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MAINTENANCE MANUAL

1. Q C Eyebolts 3 locations o 77 1067 14 E i O a D O AS co E O N A N 042 65 Rc1 8 4 M5x0 8 depth 8 20 depth 3 5 75 0 02 View A 195H7 depth 10 p 4 2 A A Calibration tool a B y axes Post a sign indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power Enter the safety enclosure Secure the calibration tool to the base Secure the end of the calibration tool to the jig attachment holes on the base with the M12 hex socket head bolts provided The arm is moved at Step 5 and if it hits the calibration tool at that time temporarily secure the tool move the arm to a position above the tool at Step 5 apply the brake secure the tool and then perform Steps 4 and 5 Release the motor brake for a axis CAUTION When performing origin position adjustment release the brake one axis at a time Never release the brake for all three axes at the same time Doing so will result in a drop in origin position accuracy leading to malfunctions p gt Step 3 Securing the calibration tool ia k W A M12 hextsocketiheadibolt Gr a Calibration tool p N W ar gt e C JA O gt UIDIIO 4 3 lt 5 Move the arm slowly until the link gt Steps Position lin
2. A gt Step 13 Duct attachment gt Q O u O O L Q O gt O Q Q O 19 O O O 5 O O lt 2 2 11 lt gt O O gt Q Q L Q O u O O Q je O O O gt O O lt oO 14 15 16 p 2 12 Attach the bracket to the robot cable Step 14 Bracket attachment Insert the bracket in the boot Insert the boot in the duct Bracket gt Step 15 Bracket insertion gt Step 16 Boot insertion 1 2 Detaching or attaching the 0 axis cover To detach the covers remove the bolts and screws shown in the Fig below WARNING IN e IF THE COVERS ARE REMOVED FOR MAINTENANCE WORK BE SURE TO RETURN THEM TO THEIR ORIGINAL POSITIONS USING THE BOLTS USED TO SECURE THEM e IF ANY OF THE BOLTS BECOME LOST USE THE SPECIFIED BOLTS AND QUANTITIES TO SECURE THE COVERS WHILE REFERRING TO THE FIG BELOW e IF THE COVERS ARE NOT SECURED FIRMLY NOISE MAY OCCUR THE COVERS MAY DROP AND FLY OUT HANDS MAY BECOME ENTANGLED IN THE DRIVE UNIT DURING TEACHING OR COME INTO CONTACT WITH THE HOT DRIVE UNIT CAUSING BURNS OBSERVE THESE CAUTIONS STRICTLY TO PREVENT SUCH TROUBLE R6Y31110L03067NJ5 R6Y31110H03067NJ5 0 axis axis motor cover 6 M4x1 5 hex bolt 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks 0 axis motor cover KDL M182E 00x 0 axis motor cover attachment 90780 04010 M4 length 10 bolt Washer KDL M1861 00x
3. Arm 1 2 3 1000W Servo motor Rotational axis 4 50W X Y Z axis 0 2mm Repeatability 0 axis Maximum payload 3kg Maximum through put 150 CPM 0 axis tolerable moment of inertia 0 01kgm 50W 0 035kgm 100W User tubing outer diameter 6x1 moveable tool Travel limit Soft limit Protection class IP67 1 This is the value at a constant ambient temperature 2 With 0 1kg payload When reciprocating 305mm in horizontal and 25mm in vertical directions 3 There are limits to acceleration coefficient settings 4 CPM Cycle per minutes Check the note 2 for the cycle definition SLIOd SIUDUAJUIDIA gt 11 2 Revision history A manual revision code appears as a suffix to the catalog number on the front cover manual Cat No I195E EN 01 Revision code The following table outlines the changes made to the manual during each revision 01 June 2013 Original production OMRON Authorized Distributor Cat No 1195E EN 01A Note Specifications subject to change without notice Printed in Europe
4. KDL M4813 00x Motor cable 0 axis cable cover side KDL M4814 00x Encoder cable gt a O o D O O 7 O o Q O 9 O O O 5 D O O lt D 0 axis cable securing bolt 91380 03006 M3 length 6 Secured to motor cover KDL M4811 00x Motor cable 0 axis cable motor side KDL M4812 00x Encoder cable Farth bolt 97980 04308 2 13 lt gt Q O 5 Q D O O 5 O O 5 Q 9 O O 5 O 3 D O lt 1 2 1 O axis motor cover removal N CAUTION When removing the 0 axis motor cover first disconnect the cable from the outside of the motor cover and then remove the moveable base from the a B and y axis shafts before proceeding There is a risk of bodily injury if the cable is damaged or a robot malfunction occurs inside the robot movement range l Remove the M4 hex bolts securing the p Step1 M4 hex bolt removal axis motor cover and moveable base Loosen with a spanner and then remove 2 Lift the 0 axis motor cover from the moveable base 3 Disconnect the cable connectors inside the cover Disconnect the motor cable connector and encoder cable connector Remove the two earth bolts gt Step 2 4 Inside the motor cover 5 Remove the axis motor cover Take care not to cover the washers attached to the axis motor cover Encoder cable connector p 2 14 Remove the cables from the inside of P S
5. gt 5 4 Attach the spring covers gt Step 4 There are a total of six spring covers one at the arm and one at the moveable base for each of the three axes The top and bottom positions of the spring covers are fixed If the shaft direction is correct at Step 3 the cover attached at the top will be wide as shown in the Fig The spring covers come as a top and bottom set when shipped Attach the covers so that they snap together at the guide clips Spring cover attachment Spring cover top 9 5 lt nm lt 3 lt O O O O O O O O Q Q O 9 O O lt O 9 O O O 3 O 1 2 2 R6Y31110L03067NJ5 R6Y31110H03067NJ5 4 axes specification With the R6Y31110L03067NJ5 and R6Y31110H03067NJ5 4 axes specification robots the cable protrudes from the a axis shaft Shaft moveable base and spring cover attachment is the same as that for the 3 axes specification robot l Post a sign indicating that the robot P Step 3 Shaft attachment is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power Depression 2 Enter the safety enclosure a Attach the shafts Attach the shafts while ensuring to hook the shaft plastic bearings onto the arm and moveable base link balls The link balls can be stretched by hand at the end of the shaft as shown in the Fig The depression on the shafts for spring cover attachment should fa
6. OPTA Motor replacement Contents a B y axis motor replacement 1 1 a B y axis motor replacement procedure 9 1 1 1 1 a B y axis motor removal 1 1 1 2 a B y axis motor attachment 5 2 60 axis motor replacement 9 4 2 1 0 axis motor removal 9 4 1 a B y axis motor replacement WARNING IF REPLACING A MOTOR WITH SHAFTS MOVEABLE BASE AND ARM ATTACHED PLACE A SUPPORT UNDER THE MOVEABLE BASE TO PREVENT IT FALLING AND IF REPLACING A MOTOR WITH ONLY THE ARM ATTACHED PLACE A SUPPORT UNDER THE ARM OR STRAP IT UP WITH SOME STRING TO PREVENT IT FALLING 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks Motor R88M K1K030T BS2 1000W 200 V with brake For a B and y axes Motor securing bolt 91312 08020 MS length 20 Attached to speed reduction gear O ring 90200 03J850 groove Quantity per axis 2 For installation remove the key 1 1 a B y axis motor replacement procedure 1 1 1 a P y axis motor removal S o O pe O O O 3 O H NOTE The same procedure is used to replace the a B and y axis motors l Post a sign indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power Enter the safety enclosure gt Step 4 Cap bolt removal 3 Remove the motor cover N Refer to 1 Detaching attaching and replacing the
7. The cable leading from the brake release connector should be prepared by the user Switch connector and brake release gt Step 4 connector connection gt O O Q Q y O O O O Q O 9 O O O v 5 O O lt O 2 7 lt 5 Route the encoder wire gt Step 5 Encoder wire routing Insert the encoder wire only through the hole for the motor connector and pull it out from the adjacent cap hole Encoder wire Encoder wire Pull out from cap hole side gt O O gt O Q D O O O Q gt Q Y O O gt O 5 O O lt OD Temporarily insert the motor cover Insert the motor cover so that the internal switch does not interfere with the motor connector Pull the brake release wire and encoder wire out from the gap next to the motor connector gt Step 6 Temporary motor cover insertion Motor cover WE ull outsfrom gap i i y Cables removed when temporarily inserting cover 2 9 lt gt Q O Q Q y O O O Q Q 9 O O O gt O O lt O 7 Insert the cover so that the rubber on b Step Gap the bottom fits in There will be a gap when the cover catches on the first clip Insert the cover so that the rubber on the top fits in N CAUTION Insert the rubber a little at a time and avoid trying to force it in If forced in the rubber will end up d
8. N CAUTION Release the brake axis by axis NOTE H For details about the brake release wire connector see 4 2 Wiring the brake release wire connector in Chapter 2 of the Installation Manual S 13 SUOIJONIISU A19JOS SUOIJONIISU A19JOS 6 Using the robot safely 6 1 Robot protective functions 1 Soft limits Soft limits can be set on each axis to limit the working envelope in manual operation after return to origin and during automatic operation The working envelope is the area limited by soft limits WARNING IN SOFT LIMIT FUNCTION IS NOT A SAFETY RELATED FUNCTION INTENDED TO PROTECT THE HUMAN BODY ENSURE SAFETY BY INSTALLING A SAFETY ENCLOSURE AND SO ON 2 a axis P axis and y axis brakes An electromagnetic brake is installed on the a axis B axis and y axis to prevent them from sliding downward when the servo is OFF WARNING IN THE a AXIS B AXIS OR y AXIS WILL SLIDE DOWNWARD WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION TAKE ADEQUATE SAFETY MEASURES BY TAKING THE WEIGHT AND SHAPE INTO ACCOUNT e BEFORE RELEASING THE BRAKE AFTER PRESSING THE EMERGENCY STOP BUTTON PLACE A SUPPORT UNDER THE a AXIS B AXIS OR y AXIS SO THAT IT WILL NOT SLIDE DOWN e WHEN PERFORMING TASKS DIRECT TEACHING ETC WITH THE BRAKE RELEASED BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE MOVABLE BASE AND THE INSTALLATION BASE 6 2 Residual risk To ensure safe and correct use of OMRON robots System integra
9. OPS 8 Overview Contents 1 Overview WARNING A e ADJUSTMENT MAINTENANCE AND REMOVAL OF ARMS SHAFTS OR THE 0 AXIS ASSEMBLY REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND ALSO MAY INVOLVE HAZARDS THIS WORK MUST BE CARRIED OUT BY REFERENCING THIS MANUAL BY SUFFICIENTLY SKILLED AND OUALIFIED PERSONNEL IN ACCORDANCE WITH THE LAWS AND REGULATIONS OF EACH COUNTRY e PLACE A CONSPICUOUS SIGN INDICATING THE ROBOT IS BEING ADJUSTED TO PREVENT OTHERS FROM TOUCHING THE CONTROLLER SWITCH OR OPERATION PANEL e IF A SAFETY ENCLOSURE HAS NOT YET BEEN PROVIDED RIGHT AFTER INSTALLATION OF THE ROBOT ROPE OFF OR CHAIN OFF THE MOVEMENT RANGE AROUND THE MANIPULATOR IN PLACE OF A SAFETY ENCLOSURE AND OBSERVE THE FOLLOWING POINTS O MdIAIOA 1 USE STABLE POSTS WHICH WILL NOT FALL OVER EASILY 2 THE ROPE OR CHAIN SHOULD BE EASILY VISIBLE BY EVERYONE AROUND THE ROBOT 3 PLACE A CONSPICUOUS SIGN PROHIBITING THE OPERATOR OR OTHER PERSONNEL FROM ENTERING THE MOVEMENT RANGE OF THE MANIPULATOR e IF CHECKING OPERATION FOLLOWING ADJUSTMENT REFER TO THE CONTROLLER USER S MANUAL N CAUTION Use only the lubricants specified by your distributors 1 1 lt 1 Contents OTE SEA Attaching detaching and replacing the cover 1 1 w gt 1 2 Yoi 122 Attaching detaching and replacing the cover Detaching or attaching the a B y axes covers a B y axis cover removal procedure a B and y axis cover attach
10. AND THEN CHECK THAT THE TEMPERATURE HAS SUFFICIENTLY COOLED DEGREASING AND WASHING PRECAUTIONS e THE EYES MAY BECOME INFLAMED IF EXPOSED TO GREASE OR DETERGENT ON THE WASTE CLOTH USED FOR GREASE REMOVAL BEFORE HANDLING THE GREASE WEAR YOUR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES e INFLAMMATION MAY OCCUR IF THE GREASE COMES INTO CONTACT WITH SKIN BE SURE TO WEAR PROTECTIVE GLOVES TO PREVENT CONTACT WITH SKIN e DO NOT TAKE ORALLY OR EAT EATING WILL CAUSE DIARRHEA AND VOMITING e KEEP OUT OF THE REACH OF CHILDREN EMERGENCY TREATMENT e IF GREASE OR DETERGENT SPLATTERS AND GETS INTO THE EYES RINSE WITH CLEAN WATER FOR 15 MINUTES AND THEN CONSULTA PHYSICIAN e IF THIS GREASE COMES IN CONTACT WITH THE SKIN WASH AWAY COMPLETELY WITH SOAP AND WATER e IF TAKEN INTERNALLY DO NOT INDUCE VOMITING BUT PROMPTLY CONSULT A PHYSICIAN FOR TREATMENT N CAUTION About the speed reduction gear e Do not apply strong force to any of the parts with a hammer and so on Furthermore be careful not to drop any of the parts as this may result in scratches or dents leading to likely speed reduction gear damage e Ifthe speed reduction gear is used in a damaged condition it will not function at its specified performance Furthermore using in this condition may lead to problems such as complete gear break down e The speed reduction gear will shift when replaced and therefore it is necessary to adjust the origin po
