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INSTALLATION MANUAL

1. 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 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 a axis p axis or y axis brakes An electromagnetic brake is installed on the a axis P axis and y axis to prevent them from sliding downward when the servo is OFF WARNING A 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 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 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 integrators 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
2. r Density kg m kg cm 5 g Gravitational acceleration cm sec m Mass of cylinder kg W Weight of cylinder kgf 2 15 lt Ya o o O gt gt 2 16 In the same manner the moment of inertia of a cylinder as shown in the Fig below is given by Moment of inertia of a cylinder Centerline gt rpD h D h tpD h x I 16 4 3 4 m D h a mx kgm 4 4 3 rpD h D h rpD h x 16g 4 3 4g h W D h Wx SE DE kgfemsec 4g 3 1 6 In the same manner the moment of inertia of a prism as shown in the Fig below is given by Moment of inertia of a prism Center line lt D rabc a b m a b E rabex mx kgm 12 12 rabc a b rabex J 12g g W a b Wx 2 kgfcmsec 12g g N m Mass of prism kg W Weight of prism kgf 6 3 Example of moment of inertia calculation Let s discuss an example in which the chuck and workpiece are at a position offset by 10cm from the 0 axis by the stay as shown in the Fig below The moment of inertia is calculated with the following three factors assuming that the load material is steel and its density p is 0 0078kg cm Example of moment of inertia calculation The chuck and workpiece are at a position offset by 10cm from the 0 axis by the stay 0 axis I I I I I I I 5
3. The cover will catch at this point and so will not come off completely Cover bottom temporarily removed gt wn Q Q O gt Cover top temporarily removed gt 2 24 Pull out the cover gt Step6 Pull out the cover 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 wn Q Q O gt Internal switch 2 25 M Clip structure The cover clips will catch on the step on the bracket below the reduction gear There are two steps and the clips catch on the second step Clip construction Reduction gear Bracket wn Q o O gt Clip construction on inside Inside of removed cover Connection cable Brake release switch gt 2 26 8 1 2 a B 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 AXIS B AXIS AND y AXIS CONNECT THE CABLES SO THAT THEY MATCH THE RESPECTIVE AX
4. e Q Q O 6cm Le Chuck Workpiece 4cm 1 Moment of inertia of the stay Moment of inertia of the stay Center line TD The weight of the stay Ws is given as follows Ws rabc 0 0078 x 12 x 2 x 2 0 37 kgf The moment of inertia of the stay Js is then calculated from Eq 7 0 37 x 1222 0 37 x 5 i Js 0 014 kgfemsec 12 x 980 980 2 17 lt gt wn o o O gt 2 Moment of inertia of the chuck Moment of inertia of the chuck 0 axis 6cm 3 Moment of inertia of workpiece Moment of inertia of workpiece 10cm 0 axis 4cm 2cm 4 Total weight When the chuck form resembles that shown in figure the weight ofthe chuck We is We 0 0078 x 2 x 4 x 6 0 37 kgf The moment of inertia of the chuck Jc is then calculated from Eq 7 0 37 x 2 4 0 37 x 10 Je 12 x 980 980 0 038 kgfemsec When the workpiece form resembles that shown in figure the weight of the workpiece Ww is D h 0 0078p x 2 x 4 ww P n p 4 4 0 098 kgf The moment of inertia of the workpiece Jw is then calculated from Eq 5 0 097 x 2 0 097 x 10 Jw 8 x 980 980 0 010 kgfemsec The total weight W is calculated as follows W Ws Wc Ww 0 84 kgf 5 Total moment of inertia The total moment of inertia J is then obtained as follows J Js Jc Jw 0 062 kgfemsec 2 18 6
5. the origin position in the following cases 1 If the origin position 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 Ifany of the axis arms are removed A CAUTION ur Ifany of the 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 spulas Joqoy gt 3 2 2 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 o p Eyebolts 3 locations a 1067 o a N Te T a ale e a wi A 042 65 4 M5x0 8 depth 8 920 depth
6. 3 Rel 8 15 75 0 02 View A 95H7 6 depth 10 3 3 lt Calibration tool a B and y axis 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 AJ O o O ta wn gt Q wn gt Step 3 Securing the calibration tool 3 Secure the calibration tool to the base we Secure the end of the calibration tool to the jig Bi attachment holes on the base with the M12 hex Mi2ihextsocket head bolt socket head bolts provided The arm is moved at Step 5 and if it hits the de Calibration tool tool move the arm to a position above the tool at y a Step 5 apply the brake secure the tool and then perform Steps 4 and 5 calibration tool at that time temporarily secure the 4 Release the motor brake for a axis CAUTION A 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 gt 3 4 Move the arm slowly until the link gt Step5 Position link ball against tool ball on the end of the arm contacts the top of the calibration tool Calibrationftool Apply the motor brake for a axis Remove the calibration tool from the base By loosening the M12 hex socket
7. ADJUSTMENT BY REMOVING A COVER REQUIRE 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 THE PRODUCT E 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 A 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 or cables and poor cable contact will cause the controller or robot to malfunction 3 Precautions for cable routing and installation CAUTION A 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
8. 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 OMRON ROBOTS ARE NOT DESIGNED TO BE EXPLOSION PROOF 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 E 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 E Installation 1 Protect electrical wiring 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 gt S 6 E Adjustment 1 Adjustment that requires removing a cover WARNING A
9. MAXIMUM MOVEMENT RANGE Note that the robot s TCP tool center point movement range is larger than the actual working envelope Be sure to specify the robot working envelope at the controller side Movement range wn Q Q O gt Cabl E 350 81200 arm rotation range interference 1800 tool movement range x Arm rotation range 255 x N N A tH Pol 2 LL a ca ma F el g n er S n ER 5 u Tool movement area I l ool movement area S I N I RIO I I S a N x t I a No gt gt NS ie Y lt lt 7 Su pe 6580 81100 gt 2 20 8 Detaching or attaching the covers 8 1 Detachingor attaching the a B and y axes covers WARNING A IF THE COVERS ARE REMOVED FOR MAINTENANCE WORK BE SURE TO RETURN THEM TO THEIR ORIGINAL POSITIONS USING THE SCREWS AND BOLTS USED TO SECURED THEM IF ANY OF THE SCREWS OR BOLTS BECOME LOST USE THE SPECIFIED SCREWS BOLTS AND QUANTITIES TO SECURE THE COVERS WHILE REFERRING TO THE FIG BELOW 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 A CAUTION The a and y axes motor cover construction does not c
10. 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 A gt S 10 WARNING 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 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 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 4 If the a axis B axis y axis or 8 axis rotation angle is small A WARNING 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 IT BECOMES DIFFICULT TO FORM AN OIL FILM ON THE SPEED REDUCTION GEAR THIS MAY SHORTEN THE SERVICE LIFE OF THE SPEED REDUCTION GEAR IN THIS TYPE OF OPERATION ADD A RANGE OF MOTION SO THAT EACH AXIS MOVES THROUGH 120 DEGREES OR MORE ABOUT 5 TIMES A DAY 4 6 Inspec
