1axis Positioner Maintenance Manual [B-82545EN 02]

FANUC

1-Axis

SERVO

POSITIONER

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content.

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content.

B-82545EN/02

1

SAFETY PRECAUTIONS

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

SAFETY PRECAUTIONS

1.1

B-82545EN/02

OPERATOR SAFETY Operator safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. consideration must be made to ensure operator safety.

Careful

(1) Have the robot system operators attend the training courses held  by FANUC. FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot and positioner are stationary, it is possible that the robot is still ready to move state and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure operator safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion. (3) Install a safety fence with a gate so that no operator can enter the work area without passing through the gate. Equip the gate with an interlock that stops the robot when the gate is opened.

B-82545EN/02

SAFETY PRECAUTIONS

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

SAFETY PRECAUTIONS

1.1.1

B-82545EN/02

Operator Safety The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) When the robot and positioner do not need to operate, turn off the  power of the robot controller or press the emergency stop button  before work. (2) The operator must operate the robot system outside the work area of the robot or positioner. (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and also to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operator's reach. The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation when the external EMERGENCY STOP button is pressed. See the diagram below for connection. External EMERGENCY STOP button

Panel board

B-82545EN/02

1.1.2

SAFETY PRECAUTIONS

Safety of the Teach Pendant Operator When teaching the robot and positioner, the teach pendant operator needs to enter the work area of the robot or positioner. The teach  pendant operator must give special consideration to safety. (1) When it is not necessary to enter the work area of the robot or  positioner, perform work outside the work areas. (2) Before teaching work, check that the robot, positioner, and  peripheral device are not placed in a dangerous or abnormal state. (3) When it is necessary to enter the work area of the robot or  positioner for teaching work, check the place and state of safety apparatus such as the emergency stop button and dead man's switch of the teach pendant. The teach pendant supplied by FANUC is provided with a teach pendant enable switch and a deadman's switch in addition to the EMERGENCY STOP button. The functions of each switch are as follows. EMERGENCY STOP button : Pressing this button stops the robot in an emergency, irrespective to the condition of the teach pendant enable switch. Deadman's switch : The function depends on the state of the teach pendant enable switch.

SAFETY PRECAUTIONS

B-82545EN/02

(4) The teach pendant operator needs to exercise special caution to  prevent other people from entering the work area of the robot or  positioner.

NOTE In addition to the above, the teach pendant enable switch and the deadman's switch also have the following function.By pressing the deadman's switch while the enable switch is on, the emergency stop factor (normally the safety gate) connected to the controller is invalidated. In this case, it is possible for an operator to enter the fence during teach operation without pressing the EMERGENCY STOP button. In other words, the system understands that the combined operations of pressing the teach pendant enable switch and pressing the deadman's switch indicates the start of teaching. The teach pendant operator should be well aware that the safety gate is not functional under this condition and bear full responsibility to ensure that no one enters the fence during teaching.

B-82545EN/02

SAFETY PRECAUTIONS

(6) To start the robot by the operator's panel, confirm that there is no  people near the robot or positioner and that there is no abnormality. (7) When a program is completed, be sure to carry out a test run according to the procedure below. (a)

Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the automatic operation mode. (8) While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

SAFETY PRECAUTIONS

1.1.3

B-82545EN/02

Safety During Maintenance For the safety of maintenance personnel, pay utmost attention to the following. (1) Except when specifically necessary, turn off the power of the controller while carrying out maintenance. Lock the power switch, if necessary, so that no other person can turn it on. (2) When disconnecting the pneumatic system, be sure to reduce the supply pressure. (3) Before the start of teaching, check that the robot and positioner and its peripheral devices are all in the normal operating condition. (4) When performing maintenance within the work area of the robot or positioner with the power on, maintenance personnel needs to indicate that maintenance is in progress and exercise caution to  prevent anyone from starting the robot accidentally. (5) Do not operate the robot in the automatic mode while anybody is in the robot work area. (6) When it is necessary to maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed. (7) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful

B-82545EN/02

SAFETY PRECAUTIONS

1.2

SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1

Precautions in Programming (1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal. (3) In a system in which the robot or positioner operates in sync with  peripheral devices, exercise caution against mutual interference. (4) The interlock between the robot and peripheral devices is necessary to check the states of all devices in the system using the robot or positioner, so that the robot and positioner can be stopped as needed.

1.2.2

Precautions for Mechanism (1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust.

SAFETY PRECAUTIONS

1.3

SAFETY OF THE ROBOT MECHANISM

1.3.1

Precautions in Operation

B-82545EN/02

(1) When operating the robot or positioner in the jog mode, keep an appropriate speed so that the operator can take a responsive action in any eventuality. (2) Before pressing the jog key, be sure to understand in advance how the robot or positioner operates by the key.

1.3.2

Precautions in Programming (1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other. (2) Be sure to specify a certain work origin in a motion program for the robot or positioner and make sure that the motion program starts from and ends at the origin. This makes it clear at a glance whether the robot has completed work.

1.3.3

Precautions for Mechanisms

B-82545EN/02

SAFETY PRECAUTIONS

1.4

SAFETY OF THE END EFFECTOR

1.4.1

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

1.5

SAFETY IN MAINTENANCE (1) Never enter the work area of the robot or positioner during operation. When entering the work area of the robot or positioner for inspection or maintenance, turn off the power. (2) If it is necessary to enter the robot work area with the power turned on, first press the EMERGENCY STOP button on the operator's  box. (3) When replacing or reinstalling components, take care to prevent foreign matter from entering the system. When replacing the parts

SAFETY PRECAUTIONS

1.6

WARNING LABEL (1) Greasing and degreasing label

Fig. 1.6 (a) Greasing and Degreasing Label

Description

B-82545EN/02

B-82545EN/02

SAFETY PRECAUTIONS

(2) Step-on prohibitive label

Fig. 1.6 (b) Step-on Prohibitive Label

Description Do not step on or climb the robot or controller as it may adversely affect the robot and positioner and you may get hurt if you lose your footing as well.

SAFETY PRECAUTIONS

B-82545EN/02

(4) Transportation label

>200kg >200kg >150kg

Fig. 1.6 (d) Transportation label (300kg load capacity type)

Description When transporting the positioner, observe the instruction on the transportation label. The above label includes the following

B-82545EN/02

SAFETY PRECAUTIONS

>600kg >600kg >450kg

Fig. 1.6 (e) Transportation label (1000kg load capacity type)

Description

B-82545EN/02

PREFACE

PREFACE This manual describes maintenance and connection work for the servo  positioner. Before replacing parts, check the specifications of the mechanical unit. Model name

Mechanical unit specification No.