11. Daily inspection 3 Monthly inspection 4 Six month inspection Chapter 4 Adjusting the origin 1 Adjusting the origin 1 1 Adjusting the a B and y axis origin position 1 2 Adjusting the 0 axis origin position 4 axes specification only Chapter 5 Shaft moveable base and spring cover replacement 1 Shaft moveable base and spring cover replacement procedure 1 1 Detaching the shafts moveable base and spring cover 1 2 Attaching the shafts moveable base and spring covers 1 2 1 R6Y30110S03067NJ5 3 axes specification 1 2 2 R6Y31110L03067NJS R6Y31110H03067NJ5 4 axes specification 2 Moveable base link ball replacement Chapter 6 Spring mechanism replacement 1 Spring mechanism replacement procedure 1 1 Spring mechanism removal 1 2 Spring mechanism attachment R6Y3 Maintenance Manual 1 1 2 1 2 1 33 27 2 13 2 14 2 16 3 1 4 1 4 2 4 5 5 1 5 1 5 4 5 4 5 6 5 9 6 1 6 1 6 2 CONTENTS Chapter 7 Plastic bearing replacement 1 Plastic bearing replacement procedure 1 1 Removing the plastic bearing from the link ball sliding part 1 2 Attach the jig with threaded screw to the tapping hole on the end of the shaft 1 3 Spring mechanism plate plastic bearing removal 1 4 Spring mechanism plate plastic bearing attachment 2 Plastic bearing inspection Chapter 8 6 axis seal O ring replacement 1 0 axis seal O ring replacement procedure 1 1 0 axis seal O ring removal 1
12. f y axis motor attachment Attach the motors using the opposite of the procedure used for removal When doing so the following additional procedures are necessary e Use a waste cloth to remove any grease from the motor shaft and speed reduction gear attachment surfaces e To make it easier to secure the motor shaft to the speed reduction gear rotate the speed reduction gear beforehand so that the gear hex socket head bolt is visible from the cap attachment hole e When attaching the motor fit an O ring to the speed reduction gear e Attach the motor with the connector facing to the inside O ring attachment S o 9 D 9 O O O 3 O Motor attachment direction 9 3 lt 1USEWSOPIIS JOLOIN motor replacement OMRON Part No Part No Specs R88M K05030T S2 50W 200 V without brake R88M K10030T S2 100W 200V without brake Remarks For R6Y31110L03067NJ5 For R6Y31110H03067NJ5 Motor securing bolt 91380 04014 MA length 14 1 For installation remove the key 2 1 0 axis motor removal Common to R6Y31110L03067NJ5 R6Y31110H03067NJ5 The procedure required to replace the 0 axis motor only is described below Refer to 2 3 0 axis speed reduction gear replacement in Chapter 10 if removing the speed reduction gear also l Remove the moveable base from the shaft Refer to the 1 Shaft moveable base and spring cover replacement procedure in Chapter 5 for details
13. 3 KDL M1574 00x Plastic block 3 Pin 99480 03008 3 Clamp securing bracket 91312 04010 M4 length 10 3 Quantity per axis 2 With the R6Y30110S03067NJ5 3 axes specification this is necessary for the arms of each axis With the R6Y31110L03067NJ5 and R6Y31110H03067NJ5 4 axes specification it is necessary for the B and y axis arms 3 These are only for the R6Y31110L03067NJ5 and R6Y31110H03067NJ5 4 axes specification and are used when securing the 0 axis cable to the a axis arm gt 10 2 2 Required tools Name Part No Manufacturer Remarks Cleaning wipe Hex wrench set The arm removal procedure is described below Use the opposite procedure to perform arm attachment 2 1 1 Post a sign indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power Enter the safety enclosure Remove the cap white from each axis arm The hex socket head bolt attachment surface is exposed by removing the cap Adjust the arm position if replacing the speed reduction gear Remove the length 20 M8 hex socket head bolt used to secure the arm for each axis to its respective speed reduction gear Tighten the bolts with a tightening torque of 37Nm when attaching the arm Remove each axis arm gt Step 3 When cap removed from arm M8 hex socket head bolt Work required
14. A e DO NOT TOUCH THE ROBOT DURING OPERATION THE ROBOT BODY IS VERY HOT DURING OPERATION SO BURNS MAY OCCUR IF YOU TOUCH THESE SECTIONS e THE MOTOR AND SPEED REDUCTION GEAR CASING ARE VERY HOT SHORTLY AFTER OPERATION SO BURNS MAY OCCUR IF THESE ARE TOUCHED BEFORE TOUCHING THOSE PARTS FOR INSPECTIONS OR SERVICING TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THEIR TEMPERATURE HAS COOLED 3 Use caution when releasing the a axis B axis or y axis brake To release the brake it is necessary to install a brake release circuit on the user side WARNING A THE a AXIS B AXIS OR y AXIS WILL SLIDE DOWNWARD WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION TAKE ADEOUATE SAFETY MEASURES BY TAKING THE WEIGHT AND SHAPE INTO ACCOUNT e BEFORE RELEASING THE BRAKE AFTER PRESSING THE EMERGENCY STOP BUTTON PLACE A SUPPORT UNDER THE a AXIS B AXIS OR y AXIS SO THAT IT WILL NOT SLIDE DOWN e WHEN PERFORMING TASKS DIRECT TEACHING ETC WITH THE BRAKE RELEASED RELEASE THE BRAKE OF ONLY NECESSARY AXIS AND BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE MOVABLE BASE AND THE INSTALLATION BASE gt S 10 4 If the a axis P axis y axis or 0 axis operating angle is small WARNING A IF THE a AXIS B AXIS y AXIS OR 0 AXIS ROTATION ANGLE IS SET SMALLER THAN 5 DEGREES THEN IT WILL ALWAYS MOVE WITHIN THE SAME POSITION IF THE ROTATION ANGLE OF THE a AXIS B AXIS y AXIS OR 0 AXIS IS SETAS SMALLER THAN 5 DEGREES MOVEMENT WILL ALWAYS O
15. L Q O un O O Q 9 O L O gt O O lt O Brake release switch gt 2 6 1 1 2 a Pp and y axis cover attachment procedure Attach the cover using the opposite of the procedure used for removal WARNING A THE SAME TYPE OF MOTOR WIRE AND ENCODER WIRE IS USED FOR THE a B AND y AXES CONNECT THE CABLES SO THAT THEY MATCH THE RESPECTIVE AXES AT THE CONTROLLER DRIVER THE ROBOT WILL NOT OPERATE CORRECTLY RESULTING IN POSSIBLE DANGER IF THE CABLES ARE CONNECTED INCORRECTLY l Insert the motor wire from smaller gt Stepl Insert the motor wire hole on the boot with small hole The motor wire connector is larger and should therefore be inserted first Motor wire The motor wire connector should still be inserted first even if using L shaped connectors 2 Insert the encoder wire and brake release wire prepared by user from smaller hole on the boot N CAUTION The encoder wire must pass through the inside of the cover and therefore a sufficient length of wire should be inserted sitio encoder est Drake gt Step 2 release wire prepared by user 3 Pull the cover internal cables from the hole with the boot On the outside of the cover is the cap and the motor Encoder wire gt HH connector part should be the boot Brake release wire 4 Connect the cover internal switch connector and brake release connector Store the joint inside the cover a prepared by user
16. MANUAL AND COMPLY WITH THE INSTRUCTIONS e NEVER ATTEMPT ANY REPAIR PARTS REPLACEMENT AND MODIFICATION UNLESS DESCRIBED IN THIS MANUAL THESE TASKS REOUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS PLEASE CONTACT YOUR DISTRIBUTOR FOR ADVICE NOTE For details on warning labels see 3 Warning labels in Safety instructions Draw up work instructions and make the operators workers understand them WARNING DECIDE ON WORK INSTRUCTIONS IN CASES WHERE PERSONNEL MUST WORK WITHIN THE ROBOT SAFETY ENCLOSURE TO PERFORM STARTUP OR MAINTENANCE WORK MAKE SURE THE WORKERS COMPLETELY UNDERSTAND THESE WORK INSTRUCTIONS Decide on work instructions for the following items in cases where personnel must work within the robot safety enclosure to perform teaching maintenance or inspection tasks Make sure the workers completely understand these work instructions 1 Robot operating procedures needed for tasks such as startup procedures and handling switches 2 Robot speeds used during tasks such as teaching 3 Methods for workers to signal each other when two or more workers perform tasks 4 Steps that the worker should take when a problem or emergency occurs 5 Steps to take after the robot has come to a stop when the emergency stop device was triggered including checks for cancelling the problem or error state and safety checks in order to restart the robot 6 In cases other than above the following actions should be
17. THE MOTOR e BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE MOVABLE BASE AND THE INSTALLATION BASE 4 7 _ Disposal When disposing of robots and related items handle them carefully as industrial wastes Use the correct disposal method in compliance with your local regulations or entrust disposal to a licensed industrial waste disposal company 1 Disposal of packing boxes and materials When disposing of packing boxes and materials use the correct disposal method in compliance with your local regulations We do not collect and dispose of the used packing boxes and materials p S 12 5 Emergency action when a person is caught by robot If a person is caught in between the robot and mechanical section such as installation base use the brake release switch on the robot main unit to release the axis Brake release switch Brake release switch As the robot is put in the emergency stop state the robot drive power is shut down However the axis cannot be moved since the brake is activated So release the brake and then push the axis by hand to move it WARNING IN THE a AXIS B AXIS OR y AXIS WILL SLIDE DOWNWARD WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION e BEFORE RELEASING THE BRAKE BE SURE TO PLACE A SUPPORT UNDER THE a AXIS B AXIS OR y AXIS SO THAT IT WILL NOT SLIDE DOWN e WHEN RELEASING THE BRAKE BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE MOVABLE BASE AND THE INSTALLATION BASE
18. after replacing arm link balls The link ball attachment method 1s described here Apply a thin layer of Loctite screw lock to the link ball screw Use Henkel Loctite 241 blue Attach a link ball to two locations on each axis arm Attach to a total of six locations on the a p and y axes gt Step 2 Link ball attachment 10 3 lt juanda UD 11086 UOYONpel poods A 3 Tighten the link balls with a tool gt Step 3 Tightening with tool e Tightening torque 20Nm 27 a B y axis speed reduction gear replacement NOTE 14 The same procedure is used to replace the a B and y axis speed reduction gears The requirements for a B and y axis speed reduction gear replacement are as follows 1 Replacement parts Part Name OMRON Part No Part No Specs j Remarks Speed reduction gear KDL M211A 00x For a B and y axes Speed reduction gear i 90112 10J030 M10 length 30 mounting bolt Quantity per axis 2 Required tools Part No Manufacturer Remarks Cleaning wipe Hex wrench set Screw thread locking agent Loctite 241 Medium strength type blue JUOLUSDDICAI UD 110980 UOYONpel poods S H Removal l Post a sign indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power 2 Enter the safety enclosure N CAUTION The robot body is extremely heavy a
19. attachment port is on the f axis side After pushing in tighten the six length 20 M4 hex socket head bolts e Tightening torque 2Nm CAUTION A Attach the housing with the housing side O ring attached to the moveable base part Furthermore ensure that the housing is aligned with the underside of the moveable base Pickup will not be possible if the O ring has not been attached or the housing has not been attached sufficiently T 9 n n D F gt O D gt 9 A D 3 D gt 8 5 6 Install the tool flange gt Step6 7 Tool flange installation Remove grease from the 0 axis shaft tool flange attachment part The tool flange is shaped so that it fits into the 6 axis shaft groove 7 Attach the tool flange with the two M4 hex socket head bolts e Tightening torque 4 5Nm N CAUTION Tighten the two M4 hex socket head bolts evenly Slippage may occur between the 0 axis shaft and seal flange Degrease this part if one bolt is tightened more than the other y x n n D O gt O D y A D D 5 or Tool flange gt 8 6 8 Attach the rubber cover to the tool flange 9 Attach the O ring to the groove in the moveable base at the motor side 10 Attach the 0 axis motor cover Refer to 1 2 Detaching or attaching the 0 axis cover in Chapter 2 for details gt Step 8 Rubber cover attachment gt Step 9 O ring attachment 8
20. ensure safe and efficient operation This chapter describes the periodic inspection items and procedures for the R6Y3 robots Periodic inspection includes e Daily inspection e Monthly inspection e 6 month inspection Make sure that you thoroughly understand details of the inspection and follow the procedures and precautions explained in this chapter WARNING IN SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS ARE REQUIRED WHEN ARMS SHAFTS AND THE 0 AXIS ASSEMBLY ARE DETACHED TO ADJUST OR MAINTAIN OPERATIONS PERFORMED BY WORKERS WHO DO NOT POSSESS THESE SPECIAL KNOWLEDGE AND SKILLS MAY LEAD TO DANGER THIS WORK MUST BE CARRIED OUT BY REFERENCING THIS MANUAL BY SUFFICIENTLY SKILLED AND QUALIFIED PERSONNEL IN ACCORDANCE WITH THE LAWS AND REGULATIONS OF EACH COUNTRY WARNING IN e WHEN INSPECTION IS REQUIRED INSIDE THE SAFETY ENCLOSURE ALWAYS TURN OFF THE CONTROLLER AND ALSO THE EXTERNAL SWITCH BOARD e IF THE INSPECTION OR MAINTENANCE PROCEDURE CALLS FOR OPERATION OF THE ROBOT STAY OUTSIDE THE SAFETY ENCLOSURE e PLACE A SIGN INDICATING THE ROBOT IS BEING INSPECTED TO KEEP OTHERS FROM OPERATING THE CONTROLLER SWITCH OR OPERATION PANEL e IF CHECKING OPERATION FOLLOWING INSPECTION REFER TO THE CONTROLLER USER S MANUAL O Y G D O gt N CAUTION Use only the lubricants specified by your distributors 3 1 O Y lt OD O 5 gt 2 Daily inspection The following is
21. indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power Enter the safety enclosure 3 Secure the calibration tool The 0 axis origin position is the position in which the tool flange dowel hole is facing the a axis 0 axis origin position Tool flange gt e C s O gt UIDIIO 4 Align the 0 axis calibration tool pin with the tool flange dowel hole 4 5 lt 5 Secure at the two tool flange M5 holes Securing the calibration tool Dowel hole Secure at these two points Knock pin axis calibration tool axis calibration tool gt e C sa gt O 5 uI IO gt 4 6 OON Shaft moveable base and spring cover replacement Contents 1 Shaft moveable base and spring cover replacement procedure 1 1 Detaching the shafts moveable base and spring cover 1 2 Attaching the shafts moveable base and spring covers 1 2 1 R6Y30110S03067NJ5 3 axes specification 1 2 2 R6Y31110L03067NJ5 R6Y31110H03067NJ5 4 axes specification 5 1 5 4 5 4 5 6 2 Moveable base link ball replacement 1 Shaft moveable base and spring cover replacement procedure 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks KDL M1542 00x Upper side cover 1 Spring cover KDL M1543 00x Lower side cover 1 a B and y axes KDL M150A 00x 3 axes s
22. right so as not to incline the plastic bearing gt Step 2 Plastic bearing attachment jig 2 attachment Plastic bearing attachment jig 2 7 USWSIHIIASI Bullbaq IUSP Id gt 2 Press in the plastic bearing with tool gt Step 3 Press in the plastic bearing capable of gripping such as a pair of water pump pliers Remove plastic bearing attachment jig 1 from the shaft and then attach the cap After being pressed in when attachment complete Plastic bearing attachment condition gt Step 4 and cap attachment 7 USWSIDHIIASI unpad IUSPId 1 3 lt 1 3 Spring mechanism plate plastic bearing removal l Push the plate down from above with Step1 Plastic bearing removal the protruding part of the plastic bearing facing down The plastic bearing will pop up allowing it to be Plastic bearing removed If it still cannot be removed even after popping up use a flat screwdriver or similar tool to remove it A CAUTION The bearing is press fit when attached and should therefore be removed using a tool 1 4 Spring mechanism plate plastic bearing attachment l Pay attention to the plastic bearing gt Step 1 attachment direction and attach by press fitting Attach with the plastic bearing and plate facing in the R N N m P I we n directions shown on the right P j N rey h Plastic bearing attachment N CAUTION It will not be possible to attach the spring cover ifthe directio
23. side and moveable base side however the plastic block direction should be the same for both 5 Attach the other plate and spring assembly assembly without plastic block to the shaft Attach the plate and plastic block assembly to one side of the shaft beforehand N gt Step 5 Plate and spring assembly attachment 6 Secure the plastic block with the M3 screws as described in Step 3 Attach so that the plate and plastic block are level 7 Attach the plate and plastic block assembly on the opposite of the side already attached using the same procedure described in Steps 3 to 6 Ensure that the plate and plastic block are level YN 9 O 3 O O O 3 D pe O O O 3 O 6 3 lt OLETTI Plastic bearing replacement Contents 1 1 12 1 3 1 4 2 Plastic bearing replacement procedure Removing the plastic bearing from the link ball sliding part Attach the jig with threaded screw to the tapping hole on the end of the shaft Spring mechanism plate plastic bearing removal Spring mechanism plate plastic bearing attachment Plastic bearing inspection 7 1 gt 7 4 7 4 1 Plastic bearing replacement procedure N CAUTION Plastic bearings are consumable parts and should therefore be replaced periodically 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks Plastic bearing 1 KDL M152K 00x Spring mechanism Plastic bear
24. the moveable base 3 Tighten the link balls with a tool e Tightening torque 20Nm gt Step 3 Tightening nm lt 3 lt O O O O O O O O Q Q O 9 O O lt O O 9 O O O 3 O 5 9 lt Skies Spring mechanism replacement Contents 1 Spring mechanism replacement procedure 1 1 Spring mechanism removal _ 6 1 1 2 Spring mechanism attachment 6 2 1 Spring mechanism replacement procedure 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks KDL M1534 00x Spring KDL M152M 00x Plastic block KDL M153A 00x Screw 98980 03006 M3 length 6 Quantity per axis 1 1 Spring mechanism removal 1 Remove the shaft from the arm and gt Stepl Shaft removed from arm and moveable base moveable base Refer to Shaft moveable base and spring cover replacement in Chapter 5 for details Ey Remove the M3 screws at four locations By removing the screws the springs plate assembly and plastic blocks come free of the shaft 3 Remove the springs Perform this procedure only when replacing springs A Remove the press fit plastic bearings b Step2 Screw removal Perform this procedure only when replacing plastic bearings Refer to Plastic bearing replacement in Chapter 7 for details Plastic bearings wm 9 O 3 O O gt O 3 D pe O O O 3 O 6 1 lt 1 2 Spring mechan
25. u N covers in Chapter 2 for details r y den 4 Remove the speed reduction gear cap bolt If the set screw is not visible inside the hole when the cap bolt is removed release the motor brake move the arm to a position at which the set screw becomes visible and then adjust ifthe arm has been removed rotate the speed reduction gear to adjust the position CAUTION A If removing the motor with the arm still attached it will fall suddenly when the motor brake is released and must therefore be supported And if removing the motor with the shafts and moveable base still attached the moveable base must be supported to prevent it dropping suddenly Hex socket head bolti 9 1 lt 5 Loosen the M6 hex socket head bolt gt Step5 Loosen the M6 hex socket head bolt connecting the speed reduction gear and motor shaft 6 Remove the four M8 hex socket head bolts securing the motor to the speed reduction gear When attaching tighten with a torque of 37Nm N CAUTION Take care to prevent the motor falling when the bolts are removed I Pull the motor from the speed p Step 6 Hex socket head bolt removal reduction gear to remove N CAUTION The motor is relatively heavy and should therefore be supported with both hands when removing 8 Attach the O ring to the groove in the speed reduction gear when replacing the O ring S o O O Y O O O 3 O gt Step7 Motor removal p 9 2 1 1 2 a
26. 08 MS length 8 1 Brake release switch KDL M4851 00x 1 KDL M1172 00x Motor cover upper attachment 1 Bracket KDL M1173 00x Motor cover lower attachment 1 Bracket securing bolt 91380 04020 M4 length 20 Cap KDL M2165 00x Boot KDL M212A 00x Quantity per cover 1 1 1 a B y axis cover removal procedure WARNING A WHEN HANDLING MOTORS TAKE CARE TO AVOID ELECTRIC SHOCK OR BURNS OWING TO THE HEAT GENERATED BY THE MOTORS l Remove the duct boot and cap gt Step 1 Duct boot and cap removal M NOTE The boot and cap are merely inserted when the robot is shipped 2 Disconnect the robot cable connector Boot removal gt O O gt O O 2 Q O O Q Q je O O O 5 O O lt O Cap removal p 2 2 3 Remove the M3 hex bolt from the top gt Step3 Bolt removal of the motor cover 4 Remove the cover a little Grasp the rear of the cover and pull it out while shaking it up and down to remove the cover a little About 10mm of the rubber will come out within 5mm when attached M NOTE The inside ofthe cover will catch and so will not come off completely gt Step 4 Temporarily removed cover Cover Pull out a little at a time while shaking up and down Cover bottom temporarily removed gt Q O u O O y O O O Q Q O 2 Q O O gt O O lt O Cover top temporari
27. 2 0 axis seal O ring attachment Chapter9 Motor replacement 1 a B y axis motor replacement 1 1 a B y axis motor replacement procedure 1 1 1 a B y axis motor removal 1 1 2 a B y axis motor attachment 2 9 axis motor replacement 2 1 0 axis motor removal Chapter 10 Speed reduction gear arm replacement 1 Speed reduction gear replacement precautions 2 Speed reduction gear and arm replacement procedure 2 1 a PB y axis arm replacement 2 1 1 Work required after replacing arm link balls 2 2 a B y axis speed reduction gear replacement 2 3 0 axis speed reduction gear replacement Chapter 11 Maintenance parts 1 Consumable parts 2 Basic specification R6Y3 Maintenance Manual 7 1 7a gt 7 4 7 5 8 1 8 1 8 3 9 1 9 1 9 1 9 3 9 4 10 1 10 2 10 2 10 3 10 4 10 7 11 1 11 2 Safety Instructions Contents 1 Safety Information 2 Signal words used in this manual 3 Warning labels 3 1 Warning labels S 3 3 1 1 Contents of warning label messages S 3 3 1 2 Supplied warning label S 4 3 2 Warning symbols S 4 Major precautions for each stage of use 4 1 Precautions for using robots S 5 4 2 Design S 5 4 3 Moving and installation S 6 4 4 Safety measures S 8 4 4 1 Safety measures S 8 4 4 2 Installing a safety enclosure S 9 4 5 Operation S 10 4 5 1 Trial operation S 10 4 5 2 Automatic operation S 10 4 5 3 Precautions during operation S 10 4 6 Inspect
28. 2 Remove the 0 axis motor cover Refer to the 1 Shaft moveable base and spring cover replacement procedure in Chapter 5 for details 3 Remove the two M4 hex socket head gt Step3 bolts securing the motor to the speed reduction gear F 4 Loosen the two speed reduction gear set screws Remove the gasket and then loosen the set screws a Remove the motor from the speed reduction gear Attach the motor using the opposite of the procedure used for removal Refer to 2 3 0 axis speed reduction gear replacement in Chapter 10 for details p Step 4 M4 hex socket head bolt removal Siew Speed reduction gear arm replacement e 2 948 2 9280 2 3 Contents Speed reduction gear replacement precautions Speed reduction gear and arm replacement procedure a B y axis arm replacement 10 2 Work required after replacing arm link balls 10 3 a B y axis speed reduction gear replacement 10 4 0 axis speed reduction gear replacement 10 7 1 Speed reduction gear replacement precautions Speed reduction gear replacement precautions are described below Always read the following replacement procedures and precautions before carrying out replacement work MH Speed reduction gear replacement precautions WARNING A e THE MOTOR AND SPEED REDUCTION GEAR CASING WILL BECOME VERY HOT SHORTLY AFTER OPERATION RESULTING IN BURNS IF TOUCHED BEFORE TOUCHING THESE PARTS TURN OFF THE CONTROLLER WAIT FOR A WHILE
29. CCUR AT THE SAME POSITION MAKING IT DIFFICULT FOR A PROPER OIL FILM TO FORM ON THE SPEED REDUCTION GEAR POSSIBLY SHORTENING ITS SERVICE LIFE TO PREVENT THIS ADD A RANGE OF MOTION SO THAT EACH AXIS MOVES THROUGH A RANGE OF 120 DEGREES OR MORE ABOUT 5 TIMES A DAY 4 6 Inspection and maintenance Always perform daily and periodic inspections and make a pre operation check to ensure there are no problems with the robot and related equipment If a problem or abnormality is found then promptly repair it or take other measures as necessary Keep a record of periodic inspections or repairs and store this record for at least 3 years 4 6 1 Before inspection and maintenance work 1 Do not attempt any work or operation unless described in this manual Never attempt any work or operation unless described in this manual WARNING A NEVER ATTEMPT INSPECTION MAINTENANCE REPAIR AND PART REPLACEMENT UNLESS DESCRIBED IN THIS MANUAL THESE TASKS REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS PLEASE BE SURE TO CONTACT YOUR DISTRIBUTOR FOR ADVICE 2 Precautions during repair and parts replacement WARNING A IF IT IS ABSOLUTELY REQUIRED TO REPAIR OR REPLACE ANY PART OF THE ROBOT PLEASE BE SURE TO CONTACT YOUR DISTRIBUTOR AND FOLLOW THE INSTRUCTIONS THEY PROVIDE INSPECTION AND MAINTENANCE OF THE ROBOT BY AN UNSKILLED OR UNTRAINED PERSON IS EXTREMELY HAZARDOUS Adjustment maintenance and parts replacement require spec
30. Delta Robot MAINTENANCE MANUAL CONTENTS aitoo Safety Instructions 1 Safety Information S 1 2 Signal words used in this manual S 2 3 Warning labels S 3 3 1 Warning labels S 3 3 1 1 Contents of warning label messages S 3 3 1 2 Supplied warning label S 4 3 2 Warning symbols S 4 4 Major precautions for each stage of use S 5 4 1 Precautions for using robots S 5 4 2 Design S 5 4 3 Moving and installation S 6 4 4 Safety measures S 8 4 4 1 Safety measures S 8 4 4 2 Installing a safety enclosure S 9 4 5 Operation S 10 4 5 1 Trial operation S 10 4 5 2 Automatic operation S 10 4 5 3 Precautions during operation S 10 4 6 Inspection and maintenance S 11 4 6 1 Before inspection and maintenance work S 11 4 6 2 Precautions during service work S 12 4 7 Disposal S 12 5 Emergency action when a person is caught by robot S 13 6 Using the robot safely S 14 6 1 Robot protective functions S 14 6 2 Residual risk S 14 6 3 Special training for industrial robot operation S 14 Warranty CONTENTS Chapter 1 Overview 1 Overview Chapter 2 Attaching detaching and replacing the cover 1 Attaching detaching and replacing the cover 1 1 Detaching or attaching the a B y axes covers 1 1 1 a B y axis cover removal procedure 1 1 2 a B and y axis cover attachment procedure 1 2 Detaching or attaching the 0 axis cover 1 2 1 0 axis motor cover removal 1 2 2 axis motor cover attachment Chapter 3 Periodic inspection 1 Overview 2
