S-420i Mechanical Unit Maintenance [B-80505EN_06]

( R--J2 CONTROLLER )

S-420i Maintenance MANUAL

B - 8 0505EN / 06 E FA N U C LT D , 1 9 9 6

B--80505E/06

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

IMPORTANT! Before operating, servicing or in any other way handling the robot, the ”FANUC Robot SAFETY HANDBOOK (B--80687E)” must be thoroughly studied. Consider the following notes in addition to the items described in the SAFETY HANDBOOK. D Please use appropriate lighting (e.g. a handy light) for maintenance work. The lighting shall not create new dangerous situations. D Whenever possible, perform maintenance, inspection and adjusting with the power function off. D When replacing parts, be sure to use those specified by FANUC. D When replacing or installing components, make sure dirt and debris do not enter the system. D Be aware that when you remove a servomotor or brake, the associated axis will fall if it is not supported or resting on a hard stop. D Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked. D If it is necessary to operate the robot during the inspection, pay careful attention to the robot’s motion and be sure to press the EMERGENCY STOP button immediately when necessary. D Be careful not to slip during maintenance by spilling grease. D Do not climb on the robot. D Be careful when touching the hot parts below. (1) Servo motor (CAUTION LABEL fixed) (2) Inside of controller If touching is unavoidable, wear protective garments (heat resistant gloves, etc.). D Do not try to remove any mechanical component from the robot before thoroughly reading and undestanding the procedures in the manual. Doing so can result in serious personal injury and component destruction. D After replacement, be sure to fix all removed parts that include screws. D The motor and reducer are heavy. Be careful when replacing. D After replacing parts or performing adjustment, be sure to test operation according to the following procedure. 1. Using a low motion speed, single step the program for at least one full cycle. 2. Using a low motion speed, test run the program continuously for at least one full cycle.

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SAFETY PRECAUTIONS

B--80505E/06

3. As speed is increased. the path may vary slightly. Run through the program at 5--10% intervals up to 100%. 4. Using the programmed speed, test run the program continuously for at least one full cycle. Make sure all personnel are outside the fence before test running. D After maintenance work, the robot must be clean of oil, water, or debris.

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B--80505E/06

PREFACE

PREFACE

This manual describes the maintenance and connection of the following robot mechanical unit. Product name

Mechanical unit specification number

FANUC Robot S--420i F FANUC Robot S--420i F/2.85 FANUC Robot S--420i W FANUC Robot S--420i S FANUC Robot S--420i L FANUC Robot S--420i R FANUC Robot S--420i R/120

A05B--1313--B201 A05B--1313--B281 A05B--1313--B203 A05B--1313--B241 A05B--1313--B261 A05B--1313--B401 A05B--1313--B402

120kg 120kg 155kg 80kg 75kg 100kg 120kg

FANUC Robot S--420i F FANUC Robot S--420i F/2.85 FANUC Robot S--420i W FANUC Robot S--420i S FANUC Robot S--420i L

A05B--1318--B201 A05B--1318--B281 A05B--1318--B203 A05B--1318--B241 A05B--1318--B261

120kg 120kg 155kg 80kg 75kg

FANUC Robot S--420i F FANUC Robot S--420i F/2.85 FANUC Robot S--420i W FANUC Robot S--420i W/175 FANUC Robot S--420i W/2.85 FANUC Robot S--420i S FANUC Robot S--420i L FANUC Robot S--420i R FANUC Robot S--420i R/120

A05B--1313--B501 A05B--1313--B581 A05B--1313--B503 A05B--1313--B511 A05B--1313--B521 A05B--1313--B541 A05B--1313--B561 A05B--1313--B601 A05B--1313--B602

120kg 120kg 155kg 175kg 155kg 80kg 75kg 100kg 120kg

FANUC Robot S--420i F FANUC Robot S--420i F/2.85 FANUC Robot S--420i W FANUC Robot S--420i S FANUC Robot S--420i L

A05B--1318--B701 A05B--1318--B781 A05B--1318--B703 A05B--1318--B741 A05B--1318--B761

120kg 120kg 155kg 80kg 75kg

Compact type

FANUC Robot S--420i F FANUC Robot S--420i F/2.85 FANUC Robot S--420i W FANUC Robot S--420i L FANUC Robot S--420i R

A05B--1313--B701 A05B--1313--B781 A05B--1313--B703 A05B--1313--B761 A05B--1313--B801

120kg 120kg 155kg 75kg 100kg

Severe dust/liquid protection (Only remote controller)

FANUC Robot S--420i F FANUC Robot S--420i L FANUC Robot S--420i R FANUC Robot S--420i R/120

A05B--1320--B501 A05B--1320--B561 A05B--1320--B601 A05B--1320--B602

120kg 75kg 100kg 120kg

High duty type

Load capacity

Remark

Compact type

With positioning surface

With positioning surface

With positioning surface

With positioning surface

The mechanical unit specification numbers are attached at the following positions. Therefore, read the description in each section when checking.

p--1

PREFACE

B--80505E/06

The attachment position for the mechanical unit specification number

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PREFACE

B--80505E/06

Table Specifications Item

S-420i F

S-420iF/ 2.85

S-420i W

S-420i W/175

Type

Reach

Maximum load capacity Allowable load momentt at wrist *1

Allowable load inerti att wrist tia i t *1

2.4 m

2.85 m

2.4 m

S-420i R

2.4 m

2.85 m

2.25m

3.0m

S-420i R/120

3.1m

Floor mount

Rack mount

J1 axis

360° (6.28rad)

360° (6.28rad)

360° (6.28rad)

360° (6.28rad)

360° (6.28rad)

360° (6.28rad)

360° (6.28rad)

360° (6.28rad)

360° (6.28rad)

J2 axis

142° (2.48rad)

142° (2.48rad)

142° (2.48rad)

142° (2.48rad)

142° (2.48rad)

142° (2.48rad)

142° (2.48rad)

123° (2.15rad)

123° (2.15rad)

J3 axis

135° (2.36rad)

135° (2.36rad)

135° (2.36rad)

135° (2.36rad)

135° (2.36rad)

135° (2.36rad)

135° (2.36rad)

106° (1.85rad)

106° (1.85rad)

J4 axis

600° (10.47rad)

600° (10.47rad)

600° (10.47rad)

600° (10.47rad)

600° (10.47rad)

480° (8.38rad)

600° (10.47rad)

600° (10.47rad)

600° (10.47rad)

J5 axis

260° (4.54rad)

260° (4.54rad)

260° (4.54rad)

260° (4.54rad)

260° (4.54rad)

260° (4.54rad)

260° (4.54rad)

260° (4.54rad)

260° (4.54rad)

J6 axis

720° (12.57rad)

720° (12.52rad)

720° (12.57rad)

720° (12.57rad)

720° (12.52rad)

720° (12.57rad)

720° (12.57rad)

720° (12.57rad)

720° (12.57rad)

J1 axis

100°/sec (1.75rad/ sec)

90°/sec (1.57rad/ sec)

90°/sec (1.57rad/ sec)

90°/sec (1.57rad/ sec)

90°/sec (1.57rad/ sec)

70°/sec (1.22rad/ sec)

100°/sec (1.75rad/ sec)

100°/sec (1.75rad/ sec)

90°/sec (1.57rad/ sec)

J2 axis

110° (1.92rad/ sec)

100° (1.75rad/ sec)

100° (1.75rad/ sec)

100° (1.75rad/ sec)

100° (1.75rad/ sec)

110° (1.92rad/ sec)

110° (1.92rad/ sec)

100° (1.75rad/ sec)

90° (1.57rad/ sec)

J3 axis

100° (1.75rad/ sec)

90° (1.57rad/ sec)

75° (1.31rad/ sec)

75° (1.31rad/ sec)

75° (1.31rad/ sec)

100° (1.75rad/ sec)

100° (1.75rad/ sec)

100° (1.75rad/ sec)

90° (1.57rad/ sec)

J4 axis

210° (3.67rad/ sec)

210° (3.67rad/ sec)

140° (2.44rad/ sec)

140° (2.44rad/ sec)

140° (2.44rad/ sec)

210° (3.67rad/ sec)

210° (3.67rad/ sec)

210° (3.67rad/ sec)

210° (3.67rad/ sec)

J5 axis

150° (2.62rad/ sec)

150° (2.62rad/ sec)

110° (1.92rad/ sec)

110° (1.92rad/ sec)

110° (1.92rad/ sec)

150° (2.62rad/ sec)

150° (2.62rad/ sec)

150° (2.62rad/ sec)

150° (2.62rad/ sec)

J6 axis

210° (3.67rad/ sec)

210° (3.67rad/ sec)

140° (2.44rad/ sec)

140° (2.44rad/ sec)

140° (2.44rad/ sec)

210° (3.67rad/ sec)

210° (3.67rad/ sec)

210° (3.67rad/ sec)

210° (3.67rad/ sec)

80kg

75kg

Wrist

120kg

120kg

155kg

175kg

155kg

100kg

120kg

J3 arm

20kg

20kg

20kg

20kg

20kg

20kg

20kg

20kg

20kg

J2 base

250kg

250kg

250kg

250kg

250kg

250kg

250kg

250kg

250kg

J4 axis

60kgfm (588Nm)

60kgfm (588Nm)

86kgfm (842Nm)

90kgfm (882Nm)

86kgfm (842Nm)

54kgfm (529Nm)

53kgfm (519Nm)

57kgfm (558Nm)

60kgfm (588Nm)

J5 axis

60kgfm (588Nm)

60kgfm (588Nm)

86kgfm (842Nm)

90kgfm (882Nm)

86kgfm (842Nm)

54kgfm (529Nm)

53kgfm (519Nm)

57kgfm (558Nm)

60kgfm (588Nm)

J6 axis

30kgfm (294Nm)

30kgfm (294Nm)

50kgfm (490Nm)

52kgfm (510Nm)

50kgfm (490Nm)

28kgfm (274Nm)

27kgfm (264Nm)

29kgfm (284Nm)

30kgfm (294Nm)

J4 axis

306kgfcms2 (30.0kgm2)

306kgfcms2 (30.0kgm2)

486kgfcms2 (47.6kgm2)

472kgfcms2 (46.3kgm2)

486kgfcms2 (47.6kgm2)

376kgfcms2 (36.8kgm2)

387kgfcms2 (37.9kgm2)

337kgfcms2 (33.0kgm2)

306kgfcms2 (30.0kgm2)

J5 axis

306kgfcms2 (30.0kgm2)

306kgfcms2 (30.0kgm2)

486kgfcms2 (47.6kgm2)

472kgfcms2 (46.3kgm2)

486kgfcms2 (47.6kgm2)

376kgfcms2 (36.8kgm2)

387kgfcms2 (37.9kgm2)

337kgfcms2 (33.0kgm2)

306kgfcms2 (30.0kgm2)

J6 axis

77kgfcms2 (7.5kgm2)

77kgfcms2 (7.5kgm2)

164kgfcms2 (16.1kgm2)

158kgfcms2 (15.5kgm2)

164kgfcms2 (16.1kgm2)

100kgfcms2 (9.8kgm2)

104kgfcms2 (10.1kgm2)

86kgfcms2 (8.4kgm2)

77kgfcms2 (7.5kgm2)

0.4mm

0.4mm

0.4mm

0.4mm

0.4mm

0.4mm

0.4mm

0.4mm

0.4mm

1500kg

1600kg

1500kg

1600kg

1600kg

1500kg

1600kg

1700kg

1700kg

Max. weld force Repeatability Weight

S-420i L

6 axes (J1, J2, J3, J4, J5, J6)

Installation

Maximum speed

S-420i S

Articulated type

Controlled axes

Motion g range

S-420iW/ 2.85

*2

Installation condition

500kg

Ambient temperature : 0 to 45°C Humidity : Normal Short period (One month or less) Vibration : 0.5G (4.9m/s2) or less

75% RH or less 95% RH or less (No dew, nor frost allowed)

NOTE The direction of weld reaction force should always be through the cross point of J4, J5 and J6 axes.

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PREFACE

B--80505E/06

NOTE 1 At maximum payload. Allowable load moment and inertia at wrist are changed by load. 2 Including Controller (i F/i W/i S/i L), Not including controller (i R, i R/120) Table of dust proof water proof performance

MANUALS

Standard model

Severe dust/liquid protection

Wrist + J3 arm

IP55

IP67

Other part

IP54

IP55

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

Safety handbook B--80687E All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook R--J2 controller

Setup and Operations manual SPOT TOOL B--80524E--10 HANDLING TOOL B--80524E--11 SEALING TOOL B--80524E--14 Maintenance manual B--80525E B--80525E--1 (European specification)

Mechanical unit

Maintenance manual

Intended readers : All persons who use FANUC Robot, system designer Topics : Safety items for robot system design, operation, maintenance Intended readers : Operator, programer, maintenance person, system designer Topics : Robot functions, operations, programing, 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 : Maintenance person, system designer Topics : Installation, connection to the controller, maintenance Use : installation, start--up, connection, maintenance

FANUC Robot S--420iF/iL/iW/iR/iS -- Spot welding, general--purpose large robot

B--80505E

WARNING 1 For S--420i of severe dust/liquid protection, set up the regulated air--pressure. Otherwise, not only the sufficient performance of dust proof/water proof can’t be obtained but also the oil seals may be broken. It must be set the air pressure to 0.20.05kgf/cm2. 2 Prepare the dry air for purge line, removed water. The air filter only remove garbage and oil from air flows, can’t remove water and vapor. Moist air will damage to the robot.

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PREFACE

B--80505E/06

NOTE 1 Definitions of the IP protection levels. -- Formal definition of IP67. 6=”dust--tight; no ingress of dust” 7=”protected against the effects of temporary immersion in water; ingress of water in quantities causing harmful effects shall not be possible when the enclosure is temporarily immersed in water under standardized conditions of pressure” -- Formal definition of IP55. 5=”dust protected; ingress of dust is not totally prevented but dust shall not penetrate in a quantity to interfere with satisfactory operation of the apparatus or to impair safety” 5=”protected against water jets; water projected in jets against the enclosure from any direction shall have no harmful effects” -- Formal definition of IP54. 5=’dust protected; ingress of dust is not totally prevented but dust shall not penetrate in a quantity to interfere with satisfactory operation of the apparatus or to impair safety” 4=”protected against splashing water; water splashed against the enclosure from any direction shall have no harmful effects” 2 ”Severe dust/liquid protection” in not retrofittable.

Performance of resistant chemicals and resistant solvents

The following materials can’t use the robot, severe dust/liquid protection model, because they will harm rubber parts (packings, oil seals O--rings). 1)

Organic solvents Aromatic hydrocarbon Petroleum hydrocarbon, ether

2)

Coolant for machine tools

3)

Other liquid or solution, that they will harm NBR.

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I MAINTENANCE

MAINTENANCE

B--80505E/06

1

1. CONFIGURATION

CONFIGURATION

The configuration of the mechanical unit is shown in Fig. 1 (a) to (f).

Fig.1(a) Mechanical unit configuration (S--420iF, W, W/175)

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1. CONFIGURATION

MAINTENANCE

Fig.1(b) Mechanical unit configuration (S--420iF/2.85, S--420iW/2.85)

Fig.1(c) Mechanical unit configuration (S--420iS)

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B--80505E/06

MAINTENANCE

Fig.1(d) Mechanical unit configuration (S--420iL)

Fig.1(e) Mechanical unit configuration (S--420iR)

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1. CONFIGURATION

1. CONFIGURATION

MAINTENANCE

Fig.1(f) Mechanical unit configuration (Compact type)

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B--80505E/06

1. CONFIGURATION

MAINTENANCE

B--80505E/06

1.1 J1--AXIS DRIVE MECHANISM

Fig. 1.1 shows the J1--axis drive mechanism. Rotation of the J1--axis motor (M1)(α22/2000 or αM30/3000HV) is input to the reducer via the center gear, and the output rotates the table. The table is held to the base via a cross roller bearing.

J1 motor (M1) (α22/2000 or αM30/3000HV)

Fig.1.1 J1--axis drive mechanism

1.2 J2/J3--AXIS DRIVE MECHANISM

Fig. 1.2 (a) shows the J2/J3--axis drive mechanism. Rotation of the J2--axis motor (M2)(α22/2000 or αM30/3000HV) is directly fed to the reducer, and the output moves the J2--axis. Rotation of the J3--axis motor (M3)(α22/2000 or αM30/3000HV) is directly fed to the reducer. The reducer output is coupled to the J3--axis link 1 and moves the J3--axis arm via the J3--axis link 2. J3--axis arm

J3--axis link 2

J2--axis arm

J3--axis link 1

J3 motor (M3)(α22/2000 or αM30/3000HV)

J2 motor (M2)(α22/2000 or αM30/3000HV)

J3--axis reducer

J2--axis reducer Fig.1.2(a) J2/J3--axis drive mechanism

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1. CONFIGURATION

MAINTENANCE

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Fig. 1.2 (b) shows the J2/J3--axis drive mechanism on S--420i compact type. The rotation of J3--axis motor is inputted to the reducer via bevel gear. The output of reducer is linked to J3--axis link 1, and the J3--aixs arm is moved via the J3--axis link 2. At the same time, the rotation of J2--axis motor is inputted to the reducer via the bevel gear, and the reducer output moves the J2--axis arm.

Fig.1.2(b) J2/J3--axis drive mechanism (Compact type)

1.3 J4--AXIS DRIVE MECHANISM

Fig. 1.3 shows the J4--axis drive mechanism. Rotation of the J4--axis motor (M4)(α22/1500) is transmitted to the reducer through the center gear, and the reducer output directly rotates the J4--axis (J3--axis arm + wrist unit).

J4--axis reducer (Hollow shaft)

Fig.1.3 J4--axis drive mechanism

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B--80505E/06

1.4 J5/J6--AXIS DRIVE MECHANISM

MAINTENANCE

1. CONFIGURATION

Fig. 1.4 shows the J5/J6--axis drive mechanism. Rotation of the J5--axis motor (M5)(α12/2000) is reduced with four gears and fed to rotate the J6--axis unit. This causes J5--axis to rotate (wrist bending). Rotation of the J6--axis motor (M6)(αM6/300) is directly fed to the reducer and rotates the wrist flange.

Fig.1.4 J5/J6--axis drive mechanism

NOTE An electrically released brake is incorporated in the motors for all axes (J1, J2, J3, J4, J5, and J6 axes) and applies at power off or in an emergency stop.

