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VS-G SERIES INSTALLATION & MAINTENANCE GUIDE

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1. Step 4 Padlock the lockout bar eee Step 3 Put the lockout bar on the upper side of the power switch D 12 Chapter 2 Customizing Your Robot 2 1 What Is Customization You may customize your robot by modifying or setting the following Software motion limits for defining motion space Mechanical ends for defining restricted space Control set of motion optimization Robot installation conditions You are recommended to define new motion space and restricted space in order to prevent interference with other devices or entanglement of the end effector wiring and piping WARNING Always set the software motion limits and mechanical ends so that the motion space will be within the restricted space Otherwise the robot will bump the mechanical stops causing serious accidents 2 2 Modifying Software Motion Limits to Define New Motion Space 2 2 1 What Is a Software Motion Limit A limit to the operation range of the robot defined by the software is called a software motion limit Software motion limits become valid after CAL of the robot has been completed and the robot has entered the range set by the limits A mechanical operation limit is called a mechanical end and set by a mechanical stop To prevent the robot from striking against a mechanical stop each software motion limit is set slightly in front of the mechanical end as shown in the figure below
2. Upon completion of transfer of the CALSET related arm data restart the robot controller 96 Vertical Articulated Robot VS G SERIES INSTALLATION amp MAINTENANCE GUIDE First Edition July 2005 Eighth Edition April 2009 Ninth Edition March 2010 DENSO WAVE INCORPORATED 3M C The purpose of this manual is to provide accurate information in the handling and operating of the robot Please feel free to send your comments regarding any errors or omissions you may have found or any suggestions you may have for generally improving the manual In no event will DENSO WAVE INCORPORATED be liable for any direct or indirect damages resulting from the application of the information in this manual
3. 3 10 Setting the robot s The area required for the robot to work is called the robot s motion space operating space If the robot s motion space is greater than the operating space it is recommended that you set a smaller motion space to prevent the robot from interfering or disrupting other equipment Refer to the INSTALLATION amp MAINTENANCE GUIDE Chapter 2 3 11 No robot modification allowed 3 12 Cleaning of tools 3 13 Lighting 3 14 Protection from objects thrown by the end effector 3 15 Affixing the warning label 3 16 Posting the moving directions of all axes Never modify the robot unit robot controller teach pendant or other devices If your robot uses welding guns paint spray nozzles or other end effectors requiring cleaning it is recommended that the cleaning process be carried out automatically Sufficient illumination should be assured for safe robot operation If there is any risk of workers being injured in the event that the object being held by the end effector is dropped or thrown by the end effector consider the size weight temperature and chemical nature of the object and take appropriate safeguards to ensure safety Place the warning label packaged with the robot on the exit entrance of the safety fence or in a position WARN N G where it is easy to see TROENSI o Risk iT Do not enter safety fence area Unfallgefahr Nicht den Sicherheitsbereich des Roboters betr
4. 2 4 4 Mounting the CALSET Jig To CALSET the 6th axis on all models or the 4th axis on models having no mechanical stop you need to mount the CALSET jig on the axis beforehand according to the procedure given in 1 below or 2 given later respectively To CALSET all axes including the above axes follow those procedures 1 and 2 1 Mounting the CALSET jig on the 6th axis STEP 4 Fit a stopper pin in the CALSET jig Outline View CALSET jig Knock Pin Pin 3 for VP F VP Gi VS Ef VS G Pin 2 for VC E Pin 2 for VS C D Pin 1 for VS B Dimensions Pin 2 for VC E STEP D l Release the brake of the 6th axis 63 STEP 23 Install the CALSET jig on the 6th axis flange as shown in the figure below TIP The CALSET position of the 6th axis refers to the point where the stopper pin shown in the figure below comes into contact with bolt A by turning the flange of the 6th axis Viewed from B Bring the stopper pin into Bolt A contact with this bolt Wiring plate Bolt A Knock hole Flange of the 6th axis Mounting a CALSET Jig VS G series 64 2 oe the CALSET Jig on the 4th axis For models having no mechanical Stop on the 4th axis As a CALSET jig a special bolt CALSET bolt is provided inside the 3rd axis motor cover in the robot unit STEP 1 Remove the 3rd axis motor cover and unscrew the CALSET bolt NOTE After CALSETing be sure to set the bolt back into place and torque it to 1
5. The system message appears asking whether you want to carry out CALSET and showing a caution that the robot reference position will change STEP 4 o Press OK The system message appears informing that CALSET is completed 72 STEP 20 STEP 21 STEP 22 STEP 23 STEP 24 Press the ROBOT STOP button The robot brake becomes activated Turn the ROBOT STOP button to cancel robot stop Press the MOTOR to turn ON the power to the motor Caution A motor lock overload error may occur just after the power to the motor is turned ON In this case try to turn ON the power several times or release the brake move the axis a little in the opposite direction of the mechanical end and turn ON the power again Move the CALSETed axis in the opposite direction from the mechanical end by the manual operation of the teach pendant Perform CAL The single axis CALSET of the specified axis is completed 2 4 6 2 CALSETing All Axes The CALSET of all axes is called all axis CALSET The procedure is the same as that for single axis CALSET except that you should select all axes when releasing brakes and performing CALSET For details of the procedure see Section 2 4 6 1 CALSETing a Single Axis 73 2 4 6 3 5 axis or 6 axis CALSET Procedure for cleanroom type The flange and cover described are originally attached to the 6 axis of the cleanroom type robot as shown in Figure below Therefore perform 5 axis or 6 axis CALSET