31. EATMENT e IF THIS GREASE COMES IN CONTACT WITH THE SKIN WASH AWAY COMPLETELY WITH SOAP AND WATER e IF TAKEN INTERNALLY DO NOT INDUCE VOMITING BUT PROMPTLY CONSULT A PHYSICIAN FOR TREATMENT DISPOSING OF GREASE AND THE CONTAINER e PROPER DISPOSAL IS COMPULSORY UNDER FEDERAL STATE AND LOCAL REGULATIONS TAKE APPROPRIATE MEASURES IN COMPLIANCE WITH LEGAL REGULATIONS WM Inspection to be performed with the controller turned off Be sure to perform the inspection with controller power off O Y G D O gt l Place a sign indicating the robot is being adjusted Place a sign showing that the robot is being inspected to keep others from operating the controller switch 2 Perform the daily inspection Enter the safety enclosure and check the following points Checkpoint Procedure Check for deformation damage 0 axis assembly seal Is there sufficient grease If not lightly apply some grease 3 3 lt O O Y lt D O 5 I 4 Six month inspection Take the following precautions when performing 6 month inspection W Inspection to be performed with the controller turned off Be sure to perform the inspection with controller power off l Place a sign indicating the robot is being adjusted Place a sign showing that the robot is being inspected to keep others from operating the controller switch 2 Perform the daily inspection Arm Enter the safety enclosure an
32. ECT IT WILL NOT BE POSSIBLE TO PROPERLY EARTH THE 0 AXIS MOTOR COVER WHEN ATTACHED RESULTING IN POSSIBLE ELECTRIC SHOCK gt Step 1 Speed reduction gear attachment gt Step 3 Bolt attachment gt Step 4 Assembly attachment a axis side a axis side Identified by 2 punch holes and earth bolt holes 10 9 JUOLUSDD Cel LUD Pep Uoyonpei poodgs iSi JUOLUSDD Cel UUP Pep LONONPSI1 peeds S gt 10 10 Temporarily tighten the speed reduction gear to the moveable base with the four length 10 M3 hex socket head bolts Center the rotational axis Align the rotation centering jig with the center of the speed reduction gear axis Secure to the moveable base at two of the six bolt locations with the M4 bolts adjust to center the 0 axis and then fully tighten the bolts temporarily tightened at Step 5 e Tightening torque 2Nm After tightening remove the two M4 bolts used to secure the moveable base and then remove the rotation centering jig gt Step 5 Temporary tightening D gt Step 6 Rotation centering jig attachment 7 Align centers 10 11 Attach the spacer Use a spanner to prevent the axis rotating and then attach the three length 8 M4 hex socket head bolts e Tightening torque 4 5Nm Attach the shaft Insert a hex wrench through the shaft through hole to prevent the axis rotating and then attach the six length 8 M3 hex socket head bolts e Tightenin
33. JUOLUSDD Cel LUD Pep Uoyonpei poodgs iS H Attachment Attach the speed reduction gear using the opposite of the procedure used for removal Attach the speed reduction gear so that the cap bolts are on the outside CAUTION A e The speed reduction gear is extremely heavy and should therefore be supported with both hands when attaching e Insert the speed reduction gear slowly while holding it perpendicular to the base at the same angle It will be difficult to insert the reduction gear into the base 1f at angle e Try again if unable to insert the speed reduction gear properly Using excessive force to insert the gear may damage it Speed reduction gear attachment condition Arm side E TheJattachment condition at both the top and bottom is the same o 2 O Motor side O 3 Q Q o D D gt 10 6 25 0 axis speed reduction gear replacement The requirements for 0 axis speed reduction gear replacement are as follows 1 Replacement parts Part Name OMRON Part No Part No Specs i Remarks KDL M1822 00x For R6Y31110L03067NJ5 Speed reduction gear KDL M1822 10x For R6Y31110H03067NJ5 Speed reduction gear Common to R6Y31110L03067NJ5 E 91380 03010 M3 length 10 mounting bolt R6Y31110H03067NJ5 0 axis shaft KDL M1870 00x Shaft securing bolt 91380 03008 M3 length 8 Spacer KDL M1830 00x Spacer securing bolt 91380 04008 M4 length 8 2 Required tools Part
34. MPTED BY AN UNSKILLED PERSON THESE TASKS MUST BE PERFORMED ONLY BY PERSONS WHO HAVE ENOUGH ABILITY AND OUALIFICATIONS IN ACCORDANCE WITH LOCAL LAWS AND REGULATIONS FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT 4 2 Design 1 Restricting the movement range WARNING A SOFT LIMIT FUNCTION IS NOT A SAFETY RELATED FUNCTION INTENDED TO PROTECT THE HUMAN BODY ENSURE SAFETY BY INSTALLING A SAFETY ENCLOSURE AND SO ON 2 Provide safety measures for end effector gripper etc WARNING A e END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY CAUSE NO HAZARDS SUCH AS A LOOSE WORKPIECE OR LOAD EVEN IF POWER ELECTRICITY AIR PRESSURE ETC IS SHUT OFF OR POWER FLUCTUATIONS OCCUR e IF THE OBJECT GRIPPED BY THE END EFFECTOR MIGHT POSSIBLY FLY OFF OR DROP THEN PROVIDE APPROPRIATE SAFETY PROTECTION TAKING INTO ACCOUNT THE OBJECT SIZE WEIGHT TEMPERATURE AND CHEMICAL PROPERTIES 3 Provide adeguate lighting Provide enough lighting to ensure safety during work S 5 lt SUOIJONIISU JOJOS SUOIJONIISU JOJOS 4 Install an operation status light WARNING A INSTALL A SIGNAL LIGHT SIGNAL TOWER AT AN EASY TO SEE POSITION SO THAT THE OPERATOR WILL BE AWARE OF THE ROBOT STOP STATUS TEMPORARILY STOPPED EMERGENCY STOP ERROR STOP ETC 4 3 Moving and installation H Installation environment 1 Do not use in strong magnetic fields WARNING A DO NOT USE THE ROBOT NEAR EQUIPMEN
35. No Manufacturer Remarks Cleaning wipe Hex wrench set Screw thread locking agent Loctite 241 Medium strength type blue MH Removal l Post a sign indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power Enter the safety enclosure 3 Remove the end effector Refer to 6 Attaching the end effector in Chapter 2 of the installation manual for details 4 Disconnect the air tube from the joint on the user tubing CAUTION A Do not carry out replacement work with the air tube still attached to the joint on the user tubing By doing so the air tube may bend 5 Disconnect the cable from the 0 axis motor cover Refer to 1 Shaft moveable base and spring cover replacement procedure in Chapter 5 for details N CAUTION Do not carry out replacement work with the cable still attached to the 0 axis motor By doing so the cable may be damaged 10 7 lt 7 8 11 i 12 C O 13 S E 14 o 3 D 15 Q 16 Z gt 17 gt 10 8 Remove the moveable base from the shafts Refer to 1 Shaft moveable base and spring cover replacement procedure in Chapter 5 for details Remove the 0 axis motor cover Refer to 1 Detaching attaching and replacing the covers in Chapter 2 for details Remove the motor cover side O ring Remove the tool flange Refer to 1 1 0 axis seal O ring r
36. ON 4 Products utilized for example in radiological equipment biological test equipment applications or for other purposes whose warranty repairs are judged as hazardous by OMRON WARRANTY OMRON s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year after the date of manufacturing as shown on the product serial number plate OMRON MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED REGARDING NONINFRINGEMENT MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUERIMENTS OF THEIR INTENDED USE OMRON DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED LIMITATIONS OF LIABILITY OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR COMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS WETHER SUCH CLAIM IS BASED ON CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY REPAIR OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED STORED INSTALLED AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION ABUSE MISUSE OR INAPPROPIATE MODIFICATION OR REPAIR 1
37. SERIOUS INJURY MAY RESULT FROM CONTACT WITH A MOVING ROBOT e KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION e PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE Instructions on this label DANGER fe BSF Always install a safety enclosure to keep all persons away from the robot movement range and prevent injury from O al BR contacting the moving part of the robot Install an interlock that triggers emergency stop when the Stay clear of moving machine Can cause serious injury door or gate of the safety enclosure is opened Riz HSE The safety enclosure should be designed so that no one BEE SRN a Seg ord can enter inside except from the door or gate equipped with an interlock device HART S EEKKI EI SENG Warning label 1 that comes supplied with a robot should 90K41 001470 be affixed to an easy to see location on the door or gate of the safety enclosure HISSIN HALO 915101 9 Potential hazard to human body Serious injury may result from contact with a moving robot N e Keep outside of the robot safety enclosure during operation To avoid hazard e Press the emergency stop button before entering the safety enclosure 2 Warning label 2 N WARNING MOVING PARTS CAN PINCH OR CRUSH HANDS KEEP HANDS AWAY FROM THE MOVABLE PARTS OF THE ROBOT Instructions on this label Use caution to prevent hands and fingers from being pinched Pinch or crush hazard or crush
38. SO THAT YOU CAN IMMEDIATELY STOP THE ROBOT OPERATION IN CASE OF AN ABNORMAL OR HAZARDOUS CONDITION ADDITIONALLY SET THE ROBOT MOVING SPEED SO THAT IT COMPLIES WITH THE ROBOT SAFETY STANDARDS WARNING IN e DURING STARTUP OR MAINTENANCE TASKS DISPLAY A SIGN STATING WORK IN PROGRESS ON THE OPERATION PANEL OR LOCK THE COVER OF THE OPERATION PANEL IN ORDER TO PREVENT ANYONE OTHER THAN THE PERSON FOR THAT TASK FROM MISTAKENLY OPERATING THE START OR SELECTOR SWITCH e ALWAYS CONNECT THE ROBOT AND ROBOT CONTROLLER IN THE CORRECT COMBINATION USING THEM IN AN INCORRECT COMBINATION MAY CAUSE FIRE OR BREAKDOWN 4 Install brake release circuit The DELTA robot is equipped with a brake release switch for the manual teaching or maintenance inspection To use this brake release switch it is also necessary to install a brake release circuit on the user side For details see 4 2 Wiring the brake release wire connector in Chapter 2 of the Installation Manual WARNING A WHEN PERFORMING THE TEACHING OR MAINTENANCE INSPECTION MANUALLY INSTALL THE BRAKE RELEASE CIRCUIT TO ENSURE THE SAFETY 5 Install system When configuring an automated system using a robot hazardous situations are more likely to occur from the automated system than the robot itself So the system manufacturer should install the necessary safety measures reguired for the individual system The system manufacturer should provide a proper manual for safe correct operation and se
39. T OR IN LOCATIONS THAT GENERATE STRONG MAGNETIC FIELDS THE ROBOT MAY BREAK DOWN OR MALFUNCTION IF USED IN SUCH LOCATIONS 2 Do not use in locations subject to possible electromagnetic interference etc WARNING A DO NOT USE THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC INTERFERENCE ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE THE ROBOT MAY MALFUNCTION IF USED IN SUCH LOCATIONS CREATING HAZARDOUS SITUATIONS 3 Do not use in locations exposed to flammable gases WARNING A e OMRON ROBOTS ARE NOT DESIGNED TO BE EXPLOSION PROOF e DO NOT USE THE ROBOTS IN LOCATIONS EXPOSED TO EXPLOSIVE OR INFLAMMABLE GASES DUST PARTICLES OR LIQUID FAILURE TO FOLLOW THIS INSTRUCTION MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH OR LEAD TO FIRE H Moving 1 Use caution to prevent pinching or crushing of hands or fingers WARNING A KEEP YOUR HAND AWAY FROM THE ROBOT INSTALLATION SURFACE DURING MOVING OTHERWISE YOUR HAND IS ENTANGLED CAUSING SERIOUS PERSONAL INJURY As instructed in Warning label 2 use caution to prevent hands or fingers from being pinched or crushed by movable parts when transporting or moving the robot For details on warning labels see 3 Warning labels in Safety instructions 2 Take safety measures when moving the robot To ensure safety when moving the DELTA robot use the eyebolts that come with the robot Refer to the Robot Manual for details H Installation 1 Protect electrical wiring
40. able cable to the 0 axis motor when replacing the motor speed reduction gear When attaching the 0 axis motor cover secure the cables with cable ties to prevent them from moving 2 Connect the cable motor side on the inside of the 0 axis motor cover Attach Ak connector so that it is facing the p Step 2 DION O non notoriety outside of the cover Ensure that the mark on the connector is facing upward If replacing the cable on the inside of the cover fit O ring motor cable side an O ring to the connector Secure the connector connection on the outside of the 0 axis motor cover with the four length 6 M3 hex bolts 19109 OU BUIoPp da 1 pub Hulyoojep OUIUOPIIV e Tightening torque 2Nm Pull toward outside of cover CAUTION A If replacing cables on the inside of the cover it will not be possible to guarantee waterproofing properties if the connector O rings are not fitted and therefore caution is advised p 2 16 3 Connect the cable at the encoder side gt Step 3 Cable connection encoder cable side in the same manner as that described in Step 2 Attach the cable connector so that the mark groove O ring encoder cable side is facing upward N CAUTION If replacing cables on the inside of the cover it w ll not be possible to guarantee waterproofing properties if the connector O rings are not fitted and therefore caution is ee of Attach connector advised N e Tigh
