (J1-axis and J4-axis) to which the cables are connected is turned one turn in the correct mastering position, the cables in the mechanical unit are damaged. If the correct rotation position is not clear because the axis is moved too much during mastering, remove the connector panel or cover, check the states of the internal cables, and perform mastering in the correct position. For the checking procedure, See Fig. 6.1 (a) to 6.1 (c).
Confirm cable is not twisted when J1=0°. Bolt M8X12 (4)
J1 connector panel
Fig.6.1 (a) (a) Conf Conf irmi ng t he state of cable (J1-axis) (J1-axis)
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6.MASTERING Packing (*) A290-7221-X441 (*) Packing is can not be reused. If you remove cover, replace packing to new one. Bolt M5X12 (9) Apply LOCTITE 242. Tightening torque : 4.5Nm
Confirm cable is wound four times when J4=0 . v
Plate
Fig.6.1 (b) Confirmi ng t he state of cable (J4-axis) (J4-axis) (1/2) (1/2)
Confirm these nylon bands are attached.
Fig.6.1 (c) (c) Confir ming the st ate of c able (J4-axis) (J4-axis) (2/2)
6.2
REGISTER OF MASTERING POSTURE
If the number of soft versions is Edition 24 or earlier of the V7.30 When FIXTURE POSITION MASTER is done for the first time. It is necessary to input the mastering posture according to the following procedure beforehand. (It is not necessary when FIXTURE POSITION MASTER is done for the second time or more.)
Procedure 1 2
Press the screen selection key. Press [0 NEXT] and Select [6 SYSTEM]. - 121 -
6.MASTERING 3 4 5 6 7 8
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Press F1 [TYPE], and select [SYSTEM Variable] from the menu. Place the cursor on $PARAM_GRP, then press [ENTER]. [$MRR_GRP_T] is displayed then press [ENTER]. Place the cursor on $MASTER _POS, then press [ENTER]. Input MASTERING POSTURE in Fig.6.4 (e). Turn off the power of the controller and turn on it. (If the power supply of the controller is never turned on again, the value of the mastering posture is not updated.
6.3
RESETTING RESETTING ALARMS AL ARMS AND A ND PREPARING FOR FOR MASTERING
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and display the positioning menu.
Al arm d is pl ayed “Servo 062 BZAL” or “Servo 075 Pulse not established”
Procedure 1
Display the positioning menu by following steps 1 to 6. 1 Press the screen selection key. 2 Press [0 NEXT] and Select [6 SYSTEM]. 3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4 Place the cursor on $MASTER_ENB, then key in “1” and press [ENTER]. 5 Press F1 [TYPE], and select[Master/Cal] from the menu. 6 Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5. 1 Press the MENUS key. 2 Select [0 NEXT] and select [6 SYSTEM]. 3 Press F1 [TYPE], and select [SYSTEM Variable] from the menu. 4 Place the cursor on F3 RES_PCA, then press F4 [TRUE]. The message “ TRUE” appears and disappears immediately. 5 Turn off the controller power and on again.
3
To reset the “Servo 075 Pulse not established” alarm, follow steps 1 to 3. 1 When the controller power power is switched on again, the the message “Servo 075 075 Pulse not established ” appears again. 2 Move the axis for for which the message mentioned above has appeared till alarm disappears when when press [FAULT RESET] in either direction.
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6.4
6.MASTERING
FIXTURE POSITION MASTER
Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering fixture is used. When mastering the robot, arrange the robot to meet the following conditions. Make the robot mounting base horizontal within 1 mm. (The overall levelness of the robot mounting surface shall be 1 mm or less.) Remove the hand and other parts form the wrist. Set the robot in the condition protected from an external force.
As s embl em bl in g t h e fix f ix t u re b ase as e 1
Assemble the fixture base as shown in Fig. 6.4 (a). Bolt M5X20 (4) Mastering fixture B A290-7221-X952 Plate
Bolt M5X20 (3) Plate
Fig.6.4 (a) Assemblin g th e fixtu re base
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6.MASTERING 2
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Adjust the dial gauge to 3.00 3.00 mm using the calibration block, block, and tighten it with M5 bolt as shown in Fig. 6.4 (b). (Do not tighten the bolt too strongly or the dial gauge will be broken.) Bolt M5X16 (6) Plate
Calibration block
E A D
B
F
C Dial gauge (All dial gauge indicate 3mm in calibration.)
Assembling method of dial gauge
Bolt M5
m m 0 2
Fig.6.4 (b) Mount Mount ing d ial gauge
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Clamp Calibration block
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3
6.MASTERING
Mount the fixture to the wrist flange as shown Fig. 6.4 (c). When assembling pin A290-7221-X955, pay attention to the direction of the pin refer to Fig.6.4 (c).
Bolt M6X20 (2) Pin A290-7221-X955 A290-7221-X956
Assembling pin A290-7221-X955
Robot front
Fig.6.4 (c) Assembling the fixture base
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Assemble pin to show the position of parallel part of pin and robot front in figure.
6.MASTERING 4
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Assemble the fixture to the wrist flange as shown in Fig. 6.4 (d). When assembling pin, pay attention the parallel pin turn to radial part of hollow flange. Refer to Fig.6.4 (d). Pin A290-7221-X954 Face for dial gauge D and F Face for dial gauge A and B
Bolt M4X16 (4) Mastering fixture A A290-7221-X951
Face for dial gauge E Face for dial gauge C Assemble pin the parallel part of pin turn to radial part of hollow flange.
Fig.6.4 Fig.6.4 (d) (d) Assembling the fi xture to the wrist flange
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6.MASTERING
Mastering 1 2 3 4
Press MENUS. Press NEXT and select SYSTEM. Press F1, [TYPE]. Select Master/Cal. AUTO SYSTEM Master/Cal 1 2 3 4 5 6
JOINT TORQUE= [ON] FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE
Press‘ENTER’or number key to select. [TYPE] LOAD RES_PCA
5
DONE
Release brake control, and jog the robot into a posture for mastering. A to F (see Fig.6.4 (b)) of the fixture attached to the wrist are dial gauges A to F (see Figs.6.4 (d)) and make adjustments so that dial gauges A to F indicate 3 mm. mm. A posture as shown in Fig.6.4 (e) should be taken. See this figure for reference.
NOTE
Brake control can be released by setting the system variables as follows: $PARAM_GROUP.$SV_OFF_ALL: $PARAM_GROUP.$SV_OFF_ALL: FALSE $PARAM_GROUP.$SV_OFF_ENB[*]: $PARAM_GROUP.$SV_OFF_ENB[*]: FALSE (for all axes) After changing the system variables, variables, switch the controller power off and on again. 6
Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES. "MASTER POSITION" shown in Fig. 6.4 (e) is set in this position. AUTO SYSTEM Master/Cal
JOINT TORQUE= [ON] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0><11808249><3876856> <9873638><122000309><2000319> [TYPE] LOAD RES_PCA
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DONE
6.MASTERING 7
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Select “ 6 CALIBRATE “ and press F4, YES. Mastering will be performed Alternatively, switch the power off and on again. Switching the power on always causes positioning to be performed. AUTO SYSTEM Master/Cal
JOINT TORQUE= [ON] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg) < 0.0000>< 0.0000>< 0.0000> < 0.0000>< 0.0000>< 0.0000> [TYPE] LOAD RES_PCA
8 9
DONE
After completing the calibration, press F5 Done. Return brake control to original setting, and turn off the controller power and on again.