6. This section provides safety precautions to be observed for the robot system The installation shall be made by qualified personal and should confirm to all national and local codes The robot unit and controller have warning labels These labels alert the user to the danger of the areas on which they are pasted Be sure to observe the instructions printed on those labels Instructions printed on the label Risk of injury Never enter the restricted space For UL Listed robot units only Risk of injury This label alerts the user that pressing the brake release switch could drop the arm Risk of electrical shock Never open the controller cover when the power is on Never touch the inside of the controller for at least 3 minutes even after turning the power off and disconnecting the power cable Risk of injury Be sure to perform before starting servicing lockout tagout Turning the power ON when a person is inside the safety fence may move the arm Causing injuries SAFETY PRECAUTIONS 3 Installation Precautions 3 1 Insuring the proper installation environment E For standard type and The standard and cleanroom types have not been designed to cleanroom type withstand explosions dust proof nor is it splash proof Therefore it should not be installed in any environment where 1 there are flammable gases or liquids 2 there are any shavings from metal processing or other conductive material flying
7. Strength class 12 9 ree s Thread length 32 mm Two bolts i Tightening torque 10 Nm 20 DE m M5x35 Strength class 12 9 3rd axis Po gt SO Tightening torque 5 9 Nm 20 mechanical stop Four bolts M6x20 Strength class 12 9 Tightening torque 9 8 Nm 20 Two sets of bolts and nuts M6x20 Strength class 12 9 Tightening torque 9 8 Nm 20 45 2 Reference Drawings of 3rd axis Mechanical Stop VS6556G The figures below show the mechanical end configured with a 3rd axis mechanical stop The reference drawings of the mechanical stop and the related parts are given on the following pages The 3rd axis mechanical stop is designed to set the 3rd axis motion range between 128 in the positive direction and 14 5 in the negative direction 3rd axis Mechanical Stop Mounted on the Robot Unit VS6556G L memmen 4 PER 7 8 eaS 2 SS y eae te i 2 M5 12DEEP rina N S W ZIN wr ANNE WBA WAT YVI T V 63 NANN Ta _ 2XM5X30 p e af a Y ay 2 M8X25 A Pee L KA F HIINC Il J DHIN gt gt S A WASZ M6X45 A AWS YEN a e e e a a e a a a a a 4XM6X20 XN NS S88 LZ TN RAR AO ss FBG a a ee e ee e m e e _ _ aanas meaane m a m m e 46 Reference Drawing of Stay for 3rd axis Mechanical End VS6556G tl o ii l
8. UL Listed robot units have motor ON lamps on their robot arms SAFETY PRECAUTIONS 3 9 Setting up a safety A safety fence should be set up so that no one can easily enter fence the robot s restricted space 1 The fence should be constructed so that it cannot be easily moved or removed 2 The fence should be constructed so that it cannot be easily damaged or deformed through external force 3 Establish the exit entrance to the fence Construct the fence so that no one can easily get past it by climbing over the fence 4 The fence should be constructed to ensure that it is not possible for hands or any other parts of the body to get through it 5 Take any one of the following protections for the entrance exit of the fence 1 Place a door rope or chain across the entrance exit of 09 d the fence and fit it with an interlock that ensures the XS y emergency stop device operates automatically if it is opened or removed 2 Post a warning notice at the entrance exit of the fence stating In operation Entry forbidden or Work in progress Do not operate and ensure that workers follow these instructions at all times When making a test run before setting up the fence place an overseer in a position outside the robot s restricted space and one in which he she can see all of the robot s movements The overseer should prevent workers from entering the robot s restricted space and be devoted solely to that task
9. VS G Series If the 1st axis comes into contact with any mechanical stop because of the width of the stopper and its bolt the angle of the 1st axis is different between the positive direction and the negative direction The table below shows the angles of the 1st axis in the positive and negative directions when it is in contact with each mechanical stop Stroke of the 1st Axis to Mechanical Ends Mechanical stop position Positive direction 21 VS G series For 1st axis Rz 100 2 9 DRILL Material A2017 Note 1 Unless otherwise specified corners should be C0 1 to CO 5 Mechanical Stop VS G series For 1st axis SSR 2 9 DRILL 14 DIA x 9 DEEP SF 2 9 DRILL 14 DIAx 11 DEEP SF Material S45C Note 1 Unless otherwise specified corners should be C0 1 to CO0 5 Fixture Block A 22 VS G series For 1st axis Material S45C Note 1 Unless otherwise specified corners should be C0 1 to CO0 5 Fixture Block B VS G series For 1st axis SOS Material S45C Note 1 Unless otherwise specified corners should be C0 1 to CO 5 Note 2 a and 6 are arbitrary angles In the above sample mechanical stop positions A and B are 5 and 95 respectively Plate 23 Precautions When Changing the Mechanical Ends After a mechanical end change the software motion limits PLIMs NLIMs must be changed And also if you change the RANG values after a mechanical end change the CAL