11. Usually the 0 axis load is not a simple form and the calculation of the moment of inertia is not easy As a method the load is replaced with several factors that resemble a simple form for which the moment of inertia can be calculated The total of the moment of inertia for these factors is then obtained The objects and equations often used for the calculation of the moment of inertia are shown below Incidentally there is the following relation J kgfemsec I kgm x 10 2 1 Moment of inertia for material particle The equation for the moment of inertia for a material particle that has a rotation center such as shown in the Fig below is as follows This is used as an approximate equation when x is larger than the object size Moment of inertia for material particle CD I mx kgm 2 kgfemsec Ya Q o O 1 g Gravitational acceleration cm sec m Mass of material particle kg W Weight of material particle kgf 2 Moment of inertia for cylinder part 1 The equation for the moment of inertia for a cylinder that has a rotation center such as shown in the Fig below is given as follows Moment of inertia for cylinder part 1 rpD h mp kgm 32 rpD h WD J kgfemsec 32g 8g h O r Density kg m kg cm H Gravitational acceleration cm sec m Mass of cylinder kg W Weight of cylinder kgf gt 2 14 3 Moment of inertia
12. axes specification The replacement procedure for the shafts moveable base and spring covers is the same as that for the a and y axes gt Step 3 Shaft attachment 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 Depression power 5 wn Q Q O gt Enter the safety enclosure 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 2 2 Adjusting the 0 axis origin position in Chapter 3 for details CAUTION A 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 Arm side 2 33 lt 4 Attach the spring covers gt Step4 Spring cover attachment There are a total of six spring covers one at the arm and one at the moveable
13. 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 wn Q o O gt The top of the spring cover widens Spring cover top Spring coverjbottom gt 2 34 9 1 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 1 Post a sign indicating that the robot gt 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 Enter the safety enclosure 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 2 2 Adjusting the 9 axis origin 5 wn Q Q O gt positi
14. for cylinder part 2 The equation for the moment of inertia for a cylinder that has a rotation center such as shown in the Fig below is given as follows Moment of inertia for cylinder part 2 rp D h D h m p h E el kgm CD 16 4 3 4 4 3 rp D h D h W D h E ai kgfemsec 16g 4 3 4g 4 3 D a 3 h r Density kg m kg cm Gravitational acceleration cm sec la h m Mass of cylinder kg W Weight of cylinder kgf wn Q Q O gt 4 Moment of inertia for prism The equation for the moment of inertia for a prism that has a rotation center as shown in the Fig below is given as follows Moment of inertia for prism gt rabc a b m a b _ km 12 12 rabc a b W a b kgfenmsec 12g 12g cu 4 r Density kg m kg cm g Gravitational acceleration cm sec m Mass of prism kg W Weight of prism kgf 5 When the object s center line is offset from the rotation center The equation for the moment of inertia when the center of the cylinder is offset by the distance x from the rotation center as shown in the Fig below is given as follows When the object s center line is offset from the rotation center Center line 1 rpD h x rpD hx mD mud a a gm Rotation 32 hi 8 center rpD h rpD hx A AA SOL 32g 4g WD Wx kgfemsec i 8g g 5
15. 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 Perform the procedure in Steps 3 to 7 for the y and f axes also Calibration tool A O o O wn wn 3 5 lt 2 2 Adjusting the 0 axis origin position 4 axes specification only The 0 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 A 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 9 1 Attaching the shafts moveable base and spring covers in Chapter 2 for details on attaching the moveable base With the 4 axes robot it is necessary to adjust the 0 axis origin 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 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 3 Secure
16. not avoided could result in minor or moderate injury or damage to the equipment Lal NOTE Explains the key point in the operation in a simple and clear manner gt S 2 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 A IF WARNING LABELS ARE REMOVED OR DIFFICULT TO SEE THEN THE NECESSARY PRECAUTIONS MAY NOT BE TAKEN RESULTING IN AN ACIDENT DO NOT REMOVE ALTER OR STAIN THE WARNING LABELS ON THE ROBOT BODY DO NOT ALLOW WARNING LABELS TO BE HIDDEN BY DEVICES INSTALLED ON THE ROBOT BY THE USER 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 SERIOUS INJURY MAY RESULT FROM CONTACT WITH A MOVING ROBOT KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE Instructions on this label DANGER fe Pz Always install a safety enclosure to keep all persons away from the robot movement range and prevent injury from Sl 3 a 63 c
17. socket head bolts as shown in the Fig below WARNING A WHEN INSTALLING THE ROBOT BE SURE TO USE THE SPECIFIED SIZE AND QUANTITY OF BOLTS THAT MATCH THE DEPTH OF TAPPED HOLES IN THE INSTALLATION BASE AND SECURELY TIGHTEN THE BOLTS WITH THE CORRECT TORQUE IF THE BOLTS ARE NOT TIGHTENED CORRECTLY THE ROBOT MIGHT DROP OR FALL OVER If using M12 tapping holes on robot base If using 016 through holes on robot base M12 M14 Bolts Used Tightening torque 128Nm 1310 kgfem 205Nm 2090 kgfem Depth of tapped holes in installation base Iron installation base Bolt diameter x 1 5 or more Aluminum installation base Bolt diameter x 3 0 or more Recommended bolt JIS B 1176 hex socket head bolt or equivalent Strength class JIS B 1051 12 9 or equivalent Attachment area details UOIDI O4SU uspension eyebolt 950 position M4x0 7 depth 8 Attention should be paid to installation range for securing cables Installation surface details gt 2 8 3 Protective bonding A WARNING ALWAYS GROUND THE ROBOT TO PREVENT ELECTRIC SHOCK TURN OFF THE CONTROLLER BEFORE GROUNDING THE ROBOT Provide a terminal marked PE for the protective conductor of the entire system and connect it to an external protective conductor In addition securely connect the ground terminal on the robot pedestal to the same protective conductor See the Fig below Symbol 417 IEC 5019 Example
18. 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 AO O O O j wn D gt Q wn Tool flange a axis 4 Align the 0 axis calibration tool pin with the tool flange dowel hole gt 3 6 Secure at the two tool flange M5 holes Securing the calibration tool Dowel hole Secure at these two points 0 axis calibration tool AJ O o O f wn Q wn 0 axis calibration tool 3 7 lt 3 Setting the soft limits With the R6Y3 robot by setting the plus and minus soft limits for each axis with the origin position 0 as the reference the movement range is limited by setting the movement angle from the 0 position Refer to the controller user s manual when setting the soft limits A CAUTION When performing actual checks of the soft limit settings operate the robot manually from outside the safety enclosure NOTE La Refer to 1 2 External view and dimensions in Chapter 5 for the robot movement range 3 1 Setting the a B and y axis soft limits Set the soft limits within the movement range or within the range where the robot does not interfere with peripheral equipment but within movement range Furthermore reduce the soft limits to narrow the movement range when the actual movement range of the robot is small or it interferes with the peripheral equipment The reference v
19. 4 Attaching the end effector It is necessary to prepare the user s end effector attaching part to the robot that has adequate strength and rigidity as well as gripping force to prevent positioning errors WARNING A BEFORE ATTACHING THE END EFFECTOR BE SURE TO TURN OFF THE CONTROLLER WHEN THE END EFFECTOR IS ATTACHED USING THE SLOT CLAMPING ALWAYS OBSERVE THE CONDITIONS LISTED IN THE TABLE MAXIMUM LOAD APPLIED TO END EFFECTOR ATTACHMENT IF THESE ARE IGNORED THE END EFFECTOR MAY COME LOOSE AND FLY OFF DURING ROBOT OPERATION RESULTING IN AN ACCIDENT OR INJURY NOTE La Refer to the controller user s manual for details on the end effector operation check The recommended end effector attachment method is shown below End effector attachment If attached to tool flange M5 hole wn Q Q O MS hole N WARNING ONLY USE THE TAP IN THE CENTER AT THE BOTTOM OF THE END EFFECTOR ATTACHMENT AREA FOR ATTACHING TUBING JOINTS End effector attachment area in detail ISO9409 65 H7 Depth 10 40 20 Depth 3 RZ N 4 M5x0 8 Depth 10 A e Le 2 19 lt 7 Working envelope and maximum movement range The robot s working envelope and maximum movement range are shown below E For a f and y axes WARNING A IN ORDER TO PREVENT INTERFERENCE WITH OTHER USER EQUIPMENT BE SURE TO PROVIDE ADEQUATE SPACE TO ACCOMMODATE THE ROBOT S MAXIMUM MOVEMENT RANGE INCLUDING THE ARM S