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1. CONFIGURATION

MAINTENANCE

1.5

1) Motor

MAJOR COMPONENT SPECIFICATIONS

Motor

B--80505E/06

Specifications

Model

Axis

A06B--0147--B675

α 22/2000

A06B--0186--B675#0011

α M30/3000HV

A06B--0147--B675

α 22/2000

A06B--0186--B675#0011

α M30/3000HV

A06B--0147--B675

α 22/2000

A06B--0186--B675#0011

α M30/3000HV

M4

A06B--0146--B675

α 22/1500

J4

M5

A06B--0142--B675#0006

α 12/2000

J5

M6

A06B--0162--B675#0006

α M6/3000

J6

M1 M2 M3

Remark

J1 High duty J2 High duty J3 S--420iW/2.85

2) Reducer Axis

Specifications

Model

J1--axis reducer

A97L--0118--0939#250C--35

S--420i F/W/S/L/R

J2--axis reducer

A97L--0118--0940#250A--118

S--420i F/S/L

J3--axis reducer

A97L--0118--0940#250A--129

S--420i W/R

A97L--0118--0940#250A--141

S--420i R/120

A97L--0118--0941#250A--129

S--420i F/S/L/R

A97L--0118--0941#250A--141

S--420i F2.85/R120

A97L--0118--0941#250A--171

S--420i W

J4--axis reducer

A97L--0118--0936#70C--36

S--420i F/W/S/L/R

J6--axis reducer

A97L--0118--0942#30A--81

S--420i F/S/L/R

A97L--0118--0942#30A--121

S--420i W

3) Gear Axis

Specifications

Model

J1--axis pinion p gear g

A290--7313--X221

S--420i F/W/L/R

J1--axis center gear g

J4--axis pinion p gear g J4--axis center gear g J5--axis gear g 1 assemblyy J5--axis gear g 2 assemblyy J5--axis gear g 3 assemblyy J5--axis gear g 4 J2/J3 gear box assembly

A290--7313--Y221

S--420i S

A290--7313--Z221

S--420i R/120 F/2.85, W/2.85

A290--7313--X222

S--420i F/W/L/R

A290--7313--Y222

S--420i S

A290--7313--Z222

S--420i R/120 F/2.85, W/2.85

A290--7313--X404

S--420i F/S/L/R

A290--7313--Y404

S--420i W

A290--7313--X405

S--420i F/S/L/R

A290--7313--Y405

S--420i W

A290--7313--V521

S--420i F/S/L/R

A290--7313--V524

S--420i W

A290--7313--V522

S--420i F/S/L/R

A290--7313--V525

S--420i W

A290--7313--V523

S--420i F/S/L/R

A290--7313--V526

S--420i W

A290--7313--X508

S--420i F/S/L/R

A290--7313--Y508

S--420i W

A290--7313--V351

S--420i F/W/S/L (Compact type)

4) Others Item

Specifications

Model

Wrist unit (Standard (St d d model) d l)

A290--7313--T501

S--420i F/S/L/R

A290--7313--T503

S--420i W

Wrist unit (S (Severe dust/liquid d t/li id protection) t ti )

A290--7313--T511

S--420i F/L/R

A290--7313--T513

S--420i W

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2

2. PREVENTIVE MAINTENANCE

MAINTENANCE

B--80505E/06

PREVENTIVE MAINTENANCE

Optimum performance of the robot can be maintained for a long time by performing the periodic maintenance procedures presented in this chapter.

2.1

Clean each part, and visually check component parts for damage before daily system operation. Check the following items as the occasion demands.

DAILY CHECKS

1) Before turning on power Item 1

Check items

Check points

When air Air pressure control set is combined

2

Oiler oil quantity

3

Oiler oil level

4

Leakage hose

Check air pressure using the pressure gauge on the air regulator as shown in Fig. 2.1. If it does not meet the specified pressure of 5 -- 7 kgf/cm2 (0.49 to 0.69 MPa), adjust it using the regulator pressure setting handle.

mist Check the drop quantity during wrist or hand motion. If it does not meet the specified value (1 drop/10 -- 20 sec), adjust it using the oiler control knob. Under normal usage the oiler becomes empty in about 10 to 20 days under normal operation. Check to see that the oiler level is within the specified level shown in Fig. 2.1.

from Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.

Oil inlet

Adjusting knob Oiler mist amount check

Oiler Pressure gauge Filter

Regulator pressure setting handle Fig.2.1 Air control set

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2. PREVENTIVE MAINTENANCE

MAINTENANCE

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Severe dust/liquid protection Item

Check items Air pressure

Check air pressure using the pressure gauge on the air filter unit as shown in following figure. If it does not meet the specified pressure of 0.20.05kgf/cm2, adjust it using the regurator pressure setting handle.

Stains of filter elements

Check to see element. If it has harsh stains, change elements. Refer to following item.

Leakage from horse

Check the joints, tubes, etc. for leaks. Repair leaks, or replace parts, as required.

1 2 3

Check points

WARNING For severe dust/liquid protection of the S--420i, set up the regulated air--pressure. Otherwise, not only the sufficient performance of dust proof/water proof cannot be obtained but also the oil seals might be broken. Set the air pressure to 0.20.05kgf/cm2.

2) After automatic operation 5 6

Vibration, abnormal noises, Check whether the robot moves along and about the axes smoothly without unusual and motor heating vibration or sounds. Also check whether the temparature of the motors are excessively high. Changing repeatability

Check to see that the stop positions of the robot has not deviated from the previous stop positions.

7

Peripheral devices for proper Check whether the peripheral devices operate properly according to commands operation from the robot.

8

Brakes for each axis

Check that the end effector drops within 0.2 mm when the power is cut.

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MAINTENANCE

B--80505E/06

2.2 3--MONTH CHECKS Item 1 2

2. PREVENTIVE MAINTENANCE

1) Check the following items once every three months. Additional inspection areas and times should be added to the table according to the robot’s working conditions, environment, etc.

Check items

Check points

Control unit cable

Check whether the cable connected to the teach pendant is unevenly twisted.

Ventilation portion of control unit

If the ventilation portion of the control unit is dusty, tum off power and clean the unit.

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

Check items

Check points

4

Cables used in mechanical unit

5

Cleaning and checking each part

6

Further tightening external main Further tighten the end--effecter mounting bolts and external main bolts. bolts

2.3

Check whether the jackets of the mechanical unit cables are damaged. Also check whether the cables are excessively bent or unevenly twisted. Check that the connectors of the motors and connector panels are securely engaged.See section 7.2. Clean each part (remove chips, etc.) and check component parts for cracks and flaws.

Check the following item once every six months.

6--MONTH CHECKS Item 1

Check items

Check points

Greasing balancer bushing

2.4

Grease to the balancer bushing. Refer to item 3.2.

Check the following items once every year.

ANNUAL CHECKS Item

Check items

Check points

1

Battery

Replace battery in the mechanical unit. Refer to 3.3.

2

Cables used in mechanical unit

Refer to previous item.

3

Cleaning each parts and inspec- Refer to previous item. tion

4

Tightness of major external bolts

5

Greasing of balancer joint bearing Supply grease to the bearing (only for the S--420i R). (See Section 3.2.)

6

Filter element

2.5

Refer to previous item.

Replace filter elements in the air filter unit. Refer to 3.4.

Check the following items once every 3 years.

3--YEAR CHECKS Item

Check items

Check points

1

Replacing grease of each axis, re- Refer to item 3.1 ducer and gear box

2

Greasing to cross--roller bearing

Grease to the required positions. Refer to item 3.2.

13

2. PREVENTIVE MAINTENANCE

2.6 MAINTENANCE TOOLS Instruments Dialgauge accuracy Slide calipers Push/pull tension gauge

MAINTENANCE

B--80505E/06

The following tools and instruments are required for the maintenance procedures contained in this manual. 1) Measuring instruments Accuracy/Tolerance 1/100 mm

Applications Measurement of positioning and backlash

150 mm 10 kgf (98N)

Measurement of backlash

2) Tools Cross--point(+)screwdrivers : Conventional(--)screwdrivers : Hexagonal wrench key sets : (metric) Adjustable wrenches : Pliers Cutting pliers Cutting nippers Double hexagon offset wrench Grease gun Pliers for C--retaining ring Torque wrench Dial indicator and base

2.7 CAUTION STICKERS FOR DAILY CHECKS (ONLY SEVERE DUST/LIQUID PROTECTION)

Large, medium, and small sizes Large, medium, and small sizes M3 -- M16 Medium and small sizes

For severe dust/liquid protection of the S--420i, follow the attached caution stickers, and pay attention to the air pressure and purge and maintenance of the air filter. Place them, where the robot operator can see them easily ; on the front of the R--J2 controller, and the front of operating box near the main switch.

14

MAINTENANCE

B--80505E/06

3

3. PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

3.1 REPLACING GREASE OF THE DRIVE MECHANISM

Replace the grease of the reducers of J1, J2, J3, J4, and J6 axes, and the J5--axis gear box, every three years or 20,000 hours by using the following procedures. 3.1 Grease for 3--year periodical replacement Supply position

Grease name

Quantity

J1--axis reducer

4670 cc (4130g)

J2--axis reducer

1470 cc (1300g)

J3--axis reducer

1470 cc (1300g)

J4--axis reducer J5--axis gear box J6--axis reducer

Kyodo yushi Moly white Re no.00 (Spec.: A98L--0040--0119)

900 cc (800g) 4770 cc (4220g) 370 cc (330g)

J2--axis reducer and gear box (Compact type)

2600 cc (2300g)

J3--axis reducer and gear box (Compact type)

2600 cc (2300g)

1) Replacing procedure of grease to the reducer and the gear box 1 Turn off the power. 2 Remove the grease outlet plug. Also remove the ventilation plug for J5--axis. 3 Apply new grease from the grease inlet until it comes out from the grease outlet. 4 Remount the plug at the grease outlet. NOTE 1 Be sure to use the procedure described in this manual when supplying grease at the grease nipple. If an attempt is made to supply grease without unplugging the grease outlet, the seal may be broken, and grease leakage may result. 2 Check for grease leakage due to the broken seal if one of the following occurs when supplying new grease at the grease inlet: . Old grease is slow in coming out of the grease outlet. . Very little old grease comes out of the grease outlet. 3 To prevent accidents caused by slipping, completely remove any excess grease from the floor or robot.

15

3. PERIODIC MAINTENANCE

MAINTENANCE

Fig.3.1 (a) Replacing grease of J1--axis reducer (S--420iF/W/S/L)

Fig.3.1 (b) Replacing grease of J1--axis reducer (S--420iR)

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B--80505E/06

MAINTENANCE

3. PERIODIC MAINTENANCE

(Standard type)

(Compact type) Fig.3.1 (c) Replacing grease of J2/J3--axis reducer

17

3. PERIODIC MAINTENANCE

MAINTENANCE

Fig.3.1 (d) Replacing grease of J4--axis reducer

Fig.3.1 (e) Replacing grease of J5--axis gear box

Fig.3.1 (f) Replacing grease of J6--axis reducer

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MAINTENANCE

3. PERIODIC MAINTENANCE

When replacing or supplying grease, orient the robot as shown in Fig 3.1 (g). For the S--420i R, position the robot to the zero--degree attitude.

Fig.3.1 (g) Greasing posture (S--420iF/W/S/L)

19

3. PERIODIC MAINTENANCE

MAINTENANCE

3.2

B--80505E/06

Supply grease to the parts periodically. If the robot is installed in a severe environment, apply grease whenever necessary. If water splashes on the robot, apply grease immediately. Fig. 3.2(a), (b) and Table 3.2(a) show greasing points. Table 3.2 (b) Shows substitute greases.

GREASING

Table3.2 (a) Greasing points Positions

Grease

Amount

Method

J1--axis cross roller bearing

40 cc each (2 locations)

Supply to the grease nipple

Balancer

100 cc each (2 locations)

Supply to the grease nipple

10 cc each (4 locations) (S--420iR has 2 locations)

Supply to the grease nipple

J2/J3--axis joint bearing

20 cc each (2 locations)

Supply to the grease nipple

Balancer joint bearing (Only for S--420iR)

20 cc each (2 locations)

Supply to the grease nipple

Balancer bushing SHELL ALVANIA No. 2 (Spec: A97L--0001--0179#2)

Greasing interval Every 3 years Every 3 years Every 6 months

Every 3 years Every year

Table3.2 (b) Substitutes for ALVANIA NO.2 MOBIL OIL

MOBILACK GREASE NO.2

NIPPON OIL

EPNOC NO.2

ESSO STANDARD

VICON NO.2

IDEMITSU KOHSAN

DAPHNE COLONEX GREASE NO.2

MITSUBISHI

DIAMOND MULTIPURPOSE GREASE NO.2

COSMO OIL

LIMAX NO.2

Fig.3.2 (a) Greasing points (S--420iF/W/S/L)

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MAINTENANCE

Fig.3.2 (b) Greasing points (S--420iR)

21

3. PERIODIC MAINTENANCE

3. PERIODIC MAINTENANCE

3.3 REPLACING BATTERY

MAINTENANCE

B--80505E/06

The position data of each axis is preserved by the backup battery. The battery needs to be periodically replaced every year. Also use the following procedure to replace when the backup battery voltage drop alarm occurs. 1

2 3 4 5

Keep the power on. Press the EMERGENCY STOP button to prohibit the robot motion. Replacing the battery with the power supply turned off causes all current position data to be lost. Therefore, mastering will be required again. Remove the battery case cap. Take out the old batteries from the battery case. Insert new batteries into the battery case. Pay attention to the direction of batteries. Close the battery case cap.

Fig.3.3 Replacing Battery

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3.4 REPLACING FILTER ELEMENT

MAINTENANCE

3. PERIODIC MAINTENANCE

Severe dust/liquid protection for the S--420i is used to purge air into the wrist and J3--axis arm. Air filter elements (air filter, and oil mist filter) need to be periodically replaced every year. Use the following procedure to replace the filter element when harsh stains exist. WARNING If harsh stains exist on the filter element, it cannot hold oil, and will make flowing oil and mist. 1) Turn off the power. 2) Shut off the purge air. NOTE Be sure to shut off the primary valve. 3) Check that the air filter’s gauge indicated zero. WARNING When air filter and oil mist filter are broken up, it reduces residual pressure; otherwise you could injure personnel or damage equipment. 4) Replace the filter element as shown in the following figure. Air filters and oil mist filter are replaced at the same time.

Fig.3.4 Replacing Battery

23

4. TROUBLESHOOTING

4

MAINTENANCE

B--80505E/06

TROUBLESHOOTING

4.1 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.

4.2

Table 4.1 shows the main mechanical unit problems and their causes. If a cause of remedy is unclear, please contact this company.

PROBLEMS AND CAUSES

Table4.1 Problems and causes Cause

Symptom

Remedy

The robot does not correctly Low voltage of the memory Replace the battery. return to the zero position. backup battery

Remarks Refer to section 3.3.

Unusual external start signal Investigate the cause.

Position offset

Incorrect parameter

Revise parameters.

The robot has been hit.

Revise the teaching points.

Refer to the parameter table in Setup and Operations manual.

The robot is not firmly fas- Re--tighten. tened. Peripheral shifted.

device

was Reposition.

Incorrect parameters.

Revise parameters.

Refer to the parameter table in Setup and Operations manual.

Defective pulse coder cable

Replace the cable.

Refer to section 8.

APC (Absolute Position Replace the motor or the Refer to sections 6. Checker) malfunction. pulse coder. Play in mechanical unit. See below. Vibration

The robot is not firmly fas- Re--tighten. tened. Floor vibration. (especially Investigate the installation when installed above the first location. floor) Incorrect servo adjustment.

Adjust the servo.

Contact the service representative.

Defective cable.

Replace the cable.

Refer to section 8.

Not grounded.

Connect to ground.

Defective motor.

Replace the motor.

Refer to section 6.

Defective reducer.

Replace the reducer.

Refer to sections 6.

Incorrect time constant

Revise the time constant

Refer to the parameters.

Play in mechanical units. See below.

24

Symptom There is play. (See Table 4.2 (b).) There is play. (See Table 4.2.) 42)

Unusual noise

4. TROUBLESHOOTING

MAINTENANCE

B--80505E/06

Cause

Remedy

Remarks

Loose screws or pins.

Tighten and apply LOCTITE as specified.

Defective reducer.

Replace the reducer.

Refer to section 6.

Incorrect gear adjustment.

Adjust the gears.

Refer to section 5.4.

Worn gears.

Replace the gears.

Refer to section 6.

Worn bearings.

Replace the bearings.

Contact the service representative.

Cracked casting, etc.

Replace cracked parts.

Contact the service representative.

Insufficient gear or reducer Lubricate. lubrications.

Refer to section 3.

Foreign matter in gears or re- Clean and lubricate. ducer.

Refer to section 3.

Excessive pressure on bear- Reduce the pressure on the Contact the service repreings. bearings. sentative.

Unusual heating

Defective reducer.

Replace the reducer.

Refer to section 6.

Incorrect gear adjustment.

Adjust the gears.

Refer to section 5.4.

Worn gears.

Replace the gears.

Refer to section 6.

Worn bearings.

Replace the bearings.

Contact the service representative.

Incorrect servo adjustment.

Adjust the servo.

Contact the service representative.

Insufficient lubrication to the Lubricate (900 cc) inside of balancer

Refer to section 3.2.

Insufficient gear or reducer Lubricate. lubrication.

Refer to section 3.

Specified grease not used.

Replace with the specified Refer to section 3. grease.

Excessive pressure on bear- Reduce the pressure on the Contact the service repreings. bearings. sentative. Excessive load.

Reduce the load/restrict movement conditions.

Incorrect gear adjustment.

Adjust the gears.

Refer to section 5.4.

Incorrect time constant.

Revise the time constant.

Refer to the parameters.

Drops when the power supply is off

Brake gap too large.

Replace the motor.

Fused brake drive relay.

Replace the relay.

Refer to section 6 and Table 4 3 (*). 4.3 (*)

Grease leakage

Deteriorated O--ring, oil seal Replace the O--ring, oil seal or packing. or packing. Cracked casting, etc.

Replace cracked parts.

Loose screws.

Tighten.

Contact the service representative.

(*) Refer to the maintenance manual of the controller.