10. as follows 1 Before performing 5 axis or 6 axis CALSET remove the flange and cover Caution When removing the flange and cover dusts inside robot may be splashed 2 Perform 5 axis or 6 axis CALSET according to the CALSET procedure described on VS G SERIES INSTALLATION amp MAINTEANACE GUIDE 3 Reinstall the flange and cover using three bolts Bolt fixing torque 1 57 Nm 20 Added parts for cleanroom robot 6 axis of VS 65 G P100 74 2 5 Setting Control Set of Motion Optimization 6th a facef The optimum speed or acceleration will vary depending upon the payload and center of gravity of an end effector or workpiece that is to be set at the end of the robot flange Set the payload and center of gravity position of the end effector or workpiece and the control set of motion optimization according to the payload and robot posture The mass of payload is a total mass of an end effector and workpiece expressed in grams For further information see the PROGRAMMER S MANUAL Section 4 7 Setting the Master Control Parameters in User Preferences For the setting procedure refer to the SETTING UP MANUAL Section 2 9 Setting the Master Control Parameters of the Payload Center of Gravity and Control Set of Motion Optimization The payload center of gravity is represented by the TOOLO coordinate system see the figure below in the unit of mm The origin of the TOOLO coordinate system is the center of
11. axis Mechanical End Change The 2nd and 3rd axis mechanical end change procedure differs depending upon whether the robot unit has particular internal threads specified below UL Listed robot units or not Standard type For the standard type proceed to item 3 for the UL Listed robot units proceed to item 4 5 internal threads dedicated to mounting a 2nd axis mechanical stop 5 internal threads dedicated to mounting a 2nd axis mechanical stop bolt Locations of Internal Threads Dedicated to 2nd axis Mechanical End Change 5 internal threads dedicated to mounting a 3rd axis mechanical stop bolt 4 internal threads dedicated to mounting a 3rd axis mechanical stop Locations of Internal Threads Dedicated to 3rd axis Mechanical End Change 40 3 Changing the 2nd and 3rd axis Mechanical Ends for Robot Units Having No Particular Internal Threads Standard Type For robot units having no internal threads dedicated to mechanical end change use undedicated internal threads as shown below The 2nd axis mechanical stops for the VS 6556G and VS 6577G are of the same shape so the description of mechanical end change in 4 1 is common to both models The 3rd axis mechanical stops for the VS 6556G and VS 6577G are of different shapes so the descriptions are separately provided for each model 4 2 for VS 6556G and 4 3 for the VS 6577G 3 1 2nd axis Mechanical End Change Common to VS 6566G and VS 6577G 1 O
12. cuieenet eae ieee cnet eRe ee eee 81 341 Battery Replacement and C beck Mems 55 eaecneet aida casera a a a A A atearaeeants 81 3 4 2 Replacing the Encoder Backup Battery cccccccccccccccccccccceeeeececeeeceeeeeceececeeeeeececececeeeeeeeeeaeeeeaeeeeeeeeeeeeeeeeeeeess 82 3 4 3 Replacing the Memory Backup Battery ixj cx shaceacsaensctehdonsnansdensasendbadadeacens adic donsnansdeesaeendbadadeaaessstehdaacegeaseeiden 86 344 Settme the Next Battery Replacement Dale ia arenan Eaa EEEE EA E A E 86 3 5 Supplies and Tools for Maintenance nnnnnnennnnnnnennneessssesssesresrrerersrssssrsressreresrererrseserererresrssssssrrrrrrrrrrrrrrrreeeees 87 26 Replace Fuses and Output IG Serrin e E E R Da 87 SF Checkine the Odometer and Itip Mete asa eaire a a a e a a a a aaa ia 88 3 7 1 Displaying the Odometer Trip Meter and Oil Change Intervals 00000nnnnnnnnnnnnnnnnnnnsnnnnsssssseseseserseseseeee 88 5 72 Resetting the Trip WIGter 0 ei xesis5 acces eens ones atased deen E ec 90 3 8 Checking the Controller ON Time and the Robot Running Time and Resetting Their User Counters 91 3 8 1 Displaying the Controller ON time and the Robot Running Time sseeeseeseeseseeeeenennesnsesssreeeseeeseeseseseeee 9 3 8 2 Resetting the User Counters of the Controller ON Time and the Robot Running Time ccceeeee 92 29 Resetine TMCOGEIS orreri aE ease co Aun ae Neen e eee ease oo ease aoe ec eo 94 3 10 Usine the Init
13. mechanical stop check the normal 4th axis position first as described below When the 4th axis section is rotated once 360 the internal wiring may be caught in the cast crank and broken 4th axis motor Internal wiring Note that turning the 4th axis section by more than 360 may break the internal wiring 59 Checking of 4th axis Position before Carrying Out CALSET 1 Manually move the 4th axis section until the hand control signal connector comes to the upper side 2 Dismount the cover from the second arm so that the internal wiring can be checked The cover to dismount for each model is shown below Hand control signal Hand control signal connector CN21 connector CN21 Remove 4 screws to dismount the cover Remove 3 screws to dismount the cover Ath axis motor VS 6577G VS 6556G 3 Check that the 4th axis section is at a designated position The hand control signal connector CN21 of the second arm comes to the upper side and the internal wiring is not caught in the crank at this time W Checking the 4th axis position for VS 6577G The internal wiring is visible in the normal condition It is not visible if caught in the crank Internal wiring Ath axis motor 60 W Checking the 4th axis position for VS 6556 The internal wiring is visible in the normal condition When the 4th axis section is rotated from where it is as below as shown on the left the internal wiring i