1-Axis Servo Positioner (300kg)

A05B-1220-J101

1-Axis Servo Positioner (1000kg)

A05B-1220-J102

 

PREFACE

B-82545EN/02

Specification Item Motion range Maximum operation speed Max. load capacity  Allowable load moment  Allowable bending moment  Allowable load inertia Drive method Weight Follower unit (option) weight Installation environment

Specifications 740  (-370  to +370 ) 12.9 rad (-6.45 rad to +6.45 rad) Continuous rotation is available. 160 /sec 2.79 rad/sec 120 /sec 2.09 rad/sec °

°

°

°

°

300 kg 36 kgf . m

353 N . m

250 kgf . m

2450 N . m

1000 kg 160 kgf . m 1,568 N . m 2100 kgf . m

20,580 N . m

2 2 2 2 2,350 kgf . cm . s 240 kg . m 4,700 kgf . cm . s 460 kg . m Electric servo drive by AC servo motor About 85 kg About 280kg  About 40 kg -

 Ambient temperature :  Ambient humidity : :

Vibration

:

0 - 45 C Normally: 75%RH or less Short time 95%RH or less (within 1 month) (No dew or frost allowed) 2 0.5G (4.9m/s ) or less °

PREFACE

B-82545EN/02

RELATED MANUALS Safety handbook

For the FANUC Robot series, the following manuals are available:

B-80687EN

 All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook R-J3iB Mate Setup and Operations controller manual LR ARC TOOL B-82094EN LR HANDLING TOOL B-81524EN

Maintenance manual B-81525EN B-81525EN-1 (European specification) R-J3iB controller

Setup and Operations manual

Intended readers :  All persons who use FANUC Robot, system designer Topics : Safety items for robot system design, operation, maintenance Intended readers : Operator, programmer, maintenance person, system designer Topics : Robot functions, operations, programming, setup, interfaces, alarms Use : Robot operation, teaching, system design Intended readers : Maintenance person, system designer Topics : Installation, connection to peripheral equipment, maintenance Use : Installation, start-up, connection, maintenance Intended readers : Operator, programmer, maintenance person, system

TABLE OF CONTENTS

B-82545EN/02

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

MAINTENANCE

1

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

2

PREVENTIVE MAINTENANCE............................................................... 5

3

2.1

DAILY INSPECTION ..................................................................................... 6

2.2

QUARTERLY INSPECTION.......................................................................... 8

2.3

ONE-AND HALF-YEAR PERIODIC INSPECTION (5,760 hours).................. 8

2.4

THREE-YEAR PERIODIC INSPECTION (11,520 hours) .............................. 8

2.5

MAINTENANCE TOOLS ............................................................................... 9

PERIODIC MAINTENANCE..................................................................11 3.1

GREASE REPLACEMENT

12

TABLE OF CONTENTS

7

8

6.2

REPLACING THE REDUCER ..................................................................... 53

6.3

SEALANT APPLICATION............................................................................ 55

PIPING AND WIRING ...........................................................................57 7.1

WIRING DIAGRAMS ................................................................................... 58

7.2

CABLING (WHEN THE HARTING CONNECTOR OPTION IS SELECTED)59

CABLE REPLACEMENT ...................................................................... 60 8.1

II

1

POSITIONER OUTLINE DRAWING ..................................................... 65 OUTLINE DRAWING AND OPERATION AREA DIAGRAM ........................ 66

MOUNTING DEVICES ON THE POSITIONER.....................................68 2.1

3

REPLACING CABLES................................................................................. 61

CONNECTION

1.1

2

B-82545EN/02

POSITIONER LOAD CONDITION............................................................... 69

TRANSPORTATION AND INSTALLATION

71

I. MAINTENANCE

B-82545EN/02

1

1.CONFIGURATION

MAINTENANCE

CONFIGURATION Fig. 1 shows the configuration of the mechanical unit. The axis drive mechanism is configured in such a way that the flange  base is rotated by reducing the rotation speed of an AC servo motor with a reducer. The flange base is supported on the base through the reducer. Flange Reducer Base Motor

1.CONFIGURATION 

MAINTENANCE

B-82545EN/02

SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS Table 1 (a) Motor Specification  A06B-0235-B605#S000  A06B-0265-B605#S000

Name S8/4000 αiS22/4000 αi

Load capacity 300kg 1000kg

Table 1 (b) Reducer Specification  A97L-0218-0805#37  A97L-0218-0819

Weight

Load capacity

19.5 kg 91kg

300kg 1000kg

Table 1(c) Gear Specification  A290-7216-X212  A290-7220-X111

Name Center gear Input gear

Load capacity 300kg 300kg

B-82545EN/02

2

MAINTENANCE

2.PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE Daily inspection, periodic inspection, and periodic maintenance can keep the performance of the positioner stable for a long period of time.

NOTE The annual operating time of the 1-axis servo positioner is assumed to be 3840 hours. When using the positioner beyond this annual operating time, correct the maintenance frequency in this chapter, which is determined on assumption that the positioner is used for 3860 hours per year, and perform maintenance as appropriate.

2.PREVENTIVE MAINTENANCE 

2.1

MAINTENANCE

B-82545EN/02

DAILY INSPECTION Clean and maintain each robot component during everyday system operations. At the same time, check the components to see if there is a crack or break in them. Also check and maintain the following items as required. a)

Before automatic operation

No.

Inspection item

1

2

For machines with a

Inspection procedure

Pneumatic pressure check

Make a pneumatic pressure check, using the three-piece pneumatic option shown in Fig. 2.1. If the measured pneumatic pressure does not fall in the range between 0.5 and 0.7 MPa (5 and 7 kg/cm2), make adjustments, using the regulator pressure setting handle.

Check on the amount of oil mist

Put the pneumatic pressure system in operation and check the amount of oil dripping. If the measured amount of oil dripping does not

MAINTENANCE

B-82545EN/02

No. 9

10

Inspection item

2.PREVENTIVE MAINTENANCE Inspection procedure

Reliable operation of peripheral Check to see if the machine equipment operates exactly according to directions from the robot and peripheral equipment. Check on the operation of the See Section 4.2. brake.

2.PREVENTIVE MAINTENANCE 

2.2

MAINTENANCE

B-82545EN/02

QUARTERLY INSPECTION Inspect the following items at regular intervals of about three months. Increase the locations and the frequency of inspection if necessary (or 960 hours operating). No.

2.3

Inspection item

1

Loose connector

2

Loose bolt

3

Debris removal

Inspection procedure Check that the motor connectors or other connectors are not loose. Check that the cover retaining bolts or external bolts are not loose. In particular, check the following three points. 1 axis positioner, Follower unit base fixing bolts Bolts fixing jigs to the flange surface motor cover retaining bolts Remove any spatter, debris, and dust from the mechanical unit.

ONE-AND HALF-YEAR PERIODIC INSPECTION

MAINTENANCE

B-82545EN/02

2.5

2.PREVENTIVE MAINTENANCE

MAINTENANCE TOOLS You should have the following instruments and tools ready for maintenance. a)

Measuring instruments Instrument

Condition

Dial gauge

1/100mm

Calipers

150mm

 b)

Use For positioning precision and backlash measurement

Tools Phillips screwdrivers (large, medium, and small sizes) Flat-blade screwdrivers (large, medium, and small sizes) Box wrenches (M3 to M6) Allen wrenches (M3 to M20) Torque wrench See Table 2.6. Long T wrenches (M5, M6 and M8) Adjustable wrenches (medium and small sizes) Pliers Long-nose pliers Cutting pliers

2.PREVENTIVE MAINTENANCE 

MAINTENANCE

B-82545EN/02

Table 2.5 Bolt size M3 M4 M5 M6 M8 M10 M12 M14 M16

Torque setting value 1.3 Nm (13 kgfcm) 4 Nm (41 kgfcm) 9 Nm (92 kgfcm) 15.6 Nm (159 kgfcm) 37.2 Nm (380 kgfcm) 73.5 Nm (750 kgfcm) 128.4 Nm (1310 kgfcm) 204.8 Nm (2090 kgfcm) 318.5 Nm (3121 kgfcm)

B-82545EN/02

3

MAINTENANCE

3.PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

3.PERIODIC MAINTENANCE 

3.1

MAINTENANCE

B-82545EN/02

GREASE REPLACEMENT The grease for the reducers needs to be replaced every three years or 11,520 hours in the procedure shown below. For greasing points, see Figs. 3.1 (a) and (b). Remove the seal bolts and plugs of the grease outlets shown in Figs. 3.1(a) and (b). Attach the grease nipple supplied with the positioner. Apply the grease specified in Table 3.1(a) and (b) until the old grease is replaced and the new grease is output from the grease outlets. Use grease outlet 1 shown in Figs. 3.1 (a) and (b). Only when grease outlet 1 cannot be used due to the installation state of the jig, use grease outlet 2. At this time, confirm that the same amount of the old grease as that of applied grease has been output to prevent the grease bath from overflowing. After applying grease, release the residual pressure in the grease  bath as instructed by the procedure in Section 3.2.