WARNING
Since the axis stroke is not checked during the mastering, be careful to stay clear of the robot motion.
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6.MASTERING
ARC Mate 100 iC M-10iA ARC Mate 100 iCe M-10iAe
ARC Mate 100 iC/6L M-10 iA/6L ARC Mate 100 iCe/6L M-10 iAe/6L
Mastering position
Mastering position J1 0.00000 J2 22.9302 J3 -94.7411 J4 0.00000 J5 -85.2589 J6 -90.0000
J1 J2 J3 J4 J5 J6
0.00000 55.9747 -118.993 0.00000 -61.0069 -90.0000
ARC Mate 100 iC/10S M-10iA/10S Mastering position J1 0.00000 J2 55.6176 J3 -108.076 J4 0.00000 J5 -71.9238 J6 -90.0000
Fig.6.4 (e) (e) Mastering Mastering post ure
- 129 -
6.MASTERING
6.5
B-82755EN/05
CHECKING THE MA STERING STERING
1
Checking whether mastering has been made correctly Usually, positioning is performed automatically automatically at power-on. power-on. To check whether whether mastering has been made correctly, note whether the displayed current position agrees with the actual robot position. Use the procedure described below: (1) Reproduce a particular point in a program. Check whether the point agrees with the specified position. (2) Set all axes of the robot to their 0-degree (0rad) positions. Check that the zero-degree position marks indicated in section 8.3 of OPERATOR’S MANUAL are aligned. There is no need to use any visual aid. (3) Using fixtures, set the robot to the mastering mastering position in the same way as when performing performing mastering. Check that the displayed current position agrees with the actual mastering position. If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been invalidated as a result of an alarm described below 2. Alternatively, the mastering data in system variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation error or some other reason. Compare the data with the values indicated on the supplied data sheet. This system variable is overwritten whenever whenever mastering is performed. performed. Whenever mastering is performed, record the value of the system variable on the data sheet.
2
Alarms that may be output during mastering This section describes those alarms related to Pulsecoders, as well as the actions required to clear them. (1) BZAL alarm This alarm is output if the voltage of the Pulsecoder's backup battery falls to 0 V while the power to the controller is disconnected. To clear the alarm, fit a new battery, execute the pulse reset (See Section 6.3.), then turn off the controller power then on on again. Note that, if this alarm occurs, all data originally held by the Pulsecoder will have been lost. Mastering must be performed again. (2) BLAL alarm This alarm is output if the voltage of the Pulsecoder's backup battery has fallen to a level where backup is no longer possible. If this alarm is output, fit a new battery immediately while keeping the power turned on. Check whether the current position data is valid, using the procedure described in 1. (3) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, CRCERR, STBERR, and SPHAL, alarms If any of of these alarms alarms is output, output, contact the FANUC service section. The Pulsecoder may be defective.
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APPENDIX A PPENDIX
A
A.SPARE PARTS LIST
APPENDIX
B-82755EN/05
SPARE PARTS LIST Table A (a) Cables Cables (basic cabl e) Cable No.
Specificati ons
Functi on
Model
K101 K102
A05B-1221-D001 A05B-1221-D002
J1 to J6 MOTOR+EE(RI/OX8) J1 to J6 MOTOR +EE(RI/OX1) (Non-correspondence to CE) J1 to J6 MOTOR+EE(RI/OX1) J1 to J6 MOTOR+EE(RI/OX8) (Severe dust/liquid protection option) J1 to J6 MOTOR
K103 K111
A05B-1221-D003 A05B-1221-D011
K121
A05B-1221-D021
K131 K132
A05B-1221-D031 A05B-1221-D032
K133 K141
A05B-1221-D033 A05B-1221-D041
K151
A05B-1221-D051
J1 to J6 MOTOR+EE(RI/OX8) J1 to J6 MOTOR+EE(RI/OX1) (Non-correspondence to CE) J1 to J6 MOTOR+EE(RI/OX1) J1 to J6 MOTOR+EE(RI/OX8) (Severe dust/liquid protection option) J1 to J6 MOTOR
K161 K162
A05B-1221-D061 A05B-1221-D062
J1 to J6 MOTOR+EE(RI/OX8) J1 to J6 MOTOR+EE(RI/OX1)
ARC Mate 100iC M-10 A i A
ARC Mate 100iCe M-10 Ae i Ae ARC Mate 100iC/6L M-10 A/6L i A/6L
ARC Mate 100iCe/6L M-10 Ae/6L i Ae/6L ARC Mate 100iC/10S M-10 A/10S i A/10S
Table A (b) Cables Cables (opti on cabl e) Cable No.