25

4. TROUBLESHOOTING

MAINTENANCE

B--80505E/06

4.3 THE MEASUREMENT OF THE BACKLASH

(1) Method 1 Move the robot to the designated posture(Refer to table 4.3(a), and Fig 4.3 (b) ). 2 Release the brake control (Refer P85). 3 Apply pressure on each axis as Fig 4.3 (a). 4 Measure the moving distance. Apply pressure on each axis 3 times, and measure the moving distance at 2nd and 3rd attempt. The backlash is calculated by the average of them.

Home Position 0 +10kg 1st attempt (Dont measure) --10kg

+10kg 2nd attempt (B2 = L1 + L2)

L1

--10kg L2

+10kg L3

--10kg

3rd attempt (B3 = L3 + L4)

L4

Fig.4.3 (a) How to measure the backlash

The backlash is calculated as B =

B2 + B3 . 2

(2) Measuring posture and position. 1 For iF, iF/2.85, iW, iW/175, iW/285, iS, iL, Table4.3 (a) Posture for measuring backlash Posture

Measuring axis J1

J2

J3

J4

J5

J6

70_

0_

------

------

------

J2

0_

0_

------

--90_

------

J3

50_

--90_

--90_

--90_

90_

J4

50_

--90_

90_

90_

--90_

J5

70_

0_

90_

90_

--180_

J6

70_

0_

90_

90_

--90_

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4. TROUBLESHOOTING

MAINTENANCE

B--80505E/06

Fig.4.3 (b) Posture for measuring backlash

Table4.3 (b) Position for measuring backlash Item

A

B

C

D

E

F

S--420iF

2193

1190

1300

233

233

250

S--420iW

2193

1190

1300

251

251

323

S--420iW/175

2193

1190

1300

220

220

298

S--420iW/2.85

2655

1190

1752

251

251

323

S--420iS

2043

1190

1150

377

377

350

S--420iL

2795

1190

1902

408

408

360

S--420iF/2.85

2655

1190

1752

233

233

250

2

For iR,iR/120 Table4.3 (c) Posture for measuring backlash Posture

Measuring axis

J2

J3

J4

J5

J6

J1

0_

30_

------

------

------

J2

------

------

------

------

------

J3

--20_

0_

------

------

------

J4

--20_

0_

--90_

90_

--90_

J5

--30_

0_

180_

30_

0_

J6

--30_

0_

--90_

30_

0_

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4. TROUBLESHOOTING

MAINTENANCE

B--80505E/06

Fig.4.3 (c) Posture for measuring backlash

NOTE In the case of S--420iR and iR/120, the backlash of J2 can’t measure. Because the gravity acts on the direction of J2, constantly. (3) Allowable backlash tolerances Table4.3 (d) Allowable backlash tolerances (S--420iF) J1

J2

J3

J4

J5

J6

Angle conversion (arc--min)

3.1

1.45

0.89

11.98

4.79

14.18

Displacement conversion (mm)

1.98

0.5

0.33

1.51

0.6

1.03

Distance (mm)

2193

1190

1300

433

433

250

Table4.3 (e) Allowable backlash tolerances (S--420iW) J1

J2

J3

J4

J5

J6

Angle conversion (arc--min)

3.1

1.45

0.89

11.04

4.42

11.89

Displacement conversion (mm)

1.98

0.5

0.33

1.45

0.58

1.12

Distance (mm)

2193

1190

1300

451

451

323

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4. TROUBLESHOOTING

MAINTENANCE

B--80505E/06

Table4.3 (f) Allowable backlash tolerances (S--420iW/175) J1

J2

J3

J4

J5

J6

Angle conversion (arc--min)

3.1

1.45

Displacement conversion (mm)

1.98

0.5

0.89

11.6

4.64

11.98

0.33

1.48

0.59

1.04

Distance (mm)

2193

1190

1300

440

440

298

Table4.3 (g) Allowable backlash tolerances (S--420iW/2.85)

Angle conversion (arc--min)

J1

J2

J3

J4

J5

J6

2.78

1.45

0.98

11.04

4.42

11.89

Displacement conversion (mm)

2.15

0.5

0.5

1.45

0.58

1.12

Distance (mm)

2655

1190

1752

451

451

323

Table4.3 (h) Allowable backlash tolerances (S--420iS) J1

J2

J3

J4

J5

J6

Angle conversion (arc--min)

3.34

1.45

1

6.74

2.7

7.24

Displacement conversion (mm)

1.98

0.5

0.33

1.13

0.45

0.74

Distance (mm)

2043

1190

1150

577

577

350

Table4.3 (i) Allowable backlash tolerances (S--420iL) J1

J2

J3

J4

J5

J6

Angle conversion (arc--min)

2.38

1.45

0.6

8.5

3.4

9.57

Displacement conversion (mm)

1.94

0.5

0.33

1.5

0.6

1

Distance (mm)

2795

1190

1902

608

608

360

Table4.3 (j) Allowable backlash tolerances (S--420iF/2.85) J1

J2

J3

J4

J5

J6

Angle conversion (arc--min)

2.78

1.45

0.98

11.98

4.79

14.18

Displacement conversion (mm)

2.15

0.5

0.5

1.51

0.6

1.03

Distance (mm)

2655

1190

1752

433

433

250

Table4.3 (k) Allowable backlash tolerances (S--420iR,iR/120)

Angle conversion (arc--min) Displacement conversion (mm) Distance (mm)

J1

J2

J3

J4

J5

J6

2.21

------

0.98

14.37

4.79

11.35

2

------

0.5

1.81

0.6

0.83

3113

------

1752

496

496

288

29

5. ADJUSTMENTS

5

MAINTENANCE

B--80505E/06

ADJUSTMENTS

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

5.1 AXIS LIMITS SETUP

Axis limits define the motion range of the robot. The operating range of the robot axes can be restricted because of: D Work area limitations D Tooling and fixture interference points D Cable and hose lengths There are three methods used to prevent the robot from going beyond the necessary motion range. These are D D D

Axis limit software settings Axis limit switches -- optional Axis limit hardstops WARNING Do not use axis software limits as the only method for restricting robot motion. Change the hard stops to match the software modifications, otherwise injury to personnel and damage to equipment can occur.

Software Settings

Axis limit software settings are upper and lower motion degree limitations. The limits can be set for all robot axes and will stop robot motion if the robot is calibrated. If the robot is not calibrated, overtravel limit switches or hardstops are contacted two to three degrees beyond the software limits. Overtravel switches for axis 1 are available as an option.

Limit Switches

Axis limit switches are overtravel switches that, when tripped, cut power to the servo motors. These are located about 0.5 degrees beyond the software limits. Overtravel switches for J1--axis are available as an option.

Hardstops

Axis limit hardstops are physical barriers that are located two or three degrees beyond the overtravel limit switch or software setting on the three major axes. The robot cannot move beyond a hardstop. Setting the axis limits software settings changes the motion range of the robot. The axis limit screen displays the current upper and lower axis limits, for each robot axis, in degrees.

Upper Limits

Displays the upper limits of each axis, or the axis limits in a positive direction. 30

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MAINTENANCE

5. ADJUSTMENTS

Lower Limits

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

Saving Limits

After you change the axis limits, turn off the controller and then turn it on again so the new settings can be used. CAUTION Changing the axis limits will affect the robot work area, and could change robot motion. Anticipate the effects of changing axis limits before changing them; otherwise unexpected results could occur, such as errors in previously recorded positions.

31

5. ADJUSTMENTS

5.1.1 Zero Point Position and Motion Limit

MAINTENANCE

B--80505E/06

Zero point and software motion limit are provided for each controlled axis. The robot cannot exceed the software motion limit unless there is a failure of the system causing loss of zero point position or there is a system error. Exceeding the software motion limit of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of J1--axis by an optional adjustable OT switch. Overtravel is not detected on any other axis. The total travel (stroke) of J1--axis through J5--axis beyond the software motion limit is restricted by a mechanical stopper. A mechanical stopper is not provided for J6--axis. Fig.5.1.1 (a) -- (j) show the zero point and motion limit OT detection position, and mechanical stopper position of each axis.

Fig.5.1.1 (a) J1--axis (S--420iF/W/S/L/R)

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Fig.5.1.1 (b) J2--axis (S--420iF/W/S/L)

Fig.5.1.1 (c) J2--axis (S--420iR)

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5. ADJUSTMENTS

5. ADJUSTMENTS

MAINTENANCE

Fig.5.1.1 (d) J3--axis (S--420iF/W/S/L)

Fig.5.1.1 (e) J3--axis (S--420iR)

Fig.5.1.1 (f) J2/J3--axis interference angle (S--420iF/W/S/L/R)

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5. ADJUSTMENTS

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Fig.5.1.1 (g) J4--axis (S--420iF/W/L/R)

( + 250_)

( -- 250_)

Fig.5.1.1 (h) J4--axis (S--420iS)

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5. ADJUSTMENTS

MAINTENANCE

Fig.5.1.1 (i) J5--axis (S420iF/W/S/L/R)

Fig.5.1.1 (j) J6--axis (S--420iF/W/S/L/R)

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5. ADJUSTMENTS

MAINTENANCE

B--80505E/06

5.1.2

Axis limit software settings are upper and lower motion degree limitations. The limits can be set for all robot axes and will stop robot motion if the robot is calibrated. Use Procedure 5--1 to set up axis limits.

Software Setting

Procedure 5--1 Setting Up Axis Limits Step

1 Press MENUS. 2 Select SYSTEM. 3 Press F1, [TYPE]. 4 Select Axis Limits. You will see a screen similar to the following. System Axis Limits AXIS

GROUP 1 1 1 1 1 1 0 0 0

1 2 3 4 5 6 7 8 9

JOINT LOWER -180.00 -70.00 -105.00 -300.00 -130.00 -360.00 0.00 0.00 0.00

100% 1/16

UPPER 180.00 72.00 30.00 300.00 130.00 360 00 0.00 0.00 0.00

dg dg dg dg dg dg mm mm mm

[ TYPE ]

NOTE 0 indicates the robot does not have these axes. 5 Move the cursor to the axis limit you want to set. WARNING Do not depend on axis limit software settings to control the motion range of your robot. Use the axis limit switches or hardstops also; otherwise injury to personnel or damage to equipment could occur. 6 Type the new value using the numeric keys on the teach pendant. 7 Repeat Steps 5 through 6 until you are finished setting the axis limits. WARNING You must turn off the controller and then turn it back on to use the new information; otherwise injury to personnel or damage to equipment could occur. 8 Turn off the controller and then turn it back on again so the new information can be used. 37

5. ADJUSTMENTS

5.1.3 Hard Stopper and Limit Switch Setting

MAINTENANCE

B--80505E/06

The J1--axis stroke can be limited depending on the operating environment of the robot. The stroke can be changed by changing the locations of the dog and mechanical stopper and the settings of the motion limits using the following procedure. The stroke can be changed every 15 degrees in the upper limit of --135 degrees to +180 degrees and the lower limit of --180 degrees to +135 degrees. If mastering position (0 degree) does not exist within the changed stroke, the stroke must be reset so that it contains 0 degree position. Changing the dog position and the mechanical stopper Change the dog position and the mechanical position as shown in Figs. 5.1.3 (a), (b) to match with a desired stroke position.

Fig.5.1.3 (a) Mechanical stopper locations

Fig.5.1.3 (b) Dog (option) locations

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5.2 ADJUSTING J1--AXIS LIMIT SWITCH (OPTION)

MAINTENANCE

5. ADJUSTMENTS

Axis limit switches are overtravel switches that, when tripped, cut power to the servo motors. These are located 10.5 degrees beyond the software limits. Overtravel switches for axis 1 are available as an option. The optional J1--axis OT limit switch is actuated by a pivoting dog mounted on a bracket bolted to the rotating J1--axis table. See Figure 5.2. Use these steps to adjust the OT switch. The J1--axis stroke may be limited by moving the mechanical stoppers and OT limit switch dog. Refer to Section 5.3. When the J1--axis stroke is to be limited, a second mechanical stopper and dog must be used. 1 Set the $MOR_GRP.$CAL_DONE system parameter to FALSE. This disables the motion limit specified by the software. As a result, the operator can rotate the robot around the J1--axis by a jog feed which goes beyond the motion limit. 2 Press the emergency stop button to stop the robot moving. 3 Loosen the two M6×8 bolts and the two M4X25 bolts that secure the J1--axis limit switch. 4 Move the limit switch so that the robot activates it at about 0.5 degrees before the stroke end around the J1--axis. 5 When the limit switch operates and detects overtravel (OT), the robot stops, and an error message, ”OVERTRAVEL”, is displayed. To restart the robot, hold on the SHIFT key and press the RESET key. Then, while holding on the SHIFT key, move the J1--axis off the OT limit switch by jogging in joint mode. 6 Check that the robot also activates the limit switch when the robot is approx. 0.5 degrees from the opposite stroke end in the same way as above. If the limit switch does not operate at the position, adjust the position of the switch again. 7 Set the $MOR_GRP.$CAL_DONE system parameter to TRUE. 8 Turn off the power, then turn it on again to restart the controller.

Fig.5.2 Adjusting J1--axis OT (option)

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5.3 MASTERING 5.3.1 General

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When you master a robot you define the physical location of the robot by synchronizing the mechanical information with the robot’s positional information. A robot must be mastered to operate properly. Robots are usually mastered before they leave FANUC However, it is possible that a robot might lose its mastering data and require to be remastered. You can master the robot using several different methods. Refer to Table 5.3.1 to select the method that best meets your needs. Table5.3.1 Mastering Methods Mastering Method

When to Use

Mastering to a fixture (Master Position Master)

D When mastery is lost due to mechanical disassembly or repair. D When a quick master reference position was not previously set. D Method of choice for P--and A--series robots. Used for S-- and M--series robots when extreme precision is required.

mastering to zero degrees

D When mastery is lost due to mechanical disassembly or repair. D When a quick master reference position was not previously set. D Method of choice for S-- and M--series robots when extreme precision is not required.

Single axis mastering

When mastery was lost due to mechanical disassembly or repair of a single axis (usually due to motor replacement).

Recording the quick master reference position

To record mastering data as a reference for future quick mastering.

Quick mastering

To retrieve mastery data that has been stored as a quick master reference position when mastery is lost due to an electrical or software problem. Do not use if mastery is lost due to mechanical disassembly or repair.

Quick mastering is a convenient way to master an robot after you have recorded a reference position. You cannot quick master a robot unless the reference position was taught before mastering was lost. CAUTION Record the quick master reference position after the robot is installed to preserve the factory mastering settings for future remastering.

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5.3.2 Resetting Alarms and Preparing for Mastering

Procedure 5--2 Condition Step

When you power up the robot after disconnecting the pulse coder backup batteries you may see a SRVO--062 BZAL or SRV0--038 Pulse mismatch alarm. Before mastering the robot you must reset the alarm and rotate the motor of each axis that lost battery power to prepare the robot for mastering. Use Procedure 5--2 to reset these alarms and prepare the robot for mastering. Preparing the Robot for Mastering H

You see a SRVO--062 BZAL or SRVO--038 Servo mismatch alarm.

1 Replace the robot batteries with four new 1.5 volt alkaline batteries, size D. Observe the direction arrows in the battery box for proper orientation of the batteries. 2 Press MENUS. 3 Select SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following. SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

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

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RES_PCA

DONE

5. ADJUSTMENTS

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6 To reset a SRVO--062 alarm when RES_PCA does not appear on the Master/Cal menu, do the following: a Press F1, [TYPE]. b Select Variables. c Move the cursor to $MCR and press ENTER. d Move the cursor to $SPC_RESET and press F4, TRUE. The value will change to TRUE momentarily, and will then change to FALSE. e If the value does not change to TRUE momentarily, repeat Step 6. f Press RESET on the operator box. 7 Perform a cold start. a Turn off the robot. b Press and hold the FAULT RESET button on the operator box. c While still pressing FAULT RESET, press the ON button on the operator box. 8 If the SRVO--062 alarm is still present; there is a battery, cable or pulse coder problem. Refer to the SYSTEM R-J2 Controller Series Electrical Connection and Maintenance Manual for further information. 9 If a SRVO--038 alarm is present at this time, repeat step 6 to reset it. It is not necessary to cold start the robot after resetting to clear this alarm. 10 Rotate each axis that lost battery power by at least one motor revolution in either direction. a Jog each rotary axis at least twenty degrees. b Jog each linear axis at least thirty millimeters. 11 Perform any of the mastering procedures from the MASTER/CAL menu.

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5.3.3 Mastering to a Fixture (Master Position Master)

5. ADJUSTMENTS

MAINTENANCE

When a major part of the robot mechanical unit is replaced and the actual position of each axis is displaced from the current value stored through an absolute pulse coder (hereinafter abbreviated as APC), the mastering is executed to set the geometric position of the robot. Mastering has been performed before shipment. When mastering the robot, arrange the robot to meet the following conditions. D Make the robot mounting base horizontal within 1 mm. D Remove the hand and other parts from the wrist. D Set the robot in the condition protected from an external force. D Have the appropriate mastering fixture for your robot. D Clear any servo faults that prevent you from jogging the robot. D Jog each axis that has lost mastery at least one motor turn. NOTE Since the axis stroke is not checked during the mastering, be careful to stay clear of the robot motion. 1) Assembling the fixture base Assemble the fixture base as shown in Fig. 5.3.3 (a).

Bolts M5X20

Plate

Bolts M5X20

Base

ADAPTOR Plate

Note) The shape of the adapter plate varies with the model. Fig.5.3.3 (a) Assembling fixture base

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

A

B F

0

3

C

M5 bolt D

E

20

Calibration block

Fig.5.3.3 (b) Mounting dial indicator

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

Fig.5.3.3 (c) Mounting fixture base (S--420iF/W/S/L)

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5. ADJUSTMENTS

Fig.5.3.3 (d) Mounting fixture base (S--420iR)

4) Mounting the fixture to the wrist Mount the fixture to the J6--axis flange as shown in Fig. 5.3.3 (e).