CAUTION When reusing a grease nipple once used, wind

B-82545EN/02

MAINTENANCE

Seal bolt for grease outlet 2 排脂口2 シールボルト

3.PERIODIC MAINTENANCE

Seal bolt for grease outlet 1 排脂口1 シールボルト

Plug for grease 給脂口 埋栓 inlet

Fig. 3.1 (a) Grease inlet and outlet ( 300kg load capacity) Seal bolt for grease outlet 2 排脂口2 シールボルト Seal bolt排脂口1 for grease outlet 1 シールボルト

3.PERIODIC MAINTENANCE 

MAINTENANCE

B-82545EN/02

CAUTION If you grease incorrectly, the pressure in the grease bath will increase, leading to a broken seal, which will eventually cause grease leakage or malfunction. When greasing, be sure to follow the cautions stated below. 1 Before starting greasing, open the grease outlets (remove bolts and the like from the grease outlets). 2 Using a manual greasing pump, grease gently and slowly. 3 Avoid using a pneumatic pump driven from a factory pneumatic line as much as possible. Even when using a of Table 3.1 (a) and (b) less during application of grease. 4 Be sure to use the specified grease. Otherwise, damage to reducers or a similar abnormality may occur. 5 After applying grease, release the residual pressure within the grease bath as described in the procedure in Section 3.2. 6 Wipe off any grease from the floor and positioner

MAINTENANCE

B-82545EN/02

3.3

3.PERIODIC MAINTENANCE

BATTERY REPLACEMENT A backup battery is used to keep the reference-position data for the  positioner. The battery needs to be replaced at regular intervals of one y ear and half. Follow this procedure for battery replacement. This section describes the battery replacement procedure to follow when the HARTING connector option is selected. Replace the battery on the controller side when the HARTING connector option is not selected. 1)

Keep the power turned on. Press the EMERGENCY STOP button of the robot to keep robot and positioner from moving.

CAUTION Be sure to turn on the power. If the battery is replaced when the power is off, the current position information is lost, so that mastering becomes necessary.

3.PERIODIC MAINTENANCE 

MAINTENANCE

B-82545EN/02

Cap

Battery case

Battery specifications: A98L-0031-0005 (1.5V size-D 4 pcs)

Fig. 3.3 (b) Battery replacement 2

B-82545EN/02

4

MAINTENANCE

TROUBLESHOOTING

4.TROUBLESHOOTING

4.TROUBLESHOOTING 

4.1

MAINTENANCE

B-82545EN/02

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.

B-82545EN/02

4.2

MAINTENANCE

4.TROUBLESHOOTING

PROBLEMS AND CAUSES Table 4.2(a) shows the main mechanical unit problems and their causes . If a cause of remedy is unclear, please contact your FANUC service representative.

Symptom Vibration Noise (Continued)

Table 4.2 (a) Problems and causes Description Cause -The base lifts off the floor plate [Base fastening] as the positioner operates. -It is likely that the positioner base is -There is a gap between the not securely fastened to the floor plate. base and floor plate. -Probable causes are a loose bolt, an -A base retaining bolt is loose. insuffcient degree of surface flatness, or foreign material caught. -If the positioner is not securely fastened to the floor plate, the base lifts the floor plate as the positioner operates, allowing the base and floor plates to strike each other wihich, in turn, leads to vibration. -The rack or floor vibrates [Rack or floor] during operation of the -It is likely that the rack or floor is not

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 tolenrance. -If there is any foreign matter between the base and floor plate, remove it.

-Reinforce the rack or floor to make it more rigid.

4.TROUBLESHOOTING  Symptom Vibration Noise (Continued)

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

MAINTENANCE

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

B-82545EN/02

Measure -Remove the motor, and replace the gear , the bearing, and the reducer. For the spec. of parts and the method of replacement, contact FANUC. -Using the positioner within its maximum rating prevents problems with the drive mechanism. -Regularly changing the grease with a specified type can help prevent problems.

MAINTENANCE

B-82545EN/02

Symptom Vibration Noise (Continued)

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

Cause [Controller, cable, and motor] -If a failure occurs in a controller circuit, preventing control commands from being supplied to the motor normally, or preventing motor information from being sent to the controller normally, vibration might occur. -If the pulse coder develops a fault, vibration might occur because information about the motor position cannot be transferred to the controller accurately. -If the motor becomes defective, vibration might occur because the motor cannot deliver its rated performance. -If a connection cable between them has an intermittent break, vibration might occur. -If the power cable has an i ntermittent break, vibration might occur. -If the power source voltage drops below the rating, vibration might occur.

4.TROUBLESHOOTING Measure -Refer to the Controller Maintenance Manual for troubleshooting related to the controller and amplifier. -Replace the pulse coder for the motor, and check whether the vibration still occurs. -Also, replace the motor, and check whether vibration still occurs. For the method of replacement, contact FANUC. -Check that the positioner is supplied with the rated voltage. -Check whether the sheath of the power cord is damaged. If so, replace the power cord, and check whether vibration still occurs. -Check whether the sheath of the cable connecting the mechanical section and controller is damaged. If so, replace the connection

4.TROUBLESHOOTING  Symptom Vibration Noise (Continued)

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

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

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

MAINTENANCE

Cause [Noise from a nearby machine] -If the positioner is not grounded properly, electrical noise is induced on the grounding wire, preventing commands from being transferred accurately, thus leading to vibration. -If the positioner is grounded at an unsuitable point, its grounding potential becomes unstable, and noise is likely to be induced on the grounding line, thus leading to vibration. -There may be an unusual sound when using other than the specified grease. -Even for the specified grease, there may be an unusual sound during operation at low speed immediately after replacement or after a long period of time. [Mechanical section coupling bolt] -It is likely that overloading or a collision has loosened a mounting bolt in the positioner mechanical section.

B-82545EN/02

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, an usual sound will disappear. -Check that the following bolts are tight. If any of these bolts is loose, apply loctite and tighten it to the appropriate torque. -Motor retaining bolt

MAINTENANCE

B-82545EN/02

Symptom Motor overheating

Description -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.

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

4.TROUBLESHOOTING Measure -The teach pendant can be used to monitor the average current. Check the average current when the robot control program is running. The allowable average current is specified for the positioner according to its ambient temperature. Contact FANUC for further information. -Relaxing the positioner control program and conditions can reduce the average current, thus preventing overheating. -Reducing the ambient temperature is the most effective means of preventing overheating. -Having the surroundings of the motor well ventilated enables the motor to release heat efficiently, thus

4.TROUBLESHOOTING  Symptom Grease leakage

Description -Grease is leaking from the mechanical unit.

