1801, MESEN-296-003, 001 MANIPULATOR INSTRUCTION MANUAL ES-01 series [CFD] 3rd edition ・Before attempting to operate the robot, please read through this operating manual carefully, and comply with all the safety-related items and instructions in the text. ・The installation, operation and maintenance of this robot should be undertaken only by those individuals who have attended one of our robot course. ・When using this robot, observe the low related with industrial robot and with safety issues in each country. ・This operating manual must be given without fail to the individual who will be actually operating the robot. ・Please direct any queries about parts of this operating manual which may not be completely clear or any inquiries concerning the after-sale service of this robot to any of the service centers listed on the back cover. This manual explains the robot specifications, structure of each part and the basic handling precautions for inspection and maintenance to maintain function of the robot for a long period of time. Basic operation and other optional installation method are also written in this manual. It is strongly recommended that this manual is read by robot utilization planners and installation staff as well as inspectors and maintenance staff for handling robot. And the robot is handled only after understanding this manual thoroughly. This product applies to the object of freight/ technology of the export controls according to the regulation of Foreign Exchange and Foreign Trade Management Law. Therefore, an export license is necessary based on the law in case of exporting. Safety Precautions Always read the following precautions and the separate “Precautions for Industrial Robots” before starting use of the robot to learn the required measures to be taken. CAUTION CAUTION WARNING CAUTION DANGER CAUTION CAUTION CAUTION All teaching work must be carried out by an operator who has received special training. (This also applies to maintenance work with the power source turned ON.) Enforcement of safety training For teaching work, prepare a work plan related to the methods and procedures of operating the robot, and to the measures to be taken when an error occurs or when restarting. Carry out work following this plan. (This also applies to maintenance work with the power source turned ON.) Preparation of work plan Prepare a device that allows operation to be stopped immediately during teaching work. (This also applies to maintenance work with the power source turned ON.) Setting of emergency stop switch During teaching work, place a sign indicating that teaching work is in progress on the start switch, etc. (This also applies to maintenance work with the power source turned ON.) Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact of the operator and robot. Installation of safety fence Establish a set signaling method to the related operators for starting work, and follow this method. Signaling of operation start As a principle turn the power OFF during maintenance work. Place a sign indicating that maintenance work is in progress on the start switch, etc. Indication of maintenance work in progress Before starting work, inspect the robot, emergency stop switch and other related devices, etc., and confirm that there are no errors. Inspection before starting work The points of the precautions are given below. DANGER When automatic operation of the robot is performed using multiple control devices (Sequencer, push-button switch), the interlocking of operation rights of the devices, etc. must be designed by the customer. CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION WARNING WARNING CAUTION WARNING CAUTION CAUTION Use the robot within the environment given in the specifications. Failure to do so could lead to a drop or reliability or faults. (Temperature, humidity, atmosphere, noise environment, etc.) Transport the robot with the designated transportation posture. Transporting the robot in a non-designated posture could lead to personal injuries or faults from dropping. Always use the robot installed on a secure table. Use in an instable posture could lead to positional deviation and vibration. Wire the cable as far away from noise sources as possible. If placed near a noise source, positional deviation or malfunction could occur. Do not apply excessive force on the connector or excessively bend the cable. Failure to observe this could lead to contact defects or wire breakage. Make sure that the workpiece weight, including the hand, does not exceed the rated load or tolerable torque. Exceeding these values could lead to alarms or faults. Securely install the hand and tool, and securely grasp the workpiece. Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation. Securely ground the robot and controller. Failure to observe this could lead to malfunctioning by noise or to electric shock accidents. Indicate the operation state during robot operation. Failure to indicate the state could lead to operators approaching the robot or to incorrect operation. When carrying out teaching work in the robot's movement range, always secure the priority right for the robot control. Failure to observe this could lead to personal injuries or damage if the robot is started with external commands. Keep the jog operation speed by the teach pendant（Manual operation）as low as possible, and always watch the robot. Failure to do so could lead to interference with the workpiece or peripheral devices. After editing the program, always confirm the operation with step operation（Check go operation ） before starting automatic operation. Failure to do so could lead to interference with peripheral devices because of programming mistakes, etc. CAUTION CAUTION WARNING CAUTION CAUTION CAUTION CAUTION Make sure that if the safety fence entrance door is opened during automatic operation, the door is locked or that the robot will automatically stop. Failure to do so could lead to personal injuries. Never carry out modifications based on personal judgments, or use non-designated maintenance parts. Failure to observe this could lead to faults or failures. When the robot arm has to be moved by hand from an external area, do not place hands or fingers in the openings. Failure to observe this could lead to hands or fingers catching depending on the posture. Do not stop the robot or apply emergency stop by turning the robot controller's main power OFF. If the robot controller main power is turned OFF during automatic operation, the robot accuracy could be adversely affected. Moreover, it may interfere with the peripheral device by drop or move by inertia of the arm. Do not turn off the main power to the robot controller while rewriting the internal information of the robot controller such as the program or parameters. If the main power to the robot controller is turned off while in automatic operation or rewriting the program or parameters, the internal information of the robot controller may be damaged. Make sure there are no mistakes in the wiring. Connecting differently to the way specified in the manual can result in errors, such as the emergency stop not being released. In order to prevent errors occurring, please be sure to check that all functions (such as the controller operation panel / teach pendant emergency stop, customer emergency stop, and door switch) are working properly after the wiring setup is completed Use the network equipments (personal computer, USB hub, LAN hub, etc) confirmed by manufacturer. The thing unsuitable for the FA environment (related with conformity, temperature or noise) exists in the equipments connected to USB. When using network equipment, measures against the noise, such as measures against EMI and the addition of the ferrite core, may be necessary. Please fully confirm the operation by customer. Guarantee and maintenance of the equipment on the market (usual office automation equipment) cannot be performed. Cautions on primary power connection of the controller CAUTION For leakage protection, make sure to set up earth leakage circuit breaker to the side of primary power supply of robot controller “CFD controller”. Failure to observe this could lead to shock hazard. Please refer to the following manuals concerning to connection and settings of primary power of CFD controller. “CFD controller/ operation manual / set up” (TCFEN-159) Chapter 2”Settings and connection” CAUTION Be careful of interference with peripheral equipment. Especially don't give a shock to the shaft (J3 axis). When you install the hand, be careful not to knock at the shaft end by the hammer etc. The shaft may be damaged. Take care also of the following items. At Check go /back operation, when selecting ”Continuous check go mode” of this robot’s controller, the function will work to simulate the locus of the time of playback operation（High speed operation） at the time of low speed operation based on accuracy settings（A1～A8） and the recorded speed. However, the robot's locus of movement may change with specified speed. Especially as for the corner section, short cut distance may change. Therefore, when beginning automatic operation, moves at low speed at first, and you should gather speed slowly with being careful of interference with peripheral equipment. Short cut Arch movement （Reference） ＜Constant setting＞［5 Operation/Teaching condition］［1 Operation condition］ → “28 Constant path of teach mode” (1) By performing settings at ＜Constant setting＞［9 Territory］menu, it is possible to check from the external PLC, etc that whether or not the robot locates at the designated area. Please utilize this setting to avoid interlock (crush avoidance). Please refer to the following manuals for details of settings. “CFD controller / Operation manual / Set up” (TCFEN-159) Chapter 4 “Preparation for playback operation” *Introduction Thank you for purchasing the Fujikoshi industrial robot. This instruction manual explains the method of unpacking, installation and maintenance and inspection of the robot arm. Always read through this manual before starting use to ensure correct usage of the robot. The information contained in this document has been written to be accurate as much as possible. Please interpret that items not described in this document "cannot be performed." This document explains for the following robot type. <Robot type> ・ES06 series ・ES12 series No part of this manual may be reproduced by any means or in any form. The details of this manual are subject to change without notice. The information contained in this document has been written to be accurate as much as possible. However, if you find any doubtful, wrong or skipped point, contact your nearest NACHI service branch. Contact information is written on the back cover. This specification is original. Company names and production names in this document are the trademarks or registered trademarks of their respective owners. Copyright(C) 2016 NACHI-FUJIKOSHI CORP. CONTENTS 1 Before starting use.................................................................................................................................................... 1-1 1.1 Using the instruction manuals ............................................................................................................................. 1-1 1.1.1 The details of each instruction manuals .................................................................................................. 1-1 1.1.2 Symbols used in instruction manual ........................................................................................................ 1-2 1.2 Safety Precautions.............................................................................................................................................. 1-3 1.2.1 Precautions ............................................................................................................................................. 1-3 ......................................................................................................................................................................... 1-4 2 Unpacking to Installation........................................................................................................................................... 2-7 2.1 Confirming the product........................................................................................................................................ 2-7 2.2 Installation........................................................................................................................................................... 2-8 2.2.1 Unpacking ............................................................................................................................................... 2-8 2.2.2 Transportation procedures ...................................................................................................................... 2-9 2.2.3 Installlation procedures.......................................................................................................................... 2-12 2.2.4 Grounding procedures........................................................................................................................... 2-14 2.2.5 Connecting with the controller ............................................................................................................... 2-15 2.2.6 Ethernet Cables..................................................................................................................................... 2-17 2.2.7 Passing air hoses and cables through the shaft .................................................................................... 2-20 2.3 Setting the origin ............................................................................................................................................... 2-24 2.3.1 Installing the teach pendant................................................................................................................... 2-24 2.3.2 Setting the origin with the origin data input method（Numerical value input method） ............................ 2-25 2.4 Confirming the operation................................................................................................................................... 2-29 3 Installing the option devices.................................................................................................................................... 3-47 3.1 Installing the solenoid valve set ........................................................................................................................ 3-47 3.2 Installing the hand input cable........................................................................................................................... 3-51 3.3 Installing the hand output cable ........................................................................................................................ 3-52 3.4 Changing the operating range........................................................................................................................... 3-53 3.5 Hand internal wiring and piping set ................................................................................................................... 3-55 3.6 External Wiring and Piping Box......................................................................................................................... 3-59 4 Basic operations ..................................................................................................................................................... 4-61 5 Maintenance and Inspection ................................................................................................................................... 5-63 5.1 Maintenance and inspection interval................................................................................................................. 5-63 5.2 Inspection items ................................................................................................................................................ 5-64 5.2.1Daily inspection items............................................................................................................................. 5-64 5.2.2 Periodic inspection ................................................................................................................................ 5-65 5.3 Maintenance and inspection procedures .......................................................................................................... 5-66 5.3.1 Robot arm structure............................................................................................................................... 5-66 5.3.2 Installing/removing the cover................................................................................................................. 5-67 5.3.3 Packing Replacement Procedure .......................................................................................................... 5-69 5.3.4 Inspection, maintenance and replacement of timing belt ....................................................................... 5-73 5.3.5 Lubrication............................................................................................................................................. 5-81 5.3.6 Replacing the backup battery ................................................................................................................ 5-85 5.4 About Overhaul................................................................................................................................................. 5-87 5.5 Maintenance parts ............................................................................................................................................ 5-88 5.6 Resetting the origin（Encoder correction） ......................................................................................................... 5-89 5.6.1Jig method（Position recording method）................................................................................................. 5-90 5.6.2 Recording the origin data（Encoder correction value） ........................................................................................................5-101 6 Appendix....................................................................................................................................................Appendix107 Spare parts.........................................................................................................................................................Appendix109 NOTE 1Before starting use 1 Before starting use This chapter explains the details and usage methods of the instruction manuals, the basic terminology and the safety precautions. 1.1 Using the instruction manuals 1.1.1 The details of each instruction manuals The contents and purposes of the documents enclosed with this product are shown below. Use these documents according to the application. Th t t d Standard specifications ES06-01-CFD / ES12-01-CFD (SESEN-087) f th Instruction manual / Manipulator ES-01 series [CFD] (MESEN-296) Explains the product's standard specifications and option configuration. This manual. Explains the procedures from unpacking to installation, home position setting procedure, installation procedure for optional device, basic operation, and the maintenance and inspection procedures. CFD controller / Instruction manual / Option(Hardware) (ECFEN-182) Explains the hardware option of the CFD controller. CFD controller / Instruction manual / Option(I/O connection) (ECFEN-183) Explains the connection and set up procedure of some I/O function. (24VDC digital IO, DeviceNet, CC-LINK) CFD controller / Instruction manual / Set up (TCFEN-159) Explains the setting procedure. (Installation and connection procedure of the controller, Tool parameter, Ethernet, Home position, User coordinate system and etc.) CFD controller / Instruction manual / Basic operation (TCFEN-160) Explains the teaching and playback operations, usage procedure of file operation panel. FD controller / Instruction manual / External output input (TFDEN-007) Explains the external output/ input signal. Please refer in case of starting from External PLC. FD/CFD controller / Instruction manual / Software PLC (TFDEN-010) Explains the Software PLC function. FD controller / Instruction manual / Robot language (TFDEN-008) Explains the Robot language functions. FD controller / Instruction manual / Command reference (TFDEN-092) Explains the function command.