Fig.5.3.3 (e) Mounting fixture to wrist

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5) To release the brake control, set the system variable $PARAM_GROUP.$SV_OFF_ALL to false. Then set system variable $PARAM_GROUP.$SV_OFF_ENB for each axis to false, turn off the power, and power on. 6) Jog each axis to a calibration point or near it where calibration using a fixture is to be performed. (See Fig. 5.3.3 (f) to (j).) When jogging the robot, be careful not to hit the wrist of the robot onto the mastering fixture. 7) Jog the robot slowly until the dial indicators A to F shown in Fig. 5.3.3 (b) meet arrows A to F shown in Fig. 5.3.3(e).To set each axis to the mastering fixture position, jog the robot in a direction in which the dial indicator reading decreases to prevent an error caused by axis backlash. 8) Press MENUS. 9) Select SYSTEM. 10)Press F1, [TYPE]. 11)Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 12. a) Select VARIABLE from the [TYPE] menu. b) Move the cursor to $MASTER_ENB. c) Press the numeric key “1” and then press ENTER on the teach pendant. d) Press F1, [TYPE]. e) Select Master/Cal. You will see a screen similar to the following: SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

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

DONE

12)Select Master Position Master. 13)Press F4, YES. Mastering will be performed automatically. 14)Select Calibrate. 15)Press F4, YES. 16)To re-enable brake control, set system variable $PARAM_GROUP.$SV_OFF_ALL to true. Then set system variable $PARAM_GROUP.$SV_OFF_ENB for each axis to true. 17)Turn off the power, and power on.

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Fig.5.3.3 (f) Mastering attitude (S--420iF, W, W/175)

Fig.5.3.3 (g) Mastering attitude (S--420iF, 2.85, W/2.85)

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5. ADJUSTMENTS

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Fig.5.3.3 (h) Mastering attitude (S--420iS)

Fig.5.3.3 (i) Mastering attitude (S--420iL)

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Fig.5.3.3 (j) Mastering attitude (S--420iR)

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5. ADJUSTMENTS

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5.3.4 Zero Degree Mastering

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When you master to zero degrees, you position all axes at their zero degree witness marks and record the zero degree position. Use Procedure 5--3 to master to zero degrees.

Procedure 5--3 Condition

Step

Mastering to Zero Degrees H

You have cleared any servo faults that prevent you from jogging the robot.

H

You have jogged each axis that has lost mastery at least one motor turn. (Procedure 5--2).

1 Using the joint coordinate system, jog each axis of the robot to the zero degree witness mark. 2 Press MENUS. 3 Press SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following.

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SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

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

DONE

6 Select Zero Position Master. 7 Press F4, YES. Mastering will be performed automatically. 8 Select Calibrate. 9 Press F4, YES. Table5.3.4 Attitude with position marks aligned Axis

S--420iF/W/S/L

S--420iR

J1--axis J2--axis J3--axis J4--axis J5--axis J6--axis

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

0 deg --15 deg +15 deg 0 deg 0 deg 0 deg

NOTE For the S--420i R, the attitude assumed by aligning the position marks differs from the zero--degree attitude.

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Fig.5.3.4 Zero degree position arrow mark for each axis

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5.3.5 Quick Mastering

MAINTENANCE

5. ADJUSTMENTS

Quick mastering allows you to minimize the time required to remaster the robot using a reference position you established when the robot was properly mastered. You cannot quick master the robot unless you have previously recorded this quick master reference position. Record the quick master reference position when the robot is properly mastered. The best time to record the quick master reference position is when the robot is still factory-mastered. If you lose mastery due to an electrical or software problem, you can use this reference position to master the robot in a minimum amount of time. If you lose mastery due to mechanical disassembly or repair, you must master to a fixture or perform zero degree mastering. Use Procedure 5--4 to record the quick master reference position. Use Procedure 5--5 to quick master the robot. CAUTION Record the quick master reference position after the robot is installed to preserve the factory mastering settings for future remastering.

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Procedure 5--4 Condition

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Recording the Quick Master Reference Position H

The robot is properly mastered.

1 Align the witness marks on the robot. This is the zero position, which will be the quick master reference position. . 2 Press MENUS. 3 Select SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following.

SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

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

DONE

6 Move the cursor to SET QUICK MASTER REF and press ENTER. Set quick master ref? [NO]

7 Press F4, YES.

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Procedure 5--5 Condition

5. ADJUSTMENTS

Quick Mastering the Robot H

The robot has lost mastery due to an electrical or software problem.

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

H

The quick master reference position was recorded before the robot lost mastery.

H

You have cleared any servo faults that prevent you from jogging the robot.

H

You have jogged each axis that has lost mastery at least one motor turn.

1 Jog the robot to the quick master reference position (zero degree position). 2 Press MENUS. 3 Select SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following.

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SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

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

DONE

6 Move the cursor to QUICK MASTER and press ENTER. Quick master? [NO]

7 Press F4, YES. 8 Move the cursor to CALIBRATE and press ENTER 9 Press F4, YES.

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5.3.6 Single Axis Mastering

You can master a single axis of an S-series robot when mastery was lost due to mechanical disassembly or repair of a single axis. Use Procedure 5--6 to master a single axis.

Procedure 5--6 Condition

Step

Mastering a Single Axis H

You have cleared any servo faults that prevent you from jogging the robot.

H

You have jogged each axis that has lost mastery at least one motor turn. (Procedure 5--2).

1 Using the joint coordinate system, jog the unmastered axis of the robot to the zero degree witness mark. 2 Press MENUS. 3 Select SYSTEM. 4 Press F1, [TYPE]. 5 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 6. a Select VARIABLE from the [TYPE] menu. b Move the cursor to $MASTER_ENB. c Press the numeric key “1” and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following. SYSTEM Master/Cal 1 2 3 4 5 6

JOINT 10%

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

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

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SINGLE AXIS MASTER ACTUAL POS J1 0.000 J2 3.514 J3 -7.164 J4 -357.366 J5 -1.275 J6 4.571 E1 0.000 E2 0.000 E3 0.000 [ TYPE ]

(MSTR POS) ( 0.000) ( 35.000) (-100.000) ( 0.000) ( -80.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000)

JOINT 10% 1/9 (SEL) [ST] (0) [2] (0) [0] (0) [2] (0) [2] (0) [2] (0) [2] (0) [0] (0) [0] (0) [0]

GROUP

EXEC

7 Move the cursor to the MSTR POS column for the unmastered axis and press the “0” key. 8 Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. 9 Move the cursor to the SEL column for the unmastered axis and press the numeric key “1.” 10 Press ENTER. 11 Press F5, EXEC. Mastering will be performed automatically. 12 Press PREV. 13 Select Calibrate. 14 Press F4, YES.

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5.4 ADJUSTING J5--AXIS BACKLASH

MAINTENANCE

5. ADJUSTMENTS

When the backlash of the J5--axis exceeds the tolerance (six minutes), listed in Table 4.2, adjust the backlash as described below. 1) Adjusting the backlash of the gear 1 and gear 2 assemblies a) Position a lever type dial test indicator on the notched portion of the U nut of the gear 1 assembly and secure the indicator. (Make the measurement at a point 36 mm from the center of rotation of the gear 1 assembly.) b) While holding the gear 2 assembly still, measure the play in the gear 1 assembly. c) Change the thickness of the spacers used with each assembly to adjust the backlash to within 0 to 0.15 mm. (The J5--axis must have some backlash.) 2) Adjusting the backlash of the gear 2, 3, and 4 assemblies. a) Position a lever type dial indicator on the tooth surface of the gear 4 assembly and secure the indicator. (Make the measurement at a point 136 mm from the center of rotation of the gear 4 assembly.) b) While holding the gear 2 assembly still, measure the play in the gear 4 assembly. c) Adjust the position of the gear 3 assembly so that the backlash within 0 to 0.10 mm. (The J5--axis must have some backlash.)

Fig.5.4 Adjusting J5--axis Backlash

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REPLACING PARTS

Replace the main parts of the mechanical unit as described below.

6.1 PART REPLACEMENT AND CORRESPONDING ADJUSTMENT

1) When a part is replaced, the corresponding adjustment must be made. Table 6.1 lists those parts that can be replaced and the corresponding adjustment. After replacing a part, perform the appropriate adjustment, as listed below. Table 6.1 Parts to be Replaced and Adjustment Items Adjustment

Parts to be replaced

Method

Motor, reducer, gear

Mastering

See 5.3

Wrist unit

Mastering

See 5.3

Cable (*)

Mastering

See 5.3

Limit switch (*)

Adjusting, limit switch

See 5.2

* Refer to Section 1, item 8 for replacement of cables and limit switches. NOTE The following components are heavy. Be particularly careful when carrying or assembling them. Component Servo motors

Reducers

Weight (approximate)

J1, J2, J3, J4 (M1, M2, M3, M4)

30 kg

J5 (M5)

20 kg

J1--axis

55 kg

J2-- and J3--axes

50 kg

J4--axis

20 kg

J1--axis table

60 kg

J1--axis holder

30 kg

J1--axis cross roller bearing

30 kg

J2--axis arm

90 kg

Balancer (S--420 iF/W/S/L)

45 kg

J3--axis link 1

285 kg

Wrist unit

100 kg

J2--J6--axis unit (See Fig. 6.2 (b).)

1100 kg

J4--J6--axis unit (See Fig. 6.3 (j).)

300 kg

Balancer (S--420 iR)

100 kg

J3--axis link 1 (with add. weight)

345 kg

Controller (i--cabinet)

100 kg

J2/J3 gear box (Compact type)

60

25 kg

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6. REPLACING PARTS

In case of reusing sealbolts for S--420i, observe following notes strictly. (If possible, change them to new sealbolts) 1) Apply LOCTITE to the sealbolts. 2) Notice the following 3 notes. a) Remove excessive bits of sealant on the sealbolt. (Not necessary to remove sealant which is fixed tightly.) b) The length of application is 2d (d : diameter of the bolt) from the tip of the bolt, and spread it evenly around it. c) Spread LOCTITE on whole threaded portion and rubbing 2 bolts together in order to spread it to the bottom of groove.

Fig.6.1 Standard application of sealant

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6.2 REPLACING J1--AXIS MOTOR (M1) AND REDUCER

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1) Replacing J1--axis motor (Fig. 6.2 (a) ) 1 Turn off the power. 2 Remove the J1--axis motor connectors. (For the S--420i R, remove the cover from the J2 angle base.) 3 Remove four motor mounting bolts (M12×35) and then remove the motor. 4 Remove the nut and gear in order. 5 Replace the motor, and remount a new motor reversing above procedure. Polish the motor flange with oil stone. Apply LOCTITE No. 242 to the thread of the nut. Be careful not to damage the tooth surface of the spur gear. Install an O ring correctly. 6 Perform mastering (Refer to section 5.3).

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

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6. REPLACING PARTS

2) Replacing J1--axis reducer (Fig. 6.2 (b) ) 1 Turn off the power. 2 Remove J1--axis motor (M1) by the above procedure. 3 When equipped with integrated controller, open the side cover of the controller and disconnect the cables. 4 Remove the controller mounting bolts (M10 x 30 2pcs and M10 x 35 2 pcs) and remove the controller. 5 Remove the cables and air tubes from the connector box (option) at the side of J1--axis base and remove the grease supply tube. 6 Remove two M8 x 12 bolts in the J1--axis base and extract a plate with a cable halfway. 7 Remove a cable clamp and nylon band attached to the plate and draw out the plate from J1--axis base. 8 Remove J2--base mounting bolts (M12 x 35 12 pcs) and lift up the robot body taking care of the cable to separate the J1--axis unit. (For the S--420i R, remove the 9 bolts (M12x35) and 3 bolts (M12x80) securing the J2 angle base.) 9 Remove the table mounting bolts (M12 x 70 13 pcs) and remove the table. 10 Remove the holder mounting bolts (M12×45 12 pcs) and remove the holder. 11 Remove the center gear. 12 Remove the reducer mounting bolts (M16×110 9 pcs) and remove the reducer with cross roller bearing from the J1--axis base. 13 Remove the cross roller bearing and the pipe from the reducer. 14 Replace the reducer. 15 Reassemble by reversing the above procedure. Polish the reducer and motor flange mounting surfaces using an oil stone. Apply LOCTITE No. 262 to the bolts shown in Fig. 6.2 (b). Coat sealant enough to the connections between the bolts and the J1 base. Install O ring at a correct position. Be careful not to damage the tooth surface of the center gear. 16 Form the cables (Refer to section 8). 17 Lubricate with grease (Refer to section 3). 18 Perform mastering (Refer to section 5.3).

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Fig.6.2 (b) Replacing J1--axis reducer

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6.3 REPLACING J2/J3--AXIS MOTOR (M2/M3) AND REDUCER

MAINTENANCE

6. REPLACING PARTS

1) Replacing the J2/J3--axis motor (M2/M3) i) Standard type (See Fig. 6.3(a)) 1 Turn off the power. 2 Suspend the J3--axis arm with a rope. Also, suspend the J3--axis link for safety. (See Fig. 6.3(c).) (For S--420iR, suspend it as shown in Fig. 6.3(d).) 3 Remove the connectors. 4 Remove the mounting bolts (M12×40) of the motor to be replaced, and remove the motor to be replaced. 5 Remove the nut, the input gear and the draw bolt in order. 6 Replace the motor, and remount a new motor reversing the above procedure. Polish the motor flange with an oil stone. Apply LOCTITE No. 242 to the draw bolt and the motor thread. Mount the O--ring correctly. Use new motor mounting sealbolts. (In case of reusing sealbolts, apply LOCTITE No.242 to them. (Refer to section 6.1) Be careful not to damage the tooth surface of the input gear. 7 Replenish the grease (Refer to section 3). 8 Perform mastering (Refer to section 5.3).

Fig.6.3 (a) Replacing J2/J3--axis motor (M2/M3)

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ii) Compact type (See Fig. 6.3(b)) 1 Turn off the power. 2 Suspend the J3--axis arm with a rope. Also, suspend the J3--axis link for safety. (See Fig. 6.3(c).) 3 Remove the connectors. 4 Remove the mounting bolts (M12×35) of the motor to be replaced, and remove the motor to be replaced. 5 Remove the draw bolt and input spline in order. 6 Replace the motor, and remount a new motor reversing the above procedure. Polish the motor flange with an oil stone. Apply LOCTITE No. 242 to the draw bolt and the motor thread. Mount the O--ring correctly. Be careful not to damage the tooth surface of the input gear. 7 Replenish the grease (Refer to section 3). 8 Perform mastering (Refer to section 5.3).

Fig.6.3 (b) Replacing J2/J3--axis motor (Compact type)

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Fig.6.3 (c) J2/J3--axis reducer replacing posture (S--420iF/W/S/L)

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Fig.6.3 (d) J2/J3--axis reducer replacing posture (S--420iR)

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6. REPLACING PARTS

2) Replacing J3--axis reducer i) Standard type (See Fig. 6.3(e)) 1 Turn off the power supply. 2 Remove J3--axis motor (M3) following the above procedure. 3 Remove the bracket mounting bolts (M12×60 16 pcs), and then the bracket. 4 Remove the reducer mounting bolts (M16×140 3 pcs) and taper pin (φ16×60 3 pcs). 5 Remove and replace the reducer. 6 Remount a new reducer reversing the above procedure. Polish the reducer mounting surface and the motor flange mounting surface using an oil--stone. Apply LOCTITE No. 262 to the bolts shown in Fig. 6.3 (e). Apply LOCTITE No. 242 to the taper pins removed in the step 4, and insert the pins after reaming. ⋅Take care to use the O--ring at the specified position. ⋅Use new motor mounting sealbolts. (In case of reusing sealbolts, apply LOCTITE No.242 to them. (Refer to section 6.1) ⋅Be careful not to damage the tooth surface of the input gear. 7 8

Apply grease to the reducer (Refer to section 3). Perform mastering (Refer to section 5.3).

Reducer mounting bolts M16 x 140

Fig.6.3 (e) Replacing J3--axis reducer

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ii) Compact type (See Fig. 6.3(f)) 1 Turn off the power supply. 2 Remove J3--axis motor (M3) following the above procedure. 3 Remove the gear box mounting bolts (M12×60 8 pcs, M12×50 8 pcs) 4 Remove the reducer mounting bolts (M16×140 3 pcs) and taper pin (φ16×60 3 pcs). 5 Remove and replace the reducer. 6 Remount a new reducer reversing the above procedure. Polish the reducer mounting surface and the motor flange mounting surface using an oil--stone. Apply LOCTITE No. 262 to the bolts shown in Fig. 6.3 (f). Apply LOCTITE No. 242 to the taper pins removed in the step 4, and insert the pins after reaming. ⋅Take care to use the O--ring at the specified position. ⋅Be careful not to damage the tooth surface of the input gear. 7 8

Apply grease to the reducer (Refer to section 3). Perform mastering (Refer to section 5.3).

Fig.6.3 (f) Replacing J3--axis reducer (Compact type)

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Guide Rods

6. REPLACING PARTS

Guide Rods

Fig.6.3 (g) Replacing J2/J3--axis reducer

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3) Replacing J2--axis reducer i) In case of S--420iF/W/S/L 1 Position the J2--axis to 0 degrees. 2 Turn off the power. 3 Remove the cables, threaded through the connection section of the J3--axis arm into the cable track, from the mechanical unit. (See item 8.) 4 Suspend the J3--axis arm with a rope. WARNING THE J2--AXIS MUST BE SET TO ZERO DEGREES BEFORE ATTEMPTING TO REMOVE THE SPRING BALANCERS. OTHERWISE, INJURY TO PERSONNEL MAY RESULT. Remove the C ring from the shaft of the J2/J3--axis connection section, then remove the balancer. 6 Remove the bolts (M8x25 6pcs) from the lower part of the link 1/link 2 connection section, then remove the shaft. 7 Remove (M10x110 16pcs) bolts from the J2/J3--axis connection section, then remove the shaft. 8 Remove the J4--axis unit and link 2 from the robot. (See Fig. 6.3 (j).) 9 Suspend the J2--axis arm with a rope. Remove the J2--axis motor (M2) as described previously. Butt the J2--axis arm against the front stopper. 10 Suspend link 1 with a rope. Remove the J3--axis motor (M3), bracket or gear box (compact type) and reduction unit. 5

WARNING LINK 1 IS A COUNTERWEIGHT FOR THE J4--AXIS UNIT. IT MUST BE SECURELY RIGGED BEFORE REMOVING THE SHAFT OR IT MIGHT FALL. INJURY TO PERSONNEL MAY RESULT. 11 Remove shaft mounting bolts (M12x100 8pcs) and remove the 12 13

14

15 16

shaft. Remove link 1. Again suspend the J2--axis arm with a rope. Remove the (M12x60) bracket mounting bolts and bracket with the J2--axis set to 0 degrees. Remove the reduction--unit mounting bolts (M16x50 6pcs and M10x35 18pcs). Insert guide rods, threaded M12, into the bracket mounting bolt holes and withdraw the reduction unit, as shown in Fig.6.3 (g). Separate the J2--axis arm from the robot. Replace the reduction unit.