Specificati ons
K301 K311 K312 K315
A660-2006-T755 A660-8016-T454 A660-2007-T053 A66-8017-T649
K321 K323 K331 K351 K701 K702 K314 K331 K703
A660-8040-T023 A660-8040-T024 A660-8016-T828 A660-2007-T032 A05B-1221-D301 A05B-1221-D302 A660-8017-T499 A660-8016-T828 A05B-1221-D303
Functi on
Model
Wire feeder power cable User cable (signal) User cable (power) User cable (signal usable to force sensor and 3DL sensor) Welding power cable (38SQ) Welding power cable (60SQ) Earth cable for camera Force sensor, 3DV sensor cable Camera cable (Non-waterproof type) Camera cable (Waterproof type) User cable (signal) Earth cable for camera Camera cable (Waterproof type)
ARC Mate 100iC M-10i A A ARC Mate 100iC/6L M-10i A/6L A/6L
ARC Mate 100iC/10S M-10 A/10S i A/10S
Table A (c) Motor Axi s
J1, J2 J3 J4 J5, J6 J1 J2 J3 J4,J5,J6
Specif Spec if ic ati on s
A06B-0235-B605#S000 A06B-0235-B605#S000 A06B-0212-B605#S000 A06B-0115-B804 A06B-0115-B855#0048 A06B-0115-B855#0048 A06B-0235-B005#S000 A06B-0235-B605#S000 A06B-0212-B605#S000 A06B-0115-B205#S000
Remark s αiS8/4000 αiS2/5000 βiS0.5/6000
Mod el
ARC Mate 100iC, M-10 A i A ARC Mate 100iC/6L, M-10 A/6L i A/6L ARC Mate 100iC/10S, M-10 A/10S i A/10S
βiSR0.5/6000 αiS8/4000 αiS8/4000 αiS2/5000 βiSR0.5/6000
- 133 -
ARC Mate 100iCe, M-10 Ae i Ae ARC Mate 100iCe/6L, M-10 Ae/6L i Ae/6L
A.SPARE PARTS LIST
APPENDIX
B-82755EN/05
Table A (d) Reducer Parts name
J1-axis reducer J2-axis reducer J3-axis reducer
Specificati ons
Remarks Remarks
A97L-0218-0822#33(*1) A97L-0218-0822#33(*1) A97L-0218-0885$33(*2) (*3) A97L-0218-0886#127(*1)(*2) A97L-0218-0886#127(*1 )(*2) A97L-0218-0886#93 (*3) (*3) A97L-0218-0824#150(*1) A97L-0218-0824#150(* 1) A97L-0218-0887#150(*2) A97L-0218-0887#150(* 2) A97L-0218-0887#108
Model
(*1) (*2) (*3) (*1) (*2) (*3) (*1) (*2) (*3)
(*1) Old spec robot ARC Mate 100 iC,M-10iA, ARC Mate 100 iC/6L,M-10iA6L shipped before March, 2010. (*2) New spec: robot ARC Mate 100 iC,M-10iA, ARC Mate 100 iC/6L,M-10iA6L shipped after April, 2010 or ARC Mate 100 iC/10S, M-10iA/10S, ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L,M-10iAe/6L. (*3) ARC Mate 100iC/10S,M-10iA/10S
NOTE
Specify the following draw nut for the J2, J3-axes reducer. Table A (e) (e) Input g ear, draw nut , gear and key Parts name
J1-axis gear Input gear Input gear Draw nut Draw nut Gear Gear Key
Specificatio ns
A290-7215-X211 A290-7221-X311 A290-7221-X411 (*1) (*1) A290-7221-Z411 (*2) A290-7221-Z415 (*3) A290-7221-X321 A290-7221-X421 A290-7221-X511 A290-7221-X521 JB-HKY-3X3X8A
Used place
J1-axis Motor J2-axis Motor J3-axis Motor J2-axis Motor J3-axis Motor J5-axis Motor J6-axis Motor J5, J6-axis Motor
(*1) Old spec robot ARC Mate 100 iC,M-10iA, ARC Mate 100 iC/6L,M-10iA6L shipped before March, 2010. (*2) New spec: robot ARC Mate 100 iC,M-10iA, ARC Mate 100 iC/6L,M-10iA6L shipped after April, 2010 or ARC Mate 100iCe,M-10iAe,ARC Mate 100iCe/6L,M-10iAe/6L. (*3) ARC Mate 100 iC/10S, M-10iA/10S Table A (f) Other Other (mechanic al uni t) Parts name
Specificati ons
Model
ARC Mate 100iC,M-10 A, i A, ARC Mate 100iC/6L,M-10 A/6L i A/6L Old specification: Robot shipped before March, 2010 ARC Mate 100iC,M-10 A, i A, ARC Mate 100iC/6L,M-10 A/6L i A/6L New specification: Robot shipped after April, 2010 or ARC Mate 100iCe,M-10 Ae, i Ae, ARC Mate 100iCe/6L, M-10i Ae/6L Ae/6L ARC Mate 100iC/10S,M-10 A/10S i A/10S All models All models
A05B-1221-K401
J4-axis gearbox A05B-1221-K411
Wrist unit Fluoric resin
A05B-1221-K413 A290-7221-V504 A290-7221-X571
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A.SPARE PARTS LIST
APPENDIX
B-82755EN/05
The following service parts are appended to J4-axis gearbox (A05B-1221-K401, K411, K413) for maintenance. Please exchange these with the J4-axis gearbox. Par t s n am e
Packing Packing Bolt Bolt Washer Seal bolt Seal bolt Seal Seal bolt bolt Packing
Sp ec i f i c at i o n s
Nu m b er
A98L-0040-0042#03 A98L-0040-0042#07 A6-BA-8X25 A6-BA-5X14 A97L-0001-0823#M8H A97L-0218-0502#5X10 A97L-0218-0417#081010 A97L-0218-0417#081 010 10 A97L A97L-0 -021 2188-04 0417 17#0 #060 6080 808 8 A290-7221-X441
1 1 8 or 9 7 8 or 9 4
A290-7221-X442
Us ed p l ac e
J3-axis Motor J4-axis Motor Between J3 casing and J3-axis reducer J4-axis Motor mounting part Between J3 casing and J3-axis reducer J4-axis Motor
1
J4-axis oil outlet
1 1