（FN） CFD controller / Instruction manual / Conveyor synchronization function (TFDEN-050) Explains the Conveyor tracking function. CFD controller / Instruction manual / Shift function (TFDEN-047) Explains the shift function, which used shift register. FD on Desk Light/Regular/Pro / Instruction manual (TFDEN-904) Simple simulation software, which operates by Windows PC. It is possible to perform Setting of CFD controller, programming, operation simulation at Window PC. CFD controller / Instruction manual / Error code list (ECFEN-008) Explains the causes and remedies to be taken when an error occurs. Explanations are given for each error No. （Supplement）Instructions for other optional functions are also included in the attached disk. 1-1 Using the instruction manuals 1Before starting use 1.1.2 Symbols used in instruction manual The symbols and expressions shown in Table 1-1 are used throughout this instruction manual. Learn the meaning of these symbols before reading this instruction manual. Table 1-1:Symbols in instruction manual Terminology Item/Symbol Meaning Indicates the controller, which controls robot itself. The box, which mounts controlling part of robot CPU, the servo amplifier, the safety circuit, etc. Item CFD controller device （CFD controller） DANGER WARNING CAUTION Example） ［Emergency stop button］ Symbol Example) [Enable] ＋ [ON/1] （A） （B） Precaution indicating cases where there is a risk of operator fatality or serious injury if handling is mistaken. Always observe these precautions to safely use the robot. Precaution indicating cases where the operator could be subject to fatalities or serious injuries if handling is mistaken. Always observe these precautions to safely use the robot. Precaution indicating cases where operator could be subject to injury or physical damage could occur if handling is mistaken. Always observe these precautions to safely use the robot. Anything, which has ［ ］, indicating the operation panel of the robot controller and/ or the key and switch of Teach pendant. Indicating while holding down （A） key, press （B） key. In this example, while holding down the [Enable] key, press [ON/1] key. There are some cases to indicate by icons like below. ＋ Indicates the Teach Pendant. T/P Indicates the operating panel on the front of controller. [Emergency stop button] and / or [Mode selection switch] are equipped. O/P Using the instruction manuals 1-2 1Before starting use 1.2 Safety Precautions Always read the following precautions and the separate manual, ”Precautions (TFDEN-905)” carefully before starting use of the robot to learn the required measures to be taken. 1-3 Safety Precautions 1Before starting use 1.2.1 Precautions DANGER When automatic operation of the robot is performed using multiple control devices (Sequencer, push-button switch), the interlocking of operation rights of the devices, etc. must be designed by the customer. CAUTION Use the robot within the environment given in the specifications. Failure to do so could lead to a drop of reliability or faults. (Temperature, humidity, atmosphere, noise environment, etc.) CAUTION Transport the robot with the designated transportation posture. Transporting the robot in a non-designated posture could lead to personal injuries or faults from dropping. CAUTION Always use the robot installed on a secure table. Use in an instable posture could lead to positional deviation and vibration. CAUTION Wire the cable as far away from noise sources as possible. If placed near a noise source, positional deviation or malfunction could occur. CAUTION Do not apply excessive force on the connector or excessively bend the cable. Failure to observe this could lead to contact defects or wire breakage. CAUTION Make sure that the workpiece weight, including the hand, does not exceed the rated load or tolerable torque. Exceeding these values could lead to alarms or faults. WARNING Securely install the hand and tool, and securely grasp the workpiece. Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation. WARNING Securely ground the robot and controller. Failure to observe this could lead to malfunctioning by noise or to electric shock accidents. CAUTION Indicate the operation state during robot operation. Failure to indicate the state could lead to operators approaching the robot or to incorrect operation. WARNING When carrying out teaching work in the robot's movement range, always secure the priority right for the robot control. Failure to observe this could lead to personal injuries or damage if the robot is started with external commands. CAUTION Keep the jog operation (manual operation) speed as low as possible, and always watch the robot. Failure to do so could lead to interference with the workpiece or peripheral devices. CAUTION After editing the program, always confirm the operation with step operation (Check go or Check back) before starting automatic operation. Failure to do so could lead to interference with peripheral devices because of programming mistakes, etc. CAUTION Make sure that if the safety fence entrance door is opened during automatic operation, the door is locked or that the robot will automatically stop. Failure to do so could lead to personal injuries. Safety Precautions 1-4 1Before starting use CAUTION WARNING CAUTION CAUTION CAUTION CAUTION 1-5 Never carry out modifications based on personal judgments, or use non-designated maintenance parts. Failure to observe this could lead to faults or failures. When the robot arm has to be moved by hand from an external area, do not place hands or fingers in the openings. Failure to observe this could lead to hands or fingers catching depending on the posture. Do not stop the robot or apply emergency stop by turning the robot controller's main power OFF. If the robot controller main power is turned OFF during automatic operation, the robot accuracy could be adversely affected. And also some cases, may interfere with circumference device by arm drop and coasting. Do not turn off the main power to the robot controller while rewriting the internal information of the robot controller such as the program or parameters. If the main power to the robot controller is turned off while in automatic operation or rewriting the program or parameters, the internal information of the robot controller may be damaged. Make sure there are no mistakes in the wiring. Connecting differently to the way specified in the manual can result in failures, such as the emergency stop not being released. In order to prevent from occurring, please be sure to check that all functions (such as the controller drive unit operation panel emergency stop, teaching box emergency stop, customer emergency stop, and door switch) are working properly after the wiring setup is completed. Use the network equipments (personal computer, USB hub, LAN hub, etc) confirmed by manufacturer. The thing unsuitable for the FA environment (related with conformity, temperature or noise) exists in the equipments connected to USB. When using network equipment, measures against the noise, such as measures against EMI and the addition of the ferrite core, may be necessary. Please fully confirm the operation by customer. Guarantee and maintenance of the equipment on the market (usual office automation equipment) cannot be performed. Safety Precautions 1Before starting use NOTE Safety Precautions 1-6 2Unpacking to Installation 2 Unpacking to Installation 2.1 Confirming the product The standard configuration of the robot arm, part of the purchased product, is shown in Table 2-1. Confirm the parts. Users who have purchased optional products should refer to the separate "Standard Specifications". Table 2-1 ： Standard configuration No Part name Type Qty. Remarks ES06 series 1 Robot arm 1 unit 2 Guarantee card 3 Installation bolts M8×40 1 copy 4 pcs. 4 Spring washer for installation For M8 bolts 4 pcs. 5 Plain washer for installation For M8 bolts 4 pcs. 6 Fixing plates 1 set 7 Fixing plates installation bolt 1 set For robot arm installation For robot arm transportation ES12 series 1 Robot arm 1 unit 2 Guarantee card 1 copy 3 Installation bolts M12×45 4 pcs. 4 Spring washer for installation For M12 bolts 4 pcs. 5 Plain washer for installation For M12 bolts 4 pcs. 7 Fixing plates 1 set 8 Fixing plates installation bolt 1 set 9 Hanging jig 1 set 10 Hanging jig fixing bolt 1 set For robot arm installation For robot arm transportation Note1) The numbers 3 to 5 are contained in the plastic bag of attachment in the robot arm. 2-7 Confirming the product 2Unpacking to Installation 2.2 Installation 2.2.1 Unpacking <2>②上ブタ Upper lid 引き抜く Pull out <1> Tape ①テープ （ａ） Fixing 固定台 （ｂ） board ③六角穴付ボルト <3> Hexagon socket （４箇所） ロボット本体 Robot arm bolts (Four positions) 固定具B Fixing plate B Fixing plate A 固定具A （ｃ） Fig. 2-1 : Unpacking the robot arm *The grease for preventing rust is applied at the tip of the shaft (J3 axis) in general-purpose environment robot. The robot is shipped from the factory in cardboard and plywood frame packing. Always refer to Fig. 2-1 and unpack the robot.. Handle the robot arm according to "2.2.2 Transportation procedures". CAUTION Always unpack the robot at a flat place. The robot could tilt over if unpacked at an unstable place. The unpacking process is shown below. 1) Using a knife, etc., slit the tape <1> fixing the upper lid <2> of the cardboard box. (Fig. 2-1 (a)) 2) Pull the upper lid <2> of the cardboard box off with both hands. (Fig. 2-1 (b)) 3) Remove the hexagon socket bolts <3> (four positions) which fix the robot. (Fig. 2-1 (c)) This completes the unpacking. Note) The robot must be transported without removing the fixing plate A and B. Remove after installing. CAUTION When repackaging the robot in the wooden frame, always use the fixing plate. Installation 2-8 2Unpacking to Installation 2.2.2 Transportation procedures ES06 series (1) Mass ES06-35**-01 series: Approx. 39kg ES06-45**-01 series: Approx. 40kg ES06-55**-01 series: Approx. 41kg No.2 arm No.1 arm (C) (B) Fixing plate B (A) Fixing plate A *The grease for preventing rust is applied at the tip of the shaft (J3 axis) in general-purpose Fig. 2-2 : Transportation of robot arm environment robot. 1) The robot must be transported by two workers with putting the fixing plate A and B. Place the robot on a cart, etc., and move it to near the installation place. Transporting the robot with the following should be limited to placing the robot on the frame or cart, and to positioning. 2) When transporting the robot arm, one person should hold the fixing plate A of No.2 arm (A) and No.2 arm (B) and another person should hold the fixing plate A of base (C). Holding robot cover can cause robot to fall over or damage of the cover, thus result in accident. So avoid holding the cover. When transporting the robot, do not apply force to the cover, or apply a strong shock on the robot. 3) Remove the fixtures after installing the robot. CAUTION CAUTION CAUTION CAUTION 2-9 Installation To prevent accidents, do not hold the robot from the left/right sides, or hold covers that have no grips. Be careful not to apply force to the shaft section (J3 axis). The shaft may be damaged and the overload error may occur at the time of movement. When installing the fixing tool again, place the robot in the posture where each axis shows the values listed in the table below. The robot should keep vertical. (not be horizontal) It becomes the cause of the grease leakage or the trouble. 2Unpacking to Installation Table 2-2 Transportation posture Axis (2) ES06- 35**-01 ES06-45**-01 ES06-55**-01 J1 57.5° 28° 19° J2 -147.5° -118° -109° J3 290.4mm J4 Not fixed ES12 series wire No,2 arm Mass ES12FH55**-01 series: Approx. 65kg ES12FH70**-01 series: Approx 67kg ES12FH85**-01 series: Approx 69kg Wire hook Eye bolt Suspension fitting No,1 arm Fixing plate Self-supporting plate Base *The grease for preventing rust is applied at the tip of the shaft (J3 axis) in general-purpose environment Fig. 2-3 : Transportation of robot arm robot. 1) Hook the wires to each of the four eyebolts attached to the suspension fitting. (Make sure the bolts are securely hooked.) 2) Lift with a crane to transport the robot to the designated location. 3) At this time, make sure that the wires, etc., do not interfere with the robot arm or the covers. Always place the cloth, etc., at interfering places. 4) Be careful not to subject the robot to physical shock during transport. 5) After installing the robot (refer to “2.2.3 Installation procedures”), remove the wire hooks (the robot will stand by itself) the self-supporting plate, Suspension fitting and fixing plate. 6) Always follow the above procedures and methods to transport the robot for secondary transportation, If the arm is directly suspended without using the specified suspension fittings, or if it is suspended in the work posture, the configuration devices could be damaged, and the transportation workers will be subject to risk due to an inadequate center of gravity position. CAUTION CAUTION CAUTION When transporting a robot, always attach four wires. To reattach the fixing plate again, set the axes of the robot to the positions according to the table below. The robot should keep vertical. (not be horizontal) It becomes the cause of the grease leakage or the trouble. Installation 2-10 2Unpacking to Installation Table 2-3: Transportation posture(ES12-01 seires) Axis ES12-55**-01 ES12-70**-01 ES12-85**-01 J1 -37.5° -21.4° -15.1° J2 127.5° 111.4° 105.1° J3 注 1） 340mm J4 Not fixed Note1) The bottom surface of the shaft will interfere with the floor if the J3 axis is lowered down to the upper mechanical stopper. Position the axes as indicated when transporting the robot. J2 (NOTE) Definition of J1 to J4 － J2軸 ＋ J1 J1軸 － ＋ J3 J3軸 － － ＋ J4軸 J4 2-11 Installation ＋ 2Unpacking to Installation 2.2.3 Installation procedures The installation procedure of the robot arm is shown below. 4-M8x40(ES06 series) 4-M12x45(ES12 series) (Four positions) Spring washer 90 150 60 Rz25 (120) 2-φ6穴 φ (for φφ8 positioning pins) (φ8位置決めピン用下穴) Installation reference surface (据付基準) 122 120 (158) 200 4-φ16 φInstallation holes 4-φ16据付用穴 80 Rz25 200 220 200 240 242 174 150 160 180 182 reference 2-φ6 holes 92 (据付基準) 92 280 122 Installation reference surface 212 Rz25surface (据付基準) φ 2-φ6穴 (for φ φ8 positioning pins) (φ8位置決めピン用下穴) 4-φ9据付用穴 φ 4-φ9 installation holes ES12 series Installation 2-φ6 holes Rz25 <Base bottom> ES06 series Installation (据付基準) reference surface Plain washer Fig. 2-4 : Installation dimensions 1) The robot installation surface has been machine finished. Use the installation holes (ES06series: 4-φ9 holes, ES12 series: 4-φ16 holes) opened at the four corners of the base, and securely fix the robot with the enclosed installation bolts (hexagon socket bolts) 2) Install the robot on a level surface. 3) It is recommended that the surface roughness of the table onto which the robot is to be installed by Rz25 or more. If the installation surface is rough, the contact with the table will be poor, and positional deviation could occur when the robot moves. 4) When installing, use a common table to prevent the position of the devices and jigs subject to robot work from deviating. 5) The installation surface must have sufficient strength to withstand the arm reaction during operation, and resistance against deformation and vibration caused by the static (dynamic) load of the robot arm and peripheral devices, etc. 6) After installing the robot, remove the self-supporting plate, hanging jig, and fixing plate. 7) If you operate the robot at a high speed, reaction forces are applied to the installation stand by the robot's operation. Make sure that the installation stand on which the robot is placed has sufficient strength and Installation 2-12 2Unpacking to Installation rigidity. Table 2-2 shows the maximum reaction force (design values) that may be applied to an installation stand. Please use these values as reference when designing the installation stand. Table 2-4: Magnitude of each reaction force Unit Value Tilt moment : ML N･m 1,640 Torsional moment : MT N･m 710 Horizontal direction translation force : FH N 1,653 Vertical direction translation force : FV N 2,318 Tilt moment : ML N･m 3,190 Torsional moment : MT N･m 1,840 Horizontal direction translation force : FH N 2,240 Vertical direction translation force : FV N 2,500 ES06 series ES12 series CAUTION 2-13 Installation When installing the robot, secure enough space for connection of the machine cable and replacement of the backup battery in front of or behind the robot base. And don't install the robot arm in the position where direct rays or the heat of lighting hits. The skin temperature of the robot arm may rise, and the error may occur. 2Unpacking to Installation (1) 2.2.4 Grounding procedures Grounding methods 1) There are three grounding methods as shown in Fig. 2-5, but the dedicated grounding (Fig. 2-5 (a)) should be used for the robot arm and controller when possible. (Refer to the separate” CFD controller, Instruction manual / Set up (TCFEN-159)” for details on the controller grounding.) 2) Use Class D grounding (grounding resistance) 100Ω or less). Dedicated grounding separated from the other devices should be used. 3) Use a AWG#11(4.2mm2) or more standard wire for the grounding wire. The grounding point should be as close to the robot arm and controller as possible, and the length of the grounding wire should be short. Robot ロボット Controller ロボット本体 コントローラ arm and および パソコン computer Robot ロボット Controller ロボット本体 コントローラ arm And および パソコン (a) Dedicated grounding (a) 専用接地 [最良] (Optimum) Controller ロボット And ロボット本体 コントローラ arm および computer パソコン Robot computer (b) Common grounding (b) Common grounding (Good) (Normal) (b) 共用接地 [良] (c) 共通接地 [普通] Fig. 2-5 : Grounding methods (2) Grounding procedures M4×10 1) Prepare the grounding cable (AWG #11(4.2mm2) or more) and robot side installation screw and washer. Spring washer Plain washer 2) If there is rust or paint on the grounding screw section (A), remove it with a file, etc. A 3) Connect the grounding cable to the grounding screw section. Robot grounding cable (AWG#11(4.2mm2) or more) (Prepared by customer) Fig. 2-6 : Connecting the grounding cable Installation 2-14 2Unpacking to Installation 2.2.5 Connecting with the controller Robot arm CFD controller CONBOX cover CNMP CNMB SEN41 SEN42 Motor power cable Machine cables （Wire harness） Motor signal cable CNAMP CN2 CNBRK Controller side CNMP CNMB SEN41 SEN41 Plate fixing the cable clamp (two plates) Hollow Robot arm side Go through from openings Cable clamp fixing plate The each boards are fixed in the condition of having been inserted in the hollow. Fig. 2-7 : Connecting the machine cables Please refer to “CFD controller / instruction manual / set up(TCFEN-159)” to install the controller. Furthermore, carry out the following procedure to install. Fig. 2-7: shows the connection procedure. 1) Make sure that the power switch of the controller is turned OFF. 2) Connect the machine cable to its corresponding connector on the robot arm side. ① Refer to Page 79, "5.3.2 Installing/removing the cover", and remove the CONBOX cover. ② Feed the connector of robot side to the opening on the back of the robot base. ③ Insert the cable clamp fixing plate attached to the machine cable into the hollow just under the opening. Fixing the plate by two screws securely under the condition that the plates inserted into the hollow. 2-15 Installation 2Unpacking to Installation ④ Connect the machine cable to its corresponding connector on the robot arm side. Connect the connector (CNAMP, CNBRK, CN2) securely. ⑤ Install the CONBOX cover securely as before. 3) Connect the machine cable to the corresponding connector of back of the controller. Connects the connector (CNMP, CNMB, SEN41, SEN42) surely. This completes connecting the machine cables. CAUTION CAUTION CAUTION CAUTION The machine cable connectors are dedicated for the controller side and robot arm side, so take special care when connecting. If connected incorrectly, the connector pins could bend or break. Thus, even if connected correctly, the robot will not operate correctly, creating a dangerous situation. Take special care to the leading of the connection cable. If the cable is pulled with force or bent excessively, wires could break or the connector could be damaged. Connect the machine cable at the place without the effect of the dust or oil mist. Please keep the dust and oil mist from being applied to of the robot-arm connector section, in the condition that the machine cable is removed. Since it becomes the cause of failure. Please be careful not to catch the hand at installation and removal. Installation 2-16 2Unpacking to Installation 2.2.6 Ethernet Cables Ethernet cables (4 pairs, totaling 8 lines, of AWG#26 (0.13mm2) cabtyre cables) are installed within the robot arm from the base unit up to the No. 2 arm, and can be used. LAN connectors are mounted to both ends of the cables, and can therefore be used to connect to LAN connection devices. Users may also remove the LAN connectors, replace them with their own connectors, and use them as spare wiring by connecting them to user supplied cables. Further, when passing through the inside of the shaft and using, please use the optional hand internal wiring and piping set in order to prevent the cable disconnection. (Re-cover the connector of the hand input cable that is attached to this option before using) (1) No.2 arm <a> Ethernet cable: 4 pairs, totaling 8 lines, of AWG#26(0.13mm2) When using as the Ethernet cable シャフト Customer prepared LAN connector Robot side When using as spare wiring Cut the LAN connectors Connect the customer's conCustomer prepared Robot side Note) When using by passing through the shaft, please use the optional hand internal wiring and piping set to prevent the cable disconnection. Note) Although the figure is RH-6FH, the connection method is the same also in RH-3FH/12FH/20FH. Fig. 2-8 : Pulling out the Ethernet cable How to connect the Ethernet cable is shown below. 