14. positive direction software motion limit value then press OK The screen returns to the Motion Space Software motion limit window STEP 8 Press OK The screen returns to the Maintenance Functions Arm window STEP 9 31 Changing Set RANG Values STEP 1 O onc a saaen appears as shown below 00000 00000 00000 Q 00000 O 00000 STEP 11 a Eda e ommeus Using the numeric keys enter RANG values then press OK STEP 1 2 The screen returns to the RANG window 32 STEP 13 STEP 14 STEP 15 STEP 16 STEP 17 STEP 18 Press OK The screen returns to the Maintenance Functions Arm window Turn the power switch of the robot controller to OFF Turn the power switch of the robot controller to ON Press F2 Arm on the top screen CALSET of the Ist Axis NOTE For UL Listed robot units release the brake on the 1st axis before CALSETing Press SHIFT Press F12 Maint The Maintenance Functions Arm window appears g wm sem Joint woro 1 Maintenance Functions Arm e 2 M Space RANG Brake CALSET F1 F2 F3 F6 o o o ENC inf ENC rst ENC set F19 F11 F12 a Bring the 1st axis into contact with the positive direction mechanical end by hand 33 Press F6 CALSET on the window in Step 18 STEP 1 Q The Set CALSET window appears STEP 20 l Touch the J1 field and confirm that the mark turns green Press OK STEP 21 The messag
15. space to perform teaching regulations and or maintenance inspections set working regulations for the assuring worker following items and ensure workers adhere to them adherence 1 Operating procedures required to run the robot 2 Robot speed when performing teaching 3 Signaling methods to be used when more than one worker is to perform work 4 Steps that must be taken by the worker in the event of a malfunction according to the contents of the malfunction 5 The necessary steps for checking release and safety of the malfunction status in order to restart the robot after robot movement has been stopped due to activation of the emergency stop device 6 Apart from the above any steps below necessary to prevent danger from unexpected robot movement or malfunction of the robot 1 Display of the control panel See Section 4 2 on the next page 2 Assuring the safety of workers performing jobs within the robot s restricted space See Section 4 3 on the next page 3 Maintaining worker position and stance Position and stance that enables the worker to confirm normal robot operation and to take immediate refuge if a malfunction occurs 4 Implementation of measures for noise prevention 5 Signaling methods for workers of related equipment 6 Types of malfunctions and how to distinguish them Please ensure working regulations are appropriate to the robot type the place of installation and to the content of the w
16. the Interval value the oil change prompt message will appear 89 3 7 2 Resetting the Trip Meter to Zero STEP 1 Display the Odometer window as shown below Access F6 Set F6 Maint F5 Odometer from the top screen Press F6 Reset STEP 2 The following message appears Press the OK button The trip meter has been reset to zero 90 3 8 Checking the Controller ON Time and the Robot Running 3 8 1 STEP 1 Time and Resetting Their User Counters You may check the robot controller ON time and the robot running time in the Total hours window of the teach pendant The Total hours window shows the following items Total operation Shows the grand total of the robot controller ON time counted after the controller leaves the factory Total running Shows the grand total of the robot running time counted after the robot leaves the factory Cumu operation Shows the total of the robot controller ON time counted after you reset the user counter to zero Cumu running Shows the total of the robot running time counted after you reset the user counter to zero Operation Shows the ON time of the robot controller counted after it is turned ON this time Running Shows the running time of the robot counted after the robot controller is turned ON this time You can reset the user counters of the robot controller ON time and the robot running time only Displaying the Controller ON time and the Robot R
17. 0 Nm 20 Motor cover of the 3rd axis fa EYES Nb haf CALSET bolt i CALSET bolt Removing the CALSET Bolt VS G series STEP 2 f Rotate the second arm to the position specified in the Step 4 STEP 2 Release the brake of the 4th axis 65 STEP 4 set the CALSET bolt to the end of the 3rd axis housing as shown in the figure below Tightening torque of the CALSET bolt 2 9 Nm 20 NOTE Be sure to use the CALSET bolt as a CALSET jig Using any other bolt will result in a positional error in CALSET TIP The CALSET position of the 4th axis refers to the point where the notch of the second arm comes into contact with the head of the CALSET bolt by turning the second arm Second arm CALSET bolt Second arm notch Mounting the CALSET Bolt VS G series 66 2 4 55 What Is a CALSET Position The limit position of an arm to be CALSET is called a CALSET position Each axis has a mechanical end in each of the positive and negative directions The mechanical ends shown in the figure below are the CALSET positions counterclockwise end when viewed from top Turning end in the negative direction Turning end in the positive direction Turning end in the positive direction which is set by a CALSET jig 4th axis See Section 2 4 4 counterclockwise end when viewed from the arm end Turning end in the positive direction upward end of the 5th axis arm Turning end in the positive directi