 Axis rotation

-An axis rotates because the brake does not function. -An axis rotates gradually when

MAINTENANCE

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

[Brake drive relay and motor] -It is likely that brake drive relay contacts are stuck to each other to

B-82545EN/02

Measure -If a crack develops in the casting, sealant can be used as a quick-fix to prevent further grease leakage. However, the component should be replaced as soon as possible, because the crack might extend. -O-rings are used in the locations listed below. -Motor coupling section -Reducer (case and shaft) coupling section -Oil seals are used in the locations stated below. -Inside the reducer -Seal bolts and nipples are used in the locations stated below. -Grease drain inlet and outlet -Check whether the brake drive relay contacts are stuck to each other. If they are found

MAINTENANCE

B-82545EN/02

Symptom Description Displacement -Displacement occurred after a (Continuted) parameter was changed.

BZAL alarm occured

-BZAL is displayed on the controller screen

Troubles related to arc welding

-Starting of an arc is not good. -An arc is unstable. -Beads are irregular.

Cause [Parameter] -It is likely that the mastering data was rewritten in such a way that the positioner origin was shifted.

-The voltage of the memory backup battery may be low. -The pulse coder cable may be defected. -The welding ground cable may be loosened or broken(NOTE).

4.TROUBLESHOOTING Measure -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.

-Tighten the connection part of the ground cable. -Replace the ground cable.

NOTE  Arc welding troubles may be caused by a welding unit such as a welding power supply or torch. When a trouble occurs, see the manual of each unit to f ind the cause.

4.TROUBLESHOOTING 

4.3

MAINTENANCE

B-82545EN/02

BACKLASH MEASUREMENT

Measurement method 1. 2. 3.

Maintain the positioner in a specified posture. (See Fig. 4.3 (a)) Apply positive and negative loads to each axis as shown in Fig. 4.3(a). Remove the loads and measure the displacement.

Apply positive and negative loads three times and then remove the loads. Calculate the average of the displacements in the second and third measurements as the backlash.

Stop position 0

+10kg -10kg

Firtst step (Do not measure)

4.TROUBLESHOOTING

MAINTENANCE

B-82545EN/02

Table 4.3 (a) Backlash measurement posture and measurement position Measured posture

Measurement position (mm)

0

See fig 4.3(b)

°

Table 4.3 (b) Backlash allowable rattling of each axis (300kg load capacity)  Angle conversion (arc-min) Displacement conversion (mm) Distance from rotation center to measurement position (mm)

2.5 0.127 175

Table 4.3 (c) Backlash allowable rattling of each axis (1000kg load capacity)  Angle conversion (arc-min) Displacement conversion (mm) Distance from rotation center to measurement position (mm)

2.5 0.164 225

NOTE The displacement conversion value indicates play in the direction of rotation from the center of the axis

4.TROUBLESHOOTING 

4.4

MAINTENANCE

B-82545EN/02

COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS Adjustments are needed after a component is replaced. The following table lists components and the adjustment items that must be made after their replacement. After replacing a component, make necessary adjustments according to this table. Component replacement or function change

Adjustment item

Cable replacement Battery replacement (The battery should be replaced once 1.5 years.)

Quick mastering Replace the battery with the power kept on. No adjustment is needed.

B-82545EN/02

5

MAINTENANCE

5.ADJUSTMENTS

ADJUSTMENTS Each part of the mechanical units of a positioner is set to the best condition before the positioner is shipped to the customer. The customer does not need to make adjustments on the positioner when it is delivered. If a mechanical unit of the positioner has a large backlash because of a long-term use or component replacement, make adjustments according to this section.

5.ADJUSTMENTS 

5.1

MAINTENANCE

B-82545EN/02

REFERENCE POSITION AND MOVING RANGE Zero point and software motion limits are provided for controlled axis. Exceeding the software motion limit of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit for each axis. The positioner cannot exceed the software motion limit unless there is a failure of the system causing loss of zero point position or there is a system error. Fig. 5.1(a) shows the zero point and motion limit (stroke). Fig. 5.1(b) shows the motion direction ( +/−).

+370° 0° -370°

B-82545EN/02

5.ADJUSTMENTS

MAINTENANCE

+

740° (±370°)

-

Fig. 5.1(b) Axis motion direction

5.ADJUSTMENTS 

5.2

MAINTENANCE

B-82545EN/02

MASTERING

Mastering method There are following five methods of mastering. Table 5.2 Mastering method Fixture position This is performed using a mastering fixture before mastering the machine is shipped from the factory. Zero-position This is performed with all axes set at the 0-degree mastering (eye mark position. A zero-position mark (eye mark) is mastering) attached to each positioner axis. This mastering is performed with all axes aligned to their respective eye marks. Simplified mastering This is performed at a user-specified position. The corresponding count value is obtained from the rotation speed of the pulse coder connected to the relevant motor and the rotation angel within one rotation. simplified mastering uses the fact that the absolute value of a rotation angel within one rotation will not be lost. One-axis mastering One-axis mastering is not used. Mastering data entry Mastering data is entered directly.

MAINTENANCE

B-82545EN/02

5.2.1

5.ADJUSTMENTS

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

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

Procedure 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[Mater/Cal] from the menu. 6 Select the desired mastering type from the [Master/Cal] menu.

2

Toreset the “Servo 062 BZAL” alarm, follow steps 1 to 5.

5.ADJUSTMENTS 

5.2.2

MAINTENANCE

B-82545EN/02

Fixture position master Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering fixture is used. Fixture position mastering is not required in daily operations because it is factory-performed. When mastering the positioner, arrange the positioner to meet the following conditions. - Make the positioner mounting base horizontal. (Set the positioner mounting surface so that the levelness of the entire surface is 1 mm or less.) - Remove the hand and other parts form the wrist. - Set the positioner in the condition protected from an external force.

CAUTION

Be extremely careful in moving the positioner during mastering because an axis movement range is not checked.

5.ADJUSTMENTS

MAINTENANCE

B-82545EN/02

Assembling mastering fixtures Attach the mastering fixture to the positioner as shown in Fig. 5.2.2 (a) to (e). Remove the seal from the mastering fixture attaching surface. Be sure to restore the original condition after completion of mastering. PIN D A290-7220-X956 Bolt M10X20(2pcs) BOLT M5X16 CLAMP A290-7022-X954

MASTERING FIXTURE A A290-7220-X951

PIN C A290-7220-X955

Mastering fixture B A290-7220-X952

5.ADJUSTMENTS 

MAINTENANCE

BOLT M5X16

MASTERING FIXTURE A A290-7220-X957 PIN A A290-7220-X953 PIN B A290-7220-X954 BOLT M8X20(2pcs)

CLAMP A290-7022-X954

B-82545EN/02

B-82545EN/02

MAINTENANCE

5.ADJUSTMENTS

Fig. 5.2.2 (d) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity) THE DIRECTION OF PIN O 6

THE DIRECTION OF PIN O10

Fig. 5.2.2 (e) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity)

5.ADJUSTMENTS 

MAINTENANCE

B-82545EN/02

Mastering 1 2 3 4

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

G2

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

Calibrate key select? [NO]

1%

5.ADJUSTMENTS

MAINTENANCE

B-82545EN/02

6

Select “ 1 FIXTURE POSITION MASTER” and Press F4, YES.  AUTO SYSTEM Master/Cal

G2

JOINT

1%

TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data : <

0.0000> < 90.0000> <

0.0000>

<

0.0000> <

0.0000>

[ TYPE ]

LOAD

0.0000> <

RES_PCA

DONE

5.ADJUSTMENTS 

MAINTENANCE

9

B-82545EN/02

Restore brake control. Reset system variables $PARAM_GROUP.$SV_OFF_ALL and $PARAM_GROUP.$SV_OFF_ENB to their original values, and turn the power off and then back on. 10 After mastering, update the mastering data listed in the factory-supplied data sheet with new mastering data ($DMR_GROUP.$MASTER_COUN [*]). ([*] is the axis number of the positioner.).