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17 Reassemble the unit by reversing the above procedure. Keep the

following points in mind. Polish the surface where the reduction unit is mounted, as well as the motor flange, with an oilstone. Apply Loctite No. 262 to the bolts specified in Fig. 6.3. (h), (i). Mount the O--ring in the specified position. Use new motor mounting sealbolts. (In case of reusing sealbolts, apply LOCTITE No.242 to them. (Refer to section 6.1) Be careful not to scratch the teeth surfaces of the input gear. Arrange the cables correctly. (See item 8.) 18 Perform regreasing. (See item 3.) 19 Perform mastering. (See item 5.3.)

Bracket mounting bolts M12 x 60

Fig.6.3 (h) Replacing J2--axis reducer

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ii) For the S--420i R 1 Set the J2--axis arm to --85 and the J3--axis arm to +45 , then turn the power off. 2 Perform steps 3 and 4 in (i). 3 Remove the four balancer securing bolts (M12x40) and C--ring, then remove the balancer. 4 Perform step 6 in (i). 5 Remove the U--shaped nut and bearing, then remove the housing from the shaft. 6 Perform steps 7 to 12 in (i). (Fig. 6.3 (k)) 7 Support the J2--axis with a rope, set the J2--axis arm to --85 , then remove the bracket. 8 Perform steps 14 to 19 in (i).

Fig.6.3 (i) Replacing J2--axis reducer (Compact type)

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Fig.6.3 (j) Replacing J2--axis reducer (S--420iF/W/S/L)

Fig.6.3 (k) Replacing J2--axis reducer (S--420iR)

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6.4 REPLACING J4--AXIS MOTOR (M4) AND J4--AXIS REDUCER

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1) Replacing J4--axis motor (M4) 1 Set the posture of the wrist such that no load is applied to the wrist axis. 2 Turn off the power. 3 Remove the connector. 4 Remove four bolts (M12 x 40 2pcs, M12 x 55 2pcs) for mounting the motor, then the motor. 5 Remove the nut and take out the center gear. 6 Replace the motor with a new one. And reassemble it in a reverse order. Also replace the O--ring (as a precaution). Apply Locktite No. 242 to the threaded portion of the motor shaft. Be sure to mount the O- -ring at the appropriate position. Pay special attention so as not to scratch the tooth face of the super gear. 7 Apply grease to the motor (Refer to section 3). 8 Perform mastering (Refer to section 5.3).

Fig.6.4 (a) Replacing J4--axis motor (M4)

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2) Replacing J4--axis reducer 1 Remove any load on the robot’s wrist such as a hand or a workpiece. 2 Turn off the power. 3 Remove the plate, a grommet and cable ties (See Fig. 6.4(b)). 4 Remove the plate of the J3--axis arm, remove all the connectors, cable ties and the plates. Pull out the cables from J3--axis arm. Refer to Fig.8.2 (g) to (i) 5 Remove the J4--axis motor (M4) by the procedure shown above. 6 Remove six gear box mounting bolts (M10 x 50) and, then the gear box. 7 Remove the center gear. 8 Support the J3--axis arm with a crane. Remove J3--axis arm mounting mounting bolts (M14 x 95 6 pcs), then J3--axis arm. 9 Remove the reducer mounting bolts (M10 x 30), and remove the reducer. 10 Replace the reducer. 11 Reassemble the removed components. Polish the surface on which the reducer is to be mounted with an oilstone to remove burrs. Apply Loctite No. 262 to the bolts shown in Fig. 6.4(b). Be sure to mount the O- -ring at the appropriate position. Pay special attention so as not to scratch the tooth face of the center gear. 12 Form the cables (Refer to section 8). 13 Apply grease to the reducer (Refer to section 3). 14 Perform mastering (Refer to section 5.3).

Fig.6.4 (b) Replacing J4--axis reducer

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6.5 REPLACING WRIST UNIT

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Remove loads from the robot’s wrist such as a hand and workpieces. Support the wrist with a crane. Turn off the power. Remove the J3--axis arm plate, then remove the connectors, cut the cable ties and the plates. Refer to Fig.8.2 (h), (i). Remove the wrist unit mounting bolts (M12 x 35 8 pcs) and the wrist unit. Replace the wrist unit with a new one. Reassemble the removed components. Perform mastering (Refer to section 5.3).

Spring pin for alignment φ12 x 30

Fig.6.5 Replacing wrist unit

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6. REPLACING PARTS

1) Replacing J5--axis motor (M5) 1 Remove loads from the robot’s wrist such as a hand and workpieces. 2 Turn off the power. 3 Remove the J5--axis cover, the connector of the J5--axis motor (M5), then the plate. Cut the nylon cable tie. (See Section 8.2, ”Replacing the Cables.”) 4 Remove the bolt (M12 x 40) for mounting the motor, then remove the motor. 5 Remove the draw bolt and spline from the motor shaft. 6 Replace the motor with a new one. Also replace the O--ring (as a precaution). Reassemble the removed components. Be sure to mount the O--ring at the appropriate position. Use new motor mounting sealbolts. (In case of reusing sealbolts, apply LOCTITE No.242 to them. (Refer to section 6.1) Fasten the excess part of the cable to the plate with a nylon tie. See 8.2 for an explanation of how to lay the cable. 7 Apply grease to the reducer (Refer to section 3). 8 Perform mastering (Refer to section 5.3).

Fig.6.6 (a) Replacing J5--axis motor (M5)

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2) Replacing J5--axis gear 1 Remove J5--axis motor (M5) by the previous method. 2 Remove drain plugs from the J5--axis cover and drain grease. 3 Remove four gear 1 assembly bolts (M6 x 16) and remove the gear 1 assembly. (Fig.6.6 (b)) 4 Remove ten J5--axis cover mounting bolts (M6 x 16) (M6 x 40 for S--420iW), two spring pins (6 dia. x 20) gasket and the cover. (Fig.6.6 (b)) 5 Remove six gear 3 assembly bolts (M12 x 30) while rotating gear 3 and remove gear 3 assembly. (Fig.6.6 (c)) 6 Remove eight J5--axis gear 2 mounting bolts (M6 x 16) and the gear 2 assembly. 7 Remove sixteen J5--axis gear 4 assembly seal bolts (M10 x 50) and gear 4 (Do not re--use the seal volts.) 8 Change the gear. 9 Adjust backlash and assemble it in the reverse order (See 5.4). Apply Loctite No. 262 to the bolts shown in the figure. Change the gasket to a new one, and fix it temporarily with tightening torque of 1.0--1.6 kgfm. Retighten it after 20--60 minutes with 1.6 kgfm. Use new gear4 mounting sealbolts. (In case of reusing sealbolts, apply LOCTITE No.262 to them. (Refer to section 6.1)) 10 Refill with grease.

J5--axis gear 1 assembly Cover mounting bolts M6x16 (M6 x 40 for S--420iW)

Gasket

Fig.6.6 (b) Replacing J5--axis reducer

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Fig.6.6 (c) Replacing J5--axis gear

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6.7 REPLACING J6--AXIS MOTOR (M6) AND J6--AXIS REDUCER

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1) Replacing J6--axis motor (M6) 1 Remove loads from the robot’s wrist such as a hand and workpieces. 2 Turn off the power at the position of J5=--90 degrees. 3 Remove the cover, motor cover and cable connectors. 4 Remove J5--axis cover 2, a plate, a grommet and a clamp. (Do not remove plate and Teflon sheet attached to the J5--axis cover 2). 5 Remove rubber block mounting bolts and take out the cable. 6 Remove four bolts (M8×22) for mounting the motor, then remove the motor. 7 Remove the nut, input gear and the draw bolt. 8 Replace the motor with a new one. Reassemble the removed components. Polish the motor flange with oil stone. Apply Locktite No. 242 to the threaded portion of the motor shaft. Be sure to mount the O--ring at the appropriate position. Pay special attention so as not to scratch the tooth face of the input gear. Use new motor mounting sealbolts. (In case of reusing sealbolts, apply LOCTITE No.242 to them. (Refer to section 6.1) Fasten two bolts (M4 x 60) of the rubber block, so that the ends protrude 2.5mm through the plate. 9 Apply grease to the reducer (Refer to section 3). 10 Perform cable forming (See section 8). 11 Perform mastering (Refer to section 5.4).

(Do not overstrike)

Washer

Fig.6.7 (a) Replacing J6--axis motor (M6)

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Fig.6.7 (b) Replacing J6--axis motor

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6. REPLACING PARTS

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2) Replacing J6--axis reducer 1 Remove loads from the robot’s wrist such as a hand and workpieces. 2 Turn off the power. 3 Remove the flange mounting bolts (M14 x 25 4pcs and M6 x 20 4pcs) and the wrist flange. 4 Remove eight bolts (M8 x 40) for mounting the reducer, then remove the reducer. 5 Replace the reducer with a new one. Reassemble the removed components. Be sure to mount the O--ring at the appropriate position. Pay special attention so as not to scratch the tooth face of the center gear. Apply Loctite gasket eliminator No. 518 to the flange mounting face of the reducer. Apply Loctite No. 262 to the bolts shown in Fig. 6.7 (c). 6 Apply grease to the reducer (Refer to section 3). 7 Perform mastering (Refer to section 5.4).

LOCTITE Gasket Eliminator No.518

Flange mounting bolts Tool mounting flange

Fig.6.7 (c) Replacing J6--axis reducer

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6.8 RELEASING A BRAKE (OPTION)

MAINTENANCE

6. REPLACING PARTS

By using the optional brake release unit, the motor brake for each a axis can be released while power is not supplied, enabling the attitude of the robot to be changed arbitrarily. When using the brake release unit, observe the following precautions: NOTE 1 When releasing the brake of the J2-- or J3--axis motor, support the robot using a crane, as shown in Fig. 6.8 (a) to (d). 2 When releasing the brake of the J4--, J5--, or J6--axis motor, support the end effector using a crane, to prevent it from fall. 3 Before releasing a brake, apply sufficient tension to the sling. 4 Do not release the brake for two or more axes simultaneously.

Fig.6.8 (a) J2--axis brake releasing (S--420iF/W/S/L)

Fig.6.8 (b) J3--axis brake releasing (S--420iF/W/S/L)

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Fig.6.8 (c) J2--axis brake releasing (S--420iR)

Fig.6.8 (d) J3--axis brake releasing (S--420iR)

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7

7. PIPING AND WIRING

PIPING AND WIRING

7.1

Fig. 7.1 (a) and (b) show the piping diagram of the mechanical unit.

PIPING DIAGRAM

Fig.7.1 (a) Piping diagram

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Fig.7.1 (b) Piping diagram for purge air (for severe dust/liquid protection)

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7.2

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7. PIPING AND WIRING

Fig. 7.2 (a) to (t) show the wiring diagram of the mechanical unit.

WIRING DIAGRAM

Fig.7.2 (a) Wiring diagram (schematics) in mechanical unit (S--420iF, W, W/175, integrated type)

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K524 (Devicenet (Signal)) [option] K525 (Devicenet (Power)) [option]

Fig.7.2 (b) Wiring diagram (schematics) in mechanical unit (S--420iF, W, W/175, Remote type)

Fig.7.2 (c) Wiring diagram (schematics) in mechanical unit (S--420iF/2.85, S--420iW/2.85 Integrated type)

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K524 (Devicenet (Signal)) [option] K525 (Devicenet (Power)) [option]

Fig.7.2 (d) Wiring diagram (schematics) in mechanical unit (S--420iF/2.85, S--420iW/2.85, Remote type)

Fig.7.2 (e) Wiring diagram (schematics) in mechanical unit (S--420iS, Integrated type)

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K524 (Devicenet (Signal)) [option] K525 (Devicenet (Power)) [option]

Fig.7.2 (f) Wiring diagram (schematics) in mechanical unit (S--420iS, Remote type)

Fig.7.2 (g) Wiring diagram (schematics) in mechanical unit (S--420iL, Integrated type)

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K524 (Devicenet (Signal)) [option] K525 (Devicenet (Power)) [option]

Fig.7.2 (h) Wiring diagram (schematics) in mechanical unit (S--420iL, Remote type)

Fig.7.2 (i) Wiring diagram (schematics) in mechanical unit (S--420iR)

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Fig.7.2 (j) Wiring diagram (block) in mechanical unit (S--420iF, W, W/175, Integrated type)

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Fig.7.2 (k) Wiring diagram (block) in mechanical unit (S--420iF, W, W/175, Remote type)

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Fig.7.2 (l) Wiring diagram (block) in mechanical unit (S--420iF/2.85, W/2.85, Integrated type)

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Fig.7.2 (m) Wiring diagram (block) in mechanical unit (S--420iF/2.85, W/2.85, Remote type)

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Fig.7.2 (n) Wiring diagram (block) in mechanical unit (S--420iS, Integrated type)

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Fig.7.2 (o) Wiring diagram (block) in mechanical unit (S--420iS, Remote type)

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Fig.7.2 (p) Wiring diagram (block) in mechanical unit (S--420iL, Integrated type)

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Fig.7.2 (q) Wiring diagram (block) in mechanical unit (S--420iL, Remote type)

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Fig.7.2 (r) Wiring diagram (block) in mechanical unit (S--420iR)

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(AS2, AP2, EE, I/O, AIR2, DS3, DP3)

(DS2, DP2)

(AS1, AP1, AIR1, DS1, DP1)

Fig.7.2 (s) Connector locations

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7. PIPING AND WIRING

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S--420i F2.85/W2.85/R

(AS1, AP1, AIR1, DS1, DP1)

Fig.7.2 (t) Connector locations

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8

8. REPLACING CABLE

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REPLACING CABLE

Replace the cable every four years. When the cable is broken or damaged, or shows signs of wear, replace it according to this chapter. Precautions to be observed when handling the pulse coder cable The pulse coder cable is provided with a marking tie, as shown below, to warn against disconnecting the cable during transportation, installation, or maintenance. If the cable with the marking tie is disconnected, mastering must be performed again. Therefore, do not disconnect the cable except when replacement of the cable is necessary.

BATTERY BACKUP DON’T DISCONNECT

MARKING TIE

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8.1 CABLE FORMING

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Fig. 8.1 (a) to (g) shows the cable clamp position. When replacing cables, clamp the cable at the position specified in Figure 8.1 (a) to (g) using a clamp or a nylon band. Otherwise, cables are loosened or forcedly pulled to cause their disconnection. Refer to the figures in section 8.2 for the cable clamp position not listed in the Table. Table8.1 (a) Cable clamp position

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Table8.1 (b) Cable clamp position

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8. REPLACING CABLE

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Table8.1 (c) Cable clamp posiiton

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Table8.1 (d) Cable clamp posiiton

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8. REPLACING CABLE

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Table8.1 (e) Cable clamp posiiton

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Table8.1 (f) Cable clamp posiiton

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8. REPLACING CABLE

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Table8.1 (g) Cable clamp posiiton

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Table8.1 (h) Cable clamp posiiton MARK

CABLE CLAMPING POSITION

MARK

CABLE No.

DS 3

K524

DS 1 DS 2

DP 3 DP 1 DP 2

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K525

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8.2 REPLACING THE CABLES

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This section describes the procedure for replacing all cables during routine cable replacement for the mechanical unit. To replace one or a few damaged cables only, refer to this section to replace them. The cables in the mechanical unit consist of those for the basic axes (J1 to J4 axes) and those for the wrist section (J5 and J6 axes). They can be divided into two parts at the connector section of the J3--axis arm. (See Fig. 7.2) WARNING Removing the cables will cause loss of mastering data, so mastering must be performed once the cables have been replaced. (When the pulse coder cable is not to be replaced, mastering is not required.) Before replacing the cables, refer to Item 5.7, ”Quick Mastering.” Perform cable replacement with each axis at the zero degree mark. Cable replacement procedure 1) Replacing the cables for the basic axes 1 Turn off the power. Remove the side cover of the controller, then disconnect all cables. Separate the controller from the robot. (For the S--420i F/W/S/L having a separate control unit or the S--420i R, disconnect the cables (except those for the mechanical unit) from the connector panel, remove the connector panel, then disconnect the mechanical unit cables.) 2 Disconnect the cables from the J1-- to J4--axis motors. (M1 to M4) 3 Remove the optional connector panel, then remove the connectors and air tube. (See Fig. 8.2 (a) (b) (c).) 4 Remove the plate from the J1--axis base. Draw the plate out of the base and remove its clamps and cable ties. (See Fig. 8.2 (d).) 5 Remove the two plates from the J2--axis base. Remove the clamps and cable ties from the plates, then remove the cable track. (See Fig. 8.2 (e).) (For the S--420i R, remove the cover from the J2 angle base, then remove the clamp and cable tie. See Fig. 8.2 (f).) 6 Remove the cable track and cover from the J2--axis arm. Cut the cable ties. (See Fig. 8.2 (g).) 7 Draw the plate, together with the cables, out of the cast hole in the upper part of the J2--axis arm. Remove the clamps and cable ties. (See Fig. 8.2 (h).) 8 Remove all plates, clamps, and cable ties from the J3--axis casing. 9 Remove the two covers from the J3--axis arm. Cut the cable ties and remove all connectors. Also, remove the plates. (Fig. 8.2 (i).) 10 Draw the grommet out of the J3--axis casing, then remove the cables. 2) Replacing the cables for the wrist section 114

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11 Perform step 9 described above. 12 Remove the J6--axis cover. Remove all connectors. (See Fig. 6.7

(a).) 13 Remove the J6--axis motor cover and rubber block. Draw out the 14 15 16 17

18

19

cables.(See Fig. 6.7 (a).) Remove the J5--axis cover, then remove the supprt mounted on the J5--axis cover. (See Fig. 8.2 (j).) Cut the cable ties for the support, then remove the cables. Remove the clamps, cable ties, plates and grommet, as shown in Fig. 8.2 (j). Draw the cables out of the robot. Open the lid of the cable track with a screwdriver and draw the cables out of the track. (See Fig. 8.2 (k).). Replace the cables. Assemble the cables by reversing the above procedure. Arrange the cables correctly and clamp them at the correct positions. (See Figs. 8.1 (a) to (e), and 8.2 (a) to (k).) Perform mastering. (See 5.3 through 5.4)

Fig.8.2 (a) Replacing the cable

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Fig.8.2 (b) Replacing the cable (Severe dust/liquid protection)

J1 BASE PANEL (INPUT)

J3 CASING PANEL (OUTPUT) User cable (signal) interface

Air supply

User cable (power) interface

DeviceNet cable (power) interface

DeviceNet cable (signal) interface End effector interface (RDI/RDO)

Air supply I/O unit model Binterface DeviceNet cable (power) interface

DeviceNet cable (signal) interface

J2 BASE PANEL (OUTPUT)

Fig.8.2 (c) Replacing the cable (With DeviceNet Cable)

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Fig.8.2 (d) Replacing the cable

(DP) (DS)

(DP) (DS)

Fig.8.2 (e) Replacing the cable

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(DP) (DS)

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Fig.8.2 (f) Replacing the cable

(DP)

(DP)

(DS)

Fig.8.2 (g) Replacing the cable

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(DS)

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Fig.8.2 (h) Replacing the cable

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8. REPLACING CABLE

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S420i F2.85/W2.85/R

Fig.8.2 (i) Replacing the cable

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Fig.8.2 (j) Replacing the cable

Fig.8.2 (k) Replacing the cable

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8. REPLACING CABLE

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8.3 REPLACING THE OPTIONAL J1--AXIS LIMIT SWITCH (OPTION)

1) Remove the limit--switch box, then remove the limit switch from the box. 2) Disconnect the cable from the limit switch. 3) Open the side cover of the controller. Disconnect the limit--switch cable. If the remote controller is employed, remove the connector plate at the base of robot. Disconnect the limit switch cable at back side of P1 connector. 4) Remove the side cover of the J1--axis. Draw out the cable. Replace the limit switch with a new one. 5) Reassemble the unit by reversing the above procedure. 6) Adjust the limit switch. (See item 5.2)

Fig.8.3 J1--axis limit switch mounting diagram

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1

CONNECTION

1. ROBOT INTERFERENCE AREA

ROBOT INTERFERENCE AREA

Fig. 1 (a), (d), (g), (j) and (m) shows the external dimensions of the robot. Fig. (b), (e), (h) and (k) shows the external dimensions of the compact type robot. When installing peripheral devices, be careful to clear away any objects that are in the robot’s motion path in normal operation. Fig. (c), (f), (i), (l) and (n) shows operation range of the robot. NOTE If an adjacent type controller is used, when the robot moves along the J3 axis in the positive direction, the gap between link 1 and the controller becomes small, and an object like a tool or part (if placed on the controller) may be caught between link 1 and the controller, leading to damage to the controller. Be careful when starting the robot. (See part P in the figure.)