20. 5 REMOVE THE SHAFTS MOVEABLE BASE AND LOAD FROM THE END OF THE ROBOT ARM FAILURE TO REMOVE YN THESE LOADS MAY RESULT IN ROBOT MALFUNCTION oi DO NOT APPLY FORCE TO THE ROBOT BODY o WHEN UNPACKING THE ROBOT PLEASE PAY ATTENTION TO THE FOLLOWING ADDITIONAL POINT THE ARMS ARE ADJUSTED TO THEIR RESPECTIVE ORIGIN POSITIONS PRIOR TO SHIPPING AND THEREFORE O SHOULD NOT BE TOUCHED gt CAUTION e When moving the robot by equipment such as cranes that require a license only properly qualified personnel may operate it e The equipment and tools used for moving the robot should be serviced daily Refer to 1 1 Basic specifications in Chapter 5 for details on the robot weight 2 3 1 Installing on base prepared by user Lal NOTE The robot is fixed at the origin position when shipped from the factory 1 Pass three ropes through the eyebolts and hang them on the hoist Use looped ropes with the same length to allow a good lifting balance Remove the wooden screws securing the pallet and wooden supports 3 Hold the robot remove the bolts used to secure the wooden supports and robot body and then remove the wooden supports Slightly lift the hoist so that the tension is lightly applied to each rope to hold the robot and then remove the mounting bolts used to secure the wooden supports Wooden support bolt removal Bolts Wooden support gt 2 4 4 Move the robot Move the robot carefully to the installation base u
21. Delta Robot INSTALLATION MANUAL CONTENTS a 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 42 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 1 Introduction Before using the robot Be sure to read the following notes i Introduction ii CONTENTS Fr Installation Manual Chapter 1 Functions 1 Robot manipulator 1 1 1 1 Manipulator movement 1 1 1 2 Part names 1 2 Chapter 2 Installation 1 Robot installation conditions 2 1 1 1 Installation environments 2 1 1 2 Installation base 2 2 2 Installation 2 3 2 1 Unpacking 2 3 2 2 Checking the product 2 3 2 3
22. EN 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 KEEP OUTSIDE OF THE ROBOT SAFETY ENCLOSURE DURING OPERATION PRESS THE EMERGENCY STOP BUTTON BEFORE ENTERING THE SAFETY ENCLOSURE WARNING A INSTALL AN INTERLOCK THAT TRIGGERS EMERGENCY STOP WHEN THE DOOR OR GATE OF THE SAFETY ENCLOSURE IS OPENED THE SAFETY ENCLOSURE SHOULD BE DESIGNED SO THAT NO ONE CAN ENTER INSIDE EXCEPT FROM THE DOOR OR GATE EQUIPPED WITH AN INTERLOCK DEVICE WARNING LABEL 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 SUOION1 SU JOJOS SUOYONYSUJ JOJOS 4 5 Operation When operating a robot ignoring safety measures and checks may lead to serious accidents Always take the following safety measures and checks to ensure safe operation A DANGER CHECK THE FOLLOWING POINTS BEFORE STARTING ROBOT OPERATION NO ONE IS WITHIN THE ROBOT SAFETY ENCLOSURE THE ROBOT AND PERIPHERAL EQUIPMENT ARE IN GOOD CO
23. ES AT THE CONTROLLER DRIVER THE ROBOT WILL NOT OPERATE CORRECTLY RESULTING IN POSSIBLE DANGER IF THE CABLES ARE CONNECTED INCORRECTLY 1 Insert the motor wire from smaller DP Step 1 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 gt n Q Q O gt A CAUTION The encoder wire must pass through the inside of the cover and therefore a sufficient length of wire should be inserted Insert the encoder wire and brake 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 AO connector part should be the boot Brake rel i 4 Connect the cover internal switch nr connector and brake release GE connector Store the joint inside the cover The cable leading from the brake release connector should be prepared by the user I Switch connector and brake release gt Step 4 connector connection 2 27 wn Q Q O gt 2 28 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 o
24. GN 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 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 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 required for the individual system The system manufacturer should provide a proper manual for safe correct operation and servicing 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 WILL ALWAYS WORK SAFELY 6 Do not modify WARNING A NEVER ATTEMPT TO MODIFY THE ROBOT DO NOT OP
25. 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 END EFFECTORS MUST BE DESIGNED AND MANUFACTURED SO THAT THEY CAUSE NO HAZARDS SUCH ASA LOOSE WORKPIECE OR LOAD EVEN IF POWER ELECTRICITY AIR PRESSURE ETC IS SHUT OFF OR POWER FLUCTUATIONS OCCUR 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 adequate lighting Provide enough lighting to ensure safety during work S 5 SUONYONYSUJ JOJOS SUOYONYSUJ 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 EQUIPMENT 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
26. LIZED 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 SUONYONYSUJ JOJOS SUONYONYSUJ JOJOS 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 TURN OFF THE CONTROLLER AND PLACE A SUPPORT UNDER THE a AXIS B AXIS OR y AXIS BEFORE REMOVING THE MOTOR 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
27. MS THAT SIGNIFICANTLY AFFECT SOCIETY AND THE GENERAL PUBLIC e IN EQUIPMENT INTENDED TO CARRY OR TRANSPORT PEOPLE e IN ENVIRONMENTS WHICH ARE SUBJECT TO VIBRATION SUCH AS ONBOARD SHIPS AND VEHICLES 2 Qualification 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 qualified persons who meet requirements established by local regulations and standards for industrial robots WARNING A THE ROBOT MUST BE OPERATED ONLY BY PERSONS WHO HAVE RECEIVED SAFETY AND OPERATION TRAINING OPERATION BY AN UNTRAINED PERSON IS EXTREMELY HAZARDOUS ADJUSTMENT AND MAINTENANCE BY REMOVING A COVER REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS IF ATTEMPTED BY AN UNSKILLED PERSON THESE TASKS MUST BE PERFORMED ONLY BY PERSONS WHO HAVE ENOUGH ABILITY AND QUALIFICATIONS 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
28. Moving the robot 2 4 2 3 1 Installing on base prepared by user 2 4 2 3 2 Moving the robot to another installation base or removing the robot 2 5 2 4 Installing the robot 2 7 3 Protective bonding 2 9 4 Connection 2 10 4 1 Robot cable connection 2 10 4 2 Wiring the brake release wire connector 2 10 4 3 0 axis connection wiring specifications R6Y31110L03067NJ5 R6Y31110H03067NJ5 2 11 5 User tubing 2 12 6 Attaching the end effector 2 13 6 1 0 axis tolerable moment of inertia and acceleration 2 13 6 1 1 0 axis moment of inertia of load and acceleration coefficient 2 13 6 2 Equation for moment of inertia calculation 2 14 6 3 Example of moment of inertia calculation 2 17 6 4 Attaching the end effector 2 19 7 Working envelope and maximum movement range 2 20 8 Detaching or attaching the covers 2 21 8 1 Detaching or attaching the a B and y axes covers 2 21 8 1 1 a B y axis cover removal procedure 2 22 8 1 2 a B and y axis cover attachment procedure 2 27 CONTENTS nn Installation Manual 9 Detaching or attaching the shafts moveable base and spring covers 2 33 9 1 Attaching the shafts moveable base and spring covers 2 33 9 1 1 R6Y30110803067NJ5 3 axes specification 2 33 9 1 2 R6Y31110L03067NJ5 R6Y31110H03067NJ5 4 axes specification 2 35 9 2 Detaching the shafts moveable base and spring cover 2 38 Chapter 3 Robot settings 1 Overview 3 1 2 Adjusting the origin 3 2 2 1 Adjusting the a B and y axis ori
29. NDITION 4 5 After 1 Trial operation installing adjusting inspecting maintaining or repairing the robot check the trial operation items stated in the controller manual and perform the trial operation while strictly observing the instructions 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 A WARNING 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 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 P axis or y axis brake malfunction Shaft or movable base falling or related part fly off 2 High temperature hazard A WARNING DO NOT TOUCH THE ROBOT DURING OPERATION THE ROBOT BODY IS VERY HOT DURING OPERATION SO BURNS MAY OCCUR IF YOU TOUCH THESE SECTIONS THE MOTOR AND SPEED