5.2.3

5.ADJUSTMENTS

MAINTENANCE

B-82545EN/02

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

Procedure Mastering to Zero Degrees Step

1 2 3 4

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

G2

JOINT

TORQUE = [ON ] 1 FIXTURE POSITION MASTER

1%

5.ADJUSTMENTS 

MAINTENANCE

6

B-82545EN/02

Select Zero Position Master.  AUTO SYSTEM Master/Cal

G2

JOINT

1%

TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data:

[ TYPE ]

LOAD RES_PCA

DONE

MAINTENANCE

B-82545EN/02

9

5.ADJUSTMENTS

Reset the brake control release settings to the original state. Set system variables $PARAM_GROUP, $SV_OFF_ALL, and $SV_OFF_ENB to their original values, then turn off then back on the power.

A

DETAIL A

5.ADJUSTMENTS 

5.2.4

MAINTENANCE

B-82545EN/02

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

CAUTION

1 Simplified mastering can be used, if the pulse count value is lost, for example, because a low voltage has been detected on the backup battery for the pulse counter. 2 Simplified mastering cannot be used, after the pulse coder is replaced or after the mastering data is lost from the robot control unit. 3 This operation cannot be performed if mastering data

5.ADJUSTMENTS

MAINTENANCE

B-82545EN/02

3 Set quick master ref? [NO]

4

Release brake control, and jog the positioner to the simplified mastering reference position. Move the cursor to SET QUICK MASTER REF and press ENTER. Press F4, YES.

Procedure Quick Mastering Step

1

Display the Master/Cal screen  AUTO SYSTEM Master/Cal

JOINT

1%

TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE

5.ADJUSTMENTS 

5.2.6

MAINTENANCE

B-82545EN/02

Mastering Data Entry Method Step

1 2

Select [6 SYSTEM] and press ENTER. Select [Variable]. The system variable screen appears.

3

Change the mastering data. The mastering data is saved to the $DMR_GRP(∗).$MASTER_COUN system variable.(∗ is the axis number of the positioner.)

5.ADJUSTMENTS

MAINTENANCE

B-82545EN/02

5

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

G2

SYSTEM ｼｽﾃﾑ ﾍﾝｽｳVariables

JOINT ｶｸｼﾞｸ

$DMR_GRP[2].$MASTER_COUN 1

[1]

95678329

2

[2]

0 10223045

3

[3]

0

4

[4]

0

5

[5]

0

6

[6]

0

7

[7]

0

8

[8]

0

9

[9]

0

ｶﾞﾒﾝ ] [ TYPE

1% 1/9

5.ADJUSTMENTS 

5.2.7

MAINTENANCE

B-82545EN/02

Confirming Mastering 1)

2)

Confirming that mastering was performed normally Usually, positioning is performed automatically when the power is turned on. To confirm that mastering was performed normally, normally, check that the current-position display matches the actual position of the positioner, using this procedure. a) Replay the taught operation of the positioner to set zero degrees, and visually check that the zero-degree position marks shown in Fig. 5.2.3 (a) and (b) are aligned.  b) Replay a specific portion of the program, and check that the  positioner has moved to the taught position. Possible alarms in positioning The following paragraphs describe alarms that may occur in  positioning and explain how to handle them. a) BZAL alarm

B-82545EN/02

6

6. COMPONENT REPLACEMENT AND ADJUSTMENTS

MAINTENANCE

COMPONENT REPLACEMENT ADJUSTMENTS

AND

Adjustments are needed after a component is replaced. The following table lists components and the adjustment items that must be made after the components are replaced. After replacing a component, make necessary adjustments according to this table. Replacement component Motor Reducers

Adjustment item (a) Mastering (a) Mastering

NOTE Be very careful when dismounting and mounting the heavy components that are listed below. Component

Weight (about)

Load capacity

6. COMPONENT REPLACEMENT AND   ADJUSTMENTS

6.1

MAINTENANCE

B-82545EN/02

REPLACING THE MOTOR

In the case of 300kg load capacity 1 2 3

4 5 6

7 8

Turn off the power to the controller. Remove the four M8 ×12 bolts and remove the motor cover. (Only when the motor cover option is selected) After removing the battery box fixing plate while referencing Fig. 6.1 (b), remove the four M6 ×10 bolts and remove the connector  box. (Only when the HARTING connector option is selected) Remove the motor connector. Remove the four M8 ×20 motor mounting bolts and washer and remove the motor. Attach the input gear to a new motor, and reverse the removal steps to mount the motor. Replace the O-rings with new ones, and  put the new O-rings in place. See Fig. 6.1 (a) for the tightening torque and Loctite application. Supply the grease bath with the specified grease as described in Section 3.1. Perform mastering while referencing Chapter 5.

MAINTENANCE

B-82545EN/02

6. COMPONENT REPLACEMENT AND ADJUSTMENTS

BATTERY BOX BOLT M6X10,4pcs

PLATE FOR FIXATION OF BATTERY BOX Fig. 6.1 (b) Removing the connector box (when the HARTING connector option is selected)

In the case of 1000kg load capacity

6. COMPONENT REPLACEMENT AND   ADJUSTMENTS

Nut Loctite ナット 242 ロックタイト242塗布 Tightening Torque 3.2N.m 締付トルク3.2N.m

MAINTENANCE

B-82545EN/02

Draw bolt ドローボルト ロックタイト242塗布 Loctite 242 締付トルク 118N.m Ti htenin Tor ue 118N.m Oリング O ring アルバニヤグリースS2を塗布  Alvania rease S2 ワッシャ,4個 Washer 4 cs ボルト Bolt M12×30.4pcs M12X30,4本 Motor モータ

Washer ワッシャ CCリング ring

Motor cover モータカバー (Motor cover option is (モータカバーオプション選択時) selected.

Bearing ベアリング

インプットギヤ Input gear

Bolt ボルト Connector box M8X12,4本 M8×12.4pcs (Harting connector option(ハーテイングコネクタオプション又は  モータカバーオプション選択時) (Harting connector option or 分線箱 is setected.) motor cover option is selected.) (ハーテイングコネクタオプション選択時)

バッテリボックス固定用プレート Plate for fixation of Battery (ハーテイングコネクタオプション選択時)

Box

(Harting connector option is setected.)

Fig. 6.1 (c) Replacing the motor (1000kg load capacity)

Replacing parts (300kg load capacity)

MAINTENANCE

B-82545EN/02

6.2

6. COMPONENT REPLACEMENT AND ADJUSTMENTS

REPLACING THE REDUCER

In the case of 300kg load capacity 1 2 3 4 5 6

Remove the motor as section 6.1. Remove the covers, bolts, insulators A and B, collars, flange, and insulater in that order. Pull the pipe out of the reducer. Remove the 11 M10X45 bolts with washers that fasten the reducer on the base, and remove the reducer. Remove the gear. Reverse the removal steps to mount a new reducer. Replace the O-rings with new ones, and put the new O-rings in place. Be

careful not to damage the oil seal. 7 8 9 Bolt ボルト M10×45.11pcs

See Fig. 6.2 (a) for the tightening torque and Loctite application. Install the motor as section 6.1. Supply the grease bath with the specified grease as described in Section 3.1. Perform mastering while referencing Chapter 5.