1) 2) 3) 4) Remove the screws used to fix the No. 2 arm cover U, and then remove the No. 2 arm cover U. Ethernet cables are located in the positions shown in Fig. 2-8: <a> (coiled and stored). Remove the tying band used to coil the Ethernet cable. Connect the cable on the customer supplied tool. (When using as spare wiring please remove the LAN connectors and replace with customer's connector) 5) It is possible to use the optional hand internal wiring and piping set to feed the tool cable through the inside of the shaft. Replace the connector of the hand input cable that is attached to the hand wiring and piping set, and then connect. Please reference “3.5 Hand internal wiring and piping set”. 6) After the optional hand wiring and piping set has been installed, install the No. 2 arm cover U to its original position. When installing the cover please take care not to damage the spongy sealant material. This completed connection of the Ethernet cables on the No. 2 arm. 2-17 Installation 2Unpacking to Installation CAUTION When installing the No. 2 arm cover U to its original position please take care not to trap any cables or air hoses. If the cables/hoses are trapped when fixing the cover then cables may be disconnected or hoses punctured, leading to the robot and air driving devices to not operate properly. The sealing property of the packing may also become seriously impaired and there is a risk that the specified level of product protection may not be achievable. 正常な状態 折れた状態 Normal condition Abnormal condition Airエアホース hose CAUTION (2) When fixing the cable, please keep too much load from being applied to the cables. If too much load is applied, the may break, when the robot moves. Base area Expansion Ethernet cable Inside of ADD cover Inside the robot arm ADD cover Fix the Ethernet cable to the ADD cover by cable clamp. * The recommendation the cable clamp OA-W1608 (OHM ELECTRIC INC.) Lock nut [Note]: Measures against the noise Cable clamp Ethernet cable If the communication error considered to originate by the noise occurs, specify and remove the noise source. And, implement the measures against the noise by grounding of the Ethernet cable, and the addition of the ferrite core if needed. The recommendation the ferrite core Fig. 2-9 : Pull out the Ethernet cable (Base side) 1) Loosen the two screws and remove the ADD cover located at the back of the robot base. 2) Pull out the Ethernet cable that is stored inside the cover (coiled and stored) 3) Remove the cable tie of Ethernet cable. Installation 2-18 2Unpacking to Installation 4) Remove the lock nut attached to the cable clamp (customer prepared) and pass through the Ethernet cable 5) Remove the grommet of ADD cover. After removing the grommet please remove the sealant material that remains in the hole in the plate. 6) Feed the Ethernet cable through the hole that was created by removing the grommet. 7) Feed the end of the Ethernet cable through the cable clamp and securely fasten the ADD cover with the lock nut. 8) Install the ADD cover in its original position. When installing the cover please take care not to damage the spongy sealing material stuck to the hole. CAUTION CAUTION CAUTION CAUTION 2-19 Installation Take care against applying big force to the Ethernet cable, other cables, and the air hose. Please confirm not having broken or not having stripped the packing when installing or removing the cover. Contact our service branches close from your location. (Please refer to the back cover for information.) if packing is broken or has stripped. Failure will be caused if the robot is used under the condition that the packing is broken or stripped, because oil mist etc. will invade in the arm. When ADD cover is installed, please keep too much load from being applied to the cables and the air hoses. If too much load is applied, the cable will be broken and the hose is bent, therefore robot and pneumatic drive equipment cannot operate normally. When ADD cover is installed, catch neither the cable nor the air hose. If the bolt is tightened while it had been caught, the cable will be broken and the hose is bent, and the robot and pneumatic drive equipment cannot operate normally. Moreover, packing does not stick securely and protection specification cannot be secured. 2Unpacking to Installation 2.2.7 Passing air hoses and cables through the shaft For this robot, customer prepared air hoses and cables can be pulled out from the No. 2 arm by passing through the shaft. Procedure to pass air hoses and cables through the shaft, refer to the following. (1) Specifications of internal air hoses and cables Use the air hoses and the cables, which have flexibility, capability of being repeatedly bent and twisted, and high wear resistance, for the internal use. Select the air hose and the cable according to the specifications shown in Table 2-5. Table 2-5 ： Specifications of internal air hoses and cables Shaft inside Space factor Highest speed of Minimum R of Operating angle of diameter (recommended) J3 axis bending J4 axis ES06 φ18mm 50％ or less 2,400mm/sec 25mm ±360deg ES12 φ18mm 50％ or less 2,800mm/sec 25mm ±360deg Model (2) Customer prepared products Table 2-6 shows the necessary products for passing air hoses and cables through the shaft. The user needs to prepare the products. Table 2-6 ： Customer prepared products Name Expanding sleeve Qty. Moderate quantity Cushion rubber Cable tie Silicon grease Liquid gasket Moderate quantity Moderate quantity Moderate quantity Moderate quantity Usage and recommended product Protecting the air hoses and cables, and improving the twisting rigidity Recommended expanding sleeve: EXP-13-PT (manufactured by Kitagawa Industries Co., Ltd.) Protecting the bent portion and the fixed portion of the twisted end. Recommended cushion rubber: silicon rubber, thickness of 1mm, dimensions of 30mm × 80mm Fixing the air hoses and the cables Reducing friction and wear when the air hoses and the cables slide Recommended silicon grease: G-501 (manufactured by Shin-Etsu Chemical Co., Ltd.) Sealing the outlet at the tip of the shaft (for the oil-mist and clean specification models only) Recommended liquid gasket: 1212 (manufactured by Three Bond Co., Ltd.) Bending range Expanding sleeve 【Precautions for implementation of moving part】 1) The internal air hoses and cables are bent and twisted according to the operations of the J3 and J4 axes. Structurally, the ク twisting occurs inside the shaft, and the bending occurs inside the expanding sleeve. Without the expanding sleeve, the twisted air hoses and cables may run onto the guide portion of the fixing plate, and the air hoses may be bent or broken. 2) Do not place the connector connecting part and the air hose relay part in the binding or twisting range. Plate for fixation Twisting range Installation 2-20 2Unpacking to Installation (3) Installation procedure The installation procedure is shown below. Refer to the installation diagram shown from the next section, and perform the installation correctly. 1) Move the J3 axis to the top end with a jog operation and shut off the controller's power supply. This is necessary for space standard settings when feeding the air hose and hand input cable through the inside of the shaft. 2) Remove the screws fixing the No. 2 arm cover U, and remove the No. 2 arm cover U. 3) Pass the tool (hand) side of the internal air hoses and cables through the shaft. Make sure that the air hoses and the cables are not twisted or crossed. 4) Fix the air hoses and the cables with a cable tie so as to position the end of the expanding sleeve 10mm away from the opening of the shaft. 5) The highest point of the curved section of the air hoses and cables should be matched up with the top of the fixing plate. CAUTION If the air hoses and the cables are not long enough or too long, when the robot operates, excessive bending and friction with the shaft upper end or the cover may result in a break or abnormal operations of the tool (hand). 6) In the state of the steps 4) and 5), fix the air hoses and the cables to the (a) and (b) portions of the plate with cable ties. For the (a) portion, wrap the air hoses and the cables with cushion rubber before fixing. 7) ハ When using the hand input signal or the optional solenoid valve, refer to “3.5 Hand internal wiring and piping set”. 8) The connected connectors are stored to the (c) portion. CAUTION Do not remove the cable ties which fixing connectors. Fix the plate on the No. 2 arm, other cables and air hoses with cable ties. In this way, the internal cables and connectors do not touch the plate edge and others, or break due to the vibration during the robot operation. 9) Carry out piping and wiring on the tool side. Fix the air hoses and the cables, which are pulled out from the shaft lower end, to the hand side. Check again that the highest point of the curved section of the air hoses and the cables reaches the height of the fixing plate upper end, and then fix the air hoses and the cables at the outlet of the shaft.Apply silicon grease to the contact surface between the air hoses of the fixing plate and the cables, the cable sliding portion from the shaft upper end to the fixed portion, and the opening on the shaft upper end. 11)コ Power on the controller, perform the jog operation for the J3 and J4 axes, and check that the air hoses and the cables do not interfere with other components. CAUTION Do not power on the controller when the internal cables are connected to the connectors on the robot. If the end of the cables on the tool side is not processed, troubles such as fuse blown by ground fault or short circuit may occur. Check that the end of the cables has been processed before powering on the controller. 12)Turn off the controller’s power supply, then install the No.2 arm cover U securely as before with fixing screws (tightening torque: 1.39 to 1.89 Nm). When installing the cover, check that no air hose or cable is pinched, and no air hose is bent. Note) The installation surface of a clean and a oil-mist specification covers is using sealing material. In the event that the sealing material has been removed or has been bent or broken to the extent that it cannot be return to the original form, be sure to replace the sealing material. Please contact service branch close from your location. This completes installing cables and air hoses inside the robot’s shaft. 2-21 Installation 2Unpacking to Installation (3) ES06 series Refer to the previous page ”(3) Installation procedure” and install cables and air hoses correctly. The numbers in below figures are corresponding to the same numbers in "(3) Installation procedure". Turn the controller’s power OFF before this operation. Refer to 「5.3.2 Installing / removing the cover” for removing/installing the cover. No.2 arm cover U 2)、12) 5)、9) Match up the peak of the air hose and 4) Approx. 10mm cable with the top end of the fixing plate Connect inside the No. 2 arm cover U 8) (c) Expanding sleeve Silicone grease application places 10) 3) (a) (b) 6) 1) Top end of the J3 axis operating 11) J3 axis Perform the operation of the J3 9) and J4 axes, and check that Fixing air hoses and no interference occurs. J4 axis cables inside a hand Fig. 2-10: Installation of air hoses and cables inside the robot’s shaft (ES06 series) Installation 2-22 2Unpacking to Installation (4) ES12 series Refer to”(3) Installation procedure” and install cables and air hoses correctly. The numbers in figures below are correspond to the same numbers in "(3)Installation procedure". Turn the controller’s power OFF before this operation. Refer to”5.3.2 Installing / removing the cover” for removing/ installing the cover. No.2 arm cover U 2)、12) 5)、9) Match up the peak of the air hose and cable with the top end of the fixing plate 4) Approx.10m Connect inside the No. Expanding 2 arm cover U sleeve 8) 10) (c) Silicone grease 3) application places (a) (b) 6) 1) Top end of the J3 axis operating J3 axis 11) 9) Perform the operation of the J3 Fixing air hoses and and J4 axes, and check that no cables inside a hand interference occurs. Fig. 2-11: Installation of air hoses and cables inside the robot’s shaft (ES12 series) 2-23 Installation J4 axis 2Unpacking to Installation 2.3 Setting the origin The origin is set so that the robot can be used with a high accuracy. Setting the origin is usually conducted at shipment, however please make sure to confirm that combination of robot controller and the robot are right, and the origin setting is also right beforehand. This step must also be carried out if the combination of robot and CFD controller being used is changed. There are several methods for setting the origin, but the origin data input method (numerical input method) will be explained here as an example. Refer to”5.6 Resetting the origin” for the other methods. The teaching pendant is required for this operation. The origin data （Encoder off set / Encoder correction value） are adjusted and set with the robot, which is to be a pair in a connected condition at shipment, and they are saved in the internal memory of CFD controller. In case the origin data is not correct or operate the robot, which combination is different from the time of shipment, and then it may result in damage of robot and peripheral equipment due to unexpected movement. CAUTION [Caution] If the origin data at shipment is erased due to out of battery, it is necessary to set the origin again. Refer to “5.6 Resetting the origin” for resetting. 2.3.1 Installing and removing the Teach Pendant (T/P) When installing and removing the T/P, turn off the controller power supply. If T/P is installed or removed in the state of power supply ON, emergency stop alarm will occur. CAUTION Please do not pull the cable of T/P strongly or do not bend it too much. It becomes the breaking of a wire of the cable and the cause of breakage of the connector. Please installing and removing so that stress does not start the cable with the connector itself. Below explains about T/P installation procedure. 1) Check that the POWER (power supply) switch of the robot controller is OFF. 2) Connects T/P connector to the front side connector of the robot controller. And then fix them with two screws. Fig. 2-12: Installing and removing the T/P The installation of T/P is finished. Setting the origin 2-24 2Unpacking to Installation 2.3.2 Data input method （Numerical input value） (1) Confirming the origin data ●Table example of origin data （encoder off set / encoder correction value） Before shipping (Default) J1 8387398 J2 8388185 J3 8387517 J4 8387735 ... ... ... The origin data to be input is noted in the table of origin data as this. (Refer to Fig. 2-16) The value given in the default setting column is the origin settings set with the calibration jig (Installing pin) before shipment. J5 J6 Fig. 2-13: Origin data (an example） （supplement） Origin data is also called “Encoder off set” or ”encoder correction value”. (2) Turning ON the control power CAUTION Confirm that there are no operators near the robot before turning the power ON. 1) Turn the controller [POWER] switch ON. Turn the switch of the front ON. 2-25 Setting the origin 2Unpacking to Installation (3) Preparing the T/P Next, prepare to use the T/P. 1) Set the mode of the controller to "TEACH”. Icon below shows up on the left-upper of the display. 2) Set the T/P [TP selector switch] to "TEACH". From now on, carry out the operation at T/P. ◇◆◇ Operating from the T/P ◇◆◇ Always set the mode of the controller to "TEACH", and then set the T/P [TP selector switch] to “TEACH”. When the T/P is valid, only operations from the T/P are possible. Operations from the controller or external signals will not be accepted. Emergency stop, (which works for the operation to stop), can be operated regardless of valid / invalid of the device. Setting the origin 2-26 2Unpacking to Installation (4) Inputting the numerical value of the origin data T/P screen Input the value confirmed at ”(1) Confirming the origin data”, which described before at the left display. Fig. 2-14: Display of Encoder correction （Numerical value input） Input procedure of the origin data will be explained below. Input the value indicated at Fig. 2-16 as an example. Operation procedure 1 Set that the Teach mode is on. Before that, input [R][3][1][4][Enter][Enter] to switch operator level to EXPERT. 2 Press ＜Constant setting＞［3 Machine constants］－then, open the display of ［4 Encoder correction］.（To select the menu, use cursor key and [Enter] key. The display like below will be shown for example. （Name of the robot type, which is shown differs depending on the robot. 2-27 Setting the origin 2Unpacking to Installation 3 Check that cursor is located at the position of "J1", which shown on T/P display. 4 Input the value of J1,”8387398” then, press [Enter]. 5 Press [ ↓ ] key, and move the cursor to the input position of J2, then input the value of J2 same as above . 6 Input the value of J3, J4 as follows. 