30. OF THE REACH OF CHILDREN 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 TREATMENT IF THIS GREASE COMES IN CONTACT WITH THE SKIN WASH AWAY COMPLETELY WITH SOAP AND WATER IF TAKEN INTERNALLY DO NOT INDUCE VOMITING BUT PROMPTLY CONSULT A PHYSICIAN FOR TREATMENT DISPOSING OF GREASE AND THE CONTAINER PROPER DISPOSAL IS COMPULSORY UNDER FEDERAL STATE AND LOCAL REGULATIONS TAKE APPROPRIATE MEASURES IN COMPLIANCE WITH LEGAL REGULATIONS e DO NOT PRESSURIZE THE EMPTY CONTAINER PRESSURIZING MAY CAUSE THE CONTAINER TO RUPTURE DO NOT ATTEMPT TO WELD HEAT UP DRILL HOLES OR CUT THIS CONTAINER THIS MIGHT CAUSE THE CONTAINER TO EXPLODE AND THE REMAINING MATERIALS INSIDE IT TO IGNITE I O 5 N O O O gt 4 1 lt 2 List of inspection items WARNING A REFER TO THE INSPECTION ITEMS IN THE SEPARATE R6Y3 MAINTENANCE MANUAL WHEN CARRYING OUT INSPECTION Conduct O Conduct if trouble is found as a result of inspection A Contact your distributor Location Contents 6 month Cleaning Adjustment Replacement m Inspection with the controller turned off Robot cable Check for scratch dent or excessive bend User cable and wiring Check for scratch dent or excessive bend e Check air pressur
31. UJ JOJOS 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 HER SEFMNERFFNFRIERRNE ES HAS SA TA RETIRO oA ILE CHRIST 90K41 001290 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 warning labels and understand the contents A CAUTION 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 T
32. able base collide Take care to ensure that they do not collide A UONONPOALUI UONONPOALUI Introduction The OMRON R6Y3 industrial robot is a high speed multi joint parallel link industrial robot The R6Y3 parallel link mechanism features an a axis P axis and y axis motor arranged at 120 intervals on a base and realizes robot movement in the X Y and Z directions by rotating each axis up and down at the point TCP tool center point where each arm intersects in parallel By adding a 0 axis to the tip the tool can also be rotated 180 degrees in addition to the above mentioned movements The R6Y3 industrial robot is ideal for specialized high speed work such as part transport or box packing This user s manual describes safety measures handling adjustment inspection and maintenance of the R6Y3 robot to ensure correct safe and effective use Be sure to read this manual carefully before installing the robot Even after reading this manual keep it in a safe and convenient place for future reference This user s manual should be used with the robot and considered an integral part of it When the robot is moved transferred or sold send this manual to the new user along with the robot Be sure to explain to the new user the need to read through this manual For details regarding robot operation refer to the controller user s manual EI BE Functions 1 Robot manipulator 1 1 Manipulator movement 1 2 Partname
33. al 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 this manual relate to this product To ensure the safety of the user s final system that includes robots the user must take appropriate safety considerations 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 so
34. alues for the soft limits are as follows Plus direction soft limit Minus direction soft limit AJ O o O ta wn gt Q YN 3 2 Setting the 0 axis soft limits The 0 axis has no mechanical stoppers Set the 0 axis plus and minus soft limits to narrow the movement range when the actual 0 axis movement range of the robot is small or the robot interferes with the peripheral equipment gt 3 8 APTA Periodic inspection Contents 1 Overview 2 List of inspection items 1 Overview Daily and periodic inspection ofthe OMRON robot is essential in order to ensure safe and efficient operation Periodic inspection for the R6Y3 robot consists of daily inspection monthly inspection and 6 month inspection Be sure to perform the daily inspection before starting the robot and after completion of each day s work For details on inspection items see 2 List of inspection items in the next section For details on how to perform periodic inspection refer to the separate R6Y3 Maintenance Manual Before starting the maintenance work thoroughly read the following cautions and Safety Instructions to strictly observe the instructions M Cautions on daily inspection CAUTION A e Adjustment maintenance and parts replacement require specialized technical knowledge and skills and also may involve hazards These tasks must be performed only by persons who have enough and qualifications req
35. ation coefficient The moment of inertia of a load end effector and workpiece that can be attached to the end effector attachment area is limited by the strength of the robot drive unit and residual vibration during positioning It is therefore necessary to reduce the acceleration in accordance with the moment of inertia Model R6Y30110S03067NJ5 R6Y31110L03067NJ5 R6Y31110H03067NJ5 0 axis tolerable moment of 0 01kgm 0 035kgm inertia Methods for calculating the moment of inertia of the load are shown in 6 2 Equation for moment of inertia calculation and 6 3 Example of moment of inertia calculation However it is not easy to precisely figure out these values If a calculated value smaller than the actual moment of inertia is set residual vibrations may occur In such a case lower the acceleration even further wn Q Q O gt CAUTION A The robot must be operated with correct tolerable moment of inertia and acceleration according to the manipulator tip mass and moment of inertia Failing to observe this requirement could shorten the life of the drive units and cause robot damage due to vibration during positioning Depending on the position of the a and y axes X Y Z axes vibrations may occur during X Y or Z axis movement or during 0 axis rotation If vibrations occur lower the a B and y axes X Y Z axes and 0 axis acceleration 2 13 6 2 Equation for moment of inertia calculation
36. cify 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 equipment manufacturer technicians and workplace safety consultants etc Take safety measures DANGER 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 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 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 A DURING STARTUP OR MAINTENANCE TASKS DISPLAY A SI
37. de JN1HS10PL2 JAE Connection Remarks Blue White Yellow Brown 5 7 Q o Gg O gt Green Black Shield e Motor wire wiring left side is driver side NMS3101B 20 4 P NMS3057 12A JAE Connection Remarks Round terminal 2 11 lt 5 User tubing WARNING A THE ROBOT MAY MALFUNCTION DURING PIPING WORK AND THEREFORE THE AIR SUPPLY MUST ALWAYS BE TURNED OFF BEFOREHAND DO NOT RUN PIPES ALONG THE SHAFT OR ARM AT THE USER SIDE DOING SO MAY CAUSE PROBLEMS WITH OPERATIONS SUCH AS PICKUP The R6Y3 robot is equipped with an air tube attachment port for use by the user on the moveable base side of the robot The following air tubes may be used User tubing 86 x 1 Air tube specifications are shown below Always observe these specifications User tubing Maximum pressure 0 6Mpa 6 1 Kgf cm wn Q Q O gt Outer diameter x inner diameter o6mm x oAmm Fluid Dry clean air not containing deteriorated compressor oil ui filtration 401m or less The TCP side has a tapered screw hole for user tubing For the locations refer to 1 3 Robot inner wiring diagram in Chapter 5 gt 2 12 6 Attaching the end effector 6 1 0 axis tolerable moment of inertia and acceleration 6 1 1 0 axis moment of inertia of load and acceler
38. e Regulator Joint Check for air leak Air tube Solenoid valve e Check drain Air cylinder e Check air filter for clogging or damage Exterior of robot e Check for damage Plastic bearing Check for deformation dents link ball sliding surface e Check that wear is 0 5mm or less Plastic bearin g e Check for deformation breakage spring mechanism plate slidin spring d i Check for cracks surface Shaft e Check for deformation Spring cover e Check for damage Check for guide clip breakage Check for deformation Inside spring cover e Check the spring to see if it is overstretched spring plate etc e Check for M3 screw looseness I O o O D O O gt e Check for any grease leaking from the coupling 0 axis assembly tool e Check whether pickup is possible Drop in pickup force Arm e Check for deformation damage Link ball e Check for damage Major bolts and screws of robot main body those exposed to the Check for looseness 1 outside If any bolt or screw is loose retighten it For details about tightening torque see the table below Bolt tightening torque Bolt size Tightening torque kgfem Tightening torque Nm M3 set screw M3 M4 M4 4 axes specification axis arm cable clamp M6 M8 APTA Specifications Contents 1 Manipu