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CONNECTION

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Fig.1 (a) Mechanical unit external dimensions (S--420iF, W, W/175)

NOTE Restrict the robot’s operation to avoid hitting the adjacent type controller. (shading) If |J1| ≧ 115_ and J2 ≧ --5_, the robot is not allowed to move into the area for which the following expression is satisfied: J3+3/10×J2 ≧ --66.5_

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CONNECTION

1. ROBOT INTERFERENCE AREA

Fig.1 (b) Mechanical unit external dimensions (S--420iF/W Compact type)

NOTE If |J1| ≧ 115_ and J2 ≧ --5_, the robot is not allowed to move into the area for which the following expression is satisfied: J3+3/10×J2 ≧ --66.5_

127

1. ROBOT INTERFERENCE AREA

CONNECTION

(Note) Figures A to H show posture at positions A to H shown in Fig. 1 (a), (b).

Fig.1 (c) Mechanical unit stroke limits

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CONNECTION

1. ROBOT INTERFERENCE AREA

Fig.1 (d) Mechanical unit external dimensions (S--420iF/2.85, S--420iW/2.85)

NOTE Restrict the robot’s operation to avoid hitting the adjacent type controller (shading) If |J1| ≧ 115_ and J2 ≧ --20_, the robot is not allowed to move into the area for which the following expression is satisfied: J3+J2/2 ≧ --60_

129

1. ROBOT INTERFERENCE AREA

CONNECTION

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Fig.1 (e) Mechanical unit external dimensions (S--420iF/2.85 Compact type)

NOTE Restrict the robot’s operation to avoid hitting the adjacent type controller (shading) If |J1| ≧ 115_ and J2 ≧ --20_, the robot is not allowed to move into the area for which the following expression is satisfied: J3+J2/2 ≧ --60_

130

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CONNECTION

1. ROBOT INTERFERENCE AREA

(Note) Figures A to H show posture at positions A to H shown in Fig.1 (d), (e). Fig.1 (f) Mechanical unit stroke limits (S--420iF/2.85, S420iW/2.85)

131

1. ROBOT INTERFERENCE AREA

CONNECTION

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Fig.1 (g) Mechanical unit external dimensions (S--420iS)

NOTE Restrict the robot’s operation to avoid hitting the adjacent type controller (shading) If |J1| ≧ 115_ and J2 ≧ 5_, the robot is not allowed to move into the area for which the following expression is satisfied: J3+J2/5 ≧ --74_

132

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CONNECTION

1. ROBOT INTERFERENCE AREA

Fig.1 (h) Mechanical unit external dimensions (S--420iS Compact type)

NOTE Restrict the robot’s operation to avoid hitting the adjacent type controller (shading) If |J1| ≧ 115_ and J2 ≧ 5_, the robot is not allowed to move into the area for which the following expression is satisfied: J3+J2/5 ≧ --74_

133

1. ROBOT INTERFERENCE AREA

CONNECTION

(Note) A to H correspond to the points of Fig.1 (g), (h). Fig.1 (i) Mechanical unit stroke limits (S--420iS)

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CONNECTION

1. ROBOT INTERFERENCE AREA

Fig.1 (j) Mechanical unit external dimensions (S--420iL)

NOTE Restrict the robot’s operation to avoid hitting the adjacent type controller (shading) If |J1| ≧ 115_ and J2 ≧ --20_ , the robot is not allowed to move into the area for which the following expression is satisfied: J3+J2/2 ≧ --60_

135

1. ROBOT INTERFERENCE AREA

CONNECTION

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Fig.1 (k) Mechanical unit external dimensions (S--420iL Compact type)

NOTE Restrict the robot’s operation to avoid hitting the adjacent type controller (shading) If |J1| ≧ 115_ and J2 ≧ --20_, the robot is not allowed to move into the area for which the following expression is satisfied: J3+J2/2 ≧ --60_

136

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CONNECTION

1. ROBOT INTERFERENCE AREA

(Note) A to H correspond to the points of Fig.1 (j), (k).

Fig.1 (l) Mechanical unit stroke limits (S--420iL)

137

1. ROBOT INTERFERENCE AREA

CONNECTION

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Fig.1 (m) Mechanical unit external dimensions (S--420iR)

NOTE Restrict the robot’s operation (shading) If --61_ ≦ J3 ≦ --41_, the robot is not allowed to move into the area for which the following expression is satisfied: J2 ≧ --1.6×J3--94.6_

138

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CONNECTION

1. ROBOT INTERFERENCE AREA

(Note) A to H correspond to the points of Fig.1 (m). Fig.1 (n) Mechanical unit stroke limits (S--420iR)

139

2. MECHANICAL COUPLING TO THE ROBOT

2

CONNECTION

MECHANICAL COUPLING TO THE ROBOT

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2.1 WRIST LOAD CONDITIONS

CONNECTION

2. MECHANICAL COUPLING TO THE ROBOT

Fig. 2.1 (a), (b) is a diagram to limit loads applied to the wrist. Apply a load within the region indicated in the graph.

Fig.2.1 (a) Wrist Load Diagram (S--420iF/S/L/R)

141

2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

Fig.2.1 (b) Wrist Load Diagram (S--420iW, W/175)

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2.2 LOAD CONDITIONS ON J2--AXIS BASE AND J3--AXIS ARM

2. MECHANICAL COUPLING TO THE ROBOT

Fig. 2.7 shows J2--axis base and J3--axis arm load conditions. Keep the load below the loads shown in Table 2.2 and Fig. 2.2 (a), (b). Table2.2 Installation condition of loads to be added Installation site

Loads

J2--axis base

250kg

J3- -axis arm

20kg

Condition Within radius of 500mm from the center of rotation of J1--axis Within 500mm to the wrist direction from the center of J3- -axis

Fig.2.2(a) Load Conditions on J2--axis base and J3--axis arm (S--420iF/W/S/L)

143

2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

Fig.2.2(b) Load Conditions on J2--axis base and J3--axis arm (S--420iR)

144

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CONNECTION

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2.3 MECHANICAL COUPLING OF END EFFECTOR TO WRIST

2. MECHANICAL COUPLING TO THE ROBOT

Fig. 2.3 is the diagram for installing end effectors on the wrist. Install the end effector using a 60 mmφH7 spigot. Using the standard flange as an example, position using a dowel pin with 2--φ10H7 reamed holes and fasten using 6--M10 bolts with 6--M10 tapped holes. Take into consideration the depth of tapped and reamed holes when selecting the M10 bolts and positioning dowel pins. (Refer to the diagram for the optional dimensions.)

6--M10 tap depth 20 Equally spaced on φF circumference

2--0G depth 20 Equally spaced on φF circumference

204 for insulating flange

Standard flange

Special flange

ISO flange

Insulating flange

A Ø60H7 +0.030 0 0 B Ø110h7 --0.035 C6 F Ø90 G Ø10H7 +0.015 0

A Ø76G7 +0.040 +0.010 B Ø108f8 --0.036 --0.090 C 10 F Ø92 G Ø9H7 +0.015 0

A Ø80H7 +0.035 0 0 B Ø160h8 --0.063 C 90.15 F Ø125 G Ø10H7 +0.015 0

A Ø80H7 +0.035 0 0 B Ø160h8 --0.063 +0.3 C8 0 F Ø125 G Ø10H7 +0.015 0

Fig.2.3 End effector mounting face

145

2. MECHANICAL COUPLING TO THE ROBOT

2.4 EQUIPMENT MOUNTING FACE

CONNECTION

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As shown in Fig. 2.4 (a) to (e), tapped holes are provided to install equipment to the robot.

Note) Note) These taps can’t be used for compact type robot.

Fig.2.4 (a) Equipment mounting surfaces (S--420iF, W, W/175)

NOTE 1 For using threaded holes of equipment mounting face. (only severe dust/liquid protection) S--420i for severe dust/liquid protection is used purge air into wrist and J3 arm. Because it keeps airtight chamber, equipment mounting face threaded holes, of J3 arm, are used SUS bolts and sealing washers. When the customers set equipment on J3 arm using these threaded holes (M10), it will be used coated sealing blots or sealing washers. It will reduce leakage from J3 arm. 2 For S--420i R, severe dust/liquid protection, it fills M12 threaded holes, that is side of angle base, with M12 sus bolts. Don’t drive the robot in severe dust/liquid environment.

WARNING Incomplete leakage measure ments on these taps will make air flow and noise increase, and it will cause low pressure and will break down the robot low pressure.

146

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CONNECTION

2--

2--

2--

Fig.2.4 (b) Equipment mounting surfaces (S--420iF/2.85, S420iW/2.85)

2--

2--

2--

2--

Fig.2.4 (c) Equipment mounting surfaces (S--420iS)

147

2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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2--

2--

2--

2--

Fig.2.4 (d) Equipment mounting surfaces (S--420iL)

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2. MECHANICAL COUPLING TO THE ROBOT

Fig.2.4 (e) Equipment mounting surfaces (S--420iR)

149

2. MECHANICAL COUPLING TO THE ROBOT

2.5 SETTING OF SYSTEM VARIABLES FOR TURBO MOVE

CONNECTION

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When using the turbo move option, set the load masses (including the mass of the hand), wrist axis load moment values, and load inertia values. Set each load by setting the system variables listed below. Then, turn off and on the power to use the new information. 1 Load mass at wrist Set the same values (in kg) for both of $PARAM_GROUP. $PAYLOAD and $GROUP. $PAYLOAD. [Example of input] $PARAM_GROUP. $PAYLOAD : 120 $GROUP. PAYLOAD : 120 2 Wrist axis load moment Set a load moment (kgf--m) (an integer) to $PARAM_GROUP. $AXISMOMENT. [Example of input] When load moment is as follows; J4--axis load moment 60 kgf--m J5--axis load moment 60 kgf--m J6--axis load moment 30 kgf--m Set system variables as below : J4--axis load moment $PARAM_GROUP.$AXISMOMENT[4] : 60 J5--axis load moment $PARAM_GROUP.$AXISMOMENT[5] : 60 J6--axis load moment $PARAM_GROUP.$AXISMOMENT[6] : 30 3 Wrist axis load inertia Set a load inertia (kgf--cm--s2) (an integer) to $PARAM_GROUP. $AXIS INERTIA. [Example of input] When load inertia is as follows; J4--axis load inertia 306 kgf--cm--s2 J5--axis load inertia 306 kgf--cm--s2 J6--axis load inertia 76 kgf--cm--s2 Set system variables as below: J4--axis load inertia $PARAM_GROUP.$AXIS INERTIA[4] : 306 J5--axis load inertia $PARAM_GROUP.$AXIS INERTIA[5] : 306 J6--axis load inertia $PARAM_GROUP.$AXIS INERTIA[6] : 76 4 Load mass at J3--axis arm and J2--axis base. Set a load mass (kg) to $PARAM_GROUP.$ARM_LOAD. [Example of input] $PARAM_GROUP. $ARM_LOAD [1] : 20 (for load at J3--axis arm.) $PARAM_GROUP. $ARM_LOAD [2] : 250 (for load at J2--axis base.)

150

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2.6 AIR SUPPLY (OPTION)

CONNECTION

2. MECHANICAL COUPLING TO THE ROBOT

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

Fig.2.6 Air--pressure supply connection (option)

151

2. MECHANICAL COUPLING TO THE ROBOT

2.7 INTERFACE FOR END EFFECTER (OPTION)

CONNECTION

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Fig. 2.7 show the posiiton of the end effecter interface. End effecter interface (RDI/RDO), I/O Unit--MODEL B interface and user cable (signal lines, power lines) and devicenet cable (signal lines, power lines) are prepared as options.

Fig.2.7 (a) Interface for End Effecter (Option)

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CONNECTION

2. MECHANICAL COUPLING TO THE ROBOT

Fig.2.7 (b) Layout of interface for Option cable (Severe dust/liquid protection)

153

2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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J3 CASING PANEL (OUTPUT) DeviceNet cable (power) interface (Air supply)

DeviceNet cable (signal) interface

User cable (signal) interface End effector interface (RDI/RDO) User cable (power) interface

I/O unit model B interface J1 BASE PANEL (INPUT)

View A

User cable (power) interface User cable (signal) interface

DeviceNet cable (power) interface

(Air supply)

J2 BASE PANEL (OUTPUT)

DeviceNet cable (power) interface

DeviceNet cable (signal) interface Detail B

DeviceNet cable (signal) interface

View C

Fig.2.7 (c) Layout of interface for Option cable (With devicenet cable)

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CONNECTION

2. MECHANICAL COUPLING TO THE ROBOT

(1) End effector interface (RDI/RDO) (Option) Fig. 2.7 (d) shows pin layout for end effector interface (RDI/RDO).

*

Fig.2.7 (d) Pin layout for end effector interface (RDI/RDO)

(2) I/O Unit--MODEL B interface (Option) Fig. 2.7 (e) shows pin layout for I/O Unit--MODEL B interface.

*

Fig.2.7 (e) Pin layout for I/O Unit--MODEL B interface (option)

(3) End effector interface (RDI/RDO) (Option) (Severe dust/liquid protection) Fig. 2.7 (f) shows pin layout for end effector interface (RDI/RDO).

Fig.2.7 (f) Pin layout for end effector interface (RDI/RDO) (Severe dust/liquid protection)

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2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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(4) I/O Unit--MODEL B interface (Option) Fig. 2.7 (g) shows pin layout for I/O Unit--MODEL B interface.

Fig.2.7 (g) Pin layout for I/O Unit--MODEL B interface (option) (Severe dust/liquid protection)

(5) User cable (signal line) Interface (option) Fig. 2.7 (h) shows pin layout for user cable (signal line) interface. AS

approx. AWG21 Fig.2.7 (h) Pin layout for user cable (signal line) interface (option)

156

CONNECTION

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2. MECHANICAL COUPLING TO THE ROBOT

(6) User cable (power line) Interface (option) Fig. 2.7 (i) shows pin layout for user cable (power line) interface. AP

approx. AWG17

Fig.2.7 (i) Pin layout for user cable (power line) interface (option)

(7) User cable(for aux. axis, signal line) interface (option) Fig. 2.7 (j) shows pin layout for user cable (for aux. axis, signal line) interface. (This interface is applied in case of using A05B--2351--J310 or J311)

(Separately prepared)

Fig.2.7 (j) Pin layout for user cable (for aux. axis, singnal line) interface(option)

NOTE A05B--2351--J310 and J312 include a signal cable and two power cables for aux. axis control.

157

2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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(8) User cable(for aux. axis, power line) interface(option ) Fig. 2.7 (k) shows pin layout for user cable (for aux. axis, power line) interface.

(Separately prepared)

Fig.2.7 (k) Pin layout for user cable (for aux. axis, power line) interface (option)

NOTE 1 A05B--2351--J310 and J312 include a signal cable and two power cables for aux. axis control. 2 In case of using the user cable (Power), it is necessary to select the End Effector whose Continuous Rating Current is 10.4 A rms. If FANUC servo motor is used, following table shows the available.

Motor Model

Continuous Rating Current (A rms)

Motor Model

Continuous Rating Current (A rms)

α 0.5/3000

2.8

α 3/3000

4.6

α 1/3000

2.2

α 6/2000

5.6

α 2/2000

2.2

α 6/3000

10.0

α 2/3000

2.9

α 12/2000

8.8

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CONNECTION

2. MECHANICAL COUPLING TO THE ROBOT

(9) DeviceNet cable (signal line) interface (option) Fig 2.7 (l) shows pin layout for DeviceNet cable (signal line) interface.

Fig.2.7 (l) Pin layout for DeviceNet cable (signal line) interface (option)

(10) DeviceNet cable (power line) interface (option) Fig 2.7 (m) shows pin layout for DeviceNet cable (power line) interface.