7 After inputting all values, press [Complete] key on down-right of the display. Now it completes the setting of the origin data（Encoder correction value）. （supplement） Motor on should be OFF by pressing the emergency stop button before hand. If the Motor on is “ON”, then cannot carry out the operation of complete. ◇◆◇To move the cursor◇◆◇ Use arrow key. ◇◆◇To input the numerical value◇◆◇ Use these keys. ◇◆◇When making a mistake◇◆◇ Move the cursor to the letters, which needs correction by arrow keys. After erasing them by input the correct one. [BS] key, Setting the origin 2-28 2Unpacking to Installation 2.4 Confirming the operation In this section, the robot will be moved manually using the T/P to confirm that the operation is correct. Moving the robot manually is called ”Manual operation”. There are some coordinate systems based on manual operation（”Manual operation coordinate system”）. Further, this operation should be carried out by holding ［Enable switch］, which locates on the back of T/P lightly. ［Enable switch］（３ positions） ※Please be careful that when holding strongly and releasing will be OFF. CAUTION CAUTION CAUTION WARNING The robot will move during this operation. Make sure that there are no operators near the robot, and that there are no obstacles, such as tools, in the robot operation range. To immediately stop the robot, release the［Enable switch］ on the back of T/P. The servo power will turn OFF, and the robot will stop. The robot will also stop if the [Emergency stop button] on the front of the T/P or the [Emergency stop button] of the controller is pressed. To check whether the origin of the robot deviates, move the robot arm to the position where the ABS marks align each other, and check the displayed joint coordinates of the position. For the details of the ABS mark position and the joint coordinates, refer to ”5.6 Resetting the origin”. Confirm that the origin has been set. If the origin has not been set, there are possibilities of not operating to the right direction, or possibilities of movement beyond the designated software operation range. As a result, interference or crushing of robot structure can take place. Procedure of setting the origin are indicated at ”2.3 Setting the origin”. ◇Selecting of manual operation coordinate system◇ Press [Interpolation /Coordinate ］ key, then manual operation coordinate system will be altered. The coordinate system, which is usable including “Joint coordinates system” can be defined up to three. Those three coordinate systems are set below menu. <Constant Setting> [5 Coordinate registration] Operation constants][5 ◇◆◇Selecting of speed of manual operation◇◆◇ Press [Check speed / Manual speed］key, then speed of the manual operation will be altered by five steps. （*Speed 1 is extremely low speed, so usually don’t use.） 2-29 Confirming the operation 2Unpacking to Installation J2J2軸 axis － ＋ J1J1軸 axis － ＋ ＋ J3軸 J3 axis － － ＋ J4 J4軸 axis *Each axis moves independently. Fig. 2-15: Coordinate system of each axis ＋Z ＋Z End先端軸 axis Cartesian coordinate －X －Y － ＋ ＋X system origin point 直交座標系原点 ＋Y C －X －Y －Z ＋Y ＋X －Z * While maintaining the end axis posture, the axis moves straight along the Cartesian coordinate system originated on base unit center of the robot. (0,0,0) And also, direction of the tool can be changed by turning around the end axis. Fig. 2-16: Robot coordinate system （Cartesian coordinate system） Confirming the operation 2-30 2Unpacking to Installation ＋Z End axis Tool coordinate system reference 先端軸 originツール座標原点 －X －Y － ＋ ＋X ＋Y C －Z * While maintaining the end axis posture, the axis moves straight along the tool coordinate system. Also, while maintaining the end axis position, the end axis posture can change. Fig. 2-17: Tool coordinate system 上下 Vertical +Z ＋Z R (TCP) Radius 半径 円弧 Arc － Z －X ＋ －Y C ＋Y +X ＋X +Y θ －Z *The current position is set as the arc centering on the Z axis, and the Tool Center Point (TCP) moves along that arc, expands and contracts in the radius direction, and moves vertically. At this time, the end axis posture is maintained. Also, while maintaining the axis posture position, the end axis posture changes. Fig. 2-18: Cylinder coordinate system 2-31 Confirming the operation 2Unpacking to Installation Operating along the User Coordinate System +Z ＋Z User coordinate system +Z Origin position ツール長 －X Tool length －Y － ＋Y ＋ ＋X －Z -Z +X +Y Control point *Control point moves straight along the user coordinate system with the end axis posture’s are maintained. The coordinate of control point indicates the origin position of user coordinate system as (X,Y,Z)=(0,0,0). Also, while maintaining the axis posture position, the end axis posture can change by rotating. *When selecting user coordinate system, if manual operation is carried out and press Rx, Ry, Rz keys, robot performs rotating movement with its position of control point(X,Y,Z) fixed on the user coordinate system. However, since ES series are SCARA robot, it is possible to rotate around the vertical axis to rotating base (Z axis of user coordinates system is set to the vertical direction toward rotating base in general.） *How to make procedure of User coordinate system, please refer to ”CFD Controller instruction manual Set up”(TCFEN-159), Chapter 4. Fig. 2-19: User coordinate system Confirming the operation 2-32 2Unpacking to Installation (1) Joints coordinate system Selecting the each joint coordinate system Press [Interpolation/ Coordinate] key few times, then select [Joint coordinate system]. Setting the manual operation speed If [Check speed / Manual speed］ keys are pressed, it is possible to change the speed of manual operation by five speed level. Select speed of ”2” or “3” to operate for checking work. Axis J1 rotation Manual operation of J1 axis J1軸回転 － Press [+X] key, J1 axis will rotate toward plus direction. Press [-X] key, J1 axis will rotate toward minus direction. Axis J2 rotation J2軸回転 － ＋ Manual operation of J2 axis Press [+X] key, J2 axis will rotate toward plus direction. Press [-X] key, J2 axis will rotate toward minus direction. 2-33 Confirming the operation ＋ 2Unpacking to Installation ◇◆◇When the robot is in the transportation posture◇◆◇ The axes may be outside the movement area. Move these axes toward the inner side of the movement area. If these axes are moved toward the outer side, then alarm will show up on T/P, so the robot does not move. Manual operation of J3 ＋ J3軸 J3 axis － Press [+Z] key, J3 axis will rotate toward plus direction. Press [-Z] key, J3 axis will rotate toward minus direction. Manual operation of J4 － ＋ J4軸回転 J4 axis Press [+RX] key, J4 axis will rotate toward plus direction. Press [-RX] key, J4 axis will rotate toward minus direction. ◇◆◇If ”A0121” indicates and the robot does not move◇◆◇ If it is going to move the robot across the operation range, the alarm indicates on T/P and the robot does not move. In this case, please move to the counter direction. ◇◆◇If ”E0122” indicates and the robot does not move◇◆◇ The encoder value of that axis may be outside the movement area. In this case, Motor On turns OFF and robot does not move. In this case, please follow the following procedure. (1) Switch user level to EXPERT. ([R][3][1][4][Enter][Enter]) (2) Open the menu <Constant setting> [3 Machine constants] [5 Software Limit]. (3) Carry out Motor ON operation. ([Enable] key + [Motor ON] key) (4) Move the robot carefully to the movement range with speed 2.（Be careful with interference.） ・Robot does not go beyond the movement range usually. If “E0122” indicates, we recommend to check encoder correction value（Origin data）. Confirming the operation 2-34 2Unpacking to Installation (2) Robot coordinate system Selecting the robot coordinate system Press the [Interpolation/ Coordinate]keys few times then, select [Robot coordinates system]. Setting the speed of manual operation When the [Check speed / Manual speed］keys are pressed, it is possible to change the speed of manual operation by five speed level. Here, select speed of ”2” or “3” to operate for checking work. Operate along the Robot coordinate system ＋Z ＋Z －X －Y ＋Y ＋X －X －Y －Z ＋Y ＋X －Z When [X+] key is pressed, the robot will move along the X axis plus direction. When [X-] key is pressed, the robot will move along the minus direction. When [Y+］ key is pressed, the robot will move along the Y axis plus direction. When [Y-] key is pressed, the robot will move along the minus direction. When [Z+] key is pressed, the robot will move along the Z axis plus direction. When [Z-] key is pressed, the robot will move along the minus direction. ◇◆◇When the robot is in the transportation posture◇◆◇ There are directions from which linear movement is not possible from the transportation posture. In this case, the robot will not move. Refer to “(1) each axis coordinate system”, and move the robot to a position where linear movement is possible, and then carry out manual operation. 2-35 Confirming the operation 2Unpacking to Installation Changing the end axis posture ＋Z ＋Z －X －Y － ＋ ＋X C ＋Y －X －Y －Z ＋Y ＋X *The position of the control point will not change. －Z When [RZ+] key is pressed, the Z axis will rotate in the plus direction. When [RZ-] key is pressed, rotate in the minus direction. At this time, ”r(=”roll”)” value changes among (X,Y,Z,r,p,y) at axis monitor window. ◇◆◇Tool length◇◆◇ The default tool length is 0mm, and the control point is the center of the end axis. After installing the hand, set the correct tool length in the parameters. Refer to the separated manual Chapter 4 of “CFD controller/ instruction manual/ Set up”. Confirming the operation 2-36 2Unpacking to Installation (3) Tool coordinate system Selecting the Tool coordinate system Number indicates the tool number.(1 to 32) Press ［Interpolation/ Coordinate］key few times then, select the [Tool coordinates system]. Setting the speed of manual operation When the [Check speed / Manual speed］keys are pressed, it is possible to change the speed of manual operation by five speed level. Here, select speed of ”2” or “3” to operate for checking work. Moving along the tool coordinate system ＋Z －X －Y － ＋ ＋X ＋Y C －Z When the [X+] keys are pressed, the robot will move along the X axis plus direction of the tool coordinate system. When the [X-] keys are pressed, move along the minus direction. When the [Y+] keys are pressed, the robot will move along the Y axis plus direction of the tool coordinate system. When the [Y-] keys are pressed, move along the minus direction. When the [Z+] keys are pressed, the robot will move along the Z axis plus direction of the tool coordinate system. When the [Z-] keys are pressed, move along the minus direction. ◇◆◇When the robot is in the transportation posture◇◆◇ There are directions from which linear movement is not possible from the transportation posture. In this case, the robot will not move. Refer to “(1) Each axis coordinate system”, and move the robot to a position where linear movement is possible, and then carry out manual operation. 2-37 Confirming the operation 2Unpacking to Installation Changing the end axis posture ＋Z －X －Y － ＋ ＋X ＋Y C －Z *The Position of the end axis will not change. When the [RZ+] keys are pressed, the Z axis will rotate in the plus direction of the tool coordinate system. When the [RZ-] keys are pressed, rotate in the minus direction. At this time, ”r(=”roll”)” value changes among (X,Y,Z,r,p,y) at axis monitor window. ◇◆◇Tool length◇◆◇ The default tool length is 0mm, and the control point is the center of the end axis. After installing the hand, set the correct tool length in the parameters. Refer to the separated manual Chapter 4 of “CFD controller/ instruction manual/ Set up”. Confirming the operation 2-38 2Unpacking to Installation (4) CYLINDER coordinate system Selecting the cylinder coordinate system Press [Interpolation / Coordinate］ key few times then, select [Tool coordinates system］. *It is necessary to set the settings to be able to select “Cylinder coordinate system”. Setting the speed of manual operation When the [Check speed / Manual speed］keys are pressed, it is possible to change the speed of manual operation by five speed level. Here, select speed of ”2” or “3” to operate for checking work. Moving along an arc centering on the Z axis +Z 上下 ＋Z Control point 制御点 半径 Radius － －X 円弧 ＋ C Z －Y Arc ＋Y R ＋X －Z +X +Y θ Perform following movement, when locating the currant position on the arc centered on Z axis. When the [X+] keys are pressed, the robot will move along the arc axis plus direction.（θ） When the [X-] keys are pressed, move along the minus direction. When the [Y+] keys are pressed, the robot will move along the direction, where radius extends.（R） When the [Y-] keys are pressed, the robot will move along the direction, where radius diminish. When the [Z+] keys are pressed, the robot will move along the Z axis plus direction.（Z） When the [Z-] keys are pressed, move along the minus direction. 2-39 Confirming the operation 2Unpacking to Installation Rotating the end axis 上下 ＋Z Radius 半径 － －X 円弧 ＋ Arc －Y ＋Y C ＋X －Z *The Position of the end axis will not change. When the [RZ+] keys are pressed, rotate in the plus direction of Z axis. When the [RZ-] keys are pressed, rotate in the minus direction. At this time, ”r(=”roll”)” value changes among (X,Y,Z,r,p,y) at axis monitor window. Confirming the operation 2-40 2Unpacking to Installation (5) User coordinate system Setting of the work coordinates system is necessary. By user coordinates system, robot can be move along with the direction of work (or working table etc.), so teaching operations get easier. If using user coordinates system, teaching would become easier since it can operate the robot along the work (or work base). User coordinates system can be set up to 100, and there’s a necessity to select the robot by which user coordinate system to be operated at manual operation. The user coordinates system teaches and sets up the three points. (UO，UX，UY) +Z （ Caution ） Settings of the user coordinate system are same doesn’t matter 6 articulated robot or SCARA robot. ＋Z +Z User coordinate UO system ツール長 －X Tool length －Y － ＋Y ＋ ＋X Control point -Z +X －Z Robot coordinates system +Y UY < UX Work The jogging movement based Teaching point> UO ： Work coordinates system origin UX ： Position on the "+X" axis of user coordinates system UY ： Position at the side of "+Y" axis on the X-Y plane of user coordinates system on this work is possible. 【Supplement】：The coordinate values which use all three teaching points for setting of the user coordinates system are each only X，Y and the Z.-axis. Although the coordinate value of roll， pitch，yaw axis is not used, positioning will get easy if the robot coordinates system or tool coordinates system movement is affected with the same value. (The direction of the hand is the same.) Fig. 2-20: Setting of the user coordinates system (teaching point) 2-41 Confirming the operation 2Unpacking to Installation Following shows the setting procedure of user coordinates system. Please refer to Chapter 4 of “CFD controller instruction manual / set up” (TCFEN-159) for more detail. (1) Teach 3 points as a program such as the previous page. (2) Open <Service Utilities> [10 User Coord. Definition] (3) Input the program number made at procedure (1), and then creates user coordinates system. （Use “OXY” for “Step order”） (4) Open <Constant Setting> [5 Operation Constants] [5 Coordinate registration]. (5) Assign the user coordinates system, which was created at procedure (3), to any of the manual coordinates system. （Please assign number of the user coordinates system at this time.） To switching the coordinate system to be used, press ［Enable］＋［←］ or ［→］. ＋ An example of registering user coordinates system No.1 to 3rd coordinates system. （Supplement） ・ To change the user coordinate system, which is used during program, use function command “FN113 selecting the shift coordinate system”. ・ If using function command “FN645 MOVEX”, it is possible to teach at Cartesian coordinate value of user coordinates system. Please refer to the following instruction for more details. “CFD controller instruction manual Basic operation” (TCFEN-160) →”4.8 A movement command recorded using FN645 MOVEX (for expert)” Confirming the operation 2-42 2Unpacking to Installation Then, the operation procedure at user coordinate system is shown, continuously. Change to the user coordinates system after nearing the work. Selecting the user coordinate system Press [interpolation/ coordinate] key few times, then select Number indicates the number of user coordinate [user coordinate system］. system (1-100). *It is necessary to set the settings to be able to select “user coordinate system.” Setting the speed of manual operation When the [Check speed / Manual speed］keys are pressed, it is possible to change the speed of manual operation by five speed level. Here, select speed of ”2” or “3” to operate for checking work. CAUTION Always confirm that the number of the target number of user coordinate system is displayed correctly. （Shown at the left side of the icon.） If the user coordinates system is mistaken, the robot will move in the direction which is not meant and will cause the damage and the personal injuries. 2-43 Confirming the operation 2Unpacking to Installation Moving based on user coordinate system +Z ＋Z +Z Tool length ツール長 －X －Y － ＋Y ＋ ＋X -Z +X 制御点 Control point －Z +Y When the [X+] keys are pressed, the robot will move along the X axis plus direction on the user coordinates system. When the [X-] keys are pressed, Move along the minus direction. When the [Y+] keys are pressed, the robot will move along the Y axis plus direction on the user coordinate system. When the [Y-] keys are pressed, Move along the minus direction. When the [Z+] keys are pressed, the robot will move along the Z axis plus direction on the user coordinate system. When the [Z-] keys are pressed, Move along the minus direction. Confirming the operation 2-44 2Unpacking to Installation Changing the end axis posture +Z ＋Z +Z ツール長 Tool length －X －Y － ＋Y ＋ ＋X -Z +X Control point 制御点 －Z +Y When the [RX+] keys are pressed, the end will rotate in the plus direction. When the [RX-] keys are pressed, rotate in the minus direction. ◇◇◆◇When the robot is in the transportation posture ◇◆◇ There are directions from which linear movement is not possible from the transportation posture. In this case, robot will not move. Refer to ”(1) Joints coordinate system”, and move the robot to a position where linear movement is possible, and then carry out manual operation. ◇◆◇ ”A0121” is shown and the robot does not move ◇◆◇ If it is going to move the robot across the operation range, the alarm is shown on T/P and the robot does not move. In this case, please move to the counter direction. ◇◆◇ Tool length ◇◆◇ The default tool length is 0mm, and the control point is the center of the flange side. After installing the hand, set the correct tool length in the parameters. Refer to the separate manual “CFD controller / instruction manual / set up” chapter 4 for details. 2-45 Confirming the operation 2Unpacking to Installation NOTE Confirming the operation 2-46 3Installing the option devices 3 Installing the option devices 3.1 Installing the solenoid valve set The installation summary of the solenoid valve is shown in Fig. 3-1 and Fig. 3-2. Remove the No.2 arm cover U, and install the solenoid valve on the No.2 arm. Turn the controller’s power OFF before this installing operation. Refer to ”5.3.2 Installing / removing the cover” for removing / installing the cover. (1) ES06 series No. 2 arm cover U Solenoid valve Items for customer to prepare ・A Philips screwdriver (M4 screws) Fix to plate ・Air hose for secondary piping (φ4) Install to inside the No. 2 arm cover U Primary piping air hose (φ6) (P port) Solenoid valve exhaust hose (φ6) (R port) Note) When connecting this air hose, be sure to remove the dust cap attached on the robot base section. Hand output signal connection cables (GR1, GR2) Fixing screws (M4 x 30), two screws - left and right (included in the solenoid valve set) 注） 取付図はRH-6FH の イメージですが、 RH-3FHも同じ場所 に取付けます。 Hand output signal connection connectors (GR1, GR2) Connect to the GR1 and GR2 connectors of the robot side Solenoid valve exhaust joint (φ6) (R port) (R ポ ト) Primary piping connection joint (φ6) (P port) Secondary piping connection joint (φ4) (A, B ports) A port: From the left side in order 1, 3, 5, 7 B port: From the left side in order 2, 4, 6, 8 Base section Primary piping connection joint (φ6) (upper side: AIR IN) Solenoid valve exhaust joint (φ6) (lower side: RETURN) Figure 3-1 : Solenoid valve installation procedures (ES06 series) The installation procedure is detailed below. 1) Remove the screws fixing the No. 2 arm cover U, and remove the No. 2 arm cover U. 2) Fix the solenoid valve to the plate in the position indicated in Fig. 3-1. Place it so that the solenoid valve's primary piping connection joints (P, R ports) are located on the right hand side, and fix it securely using the M4 screws included (tightening torque: 1.39 to 1.89N ・m). 3) Connect the connector (GR1, GR2) of solenoid valve with connector of robot arm side (GR1, GR2). Connect with the same names. GR2) The hand output signal cables of the robot arm side are located close to where the solenoid valve is installed and are tied up with cable tie. Pull out and connect them to the connectors. 3-47 Installing the solenoid valve set 3Installing the option devices 4) Connect the primary piping air hose (φ6). The air hoses are located close to where the solenoid valve is installed and are tied up with cable tie. Cut the cable tie and connect them. Of the two air hoses, connect the one marked “AIR IN” to the solenoid valve's P port, and the one marked “RETURN” to the R port. Note) When connecting the RETURN air hose, be sure to remove the dust cap attached at the RETURN joint on the robot base section. If the cap is not removed, exhaust air pressure will increase and the solenoid valve may not operate properly. By connecting the exhaust air hose (φ6: customer preparation) to this RETURN air joint, exhaust air from the solenoid valve is able to escape to the designated point. 5) Connect the secondary piping air hose (φ4). The optional hand curl tube, the hand internal wiring and piping set, or the air hose prepared by customer can all be used, however when pulling the tip of the air hose out from the shaft please be sure to use the optional hand internal wiring and piping set. Connect the air hoses to solenoid valve port A and port B. Please refer to Table 3-1 and connect to the necessary ports. Covers the unused solenoid valve joints with the plugs included. Note) When pulling the tip of the air hose out from the shaft, please be sure to use the optional hand internal wiring and piping set. Silicon grease to apply to friction points is included with the product (please refer to Page 66, "3.5 Hand internal wiring and piping set" and “ External Wiring and Piping Box”). Further, when using the optional external wiring and piping box, the air hose can be pulled out from the rear of the No. 2 arm (please refer to “External Wiring and Piping Box”). 