41. an inspection list that must be performed every day before and after operating the robot W Inspection to be performed with the controller turned off Be sure to inspect with controller power off l Place a sign indicating the robot is being adjusted Place a sign indicating the robot is being inspected to keep others from operating the controller switch 2 Perform the daily inspection Enter the safety enclosure and check the following points Checkpoint Procedure Robot cable Check for scratches dents and excessive bend and kinks If the robot cable is damaged User cable and wiring contact your distributor e Check air pressure Regulator joints air tube e Check for air leaks solenoid valve air cylinder e Check drain e Check air filter for clogging or damage Robot exterior Check for damage If a damage is found contact your distributor Br e Check for deformation dents Plastic bearing link ball sliding surface e Check that wear is 0 5mm or less Plastic bearing spring mechanism plate NN Check for deformation breakage Check for cracks sliding surface Shaft Check for deformation Spring cover Check for damage Check for guide clip breakage e Check for deformation Inside spring cover spring plate etc e Check the spring to see if it is overstretched e Check for M3 screw looseness 0 axis assembly seal Check for any grease leaking from the coupling H Adjustmen
42. and hydraulic pneumatic hoses Install a cover or similar item to protect the electrical wiring and hydraulic pneumatic hoses from possible damage 2 Cautions on arm In the installation work do not hold the arm by your hand in case of an emergency H Adjustment 1 Adjustment that reguires removing a cover WARNING A ADJUSTMENT BY REMOVING A COVER REOUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATEMPTED BY AN UNSKILLED PERSON THESE TASKS MUST BE PERFORMED ONLY BY PERSONS WHO HAVE ENOUGH ABILITY AND QUALIFICATIONS IN ACORDANCE WITH LOCAL LAWS AND REGULATIONS FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THEPRODUGT m Wiring 1 Robot cable After checking the specified combinations of the robot and controller connect the robot and controller 2 Wiring safety points WARNING A ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE STARTING INSTALLATION OR WIRING WORK FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE CAUTION IN e Do not apply excessive impacts or loads to the connectors when making cable connections This might bend the connector pins or damage the internal PC board e When disconnecting the cable from the robot do not hold the cable and pull it out by hand Loosen the screws on the connector if fastened with the screws and then disconnect the cable Trying to detach by pulling on the cable itself may damage the connector o
43. ce upward The moveable base attachment direction is as shown in the Fig Refer to 1 2 Adjusting the 0 axis origin position in Chapter 4 for details N CAUTION By attaching the shafts with hands placed anywhere other than the shaft end the joint between the shaft and shaft end may deform possibly leading to malfunction Ensure to place hands on the end of the shaft as shown in the Fig on the right Take care not to pull the springs on the shafts too much If stretched too far the springs may not return to their original shape possibly leading to malfunction Meer nm gt el 2 O O O O O O O Q Q O 9 O O lt O O lt A O O O 3 O gt p 5 6 Attach the spring covers gt Step 4 Spring cover attachment There are a total of six spring covers one at the arm and one at the moveable base for each of the three axes The top and bottom positions of the spring covers are fixed If the shaft direction is correct at Step 3 the cover attached at the top will be wide as shown in the Fig below The spring covers come as a top and bottom set when shipped Attach the covers so that they snap together at the guide clips Route the arm side cable and insert it into the plastic block on the arm Route the cables along the a axis arm to the robot base while trying not to bend them too much Spring cover top N Spring coverjbottom gt Step 5 Cable routing at arm si
44. d check the following points Checkpoint Procedure Check for deformation damage Link ball Check for damage Major robot body bolts and screws Those exposed on outside Bolt tightening torgue Bolt size M3 set screw Check for looseness and tighten if necessary See the Table below Tightening torgue kgfcm Tightening torgue Nm M3 M4 M4 4 axis specification a axis arm cable clamp M6 M8 H Adjustment and parts replacement N CAUTION e If adjustment or replacement is deemed necessary following inspection turn off the controller power before entering the safety enclosure to carry out work If checking operation after work is complete do so in accordance with m Inspection with the controller turned off described above e If robot repair or part replacement is deemed necessary contact your distributor Such repair and part replacement requires specialized technical knowledge and must not be carried out by the user gt 3 4 GE 2 Adjusting the origin Contents 1 Adjusting the origin 1 1 Adjusting the a B and y axis origin position 4 2 1 2 Adjusting the 0 axis origin position 4 axes specification only 4 5 1 Adjusting the origin The R6Y3 uses a calibration tool to mechanically adjust the origin position of the a B y and 0 axes Be sure to adjust the origin position in the following cases 1 If the origin positi
45. de Y gt a 3 lt O O O O O O O O Q Q O 9 O O lt O 9 O O O 3 O 9 lt 6 Secure the attached cable with the gt Step 6 Securing the cables plastic block There are a total of three securing locations Use two tie bands for each location and secure the cables with the plastic block as shown N CAUTION Be careful not to pull the cables too much If pulled too much the cables may be damaged resulting in possible robot malfunction 7 Attach the cable at the moveable base side to the motor cover Ensure that the moveable base and a axis shaft attachment directions are correct Align the arrow on the cable connector with the connector mark on the motor cover and attach Attach both the motor cable and encoder cable to their respective connectors gt Step7 Cable attachment at moveable base side nm gt el 2 O O O O O O O Q Q O 9 O O lt O O Y O O O 3 O gt 2 Moveable base link ball replacement The link ball attachment method is described below Remove the link balls using the opposite of the method used for attachment 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks link ball KDL M152A 00x Moveable base part l Apply a thin layer of Loctite screw lock to the link ball screw Use Henkel Loctite 241 blue 2 Attach a link ball at six locations on b step Link ball attachment
46. e robots cannot be used OMRON robots are designed as general purpose industrial equipment and cannot be used for the applications listed below DANGER A ROBOTS ARE DESIGNED AS GENERAL PURPOSE INDUSTRIAL EQUIPMENT AND CANNOT BE USED FOR THE FOLLOWING APPLICATIONS e IN MEDICAL EQUIPMENT SYSTEMS WHICH ARE CRITICAL TO HUMAN LIFE e IN SYSTEMS THAT SIGNIFICANTLY AFFECT SOCIETY AND THE GENERAL PUBLIC IN EQUIPMENT INTENDED TO CARRY OR TRANSPORT PEOPLE e IN ENVIRONMENTS WHICH ARE SUBJECT TO VIBRATION SUCH AS ONBOARD SHIPS AND VEHICLES 2 Oualification of operators workers Operators or persons who handle the robot such as for teaching programming movement check inspection adjustment and repair must receive appropriate training and also have the skills needed to perform the job correctly and safely They must read the manual carefully to understand its contents before attempting the robot operation or maintenance Tasks related to industrial robots teaching programming movement check inspection adjustment repair etc must be performed by gualified persons who meet reguirements established by local regulations and standards for industrial robots WARNING A e THEROBOT MUST BE OPERATED ONLY BY PERSONS WHO HAVE RECEIVED SAFETY AND OPERATION TRAINING OPERATION BY AN UNTRAINED PERSON IS EXTREMELY HAZARDOUS e ADJUSTMENT AND MAINTENANCE BY REMOVING A COVER REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATTE
47. e spring covers are held together with clips on the inside Pull the bottom cover down at the arm side and pull the top cover up at the moveable base side to remove the spring cover N CAUTION Use both hands when removing the spring covers Use one hand for removal and the other to stop the bottom cover Topjcoyer falling If the spring cover falls and is damaged the robot may operate abnormally 4 Remove the end effector N L Refer to 6 Attaching the end effector in Chapter 2 Ru of the installation manual for details Bor EP 5 Disconnect the air tube from the joint IF on the user tubing A CAUTION Arm side Do not carry out replacement work with the air tube still attached to the joint on the user tubing By doing so the air tube may bend 6 Ensure that the 0 axis cable can be disconnected from the a axis arm R6Y31110L03067NJ5 R6Y31110H03067NJ5 only The cable is secured at three locations on the a axis arm Remove the cable ties and then remove the plastic block holding the cable in place Base side CAUTION A gt Step 6 Arm side cable Do not pull the cable too hard when removing If pulled too hard the cable may be damaged resulting in possible robot malfunction y TA N dl Disconnect the cable at the moveable p gt Step 7 Cable removal at moveable base side base side from the motor cover R6Y31110L03067NJS5 R6Y31110H03067NJ5 only The cable
48. ed by the movable parts of the robot when transporting or moving the robot or during teaching kA RTI MEI SUNG U 90K41 001460 Potential hazard to human body Moving parts can pinch or crush hands To avoid hazard Keep hands away from the movable parts of the robot S 3 SUOIJONIISU JSJOS SUOIJONIISU JSJOS 3 Warning label 3 N WARNING IMPROPER INSTALLATION OR OPERATION MAY CAUSE SERIOUS INJURY BEFORE INSTALLING OR OPERATING THE ROBOT READ THE MANUAL AND INSTRUCTIONS ON THE WARNING LABELS AND UNDERSTAND THE CONTENTS Instructions on this label Read and understand manuals before operation ZA HYS Sal 90K41 001290 ER E LITMMIRIEFMIKNERHNS RES SFIICVTZ1I7 MET TERMI Ol E e Be sure to read the warning label and this manual carefully to make you completely understand the contents before attempting installation and operation of the robot Before starting the robot operation even after you have read through this manual read again the corresponding procedures and Safety instructions in this manual Never install adjust inspect or service the robot in any manner that does not comply with the instructions in this manual Potential hazard to human body Improper installation or operation may cause serious injury To avoid hazard 3 1 2 Supplied warning label Before installing or operating the robot read the manual and instructions on the
49. eformed making it difficult to attach the motor cover Gap at top of cover 9 Push in the motor cover from the rear The rubber at the bottom of the switch should protrude approximately 5mm and the rubber at the top of the switch should protrude approximately Imm Gap at bottom of cover gt Steps Insert the rubber gt Step 9 Push in the motor cover gt O O Q Q L Q O u O O Q 9 O O O gt O O lt O 2 10 10 Adjust the motor cover position and Step10 Motor cover attachment then secure with the MS hex bolt s Adjust the motor cover position and then screw in two M5 hex bolts to secure Ensure that the motor cover has been securely attached It will not be possible to insert the bolts if the motor cover position and tapping positions for the M5 hex a bolts are not aligned gt Ge MS hex bolt i 11 Attach the robot cable connector WARNING IN CONNECT THE a BAND y AXIS ROBOT CABLES SO THAT THEY MATCH THE RESPECTIVE AXES AT THE CONTROLLER DRIVER THE ROBOT WILL NOT OPERATE CORRECTLY RESULTING IN POSSIBLE DANGER IF THE CABLES ARE CONNECTED gt Step 12 Boot cap attachment INCORRECTLY Pushithe rubber in completely 12 Attach the boot and cap to the motor cover 13 Attach the duct to the robot cable Insert the robot cable into the notch on the duct The cable can be inserted easily by inserting a thick rod such as a flat screwdriver
50. emoval in Chapter 8 for details Remove the housing Remove the O ring at the housing side Remove the shaft attached to the speed reduction gear Insert a hex wrench through the shaft through hole to prevent the axis rotating and then remove the six M3 hex socket head bolts Remove the spacer Use a spanner to prevent the axis rotating and then remove the three M4 hex socket head bolts Pull the motor and speed reduction gear assembly from the moveable base Remove the four M3 hex socket head bolts from the speed reduction gear brackets Remove the two M4 hex socket head bolts securing the motor to the speed reduction gear Loosen the two speed reduction gear set screws Remove the motor from the speed reduction gear Shaft removal Step 12 gt Step 13 Fr E gt Step 15 gt Step 17 Speed reduction gear removal H Attachment Attach the speed reduction gear using the opposite of the procedure used for removal l Attach the motor to the speed reduction gear 2 Tighten the two speed reduction gear set Screw e Tightening torque 69Nm 3 Attach the two length 14 M4 hex socket head bolts used to secure the motor to the speed reduction gear e Tightening torque 4 5Nm 4 Insert the motor and speed reduction gear assembly into the moveable base Ensure that the motor connector side is facing the moveable base a axis side WARNING A IF THE ATTACHMENT DIRECTION IS INCORR