18. 60 HEL sERT4xmMmg 2 9 9 dia drill 103 12 Lo HELI SERT 2 x M8 D ed M8 1 25 x 1 5DS EFJ N ce Lj ee 2 l O 9 o M HELI SERT AT 108 12 4x M6 Depth 12 3 123 M6 1 x 2DS 70 From the reverse side 153 166 8 21 7 174 21 Material A2017 T4 47 Reference Drawing of 3rd axis Mechanical Stop VS6556G o 25Z NX 4 x 6 5dia drill 165 74 a NS HELI SERT 2 x M6 166 66 M6 1 x 1DS Material A201 7 14 Reference Drawing of Spacer for 3rd axis Mechanical End VS6556G Material S45C 48 CAE 3 3 3rd axis Mechanical End Change VS6577G 1 Outline The 3rd axis mechanical end can be changed by mounting a mechanical stop to the undedicated internal threads as shown below The mechanical stop and the related parts should be prepared by the customer 3rd axis Mechanical Stop Mounted on the Robot Unit VS6577G Positions of Undedicated Internal Threads to be used for 3rd axis mechanical end change _ 2 undedicated internal threads Example of 3rd axis Mechanical End Configured on the Robot Unit Two sets of bolts and nuts M5x35 Strength class 12 9 Tightening torque 5 9 Nm 20 3rd axis mechanical stop Four bolts M6x20 Strength class 12 9 Stay for 3rd axis Tightening torque 9 8 Nm 20 mechanical end Six sets of bolts and nuts M8x35 Strength class 12 9 Thread length 32 mm Tightening torque 10 Nm 20 Two sets of bolts and nuts M6x20 Strength class 12 9 Tigh
19. Although there is no mechanical stop for the 6th axis a software motion limit is set If the robot reaches a software motion limit during manual or automatic operation an error message will be displayed error code starting from 6070 the first digit represents the axis number and the robot will come to a stop The power to the motor is also turned OFF in such a case during automatic operation All axes are assigned a software motion limit in both the positive and negative direction of the operation range The software motion limit in the positive direction is called the positive direction software motion limit and that in the negative direction is called the negative direction software motion limit NLIM Negative direction Restrictedyange software motion limit Software motion limit Motion range Ti 7 Mechanical end aN i j i Geo o D E eee S z x a E KESET NS me D L an Q PLIM Positive direction software motion limit Software Motion Limits and Mechanical Ends 2 2 2 Factory Defaults of Software Motion Limits The table below lists the software motion limits that are set at the time of delivery Factory Defaults of Software Motion Limits VS G series ad VS 6556G direction See NOTE i _ o n o wegalive 170 ie ug 490 420 360 direction max max direction VS 6577G direction NOTE The 2nd and 3rd axes of the VS 6556G are restricted in workable spaces according to the r
20. DENSO ROBOT Vertical articulated VS G SERIES INSTALLATION amp MAINTENANCE GUIDE Copyright DENSO WAVE INCORPORATED 2005 2010 All rights reserved No part of this publication may be reproduced in any form or by any means without permission in writing from the publisher Specifications are subject to change without prior notice All products and company names mentioned are trademarks or registered trademarks of their respective holders Preface Thank you for purchasing this high speed high accuracy assembly robot Before operating your robot read this manual carefully to safely get the maximum benefit from your robot in your assembling operations Robot series and or models covered by this manual Mini sized vertical articulated VS 6556G 6 axis type VS G VS 6556E GM 5 axis type Models configured with RC7M controller NOTE 1 Model names listed above apply to the models of robot systems The model names of robot units are followed by M If the robot system model is VS 6556G for example the robot unit model is VS 6556E GM Important To ensure operator safety be sure to read the precautions and instructions in SAFETY PRECAUTIONS How the documentation set is organized The documentation set consists of the following books If you are unfamiliar with this robot and option s please read all books and understand them fully before operating your robot and option s GENERAL INFORMATION ABOUT ROBOT Provi
21. ICs 87 3 7 Checking the Odometer and Trip Meter You may check the odometer and trip meter which count traversed distance of each axis in the Odometer window of the teach pendant The access to the Odometer window is F6 Set F6 Maint F5 Odometer The Odometer window shows the following items Odometer Shows the total distance of each axis traversed after the robot leaves the factory You cannot reset the odometer Trip meter Shows the distance of each axis traversed after you reset the trip meter to zero You can reset the trip meter by pressing F6 Reset in the Odometer window and following the guidance shown on the screen 3 7 1 Displaying the Odometer Trip Meter and Oil Change Intervals STEP 1 I the controller power ON STEP 2 the teach pendant set the mode switch to the MANUAL position STEP 3 On the top screen press F6 Set The Settings Main window appears as shown below M amp wm som zint woro iz Settings Main e e e el 2 Load Log Mem Info Set Com Maint F1 F2 a F4 F5 F6 al Options Save SaveFile F7 F8 CF9 Cancel Close this window ao Press F6 Maint 88 STEP 4 The Maintenance menu appears as shown below Maintenance o a a i Press F5 Odometer STEP D The Odometer window appears as shown below Odometer In the above Odometer window the J1 through J6 are expressed in rpm If the Trip meter count exceeds