6) If the hand output cable and the air hose have excess length, please tie the excess section by cable tie and fix it to the plate. The plate has some holes for fixing the cable/hose with a cable tie. 7) Install securely the No.2 arm cover U as before with fixing screws (tightening torque: 1.39 to 1.89 Nm). This completes installing the solenoid valve set. Installing the solenoid valve set 3-48 3Installing the option devices (2) ES12 series No. 2 arm cover U Install to inside the No. 2 arm cover U Items for customer to prepare・ ・A hexagon wrench (M4 screws) ・Air hose for secondary piping (φ6) For the elbow coupling addition KJL06-99 *SUS street elbow (SMC Corp) Primary piping air hose (φ6) (P port) Solenoid valve exhaust hose (φ6) (R port) Note) When connecting this air hose, be sure to remove the dust cap attached on the robot base section. Hand output signal connection cables (GR1, GR2) Fixing screws (M4 x 8), four screws - left and right (Included in the solenoid valve set) Solenoid valve Fix to plate. Hand output signal connection connectors (GR1, GR2) Connect to the GR1 and GR2 connectors of the robot side. Base section Primary piping connection joint (φ6) (upper side： AIR IN) Solenoid valve exhaust joint (φ6) (lower side： RETURN) Secondary piping connection joint (φ6) (A, B port) Primary piping connection joint (φ6) (P port) Solenoid valve exhaust joint (φ6) (R port) A port: From the left side in order 1, 3, 5, 7 B port: From the left side in order 2, 4, 6, 8 Figure 3-2 : Solenoid valve installation procedures (ES12 series) The installation procedure is detailed below. 1) Remove the screws fixing the No. 2 arm cover U, and remove the No. 2 arm cover U. 2) Fix the solenoid valve to the plate in the position indicated in Fig. 3-2. Place it so that the solenoid valve's primary piping connection joints (P, R ports) are located on the upper side, and fix it securely using the M4 screws included (tightening torque: 1.39 to 1.89N ・m). 3) Connect the connector (GR1, GR2) of solenoid valve with connector of robot arm side (GR1, GR2). Connect with the same names. The hand output signal cables of the robot arm side are located close to where the solenoid valve is installed and are tied up with cable tie. Pull out and connect them to the connectors. 4) Connect the primary piping air hose (φ6). The air hoses are located close to where the solenoid valve is installed and are tied up with cable tie. Cut the cable tie and connect them. Of the two air hoses, connect the one marked “AIR IN” to the solenoid valve's P port, and the one marked “RETURN” to the R port. 3-49 Installing the solenoid valve set 3Installing the option devices Note) When connecting the RETURN air hose, be sure to remove the dust cap attached at the RETURN joint on the robot base section. If the cap is not removed, exhaust air pressure will increase and the solenoid valve may not operate properly. By connecting the exhaust air hose (φ6: customer preparation) to this RETURN air joint, exhaust air from the solenoid valve is able to escape to the designated point. 5) Connect the secondary piping air hose (φ6). The optional hand curl tube, the hand internal wiring and piping set, or the air hose prepared by customer can all be used, however when pulling the tip of the air hose out from the shaft please be sure to use the optional hand internal wiring and piping set. Connect the air hoses to solenoid valve port A and port B. Please refer to Table 3-1 and connect to the necessary ports. Covers the unused solenoid valve joints with the plugs included. Note) When pulling the tip of the air hose out from the shaft, please be sure to use the optional hand internal wiring and piping set. Silicon grease to apply to friction points is included with the product (please refer to , "3.5 Hand internal wiring and piping set"). Further, when using the optional external wiring and piping box, the air hose can be pulled out from the rear of the No. 2 arm (please refer to, "3.6 External Wiring and Piping Box"). 6) If the hand output cable and the air hose have excess length, please tie the excess section by cable tie and fix it to the plate. The plate has some holes for fixing the cable/hose with a cable tie. 7) Install securely the No.2 arm cover U as before with fixing screws (tightening torque: 1.39 to 1.89 Nm). This completes installing the solenoid valve set. Table 3-1 : Solenoid valve ports and hoses: Correspondence of couplings and hand ports Hand Hand 1 Hand 2 Hand 3 Hand 4 Hand port Solenoid valve port OPEN 1 CLOSE 2 OPEN 3 CLOSE 4 OPEN 5 CLOSE 6 OPEN 7 CLOSE 8 Solenoid valve used 1 st row 2 nd row 3 rd row 4 th row Installing the solenoid valve set 3-50 3Installing the option devices 3.2 Installing the hand input cable Fig.3-3 shows the hand input cable’s storage location on the robot. Please use the optional external wiring and piping box to pull the hand input cable out externally. After connecting the hand input cable connector, reference, "3.6 External Wiring and Piping Box", and pull it out from the robot arm. When passing through the inside of the shaft and using it, please use the optional hand internal wiring and piping set. Remove the No. 2 arm cover U and connect the connector above the No. 2 arm. Turn the controller’s power OFF before this operation. Refer to, "5.3.2 Installing/removing the cover" for removing/ installing the cover. No. 2 arm cover U Connect inside the No. 2 arm cover U Connector of robot arm side Coiled and stored by cable tie CAUTION When this cable is connected to the robot the power supply is applied to the end of this cable. The end of the cable is free at factory shipping. So, if the tool side is not connected it may be cause of the trouble such as broken the fuse by short circuit. Before connecting to the robot, customer should check whether or not the cable tip has been properly treated. *The type in the diagram is the ES06 series,, however the location is the same on the ES12 Figure 3-3 :Installing the hand input cable The installation procedure for the hand input cable is shown below 1) Remove the screws fixing the No. 2 arm cover U, and remove the No. 2 arm cover U. 2) The hand input cable is stored in the location shown in Fig. 3-3. Pull out and check the connectors (HC1, HC2) 3) Connect the connector (HC1,HC2) of optional cable with connector of robot arm side (HC1, HC2). Connect with the same names 4) Pull the hand input cables out of the robot arm. Referencing Page 71, "3.6 External Wiring and Piping Box”, pull the cable out. When installation of the optional external wiring and piping box finished, installing the hand input cable is complete. 3-51 Installing the hand input cable 3Installing the option devices 3.3 Installing the hand output cable Fig. 3-4 shows the hand output cable’s storage location on the robot. Please use the optional external wiring and piping box to pull the hand output cable out externally. After connecting the hand output cable connector, reference, "3.6 External Wiring and Piping Box", and pull it out from the robot arm. Remove the No. 2 arm cover U and connect the connector above the No. 2 arm. Turn the controller’s power OFF before this operation. Refer to, "5.3.2 Installing /removing the cover" for removing/ installing the cover. No. 2 arm cover U Connect inside the No. 2 arm cover U Connector of robot arm side Coiled and stored by cable tie *The type in the diagram is the ES06 series, however the location is the same on the ES12 . Figure 3-4 : Installing the hand output cable The installation procedure for the hand output cable is shown below 1) Remove the screws fixing the No. 2 arm cover U, and remove the No. 2 arm cover U. 2) The hand output cable is stored in the location shown in Fig. 3-4. Pull out and check the connectors (GR1, GR2) 3) Connect the connector (GR1, GR2) of optional cable with connector of robot arm side (GR1, GR2). Connect with the same names. 4) Pull the hand output cables out of the robot arm. Referencing Page 71, "3.6 External Wiring and Piping Box”, pull the cable out. When installation of the optional external wiring and piping box finished, installing the hand output cable is complete. Installing the hand output cable 3-52 3Installing the option devices 3.4 Changing the operating range The operating ranges of J1 axis can be limited. Change the mechanical stopper and the operating range to be set inside of that area. If the operating range must be limited to avoid interference with peripheral devices or to ensure safety, set up the operating range as shown below. (1) Operating range changeable angle The operating range must be set up at angels indicated by Table 3-2. Table 3-2 : Operating range changeable angle axis Note1) Type note2) Direction Standard Note3) Note4) Change angle ES06 series J1 Common for ES06-35*/45*/55* +170° +150° +130° Mechanical stopper angle + side +172.3° +152.3° +132.3° Mechanical stopper position P10 P11 P12 -170° -150° -130° Mechanical stopper angle - side -172.3° -152.3° -132.3° Mechanical stopper position P10 N11 N12 ES12 series J1 Common for ES12-55*/70*/85* + side Mechanical stopper angle Mechanical stopper position +170° +150° +130° +173.3° +153.3° +133.3° P10 P11 P12 -170° -150° -130° Mechanical stopper angle -173.3° -153.3° -133.3° Mechanical stopper position P10 N11 N12 - side Note1) The "*" of the robot type indicates up/down stroke length and environment specification. It is possible to change the movement ranges shown in Table 3-2 for any model. Note2) Refer to Fig. 3-5 for mechanical stopper position. Note3) The changeable angle shown in Table 3-2 indicates the operation range by the software. The mechanical stopper angle in the table shows the limit angle by the mechanical stopper. Use caution when layout designing of the robot. Note4) The changeable angle can be set independently on the + side and - side. 3-53 Changing the operating range 3Installing the option devices (2) The change method of the operating range ■ Installation of the mechanical stopper 1) Turn off power to the controller. 2) Install the hexagon socket bolt in the screw hole to the angle to set up referring to Table 3-2 and Fig. 3-5. About the mechanical stopper position and the relation of bolt size is shown in Fig. 3-5. When the screw hole is covered by the arm, move the No.1 arm slowly by hand. P12 P11 P10 Installation bolt： Hexagon socket head cap screw ・ES06 series： M10×20 ・ES12 series： M12×20 *Changing the operating prepared optional. range is N11 N12 Figure 3-5 :Mechanical stopper position ■ Change the operating range parameters After turning on power to the controller, conduct change setting of operating range follows by the procedure below. (1) Input [R][3][1][4][Enter] [Enter] to switch operator level to EXPERT. (2) Select teach mode, then open the [Record Posi.] display from <Constant setting> [3 Machine constants] [5 Software Limit] menu. (3) By pressing [Enable] + [Motor ON], turn the Motor ON. ＋ (4) Operate the robot close to the mechanical stopper by slow speed, then input [Enter］ [Record］at the moving edge. (5) Carry out the same setting to the opposite side. In case setting ± opposite, change the numerical value at [Numerical value input] display. ■ Check the operating range After changing the parameter, turn off the controller power and turn on again. Then, move the axis changed by joint jog operation to the limit of the operating range. Confirm that the robot stops by limit over at the changed angle. This completes the procedure to change the operating range. Changing the operating range 3-54 3Installing the option devices 3.5 Hand internal wiring and piping set Remove the No. 2 arm cover U and fix this option to the plate on the No. 2 arm. Turn the controller’s power OFF before this operation. Refer to, "5.3.2 Installing/removing the cover” for removing / installing cover. (1) Installation procedure The installation procedure is shown below. Refer to the installation diagram, and perform the installation correctly. Installation diagram of ES06 series is shown in Fig.3-6 and ES12series is shown in Fig. 3-7. 1) Move the J3 axis to the top end with a jog operation and shut off the controller's power supply. This is necessary for space standard settings when feeding the air hose and hand input cable through the inside of the shaft. 2) Remove the screws fixing the No. 2 arm cover U, and remove the No. 2 arm cover U. 3) Pass the tool (hand) side of the secondary piping air hoses and hand input cables through the shaft. Make sure that the air hoses and the cables are not twisted or crossed. 4) Fix the air hoses and the cables with a cable tie so as to position the end of the expanding sleeve 10mm away from the opening of the shaft. 5) The highest point of the curved section of the air hoses and cables should be matched up with the top of the fixing plate. CAUTION If the air hoses and the cables are not long enough or too long, when the robot operates, excessive bending and friction with the shaft upper end or the cover may result in a break or abnormal operations of the tool (hand). 6) In the state of the steps 4) and 5), fix the air hoses and the cables to the (a) and (b) portions of the plate with cable ties. For the (a) portion, wrap the air hoses and the cables with cushion rubber before fixing. 7) Cut the secondary piping air hoses in appropriate length, and connect the air hoses to the solenoid valve. The diagram shows the connection to the optional solenoid valve as an example. The air hoses can also be pulled out from the rear of the No. 2 arm by using another option: an external wiring and piping box. For the details, refer to, "3.6 External Wiring and Piping Box". For the connection to the optional solenoid valve, connect the air hoses to the A and B ports of the solenoid valve. 8) When using the hand input cable connect the connectors (HC1, HC2) of optional hand input cable to connectors (HC1, HC2) of robot side. Connect with the same names. The connectors of robot side and cables are tied up by cable tie at (c) portion. Cut the cable tie and pull them out. The connected connectors are stored to the (c) portion. When the hand input cable is not used tie up the connector and fix to the plate by cable tie. CAUTION 9) Do not remove the cable ties which fixing connectors. Fix the plate on the No. 2 arm, other cables and air hoses with cable ties. In this way, the internal cables and connectors do not touch the plate edge and others, or break due to the vibration during the robot operation. Carry out piping and wiring on the tool side. Fix the air hoses and the cables, which are pulled out from the shaft lower end, to the hand side. Check again that the highest point of the curved section of the air hoses and the cables reaches the height of the fixing plate upper end, and then fix the air hoses and the cables at the outlet of the shaft. 10) Apply silicon grease to the contact surface between the air hoses of the fixing plate and the cables, the cable sliding portion from the shaft upper end to the fixed portion, and the opening on the shaft upper end. 3-55 Hand internal wiring and piping set 3Installing the option devices 11)Power on the controller, perform the jog operation at joint coordinates system for the J3 and J4 axes, and check that the air hoses and the cables do not interfere with other components. Joint coordinates system CAUTION Do not power on the controller when the internal cables are connected to the connectors on the robot. If the end of the cables on the tool side is not processed, troubles such as fuse blown by ground fault or short circuit may occur. Check that the end of the cables has been processed before powering on the controller. 12)Turn off the controller’s power supply, then install the No.2 arm cover U securely as before with fixing screws (tightening torque: 1.39 to 1.89 Nm). When installing the cover, check that no air hose or cable is pinched, and no air hose is bent. This completes installing the Hand internal wiring and piping set. Hand internal wiring and piping set 3-56 3Installing the option devices (2) ES06 series Refer to, "(1) Installation procedure" and install cables and air hoses correctly. The numbers in Fig. 3-6 are corresponding to the same numbers in "(1) Installation procedure". Turn the controller’s power OFF before this operation. Refer to Page 79, "5.3.2 Installing/removing the cover" for removing / installing the cover. No.2 arm cover U 2)、12) 5)、9) Match up the peak of the air hose and cable with the top end of the plate. 4) Approx. 10mm Connect inside the No.2 arm cover U 8) (c) Expanding sleeve Silicone grease places 10) 3) (a) (b) 6) 1) Top end of the J3 axis operating range 11) 9) Fixing air hoses and cables inside a hand. Perform the operation of the J3 and J4 axes, and check that no interference occurs Figure 3-6 :Installing the hand internal wiring and piping set (ES06 series) 3-57 Hand internal wiring and piping set J3 axis J4 axis application 3Installing the option devices (3) ES12 series Refer to Page 66, "(1) Installation procedure" and install cables and air hoses correctly. The numbers in Fig. 3-7are correspond to the same numbers in "(1)Installation procedure". Turn the controller’s power OFF before this operation. Refer to Page 79, "5.3.2 Installing/removing the cover" for removing / installing the cover. 5)、9) Match up the peak of the air hose and cable with the top end of the fixing plate No.2 arm cover U 2)、12) 4) Approx. 10mm Connect inside the No. 2 arm cover U Expanding sleeve 8) (c) 10) Silicone grease application places 3) (a) (b) 6) 1) Top end of theJ3 axis operating range J3 axis 11) 9) Fixing air hoses and cables inside a hand. Perform the operation of the、J3 and J4 axes, and check that no interference occurs. J4 axis Figure 3-7 :Installing the hand internal wiring and piping set (ES12 series) Hand internal wiring and piping set 3-58 3Installing the option devices 3.6 External Wiring and Piping Box The air hose that is connected inside the robot, the optional hand output cable, the hand input cable, etc., can all be pulled out from the rear of the No. 2 arm. These can be used to connect a customer supplied solenoid valve to the hand output cable, etc. No. 2 arm cover U External Wiring and Piping Box Fix to the rear of the No. 2 arm (remove the No. 2 arm cover B) Caution) Figure is the example of ES06 series, however ES12 series follows the same procedure. <a>Coupling φ6 two couplings (ES06 only) <b>Coupling φ4 eight couplings (ES06) φ6-eight couplings (ES12) <d> In the other side has two holes for fixing the hose and cable by cable tie. *The diagram shows an example of pulling the hand input cable <c> Cable clamp attachment hole (φ21) Two points-left and right. Blind plug Installation holes (M4 screw four places) Table 3-3 :Hose and cables which can be pulled out No Position to pull out Air hoses/cables ES06 Primary piping air hose (φ 6-2 hoses) (1) (The primary piping is equipped from rear of base <a> to No.2 arm) Secondary piping air hose (φ4-8 hoses： ES06, (2) φ6-8 hoses: ES12) (Air hose of the optional hand internal wiring <b> and piping set or prepared by the customer) (3) Optional hand output cable (4) Optional hand input cable <c> Coupling φ6 two couplings Example usage ES12 Coupling <b> φ6 couplings two Primary air supply to externally installed solenoid valve. Coupling Coupling φ4 eight φ6 eight couplings couplings Taking in the secondary air from externally installed solenoid valve. Pulling out the secondary air from optional solenoid valve φ21 hole four φ21 hole four For driving the externally installed solenoid valve. place place Taking in the input signals from tools such as the hand Note) Fix all with cable tie (sections <d> and <e> of the diagram) <f> Positions to fix with cable tie (two positions left and right) The hole for fixing the cable tie J2 axis reduction gears <e> Fix to the external wiring and piping box with cable tie (has two holes for fixing) Cable clamp Cable Air hose *Diagram shows an image of pulling out air hose and cables Figure 3-8 :External Wiring and Piping Box 3-59 External Wiring and Piping Box 3Installing the option devices Fig. 3-8 shows the installation procedure for the external wiring and piping box. The procedure is the same in ES06/12. Remove the No. 2 arm cover B and install this option using the same screw holes. The installation procedure is shown below. Turn the controller’s power OFF before this operation. Refer to, "5.3.2 Installing/ removing the cover” for removing / installing the cover. 1) Remove the each fixing screws and remove the No. 2 arm cover U and the No. 2 arm cover B. 2) Pull out the air hoses or cables from the opening which removed the No. 2 arm cover B. 3) Fix (or connect) the air hoses and cables to this option box. Previously adjust the air hose and cables to an appropriate length. Make sure that the wiring and piping lines avoid the side of the J2 reducer (because gap is narrow, it interfere with the No. 2 arm cover U). Connect the air hoses with the joint inside this option box. Remove the blind plug attached to this option box and fix the cable with the cable clamp. < How to remove the blind plug> To the inside of a robot arm ロボットアーム内へ 外部配線配管 ボックス ロックナット Lock nut Cable clamp ケーブルクランプ (Attached to a hand output cable and a hand input cable) 引出すケーブル Cable to pull out (ハンド出力ケーブルなど) (Hand output cable, etc.) 