51. g Seal large KDL M219K 10x d arge side O ring KN5 M2144 00x Housing side O ring KN6 M1895 00x axis motor cover side Housing KDL M1811 00x Housing securing bolt 91380 04020 M4 length 20 KDL M1843 00x Tool flange KDL M1844 00x Tool flange securing bolt 91380 04012 M4 length 12 Tool flange cover KDL M1816 00x Rubber cover e O axis seal recommended grease CASSIDA grease EPS2 yuswadeld31 HUL E Jeas sIxe g 1 1 0 axis seal O ring removal The procedure described below is for the R6Y31110L03067NJS and R6Y31110H03067NJ5 4 axes specification l Remove the 0 axis motor cover When removing the 0 axis motor cover first disconnect the 6 axis cable and then remove the moveable base from the shafts before proceeding Refer to 1 2 Detaching or attaching the 0 axis cover in Chapter 2 for details p Remove the O ring from the groove in p Step 2 O ring removal the moveable base at the motor cover side 8 1 8 2 Remove the tool flange Remove the rubber cover remove the M4 hex socket head bolts and then remove the tool flange Remove the six length 20 M4 hex socket head bolts from the moveable base These bolts secure the moveable base and housing Remove the housing from the moveable base The housing will still be attached to the moveable base a little gt Step 3 Tool flange removal gt Step 4 M4 hex socket head bolt removal
52. g torque 2Nm Apply a thin layer of the recommended grease to the shaft and sliding part of the housing e Recommended grease CASSIDA grease EPS2 Attach the O ring at the housing side Refer to 1 2 6 axis seal O ring attachment in Chapter 8 for details Attach the housing Refer to 1 2 6 axis seal O ring attachment in Chapter 8 for details gt Step 7 Spacer attachment 10 11 JUOLUSOD Cel LUD Pep Uoyonpei poodgs A OPTA Maintenance parts Contents 1 Consumable parts 2 Basic specification 1 Consumable parts KDL M152K 00x Plastic bearing 1 KDL M152J 00x Plastic bearing 2 Replace if wear 0 5mm or greater KDL M219K 00x Seal inside 0 axis housing small side KDL M219K 10x Seal inside 0 axis housing large side KDL M150E 00x Shaft a axis motor cable side 4 axes specification KDL M150F 00x Shaft a axis encoder cable side 4 axes specification KDL M211A 00x Speed reduction gear a B and y axes KDL M1822 00x Speed reduction gear 0 axis KDL M1822 10x Speed reduction gear 0 axis e 0 axis seal recommended grease CASSIDA grease EPS2 SLIOd SIUDUAJUIDIA 11 1 lt 2 Basic specification Robot model R6Y30110S03067NJ5 R6Y31110L03067NJ5 R6Y31110H03067NJ5 Stroke 01100mm Working volume Stroke 300mm max 01100mm 450mm center 0580mm Rotation range 180 default setting it can be changed
53. gt Step 5 Housing removal Remove the O ring from the groove gt Step 6 O ring removal on the moveable base at the housing side Remove the two seals from the housing The seals can be easily removed by prizing them free with a precision flat screw driver as shown on the right gt Step 7 Seal removal Seal large T Y x n n M O 5 O D 2 y A M 3 D gt et 1 2 0 axis seal O ring attachment Fit the seals using the opposite of the procedure used for removal Fit the two seals to the housing p Step 1 Seal attachment If unable to attach the seals properly as shown on the right attach by pressing in a little and ensure that the seals are not twisted Seal large Apply a thin layer of grease to the sliding areas between the seal and 0 axis shaft and moveable base Apply a layer of grease so that the seal groove appears slightly white e Recommended grease CASSIDA grease EPS2 gt Step 2 Grease application Grease application 8 3 lt 8 4 Apply a thin layer of the recommended grease to the 0 axis Shaft and sliding part of the housing e Recommended grease CASSIDA grease EPS2 Attach the O ring to the groove in the moveable base at the housing side gt Step 3 Grease application gt Step 4 5 Attach the housing gt Step5 Housing attachment Push the housing until it is aligned with the underside ofthe moveable base so that the air tube
54. ialized technical knowledge and skills and also may involve hazards These tasks must be performed only by persons who have enough ability and qualifications required by local laws and regulations WARNING A ADJUSTMENT AND MAINTENANCE BY REMOVING A COVER REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATTEMPTED BY AN UNSKILLED PERSON FOR DETAILED INFORMATION PLEASE CONTACT YOUR DISTRIBUTOR WHERE YOU PURCHASED THE PRODUCT 3 Shut off all phases of power supply WARNING A ALWAYS SHUT OFF ALL PHASES OF THE POWER SUPPLY EXTERNALLY BEFORE CLEANING THE ROBOT AND CONTROLLER OR SECURELY TIGHTENING THE TERMINAL SCREWS ETC FAILURE TO DO THIS MAY CAUSE ELECTRICAL SHOCK OR PRODUCT DAMAGE OR MALFUNCTION 4 Allow a waiting time after power is shut off Allow time for temperature and voltage to drop WARNING A THE MOTOR AND SPEED REDUCTION GEAR CASING ARE VERY HOT SHORTLY AFTER OPERATION SO BURNS MAY OCCUR IF THEY ARE TOUCHED BEFORE TOUCHING THOSE PARTS FOR INSPECTIONS OR SERVICING TURN OFF THE CONTROLLER WAIT FOR A WHILE AND CHECK THAT THE TEMPERATURE HAS COOLED S 11 lt SUOIJONIISU JOJOS SUOIJONIISU AJOJOS 4 6 2 Precautions during service work 1 Precautions when removing a motor WARNING A THE a AXIS B AXIS OR y AXIS WILL SLIDE DOWNWARD WHEN THE MOTOR IS REMOVED CAUSING A HAZARDOUS SITUATION e TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER THE a AXIS B AXIS OR y AXIS BEFORE REMOVING
55. ing 2 KDL M152J 00x Replace if wear 0 5mm or greater 1 1 Removing the plastic bearing from the link ball sliding part Plastic bearing replacement guideline when amount of wear reaches 0 5mm When replacing plastic bearings be sure to check and take a note of the bearing depth and periodically measure the amount of wear l Remove the cap from the end of the p Step1 Cap removal shaft The tapping hole becomes visible when the cap is removed 2 Insert an M6 bolt in the tapping hole on the end of the shaft The tapping hole is located on the opposite side to that with the plastic bearing 7 3 Push in the plastic bearing while tightening the M6 bolt with a hex wrench By pushing in while tightening the plastic bearing is gt Step 2 3 Bolt attachment pushed in and comes off USWSIDHIISI Bunpod IUSPId 1 lt 1 2 Attach the jig with threaded screw to the tapping hole on the end of the shaft l Attach plastic bearing attachment jig b Step1 Plastic bearing attachment jig 1 attachment L ee 3 0C gt gt Attach the jig with thread to the tapping hole on the end of the shaft Plastic bearing attachment jig 1 2 While pressing the protruding part on the plastic bearing attachment jig 2 against the groove on plastic bearing press into the plastic bearing attachment surface on the shaft side Press the bearing attachment jig 2 horizontally against the attachment surface as shown on the
56. ion and maintenance S 11 4 6 1 Before inspection and maintenance work S 11 4 6 2 Precautions during service work S 12 4 7 Disposal S 12 Emergency action when a person is caught by robot Using the robot safely 6 1 Robot protective functions S 14 6 2 Residual risk S 14 6 3 Special training for industrial robot operation S 14 1 Safety Information Industrial robots are highly programmable mechanical devices that provide a large degree of freedom when performing various manipulative tasks To operate the robot in safer and correct manner strictly observe the safety instructions and precautions stated in this Safety Instructions guide Failure to take necessary safety measures or incorrect handling may result in trouble or damage to the robot and also may cause personal injury to installation personnel robot operator or service personnel including fatal accidents The safety instructions and precautions described in the Safety Instructions cover only the robot mechanical sections For details about operation of the controller and safety precautions associated with the controller operation refer to the Controller Manual Before using this product read this manual and related manuals and take safety precautions to ensure correct handling The precautions listed in th s manual relate to this product To ensure the safety of the user s final system that includes robots the user must take appropriate safety consideration
57. is disconnected by rotating the connector as shown with the arrow on the cable side connector and then disconnecting it from the motor cover 8 Remove the shafts Remove the shafts from the arm and moveable base link balls When doing so the link balls can be stretched by hand at the end of the shaft as shown in the Fig on the right When removing the shafts from the moveable base disconnect the 0 axis robot cable from the motor beforehand CAUTION A e Remove the spring covers before removing the shafts The spring covers may be damaged if work is carried out without removing them e Take care not to pull the springs on the shafts too much If stretched too far the springs may not return to their original shape possibly leading to abnormal robot movement e With the R6Y31110L03067NJ5 and R6Y31110H03067NJ5 a cable is attached to the a axis shaft If the a axis shaft is removed from the moveable base without disconnecting the axis cable from the motor the cable will be pulled and possibly damaged leading to potential defects Furthermore care should be taken not to drop the moveable base Q lt 3 D Q O O O O O D Q gt O O Q O O lt O 9 O O O 3 O 7 gt A 1 2 Attaching the shafts moveable base and spring covers N CAUTION It is necessary to enter the safety enclosure in order to detach or attach the shafts moveable base or spring covers and therefore the co
58. ism attachment l Press fit the plastic bearings into the b Step1 Plastic bearing plate plate Refer to Plastic bearing replacement in Chapter 7 for details Plastic bearing Plate N CAUTION Pay attention to the attachment direction It will not be possible to attach the shaft if the plate and plastic bearing directions are not as shown on the right 2 Attach the spring Ensure that the plates are bilaterally symmetrical For two shafts two of the assemblies shown on the right are required at the arm side and two assemblies gt are required at the moveable base side Step 2 Spring attachment 3 Secure the plastic blocks with M3 SCrews As shown on the right press the protruding part of the plastic block against the protruding part of the plate and then secure with the screws Attach the plate to the other plastic block attachment surface on the other side after attaching to the shaft N CAUTION Force is applied to the plastic when tightening and therefore care should be taken to avoid over tightening gt Step3 Securing the plastic blocks wm 9 O 3 O O O 3 D Y O O O 3 O A Attach the plate and plastic block gt Step 4 Assembly attachment locations assembly to the shaft Insert the plastic bearing attached to the plate so that it catches on the shaft pin Pin M NOTE M M The assembly is attached at both the arm
59. k ball against tool ball on the end of the arm contacts the top of the calibration tool Calibration tool Apply the motor brake for a axis 7 Remove the calibration tool from the base By loosening the M12 hex socket head bolt on the end of the calibration tool the tool comes away from the arm link ball Confirm this and then remove the calibration tool 8 Perform the procedure in Steps 3 to 7 for the y and axes also gt e C sa O 5 uI IO gt 4 4 1 2 Adjusting the 0 axis origin position 4 axes specification only The 9 axis origin position reference is the position in which the tool flange dowel hole is facing the a axis The axis is adjusted to the reference position when shipped from the factory however the position may shift slightly When installing the robot for the first time it is necessary to use the calibration tool to adjust the origin position CAUTION IN The tool flange is fixed on 3 axes robots and therefore it is only necessary to attach the moveable base in the correct direction Refer to 1 1 Attaching the shafts moveable base and spring covers in Chapter 5 for details on attaching the moveable base With the 4 axes robot it is necessary to adjust the 0 axis origin position in addition to attaching the moveable base in the correct direction The 0 axis origin position should generally never be changed If changed the axis may no longer move in the right direction l Post a sign
60. ly removed 2 3 5 Pull the cover out further gt Step 5 Temporarily removed cover Make a gap between the cover and base by pulling the cover out further M NOTE ai as The cover will catch at this point and so will not come off completely Cover bottom temporarily removed Cover top temporarily removed gt Q O gt O 2 Q O O Q Q je O O O 5 O O lt O gt 2 4 Pull out the cover gt Step 6 Grasp the sides of the cover and push both sides so that the bottom deforms a little to pull out the cover The clips on the inside near the switch will come free making it easier to pull out the cover without it catching The motor connector will catch on the hole on the side of the cover and so the cover should be shifted to avoid the connector The switch on the inside will catch on the motor connector and so the cover should be pulled out while trying to avoid the connector Pull out the cover Internal switch 2 5 gt O O u O O y O O u O O Q O 2 Q O O 5 O O lt O m Clip structure The cover clips will catch on the step of the bracket under the reduction gear There are two steps and the clips catch on the second step Clip construction Reduction gear Bracket Clip construction on inside Inside of removed cover Connection cable gt O O Q Q