39. e wire connector The brake release wire connector is provided as an accessory with R6Y3 robot wn Q Q O gt Refer to the Fig below when connecting the robot and brake release wire connector Furthermore users are required to prepare the wire leading from the brake release wire connector Refer to the controller user s manual for details on the operation check after connection WARNING A THE ROBOT MAY MALFUNCTION IF THE BRAKE RELEASE WIRE CONNECTOR PINS ARE BENT OR BROKEN OR IF THE CABLE IS DAMAGED ENSURE THAT THERE IS NO SUCH DAMAGE PRIOR TO CONNECTION THE SHAPE OF THE BRAKE RELEASE WIRE CONNECTOR IS THE SAME FOR THE a AXIS B AXIS AND y AXIS EXERCISE CAUTION WHEN CONNECTING THE ROBOT MAY MALFUNCTION IF INCORRECTLY CONNECTED THE ROBOT MAY MALFUNCTION IF PIN CONTACT DEFECTS OCCUR BECAUSE THE CONNECTORS ARE NOT CONNECTED PROPERLY ENSURE THAT ALL CONNECTORS ARE SECURELY CONNECTED Brake release wire connector connection robot side Brake release wire connector Brake releasejwire robot side 1 in Contact 1 COM 2 NO 3 NC 2 10 4 3 0 axis connection wiring specifications R6Y31110L03067NJ5 R6Y31110H03067NJ5 0 axis connection wiring specifications for the R6Y31110L03067NJ5 and R6Y31110H03067NJ5 are shown below A CAUTION Take care not to wire cables incorrectly The robot will malfunction if used when incorrectly wired Encoder wire wiring left side is driver si
40. ecks and procedures If the following procedures are performed it will not be possible to set the robot origin position to the same position as the default factory setting Consequently it will be necessary to adjust the origin position and the robot may operate abnormally vibration noise or malfunction Sufficient caution is therefore advised e Arm removal arm position change The Delta robot origin position is adjusted at the factory beforehand using the jig calibration tool provided Perform the following procedure if the arm position is changed for such reasons as bending the arm when installing the robot in order to pass through the factory Adjust the arm position to the origin position with the calibration tool Refer to 2 Adjusting the origin in Chapter 3 of this manual Repetitive positioning accuracy Repetitive positioning accuracy is not guaranteed under the following conditions 1 Factors related to absolute accuracy If accuracy between the coordinate positions command positions inside the robot controller and the real space positions moving positions is required 2 Motion pattern factors If a motion approaching the teaching point from a different direction is included during repetitive operation If the power is turned off or the robot is stopped before completing the motion or the moving speed is changed even when approaching the teaching point from the same direction 3 Temperature fac
41. ecurely attached It will not be possible to insert the bolts if the motor cover position and tapping positions for the M5 hex bolts are not aligned MS hex bolt 11 Attach the robot cable connector A WARNING CONNECT THE a AXIS B AXIS AND y AXIS ROBOT CABLES SO THAT THEY MATCH THE RESPECTIVE l D Step 12 Boot cap attachment 77 AXES AT THE CONTROLLER DRIVER THE ROBOT WILL NOT OPERATE CORRECTLY RESULTING IN o POSSIBLE DANGER IF THE CABLES ARE o CONNECTED INCORRECTLY gt Pushithe rubber in completely O 12 Attach the boot and cap to the motor 3 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 A gt Step 13 Duct attachment 2 31 14 Attach the bracket to the robot cable Step 14 Bracket attachment 15 Insert the bracket in the boot 16 Insert the boot in the duct Bracket gt Step 15 Bracket insertion uN Q Q O gt gt Step 16 Boot insertion 2 32 9 Detaching or attaching the shafts moveable base and spring covers 9 1 Attaching the shafts moveable base and spring covers A 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 9 1 1 R6Y30110S03067NJ5 3
42. electrostatic discharge or radio frequency interference 5 uN Q Q O gt Vibration Do not subject to impacts or vibrations Below 0 6MPa 6 1kgf cm clean dry air not containing deteriorated compressor oil filtration Air supply pressure etc DEY 40um or less Working space Allow sufficient space margin to perform jobs teaching inspection repair etc WARNING A AVOID INSTALLING THE ROBOT IN LOCATIONS WHERE THE AMBIENT CONDITIONS MAY EXCEED THE ALLOWABLE TEMPERATURE OR HUMIDITY OR IN ENVIRONMENTS WHERE CORROSIVE GASES METALLIC POWDER OR DUST ARE GENERATED MALFUNCTION FAILURE OR SHORT CIRCUITS MAY OTHERWISE RESULT THIS ROBOT WAS NOT DESIGNED FOR OPERATION IN ENVIRONMENTS WHERE INFLAMMABLE OR EXPLOSIVE SUBSTANCES ARE PRESENT e DO NOT USE THE ROBOT IN ENVIRONMENTS CONTAINING INFLAMMABLE GAS DUST OR LIQUIDS EXPLOSIONS OR FIRE COULD OTHERWISE RESULT AVOID USING THE ROBOT IN LOCATIONS SUBJECT TO ELECTROMAGNETIC INTERFERENCE ELECTROSTATIC DISCHARGE OR RADIO FREQUENCY INTERFERENCE MALFUNCTION MAY OTHERWISE OCCUR DO NOT USE THE ROBOT IN LOCATIONS SUBJECT TO EXCESSIVE VIBRATION ROBOT INSTALLATION BOLTS MAY OTHERWISE BECOME LOOSE CAUSING THE ROBOT TO FALL OVER 2 1 1 2 Installation base e Prepare a sufficiently rigid installation base Using an insufficiently rigid base will result in vibrations and poor positioning e The arm movement area for each axis is above the robot ba
43. 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 Introduction Contents Before using the robot Be sure to read the following notes i Introduction ii Before using the robot Be sure to read the following notes Thank you for your purchase of this OMRON Delta robot 1 Before using the robot first perform the following ch
44. gin position 33 2 2 Adjusting the 0 axis origin position 4 axes specification only 3 6 3 Setting the soft limits 3 8 3 1 Setting the a P and y axis soft limits 3 8 3 2 Setting the 0 axis soft limits 3 8 Chapter 4 Periodic inspection 1 Overview 4 1 2 List of inspection items 4 2 Chapter 5 Specifications 1 Manipulator 5 1 1 1 Basic specification 5 1 1 2 External view and dimensions 5 2 1 3 Robot inner wiring diagram 5 4 1 4 Kinematics parameters 5 5 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 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 6 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 Industri
45. ion 2 13 6 1 1 0 axis moment of inertia of load and acceleration coefficient 2 13 6 2 Equation for moment of inertia calculation 2 14 6 3 Example of moment of inertia calculation 2 17 6 4 Attaching the end effector 2 19 7 Working envelope and maximum movement range 2 20 8 Detaching or attaching the covers 2 21 8 1 _ Detaching or attaching the a B and y axes covers _ 2 21 8 1 1 a B y axis cover removal procedure 2 22 8 1 2 a and y axis cover attachment procedure 2 27 9 Detaching or attaching the shafts moveable base and spring covers 2 33 9 1 Attaching the shafts moveable base and spring covers 233 9 1 1 R6Y30110S03067NJ5 3 axes specification 2 33 9 1 2 R6Y31110L03067NJ5 R6Y31110H03067NJ5 4 axes specification 2 35 del Detarhine the shafts moyeable base and SPINS Cover una 1 Robot installation conditions 1 1 Installation environments Be sure to install the robot in the following environments Setting environments Specifications Allowable ambient temperature 0 to 45 C Allowable ambient humidity 35 to 85 RH non condensation Altitude 0 to 1000 meters above sea level Ambient environments Avoid installing near cutting water oil dust metallic chips or organic solvents Avoid installation near corrosive gas and corrosive materials Avoid installation in atmosphere containing inflammable gas dust or liquid Avoid installation near objects causing electromagnetic interference