樹脂ナット用簡易スパナ Simple spanner for Cap キャップ resin nuts ロックナット Lock nut Make sure that the supplied spanner ロックナットと簡易スパナ securely holds the lock nut. の平面部を合わせます To remove the blind plug, hold the lock nut with the supplied simple spanner for resin nuts, and loosen the cap with a screwdriver. The supplied simple spanner is used when attaching a cable clamp the same way. Figure 3-9 :Fixing the Cable 4) Fix the air hoses and cables to the hole inside of this box by using the attached cable tie. (section <e> of Fig. 3-8) Note) Be sure to fix the air hoses and cables to prevent the hoses falling out and breaking the cable. Also, fix carefully so that the air hose and cables may not be pulled too much. 5) Install securely the external wiring and piping box to the screw holes that previously installed the No. 2 arm cover B by attached screw. (Tightening torque: 1.39 to 1.89Nm). When installing pull it little by little from the No. 2 arm side, making sure that the air hose and cables are not bent or trapped. 6) Make sure that the wiring and piping lines on the No.2 arm avoid the side of the J2 reducer (because gap is narrow, it interfere with the No. 2 arm cover U). Fix the hoses and cables to the hole shown in section <f> of Fig. 3-8 using cable tie. There are 2 holes, located left and right. 7) If the cables and the air hoses have excess length, please tie the excess section using cable tie. 8) Install securely the No.2 arm cover U as before with fixing screws (tightening torque: 1.39 to 1.89 Nm). This completes installing the External Wiring and Piping Box. External Wiring and Piping Box 3-60 4 Basic operation 4 Basic operation Basic operation, from making program to automatic operation, are written in a separate instruction manual, ”CFD controller / instruction manual / basic operation” (TCFEN-160). Please check it, if necessary. 4-61 4 Basic operation NOTE 4-62 5 Maintenance and Inspection 5 Maintenance and Inspection The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are described in this chapter. The types and replacement methods of consumable parts are also explained. 5.1 Maintenance and inspection interval Maintenance and inspection are divided into the inspections carried out daily, and the periodic inspections carryout at set intervals. Always carry these out to prevent unforeseen trouble, to maintain the product for a long time, and to secure safety. (1) Inspection schedule (Estimated 2 shifts) In addition to the monthly inspection, add the following inspection items every three months (estimated at 1,000Hr operation hours). 0Hr Monthly inspection Monthly inspection Monthly inspection 1,000Hr 3-month inspection 2,000Hr Daily inspection Monthly inspection Monthly inspection Monthly inspection 3-month inspection 6-month inspection Monthly inspection Monthly inspection 3,000Hr Monthly inspection 3-month inspection Monthly inspection Monthly inspection 4,000Hr Monthly inspection 3-month inspection 6-month inspection Yearly inspection 8,000Hr Monthly inspection 3-month inspection 6-month inspection Yearly inspection 2-year inspection 12,000Hr Monthly inspection 3-month inspection 6-month inspection Yearly inspection 2-year inspection 3-year inspection Operating time <Guideline for inspection period> For one shift .......... 10 Hr/day ×20 days/month × 3 months = approx. 600 Hr For two shifts ....... 15 Hr/day ×20 days/month ×3 months = approx. 1,000 Hr [Caution] When using two lines, the 3-month inspection, 6-month inspection and yearly inspection must be carried out when half the time has passed. Fig. 5-1 : Inspection schedule 5-63 Maintenance and inspection interval 5 Maintenance and Inspection 5.2 Inspection items The inspection items for the robot arm are shown below. 5.2.1 Daily inspection items Carry out the daily inspections with the procedures given in Table 5-1 Table 5-1 : Daily inspection items (details) Procedure Inspection item (details) Remedies Before turning power ON (Check the following items before turning the power ON.) 1 Securely tighten the bolts. Are any of the robot installation bolts loose? (Visual) 2 Securely tighten the screws. Is any of the cover tightening screws loose? (Visual) 3 Securely tighten the bolts Are any of the hand installation bolts loose? (Visual) 4 Securely connect. Is the power supply cable securely connected?。 (Visual) 5 Is the machine cable between the robot and controller Securely connect. securely connected? (Visual) 6 Are there any cracks, foreign contamination or obstacles on Replace with a new part, or take remedial measure the robot and controller cover? 7 Is there any abnormality in the pneumatic system? Are Drain the drainage, and remedy the air leaks (replace the part) there any air leaks, drain clogging or hose damage? Is the air source normal? (Visual) After turning the power ON (Turn the power ON while monitoring the robot.) 1 Is there any abnormal motion or abnormal noise when the Follow the troubleshooting section. power is turned ON? During operation (try running with an original program) 1 Follow the troubleshooting section Check whether the movement points are deviated? Check the following points if there is any deviation. 1. Are any installation bolts loose? 2. Are any hand installation section bolts loose? 3. Are the positions of the jigs other than the robot deviated?。 4. If the positional deviation cannot be corrected, refer to "Troubleshooting", check and remedy. 2 Is there any abnormal motion or abnormal noise? Follow the troubleshooting section (Visual) Inspection items 5-64 5 Maintenance and Inspection 5.2.2 Periodic inspection Carry out periodic inspection with the procedures given in Table 5-2. Table 5-2 : Periodic inspection items (details) Procedure Inspection item (details) Remedies Monthly inspection items 1 Are any of the bolts or screws on the robot arm loose? Securely tighten the bolts. 2 Are any of the connector fixing screws or terminal block terminal screws loose? Securely tighten the screws. 3-month inspection items 1 Is there any grease of the shaft section still? Wipe off the old grease and supply the new grease. 6-month inspection items Yearly inspection items 1 Replace the backup battery in the robot arm. Exchange it referring to “5.3.7 Replacing the backup battery”. 2-year inspection items 1 Is the friction at the timing belt teeth severe? If the teeth are missing or severe friction is found, replace the timing belt. 2 Is the timing belt tension abnormal? Is any deviation occurred originated from this? If the timing belt is loose or too tense, adjust it. 3-year inspection items Note) Supply the grease to each axis with referring to “5.3.6 Lubrication”. 5-65 Inspection items 5 Maintenance and Inspection 5.3 Maintenance and inspection procedures The procedures for carrying out the periodic maintenance and inspection are described in this section. Thoroughly read the contents, and follow the instructions. This work can be commissioned to the NACHI Service Department for a fee. (Never disassemble, etc., the parts not described in this manual.) The maintenance parts, etc., required for the customer to carry out maintenance and inspection are described in “5.5 Maintenance parts” of this manual. Always contact your dealer or Service Center close from your location when parts are needed. CAUTION The origin of the machine system could deviate when this work is carried out. "Review of the position data" and "re-teaching" will be required. 5.3.1 Robot arm structure The outline drawing is shown below. <ES06/ES12 series> No,2 arm cover U 第2アームカバーU ⑩ボールネジ <10>Ball screw ⑪ボールスプライン <11>Ball screw spline <9>J3 axis timing belt ⑨J3軸タイミングベルト <8> J3 axis motor ⑧J3軸モータ <3> J2 axis motor ③J2軸モータ <4>Reduction gears ④減速機 ⑤J4軸モータ <5>J4 axis motor No,2 arm 第2アーム No,1 arm 第1アーム No,2 arm cover D 第2アームカバーD <7> J4⑦J4軸タイミングベルト2 axis timing belt2 <6>J4 axis timing belt1 ⑥J4軸タイミングベルト1 ベース Base <2>Reduction gears ②減速機 <1> J1①J1軸モータ axis motor Fig. 5-2 : Outline structure drawing of robot arm (ES06/ES12 series) Maintenance and inspection procedures 5-66 5 Maintenance and Inspection 5.3.2 Installing/removing the cover <1> No.2 arm cover U <3> No.2 arm cover B (Back of No.2 arm cover) <2> No.2 arm cover D <6> CONBOX cover (upper side of back of base) <5> Battery cover Note) The cover on the top face of the No.1 arm is not removing. <4> ADD cover (lower side of back of base) Fig. 5-3 : Installing/removing the cover CAUTION 5-67 Check to see that the packing has not been torn or peeled off when the cover was mounted /removed. If it has been torn or peeled off, please contact Service Center near your location.（Refer to the back cover for the information.） If the cover is used with the packing torn or peeled off, oil mist and other substances may enter inside the arm and cause a malfunction. Maintenance and inspection procedures 5 Maintenance and Inspection Table 5-3 :Cover fixing screw list No. Cover name Note1) Installation screw name: Qty. Remarks Common on ES06/ES12 seires No.2 arm cover U ① Truss head screw, M4 x 10: 6 ES06 series Truss head screw, M4 x 10: 8 ES12 seires ② No.2 arm cover D ③ No.2 arm cover B Truss head screw, M4 x 10: 6 Hexagon socket screw, M4 x 8: 4 ④ ADD cover Hexagon socket screw, M4 x 8: 2 ⑤ Battery cover Truss head screw, M4 x 10: 6 ⑥ CONBOX cover Hexagon socket screw, M4 x 8: 4 Note1) The fixing torque for each screw are 1.39-1.89Nm. (1) Referring to Fig. 5-3, remove the covers. (2) The names of the covers and installation screws are given in Table 5-3. (3) When reattaching the covers after a maintenance inspection, proceed in the reverse order of their removal. Tightening the screw with the torque shown in Table 5-3. Maintenance and inspection procedures 5-68 5 Maintenance and Inspection 5.3.3 Packing Replacement Procedure The packing gets deteriorated with the passage of time and must be replaced as required. Table 5-4 provides guidelines for replacing the packing. Replace the packing in accordance with the instructions given below. If the packing is not replaced in a timely manner, water or oil will be allowed to intrude the robot, possibly making it inoperative. Table 5-4 :Packing replacement guideline Service environment General environment Whether or not robot is pressurized Note1) Not pressurized Not pressurized When packing must be replaced When signs of cracking or peeling are noted in the packing. When the cover mounted on the robot is removed/put back in place (1) Packing Replacement Instructions Stick again new packing as before. 1) Remove the old packing, and clean and degrease the surface on which it has been placed. 2) The sticking surface of packing is double-coated adhesive tape. Referring to “Fig. 5-4 : Example of sticking packing(good example)” and “Fig 5-6 : Sticking the cord-like packing”, and stick the packing in line with form. Be careful for the packing not to slide. The example of unsuitable packing slid is shown in “Fig.5-5 : Example of sticking packing(bad example)”. 3) Although the No.2 arm cover (U) sticks two or more packings per place, it has length with which packing ends overlap. Stick packing in the following procedures. For more information, see “Fig.5-7 : example of packing overlaps”. Examples of improperly treated cut edge are shown, as well. a) Stick packing in line with form of the sticking surface. Finally, cut packing so that adjoining pieces have a 1mm overlap at the end. b) Apply liquid gasket to the cut edges. (Designated liquid gasket: 1212 (Maker: Three Bond)) Place an order at our Service Center. c) Stick so that the gap may not be made to each other's packing. CAUTION Do not install the cover immediately after sticking packing. Install the cover, after the 6 hours pass after sticking packing for gasket hardening. 4) Confirm that packing is stuck correctly and install the cover. When tightening the bolts fixing the cover avoid tightening them to a specified torque at a time. Tighten the bolt in the order shown as much as possible in the”Fig.5-8 : Example of order which tighten bolts”. The torque which tightens the fixing bolt of each cover is shown in “Fig.5-3 Cover fixing screw list”. CAUTION Stick the packing securely, pressing down with the finger. If sticking is insufficient, when the cover is installed, packing slides by the pressure, and there is a possibility that it may become impossible to secure protection performance. Completion of packing replacement 5-69 Maintenance and inspection procedures 5 Maintenance and Inspection Packing is stuck securely without sliding. Fig. 5-4 : Example of sticking packing (good example) Sliding. Fig. 5-5 : Example of sticking packing (bad example) Some of the packings to be used are cord-like. Stick such packings by bending in line with the form. Location at which Location at which gasket is applied. packing is bent Stick the packing Cord-like packing Fig. 5-6 : Sticking the cord-like packing Maintenance and inspection procedures 5-70 5 Maintenance and Inspection A 1mm overlap [1]Cut the packing so that there is a 1mm [2]Apply liquid gasket to the cut overlap at the end. Join by liquid gasket [3]Stick the packing so that there is no gap between the adjacent pieces. Unsuitable overlap of packing Gasket is not applied. End of packing are not in contact with each other. Displacement at the ends of packing Ends of packing overlap each other Cut edge of packing is irregular. End of packing is cut diagonally. Fig. 5-7 : Examples of packing overlaps 5-71 Maintenance and inspection procedures 5 Maintenance and Inspection Fig. 5-8 : Example of order which tighten bolts Maintenance and inspection procedures 5-72 5 Maintenance and Inspection 5.3.4 Inspection, maintenance and replacement of timing belt This robot uses a timing belt for the drive conveyance system of the J5 axis. Compared to gears and chains, the timing belt does not require lubrication and has a low noise. However, if the belt usage method and tension adjustment are inadequate, the life could drop and noise could be generated. Sufficient aging to remove the initial elongation of the belt, and adjustment of the belt tension have been carried out before shipment from the factory. However, depending on the robot working conditions, elongation will occur gradually over a long time. The tension must be confirmed during the periodic inspection. In addition, it is serviceable if there is the sound wave type belt tension gauge in inspection and adjustment of the timing belt. The recommendation gauge is shown below. Please prepare by customer. Refer to the “(7) Timing belt tension” for the tension adjustment value of the timing belt. Maker:Gates Unitta Asia Company, Type:U-505 Image of Measurement by the sound Measurement by the push-pull gauge wave type belt tension gauge Fig. 5-9 : Tension adjustment method of timing belt (1) Timing belt replacement period The timing belt life is greatly affected by the robot working conditions, so a set time cannot be given. However, if the following symptoms occur, replace the belt. 1) When cracks from at the base or back of the belt teeth. 2) When the belt expands due to adherence of oil, etc. 3) When the belt teeth wear (to approx. half of the tooth width). 4) When the belt teeth jump due to belt teeth wear. 5) When the belt snaps CAUTION CAUTION 5-73 Due to the manufacturing of the timing belt, initial wear will occur. Wear chips may accumulate in the cover after approx. 300 Hr of operating the robot, but this is not a fault. If the wear chips appear soon after wiping them off, replace the belt. When the belt is replaced, the machine system origin may deviate. In this case, the position data must be reviewed. 5 Maintenance and Inspection (2) ES06/ES12 series ： Adjusting the J3 axis timing belt The section related to J3 axis timing belt of ES06/ES12 series and adjustment is shown in Fig. 5-10. The picture is the image which removed the No.2 arm cover. Caution） This is ES06 series, however ES12 is also same. <3>J3 axis motor <2>J3 axis motor fixing screw- loosen lightly <2>J3 axis motor fixing screw- loosen lightly <6> Timing pulley B (It locates under ball screw.) *Don’t remove the timing belt. <4> Timing belt Push <5>Timing pulley A *Don’t remove the timing belt <1>Tension adjustment screw –Loosen the nut, adjust by screw Fig. 5-10 : Inspecting/Adjusting the J3 axis timing belt (ES06/ES12) Inspection and adjustment procedure of the timing belt of J3 axis are shown below. 1) Confirm that the power supply of the controller is OFF. 2) Refer to “Fig. 5-3 ：Installing/ removing the cover”, and remove the No.2 arm cover U. 3) Visually confirm that the symptoms indicated in"(1)Timing belt replacement period" have not occurred with the <4> timing belt 4) Lightly press the center of the belt, and confirm that the value of belt slack is in”Fig.5-12 ： Belt tension”. Or measure the tension of the belt with tension meters, and confirm that the value is in the range of standard tension. When adjustment is necessary, continue to follow the procedure shown below. When adjustment is not necessary, install the No.2 arm cover U as before and finish the inspection. 5) Lightly loosen J3 motor installation screws <2> (Be careful not to overly loosen the screws.) 6) The nut which is fixing tension adjustment screw <1> is loosened, turn tension adjustment screw <1>, and adjust the tension of timing belt <4>. When the screw is turned to the right, the belt will be stretched, and when turned to the left, will loosen. Adjust tension to the above-mentioned value. Note) Be careful, if the belt is removed from pulley <5> <6>, or the mesh of belt and pulley <5> <6> is shifted by loosening the screw too much, the origin will deviate. If the position deviated, reset the origin. (Refer to, "5.6 Resetting the origin") 7) After adjustment, fasten securely the two J3 axial motor fixing screws <2>, and the nut of tension adjustment screw <1>. Improper tightening may cause the belt to loosen with vibration. 8) Install No.2 arm cover U securely as before and finish adjustment. This completes adjustment of the J3 axis timing belt. 5-74 5 Maintenance and Inspection (3) ES06/ES12 series ： Replacing the J3 axis timing belt The procedure for replacing the J3 axis timing belt on theES06/ES12 series is shown below. The diagram shows a timing belt on the RH-3FH series is shown below. The diagram shows an After replacing the J3 axis timing belt the resetting the origin of J3 and J4 axis is necessary. 1) Refer to “Fig. 5-3 ： Installing/ removing the cover”, and remove the No.2 arm cover U. 2) Loosen the nut of tension adjustment screw <1>, and loosen the tension adjustment screw <1>. Caution) This is ES06 series, however ES12 series is also same. <3>J3 axis motor-remove <2>J3 axis motor fixing screw- remove <2>J3 axis motor fixing screw- remove <6> Timing pulley B (Locates under ball screw.) <4> Timing belt <5>timing pulley A <1> Tension adjustment screw- Loosen the nut and screw. 3) Remove two fixing screws <2>, remove the J3 axis motor <3>. <3>J3 axis motor remove <2>J3 axis motor fixing screw remove <6> Timing pulley B <2>J3 axis motor fixing screw <5>timing pulley A Locates under ball screw. <4> Timing belt Remove from the <5> Timing pulley A(Motor side)、 <6> Timing pulley B(Shaft side) Caution) This is ES06 series, however ES12 series is also same. 4) Remove the timing belt <4> from the timing pulley A<5> and B<6>. 5) Install surely the new belt to the timing pulley (on the motor) <5> and timing pulley B <6>, and fix the J3 axismotor <3> with J3 axis motor fixing screw <2>. Confirms having related the timing belt <4> to the timing pulley A <5> and the timing pulley B <6> securely. 6) Adjust the tension of J3 axis timing belt with referring to”(2)ES06/ES12 series ： Inspecting/ adjusting the J3 axis timing belt”. 5-75 5 Maintenance and Inspection 7) Install No.2 arm cover U securely as before. 8) Reset the origin of J3 and J4 axis with referring to, "5.6 Resetting the origin" This completes replacement of the J3 axis timing belt. 5-76 5 Maintenance and Inspection (4) ES06/ES12 series : Inspecting/Adjusting the J4 axis timing belt As shown in Fig. 5-11 the J4 axis timing belt consists of two timing belts: timing belt A <1> and timing belt B <2>. （Shapes are different depending on the robot type, but basic structures are the same.） When adjusting the timing belts, first adjust timing belt B <2> and then proceed to adjust timing belt A <1>. <The No.2 arm bottom view (Inside of the No.2 arm cover D)> <2> Timing belt B <1> Timing belt A Adjust first Adjust next Push Shaft Push Timing pulley A Timing pulley B Timing pulley C Timing pulley D Timing belt B Adjustment screw <The No.2 arm upper view (Inside of the No.2 arm cover U)> 外す <1> Timing belt A Timing belt A adjustment screw Fig.5-11: Inspecting/Adjusting the J4 axis timing belt (ES06/ES12) 5-77 5 Maintenance and Inspection Inspection and adjustment procedure of the timing belt of J4 axis are shown below. 