61. ment procedure Detaching or attaching the 0 axis cover 0 axis motor cover removal 0 axis motor cover attachment 2 1 2 2 2 7 2 13 2 14 2 16 1 Attaching detaching and replacing the cover 1 1 Detaching or attaching the a B y axes covers WARNING A e IF THE COVERS ARE REMOVED FOR MAINTENANCE WORK BE SURE TO RETURN THEM TO THEIR ORIGINAL POSITIONS USING THE BOLTS USED TO SECURE THEM e IF ANY OF THE BOLTS BECOME LOST USE THE SPECIFIED BOLTS AND QUANTITIES TO SECURE THE COVERS WHILE REFERRING TO THE FIG BELOW e IF THE COVERS ARE NOT SECURED FIRMLY NOISE MAY OCCUR THE COVERS MAY DROP AND FLY OUT HANDS MAY BECOME ENTANGLED IN THE DRIVE UNIT DURING TEACHING OR COME INTO CONTACT WITH THE HOT DRIVE UNIT CAUSING BURNS OBSERVE THESE CAUTIONS STRICTLY TO PREVENT SUCH TROUBLE N CAUTION The a B and y axis motor cover construction does not comply with IP67 and therefore the inside of the cover should be cleaned periodically The motor and speed reduction gear inside the cover do comply with IP67 R6Y3 a axis axis NN A N 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks B y axes affixed with electric shock KDL M2163 00x gt Q O O O y O O O O Q 9 O O O 5 O O lt O caution label Motor cover KDL M2163 10x a axis warning label Seal KDL M2138 00x Motor cover attachment part 1 Cover securing bolt 97080 050
62. n is incorrect resulting in possible robot malfunction 7 USWSOIDHIIASI Bunpod IUSP Id gt 4 2 Plastic bearing inspection Measure the width of the gap between the two shaft joints with calipers and so on This measurement includes the width of two plastic bearings and therefore the amount of wear for one plastic bearing will be half of the measured value Example If the initial measurement value is 149 50mm and this value has reached 149 42mm when carrying out period measurement the amount of wear per bearing will be 0 04mm Plastic bearing replacement guideline when amount of wear reaches 0 5mm When replacing plastic bearings be sure to check and take a note of the measurement result and periodically measure the amount of wear Measurement method 7 m Plastic bearing wear debris precautions e Wear debris removal is necessary when cleaning in food related industries e Wear debris removal in industrial applications should be carried out as required USWSIDHIISI unpad IUSPId 5 lt OPTICA O axis seal O ring replacement Contents 1 0 axis seal O ring replacement procedure 1 1 0 axis seal O ring removal 8 1 1 2 0 axis seal O ring attachment 8 3 1 O axis seal O ring replacement procedure 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks Inside 0 axis housing Seal small KDL M219K 00x sid small side Inside 0 axis housin
63. nd therefore care should be taken when carrying out replacement work 3 Remove the relevant axis motor Refer to 1 1 a 6 y axis motor replacement procedure in Chapter 9 for details on motor replacement gt 10 4 A Loosen the bracket hex socket head bolts Loosen the length 20 M4 hex socket head bolts on the bracket used to secure the motor cover attached above and below the speed reduction gear The speed reduction gear can be easily removed by loosening the bracket Remove the bracket if still difficult to remove the speed reduction gear even after loosening Remove the M10 hex socket head bolts used to secure the speed reduction gear to the base Tighten the bolts with a tightening torque of 53Nm when reattaching Remove the speed reduction gear Keep the angle of the speed reduction gear steady and remove slowly while supporting with both hands If the angle is not kept steady and the speed reduction gear becomes stuck on the base it will be difficult to remove If the brackets used to secure the motor cover attached above and below the speed reduction gear become caught remove them CAUTION Do not apply excessive force to remove the speed reduction gear Doing so may result in gear malfunction gt Step 4 gt Step5 Loosen the M4 hex socket head bolts Hexssocket head bolt Speed reduction gear hex socket head bolt removal gt Step 6 Speed reduction gear removal 10 5
64. ng of each symbol and signal word and then read this manual DANGER A THIS INDICATES AN IMMEDIATELY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY WARNING THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY CAUTION This indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to the eguipment NOTE Explains the key point in the operation in a simple and clear manner A A 14 3 Warning labels Warning labels are attached to the robot body To ensure correct use read the warning labels and comply with the instructions 3 1 Warning labels WARNING IN IF WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE THEN THE NECESSARY PRECAUTIONS MAY NOT BE TAKEN RESULTING IN AN ACIDENT e DO NOT REMOVE ALTER OR STAIN THE WARNING LABELS ON THE ROBOT BODY e DO NOT ALLOW WARNING LABELS TO BE HIDDEN BY DEVICES INSTALLED ON THE ROBOT BY THE USER e PROVIDE PROPER LIGHTING SO THAT THE SYMBOLS AND INSTRUCTIONS ON THE WARNING LABELS CAN BE CLEARLY SEEN FROM OUTSIDE THE SAFETY ENCLOSURE 3 1 1 Contents of warning label messages Word messages on the danger warning and caution labels are concise and brief instructions For more specific instructions read and follow the Instructions on this label described on the right of each label shown below 1 Warning label 1 DANGER A
65. ntroller power must be turned off beforehand 1 2 1 R6Y30110S03067NJ5 3 axes specification The replacement procedure for the shafts moveable base and spring covers is the same as that for the a P and y axes l Post a sign indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller gt Step 3 Shaft attachment power Enter the safety enclosure Depression 3 Attach the shafts Attach the shafts while ensuring to hook the shaft plastic bearings onto the arm and moveable base link balls The link balls can be stretched by hand at the end of the shaft as shown in the Fig The depression on the shafts for spring cover attachment should face upward The moveable base attachment direction is as shown in the Fig Refer to 1 2 Adjusting the 0 axis origin position in Chapter 4 for details CAUTION IN By attaching the shafts with hands placed anywhere other than the shaft end the joint between the shaft and shaft end may deform possibly leading to malfunction Ensure to place hands on the end of the shaft as shown in the Fig on the right Take care not to pull the springs on the shafts too much If stretched too far the springs may not return to their original shape possibly leading to malfunction Moveable base side nm gt 3 lt O O O O O O O O Q gt Q O 9 O O lt O O 9 O O D 3 O
66. on is lost after disconnecting the robot cable connecting the controller with robot 2 If the origin position is lost after disconnecting the 0 axis cables from the 0 axis motor cover connectors and controller side robot cable connector 3 If the motor is replaced same reason as above 4 If any of the axis arms are removed CAUTION A e If any ofthe above situations occur after purchasing the robot it is necessary to adjust the origin position s using the calibration tool The robot origin positions are adjusted at the factory e Always use the calibration tool to perform origin position adjustment If adjusted without using the calibration tool the position will shift resulting in abnormal robot operation leading to robot damage and possible bodily injury This manual describes the origin position adjustment method using the calibration tool 1 Replacement parts Part Name OMRON Part No Part No Specs Remarks KDL M1501 YYY For a B and y axes Origin position jig KDL M1176 00x For 0 axis 0 axis origin position jig gt 2 C s O gt 91312 05008 MS length 8 securing bolt uIBLIO 4 1 lt 1 1 Adjusting the a B and y axis origin position The a B and y axis origin positions are shown in the Fig below Adjust each axis to its respective origin positions using the calibration jig a B y axis origin positions Do not attach tubing to 0 axis
67. ous accidents Always take the following safety measures and checks to ensure safe operation DANGER A CHECK THE FOLLOWING POINTS BEFORE STARTING ROBOT OPERATION e NO ONE IS WITHIN THE ROBOT SAFETY ENCLOSURE e THE ROBOT AND PERIPHERAL EQUIPMENT ARE IN GOOD CONDITION 4 5 1 Trial operation Refer to the controller user s manual after carrying out robot installation adjustments inspection maintenance or repair 4 5 2 Automatic operation To perform the automatic operation follow the instructions stated in the controller manual 4 5 3 Precautions during operation 1 When the robot is damaged or an abnormal condition occurs WARNING IN e IF UNUSUAL ODORS NOISE OR SMOKE OCCUR DURING OPERATION IMMEDIATELY TURN OFF POWER TO PREVENT POSSIBLE ELECTRICAL SHOCK FIRE OR BREAKDOWN STOP USING THE ROBOT AND CONTACT YOUR DISTRIBUTOR e IF ANY OF THE FOLLOWING DAMAGE OR ABNORMAL CONDITIONS OCCURS THE ROBOT THEN CONTINUING TO OPERATE THE ROBOT IS DANGEROUS IMMEDIATELY STOP USING THE ROBOT AND CONTACT YOUR DISTRIBUTOR Damage or abnormal condition Type of danger Damage to machine harness or robot cable Electrical shock robot malfunction Damage to robot exterior Damaged parts fly off during robot operation Abnormal robot operation position deviation vibration etc Robot malfunction a axis B axis or y axis brake malfunction Shaft or movable base falling or related part fly off 2 High temperature hazard WARNING
68. pecification B and y axes 4 axes specification a axis motor cable side KDL M150E 00x es 4 axes specification a axis encoder cable side KDL M150F 00x na 4 axes specification KDL M1562 00x Shaft filler plug 1 1 Quantity per axis 1 1 Detaching the shafts moveable base and spring cover With the R6Y31110L03067NJ5 and R6Y31110H03067NJ5 4 axes specification robots the cable protrudes from the a axis Shaft Shaft moveable base and spring cover detachment is the same as that for the 3 axes specification robot N CAUTION It is necessary to enter the safety enclosure in order to detach or attach the shafts moveable base or spring covers and therefore the controller power must be turned off beforehand l Post a sign indicating that the robot is being adjusted Post a sign indicating that the robot is being adjusted to prevent others from turning on the controller power 2 Enter the safety enclosure nm el lt O O O O O O O O Q Q O 9 O O lt O O Y O O O 3 O A 9 1 nm gt el 2 lt O O O O O O O O Q Q O 9 O O lt O O Y O O O 3 O 3 Remove the spring covers gt Step3 Spring cover removal There are a total of six spring covers one at the arm and one at the moveable base for each of the three axes There is a top spring cover and bottom spring cover with the top cover being wider Th
69. r cables and poor cable contact will cause the controller or robot to malfunction 3 Precautions for cable routing and installation CAUTION A e Be sure to store the cables connected to the robot in the duct or clamp them securely in place If the cables are not stored in a conduit or properly clamped excessive play or movement or mistakenly pulling on the cable may damage the connector or cables and poor cable contact will cause the controller or robot to malfunction e Do not modify the cables and do not place any heavy objects on them Handle them carefully to avoid damage Damaged cables may cause malfunction or electrical shock e Ifthe cables connected to the controller may possibly become damaged protect them with an appropriate cover etc e Check that the control lines and communication cables are routed at a gap sufficiently away from main power supply circuits and power lines etc Bundling them together with power lines or close to power lines may cause faulty operation due to noise 4 Protective measures against electrical shock WARNING A ALWAYS GROUND THE ROBOT BODY EARTH TERMINAL FAILURE TO DO SO MAY RESULT IN ELECTRIC SHOCK S 7 lt SUOIJONIISU JSJOS 4 4 Safety measures 4 4 1 Safety measures 1 A A 2 A SUOIJONIISU JSJOS 3 A Referring to warning labels and manual WARNING e BEFORE STARTING INSTALLATION OR OPERATION OF THE ROBOT BE SURE TO READ THE WARNING LABELS AND THIS