22. OFF Visually No lack of teeth or Contact DENSO the Sth and 6th excessive wear Industrial Systems axes Product Division 81 3 4 2 Replacing the Encoder Backup Battery Replace the encoder backup battery according to the procedure below STEP 1 Prepare a new set of 3 backup batteries for replacement STEP 2 Turn the controller power OFF Power switch STEP 3 Remove the cover from the robot unit Cover y Cover Cross pan head screw Hex socket head bolt Standard type Cover 82 STEP 4 SIEP 5 Remove the dummy connector cap from the battery board Dummy connector cap Connect a new battery 1st one to the pin from which you have disconnected the dummy connector cap in Step 4 NTa YS Les f a WA at New backup battery Note Do not disconnect old backup batteries before connecting a new one to the pin from which the dummy connector cap is removed If you do so the encoder positional data may be lost 83 Disconnect the old backup battery that is right next to the new battery STEP 6 connected in Step 5 and then connect a new battery 2nd one Old backup battery New backup battery Disconnect the old backup battery that is right next to the new battery STEP A connected in Step 6 and then connect a new battery 3rd one Old backup battery New backup battery Note Be sure to replace all of three batteries with new ones at one time Otherwise the battery
23. S AE aE aaoi il How this DOOK 1S OFSANIZEO wissacscocicsscesessaecctsceascatasactovecica cs saauettacdanantasacuesccancansabaausteaudimansabaceereaaaeceasusacaateaddecausasaiaaseceies iii SAFETY PRECAUTIONS Chapter 1 Installing Robot Components e cssicisacicdeccswecdscvecccdssccenicctseeialactacccsbeccdaseraniectsesiesaceaatiaductausertaswuaabudeissecedavsueeiaes 1 1 1 Preparing a Proper Environment for Installation ccccccceesseseseeeseseseeseeseeeseeeeeseeeeeeeeeeeeeeeeeeeeessessessssesseaaas l LEL Ambient Temperature and HOmidiy esee E A l WAS E N Or O E a a r e a A a e 1 1 1 3 Connecting the Robot Unit and Robot Controller iccciceosscaseeccetesdeaseadegenceicendescatsdsaipanadieMaadhalapusateesuadsieabareesteies LJ Installation Environment of the Robot Unit 2455 6 ci ei ieee ee eee 2 12 Mounie the Robor UM eneen EE EEEE 4 1 2 1 Caution in Floor mount Installation of the Dust amp Splash proof Type of Robot Units 00000000000000000000000 4 12 2 Transporting the Robot UNitesosien E ena E ae ee OA 5 12 gt SE CUriine ie RO DOE W Miles ccc ceis ccc seis cece cenertovdca cnet nocd ve E E ceneuevnan E aioe uw cee O E eee GAG 8 V24 Groodmna CNSR GW Tadeo cis a oh cide ie ew cir Sh Dh re a aS ea ac et 9 E gt lt lnstalling the RODOLG omirOllen ariccunsietsnnaielaccassauaensadcpaanousaenmaseareaouswanewascoteus de taan da wma saiads dausyaerual tam aaaseeemaa sa buuane 9 LA Cautions tor Designing the Robot Hand se6s
24. SET must also be performed RANG refers to a reference angle that determines the relationship between the reference position of the robot and the mechanical ends and is also called a ready angle 1 When CALSET is necessary e g at the time of motor replacement if you perform CALSET after removing the mechanical stop parts prepared by the customer a mechanical end change requires no RANG value change or CALSET If you perform CALSET with the mechanical stop parts prepared by the customer being mounted a mechanical end change requires RANG value change and CALSET In this case the position repeatability depends on the mechanical stop parts prepared by the customer The initialization floppy disk holds the factory defaults of the initial RANG values and CALSET values After performing CALSET the customer needs to manage the RANG values and CALSET values modified The following example for the 1st axis mechanical end change contains RANG value change and CALSET 2 Changing the Mechanical Ends The mechanical ends can be changed by mounting four types of mechanical stop parts i e mechanical stops fixture blocks A fixture block B and plates and then changing the set software motion limits and the RANG values The procedures for doing this are described in the following sections 1 Mounting mechanical stop parts Move the 1st axis of the robot until the stopper bolt comes into the STEP 1 inside of the motion spac
25. about 3 there are any acidic alkaline or other corrosive material 4 there is a mist 5 there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise E For dust amp splash proof The dust amp splash proof type has an IP54 equivalent structure type but it has not been designed to withstand explosions The HM HS G W and the wrist of the VM VS G W are an IP65 equivalent dust and splash proof structure Note that the robot controller is not a dust or splash proof structure Therefore when using the robot controller in an environment exposed to mist put it in an optional protective box The dust amp splash proof type should not be installed in any environment where 1 there are any flammable gases or liquids 2 there are any acidic alkaline or other corrosive material 3 there are any large sized inverters high output high frequency transmitters large contactors welders or other sources of electrical noise 4 it may likely be submerged in fluid 5 there are any grinding or machining chips or shavings 6 any machining oil not specified in this manual is in use or Note Yushiron Oil No 4C non soluble is specified 7 there is sulfuric cutting or grinding oil mist 3 2 Service space The robot and peripheral equipment should be installed so that sufficient service space is maintained for safe teaching maintenanc