46. lator 1 1 Basic specification let Sica cad dimensions Leda OL Dec ine iaa 1 4 Kinematics parameters 5 1 51 5 2 5 4 33 1 Manipulator 1 1 Basic specification Robot model R6Y30110803067NJ5 R6Y31110L03067NJ5 R6Y31110H03067NJ5 Stroke 1100mm Working volume Stroke 300mm max 1100mm 450mm center 580mm Rotation range 180 default setting it can be changed 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 gt 150 CPM 0 axis tolerable moment of inertia gt 0 01kgm S0W 0 035kgm 100W User tubing outer diameter 6x1 moveable tool Travel limit Soft limit Protection class IP67 Weight 75kg 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 Noise level Dn po O h Q Q O gt Equivalent sound level of robot Laeq A a y i i Position where the noise level is measured when there is 10dB or larger difference from the back ground sound pressure level Robot surface 1 0m from moveable range height 1 6m 73 7dB Note The noise level can be higher when the r
47. les with the plastic block as shown CAUTION A Be careful not to pull the cables too much If pulled too much the cables may be damaged resulting in possible robot malfunction T 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 5 wn Q Q O gt gt Step7 Cable attachment at moveable base side gt wn Q Q O gt 9 2 Detaching the shafts moveable base and spring cover The detachment procedure is the opposite of that for attachment A 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 1 Post a sign indicating that the robot DP Step 3 Spring cover removal 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 spring covers 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 The spring covers are held
48. me 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 SUONYONYSUJ JOJOS SUONYONYSUJ JOJOS 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 meaning 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 A THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY A CAUTION This indicates a potentially hazardous situation which if
49. o 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 N WARNING 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 ofthese 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 where 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 IN MEDICAL EQUIPMENT SYSTEMS WHICH ARE CRITICAL TO HUMAN LIFE IN SYSTE
50. obot is set nearby the objects that cause sound reflection 5 1 1 2 External view and dimensions R6Y30110803067NJ5 A 1067 Eyebolts 3 locations A S 673 799 DN po Q O h Q Q O v 17 0 012 View A 95H7 o depth 10 R6Y31110L03067NJ5 R6Y31110H03067NJ5 Do not attach tubing to 0 axis Eyebolts 3 locations 1067 ul E a u Io LI g aD ADN MIS e 2 N N at ERI A 942 DOS Rel 8 4 M5x0 8 depth 8 920 depth 3 5 3 DN 2 h Q Q O gt v Nm Q 2 h Q Q O gt vw 1 3 5 4 Robot inner wiring diagram KO Ao A N A y axis brake release switch i y axis motor brake DJ y axis encoder LAN N o A Y IN B axis encoder BT ul gt i N B axis motor brake x N B axis brake release switch R R a axis brake release switch User tubing air tube attachment port User tubing tapered screw hole 1 4 Kinematics parameters Kinematics parameters t Rf gm Lf Lm Kinematics parameters Rf 225mm Rm 62 5 mm Lf 340mm Rm lt gt mm Lm 840mm Rf Distance radius from the center of the fixed frame to the motor axis mm Rm Distance radius from the cen
51. of grounding Ground symbol 5 wn 2 o O gt M4 Ground terminal Calibration tool attachment hole There are two M4 earth terminals located near the attachment hole M12 for the calibration tool used to adjust the robot base origin position Use one terminal for the external protective conductor and the other terminal for the 0 axis cable grounding Use a ground cable with conductor wire cross section of at least 2 0mm and length within Im fi CAUTION The user is responsible for providing a proper grounding when the end effector includes an electrical device which could possibly malfunction causing contact with the power supply NOTE H For details on protective bonding for the robot body to comply with CE Marking follow the instructions described in the controller user s manual 2 9 lt 4 Connection 4 1 Robot cable connection The robot cable is not connected to the R6Y3 robot Refer to the controller user s manual for details on the operation check after connection WARNING A THE SHAPE OF THE MOTOR CONNECTORS AND ENCODER CONNECTORS IS THE SAME FOR THE a AXIS B AXIS AND y AXIS EXERCISE CAUTION WHEN CONNECTING THE ROBOT MAY MALFUNCTION IF INCORRECTLY CONNECTED e THE ROBOT MAY MALFUNCTION IF PIN CONTACT DEFECTS OCCUR BECAUSE THE CONNECTORS ARE NOT CONNECTED PROPERLY ENSURE THAT ALL CONNECTORS ARE SECURELY CONNECTED BEFORE TURNING ON THE CONTROLLER POWER 4 2 Wiring the brake releas
52. omply 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 5 wn Q Q O gt R6Y3 a axis axis 2 21 lt 8 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 1 Remove the duct boot and cap gt Step 1 Duct boot and cap removal Lal NOTE The boot and cap are merely inserted when the robot is shipped 2 Disconnect the robot cable connector wn Q o E O gt Boot removal Cap removal 2 22 La Remove the M5 hex bolt from the top of the motor cover 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 Smm when attached NOTE The inside of the cover will catch and so will not come off completely gt Step 3 Bolt removal MS hex bolt gt Step4 Temporarily removed cover Cover Pull out a little at a time while shaking up and down wn Q Q O gt 10mm width Cover bottom temporarily removed Cover top temporarily removed 2 23 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 Lal NOTE
53. on in Chapter 3 for details CAUTION A 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 2 35 4 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 5 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 gt wn Q Q O gt Spring cover top gt Step 5 Cable routing at arm side gt 2 36 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 cab
54. 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 Robot speeds used during tasks such as teaching Methods for workers to signal each other when two or more workers perform tasks Steps that the worker should take when a problem or emergency occurs U A U N 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 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 spe
55. ontacting the moving part of the robot Install an interlock that triggers emergency stop when the door or gate of the safety enclosure is opened Stay clear of moving machine Can cause serious injury SUOHONASU JOJOS WRR AREA YESA HO AHO US EMSS CBARTHAETSENGO 90K41 001470 The safety enclosure should be designed so that no one can enter inside except from the door or gate equipped with an interlock device Warning label 1 that comes supplied with a robot should be affixed to an easy to see location on the door or gate of the safety enclosure Potential hazard to human body Serious injury may result rom contact with a moving robot E e Keep outside of the robot safety enclosure during operation To avoid hazard Press the emergency stop button before entering the safety enclosure 2 Warning label 2 WARNING MOVING PARTS CAN PINCH OR CRUSH HANDS KEEP HANDS AWAY FROM THE MOVABLE PARTS OF THE ROBOT Pinch or crush hazard Instructions on this label SHE ae EACTTHETSBNGY Use caution to prevent hands and fingers from being pinched or crushed by the movable parts of the robot when transporting or moving the robot or during teaching 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 SUONYONYS
56. 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 S 15 Warranty For information on the warranty period and terms please contact our distributor where you purchased the product M This warranty does not cover any failure caused by 1 Installation wiring connection to other control devices 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 ope