J3-a J3-axi xis s grea grease se inle inlett J4-axis Hollow part J4-axis Motor mounting part ARC Mate 100iC,M-10 A, i A, ARC Mate 100iC/6L,M-10 A/6L i A/6L J4-axis Motor mounting part ARC Mate 100iC/10S,M-10 A/10S i A/10S Between J3 arm and J3 casing J4-axis Motor mounting part, J4-axis hollow part
1
Packing A290-7221-Z442 O-RING
A290-7221-X444
1
PIN
JB-PH-H7A-5X10S45C
2
Table A (g) Battery, grease, oil, and sealant Parts name
Specificati ons
Model
Battery Grease Grease
A98L-0031-0027 A98L-0 A98L-0040 040-01 -0174# 74#1.2 1.27KG 7KG
All Models All Models Models
Oil
A98L-0040-0233#0.8L
All Models
Sealan Sealantt
A98L-0 A98L-0040 040-02 -0238# 38#0.3 0.33KG 3KG
All Models Models
Remarks Remarks
C battery 1.5V (4pcs /per 1 robot) Kyodo Kyodo Yushi Yushi VIGOGREASE RE0 JX Nippon Oil & Energy Corporation BONNOC AX68 Three Three bond bond for gearbo gearbox x
Table A (h) O-RING Parts name
O-RING O-RING O-RING O-RING O-RING O-RING
Specificati ons
A290-7207-X342 A290-7221-X444 A98L-0001-0347#S150 A98L-0001-0347#S39 JB-OR1A-G105 JB-OR1A-G65
Model
All Models All Models All Models All Models All Models All Models
Used place
J1-axis reducer Wrist- unit J1-axis reducer J5, J6-axis Motor (2 places) J1, J2-axis Motor (2 places) J1-axis reducer
Table A (i) Packing Packing Parts name
Specificatio ns
Packing Packing Packing Packing Packing
A290-7221-X441 A290-7221-X442 A98L-0040-0042#03 A98L-0040-0042#07 A290-7221-Z236
Packing Packing Packing Packing
A290-7221-X579 A290-7221-X581 A290-7221-X582 A290-7221-X575
Model
All Models All Models All Models All Models M-10 A, i A, M-10 A/6L i A/6L (Severe dust/liquid protection option) M-10 A, i A, M-10 A/6L,M-10 i A/6L,M-10 A/10S i A/10S M-10 A, i A, M-10 A/6L,M-10 i A/6L,M-10 A/10S i A/10S M-10 A, i A, M-10 A/6L,M-10 i A/6L,M-10 A/10S i A/10S M-10 A, i A, M-10 A/6L,M-10 i A/6L,M-10 A/10S i A/10S
- 135 -
Used place
J4-axis hollow part J4-axis motor mounting part J3-axis Motor J4-axis Motor Battery cover
J5 motor cover Plate cover 1 Plate cover 2 J6 motor cover
A.SPARE PARTS LIST
APPENDIX
B-82755EN/05
Table A (j) Stopper Parts name
Stopper Stopper
Specificati ons
A290-7215-X323 A290-7221-X324
Model
All Models All Models
Used place
J2-axis J3-axis
Table A (k) M/H conduit (M-10i A, A, M-10i A/6L, A/6L, M-10i A/10S A/10S op ti on ) Parts name
M/H conduit Protection ring Conduit
Specificati ons
Model
M-10 A, i A, M-10 A/10S i A/10S M-10 A/6L i A/6L M-10i A A M-10 A, i A, M-10 A/10S i A/10S
A05B-1221-J701 A05B-1221-J702 A05B-1221-J711 FANUC Specifications: A97L-0118-0734#E36-0062 A97L-0118-0734#E360062 PMA Specifications: ESDT-36B (Note) FANUC Specifications: A97L-0118-0734#E36-0084 A97L-0118-0734#E36 -0084 PMA Specifications: ESDT-36B (Note)
M-10 A/6L i A/6L
Table A (l) No No du st M/H condui t (M-10 (M-10i A, A, M-10i A/6L, A/6L, M-10i A/10S A/10S op ti on ) Parts name
M/H conduit Conduit
Packing A Packing B Seal bolt
Specificati ons
Model
A05B-1221-J721 A05B-1221-J722 FANUC Specifications: A97L-0118-0734#E36-0062 A97L-0118-0734#E360062 PMA Specifications: ESDT-36B (Note) FANUC Specifications: A97L-0118-0734#E36-0084 A97L-0118-0734#E36 -0084 PMA Specifications: ESDT-36B (Note) A290-7221-Z641 (4 pcs/per 1 robot) A290-7221-Z642 (4 pcs/per 1 robot) A97L-0218-0546#030806SC A97L-0218-0546#030806S C (16 pcs/per 1 robot)
M-10 A, i A, M-10 A/10S i A/10S M-10 A/6L i A/6L M-10 A, i A, M-10 A/10S i A/10S
M-10 A/6L i A/6L
M-10 A, i A, M-10 A/6L,M-10 i A/6L,M-10 A/10S i A/10S
NOTE
Please cut it in the convex part when you cut Conduit. The cable might be damaged in the edge part of Conduit when cutting it in the concave portion.
Good cutting example
A
DETAIL A
B
Bad cutting example DETAIL B Fig.A Cutting Cutting example example of cond uit
- 136 -
B-82755EN/05
B
APPENDIX
CIRCUIT CIRCUIT DIAGRAM DIAGRA M
- 137 -
B.CIRCUIT DIAGRAM
B.CIRCUIT DIAGRAM
APPENDIX
B-82755EN/05
A66L-0001-0401#14 (1.25SQ*14C)Φ11.8
A66L-0001-0574
(0.2SQ*6P)Φ7.7
A66L-0001-0532
(0.4SQ*24C)Φ10.6
A66L-0001-0574
(0.2SQ*6P)Φ7.7
J1 CONNECTOR PANEL RMP
Han 72DD (2.5SQ 10A)
1 BK(J1) 13 B K( K( J2 J2 ) 25 B K( K(J 3) 3) 37 B K( K( J4 J4 ) 49 B K( K( J5 J5 ) 61 B K( K( J6 J6 ) BKC
2
J1U1
14
J2U1
26
J3U1
38 ( 20 200 V) V) 50
( 0V 0V )
62 (J1,J2,J3,
3
J1V1
15
J2V1
27
J3V 1
39
J4U1
51
J5U1
63 J6U1
4
J1W1
16
J2W1
28 J3W1
40
J4V1 J4V1
52
J5V 1
64
J 6V1
5
J1G1
17
J 2G1
29
41 J4W1
53
J5W1 65
J6W1
42
J4G1
54
J5G1
J3G1