1) Confirm that the power supply of the controller is OFF. 2) “Fig.:5-3 : Installing / removing the cover”, and remove the No.2 arm cover U and No.2 cover D. 3) Visually confirm that the symptoms indicated in"(1)Timing belt replacement period" have not occurred with the timing belt. 4) Lightly press the center of the belt, and confirm that the value of belt slack is in "Fig. 5-12: Belt tension”. When adjustment is necessary, continue to follow the procedure shown below. When adjustment is not necessary, install the No.2 arm cover U and No.2 arm cover D as before and finish the inspection. 5) Adjusts the tension of the timing belt B <2>. Lightly loosen timing pulley <B><C> fixing screws <3> (Be careful not to overly loosen the screws.). 6) Loosen the nut of tension adjustment screw <4> for timing belt B. Adjusts by turning the tension adjustment screw <4> slowly and moving the timing pulley C <5> little by little. When the screw is turned to the right, the belt will be stretched, and when turned to the left, will loosen. Adjust tension to the above-mentioned value. Note) Be careful, if the belt is removed from pulley <5> <6>, or the mesh of belt and pulley <5> <6> is shifted by loosening the screw too much, the origin will deviate. If the position deviated, reset the origin. (Refer to, "5.6 Resetting the origin") <The No.2 arm bottom view (Inside of the No.2 arm <5>Timing pulley C <2> Timing belt B <4> Timing pulley B <6> Timing pulley D Push <3> Timing pulley B, C fixing screws (three screws) -Loosen <4>Tension adjustment screw for timing belt B <3> Timing pulley B,C fixing screws (Three screws) -Loosen （Shapes are different depending on the types, but basic structures are the same.） 7) After adjustment, fasten certainly the three timing pulley <B><C> fixing screws <3>. And fasten certainly the nut of tension adjustment screw <4>. Improper tightening may cause the belt to loosen with vibration. 5-78 5 Maintenance and Inspection 8) Next, adjusts the tension of the timing belt A <1>. Lightly loosen two J4 motor fixing screws <7> (Be careful not to overly loosen the screws.). 9) Loosen the nut of tension adjustment screw <8> for timing belt A. Adjusts by turning the tension adjustment<8> screw <8> slowly and moving the J4 axis motor <9> little by little. When the screw is turned to the right, the belt will be stretched, and when turned to the left, will loosen. Adjust tension to the above-mentioned value. Note) Be careful, if the belt is removed from pulley <10> <4>, or the mesh of belt and pulley <10> <4> is shifted by loosening the screw too much, the origin will deviate. If the position deviated, reset the origin. (Refer to, "5.6 Resetting the origin"). <The No.2 arm upper view (Inside of the No.2 arm cover U)> <9> J4 axis motor <7>J4 axis motor fixing screw (two screws) *Exists in the rear of J4 axis also <1> Timing belt A <8>Tension adjustment screw for timing belt A Loosen the nut and screw <The No.2 arm bottom view (Inside of the No.2 arm cover D)> <1> Timing belt A <10>Timing pulley A Push <4> Timing pulley B （Shapes are different depending on the types, but basic structures are the same.） 10)After adjustment, fasten certainly the two J4 motor fixing fixing screws <7> And fasten certainly the nut of も tension adjustment screw <8>. Improper tightening may cause the belt to loosen with vibration. 11)Install No.2 arm cover U and No.2 arm cover D securely as before and finish adjustment. This completes adjustment of the J4 axis timing belt. 5-79 5 Maintenance and Inspection (5) Timing belt tension F f ： Pressing force s ： Span d ： Slack Pressing force Axis ES06 series J3 J4(motor side) J4(Shaft side) ES12 series J3 J4(motor side) J4(Shaft side) Belt type Span ： s (mm) Slack ： d (mm) Pressing force： f (N) 264-3GT-9 315-3GT-6 363-3GT-12 82 64 95 1.3 1.0 1.5 3 2 4 288-3GT-12 417-3GT-9 456-3GT-20 71 99 121 1.1 1.5 1.9 4 3 7 Remarks The preset value and adjustment value in the sound wave type belt tension gauge Axis Preset value Belt type M(g/m) W(mm/R) S(mm) Standard tension T(N) ES06 series J3 264-3GT-9 2.5 9 82 40 ～ 48 J4(motor side) 315-3GT-6 2.5 6 64 26 ～ 32 J4(Shaft side) 363-3GT-12 2.5 12 95 53 ～ 65 ES12 series J3 288-3GT-12 2.5 12 71 53 ～ 65 J4(motor side) 417-3GT-9 2.5 9 99 40 ～ 48 J4(Shaft side) 456-3GT-20 2.5 20 121 88 ～ 108 Note) The value given in the table is the value of proper tension. Because the tension declines by the infancy expansion when exchanged to new belt, please adjust proper tension again after the operation for the about 100 hours when exchanged to new belt Fig.5-12: Belt tension The timing belt can satisfactorily convey the drive and keep a durable force only when it has an adequate tension. The belt tension should not be too tight or too loose. Instead, it should be adjusted to a degree that elasticity is felt when the belt is pressed with the thumb. If the belt tension is too weak, the belt loosening side will vibrate. On the other hand, if the belt tension is too strong, a sharp sound will be heard and the belt tension side will vibrate. The detailed adjustment (tension) is shown in Fig. 5-12. Check and adjust with the belt pressing force f and the slack amount d between spans. 5-80 5 Maintenance and Inspection 5.3.5 Lubrication (1) Lubrication position and specifications The grease nipple position is shown in Fig. 5-17. The lubrication specifications for each place are shown in Table 5-5. Refer to the, "5.3.2 Installing/removing the cover" for the method of removing and installing the cover. <4> Ball screw section application Only ES06/ES12 Ball screw nut Inside of No.2 arm cover U <2>J2 axis lubrication port Inside of battery cover <3> Shaft section application ES06/ES12 : Ball spline Ball spline nut <1>J1 axis lubrication port Fig.5-13 ： Lubrication positions Table 5-5 :Lubrication specifications No. Parts to be lubricated Lubrication method Lubrication oil Default charge amount (maker) Lubrication interval Lubrication amount guide 24,000 Hr 12 g 24,000 Hr 8g Cover to remove ES06 series <1> J1 axis reduction gears <2> J2 axis reduction gears <3> Shaft （ball screw spline） <4> Shaft （ball screw） 5-81 Grease nipple WA-610(Only addition) Grease nipple WA-610(Only addition) Wipe the old grease, and applies 4B No.2 (Harmonic Systems Inc.) Battery cover Drive Every Multemp PS2 (KYODO YUSHI 2,000km movement CO., LTD.) 1g 1g No.2 arm cover U 5 Maintenance and Inspection No. Parts to be lubricated Lubrication method Lubrication interval Lubrication amount guide 24,000 Hr 16 g 24,000 Hr 12 g Every Multemp PS2 (KYODO YUSHI 2,000km movement CO., LTD.) 1g Lubrication oil Default charge amount (maker) Cover to remove ES12 series <1> J1 axis reduction gears <2> J2 axis reduction gears <3> Shaft （ball spline） <4> Shaft （ball screw） Grease nipple WA-610(Only addition) Grease nipple WA-610(Only addition) Wipe the old grease,、 and applies 4B No.2 (Harmonic Systems Inc.) Battery cover Drive No.2 arm cover U 1g ［Caution］ The brand name of the grease shown in the Table 5-5 is the grease put in at shipping. The lubrication time is a cumulative value of the operation at the maximum speed. If the operation has been suspended, or if the designated speed is slow, the lubrication time can be lengthened in proportion. Depending on the robot operation state, the lubrication time will fluctuate, so determine the time according to the state so that the grease does not run out. For the shaft, the lubrication interval should be shorter than one in Table 5-5 when the operation is repeated with a short stroke. The numbers in the Table 5-5 correspond to the supply positions in Fig. 5-13. When the specified time limit (24,000 Hr) is due, the overhaul work to replace internal grease is required. For the J1/J2 axis reduction gears, if the overhaul cannot be conducted at the specified timing, lubricate them at the lubrication interval in Table 5-5. Please ask dealer for more details about overhaul. (2) Lubrication method to the J1, J2 axis 1) Turn off the controller's power supply. 2) Refer to the "Fig.5-3 ： Installing/removing the cover" and remove the covers. 3) Insert the grease shown in Table 5-5 using a grease gun from the lubrication grease nipple. Add only the specified amount of grease. Adding excess grease may cause grease to leak. CAUTION Use manual grease gun, and inject grease with pressure 0.03Mpa or less. Do not use the grease gun, which derived by the factory air presser to avoid injecting by too high pressure. A grease gun that fits the grease nipple is required. Recommended grease gun: KH-120 (amount: 140ml) or KH-32 (amount: 200ml) (manufacture: Yamada Corporation Inc.,) The grease guns come with a short nozzle (HSP-1) as standard. If this short nozzle does not reach the desired areas, depending on the robot model and installation location, it may be useful to use a long nozzle (HSP-2). 4) Install the removed cover as before. This complete of lubricating to J1, J2 axis. 5-82 5 Maintenance and Inspection (3) Lubrication method to the shaft 1) Move the J3 axis to the bottom end with a jog operation and shut off the controller's power supply. 2) Refer to "Fig. 5-3: Installing/removing the cover", remove the No. 2 arm cover-U. 3) Wipe the old grease off the shaft. Wipe off the grease inside the No. 2 arm cover-U and the bracket attached vertically to the shaft fixing area. Wipe the grease off Lower end of the J3 axis ES06/ES12 series 4) Power on the controller and move the J3 axis to the top end with a jog operation. Then shut off the controller’s power supply again. 5) Wipe off the old grease beneath the ball spline nut and the ball screw nut on the shaft. Upper end of the J3 axis Wipe the grease off ES06/ES12 series 5-83 5 Maintenance and Inspection 6) Apply the specified amount of grease to the shaft. Fill the shaft grooves with the grease. Also, apply the grease lightly to the areas other than the grooves on the shaft surface to prevent rusting. Grease application area ES06/ES12 series 7) Turn on the controller's power supply. Move the J3 axis up and down for several times using the jog operation to distribute the grease inside the ball spline nut and the ball screw nut. 8) Move the J3 axis to a position around the center of the stroke using the jog operation. Then, turn off the controller's power supply. 9) Wipe off the grease adhering around the shaft ends or the nuts of the ball spline and the ball screw(indicated with the arrows below). When the ball spline and the ball screw are moved with extra grease on them, a large amount of grease is scattered inside the arm. The grease may reach the timing belt inside the No.2 arm, causing the timing belt to deteriorate early. ES06/ES12series 10) Install the No.2 arm cover U as before. This completes of applying grease to shaft. 5-84 5 Maintenance and Inspection 5.3.6 Replacing the backup battery An absolute encoder is used for the position detector, so while power of controller is turned off the encoder position must be saved by the backup battery.These batteries are installed when the robot is shipped from the factory, but as these are consumable parts, they must be replaced periodically by the customer. Lithium battery is used as battery. The guideline for replacing the battery is one year, but this will differ according to the robot's usage state. If error I1016 or E0052 occurs, please exchange the battery. Table 5-6 :The error about the battery Error number I1016 E0052 Description Measure Encoder battery voltage low Turn the power of the controller off after replacing the backup battery, and turn the power ON again. This error is released by turning ON the power of controller again after replacing the battery, however we recommend to check whether origin of each axis is correct or not. Encoder battery abnormal Turn the power of controller ON for few minutes after replacing the backup battery. And the, perform encoder reset. This error can not be released unless performing encoder reset. And also, encoder correction is necessary after encoder reset. （Re-registering of origin position） The method of replacing the battery of robot arm is shown below, so refer to and replace. And further, about the purchase of the battery refers to, "5.5 Maintenance parts". CAUTION 5-85 If an error related to encoder battery had occurred, we cannot guarantee the position of the encoder. In this case, encoder correction (setting of the origin data) becomes necessary. 5 Maintenance and Inspection (1) Replacing the battery CAUTION CAUTION The power supply for the encoder is supplied by cable connected with battery board. The cable must be connected while replacing the battery or operating usually. Thus, if the cable connection is incomplete, the encoder position data will be lost, and resetting the origin is necessary. Replace the battery one by one. If all batteries are removed the encoder data will be lost, and resetting the origin is necessary. The battery installation position is shown in Fig. 5-14. Refers to the figure and replaces the batteries in the following procedures. <2>Battery cover ②バッテリカバー ①取付ネジ（6本） <1>Fixing screw Battery バッテリー (six screws) Fig.5-14 ： Replacing the battery 1) Turn the controller control power OFF. 2) Remove the six fixing screws <1>, and remove the battery cover <2>. 3) Replaces the backup battery one by one. The battery holder is located inside the battery cover <2>. Remove the old battery from the holder, and disconnect the lead connector. 4) Insert the new battery into the holder, and connect the lead connector. Replace all batteries with new ones at the same time. 5) All the batteries should be checked that it has been exchanged newly. If the old battery is contained, generating heat and damaging may occur. 6) Install the battery cover <2> as before. Be careful so that the cable may not be inserted. [Caution] If the old battery is replaced because it has been used up, it is necessary to conduct encoder correction（resetting the origin）. Refer to, "5.6 Resetting the origin" and reset the origin. 5-86 5 Maintenance and Inspection 5.4 About Overhaul Robots which have been in operation for an extended period of time can suffer from wear and other forms of deterioration. In regard to such robots, we define overhaul as an operation to replace parts running out of specified service life or other parts which have been damaged, so that the robots may be put back in shape for continued use. Overhaul interval for robots presumably varies with their operating conditions and thus with the degree of the equipment's wear and loss of performance. It is recommended to perform the overhaul following the timings shown as below. (See Fig. 5-15. for reference) For specific information about parts to be replaced and timing of overhaul, contact your local service representative. Robot body Robot controller Every 24,000 hours of operating time (servo on time) Every 8 years If overhaul is not performed Shipment Failure rate λ Predetermined time period Periodic inspection Over haul If overhaul is performed Servo-on time Fig.5-15: Periodic inspection/overhaul periods CAUTION 5-87 When trying to use a robot or controller that has been stored for long time without using, it is strongly recommended to contact our service center and receive inspections before using those machines. About Overhaul 5 Maintenance and Inspection 5.5 Maintenance parts The consumable parts that must be replaced periodically are shown in Table 5-7, and spare parts that may be required during repairs are shown in Table 5-8. Purchase these parts from the dealer when required. [Caution]: Some NACHI-designated parts differ from the maker's standard parts. Thus, confirm the part name, robot arm and controller serial No. and purchase the parts from the dealer. Table 5-7 :Consumable part list No. 1 2 3 4 Part name Grease Lithium battery (Battery: ER6) Liquefied gasket ES06 series Timing belt 5 6 7 ES12 series Timing belt 8 9 10 Usage place Q'ty Chapter explained Reduction gears of each axis Shaft An needed An needed “5.3.5 Lubrication” Inside the battery cover Packing Note1) 3 An needed Supplier “5.3.6 Replacing the backup battery” NACHI-Fujikoshi “5.3.3 Packing Replacement Procedure” J3 axis J4 axis motor side J4 axis shaft side 1 1 1 “5.3.4 Inspection, maintenance and NACHI-Fujikoshi replacement of timing belt” J3 axis J4 axis motor side J4 axis shaft side 1 1 1 “5.3.4 Inspection, maintenance and NACHI-Fujikoshi replacement of timing belt” Note1)The liquefied gasket is necessary for the place which uses two or more packings to connect. Table 5-8 : Spare parts list No. Part name ES06 series 1 AC servo motor 2 3 4 5 Reduction gears 6 Ball screw spline 7 8 Ball screw No. Usage place Q'ty J1 axis J2 axis J3 axis J4 axis J1 axis J2 axis 1 1 1 1 1 1 J3 axis (general environment specification) 1 J3 axis (general environment specification) 1 Part name Usage place Q'ty Supplier NACHI-Fujikoshi Supplier ES12 series 1 J1 axis 1 2 J2 axis 1 3 J3 axis 1 J4 axis 1 AC servo motor 4 5 Reduction gears 6 7 8 Ball screw spline Ball screw J1 axis 1 J2 axis 1 J3 axis general environment specification) 1 J3 axis (general environment specification) 1 NACHI-Fujikoshi Maintenance parts 5-88 5 Maintenance and Inspection 5.6 Resetting the origin（Encoder correction） The origin is set（Encoder correction）so that the robot can be used with a high accuracy. After purchasing the robot, always carry out this step before starting work. The origin must be reset if the combination of robot and controller being used is changed or if the motor is changed causing an encoder area. The origin setting methods and when each origin setting method is required are shown in Table 5-9. Table 5-9 :Origin setting method No Method Explanation 1 Origin data input The origin data set as the default (encoder correction value) is input from Method (Numerical input) the T/P. Use this method at the initial startup. 2 Jig method （Recording postion） The origin posture is set with the jig etc. Cases when setting the origin is required Remarks • At the initial startup • When the controller is replaced • When the internal memory of the controller is lost. The setting method is explained in ”2, 3 Setting the origin”. When a structural part of the robot (motor, reduction gear, timing belt, etc.) is replaced •When deviation occurred by a collision. The setting method is explained in “5.6.2 Jig method”. [Remarks] The origin is set using the jig method (No.2) at factory default. The set origin data are saved at the internal memory of the controller, which is allocated the same serial number as the robot. The origin data table, which is attached at factory default, is the one which recorded set encoder correction value as decimal number by this jig method. When the robot arm does not mechanically deviate (for example caused by replacement of the reduction gear, motor, or timing belt) or does not lose the encoder data, setting the origin can be done by inputting this numerical value. The origin data is inherent to the serial number of each robot arm. It cannot be used for any other robot arm, so please be careful. 5-89 Resetting the origin（Encoder correction） 5 Maintenance and Inspection 5.6.1 Jig-method（position recording method） The method for setting the origin with the Origin Setting-Jig is explained below. In case of Origin setting-jig is needed, please ask our NACHI service branch, close from your location. （Reference）Outline of Procedure for Origin Setting at this section J1 axis Origin setting by using move hand and inserting origin setting jig. J2 axis Origin setting by using move hand and inserting origin setting jig. J3 axis Origin setting by using release brake and mechanical stopper position. J4 axis Origin setting by using hand move and a match mark position. ・It is possible to move J1,J2 and J4 axis by hand if switching motor ON to off, since there is no motor brake. ・J1 axis and J2 axis are possible to setting the origin by itself. ・J3 axis and J4 axis are needs to set the origin at a same time. RZ6.3 φ6 -0.01 -0.02 C0 .5 Fig. 5-16 shows the reference chart of the Origin setting-jig (OP-T2-095). 300 Fig. 5-16: Reference chart of the Origin setting-jig (OP-T2-095) Procedure for origin setting by origin setting-jig is explained below. This operation is performed at T/P. Switch the [Mode selection switch] of the front controller to “Teach”, and also switch [TP Selector switch] of T/P to “Teach”. → CAUTION The brakes are released here, and the J3 axis (shaft) is moved with both hands. For safety purposes, the brakes must be released by two workers. Resetting the origin（Encoder correction） 5-90 5 Maintenance and Inspection (1) J1 axis origin setting Operation procedure 1: Encoder Reset 1 Check that the teach mode in on. Set the operator level to EXPERT by inputting [R][3][1][4][Enter][Enter] in advance. 