57. 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 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 BE SURE TO GROUND THE CONTROLLER USING THE GROUND TERMINAL ON THE POWER TERMINAL BLOCK POOR GROUNDING MAY CAUSE ELECTRICAL SHOCK S 7 SUONYONYSUJ JOJOS 4 4 Safety measures 4 4 1 Safety measures 1 A La Ze A SUOHONAYSU JOJOS 3 A Referring to warning labels and manual WARNING BEFORE STARTING INSTALLATION OR OPERATION OF THE ROBOT BE SURE TO READ THE WARNING LABELS AND THIS MANUAL AND COMPLY WITH THE INSTRUCTIONS NEVER ATTEMPT ANY REPAIR PARTS REPLACEMENT AND MODIFICATION UNLESS DESCRIBED IN THIS MANUAL THESE TASKS REQUIRE SPECIALIZED TECHNICAL KNOWLEDGE AND SKILLS AND MAY ALSO INVOLVE HAZARDS PLEASE CONTACT YOUR DISTRIBUTOR FOR ADVICE NOTE For details
58. rating 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 oN a UU A U 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 OMRON 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
59. removal cap boot 4 Disconnect the robot cable A CAUTION After disconnecting the brake release wire connector store the cover cable inside the cover 5 Remove the motor cover Refer to 8 Detaching or attaching the covers in this chapter before removing the cover 6 Pass three ropes through the eyebolts and hang them on the hoist Use looped ropes with the same length to allow a good lifting balance a CAUTION Attach the eyebolts if they have been removed Always use the eyebolts and a hoist when moving the robot Failing to wn Q Q O gt do so could cause bodily injury 7 Hold the robot and remove the mounting bolts Slightly lift the hoist so that the tension is lightly applied to each rope to hold the robot and then Cap removal remove the base mounting bolts if moving the robot to another base 8 Move the robot Using caution to keep the balance of the robot and avoid subjecting it to any strong vibrations and shocks carefully move the robot to the installation base The rope angle at this time should be kept at 60 or more 9 Temporarily secure the robot to the base by tightening the bolts First temporarily secure three points near each axis Boot removal on the robot base with the bolts Then temporarily tighten the remaining three bolts 10 Fully tighten all six bolts Lal NOTE AA lt lt K lt Refer to 2 4 Installing the robot in
60. s Contents 1 Robot manipulator 1 1 Manipulator movement The R6Y3 robot consists of an a axis P axis and y axis arm shaft and a 0 axis moveable base With these 4 axes the R6Y3 robot can move as shown in the Fig below By attaching different types of end effector gripper to the end a wide range of tasks can be performed with high precision at high speeds Manipulator movement a axis 0 axis suoouny 1 1 lt 1 2 Part names R6Y3 Eyebolt Arm Ti G O O vw Ss Moveable base Tool flange Spring cover gt AG gt SIND We A o A Warning label 3 HG k I Warning label 2 Warning label 1 y axis Tool flange gt 1 2 18111994 Installation Contents 1 Robot installation conditions 2 1 1 1 Installation environments 21 1 2 Installation base 2 2 2 Installation 2 3 2 1 Unpacking 2 3 2 2 Checking the product 2 3 23 Moving the robot 24 2 3 1 Installing on base prepared by user 2 4 2 3 2 Moving the robot to another installation base or removing the robot 2 5 2 4 Installing the robot sal 3 Protective bonding 4 Connection 4 1 Robot cable connection 2 10 4 2 Wiring the brake release wire connector 2 10 4 3 0 axis connection wiring specifications R6Y31110L03067NJ5 R6Y31110H03067NJ5 2 11 5 User tubing 2 12 6 Attaching the end effector 2 13 6 1 0 axis tolerable moment of inertia and accelerat
61. se and therefore the robot must not be installed on the ceiling etc The robot may malfunction if arms crash Installation base attachment surface instruction Parallelism 0 5 Movement range Cable 350 81200 arm rotation range interference 1800 tool movement range wn Q Q O gt No Arm rotation range F Fa E F SER Na ESN Y n na a No Ji 7z 3 I N p g S oO n Y A o n NO o E gt A q LIA Tool movement area S I lt 2 RI N VEG e S I a x N Y N SA SE E 3 gt Si a e lt 0580 81100 gt 2 2 2 Installation 2 1 Unpacking WARNING A THE ROBOT AND ITS ACCESSORIES ARE EXTREMELY HEAVY TAKE SUFFICIENT CARE NOT TO DROP THEM DURING MOVING OR UNPACKING AS THIS MAY DAMAGE THE EQUIPMENT OR CAUSE BODILY INJURY A CAUTION When moving the robot or controller by equipment such as a folklift that require a license only properly qualified personnel may operate it The equipment and tools used for moving the robot should be serviced daily The R6Y3 robot comes packed with arms shafts a moveable base and accessories Using a carrying cart dolly or forklift move the package near the installation base Take sufficient care not to apply shocks to the equipment when unpacking it wn 2 o O gt Packed sta
62. sing care to keep the robot balanced and avoid subjecting it to vibrations and shocks The rope angle at this time should be kept at 60 or more CAUTION When moving the robot do not hold the robot arm or robot cover It may cause deviation of the origin position that has been adjusted and damage to the robot arm or robot cover Robot transportation 60 or more 5 YN Q Q O gt Do not hold arm and cover 5 Temporarily secure the robot to the base by tightening the bolts Move the robot to the base prepared by the user and temporarily secure three points near each axis on the robot base with the bolts Then temporarily tighten the remaining three bolts 6 Fully tighten all six bolts Lal NOTE Refer to 2 4 Installing the robot in this chapter for details on bolt attachment direction and tightening torque 7 Remove the ropes A CAUTION Ifremoving the eyebolts always attach bolts to protect the tapped eyebolt holes e Always store the eyebolts since they may be used to move the robot again 2 3 2 Moving the robot to another installation base or removing the robot 1 Move the a axis B axis and y axis to their respective origin positions 2 Remove the screw cover shafts moveable base and load from the end of the arm Refer to 9 Detaching or attaching the shafts moveable base and screw covers in this chapter 2 5 lt 3 Remove the duct and connector cover Step 3 Duct connector cover
63. te 2 2 Checking the product After unpacking check the product configuration and conditions A CAUTION If there is any damage due to transportation or insufficient parts please notify your distributor immediately Remarks Shafts 3 a B y axes Spring covers Moveable base Calibration tool a y axes a B y axes home position adjustment jig with bolts and washers Calibration tool 0 axis 0 axis home position adjustment jig Brake release wire connector Plastic bearing replacement jig Plastic bearing that slides toward link ball Duct User s Manual Warning label 1 2 3 2 3 Moving the robot WARNING A SERIOUS INJURY MAY OCCUR IF THE ROBOT FALLS AND PINS SOMEONE UNDER IT DO NOT ALLOW ANY PART OF YOUR BODY TO ENTER THE AREA BENEATH THE ROBOT DURING WORK ALWAYS WEAR A HELMET SAFETY SHOES AND GLOVES DURING WORK CHECK THAT THERE ARE NO CRACKS OR CORROSION ON THE EYEBOLTS OR EYEBOLT INSTALLATION AREA IF FOUND DO NOT USE EYEBOLTS TO MOVE THE ROBOT SCREW THE EYEBOLTS FIRMLY UNTIL THE BEARING SURFACE OF THE EYEBOLT MAKES TIGHT CONTACT WITH THE BEARING SURFACE ON THE BASE EYEBOLTS ARE ALREADY FITTED WHEN THE ROBOT IS SHIPPED USE A HOIST AND ROPE WITH CARRYING CAPACITY STRONG ENOUGH TO SUPPORT THE ROBOT WEIGHT MAKE SURE THE ROPE STAYS SECURELY ON THE HOIST HOOK AVOID DANGEROUS BEHAVIOR LIKELY TO UPSET THE BALANCE WHEN TRANSPORTING THE ROBOT
64. ter of the moving frame to the connection point of link 2 mm Lf Length of the link mm Lm Length of the link 2 mm Software limit Software limit Gearbox ratio Positive software limit 110 Main motor 1 33 ratio Negative software limit 60 0 motor Low inertia 1 9 ratio 0 motor High inertia 1 21 ratio 5 5 lt Ww po O Q Q O gt DN po Q py Q Q O Workspace parameters Rco Zu Hco Workspace parameters Zu 650mm Rey 550 mm Hcy 300 mm Rco 290 mm Hco 150 mm Zu Cylinder front position origin position from the Z axis mm Rey Cylinder radius mm Hey Cylinder height mm Rco Cone radius mm Hco Cone height mm Revision history A manual revision code appears as a suffix to the catalog number on the front cover manual Cat No I194E EN 01 L The following table outlines the changes made to the manual during each revision Revision code 01 June 2013 Original production OMRON Authorized Distributor Cat No 1194E EN 01A Note Specifications subject to change without notice Printed in Europe