70. rvicing of the system WARNING A TO CHECK THE ROBOT CONTROLLER OPERATING STATUS REFER TO THE RELATED MANUALS DESIGN AND INSTALL THE SYSTEM INCLUDING THE ROBOT CONTROLLER SO THAT IT WILLALWAYS WORK SAFELY 6 Do not modify WARNING A NEVER ATTEMPT TO MODIFY THE ROBOT DO NOT OPEN ANY COVER DOING SO MAY CAUSE ELECTRICAL SHOCK BREAKDOWN MALFUNCTION INJURY OR FIRE 4 4 2 Installing a safety enclosure Be sure to install a safety enclosure to keep anyone from entering within the movement range of the robot The safety enclosure will prevent the operator and other persons from coming in contact with moving parts of the robot and suffering injury DANGER A SERIOUS INJURY MAY RESULT FROM CONTACT WITH A MOVING ROBOT e KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION e PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE WARNING A e INSTALL AN INTERLOCK THAT TRIGGERS EMERGENCY STOP WHEN THE DOOR OR GATE OF THE SAFETY ENCLOSURE IS OPENED e THE SAFETY ENCLOSURE SHOULD BE DESIGNED SO THAT NO ONE CAN ENTER INSIDE EXCEPT FROM THE DOOR OR GATE EQUIPPED WITH AN INTERLOCK DEVICE e WARNING LABEL 1 SEE 3 WARNING LABELS IN SAFETY INSTRUCTIONS THAT COMES SUPPLIED WITH A ROBOT SHOULD BE AFFIXED TO AN EASY TO SEE LOCATION ON THE DOOR OR GATE OF THE SAFETY ENCLOSURE S 9 SUOIJONIISU A19JOS SUOIJONIISU JOJOS 4 5 Operation When operating a robot ignoring safety measures and checks may lead to seri
71. s To use robots safely and correctly be sure to strictly observe the safety rules and instructions e For specific safety information and standards refer to the applicable local regulations and comply with the instructions e Warning labels attached to the robots are written in English Japanese Chinese and Korean This manual is available in English or Japanese or some parts in Chinese Unless the robot operators or service personnel understand these languages do not permit them to handle the robot e Cautions regarding the official language of EU countries For equipment that will be installed in EU countries the language used for the manuals warning labels operation screen characters and CE declarations is English only Warning labels only have pictograms or else include warning messages in English In the latter case messages in Japanese or other languages might be added It is not possible to list all safety items in detail within the limited space of this manual So please note that it is essential that the user have a full knowledge of safety and also make correct judgments on safety procedures S 1 lt SUOIJONIISU A19JOS SUOIJONIISU A19JOS 2 Signal words used in this manual This manual uses the following safety alert symbols and signal words to provide safety instructions that must be observed and to describe handling precautions prohibited actions and compulsory actions Make sure you understand the meani
72. s operating methods inspection or maintenance that does not comply with industry standards or instructions specified in the OMRON manual Usage that exceeded the specifications or standard performance shown in the OMRON manual Product usage other than intended by OMRON Storage operating conditions and utilities that are outside the range specified in the manual Damage due to improper shipping or shipping methods Accident or collision damage Installation of other than genuine OMRON parts and or accessories oOo N A oa A O N Modification to original parts or modifications not conforming to standard specifications designated by OMRON including customizing performed by OMRON in compliance with distributor or customer requests 9 Pollution salt damage condensation 10 Fires or natural disasters such as earthquakes tsunamis lightning strikes wind and flood damage etc 11 Breakdown due to causes other than the above that are not the fault or responsibility of OMRON 12 Electrical shock when the user installs the actuator etc on the movable base or end effector in the 3 axis specifications m The following cases are not covered under the warranty 1 Products whose serial number or production date month amp year cannot be verified 2 Changes in software or internal data such as programs or points that were created or changed by the customer 3 Products whose trouble cannot be reproduced or identified by OMR
73. sition following replacement JUOLUSDD Cel WUD INS Uuoyonpei poods iS 10 1 lt 2 Speed reduction gear and arm replacement procedure The replacement procedure and precautions for speed reduction gears and arms are listed below Refer to the following table for bolt tightening torque values required when replacing speed reduction gears or arms However please follow the instructions given at each replacement procedure for the tightening torque applied to bolts used to secure reduction gears and arms OMRON bolts should be used m Bolt tightening torque Bolt size Tightening torque kgfcm Tightening torque Nm M3 set screw M3 M4 M4 4 axes specification a axis arm cable clamp M6 M8 Recommended Screw Lock LOCTITE 241 made by Henkel Corporation pA a B y axis arm replacement WARNING A CARRY OUT REPLACEMENT AFTER READING 1 DETACHING ATTACHING AND REPLACING THE COVERS IN CHAPTER 2 M NOTE The arm replacement procedure is the same for the a B and y axes The requirements for a B and y axis arm replacement are as follows 1 Replacement parts juanda UD 110980 UOYONpel poods S Part Name OMRON Part No Part No Specs Remarks KDL M1520 00x Arm securing bolt 91312 08020 MS length 20 Cap KDL M1561 00x Arm attachment part link ball KDL M152A 00x Cable attachment part Bolt hole filler plug 2 KDL M1562 10x KDL M1573 00x Plastic block
74. t and parts replacement CAUTION A e If adjustment or replacement is deemed necessary following inspection turn off the controller power before entering the safety enclosure to carry out work If checking operation after work is complete do so in accordance with m Inspection with the controller turned off described above e If robot repair or part replacement is deemed necessary contact your distributor Such repair and part replacement requires specialized technical knowledge and must not be carried out by the user p 3 2 3 Monthly inspection This inspection is carried out once a month Pay attention to the following if applying grease to the 0 axis assembly WARNING A PRECAUTIONS WHEN HANDLING GREASE e INFLAMMATION MAY OCCUR IF THIS GETS IN THE EYES BEFORE HANDLING THE GREASE WEAR YOUR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES e USE FOOD GREASE CASSIDA GREASE EPS2 WHEN USING THE ROBOT AT FOOD PLANTS e INFLAMMATION MAY OCCUR IF THE GREASE COMES INTO CONTACT WITH SKIN BE SURE TO WEAR PROTECTIVE GLOVES TO PREVENT CONTACT WITH SKIN e DO NOT TAKE ORALLY OR EAT EATING WILL CAUSE DIARRHEA AND VOMITING e KEEP OUT OF THE REACH OF CHILDREN e DO NOT HEAT THE GREASE OR PLACE NEAR AN OPEN FLAME SINCE THIS COULD LEAD TO SPARKS AND FIRES EMERGENCY TREATMENT IF THIS GREASE GETS IN THE EYES WASH LIBERALLY WITH PURE WATER FOR ABOUT 15 MINUTES AND CONSULT A PHYSICIAN FOR TR
75. taken as needed to prevent hazardous situations due to sudden or unexpected robot operation or faulty robot operation as listed below e Place a display sign on the operator panel e Ensure the safety of workers performing tasks within the robot safety enclosure e Clearly specify position and posture during work Specify a position and posture where worker can constantly check robot movements and immediately move to avoid trouble if an error problem occurs e Take noise prevention measures e Use methods for signaling operators of related equipment e Use methods to decide that an error has occurred and identify the type of error Implement the work instructions according to the type of robot installation location and type of work task When drawing up the work instructions make an effort to include opinions from the workers involved eguipment manufacturer technicians and workplace safety consultants etc Take safety measures DANGER e NEVER ENTER THE ROBOT MOVEMENT RANGE WHILE THE ROBOT IS OPERATING OR THE MAIN POWER IS TURNED ON FAILURE TO FOLLOW THIS WARNING MAY CAUSE SERIOUS ACCIDENTS INVOLVING INJURY OR DEATH INSTALL A SAFETY ENCLOSURE OR A GATE INTERLOCK WITH AN AREA SENSOR TO KEEP ALL PERSONS AWAY FROM THE ROBOT MOVEMENT RANGE e WHEN IT IS NECESSARY TO OPERATE THE ROBOT WHILE YOU ARE WITHIN THE ROBOT MOVEMENT RANGE SUCH AS FOR TEACHING OR MAINTENANCE INSPECTION TASKS BE SURE TO INSTALL AN ENABLE DEVICE IN THE EXTERNAL SAFETY CIRCUIT
76. tening torque 2Nm gt O O O O y O O O O Q 2 Q O O gt O O lt O 2 17 lt A Connect the cable connectors to the gt Step 4 6 Cable routing inside motor cover inside of the cover Connect both the motor cable connector and encoder cable connector Encoder cable Motor cable y XA Si connector Attach the two earth bolts N WARNING FAILURE TO ATTACH THE EARTH BOLTS MAY RESULT IN ELECTRIC SHOCK 6 Replace the 0 axis motor cover CAUTION A e Route the cables on the inside of the 0 axis motor cover so that they do not contact the O rings Prolonged contact with the O rings may cause them to shift leading to a possible loss of waterproofing properties e Do not bend the cables excessively or apply excessive force when replacing the 0 axis motor cover Failure to observe this may result in cable damage 7 Secure the 0 axis motor cover to the moveable base Attach the washers to the 0 axis motor cover fit the MA hex bolts to the washers and then tighten with a spanner gt Step7 Washer attachment 2 O O O O O un O Q gt Q 9 O O O gt O O lt O 2 18 CPT Periodic inspection 1 2 3 4 Contents Overview Daily inspection Monthly inspection Six month inspection 1 Overview Daily and periodic inspection of the OMRON robot is essential in order to
77. tep 6 the 0 axis motor cover when replacing the cables inside the motor cover The motor cable and encoder cable will both be removed Remove the four length 6 M3 hex bolts from the connector connection on the outside of the 0 axis motor cover and pull the cables toward the outside of the cover If replacing the cables inside the cover also replace both of the connector O rings gt Step 6 Cable removal motor cable side O ring motor cable side Pull toward outside of cover Cable removal encoder cable side O ring encoder cable side er 2 15 lt 19402 au Budo dal pub HuIyoPIop OUIUOPIIV 7 Disconnect the motor cable and gt Step 7 Motor side motor cable encoder cable removal encoder cable from the 0 axis motor when replacing the motor speed reduction gear Encoder cable Motor cable 1 2 2 0 axis motor cover attachment Attach the cover using the opposite of the procedure used for removal A CAUTION 22770000000 gt Step 1 Motor side motor cable encoder cable connection When attaching the 0 axis motor cover first disconnect the cable from the outside of the motor cover and then remove the moveable base from the a B and y axis shafts before proceeding There is a risk of bodily injury if the cable is damaged or a robot malfunction occurs inside the robot movement range Encoder cable Connect the motor cable and encoder Motor c
78. tors and or end users implement the machinery safety design that conforms to ISO12100 or JIS9700 1 2 Residual risks for OMRON robots are described in the DANGER or WARNING instructions provided in each chapter and section So read them carefully 6 3 Special training for industrial robot operation Operators or persons who handle the robot for tasks such as for teaching programming movement checks inspections adjustments and repairs must receive appropriate training and also have the skills needed to perform the job correctly and safely They must also read the manual carefully to understand its contents before attempting the robot operation or maintenance Tasks related to industrial robots teaching programming movement check inspection adjustment repair etc must be performed by qualified persons who meet requirements established by local regulations and safety standards for industrial robots gt S 14 Comparison of terms used in this manual with ISO maximum space Area limited by mechanical stoppers restricted space Area limited by movable mechanical stoppers operational space Area limited by software limits safeguarded space 9 15 Warranty For information on the warranty period and terms please contact our distributor where you purchased the product WM This warranty does not cover any failure caused by 1 Installation wiring connection to other control device
79. warning labels and understand the contents CAUTION A Attach the warning label that has been included in the robot at shipment to a legible location close to the robot such as entrance of the safety enclosure 3 2 Warning symbols Warning symbols shown below are attached to the robot body to alert the operator to potential hazards To use the OMRON robot safely and correctly always follow the instructions and cautions indicated by the symbols 1 Electrical shock hazard symbol WARNING A TOUCHING THE TERMINAL BLOCK OR CONNECTOR MAY CAUSE ELECTRICAL SHOCK SO USE CAUTION Instructions by this symbol This indicates a high voltage is present Touching the terminal block or connector may cause electrical shock 2 High temperature hazard symbol WARNING A MOTORS HEATSINKS AND REGENERATIVE UNITS BECOME HOT SO DO NOT TOUCH THEM Instructions by this symbol This indicates the area around this symbol may become very hot Motors heatsinks and regenerative units become hot during and shortly after operation To avoid burns be careful not to touch those sections 4 Major precautions for each stage of use This section describes major precautions that must be observed when using robots Be sure to carefully read and comply with all of these precautions even if there is no alert symbol shown 4 1 Precautions for using robots General precautions for using robots are described below 1 Applications wher

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