26. ange 1 Outline The 3rd axis mechanical end can be changed by mounting a mechanical stop and a mechanical stop bolt with washer to the internal threads dedicated to 3rd axis mechanical end change as shown below The mechanical stop and the related parts should be prepared by the customer 3rd axis mechanical stop bolt and washer mounted in one of the 5 internal threads provided Hex socket head bolt M5x10 Strength class 12 9 Tightening torque 6 1 2 Nm 3rd axis mechanical stop Secured with four hex socket head bolts M5x30 Strength class 12 9 Tightening torque 6 1 2 Nm Example of 3rd axis Mechanical End Configured on the Robot Unit 56 2 Items to be Prepared by the Customer for 3rd axis Mechanical End Change Shown below are the items to be prepared by the customer for 3rd axis mechanical end change Items for 3rd axis Mechanical End Change To be prepared l SaS by the customer Reference Drawings Specifications Rz 100 r 3rd axis mechanical stop 4x9 5 DIA 5 DEEP SF Material A2017 Unit mm Washer Material A2017 Unit mm e Four hex socket head bolts M5x30 Strength class 12 9 for securing a Bolts mechanical stop e One hex socket head bolt M5x10 Strength class 12 9 as a mechanical stop bolt 3 3rd axis Mechanical End Positions The 3rd axis mechanical end positions available are shown in the VS G Series INSTALLATION amp MAINTENANCE GUIDE The 3rd axis motion range defin
27. anical end change To change the mechanical ends of the 2nd axis and 3rd axis the mechanical stoppers should be prepared by the customer Caution After changing the mechanical ends change the software motion limits to the positions inside the mechanical end positions And also if you change the RANG values required after a mechanical end change the CALSET must also be performed RANG refers to a reference angle that determines the relationship between the reference position of the robot and the mechanical ends and is also called a ready angle 1 When CALSET is necessary e g at the time of motor replacement if you perform CALSET after removing the mechanical stop parts prepared by the customer a mechanical end change requires no RANG value change or CALSET If you perform CALSET with the mechanical stop parts prepared by the customer being mounted a mechanical end change requires RANG value change and CALSET In this case the position repeatability depends on the mechanical stop parts prepared by the customer The initialization floppy disk holds the factory defaults of the initial RANG values and CALSET values After performing CALSET the customer needs to manage the RANG values and CALSET values modified The following examples for the 2nd and 3rd axis mechanical end changes do not involve the RANG value change or CALSET 39 2 Checking Existence of Particular Internal Threads Dedicated to 2nd and 3rd
28. arameter to current project Configuring communication options for transfer of arm data from WINCAPSIII to the robot controller Choose Tool Option Communication tab Select Data send setting CALSET data and press OK Option setting General Editor Communication arm Monitor sampling time g Robotik 2 100 msec Program T 100 msec gA AI lt 1100 msec Othersta Data send option oK I cancel Note During ordinary operations the Data send setting CALSET data should be deselected If it is selected creating a new project and transferring arm parameters overwrites the CALSET related data in the robot controller with the transferred data causing errors in teaching positions 95 STEP 3 Transferring arm data to the robot controller Choose Connect Transfer data to display the Transfer data window Select Parameters Arm parameters and Configuration CALSET then press Send Transfer data WINCAPS IIT Controller VI Local data VS 6577G 100121 O Controller 10 6 233 7 CEA Program CICA Program JCS Source file Receive JCS Source file Executable file Map file J Executable file Map file 4 Variable l Variable w lt Tool Work Area w _ 4 Tool Work Area Parameter w a Log V Arm parameters C Parameter C 1 0 parameters Program Parameters V Configuration He
29. cement date that is two years later the current data at which you open this window assuming that the battery service life is two years Press OK NOTE If you do not want to change the replacement date press Cancel The message Are you sure you want to set the next battery replacement date appears Press OK Press F4 Battery in the Maintenance menu The Next Battery Replacement Date window appears The screen returns to the Settings Main window 86 3 5 Supplies and Tools for Maintenance The table below shows the supplies and tools for maintenance Caution 1 The battery used in this device may present a risk of fire or chemical burn if mistreated Do not recharge disassemble heat above 100 C 212 F or incinerate 2 Dispose of used battery promptly Keep away from children Do not disassemble and do not dispose of in fire Supplies and Tools for Maintenance 410053 0100 For standard type of controllers FS 1705W 1 Air filter set 410053 0110 For global type of controllers FS 1705 Memory backup battery 410076 0260 For RC M controller Fuse 1 3A 410054 0230 For LM13 for controller I O IC M54522P for controller output 6 ICforoutput PNP 41007 0020 IC M54564P for controller output e oaser 10182 0010 Foremost 3 6 Replacing Fuses and Output ICs For the replacing procedures of the fuses and output ICs refer to the RC7M CONTROLLER MANUAL Section 6 6 Replacing Fuses and Output
30. counter of the controller ON time Cumu operation for example press F4 Cumu o 92 STEP 2 The following system message appears Press the OK button The user counter of the controller ON time has been reset to zero OH 01M OH 00M a 93 3 9 Resetting Encoders You need to reset encoders and perform CALSET if Error 641 occurs due to run down encoder backup batteries or Error 677 occurs due to a great impact applied to the robot when the power is off is any of 1 to 6 denoting the object axis This section describes how to reset encoders For the encoder resetting procedure refer to the SETTING UP MANUAL Section 5 3 F2 Arm F12 Maint M11 ENC rest 94 3 10 Using the Initialization Floppy Disk STEP 1 STEP 2 The initialization floppy disk WAM holds arm data exclusively prepared for your robot lf CALSET related data in the robot controller is lost due to exhaustion of the memory backup battery for instance use the arm data held in the initialization floppy disk for recovery Loading the arm data held in the initialization floppy disk into the WINCAPSIII project Start WINCAPSIII log on as a Programmer and create a project suitable for your robot model Choose Tool Arm parameters to display the Arm Parameter window Press Load and select the arm data WAM held in the floppy disk to load Arm Parameter Save the ARM Parameter Load the ARM P