OOリング ring  Alvania grease S2 アルバニヤグリースS2を塗布

Flange フランジ Washer plate 3pcs

6. COMPONENT REPLACEMENT AND   ADJUSTMENTS

MAINTENANCE

B-82545EN/02

In the case of 1000 kg load capacity 1 2 3 4 5

6 7 8 Bolt ボルト M16×50 15pcs Loctite M16X50,15本 262Nm ロックタイト 262Nm Tightening Torque318.5Nm 締付けトルク 318.5N.m

Bolt M12×85 16pcs ボルト Loctite 262 M12X85,16本 ロックタイト262塗布 Tightening Torque

Remove the motor as described in Section 6.1. Remove the covers, bolts, washers, insulators A and B, flanges, insulators C in that order. Remove the 15 bolts (M16 ´ 50) that fix the reducer and base and then remove the reducer and the components ahead of it. Remove the 16 bolts (M12 ´ 85) and washers that secure the reducer and adapter and remove the reducer from the adapter. Apply sealant to a new reducer as described in Section 6.3 and assemble these components in the reverse order. Replace the O-rings with new ones and put them in place. Be careful not to damage the oil seal. For the tightening torque and the application of LOCTITE, see Fig. 6.2 (b). Mount the motor as described in Section 6.1. Supply the grease bath with the specified grease as described in Section 3.1. Perform mastering as described in Chapter 5. Oリング O ring アルバニヤグリースS2を塗布  Alvania grease S2

Pipe パイプ

Insulator B 18pcs インシュレータB,18個 (Insert after the insulator A.) インシュレータAの後に入れる事 インシュレータA,18個 Insulator A 18 cs Washer 18pcs

MAINTENANCE

B-82545EN/02

6.3

6. COMPONENT REPLACEMENT AND ADJUSTMENTS

SEALANT APPLICATION

Washing and degreasing the surfaces to be sealed 1

2 3 4

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

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

Applying sealant 5

Make sure that the reducer and the arm are dry (with no alcohol

6. COMPONENT REPLACEMENT AND   ADJUSTMENTS

MAINTENANCE

B-82545EN/02

B-82545EN/02

7

MAINTENANCE

PIPING AND WIRING

7.PIPING AND WIRING

7.PIPING AND WIRING 

7.1

MAINTENANCE

B-82545EN/02

WIRING DIAGRAMS Fig. 7.1 shows the wiring in the mechanical unit when the HARTING connector option is selected. The controller and motor are directly connected to each other when the HARTING connector option is not selected. Connector panel K102

Motor M1BK M1M K101

+

Battery -

M1P

MAINTENANCE

B-82545EN/02

7.2

7.PIPING AND WIRING

CABLING (WHEN THE HARTING CONNECTOR OPTION IS SELECTED) Fig. 7.2 shows the cabling in the mechanical unit when the HARTING connector option is selected. (There are no cables in the mechanical unit when the HARTING connector option is not selected.)

K101 K101 Pulse coder cable パルスコーダケーブル K102 K102 Motor cable モータケーブル

8.CABLE REPLACEMENT 

8

MAINTENANCE

B-82545EN/02

CABLE REPLACEMENT If a cable is broken or damaged, replace it according to the procedure described in this chapter.

Cautions in handling the pulse coder cable When transporting, installing, or maintaining the positioner, do not detach the pulse coder 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, pulse coder, reducer, or cable.

BATTERY BACKUP

MAINTENANCE

B-82545EN/02

8.1

8.CABLE REPLACEMENT

REPLACING CABLES When the HARTING connector option is not selected, turn off the  power to the controller, directly remove the motor connector, and replace the cables. When the HARTING connector option is selected, use the procedure below to replace the cables. 1 2 3 4

5 6 7

Make sure that the simple mastering reference point is set with reference to Section 5.2.4. Turn off the power to the controller. Remove the motor cover while referencing Chapter 6. Remove the four M6X10 bolts from the battery box fixing plate, and remove the plate together with the battery. Take care not to  break the battery connection cable by excessively pulling it. Remove the three M8X12 bolts that fasten the connector box, and remove the connector box. Remove the motor connector and the cable. Detach the cables from the connector box. The K101 cable can be detached from the connector box by removing the four M4X8  bolts, and the K102 cable can be detached by removing the four M3X8 bolts, housing, and insert.

8.CABLE REPLACEMENT 

MAINTENANCE

Fig. 8.1 (b) Replacing cables 2

B-82545EN/02

II. CONNECTION

B-82545EN/02

1

CONNECTION

1. POSITIONER OUTLINE DRAWING AND OPERATION AREA DIAGRAM

POSITIONER OUTLINE DRAWING When installing peripheral equipment, be careful not to cause interference with the positioner body. For installation, see Section 3.3 and use through holes provided on the base.

1. POSITIONER OUTLINE DRAWING AND   OPERATION AREA DIAGRAM

1.1

CONNECTION

B-82545EN/02

OUTLINE DRAWING AND OPERATION AREA DIAGRAM Figs. 1.1 (a) to (c) show the outer dimensions and the operation area of the positioner, follower unit. (300kg load capacity)

CONNECTION

B-82545EN/02

1. POSITIONER OUTLINE DRAWING AND OPERATION AREA DIAGRAM

4-φ10H8 +0.022 0 貫通 THROUGH 周上等配 EQUALLY SPECIFIED

343

12-M10 貫通 THROUGH 周上等配 EQUALLY SPECIFIED 1         5         °        

     0      6      3

     0      5      3       φ

φ11 深 さ  3 H 7 + 0 0. 0 35    6  D EP    T H 

     5      8      1

  0   3  0  φ

φ   2  7   

118 231

中    0   H     空    O    穴    L   L   径    O    W   φ    6    D    5    I    A    M   

Fig. 1.1 (b) Outline of follower unit (option)

169 205

2. MOUNTING DEVICES ON THE POSITIONER

2

CONNECTION

B-82545EN/02

MOUNTING DEVICES ON THE POSITIONER NOTE Wipe oil off the flange surface before mounting the unit. Otherwise, the unit may be misaligned.

CONNECTION

B-82545EN/02

2.1

2. MOUNTING DEVICES ON THE POSITIONER

POSITIONER LOAD CONDITION Fig. 2.2 shows the positioner load conditions. Use the positioner so that the load condition falls within the range in the table and the allowable load inertia and allowable load moment in the table are satisfied.

300        )      g250        k        (        d200      a      o        l      y150      a120        P

2. MOUNTING DEVICES ON THE POSITIONER

CONNECTION

1000

       )      g        k        (        d      a      o        l      y      a        P

800

700

600

500

Payload vs Payload C.G Displacement(mm)

320 267 229

B-82545EN/02

B-82545EN/02

3

CONNECTION 3.TRANSPORTATION AND INSTALLATION

TRANSPORTATION AND INSTALLATION

3.TRANSPORTATION AND INSTALLATION  CONNECTION

3.1

B-82545EN/02

TRANSPORTATION The positioner can be transported by suspending it. For the 300 kg load capacity, thread a rope through the M10 eyebolts. For the 1000 kg load capacity, thread a rope through the M16 eyebolts. (See Figs. 3.1 (a) and (b).) After installation, remove remove transport equipment.