Fig.2.7 (m) Pin layout for DeviceNet cable (power line) interface (option)

159

2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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Table2.7 (a) Connector specifications (Machine side) (S--420iF/W/S/L/R) Cable

Input side (J1 base)

Output side (J3 casing)

RDI/RDO

JMWR2524F

I/O

JMWR2516F

Manu. DDK

AS (Signal)

Housing Insert Contact

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

Housing Insert Contact

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

AP (Power)

Housing Insert Contact

09 20 010 0301 09 21 015 3001 (Han 15D M) 09 15 000 6103

Housing Insert Contact

09 20 010 0301 09 21 015 3101 (Han 15D F) 09 15 000 6203

AS for aux. axis (Signal)

Housing Insert Contact

09 30 006 0301 (Han 6E) 09 16 024 3001 (Han24DD M) 09 15 000 6103 (S1--S4) 09 15 000 6104 (S5--S8)

Housing Insert Contact

09 30 006 0301 (Han 6E) 09 16 024 3001 (Han24DD F) 09 15 000 6203 (S1--S4) 09 15 000 6204 (S5--S10)

Harting

Harting

Table2.7 (b) Connector specifications (User side) (S--420iF/W/S/L/R) Cable

Input side (J1 base)

Output side (J3 casing)

RDI/RDO

JMSP2524M Streight (Appendix) JMLP2524M Angle

I/O

JMSP2516M Streight (Appendix) JMLP2524M Angle Food

AS (Signal)

Side entry

Food

← The same

Top entry

Insert

09 16 024 3101 (Han 24DD F)

Insert

09 16 024 3001 (Han 24DD M)

Contact

09 15 000 6204 6203 6202 6201 6206

Contact

09 15 000 6104 6103 6102 6101 6106

Clamp

09 00 000 5083 5086 5090 5094

Food

AP

09 30 006 1540 1541 0542 0543 1440 1441 0442 0443

appox.

AWG 26--22 AWG 20 AWG 18 AWG 16 AWG 14

appox.

Clamp ← The same etc.

09 20 010 1541 0540 0541 1440 0440 0441

Side entry

Food ← The same

Top entry

Insert

09 21 015 3101 (Han 15D F)

Insert

09 21 015 3001 (Han 15D M)

Contact

09 15 000 6220 6205 6204 6202 6207

Contact

09 15 000 6120 6105 6104 6102 6107

Clamp

09 00 000 5083 5086 5090 5094

(Power)

AWG 26--22 AWG 20 AWG 18 AWG 16 AWG 14

appox. AWG 20 AWG 18 AWG 16 AWG 14 AWG 12

appox. AWG 20 AWG 18 AWG 16 AWG 14 AWG 12

Clamp ← The same etc.

160

CONNECTION

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Table2.7 (c) Connector specifications (Severe dust/liquid protection) (Machine side) Cable

Input side (J1 base)

RDI/RDO

Output side (J3 casing)

_________

housing Insert Contact

09 03 006 0301 09 16 024 3101 (Han 24DD F) 09 15 000 6203

_________

housing Insert Contact

09 20 010 0301 09 21 015 3101 (Han 15D F) 09 15 000 6202

I/O

Table2.7 (d) Appended connector (Severe dust/liquid protection) (Machine side) Cable

Input side (J1 base)

RDI/RDO

Output side (J3 casing)

_________

Hood Insert Contact Clamp

09 30 006 1440 09 16 024 3101 (Han 24DD M) 09 15 000 6104 152D (PG13.5)

_________

Hood Insert Contact Clamp

09 20 010 1440 09 21 015 3101 (Han 15D M) 09 15 000 6102, 6103, 6104 152D9 (PG13.5)

I/O

Table2.7 (e) Connector specifications (device net cable) (Mechine side) (S--420iF/W/S/L) Cable name

Input side (J1--axis base)

DS (signal line)

84854--9101

DP (power line)

Housing Insert Contact

09 30 006 0301 (Han 6E) 09 32 010 3001 (Han 10EE M) 09 33 00 6104

Manufacturer

Output side (J2--axis base)

Manufacturer

Output side (J3--axis casing)

Manufacturer

MOLEX JAPAN CO., LTD.

84854--9100

MOLEX JAPAN CO., LTD.

84854--9100

MOLEX JAPAN CO., LTD.

HARTING Elektronik Co., Ltd.

84854--9102

MOLEX JAPAN CO., LTD.

84854--9102

MOLEX JAPAN CO., LTD.

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2. MECHANICAL COUPLING TO THE ROBOT

CONNECTION

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Table2.7 (f) Connector specifications (device net cable, on the user equipment side) (S--420iF/W/S/L) Cable name

Input side (J1--axis base)

Manufacturer

DS (signal line)

MINI connector for use on the device net 5--pin, female 1

DP (power line)

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

09 32 010 3101 (Han 10 EE F)

Contact

09 33 000 6220 6214 6205 6204 6202 6207

Clamp Select one.

just

HARTING Electronik Co., Ltd.

AWG20 AWG18 AWG18 AWG16 AWG14 AWG12

09 00 000 5083 5086 5090 5094 Many other types are available.

162

Output side (J2--axis base)

Output side (J3--axis casing)

MINI connector for use on the device net 5--pin, male

MINI connector for use on the device net 5--pin, male

MINI connector for use on the device net 4--pin, male

MINI connector for use on the device net 4--pin, male

CONNECTION

B--80505E/06

3

3. TRANSPORTATION AND INSTALLATION

TRANSPORTATION AND INSTALLATION

3.1 TRANSPORTATION

1) Transportation using a crane The robot can be transported by lifting it. When transporting the robot, be sure to change the attitude of the robot to that shown in Fig. 3.1 (a), (c) and lift by attaching ropes to the four M20 eyebolts. 2) Transportation using a forklift The robots can also be transported using a forklift (Refer to Fig. 3.1 (a), (c)). Transport materials are available as an option. NOTE Always attach the transportation equipment when transporting the S--420i R. Otherwise, the robot is likely to fall forward.

163

3. TRANSPORTATION AND INSTALLATION

CONNECTION

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iF, iW, iW/175 : 2053.3 iS : 1917.3 iF/2.85 iW/2.85 : 2462.9 iL : 2598.9

Fig.3.1 (a) Transportation using a crane (S--420iF/W/S/L)

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CONNECTION

3. TRANSPORTATION AND INSTALLATION

Fig.3.1 (b) Transportation using a forklift (S--420iF/W/S/L)

165

3. TRANSPORTATION AND INSTALLATION

CONNECTION

Fig.3.1 (c) Transportation using a crane (S--420iR)

Fig.3.1 (d) Transportation using a forklift (S--420iR)

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CONNECTION

3. TRANSPORTATION AND INSTALLATION

Fig.3.1 (e) Mechanical interface for eyebolt and transport equipment

167

3. TRANSPORTATION AND INSTALLATION

3.2 ROBOT TRANSPORTATION CONSIDERATIONS

CONNECTION

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Proper shipping and handling methods will help preserve the operational usefulness of the robotic equipment. Robots are handled many times from manufacturing to final installation at the plant. All individuals involved with handling this robotic equipment should be aware of the proper methods which must be used. Special items for consideration include: D Lifting with a fork truck (pg. 160) D Overhead Crane Lifting (pg. 160) D Type of Transportation Truck to Specify D Shipping Skids and Base Plates (pg. 162) D Proper/Improper Securing to a Truck Deck (pg. 165, 166) D Shipping with Tooling Attached (pg. 164) Fork truck considerations: When using a fork truck to lift the robot, be sure that the forks are set wide enough to slide into the center of the lifting pockets. Never use forks which are set too narrow or too wide for this feature. Using improperly set forks can cause crowding of the castings and could potentially damage them. The proper fork spacing is 41” between forklift pocket centers (or 1,042mm). Overhead crane lifting: Many facilities use overhead cranes to move machinery into position. FANUC provides lifting eyebolts at the base of the robot for this purpose. To prevent damage to the upper arm components, a spreader bar is recommended. Vehicle transportation: When robots must be transported on highways, it is imperative that the selected truck be equipped with “air ride” suspension. This type of suspension provides the most protection to the equipment from road shocks and damage. Shipping skids and base plates: FANUC ships robots on skids designed for the purpose of properly handling the equipment. When robots are placed into systems, they are removed from these skids and generally placed on steel floor plates. These plates are then secured to the floor. In cases where this operation occurs at the plant, the skids may be discarded. In instances where the robots are incorporated into systems away from the plant (majority of cases), the skids must be saved. Upon completion of the system runoff, the robots (without baseplates) should be placed back onto the shipping skids for transportation to the plant.

168

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CONNECTION

3. TRANSPORTATION AND INSTALLATION

Securing robots to the vehicle: After the robots are placed onto the shipping skids, they can be loaded onto the truck. Proper securing of the robots involves chaining the shipping skid to the truck deck. Under NO circumstances should chains (or other securing devices) be attached to the robot. This practice can cause irreparable damage to the robotic equipment. Shipping with tooling attached: FANUC always recommends that heavy tooling be removed from the robot arm prior to shipping. There are instances where tooling can be left on the robot. These include medium/light weight tools, and short distance moves. In these cases, the tooling could be left on the robot, but arm blocking is required. The robot should be placed into the shipping position and blocked with wood supports between the arm and lower casting. The blocking could be secured with plastic banding which will prevent marring.

169

3. TRANSPORTATION AND INSTALLATION

CONNECTION

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Transport Equipment Transport Equipment

Shipping skid

Fig.3.2 (a) Robot Mounted on Proper Shipping Skid

FANUC ships S-420i robots to customers on special shipping skids. Usually these are made of steel, but on certain models, wood skids are used. S-420i robots should only be shipped using these skids. Under no circumstances should the robot be shipped without these skids. Robots should NOT be shipped with steel mounting plates attached.

170

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CONNECTION

3. TRANSPORTATION AND INSTALLATION

After a robot is ready for shipment, it must be placed into the shipping position. This position places the robot directly over the shipping skid which helps prevent damage from improper handling.

Fig.3.2 (b) Shipping Position of Robot

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3. TRANSPORTATION AND INSTALLATION

CONNECTION

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FANUC recommends that all tooling be removed from the robot wrist prior to shipment. In some cases where robots will be transported over a short distance, the tooling can remain mounted to the robot wrist. If the robot is to be shipped with the tooling mounted, it is imperative that the upper arm is blocked to reduce shipping damages.

Heavy Tooling

Blocking

Fig.3.2 (c) Shipping Robot with Tooling (Special Considerations)

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3. TRANSPORTATION AND INSTALLATION

To properly transport a robot, it must be mounted to a skid. This robot skid must be secured to the truck deck. Chains or straps are not to be attached to any aspect of the robot arm.

Chains or Straps

Truck Deck

Shipping Skid Truck Deck

Fig.3.2 (d) Proper Robot Securing to Truck

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CONNECTION

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Under NO circumstances are chains or straps to be run through the fork lift pockets. This method can cause structural damage to the robot mechanical unit and/or peripherals which have been mounted to them.

Never chain through fork pockets

Chains or Straps

Fig.3.2 (e) Improper Robot Securing to Truck

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3.3 INSTALLATION

3. TRANSPORTATION AND INSTALLATION

CONNECTION

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Fig. 3.3 (a) shows the robot base dimensions. Fig. 3.3 (b) shows an actual example of robot installation. The floor plate should be embedded in concrete and fastened with chemical anchors. Also fasten the base plate to the robot base using M20 x 60 bolts (strength classification 12.9). Next, position the robot and weld the base plate to the floor plate. Fig. 3.3 (c) shows another example of the robot installation for S--420iR. The floor plate should be either welded to the frame or fastended with eight M20 x 60 bolts (strength classification 12.9). Also fasten the base plate to the robot base using four M20 x 60 bolts (strength classification 12.9) and four M16 x 60 bolts (strength classification 12.9) with plain washers. Next, position the robot and weld the base plate to the floor plate. Avoid placing any object in front of the robot on the mounting surface to facilitate the installation of the mastering fixture, as shown in Fig. 3.3 (a). Fig. 3.3 (d) and table 3.3 show force and movement applied to the base plate during emergency stop state.

Fig.3.3 (a) Installation hole dimensions of the robot base

NOTE 1 Parts to be provided by the customer: i) S--420iF/W/S/L Robot mounting bolts : M20 x 60 (strength classification 12.9) Chemical anchors : M20 (strength classification 4.8) Base plates : thickness 32 Floor plate : thickness 32 ii) S--420iR Robot mounting bolts : M16 x 60 (strength classification 12.9) : M20 x 60 (strength classification 12.9) Plain washers Base plates Floor plate Frame

: M16 : thickness 32 : thickness 32

4pcs. 8pcs. 3pcs.

4pcs. 4pcs. (12pcs.) 4pcs. 3pcs.

2

Installation work (welding, anchoring, etc.) is prepared by the customer.

3

S--420i severe dust/liquid protection, installation. When the robots work in the environment, using water or liquid, complete draining must need. Incomplete draining will make robot break down.

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3. TRANSPORTATION AND INSTALLATION

CONNECTION

Fig.3.3 (b) Actual installation example (S--420iF/W/S/L)

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CONNECTION

Fig.3.3 (c) Actual installation example (S--420iR)

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3. TRANSPORTATION AND INSTALLATION

CONNECTION

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Fig.3.3 (d) Force and moment during emergency stop

Table3.3 Force and moment during emergency stop Vertical moment MV [kgm]

Force in vertical direction FV [kg]

Horizontal moment MH [kgm]

Force in horizontal direction FH [kg]

S--420i F

4500

3200

1900

1900

S--420i F/2.85

5100

3200

2100

1800

S--420i W

4600

3200

2000

1900

S--420i W/175

4900

3400

2400

2000

S--420i W/2.85

5600

3500

2500

2100

S--420i S

3600

2900

1000

1300

S--420i L

5200

3200

2200

1800

S--420i R

6800

3700

3600

2700

S--420i R/120

6700

3600

3400

2500

Model

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3.4 MAINTENANCE AREA

CONNECTION

3. TRANSPORTATION AND INSTALLATION

Fig. 3.4 (a), (b) shows the maintenance area of the mechanical unit. In mastering, it needs to take the posture of Fig. 5.3.3 (f)~(j) of Chapter I. Keep the enough space for taking the posture.

Fig.3.4 (a) Maintenance area (S--420iF/W/S/L)

Fig.3.4 (b) Maintenance area (S--420iR)

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3. TRANSPORTATION AND INSTALLATION

3.5 AIR PIPING

CONNECTION

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Fig. 3.5 (a) shows how to connect air hose to the robot. If the air control set is specified as an option, the air hose between the mechanical unit and the air control set is provided. Mount the air control set using the information in Fig. 3.5 (b).

Fig.3.5 (a) Air piping Option

NOTE Pipe used in the mechanical unit has an outer diameter of 12 mm and an inner diameter of 8 mm. You can use a different size pipe outside the mechanical unit. Fill the oiler having three air components to the specified level with turbine oil #90 to #140. The machine tool builder is required to prepare mounting bolts.

Fig.3.5 (b)Air control set Option

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3.6 PURGE AIR PIPING (FOR SEVERE DUST/LIQUID PROTECTION)

3. TRANSPORTATION AND INSTALLATION

CONNECTION

Following figure shows how to connect air tube to the robot. The air tube between the mechanical unit and air filter unit is provided. If the air tube is extended, use hard tube, because pressure drop is reduced.

Specification of air filter unit and element Name

Specifications

Air filter unit

A97L--0218--0016

Element set for replacing

A97L--0218--0016#EL

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3.7 INSTALLATION SPECIFICATIONS

Table3.7 Installation specifications Specifications

Items Air pressure

Pressure Air flow

Weight of mechanical unit

5 -- 7 kgf/cm2, 0.49 -- 0.69 Mpa (Set pressure 5 kgf/ cm2, 0.49 MPa) Max. peak 150 Nl/min, 0.15 Nm3/min (Note 1) Approx. 1500 kg (including controller) → S--420iF/W/S 1600 kg (including Controller) → S--420iF/2.85W/175, W/2.85 iL 1700 kg → S--420iR, R/120

Allowable ambient temperature

0 -- 45°C

Allowable ambient humidity

Usual: Less than 75% RH Short period (in one month): Max. 98% RH or less Condensation free

Atmosphere

Free of corrosive gases (Note 2) Less than 0.5 G, 4.9 m/s2

Vibration

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

3.8 STORAGE

To store the robot, set it to the same attitude as that used for transportation (See Fig. 3.1 (a) and (b)) and store it on a level surface.

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A

A. SPARE PARTS LIST

APPENDIX

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SPARE PARTS LIST

TableA (a) Cables (for the basic axes) No. K121 K122 K123 K124 K125 K131 K132 K136 K141 K142 K143 K144 K145 K161 K162 K181 K182 K183 K184 K185

Specifications A660--8010--T136 A660--8010--T136#C A660--4003--T305 A660--4003--T305#C A660--8010--T223 A660--8010--T223#C A660--8010--T224 A660--8010--T224#C A660--4003--T319 A660--4003--T319#C A660--8010--T148 A660--4003--T313 A660--8010--T220 A660--8010--T133 A660--8010--T133#C A660--4003--T304 A660--4003--T304#C A660--8010--T421 A660--8010--T421#C A660--8010--T422 A660--8010--T422#C A660--4003--T332 A660--4003--T332#C A660--4003--T297 A660--4003--T298 A660--8011--T005 A660--8011--T005#C A660--4003--T377 A660--4003--T337#C A660--8011--T006 A660--8011--T006#C A660--8011--T007 A660--8011--T007#C A660--4003--T378 A660--4003--T378#C

Function M1 to M6 PULCO M1 to M6 POWER

Applicable models S--420i F/W/L with a integrated control unit

M1 to M6 PULCO, EE M1 to M6 PULCO

S--420i S 420i F/W/L with a remote control unit

M1 to M6 POWER M1 to M6 PULCO, EE M1 to M6 POWER M1 to M6 PULCO M1 to M6 PULCO M1 to M6 POWER

S--420i S 420i R, R/120

S--420i S with a integrated control unit

M1 to M6 PULCO, EE M1 to M6 PULCO

S--420i S 420i S with a remote control unit

M1 to M6 POWER EXTENSION EXTENSION M1 to M6 PULCO M1 to M6 POWER M1 to M6 PULCO, EE M1 to M6 PULCO M1 to M6 POWER

S 420i L S--420i S--420i F/2.85 S 420i W/2.85 S--420i with a integrated control unit S--420i F/2.85 S--420i W/2.85 t a remote e ote with control unit

NOTE 1 “-- #C” cables are used for compact type mechanical unit. 2 Cable K161, K162 conform to CE Marking.