24V 18(OT,A1,A2, 30 XHBK A3,A4)
J4,J5,J6)
6
XROT
7
RI1
19
RI2
31
R I3
43
R I4
55
RI5
67
0V (D1,D2)
8
RO1
20
RO 2
32
RO 3
44
R O4
56
R O5
68
R I6
9
RI7
21
RI8
33
RO7
45
R O8 O8
57 X P PP PA BN BN 69
10
(SOLDERING)
66 J6G1 J6G1
A66L-0001-0574
(0.2SQ*6P)O7.7
RO6
5V 5V 5V 0V 0V 0V 34 46 58 70 22 (A1,A2) (B1,B2) (C1,C2) (A1,A2) (B1,B2) (C1,C2)
11 PRQJ1 23 PRQJ PRQJ2 2 35 PRQJ3 PRQJ3 47 PR QJ QJ 4 59 P RQ RQ J5 J5 71 PR QJ QJ 6 60 XPRQJ572 XPRQJ6 12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 G
A66L-0001-0459
(0.2SQ*24C)Φ8.3
FG
6V (BT1,BT2,BT3, BT4,BT5,BT6)
A66L-0001-0464#1
(0.2SQ*4P)Φ6.7
+ A66L-0001-0459
(0.2SQ*24C)Φ8.3
BATTERY 0V (BT1,BT2,BT3, BT4,BT5,BT6)
-
:可動部用 MOVABLE
Fig.B (a) Circuit diagram (ARC Mate 100 iC, M-10i A, A, ARC Mate 100 iC/6L, M-10i A/6L A/6L , ARC Mat e 100iC/10S, M-10i A/10S) A/10S)
- 138 -
B.CIRCUIT DIAGRAM
APPENDIX
B-82755EN/05
J1 MOTOR (αiS8/4000) IN CASE OF K101,K111,K131,K161 A63L-0001-0648#810SL3SJ A63L-0001-0653#04A IN CASE OF K102,K103,K132,K133,K162 MS3108B10SL-3S
M1BK A
BK B K(J1)
BKC(J1 )
B
M1M
IN CASE OF K101,K111,K131,K161 A63L-0001-0881#1810S A63L-0001-0881#10C IN CASE OF K102,K103,K132,K133,K162 A63L-0001-0881#1810S
A B
J1U1 J1V1
D
4
8 5V(A1) 9 10
J2
5 6
0V(A1)
7
BK B K(J2)
A63L-0001-0848#B10SL1 A63L-0001-0850
10SL-3P(1.25SQ 10SL-3P(1.25SQ 13A) BKC(J2 )
B
J2U1
C D
J2W1 J2G1
M2 P A63L-0001-0848#B10SL1 A63L-0001-0850
10
PRQJ2 7 0V(BT2)
6
0V(A2)
5V(B1)
3 4
1
2
9
J4
0V(B1)
4 5 6 7
A63L-0001-0874
J3W1 J3G1
BK(J3) BKC(J3)
5 6
10SL1(0.3SQ 3A) 6V(BT3) 1 XPRQJ3 2 PRQJ3 3 FG 0V(BT3)
MOTOR (βiS0.5/6000)
IN CASE OF K101,K103 ,K111,K131,K133,K161 A63L-0001-0866#2 A63L-0001-0864#CS IN CASE OF K102,K132,K162 A63L-0001-0865#2 A63L-0001-0864#CS
1 2
BK BK(J 4)
IN CASE OF K101,K103,K111 ,K131,K133,K161 A63L-0001-0866#1 A63L-0001-0864#CS IN CASE OF K102,K132,K162 A63L-0001-0865#1 A63L-0001-0864#CS
1
J4 J4U1 J4V1
M4 BK
MOLEX 55619-0401
4
BKC(J 4)
3
M4 M 2
MOLEX 55618-0401 4 3
J4G1 J4W1
M4 P
IN CASE OF K101,K103,K111 ,K131,K133 A63L-0001-0848#B10SL1 A63L-0001-0850 IN CASE OF K102,K132 A63L-0001-0848#E10SL1 A63L-0001-0850
10SL1(0.3SQ 3A) 4 6V(BT2) 5 XPRQJ2
8 5V(A2) 9
C
18-10P
B J2V1
A
8 10
10SL1(0.3SQ 3A) SG 6V(BT1) 1 XPRQJ1 2 PRQJ1 3 FG 0V(BT1)
M2 M
IN CASE OF K101,K111,K131,K161 A63L-0001-0881#1810S A63L-0001-0881#10C IN CASE OF K102,K103,K132,K133,K162 A63L-0001-0881#1810S
2
J3U1 J3V1
1
M3 P
J1W1 J1G1
M2 BK A
IN CASE OF K102,K103,K132,K133,K162 MS3108B10SL-3S
M3 M A63L-0001-0875#SC
C
MOTOR (αiS8/4000)
IN CASE OF K101,K111,K131,K161 A63L-0001-0648#810SL3SJ A63L-0001-0653#04A
MOTOR (αiS2/5000)
18-10P C
M1P A63L-0001-0848#B10SL1 A63L-0001-0850
J3
10SL-3P(1.25SQ 10SL-3P(1.25SQ 13A)
8 5V(B2) 9 10
0V(B2)
10SL1(0.3SQ 3A) 4 6V(BT4) 5 XPRQJ4
1
6 PRQJ4 7 0V(BT4)
3 FG
2
3 FG
J5 MOTOR (βiSR0.5/6000) M5 BK
A63L-0001-0865#2 A63L-0001-0864#CS
1 2
BK(J5) BKC(J5)
MOLEX 55619-0401
4 3
M5 M
A63L-0001-0865#1 A63L-0001-0864#CS
2
J5U1 J5V1
8
5V(C1)
1
MOLEX 55618-0401 4 3
M5 P A63L-0001-0848#E10SL1 A63L-0001-0850
9 10
0V(C1)
4 5 6 7
J5G1 J5W1 10SL1(0.3SQ 3A) 6V(BT5) 1 XPRQJ5 2 PRQJ5 3 FG 0V(BT5)
J6 MOTOR (βiSR0.5/6000) M6 BK
A63L-0001-0865#2 A63L-0001-0864#CS
A660-0001-0586
PLATE A290-7221-X431 BUSH A290-7221-X432
1 2
IN CASE OF K101,K102,K103 A660-0001-0592 IN CASE OF K131,K132,K133 A660-0001-0593
2
J6U1 J6V1
8
5V(C2)
1
3
MOLEX 55618-0401 4 3
M6 P A63L-0001-0848#E10SL1 A63L-0001-0850
IN CASE OF K101---ARC Mate 100iC,M-10iA IN CASE OF K131---ARC Mate 100iC/6L,M-10iA/6L IN CASE OF K141---ARC Mate 100iC/10S,M-10iA/10 100iC/10S,M-10iA/10S S
EE RO1 1 RO 2 RO2 3 RO3 4 RO4 5 RO5 6 RO6 7 XHBK 8 0V(D1)
EE IN CASE OF K102,K103---ARC K102,K103---ARC Mate 100iC,M-10iA IN CASE OF K132,K133---ARC K132,K133---ARC Mate 100iC/6L,M-10iA/6L IN CASE OF K142 ---ARC Mate 100iC/10S,M-10iA/10S 100iC/10S,M-10iA/10S
1
RI 1 10 RI2 11 RI3 12 RI4 13 RI8 14 XPPABN 15 RI5 RI6 16 RI
RO1
3 0V(D1) 4 RI1
19 24V(A3)
IN CASE OF K111--M-10iA SEVERE DUST/LIQUID PROTECTION IN CASE OF K141--M-10iA/6L SEVERE DUST LIQUID PROTECTION
21 RO7 22 RO8 23 0V(D1) 24
RI7
5
M-10iA SEVERE DUST/LIQUID PROTECTION K111(A05B-1221-D011)---RI/O*8
RI1
17 24V(A1) 18 24V(A2) 19 24V(A3)
12 RI4
20 24V(A4)
13 RI8
21 RO7
14 XPPABN
22 RO8
RI5
16 RI6
7
ARC Mate 100iC,M-10iA K101(A05B-1221-D001)---RI/O*8 K102(A05B-1221-D002)---RI/O*1 K103(A05B-1221-D003)---RI/O*1
+24V(A1)
11 RI3
15
6
10SL1(0.3SQ 3A) 6V(BT6) 1 XPRQJ6 2 PRQJ6 3 FG 0V(BT6)