2 Press <Constant setting> and open the screen of ［3 Machine constants］-［4 Encoder Correction］. （To selecting the menu, use cursor key and [Enter] key.） >>For example, the screen as below is displayed. （Name type indicates at screen differs depending on the robot.） 3 With both hands, slowly move the J1 axis in front direction, and align the pin hole of No.1 arm and the pin hole of the base. And then go through origin jig for J1 axis and fix it there. Origin-jig 原点治具 No.1第1アーム arm ピン穴 Pin hole Enlarged picture 5-91 Resetting the origin（Encoder correction） 5 Maintenance and Inspection 4 Touch the <Encoder reset> on the display. >>Display switch to “Encoder reset” mode. 5 Move the cursor to J1. 6 By pressing ［Enable］＋［ON/1］, J1 axis checks ON. ＋ （To checks OFF, press ［Enable］＋［OFF/2］.） 7 Touch <Execute>. >>A message window is displayed. Select ”OK” and press ［Enter］, encoder of J1 axis will be reset. Next, perform origin data setting（encoder correction）. Turn the controller power OFF, and turn it ON again, then follow the procedure below. Operation procedure 2: Setting the origin data(Encoder correction) 1 Check that the teach mode in on. Set the operator level to EXPERT by inputting [R][3][1][4][Enter][Enter] in advance. 2 3 4 Press <Constant setting> and open the screen of ［3 Machine setting］-［4 Encoder correction］. （To selecting the menu, use cursor key and [Enter] key.） >> For example, the screen as below is displayed. （Name type indicates at screen differs depending on the robot.） Touch ［Record Posi.］. >>The screen switches to “Record Position” mode. Move the cursor to J1, input ［Enter］［Record］. >>origin data of J1 axis is re-calculated. Resetting the origin（Encoder correction） 5-92 5 Maintenance and Inspection 5 Touch <Overwrite>. >>If the origin setting is successful, origin data will be saved in the internal memory. (By pressing emergency stop button, set the motor on to OFF before hand.） 6 Press ［R］key some times to exit the screen. >>Pull out the origin-jig. This completes the setting of origin data of J1 axis. ◇◆◇Select the axis of origin setting◇◆◇ Do cursor movement of origin setting of each screen by the arrow key. ([ ↑ ][ ↓ ][ ← ][ → ] key) 5-93 Resetting the origin（Encoder correction） 5 Maintenance and Inspection (2) J2 axis origin setting Operation procedure 1: Encoder reset 1 Check that the teach mode in on. Set the operator level to EXPERT by inputting [R][3][1][4][Enter][Enter] in advance. 2 Press <Constant setting> and open the screen of ［3 Machine setting］-［4 Encoder correction］. （To selecting the menu, use cursor key and [Enter] key.） >> For example, the screen as below is displayed. （Name type indicates at screen differs depending on the robot.） 3 With both hands, slowly move the J2 axis in 0° direction, and align the pin hole of No.1 arm and the pin hole of No.2 arm, and then go through origin jig and fix it there. No.2 arm 第２アーム 第1アーム No.1 arm Pin hole ピン穴(裏側) (bottom) Origin jig 原点治具 （supplement）ES06 series, in case that the arm length is 350mm, move J2 axis in +90 degree direction to align the pinhole. Resetting the origin（Encoder correction） 5-94 5 Maintenance and Inspection 4 Touch the <Encoder reset> on the display. >> Display switch to “Encoder reset” mode. 5 Move the cursor to J2. 6 By holding ［Enable］ and press ［ON/1］, put the check mark on J2 axis. ＋ （To checks OFF, press［Enable］＋［OFF/2］.） 7 Touch ＜Execute＞ >> A message window is displayed. Select ”OK” and press ［Enter］, encoder of J2 axis will be reset. Next, perform origin data setting（encoder correction）. Turn the controller power OFF, and turn it ON again, then follow the procedure below. Operation procedure 2: Setting the origin data (Encoder correction) 1 Check that the teach mode in on. Set the operator level to EXPERT by inputting [R][3][1][4][Enter][Enter] in advance. 2 3 4 5-95 Press <Constant setting> and open the screen of ［3 Machine setting］-［4 Encoder correction］. （To selecting the menu, use cursor key and [Enter] key.） >> For example, the screen as below is displayed. （Name type indicates at screen differs depending on the robot.） Touch ［Record Posi.］. >> The screen switches to “Record Position” mode. Move the cursor to J2, input ［Enter］［Record］. >> origin data of J2 axis is re-calculated. Resetting the origin（Encoder correction） 5 Maintenance and Inspection 5 Touch <Complete>. >>If the origin setting is successful, origin data will be saved in the internal memory. (By pressing emergency stop button, set the motor on to OFF before hand.） 6 Press ［R］key some times to exit the screen. >>Pull out the origin-jig. This completes the setting of origin data of J2 axis. ◇◆◇Select the axis of origin setting◇◆◇ Do cursor movement of origin setting of each screen by the arrow key. ([ ↑ ][ ↓ ][ ← ][ → ] key) Resetting the origin（Encoder correction） 5-96 5 Maintenance and Inspection (3) J3、J4 axis origin setting Origin setting of J3 axis and J4 axis must be set at a same time. Operation procedure 1: Encoder reset 1 Check that the teach mode in on. Set the operator level to EXPERT by inputting [R][3][1][4][Enter][Enter] in advance. 2 Press <Constant setting> and open the screen of ［3 Machine setting］-［4 Encoder correction］. （To selecting the menu, use cursor key and [Enter] key.） >> For example, the screen as below is displayed. （Name type indicates at screen differs depending on the robot.） 3 By using “Brake release switch”, keep the J3 axis brake off and slowly move the J3 axis in + (plus) direction with both hands, then push to the mechanical stopper. No.2 arm cover No.2 アームカバー Ｊ3 （+） J3 axis (Shaft) Ｊ3軸（シャフト） 5-97 Resetting the origin（Encoder correction） 5 Maintenance and Inspection 4 Keep J3 axis brake released and hold J4 axis by hand, and while holding J3 axis to mechanical stopper, rotate slowly. Then, align the alignment mark or scribed line. <クリーン仕様> <オイルミスト仕様> 合いマーク ケガキ線 矢視Ａ Alignment mark 合いマーク J4 A Once aligning the scribed line, release your hand from brake release switch. CAUTION ・To ensure safety, while one person operates the brake release switch, other person must support J3 axis(shaft). The brake-release procedure described above should always be done by two persons. ・Please be careful when releasing brake since J3 axis will fall down with its weight depending on the tool’s weight. ・Be careful that keep pushing the brake release switch will cause the continuous falling of J3(shaft). Please make sure to support by hand, and then start to operate the switch. 5 Touch the <Encoder reset> on the display. >> Display switch to “Encoder reset” mode. 6 By pressing ［Enable］＋［ON/1］, place check marks of both J3 and J4 axis. 7 Touch <Execute>. ＋ >> A message window is displayed. Select ”OK” and press ［Enter］, encoder of J3 and J4 axis will be reset. Resetting the origin（Encoder correction） 5-98 5 Maintenance and Inspection Next, perform origin data setting（encoder correction）. Turn the controller power OFF, and turn it ON again, then follow the procedure below. Operation procedure 2: Setting the origin data (Encoder correction) 1 Check that the teach mode in on. Set the operator level to EXPERT by inputting [R][3][1][4][Enter][Enter] in advance. 2 Press <Constant setting> and open the screen of ［3 Machine setting］-［4 Encoder correction］. （To selecting the menu, use cursor key and [Enter] key.） >> For example, the screen as below is displayed. （Name type indicates at screen differs depending on the robot.） 3 4 Touch ［Record Posi.］. >> The screen switches to “Record Position” mode. Move the cursor to J3, input ［Enter］［Record］. >> Origin data of J3 axis is re-calculated. 5 Move the cursor to J4, input ［Enter］［Record］. >> Origin data of J4 axis is re-calculated. 6 Touch <Complete>. >>If the origin setting is successful, origin data of J3 and J4 will be saved in the internal memory. (By pressing emergency stop button, set the motor on to OFF before hand.） 7 Press ［R］key some times to exit the screen. This completes the setting of origin data of J3 and J4 axis. ◇◆◇Select the axis of origin setting◇◆◇ Do cursor movement of origin setting of each screen by the arrow key. ([ ↑ ][ ↓ ][ ← ][ → ] key) 5-99 Resetting the origin（Encoder correction） 5 Maintenance and Inspection （Reference）Applied position of ABS mark（alignment mark） “ABS mark（alignment mark）” are attached on J1,J2 and J4 axis. The positions where the ABS mark is attached are shown in below. Please use as reference whether the origin data is correct or not. <クリーン仕様> <標準仕様> <Standard specification> 合いマーク 矢視Ａ <オイルミスト仕様> J4 ケガキ線 シャフト側はメカストッパの Shaft side is mechanical A 底面にあります。 stopper’s bottom Ｊ4軸ＡＢＳマークの拡大図 矢視Ａ J4 axis Ｊ4軸 J2 Ｊ2軸 axis J1 axis Ｊ1軸 ＡＢＳマーク拡大図 Alignment mark 1mm以内 Within 1mm 1mm以内 Within 1mm (プラス側ずれ量) (マイナス側ずれ量) (+side deviation) (- side deviation) ＡＢＳマークの設定範囲 Setting range of alignment mark Model J1 axis J2 axis J3 axis J4 axis ES06-3520-01 0° 103.5° 336mm 0° ES06-3534-01 0° 103.5° 300mm 0° ES06-4520-01 ES06-5520-01 0° 0° 336mm 0° ES06-4534-01 ES06-5534-01 0° 0° 300mm 0° ES12-55**-01 ES12-70**-01 ES12-85**-01 0° 0° 350.5mm 0° 0° 0° 342.5mm 0° ABS mark attachment positions ・There is no alignment mark of the J3 axis. The posture to beset is the same with the mechanical stopper method. ・To confirming the position data of each axis, please use the following monitor function. <Service>［3 Monitor 2］［2 axis monitor］ And also, this ［axis monitor］ can be opened by software key［Monitor 2］. Resetting the origin（Encoder correction） 5-100 5 Maintenance and Inspection 5.6.2 Recording the origin data（encoder correction value） In case of setting the origin by jig-method, record that origin data（encoder correction value） to the paper. By doing so, the origin setting becomes possible by origin data input method（numerical value input method） in case of replacing controller to the other one. (1) Confirming the origin data Open the menu below, then origin data（encoder correction value） can be displayed on the screen. <Constant setting> ［3 Machine setting］-［4 Encoder correction］ Numerical value input screen Origin data （encoder correction value） （Numerical value is displayed by decimal number） (2) Recording the origin data Procedure（A）- Take a note on all the data above（:decimal number）, which is displayed at T/P. Procedure（B）- By using ［Enable］＋［Export］key, data can be export to USB memory, which is connected to the controller with text file format. This file can be imported to the other controller. ＋ Please refer to instruction manual “Basic operation” operation about copying files etc. 5-101 Resetting the origin（Encoder correction） 5 Maintenance and Inspection (NOTE) The locations for zeroing jig installation (encoder correction positions) ES06-3520-01／ES06-3534-01 <J1 axis> Install the φ6 pin (zeroing pin) by referring to the following picture. This is the encoder correction position for J1 axis. ES06-35**-01 ES06-35**-01 <J2 axis> Install the φ6 pin (zeroing pin) by referring to the following picture (Move the J2 axis to +90 degree and insert the pin). This is the encoder correction position for J2 axis. ES06-35**-01 ES06-35**-01 <J3 axis and J4 axis> (1) Install the “J4 axis zeroing jig” at the edge of the spline. (2) Release the brake of J3 and J4 axis at the same time. Then move J3 to the mechanical stopper end of the + side and move J4 axis so that the jig touch the arm surface like the following picture. These are the encoder correction positions for J3 and J4 axis. (2) Touch the side surface of the arm (1) Install the jig to the edge of the spline. (align the jig onto D cut surface) Resetting the origin（Encoder correction） 5-102 5 Maintenance and Inspection ES06-4520-01 / ES06-5520-01 / ES06-4534-01 / ES06-5534-01 < J1 axis > Install the φ6 pin (zeroing pin) by referring to the following picture. This is the encoder correction position for J1 axis. ES06-45**-01 ES06-55**-01 ES06-45**-01 ES06-55**-01 < J2 axis > Install the φ6 pin (zeroing pin) by referring to the following picture. This is the encoder correction position for J2 axis. ES06-45**-01 ES06-55**-01 < J3 and J4 axis > It is the same as ES06-3520-01 and ES06-3534-01. 5-103 Resetting the origin（Encoder correction） ES06-45**-01 ES06-55**-01 5 Maintenance and Inspection ES12-55**-01 / ES12-70**-01 / ES12-85**-01 < J1 axis > Install the φ6 pin (zeroing pin) by referring to the following picture. This is the encoder correction position for J1 axis. ES12-****-01 ES12-****-01 < J2 axis > Install the φ6 pin (zeroing pin) by referring to the following picture. This is the encoder correction position for J2 axis. ES12-****-01 ES12-****-01 < J3 axis > Release the J3 brake and move the J3 axis to touch the + side mechanical stopper. This is the encoder correction position for J3 axis. ES12-****-01 ES12-****-01 Resetting the origin（Encoder correction） 5-104 5 Maintenance and Inspection < J4 axis > (1) Install the “J4 axis zeroing jig” A and B at the edge of the spline. This is the encoder correction position for J4 axis. (At this time, align the jig to the 2 D-cut surface) ES12-****-01 B A (NOTE) Location of the D-cut surface ES12-****-01 Front Right side (2) Install the “J4 axis zeroing plate” onto the edge of the No.2 arm. J4 axis zeroing plate 5-105 Resetting the origin（Encoder correction） 5 Maintenance and Inspection (3) Release the J4 brake and rotate the J4 axis so that the “J4 axis zeroing jig” touches the “J4 axis zeroing plate” and then perform encoder correction. ES12-****-01 J4 axis zeroing jig B J4 axis zeroing jig A Make the “J4 axis zeroing jig” touches the “J4 axis zeroing plate”. (NOTE) View from the other side ES12-****-01 Resetting the origin（Encoder correction） 5-106 6 Appendex 6 Appendex Appendex 1： Concerning LEFTY / RIGHTY This robot, because of its structure, can be possible to make several postures to one target point coordinate(X,Y,Z,r,p,y). Usually, robot is set to select the posture automatically close to the step’s posture just before while operation. However, in case of controlling robot by ”FN52 shift2” or “FN645 MOVEX”, possible to select each one of postures forcibly. (1) RIGHTY/LEFTY Indicates the location of the end axis relative to the line that passes through both the rotational center of the J1 axis and the rotational center of the J2 axis. （When J2 axis is minus(-) then LEFTY, J2 axis is plus(+) then RIGHTY.） RIGHTY RIGHT Fig. 6-1 : RIGHTY / LEFTY Appendex-107 LEFT LEFTY 6 Appendex Note Appendex-108 Spare parts Usage / piece Recommend/piece Recommended spare parts Grease 4B No.2 - - ○ Harmonic Drive Systems Inc. Refer to Chapter5 page19“Table Lubrication specifications” Grease Multemp PS2 - - ○ KYODO YUSHI CO.,LTD. Lithium battery ER6 3 3 ○ Nachi-Fujikoshi co Ltd. Item No. Name (type) Robot type Remarks ES06-01 ES12-01 5-5 ThreeBond Liquid gasket ThreeBond 1212 - ○ - Refer to ”5.3.3 Packing Replacement Procedure”. Timing belt - Refer to “5.3.4 Inspection, maintenance and replacement of timing belt ○ - Maintenance tool (Optional) ES06-01 Attached tool OP-T2-095 1 ○ Attached tool OP-T2-100 1 Item No. Name ES12-01 (type) Recommend/piece Robot type Remarks ES06-01 series usage zeroing pin （zeroing setting jig） ○ ES12-01 series usage zeroing pin （zeroing setting jig） Name (type) Recommend/piece Item No. Usage / piece Wire harness Robot type ES06-01 Remarks ES12-01 *= 02,05,10,15,20 2m,5m,10m,15m,20m Specification Wire harness S101C-J1-*-A 1 1 ○ 2 sets （Motor and encoder） Appendix-109 7 Note Appendix-110 Option: I/OCABLE-70 (I/O harness) This is an option cable to connect the controller’s signal wires to the robot. (Signals to control gripper, etc.) One side of this cable is pre-assembled using a connector. Please designate the cable length referring to the following table when purchasing this cable. In addition, the signal wirings inside the robot are not included in this option. Part name Specification Model name IOCABLE-70-02M IOCABLE-70-05M IOCABLE-70-10M IOCABLE-70-15M IOCABLE-70-20M IOCABLE-70-25M I/O harness for ES series I/O harness (CNHND side connector is pre-assembled) This side is not assembled. When shipping, 20 signal wires are covered by tape. Controller side Remarks 02M : L1 = 2.5m 05M : L1 = 5.5m 10M : L1 = 10.5m 15M : L1 = 15.5m 20M : L1 = 20.5m 25M : L1 = 25.5m Robot side 1 (CNR010) CNHND 5 A01 - A20 2 6 4 G L=100 3 70 L1 Robot side connector CNHND This connector is already assembled when shipping. Controller side wires This side is not assembled when shipping. Considering your system specifications etc, connect / assemble the wires. Main parts list No. 1 2 3 4 5 6 7 Appendix-111 Name Cable tie Crimp terminal Wire Composite wires Tab housing Tab contact Cap cone (Insulation cap) Model - Maker - - - AWG#22 /φ1.7 - - φ9.8 R0.5-4 1-193127-1 1903112-2 0A-WH16-06/10 Qty x 4 x 1 Remarks TYCO TYCO x1 x 20 #28 - #22 / φ1.08～1.6 Ohm electric x1 This is included in this option set. CNHND pin layout 1 A11 A20 2 A10 3 A13 A01 4 A14 A17 5 A15 A18 6 A12 A19 7 A02 A16 8 A03 A06 9 A04 A07 10 A05 A08 11 A09 B A Controller side signal wires Considering your system specifications etc, connect / assemble the following wires. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 INFO. Insulator color Light brown Yellow Light green Grey White Light brown Yellow Light green Grey White Light brown Yellow Light green Dot color Black/red Black/red Black/red Black/red Black/red Black/red Black/red Black/red Black/red Black/red Black/red Black/red Black/red Dot type Short 1 dot Short 2 dots Short 3 dots Signal name A01 / A02 A03 / A04 A05 / A06 A07 / A08 A09 / A10 A12 / A13 A14 / A15 A16 / A17 A11 / A18 A19 / A20 ---/-----/-----/--- Concerning the controller side I/O interface, please refer to the following instruction manual. “CFD/CFDL CONTROLLER INSTRUCTION MANUAL / OPTION (I/O CONNECTION)” (TCFEN-183) INFO. Concerning the robot side connection, please refer to the following instruction manual. “Standard specifications ES06-01-CFD / ES12-01-CFD” (SESEN-087) -> “8.2 Connection of Gripper wires and tubes” Appendix-112 http://www.nachi-fujikoshi.co.jp/ Japan Main Office Phone: +81-3-5568-5245 Fax: +81-3-5568-5236 Nachi Robotic Systems Inc. (NRS) North America Headquarters Shiodome Sumitomo Bldg. 17F, 1-9-2 Higashi-Shinbashi Minato-ku, TOKYO, 105-0021 JAPAN http://www.nachirobotics.com/ Phone: 248-305-6545 Fax: 248-305-6542 42775 W. 9 Mile Rd. Novi, Michigan 48375, U.S.A Indiana Service Center Phone: 248-305-6545 Fax: 248-305-6542 Greenwood, Indiana Ohio Service Center Phone: 248-305-6545 Fax: 248-305-6542 Cincinnati, Ohio South Carolina Service Center Phone: 248-305-6545 Fax: 248-305-6542 Greenville, South Carolina Canada Branch Office Phone: 905-760-9542 Fax: 905-760-9477 89 Courtland Ave., Unit No.2, Concord, Ontario, L4K 3T4, CANADA Mexico Branch Office Phone :+52-555312-6556 Fax:+52-55-5312-7248 Urbina No.54, Parque Industrial Naucalpan, Naucalpan de Juarez, Estado de Mexico C.P. 53489, MEXICO NACHI EUROPE GmbH http://www.nachi.de/ Central Office Germany Phone: +49-2151-65046-0 Fax: +49-2151-65046-90 Bischofstrasse 99, 47809, Krefeld, GERMANY U.K. branch Phone: +44-0121-423-5000 Fax: +44-0121-421-7520 Unit 3, 92, Kettles Wood Drive, Woodgate Business Park, Birmingham B32 3DB, U.K. Czech branch Phone: + 420-255-734-000 Fax: +420-255-734-001 Obchodni 132, 251 01 Cestlice, PRAGUE-EAST CZECH REPUBLIC NACHI AUSTRALIA PTY. LTD. http://www.nachi.com.au/ Robotic Division & Victoria office Phone: +61-(0)3-9796-4144 Fax: +61-(0)3-9796-3899 38, Melverton Drive, Hallam, Victoria 3803, , AUSTRALIA Sydney office Phone: +61-(0)2-9898-1511 Fax: +61-(0)2-9898-1678 Unit 1, 23-29 South Street, Rydalmere, N.S.W, 2116, AUSTRALIA Brisbane office Phone: +61-(0)7-3272-4714 Fax: +61-(0)7-3272-5324 7/96 Gardens Dr,Willawong,QLD 4110, , AUSTRALIA NACHI SHANGHAI CO., LTD. Shanghai office Phone: +86-(0)21-6915-2200 http://www.nachi.com.cn/ Fax: +86-(0)21-6915-2200 NACHI KOREA Seoul office 11F Royal Wealth Centre, No.7 Lane 98 Danba Road Putuo District, Shanghai 200062, China http://www.nachi-korea.co.kr/ Phone: +82-(0)2-469-2254 Fax: +82-(0)2-469-2264 2F Dongsan Bldg. 276-4, Sungsu 2GA-3DONG, Sungdong-ku, Seoul 133-123, KOREA Copyright NACHI-FUJIKOSHI CORP. Robot Division 1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511 Phone +81-76-423-5137 Fax +81-76-493-5252 NACHI-FUJIKOSHI CORP. holds all rights of this document. No part of this manual may be photocopied or reproduced in any from without prior written consent from NACHI-FUJIKOSHI CORP. Contents of this document may be modified without notice. Any missing page or erratic pagination in this document will be replaced. In case that an end user uses this product for military purpose or production of weapon, this product may be liable for the subject of export restriction stipulated in the Foreign Exchange and Foreign Trade Control Law. Please go through careful investigation and necessary formalities for export. Original manual is written in Japanese. ©