185

NOTE2) NOTE2)

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TableA (b) Cables (for the basic axes : CE Marking) No. K221 K222 K223 K224 K225 K231 K232 K236 K241 K242 K243 K244 K245 K281 K282 K283 K284 K285

Specifications A660--8011--T017 A660--8011--T017#C A660--4003--T381 A660--4003--T381#C A660--8011--T018 A660--8011--T018#C A660--8011--T019 A660--8011--T019#C A660--4003--T382 A660--4003--T382#C A660--8011--T020 A660--4003--T383 A660--8011--T021 A660--8011--T022 A660--8011--T022#C A660--4003--T384 A660--4003--T384#C A660--8011--T023 A660--8011--T023#C A660--8011--T024 A660--8011--T024#C A660--4003--T385 A660--4003--T385#C A660--8011--T028 A660--8011--T028#C A660--4003--T386 A660--4003--T386#C A660--8011--T029 A660--8011--T029#C A660--8011--T030 A660--8011--T030#C A660--4003--T387 A660--4003--T387#C

Function M1 to M6 PULCO M1 to M6 POWER

Applicable models S--420i F/W/L with a integrated control unit

M1 to M6 PULCO, EE M1 to M6 PULCO

S--420i S 420i F/W/L with a remote control unit

M1 to M6 POWER M1 to M6 PULCO, EE M1 to M6 POWER M1 to M6 PULCO M1 to M6 PULCO M1 to M6 POWER

S--420i S 420i R, R/120

S--420i S with a integrated control unit

M1 to M6 PULCO, EE M1 to M6 PULCO

S--420i S 420i S with a remote control unit

M1 to M6 POWER M1 to M6 PULCO M1 to M6 POWER M1 to M6 PULCO, EE M1 to M6 PULCO M1 to M6 POWER

S--420i F/2.85 S 420i W/2.85 S--420i with a integrated control unit S--420i F/2.85 S--420i W/2.85 t a remote e ote with control unit

NOTE “-- #C” cables are used for compact type mechanical unit.

TableA (c) Cables (for the basic axes : Severe dust/liquid protection) No.

Specifications

Function

K323 K331

A660--8011--T944 A660--8012--T001

M1 to M6 PULCO, EE M1 to M6 PULCO, EE

Applicable models S--420i F/W/L S--420i R

NOTE For the remote controller type, the M1 to M6 POWER cable is the same as for the CE Mark.

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TableA (d) Cables (for the wrist) No.

Specifications

K108 K109 K110

A660--2004--T285 A660--4003--T283 A660--4003--T450

Function M6P COUPLING M6MBK COUPLING EXTENSION

Applicable models S--420i S 420i F/W/S/L/R

NOTE Wrist cables conform to CE Marking.

TableA (e) Cables (optional) No.

Specifications

K111 K112 K113 K114 K115

A660--2004--T203 A660--2004--T204 A660--2004--T205 A660--8009--T796 A660--8010--T218

EE (RDI/RDO) AS (UER/SIGNAL) AP (USER/POWER) J1 OT J1 OT

Integrated type

K119

A660--2004--T325

I/O (STANDARD)

S--420i F/W/S/L

K120

A660--4003--T328

I/O (SPECIAL)

K128

A05B--1313--D001

I/O (STANDARD)

K129

A05B--1313--D003

I/O (SPECIAL)

K133 K134 K138 K139 K524 K525

A660--2004--T330 A660--2004--T345 A05B--1313--D002 A05B--1313--D004 A660--4003--T585 A660--4003--T586

AS (UER/SIGNAL) AP (USER/POWER) I/O (STANDARD) I/O (SPECIAL) DEVICENET (SIGNAL) DEVICENET (POWER)

Function

Applicable models

S 420i F/W/S/L S--420i

Integrated type Remote type with a integrated control unit S--420i F/W/S/L with a remote control unit

S 420i R S--420i

S 420i F/W/S/L S--420i

TableA (f) Cables (optional : Severe dust/liquid protection) No.

Specifications

K329 K339

A05B--1313--D023 A05B--1313--D024

187

Function I/O (SPECIAL) I/O (SPECIAL)

Applicable models S--420i F/W/L S--420i R

A. SPARE PARTS LIST

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TableA (g) Cables (optional : CE Marking) No.

Specifications

K211 K212 K213

A660--2004--T809 A660--2004--T804 A660--2004--T805

EE (RDI/RDO) AS (UER/SIGNAL) AP (USER/POWER)

Integrated type

K219

A660--2004--T817

I/O (STANDARD)

S--420i F/W/S/L

K220

A660--4003--T476

I/O (SPECIAL)

K228

A05B--1313--D011

I/O (STANDARD)

K229

A05B--1313--D013

I/O (SPECIAL)

K233 K234 K238 K239

A660--2004--T807 A660--2004--T808 A05B--1313--D012 A05B--1313--D014

AS (UER/SIGNAL) AP (USER/POWER) I/O (STANDARD) I/O (SPECIAL)

Function

Applicable models

S 420i F/W/S/L S--420i

with a integrated control unit S--420i F/W/S/L with a remote control unit

S 420i R S--420i

TableA (h) Motors Name (Axis) M1, M2, M3 (J1, J2,J3) M4 (J4) M5 (J5) M6 (J6)

Specifications A06B--0147--B675 A06B--0146--B675 A06B--0142--B675#0006 A06B--0162--B175#0006

Remarks α 22/2000 α 22/1500 α 12/2000 α M6/3000

TableA (i) For High duty (M4 to M6 are common) Name (Axis) M1, M2, (J1, J2) M3 (J3)

Specifications A06B--0186--B675#0011 A06B--0147--B675

Remarks α M30/3000HV α 22/2000

TableA (j) For S--420iW/2.85 (M4 to M6 are common) Name (Axis) M1, M2, (J1, J2) M3 (J3)

Specifications A06B--0147--B675 A06B--0186--B675#0011

Remarks α 22/2000 α M30/3000HV

NOTE The specification of the motor for J5 and J6 axis manufactured before August 1995 are J5 AXIS : A06B--0142--B675#0003 J6 AXIS : A06B--0162--B175#0003 There are two pulse--coder cable which correspond to each motor. #0003 : K107 (A660--4003--T233) #0006 : K110 (A660--4003--T450) When you change the motor (#0003), you must prepare the cable--K110 and new motor (#0006).

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NOTE5) NOTE5)

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TableA (k) Reducer Specifications

Name J1--axis reducer J2--axis J2 axis reducer

J3--axis J3 axis reducer J4--axis reducer J6 axis reducer J6--axis

A97L--0118--0939#250C--35 A97L--0118--0940#250A--118 A97L--0118--0940#250A--129 A97L--0118--0940#250A--141 A97L--0118--0941#250A--129 A97L--0118--0941#250A--171 A97L--0118--0941#250A--141 A97L--0118--0936#70C--36 A97L--0118--0942#30A--81 A97L--0118--0942#30A--121

Applicable models S--420i F/W/S/L/R S--420i F/S/L S--420i W/R S--420i R/120 S--420i F/S/L/R S--420i W S--420i F2.85/R120 S--420i F/W/S/L/R S--420i F/S/L/R S--420i W

TableA (l) Gear Specifications

Name

A290--7313--X221 A290--7313--Y221

J1--axis pinion gear

A290--7313--Z221 A290--7313--X222 A290--7313--Y222

J1--axis center gear

A290--7313--Z222

J2/J3 gearbox assembly J2/J3 gear A assembly J2/J3 gear B assembly

Applicable models S--420i F/W/L/R S--420i S S--420i R/120 S--420i F/2.85 S--420i W/2.85 S--420i F/W/L/R S--420i S S--420i R/120 S--420i F/2.85 S--420i W/2.85 NOTE6)

A290--7313--V351 A290--7313--V352

S--420i F/W/S/L Compact type

A290--7313--V353 A290--7313--X404 A290--7313--Y404 A290--7313--X405 A290--7313--Y405

S--420i F/S/L/R S--420i W S--420i F/S/L/R S--420i W

J5--axis gear 1 assembly J5--axis gear 2 assembly J5--axis gear 3 assembly

A290--7313--V521

S--420i F/S/L/R

A290--7313--V524

S--420i W

A290--7313--V522

S--420i F/S/L/R

A290--7313--V525

S--420i W

A290--7313--V523

S--420i F/S/L/R

A290--7313--V526

S--420i W

J5 axis J5--axis gear 4

A290--7313--X508 A290--7313--Y508

S--420i F/S/L/R S--420i W

J4--axis J4 axis pinion gear J4--axis J4 axis center gear

NOTE V351 includes V352, V353 and the other parts.

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TableA (m) Others (mechanical unit) Specifications

Name Balancer Balancer Wrist unit Wrist unit Shaft assembly J3--axis arm assembly J3--axis arm assembly J3--axis arm assembly J3--axis arm assembly Cable track

A05B--1313--V301 A05B--1313--V311 A290--7313--V501 A290--7313--V503 A290--7313--V321 A290--7313--V401 A290--7313--V441 A290--7313--V461 A290--7313--V471 A97L--0218--0608#27

Applicable models S--420i F/W/S/L S--420i R S--420i F/S/L/R S--420i W S--420i F/W/S/L/R S--420i F/W/L S--420i S S--420i L/R S--420i R S--420i F/W/S/L/R

TableA (n) Others (mechanical unit) for severe dust/liquid protection Specifications

Name Balancer Balancer Wrist unit Wrist unit J3--axis arm assembly J3--axis arm assembly Extended arm assembly

A290--7313--V302 A290--7313--V312 A290--7313--V551 A290--7313--V553 A290--7313--V411 A290--7313--V472 A290--7313--V462

Applicable models S--420i F/W/L S--420i R S--420i F/L/R S--420i W S--420i F/W/L S--420i R S--420i L/R

TableA (o) Battery and grease Specifications

Applicable models

Battery Grease

A98L--0031--0005 A98L--0040--0119#2KG

Grease

A97L--0001--0179#2

1.5 V, size D Kyodo Yushi Moly--white RE No.00 Shell Alvania No.2

Name

TableA (p) O--rings Specifications

Name O--ring O--ring O--ring O--ring O--ring O--ring O--ring O--ring O--ring O--ring O--ring O--ring

JB--ORIA--G125 A98L--0001--0347#S115 A98L--0040--0041#280 JB--ORIA--G135 JB--ORIA--G210 JB--ORIA--G290 JB--ORIA--G270 A98L--0040--0041#176 A98L--0001--0347#S70 JB--ORIA--G115 A98L--0040--0041#165 A98L--0040--0041#173

190

Location M1 to M5 M6 J1--axis reducer J1--axis reducer J1--axis reducer J1--axis reducer J2/J3--axis reducer J3--axis reducer J4--axis reducer J4--axis reducer J4--axis reducer J4--axis reducer

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B

APPENDIX

CONNECTION DIAGRAM

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B. CONNECTION DIAGRAM

B. CONNECTION DIAGRAM APPENDIX

Fig.B.1 Internal Connection Diagram (S--420iF, W, W/175, Integrated type)

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B. CONNECTION DIAGRAM

Fig.B.2 Internal Connection Diagram (S--420iF, W, W/175, Remote type)

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Fig.B.3 Internal Connection Diagram (S--420iF/2.85, W/2.85, Integrated type)

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B. CONNECTION DIAGRAM

Fig.B.4 Internal Connection Diagram (S--420iF/2.85, W/2.85, Remote type)

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B. CONNECTION DIAGRAM APPENDIX

Fig.B.5 Internal Connection Diagram (S--420iS, integrated type)

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B. CONNECTION DIAGRAM

Fig.B.6 Internal Connection Diagram (S--420iS, Remote type)

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B. CONNECTION DIAGRAM APPENDIX

Fig.B.7 Internal Connection Diagram (S--420iL, Integrated type)

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B. CONNECTION DIAGRAM

Fig.B.8 Internal Connection Diagram (S--420iL, Remote type)

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B. CONNECTION DIAGRAM APPENDIX

Fig.B.9 Internal Connection Diagram (S--420iR)

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C

APPENDIX

PERIODIC MAINTENANCE TABLE

TableC Maintenance list S--420iF

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Table of Contents

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SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s--1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p--1

I MAINTENANCE 1. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

1.1

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

7

1.2

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

7

1.3

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

8

1.4

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

9

1.5

MAJOR COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

2. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

2.1

DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

2.2

3--MONTH CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

2.3

6--MONTH CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

2.4

ANNUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

2.5

3--YEAR CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

2.6

MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

2.7

CAUTION STICKERS FOR DAILY CHECKS (ONLY SEVERE DUST/LIQUID PROTECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

3.1

REPLACING GREASE OF THE DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

3.2

GREASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

3.3

REPLACING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

3.4

REPLACING FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

4.1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

4.2

PROBLEMS AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

4.3

THE MEASUREMENT OF THE BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

5. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

5.1

AXIS LIMITS SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 5.1.2 5.1.3

5.2 5.3

Zero Point Position and Motion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hard Stopper and Limit Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 32 37 38

ADJUSTING J1--AXIS LIMIT SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting Alarms and Preparing for Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mastering to a Fixture (Master Position Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero Degree Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Axis Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

c--1

40 41 43 50 53 57

Table of Contents

5.4

B--80505E/06

ADJUSTING J5--AXIS BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

6. REPLACING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

6.1

PART REPLACEMENT AND CORRESPONDING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .

60

6.2

REPLACING J1--AXIS MOTOR (M1) AND REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

6.3

REPLACING J2/J3--AXIS MOTOR (M2/M3) AND REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

6.4

REPLACING J4--AXIS MOTOR (M4) AND J4--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . .

76

6.5

REPLACING WRIST UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

6.6

REPLACING J5--AXIS MOTOR (M5) AND J5--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . .

79

6.7

REPLACING J6--AXIS MOTOR (M6) AND J6--AXIS REDUCER . . . . . . . . . . . . . . . . . . . . . . . . .

82

6.8

RELEASING A BRAKE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

7. PIPING AND WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

7.1

PIPING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87

7.2

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89

8. REPLACING CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 8.1

CABLE FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106

8.2

REPLACING THE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

8.3

REPLACING THE OPTIONAL J1--AXIS LIMIT SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . .

122

II CONNECTION 1. ROBOT INTERFERENCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 2. MECHANICAL COUPLING TO THE ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 2.1

WRIST LOAD CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141

2.2

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

143

2.3

MECHANICAL COUPLING OF END EFFECTOR TO WRIST . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

2.4

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

146

2.5

SETTING OF SYSTEM VARIABLES FOR TURBO MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150

2.6

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

151

2.7

INTERFACE FOR END EFFECTER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

3. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 3.1

TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163

3.2

ROBOT TRANSPORTATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168

3.3

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175

3.4

MAINTENANCE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

179

3.5

AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

3.6

PURGE AIR PIPING (FOR SEVERE DUST/LIQUID PROTECTION) . . . . . . . . . . . . . . . . . . . . .

181

3.7

INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

3.8

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

c--2

B--80505E/06

Table of Contents

APPENDIX A. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 B. CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 C. PERIODIC MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

c--3

Index

B--80505E/06

[Numbers]

[J]

3--month Checks, 13

J1--axis Drive Mechanism, 7

3--year Checks, 13

J2/J3--axis Drive Mechanism, 7

6--month Checks, 13

J4--axis Drive Mechanism, 8 J5/J6--axis Drive Mechanism, 9

[A] [L]

Adjusting J1--axis Limit Switch (Option), 39 Adjusting J5--axis Backlash, 59

Load Conditions on J2--axis Base and J3--axis Arm, 143

Adjustments, 30 Air Piping, 180 Air Supply (Option), 151

[M]

Annual Checks, 13

Maintenance Area, 179

Axis Limits Setup, 30

Maintenance Tools, 14 Major Component Specifications, 10

[C]

Mastering, 40

Cable Forming, 106

Mastering to a Fixture (Master Position Master), 43

Caution Stickers for Daily Checks (Only Severe Dust/ Liquid Protection), 14

Mechanical Coupling of End Effector to Wrist, 145 Mechanical Coupling to the Robot, 140

Configuration, 3 Connection Diagram, 191

[P] Part Replacement and Corresponding Adjustment, 60

[D]

Periodic Maintenance, 15

Daily Checks, 11

Periodic Maintenance Table, 201 Piping and Wiring, 87 Piping Diagram, 87

[E]

Preventive Maintenance, 11

Equipment Mounting Face, 146

Problems and Causes, 24 Purge Air Piping (for Severe Dust/Liquid Protection), 181

[G] Greasing, 20

[Q] Quick Mastering, 53

[H] Hard Stopper and Limit Switch Setting, 38

[R] Releasing A Breake (Option), 85

[I]

Replacing Battery, 22 Replacing Cable, 105

Installation, 168, 175

Replacing Filter Element, 23

Installation Specifications, 182

Replacing Grease of the Drive Mechanism, 15

Interface for End Effecter (Option), 152

Replacing J1--axis Motor (M1) and Reducer, 62 i--1

Index

B--80505E/06

[T]

Replacing J2/J3--axis Motor (M2/M3) and Reducer, 65 Replacing J4--axis Motor (M4) and J4--axis Reducer, 76

The Measurement of the Backlash, 26

Replacing J5--axis Motor (M5) and J5--axis Reducer, 79

Transportation, 163

Replacing J6--axis Motor (M6) and J6--axis Reducer, 82

Transportation and Installation, 163

Replacing Parts, 60

Troubleshooting, 24

Replacing the Cables, 114 Replacing the Optional J1--axis Limit Switch (Option), 122

[W]

Replacing Wrist Unit, 78 Resetting Alarms and Preparing for Mastering, 41 Wiring Diagram, 89

Robot Interference Area, 125

Wrist Load Conditions, 141

[S] Setting of System Variables for Turbo Move, 150

[Z]

Single Axis Mastering, 57 Software Setting, 37

Zero Degree Mastering, 50

Spare Parts List, 185 Storage, 182

Zero Point Position and Motion Limit, 32

i--2

Revision Record FANUC Robot S--420i F/W/S/L/R MECHANICAL UNIT MAINTENANCE MANUAL (B--80505E)

05

Dec.,’95

S Additional descriptions for CE marking S Additional descriptions for compact type S Modification of base loading data

04

Aug.,’95

S Robot transportation consideration is added in II--Chapter 3. S Correction of errors.

03

Apr., ’95

Additional descriptions of S--420 iF/2.85

02

Feb., ’95

Additional descriptions of S--420 iW/iS/iL/iR

01

Aug., ’94

Revision

Date

Contents

06

Dec., ’97

Revision

Date

S Additional descriptions for severe dust/liquid protection S Modification of the backlash S Correction of errors. Contents