ARC Mate 100iC,M-10iA, ARC Mate 100iC/6L,M-10iA/6L ARC Mate 100iC/10S,M-10iA/10S □ R-30iA/R-30iA Mate □ FOR CE (STANDARD)
20 24V(A4)
10 RI2
9
5
18 24V(A2)
ARC Mate 100iC/6L,M-10iA/6L K131(A05B-1221-D031)---RI/O*8 K132(A05B-1221-D032)---RI/O*1 K133(A05B-1221-D033)---RI/O*1
A63L-0001-0234#R2424S
EE RO1 1 RO 2 RO2 3 RO3 4 RO4 5 RO5 6 RO6 7 XHBK 8 0V(D1)
0V(C2)
4
J6G1 J6W1
17 24V(A1)
9
A63L-0001-0234#W1305F (0.5SQ 5A)Φ3-Φ8
2 XHBK
9 10
A63L-0001-0234#W2524F (0.5SQ 5A)Φ9.6-Φ15
MOLEX 55619-0401
4
M6 M
A63L-0001-0865#1 A63L-0001-0864#CS
(0.2SQ*(12C+2P),0.3SQ*12C)
φ4.9*2 + φ5.1*2
BK(J6) BKC(J6)
M-10iA/6L SEVERE DUST/LIQUID PROTECTION K141(A05B-1221-D041)---RI/O*8
23 RI7
ARC Mate 100iC/10S,M-10iA/10S K161(A05B-1221-D061)---RI/O*8 K162(A05B-1221-D062)---RI/O*1
24
- 139 -
B.CIRCUIT DIAGRAM
APPENDIX
B-82755EN/05
A66L-0001-0401#10 (1.25SQ*10C)φ11.8
A66L-0001-0574 (0.2SQ*6P)φ7.7
A66L-0001-0532 (0.4SQ*24C)φ10.6
A66L-0001-0574 (0.2SQ*6P)φ7.7
J1CONNECTOR PANEL RMP
J1G1,J2G1
Han 72DD (2.5SQ 10A)
G J3G1,J4G1 J5G1,J6G1
1
13 BK(J2) 25 BK(J3) 37
49
61
2
J1U1 14 J2U1 26 J3U1 38
50
62
3
J1V1 15 J2V1 27 J3V1 39 J4U1 51 J5U1 63 J6U1
4
J1W1 16 J2W1 28 J3W1 40 J4V1 52 J5V1 64 J6V1
5
J1G1 17 J2G1 29 J3G1 41 J4W1 53 J5W1 65 J6W1
BKC (J2,J3)
6
18
30
42 J4G1 54 J5G1 66 J6G1
7
19
31
43
55
67
8
20
32
44
56
68
9
21
33
45
57
69
10
(SOLDERING)
A66L-0001-0574 (0.2SQ*6P)φ7.7
5V 5V 5V 0V 0V 0V 22 34 46 58 70 (A1,A2) (B1,B2) (C1,C2) (A1,A2) (B1,B2) (C1,C2)
11 PRQJ1 23 PRQJ2 35 PRQJ3 47 PRQJ4 59 PRQJ5 71 PRQJ6 12 XPRQJ1 24 XPRQJ2 36 XPRQJ3 48 XPRQJ4 60 XPRQJ5 72 XPRQJ6 G
FG
6V (BT1,BT2,BT3, BT4,BT5,BT6)
+
BATTERY 0V (BT1,BT2,BT3, BT4,BT5,BT6)
-
Fig.B (b) Circuit di agram (ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L)
- 140 -
APPENDIX
B-82755EN/05
B.CIRCUIT DIAGRAM BRAKE) J3 MOTOR (αiS2/5000 with BRAKE)
M3 M
without BRAKE) J1 MOTOR (αiS8/4000 without
M1 M A63L-0001-0881#1810S
A J1U1 B J1V1
8 5V(A1) 9 10 0V(A1)
10SL1(0.3SQ 3A)
4 6V(BT1) 5 XPRQJ1 6 PRQJ1 7 0V(BT1)
M2 BK A BK(J BK(J2) 2)
1 2 3
A J2U1 B J2V1
8 5V(A2) 9 10 0V(A2)
5 BK(J3) 6 BKC(J3)
10SL1(0.3SQ 3A)
4 6V(BT3) 5 XPRQJ3 6 PRQJ3 7 0V(BT3)
1 2 3
FG
FG
(βiSR0.5/6000 without BRAKE) J4 MOTOR (βiSR0.5/6000
C
M4 M
A63L-0001-0865#1 A63L-0001-0864#CS
1 J4U1 2 J4V1
18-10P
C J2W1 D J2G1
M2 P A63L-0001-0848#B10SL1 A63L-0001-0850
A63L-0001-0874
10SL-3P(1.25SQ 13A)
B BKC( BKC(J J 2) 2)
M2 M A63L-0001-0881#1810S
8 5V(B1) 9 10 0V(B1)
3 J3W1 4 J 3G 3G1
M3 P A63L-0001-0848#B10SL1 A63L-0001-0850
J2 MOTOR (αiS8/4000 with BRAKE) MS3108B10SL-3S
1 J3U1 2 J3V1
18-10P
C J1W1 D J1G1
M1 P A63L-0001-0848#B10SL1 A63L-0001-0850
A63L-0001-0875#SC
M4 P A63L-0001-0848#E10SL1 A63L-0001-0850
10SL1(0.3SQ 3A)
4 6V(BT2) 5 XPRQJ2 6 PRQJ2 7 0V(BT2)
1 2 3
8 5V(B2) 9 10 0V(B2)
MOLEX 55618-0401
4 J 4G1 3 J 4W1 10SL1(0.3SQ 3A)
4 6V(BT4) 5 XPRQJ4 6 PRQJ4 7 0V(BT4)
1 2 3
FG
FG
(βiSR0.5/6000 without BRAKE) J5 MOTOR (βiSR0.5/6000
M5 M
A63L-0001-0865#1 A63L-0001-0864#CS
1 J5U1 2 J5V1
M5 P A63L-0001-0848#E10SL1 A63L-0001-0850
8 5V(C1) 9 10 0V(C1)
MOLEX 55618-0401
4 J 5G1 3 J 5W1 10SL1(0.3SQ 3A)
4 6V(BT5) 5 XPRQJ5 6 PRQJ5 7 0V(BT5)
1 2 3
FG
(βiSR0.5/6000 without BRAKE) J6 MOTOR (βiSR0.5/6000
A660-0001-0592 [{0.2SQ*(6C+2P)}*2+(0.3SQ*4C+0.2SQ*2C)*2)] φ4.9*2+φ5.1*2 PLATE A290-7221-X431 BUSH A290-7221-X432
A63L-0001-0865#1 A63L-0001-0864#CS
M6 M 1 J6U1 2 J6V1
M6 P A63L-0001-0848#E10SL1 A63L-0001-0850
8 5V(C2) 9 10 0V(C2)
ARC Mate 100iCe , M-10iAe ARC Mate 100iCe/6L , M-10iAe/6L □R-30iA Mate □2BK
：可動部用 MOVABLE
K121(A05B-1221-D021) --- without RI /O K151(A05B-1221-D051) --- without RI/O
- 141 -
MOLEX 55618-0401
4 J 6G1 3 J 6W1 10SL1(0.3SQ 3A)
4 6V(BT6) 5 XPRQJ6 6 PRQJ6 7 0V(BT6)
1 2 3
FG
C.PERIODIC MAINTENANCE TABLE
C
APPENDIX
B-82755EN/05
PERIODIC MAINTENANCE TABLE FANUC Robot ARC Mate 100 iC, M-10 A, i A, ARC Mate 100iC/6L, M-10 A/6L i A/6L ARC Mate 100iC/10S, M-10 A/10S, i A/10S, ARC Mate 100iCe, M-10 Ae, i Ae, ARC Mate 100iCe/6L, M-10 Ae/6L Maintenance Table Table i Ae/6L Periodic Maintenance Working time (H)
Check time
Items
Oil First 3 6 9 1 Grease check months months months year amount 320 960 1920 2880 3840
2 years
4800
5760
6720
7680
1
Check the mechanical cable. (Damaged or twisted)
0.2H
-
○
○
○
2
Check the motor connector. (Loosening)
0.2H
-
○
○
○
0.2H
-
○
○
○
2.0H
-
○
○
○
0.1H
-
○
○
○
1.0H
-
○
○
○
○
○
○
3 Tighten the end effector bolt. Tighten the cover and main
4 bolt.