CAUTION When transporting a positioner, be careful not to damage a motor connector with a sling for lifting the positioner. CAUTION When an end effector and peripherals are installed on a positioner, the center of gravity of the positioner changes and the positioner might become unstable while being transported. If the positioner becomes unstable, remove the tooling and place the positioner into the

CONNECTION 3.TRANSPORTATION AND INSTALLATION

B-82545EN/02

NOTE)1.Weight NOTE)1.Weight of Positioner 85 kg 2.The eyebolts must conform to JIS B 1168 3.Eyebolt :1pcs 4.When you transport positioner, Take out all works. Crane weight capacity :200kg or greater

ROBOT POSTURE ON TRANSPORTATION:Arbitrary

POSITIONER

Transport equipment

Sling weight capacity :200kg or greater

>200kg >200kg >150kg

3.TRANSPORTATION AND INSTALLATION  CONNECTION

3.2

B-82545EN/02

STORING THE POSITIONER When storing the positioner, keep it in the posture with the following  NOTES.

NOTE Before storing a positioner for a long term, take measures for securing the positioner to prevent it from falling. NOTE The flange surface is likely to rust, so apply antirust oil to the flange surface to save it for a long period of time.

CONNECTION 3.TRANSPORTATION AND INSTALLATION

B-82545EN/02

3.3

INSTALLATION (1) Before installation Wipe oil off the flange because it is factory-oiled. Fig. 3.3 (a) to (c) shows the dimensions of the base of the positioner main body and the follower unit . 182

182

6-O14 貫通 THROUGH         7         4

2-O10H8 +0.022 0 貫通 THROUGH

        7         4

        9         2

         1         5

3.TRANSPORTATION AND INSTALLATION  CONNECTION

B-82545EN/02

6-DIA.18 貫通

THROUGH

        6         5

M12ボルト使用         6         1         1

        6         5

USE M12 BOLTS

        1         3

2-DIA.10H8+0.022 0 貫通

THROUGH

87

87

CONNECTION 3.TRANSPORTATION AND INSTALLATION

B-82545EN/02

Fig. 3.3 (d) shows an example of installing the 300kg load capacity type  positioner and the follower unit.(option for 300kg load capacity) In this example, the sole plate is fixed with four M20 chemical anchors (in strength category 4.8), and the positioner base is fastened to the sole  plate with six M12×40 bolts (in strength category 12.9). The follower unit base is fastened with six M12 ×70 bolts (in strength category 12.9) and six GT washers. When compatibility must be maintained in teaching the positioner mechanical unit replacement, use the mounting surface.

NOTE The customer shall arrange for the positioning pin, anchor bolts, and sole plate.

29 47

47

56

350

56 31 350

4-Φ24 THROUGH INSTALLATION BOARD

         0         5         8          1         3

         0        4

(MOUNTING FACE)

        9

FRONT

(MOUNTING FACE)

 

FRONT

        3          1         4

        4

3.TRANSPORTATION AND INSTALLATION  CONNECTION

B-82545EN/02

NOTE - Install the positioner and follower unit so that their axial centers are aligned. For the installation, follow the guidelines provided by the contractor and use a level or three-dimensional measuring instrument to ensure that the positioner and follower unit are centered. The allowable moment for the reducer is 2,450 N•m (250 kgf •m). Install the reducer so as not to exceed the allowable moment by placing the reducer off-center. - Be sure to use the supplied GT washers for the installation of the follower unit. Fig. 3.3 (e) shows an example of installing the 1000kg load capacity type positioner and the follower unit. In this example, the sole plate is fixed with four M20 chemical anchors (in strength category 4.8), and the positioner base is fastened to the sole plate with four M22×40 bolts (in strength category 12.9). The follower unit base is necessary for the customer to be prepared . When compatibility must be maintained in teaching the positioner

B-82545EN/02

CONNECTION 3.TRANSPORTATION AND INSTALLATION

NOTE - When the follower unit is installed in the customer site, the axial centers of the positioner and follower unit must be aligned. For the installation, follow the guidance provided by the contractor and use a level or three-dimensional measuring instrument to ensure that the positioner and follower unit are centered. The allowable moment for the reducer is 20,580 N×m (2100 kgf×m). Install the follower unit so that the allowable moment is not exceeded because it is placed off-center. Fig. 3.3 (c) and Table 3.3(a) and (b) explain what load is put on the base when the positioner is at a rest, accelerating or decelerating, and at an emergency stop.

3.TRANSPORTATION AND INSTALLATION  CONNECTION

3.4

B-82545EN/02

MAINTENANCE CLEARANCE Fig. 3.4 (a) and (b) show the layout of maintenance clearances.

500

         0         5         4

         0

600

CONNECTION 3.TRANSPORTATION AND INSTALLATION

B-82545EN/02

500

         0         7         5

         0         7         5

800

3.TRANSPORTATION AND INSTALLATION  CONNECTION

3.5

B-82545EN/02

ASSEMBLING THE POSITIONER FOR INSTALLATION The robot connection cables are detached from the mechanical unit when the robot is shipped (the cables are connected on the controller side). When the HARTING connector option is not selected, directly connect the cable for direct motor connection to the motor connector. When the HARTING connector option is selected, connect the cables shown in Fig. 3.5 to the connector box of the mechanical unit. During the connection, take care not to pull the HARTING connector cable. In connecting cables between the robot controller and the positioner  body, the customer needs to obtain cable ducts or the like. PP Connect the pulse coder cable from the controller. PM Connect the power cable from the controller

B-82545EN/02

3.6

CONNECTION 3.TRANSPORTATION AND INSTALLATION

INSTALLATION CONDITIONS Table 3.6 lists the installation conditions for the positioner. Table 3.6 Installation conditions Item Pneumatic pressure

Supply air pressure Consumption

 Allowable ambient temperature  Allowable ambient humidity

 Atmosphere Vibration

Specification 2

0.5 to 0.7 MPa (5 to 7 kg/cm ) 2 (set at 0.5 MPa (5 kg/cm )) Maximum instantaneous amount: 150 NI/min (Note 1) 0 to 45°C Regularly:75%RH or below Short period (within one month): 95%RH (maximum) or below No condensation is allowed. High: Up to 1,000 meters above the sea level required, no particular provision for attitude. There shall be no corrosive gas (Note 2). 0.5 G or less

 APPENDIX

B-82545EN/02

A

A.SPARE PARTS LISTS

APPENDIX

SPARE PARTS LISTS Table A (a) Cables (When the HARTING connector option is selected.) Cable No. K101 K102 K101 K102

Specifications A660-8016-T096 A660-8016-T097 A660-8016-T241 A660-8016-T243

Remarks Pulse coder Motor power, brake Pulse coder Motor power, brake

Table A (b) Motor Specifications  A06B-0235-B605#S000  A06B-0265-B605#S000

Model S8/4000 αiS22/4000 αi

Load capacity 300kg 1000kg

Table A (c) Reducer Specifications

Weight

Load capacity

Load capacity 300kg 300kg 1000kg 1000kg

A.SPARE PARTS LISTS 

APPENDIX

B-82545EN/02

Table A (h) Grease Specifications  A98L-0040-0174#1kg

Name

Load capacity

VIGOGREASE RE0

 A98L-0040-0174#4.9kg

300kg 1000kg

Table A (i) Grease nipple Specifications  A98L-0218-0013#A110

Name Grease nipple (1/8)

Table A(j) Seal bolt Specifications  A97L-0218-0417#121515  A97L-0001-0436#2-1D

Use position Outlet 2 (300kg load capacity) Outlet 1,2 (1000kg loac capacity) Outlet 1 (300kg load capacity)

NOTE For the locations of outlet 1 and 2, see I.MAINTENANCE 3.1. Table A (h) Battery Specifications  A98L-0031-0005

Name 1.5V, size D

Q’ty 4 pcs

B-82545EN/01

B

APPENDIX

B. INTRA-MECHANICAL UNIT CONNECTION DIAGRAMS

CONNECTION DIAGRAMS

Fig. B (a) and (b) show the circuit in the mechanical unit when the HARTING connector connector option is selected. When the option is not selected, a direct connection is established from the motor.