65. this chapter for details on bolt attachment direction and tightening torque 11 Remove the ropes CAUTION A Ifremoving the eyebolts always attach bolts to protect the tapped eyebolt holes e Always store the eyebolts since they may be used to move the robot again gt 2 6 2 4 Installing the robot A CAUTION Installation space A space of 200mm avobe the base is included in the movement range of the a and y axes Ensure that the installation base prepared by the user does not interfere with the arm movement range Ensure a flatness of 0 5 on the surface of the installation base prepared by the user Outline drawing Cable interference range 350 1100 Movement area 1200 arm rotation range 5 wn Q Q O gt Arm rotation range o o N sE co N a n NO Tool movement area o 2 i o m ae ts N j gt y EA ee gt SE ea a u 580 1100 I Either of the following methods may be used to secure the robot to the installation base e Bore through holes in the installation base prepared by the user and use the M12 tapping holes on the robot base to secure the robot to the installation base e Bore M14 tapping holes in the installation base prepared by the user and use the 016 through holes on the robot base to secure the robot to the installation base 2 7 lt Install the robot securely with the six hex
66. ting the 0 axis origin position 4 axes specification only son 3 Setting the soft limits 3 8 3 1 Setting the a f and y axis soft limits 3 8 3 2 Setting the 0 axis soft limits 3 8 1 Overview R6Y3 robot origin position setting is performed at the OMRON factory Specify the controller settings while referring to the controller user s manual The following describes the safety precautions to be observed when making various settings CAUTION A Read and understand the contents of this chapter completely before attempting to set the robot e Place a conspicuous sign indicating the robot is being adjusted to prevent others from touching the controller switch or operation panel e Ifa 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 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 Refer to the controller user s manual if performing an operation check after setting A O o O p a gt Q n 3 1 lt 2 Adjusting the origin The R6Y3 uses a calibration tool to mechanically adjust the origin position of the a y and 0 axes Be sure to adjust
67. tion 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 necessaty 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 specialized 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 SPECIA
68. together with clips on the Dis Topjcover Pull the bottom cover down at the arm side and pull PS the top cover up at the moveable base side to remove the spring cover CAUTION A Use both hands when removing the spring covers Use one hand for removal and the other to stop the bottom cover falling If the spring cover falls and is damaged the robot may operate abnormally 4 Remove the shafts Arm side 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 Remove the spring covers before removing the shafts The spring covers may be damaged if work is carried out without removing them Base side Take care not to pull the springs on the shafts too much gt Step 4 Shaltasinavii If stretched too far the springs may not return to their original shape possibly leading to abnormal robot movement If the shafts are removed from the moveable base without first disconnecting the 0 axis cable from the motor the cable may be stretched and damaged leading to possible malfunction Furthermore take care not to drop the moveable base 2 38 PTI Robot settings Contents 1 Overview 2 Adjusting the origin 2 1 Adjusting the a B and y axis origin position Sa 2 2 Adjus
69. tors If the ambient temperature environment changes significantly If the temperature of the robot body changes 4 Load variation factors If load conditions vary during operation the load varies depending on whether or not the workpiece is present etc If the a axis B axis y axis or 0 axis rotation angle is small If the a axis B axis y axis or 0 axis rotation angle is smaller than 5 so that it moves to almost the same position it will be difficult for an oil film to form on the reduction gear possibly leading to shortened gear lifetime With this type of operation add a movement so that the joint moves through 120 or more about 5 times a day a P and y axis arm rotation range and tool movement area The robot TCP tool center point movement area is larger than the actual movement area Always set the robot movement area at the controller Furthermore when the robot is making its maximum movement including arm maximum rotation range a sufficient space must be secured to avoid interference with user units If the above points are not observed the robot may malfunction and collide with user units resulting in possible damage to the robot Furthermore the shafts moveable base or end effector may drop out or be damaged and go flying Refer to 7 Working envelope and maximum movement range in Chapter 2 for details Shaft and moveable base collision prevention The robot may be damaged if the shaft and move
70. uired by local laws and regulations Do not perform robot inspection adjustments repair or part replacement not described in this manual This work requires specialized technical knowledge and skill and may also involve work hazards e When inspection is required inside the safety enclosure always turn off the controller and also the external switch board e Ifthe 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 Use only the lubricants specified by your distributor e Refer to the controller user s manual if performing an operation check after inspection E Monthly and 6 month inspection precaution Pay attention to the following if applying grease to the 0 axis assembly WARNING A PRECAUTIONS WHEN HANDLING GREASE INFLAMMATION MAY OCCUR IF THIS GETS IN THE EYES USE FOOD GREASE CASSIDA GREASE EPS2 WHEN USING THE ROBOT AT FOOD PLANTS BEFORE HANDLING THE GREASE WEAR YOUR SAFETY GOGGLES TO ENSURE THE GREASE WILL NOT COME IN CONTACT WITH THE EYES INFLAMMATION MAY OCCUR IF THE GREASE COMES INTO CONTACT WITH SKIN BE SURE TO WEAR PROTECTIVE GLOVES TO PREVENT CONTACT WITH SKIN DO NOT TAKE ORALLY OR EAT EATING WILL CAUSE DIARRHEA AND VOMITING HANDS AND FINGERS MIGHT BE CUT WHEN OPENING THE CONTAINER SO USE PROTECTIVE GLOVES KEEP OUT
71. ut from the adjacent cap hole Encoder wire Encoder wire Pull out from cap hole side 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 Step6 Temporary motor cover insertion Motor cover Cables removed when temporarily inserting cover 2 29 lt wn Q Q O gt 8 a gt UOND IDJSU gt 2 30 Insert the cover so that the rubber on 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 CAUTION Insert the rubber a little at a time and avoid trying to force it in If forced in the rubber will end up deformed making it difficult to attach the motor cover Push in the motor cover from the rear The rubber at the bottom of the switch should protrude approximately Smm and the rubber at the top of the switch should protrude approximately Imm Gap at top of cover Gap at bottom of cover P gt Step 8 Insert the rubber DP Step 9 Push in the motor cover MO CON 10 Adjust the motor cover position and gt Step 10 Motor cover attachment then secure with the M5 hex bolt s Adjust the motor cover position and then screw in two MS hex bolts to secure Ensure that the motor cover has been s
72. 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 gt 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 A THE a AXIS B AXIS OR y AXIS WILL SLIDE DOWNWARD WHEN THE BRAKE IS RELEASED CAUSING A HAZARDOUS SITUATION 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 WHEN RELEASING THE BRAKE BE CAREFUL NOT TO LET YOUR BODY GET CAUGHT BETWEEN THE MOVABLE BASE AND THE INSTALLATION BASE N CAUTION Release the brake axis by axis NOTE La For details about the brake release wire connector see 4 2 Wiring the brake release wire connector in Chapter 2 S 13 SUOYONYSUJ JOJOS SUONYONYSUJ JOJOS 6 Using the robot safely

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