8640
9600 10560
Check the mechanical stopper
5 and adjustable mechanical stopper
6 Remove spatter and dust etc. Check the end effector (hand)
t i n u l a c i n a h c e M
7 cable
Check the oil gauge of J4 to J6
8 axis
0.1H ○
○
○
○
○
○
○
○
○
0.1H
-
Replacing battery. *1
0.1H
-
Replacing battery. *2
0.1H
-
0.5H
872ml
0.5H
333ml
0.5H
186ml
0.5H
400ml
0.5H
400ml
4.0H
-
4.0H
-
●
1.0H
-
●
0.1H
-
0.2H
-
0.2H
-
0.1H
-
●
○
○
○
○
○
○
○
○
○
●
9 Replacing grease of J1 axis
10 reducer
Replacing grease of J2 axis
11 reducer
Replacing grease of J3 axis
12 reducer
Replacing oil of J4 axis
13 gearbox
Replacing oil of J5 and J6 axis
14 gearbox
Replacing cable of mechanical
15 unit
Replacing cable of Mechanical
16 unit welding power
Replacing M/H conduit/No dust
17 M/H conduit (option)
Check broken of fluoric resin
18 ring.
●
○
○
○
○
○
○
○
○
●
Check the robot cable, teach
19 pendant cable and robot
r e l connecting cable l o r t n 20 Cleaning the ventilator o C
21 Replacing battery *1
○ ○
○
○ ○
○
○
○ ○
○
○
○
*1 ARC Mate 100iC, M-10iA, ARC Mate 100 iC/6L, M-10iA/6L ARC Mate 100 iC/10S, M-10iA/10S
*2 ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L
*3 Refer to manual of controller. *4 ●: requires order of parts ○: doe not requires order of parts - 142 -
B-82755EN/05
C.PERIODIC MAINTENANCE TABLE
APPENDIX
3
4
5
6
7
8
years
years
years
years
years
years
11520 12480 13440 14400 15360 16320 17280 18240 1920 19200 0 2016 20160 0 2112 21120 0 2208 22080 0 2304 23040 0 2400 24000 0 2496 24960 0 2592 25920 0 26880 27840 28800 29760 30720
Item
○
○
○
○
○
1
○
○
○
○
○
2
○
○
○
○
○
3
○
○
○
○
○
4
○
○
○
○
○
5
○
○
○
○
○
6
○
○
○
○
○
7
○
○
○
○
●
○
○
○
○
●
○
○
○
○
●
○
○
○
○
●
○
○
○
○
8
●
9 ●
●
●
● l u a h r e v O
●
●
●
●
●
●
12
●
●
13
●
●
14
●
○
○
○
○
○ ○
○
○
11
15
●
●
16
●
●
17
●
○
○
○
○ ○
10
○
○
○
○
○
○ ○
○
○
○
●
○
○
○
○ ○
○
○
●
○
○
○
○
○
○ ○
○
○
○
18 19
○
○
○
20 21
- 143 -
D.MOUNTING BOLT TORQUE LIST
D
APPENDIX
B-82755EN/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 adhesion cannot be obtained. Remove the dust within the bolts and taps and wipe oil off the engaging section. Make sure that there is no solvent in the taps.Be sure to wipe the excess LOCTITE after tightening bolt. Use bolt which strengths are below. But if it is specified in text, obey it. Hexagon socket head bolt made by steel Size is M22 or less : Tensile strength 1200N/mm2 or more Size is M24 or more : Tensile strength 1000N/mm2 or more All size of bolt of the plating : Tensile strength 1000N/mm 2 or more Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc) Tensile strength 400N/mm2 or more If no tightening torque is specified for a bolt, tighten it according to this table. Recommended bolt tightening torques
Nominal diameter
Unit: Nm
Hexagon socket head bolt (Steel)
Hexagon socket head bolt (stainless)
Hexagon socket head button bolt Hexagon socket head flush bolt Low-head bolt (steel)
Tightening torque
Tightening torque
Tightening torque
Hexagon bolt (steel)
Tightening torque
Upper Upper limit limit Lower Lower limit limit Upper Upper limit limit Lower Lower limit limit Upper Upper limit limit Lower Lower limit limit Upper Upper limit limit Lower limit
M3 M4 M5 M6 M8 M10 M12 (M14) M16 (M18) M20 (M22) M24 (M27) M30 M36
1.8 4.0 7.9 14 32 66 110 180 270 380 530 730 930 1400 1800 3200
1.3 2.8 5.6 9.6 23 46 78 130 190 260 370 510 650 960 1300 2300
0.76 1.8 3.4 5.8 14 27 48 76 120 160 230
―――― ―――― ―――― ―――― ――――
―――― 0.53 ―――― 1.3 1.8 1.3 2.5 4.0 2.8 4.1 7.9 5.6 9.8 14 9.6 19 32 23 ―――― ―――― 33 ―――― ―――― 53 ―――― ―――― 82 ―――― ―――― 110 ―――― ―――― 160 ―――― ―――― ―――― ―――― ――――
- 144 -
―――― ―――― ―――― ―――― ――――
―――― ―――― ―――― ―――― ――――
―――― 1.7 3.2 5.5 13 26 45 73 98 140 190
―――― ―――― ―――― ―――― ――――
――― 1.2 2.3 3.8 9.3 19 31 51 69 96 130
―――― ―――― ―――― ―――― ――――
E.INSULATION ABOUT ARC APPENDIX
B-82755EN/05
E
WELDING ROBOT
INSULATION ABOUT ARC WELDING ROBOT
E.1
ABSTRACT
The arc welding robot performs welding, using a welding torch attached to its end effector via a bracket. Because a high welding current flows through the welding torch, the insulation between the end effector and torch is dualized. If no due consideration is taken, a poor insulation caused by a pileup of spatter can allow the welding current to leak into robot mechanical sections, possibly resulting in the motor being damaged or the sheaths of cables in the mechanical sections melting.
E.2 -
-
-
-
INSULATION AT THE WRIST Design the the insulation insulation between between the end end effector and welding torch so that no current will leak from the end effector. Concretely, when fastening the insulating material inserted between the end effector and torch bracket, use different bolts on the insulation material and torch bracket. Insert the insulating material between the torch and torch bracket so that the insulation is dualized. dualized. When installing the insulating material, be sure to set the crack in the torch holder away from that of the insulating material to prevent spatter from getting in the cracks. Insert the insulating material between the torch and torch bracket so that the insulation is dualized. dualized. When installing the insulating material, be sure to set the crack in the torch holder away from that of the insulating material to prevent spatter from getting in the cracks. Allow a sufficient distance (at least 5 mm) at the insulating materials materials in case a pileup of of spatter should occur. Even after the insulation is reinforced, it is likely that, that, if a pileup pileup of of spatter grows excessively, current may leak. Periodically remove remove spatter when the robot is in service.