B. INTRA-MECHANICAL UNIT   CONNECTION DIAGRAMS

APPENDIX

B-82545EN/01

CONNECTOR PANEL

PM

M TYPE

Hａｎ 15D (2.5SQ 10A) K102

C1 C2 C3 C4 C5

 

B1 B1 B2 B3 B4 B5 G

BKP1 BKM1

A1 J1U A2 J1V A3 J1W A4 J1G A5

Ｇ

A66L-0001-0401#10 (1.25SQ*10C)Φ11.8

PP 21 22 23 24

17 18 19 20

Hａｎ 24DD (2.5SQ 10A)

M TYPE 13 14 15 16

9 +5V(A1)

10 11 12

5 6 7 8

 0V(A1)

1 2 3  SPRQ J1 4 *SPRQ J1

K101

A66L-0001-0464#1 (0.2SQ*4P)Φ6.7

B-82545EN/01

B. INTRA-MECHANICAL UNIT CONNECTION DIAGRAMS

APPENDIX

A63L-0001-0648#810SL3SJ A63L-0001-0653#04A

J1 MOTOR (αiS8/4000) M1 BK 10SL-3P(1.25SQ 13A) A

 BKP1

A B

 J1U  J1V

A63L-0001-0881#1810S A63L-0001-0881#10C

A63L-0001-0848#A10SL1 A63L-0001-0850

B

 BKM1

C D

18-10P  J1W  J1G

M1 M M1 P 8  +5V(A1) 9 10   OV(A1)

C

10SL1(0.3SQ 3A) 4 +6V(BT1) 5 *SPRQ J1 6  SPRQ J1 7  OV(BT1)

1 2 3  SG

B. INTRA-MECHANICAL UNIT   CONNECTION DIAGRAMS

APPENDIX

B-82545EN/01

CONNECTOR PANEL

PM

M TYPE

Hａｎ 15D (2.5SQ 10A) K102

B1 B2 B3 B4 B5 G

C1 C2 C3 C4 C5

BKP1 BKM1

A1 J1U A2 J1V A3 J1W A4 J1G A5

Ｇ

A66L-0001-0401#10 (1.25SQ*10C)Φ11.8

PP 21 22 23 24

17 18 19 20

M TYPE 13 14 15 16

Hａｎ 24DD (2.5SQ 10A) 9 +5V(A1) 10 11 12

5 6 7 8

 0V(A1)

1 2 3  SPRQ J1 4 *SPRQ J1

K101

A66L-0001-0464#1 (0.2SQ*4P)Φ6.7

B-82545EN/01

B. INTRA-MECHANICAL UNIT CONNECTION DIAGRAMS

APPENDIX

A63L-0001-0648#810SL3SJ A63L-0001-0653#04A

J1 MOTOR (αiS22/4000) M1 BK 10SL-3P(1.25SQ 13A) A

 BKP1

A B

 J1U  J1V

A63L-0001-0881#1810S A63L-0001-0881#10C

A63L-0001-0848#A10SL1 A63L-0001-0850

B

 BKM1

C D

18-10P  J1W  J1G

M1 M M1 P 8  +5V(A1) 9

10   OV(A1)

C

10SL1(0.3SQ 3A) 4 +6V(BT1) 5

*SPRQ J1

6  SPRQ J1 7  OV(BT1)

1 2 3  SG

C.PERIODIC INSPECTION TABLE 

C

APPENDIX

B-82545EN/02

PERIODIC INSPECTION TABLE

FANUC 1-AXIS SERVO POSITIONER

Working Check time time (H)

Item

Check the mechanical cable.

1 (damaged or twisted) NOTE1) Check the motor connector

2 (tightness).

Tighten the loosened flange

   t    i   n   u    l   a   c

3 mounting bolts.

Tighten the cover and main

4 bolt.

PERIODIC INSPECTION TABLE

Grease First 3 6 9 amount check months months months 1 year  320 960 1920 2880 3840 4800

2 years 5760

6720

7680

8640

9600 10560

0.2H

―

○

○

○

○

○

○

○

○

○

○

○

0.2H

―

○

○

○

○

○

○

○

○

○

○

○

0.2H

―

○

○

○

○

○

○

○

○

○

○

○

0.5H

―

○

○

○

○

○

○

○

○

○

○

○

C.PERIODIC INSPECTION TABLE

 APPENDIX

B-82545EN/02

3 years

4 years

5 years

6 years

7 years

8 years

11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720 Items

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

1

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

2

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

3

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

4

D.MOUNTING BOLT TORQUE LIST 

D

APPENDIX

B-82545EN/02

MOUNTING BOLT TORQUE LIST If no tightening torque is specified for a bolt, tighten it according to this table.

Recommended bolt tightening torque

Nominal diameter

M3 M4 M5 M6

Unit: Nm (kgf-cm)

Hexagon socket head bolt (steel in strength category 12.9)

Hexagon socket head bolt (stainless)

Tightening torque Upper limit Lower limit

Tightening torque Upper limit Lower limit

1.8(18) 4.0(41) 7.9(81) 14(140)

1.3(13) 2.8(29) 5.6(57) 9.6(98)

0.76(7.7) 1.8(18) 3.4(35) 5.8(60)

0.53(5.4) 1.3(13) 2.5(25) 4.1(42)

Hexagon socket head boss bolt Hexagon socket head flush bolt (steel in strength category 12.9) Tightening torque Upper limit Lower limit 1.8(18) 4.0(41) 7.9(81)

1.3(13) 2.8(29) 5.6(57)

INDEX

B-82545EN/02

INDEX <

<

>

>

ADJUSTMENTS ............................................................29

ONE-AND HALF-YEAR PERIODIC INSPECTION

ASSEMBLING THE POSITIONER FOR

(5,760 hours).................. ....................... ...................... ...... 8

INSTALLATION............................................................82

OUTLINE DRAWING AND OPERATION AREA DIAGRAM ..................... ...................... ...................... .... 66

>

BACKLASH MEASUREMENT ..................... ............... 26 BATTERY REPLACEMENT ........................................15 <

<

>

CABLE REPLACEMENT..............................................60 CABLING (WHEN THE HARTING CONNECTOR OPTION IS SELECTED) ...............................................59 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS.............................................................................28 COMPONENT REPLACEMENT AND ADJUSTMENTS ........................................................................................49 CONFIGURATION..........................................................3

<

>

PERIODIC INSPECTION TABLE ........................ ........ 94 PERIODIC MAINTENANCE ..................... ................... 11 PIPING AND WIRING .................... ....................... ....... 57 POSITIONER LOAD CONDITION ....................... ....... 69 POSITIONER OUTLINE DRAWING............... ............ 65 PREFACE......................................................................p-1 PREVENTIVE MAINTENANCE....... ...................... ....... 5 PROBLEMS AND CAUSES........................... ............... 19 PROCEDURE FOR RELEASING THE GREASE RESIDUAL PRESSURE ...................... ...................... .... 14

INDEX

<

>

Zero Position Mastering..................................................41

B-82545EN/01