- 145 -
B-82755EN/05
INDEX
INDEX NOTES FOR ASSEMBLING ASSEMBLING CABLES WITH NO DUST M/H CONDUIT ....................... ....................... 88 NOTES OF ATTACHING ATTACHING J3-AXIS J3-AXIS MOTOR TO REDUCER ...................... ....................... .................... 58
1.5-YEAR CHECKS (5,760 (5,760 hours)............................ ....10 1-YEAR (3,840 HOURS) CHECKS................................9 2-YEAR CHECKS (7,680 (7,680 hours)................................... 10 3-MONTH (960 HOURS) HOURS) CHECKS CHECKS ......................... ......9 3-YEAR (11,520 HOURS) CHECKS............................10 4-year (13,820 hours) checks ...................... ................... 10
Oil replacement procedure for the gearbox (J4 to J6-axis) ..................... ....................... ....................... .... 24
ABSTRACT.................................................................145
PERIODIC MAINTENANCE MAINTENANCE ....................... ................ 15 PERIODIC MAINTENANCE MAINTENANCE TABLE ....................... 142 PREFACE. ....................... ........................ .................... p-1 Procedure for releasing releasing oil (J4 to J6-axis)..................... .28 Procedure for releasing remaining pressure from the grease bath (J1 to J3-axis) ........................ .................. 27
BACKLASH MEASUREMENT ....................... ............38 CABLE DRESSING .................... ....................... .........101 CABLE REPLACEMENT.............................................99 CABLE WIRING.........................................................100 CHECKING THE MASTERING ........................ ........130 CHECKS AND MAINTENANCE MAINTENANCE .................... .............. 1 CIRCUIT DIAGRAM..................................................137 COMPONENT REPLACEMENT ......................... ........43
REGISTER OF MASTERING POSTURE..................121 REPLACING CABLES...............................................110 REPLACING FLUORIC RESIN RING RING ....................... .97 REPLACING M/H CONDUIT (OPTION)....................86 REPLACING NO DUST M/H CONDUIT (OPTION) (OPTION)..93 ..93 Replacing the Batteries (1 Year (3,840 Hours) or (1.5 Year (5,760 Hours) Checks).......................................15 REPLACING THE GREASE AND OIL OF THE DRIVE MECHANISM (3 YEARS (11,520 HOURS) CHECKS)...................................................................17 REPLACING THE J1-AXIS J1-AXIS MOTOR M1 ................... 46
DAILY CHECKS.............................................................1 FAILURES, CAUSES AND MEASURES....................30 FIGURE OF DRIVE MECHANISM.............................44 FIRST 1-MONTH 1-MONTH (320 (320 HOURS) HOURS) CHECKS ................... 4 FIRST 3-MONTH 3-MONTH (960 (960 HOURS) HOURS) CHECKS ................... 5 FIXTURE POSITION MASTER.................................123
REPLACING THE THE J1-AXIS REDUCER ...................... 48 REPLACING THE J2 COVER (OPTION)....................82 REPLACING THE J2-AXIS J2-AXIS MOTOR M2 ................... 52 REPLACING THE THE J2-AXIS REDUCER ...................... 53 REPLACING THE J3-AXIS J3-AXIS MOTOR M3 ................... 56
REPLACING THE THE J3-AXIS REDUCER ...................... 63 REPLACING THE J4 COVER (OPTION)....................84 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L, ARC Mate 100iCe, M-10iAe, ARC Mate 100iCe/6L, M-10iAe/6L) ....................... ....................... ................ 69 REPLACING THE J4-AXIS GEARBOX (ARC Mate 100iC/10S, M-10iA/10S) A/10S) ................ ........................ ................ ................ ...........72 ...72 REPLACING THE J4-AXIS MOTOR M4 (ARC Mate 100iC, M-10iA, ARC Mate 100iC/6L, M-10iA/6L) A/6L) ..66 REPLACING THE J4-AXIS MOTOR M4 (ARC Mate 100iC/10S, M-10iA/10S) A/10S) ................ ........................ ................ ................ ...........68 ...68 REPLACING THE J5-AXIS J5-AXIS MOTOR M5 ................... 75 REPLACING THE J6-AXIS J6-AXIS MOTOR M6 ................... 77
GENERAL..............................................................30,119 Grease replacement procedure for the reducer (J1 to J3-axis) ..................... ....................... ....................... ....24 INSULATION ABOUT ABOUT ARC WELDING ROBOT ....145 INSULATION AT THE THE WRIST WRIST ........................ .........145
J3-axis reducer mounting phase auto adjusting function ....................................................................................66 MAINTENANCE TOOLS.............................................10 MASTERING ....................... ....................... ................ 119 MOUNTING BOLT TORQUE TORQUE LIST LIST ....................... ...144
REPLACING WRIST UNIT ..................... .................... 79 RESETTING ALARMS AND PREPARING FOR MASTERING...........................................................122
SAFETY PRECAUTIONS ....................... .................... s-1 SEALANT APPLICATION ..................... ..................... 97
NOTES FOR ASSEMBLING ASSEMBLING CABLES WITH WITH M/H CONDUIT..................................................................85
i-1
INDEX
B-82755EN/04
SPARE PARTS LIST...................................................133
TROUBLESHOOTING TROUBLESHOOTING ..................... ........................ ....30
i-2
REVISION RECORD
B-82755EN/05
REVISION RECORD Edition
Date Date
Contents • •
05
May.,2011
• • • • •
04
Jun.,2010
• • • •
03
Jul., 2009
• • • •
02
Aug., 2008
• • •
01
Addition of ARC Mate 100iCe, M-10 Ae, i Ae, ARC Mate 100iCe/6L,M-10 Ae/6L i Ae/6L Addition of stop type of robot Change of replacing method of oil of J4-axis Addition oiling method method by oil injection gun Correction of daily checks. Correction of errors Addition of ARC Mate 100iC/10S and M-10 A/10S i A/10S Addition of of new specification of ARC Mate 100iC,ARC Mate 100iC/6L M-10 A,M-10 i A,M-10 A/6L i A/6L Addition of replacing method of fluoric resin ring Correction of errors Change replacing replacing procedure procedure of J3-axis reducer,J5,J6-axes reducer,J5,J6-axes motor and wrist wrist unit Addition of replacing method of grease and and oil for top mount and and angle mount Addition of No dust M/H conduit Correction of errors Addition of M-10 A/6L i A/6L Correction of cable replacement Addition of Method of fixture fixture position master Correction of errors
Mar., 2008
r-1
B-82755EN/05
*
B -
8 2 7 5 5 E N /
0 5 *