31. d while performing all motions commanded by the task program Quoted from the ISO 10218 1 2006 Task program Refers to a set of instructions for motion and auxiliary functions that define the specific intended task of the robot system Quoted from the ISO 10218 1 2006 1 Introduction 2 Warning Labels Label 1 DENSO Label 4 Label 3 Sr Label 2 Example Location of labels Warning label A Ai BRORNG THURRAAICASS Risk of injury Do not enter restricted space Unfallgefahr Nicht die Sperrzone betreten SEA FH GS TS AB SS Yo EA EA Bae ole HEN Maer Label 1 lt Except HM gt N WARNING P LATE Moving robot can cause serious injury Durch Roboterbewegungen k nnen Verletzungen verursacht werden 2 ARM t F9 TEMAS Bo lt HM gt A WARNING SM gt P L xe tA wy Label 2 Part No 410985 406 Moving robot can cause serious injury Durch Roboterbewegungen k nnen Verletzungen verursacht werden 2 ARM 34 F79 HEME IE Z WARNING Risk of electrical shock Do not open controller cover when power is on Do not touch inside within 3 minutes of turning off power and disconnecting cable Label 3 Z WARNING Risk of injury Do not turn on power when someone is inside safety fence Lockout and tagout power before servicing Label 4
32. des the packing list of the robot and outlines of the robot system robot unit and robot controller INSTALLATION amp MAINTENANCE GUIDE this book Provides instructions for installing the robot components and customizing your robot and maintenance amp inspection procedures STARTUP HANDBOOK Introduces you to the DENSO robot system and guides you through connecting the robot unit and controller with each other running the robot with the teach pendant and making and verifying a program This manual is a comprehensive guide to starting up your robot system SETTING UP MANUAL Describes how to set up or teach your robot with the teach pendant or mini pendant For the panel designer functions refer to the Panel Designer User s Manual SUPPLEMENT WINCAPSIII GUIDE Provides instructions on how to use the programming support tool WINCAPSIII which runs on the PC connected to the robot controller for developing and managing programs PROGRAMMER S MANUAL I Program Design and Commands Describes the PAC programming language program development and command specifications in PAC This manual consists of two parts Part 1 provides the basic programming knowledge and Part 2 details of individual commands PROGRAMMER S MANUAL II PAC Library Describes the program libraries that come with WINCAPSIII as standard RC7M CONTROLLER MANUAL Provides the specifications installation and maintenance of the RC 7M controller It also describes interfaci
33. e and inspection 3 3 3 4 3 5 3 6 3 7 3 8 Control devices outside the robot s restricted space Positioning of gauges Protection of electrical wiring and hydraulic pneumatic piping Grounding resistance Positioning of emergency stop switches Positioning of operating status indicators The robot controller teach pendant and mini pendant should be installed outside the robot s restricted space and in a place where you can observe all of the robots movements and operate the robot easily Pressure gauges oil pressure gauges and other gauges should be installed in an easy to check location If there is any possibility of the electrical wiring or hydraulic pneumatic piping being damaged protect them with a cover or similar item The protective grounding resistance of the robot power supply should not be more than 1000 Emergency stop switches should be provided in a position where they can be reached easily should it be necessary to stop the robot immediately 1 The emergency stop switches should be red 2 Emergency stop switches should be designed so that they will not be released after pressed automatically or mistakenly by any other person 3 Emergency stop switches should be separate from the power switch Operating status indicators should be positioned in such a way where workers can easily see whether the robot is on a temporary halt or on an emergency or abnormal stop Note The
34. e covered on the customer s usage conditions sufficiently Design manufacture and install the mechanical stoppers according to your usage conditions The weight addition by the mechanical stoppers may affect the maximum payload The failures caused by the mechanical stoppers shall not be covered by the warranty even if the robot is under warranty 20 2 3 1 1Ist axis Mechanical End Change 1 What is the Ist axis Mechanical End Change At the time of delivery from the factory mechanical ends are set in the VS G series so that the stroke of the 1st axis will be 170 Changing the mechanical ends of the 1st axis by adding mechanical stops is called a mechanical end change The figure below shows the mechanical stop positions for mechanical end change Given below is an example when the mechanical stops are positioned as specified in the table below To change the mechanical ends the following four types of mechanical stop parts are required Mechanical stop 4 pieces Fixture blockA 2 pieces Fixture blockB 1 piece Plate 2 pieces The figures on the following pages show the reference drawings of those mechanical stop parts Referring to those drawings you should prepare mechanical stop parts as necessary so that your desired motion space may be set Plates Fixture block A X Fixture block A 7 F A A Fixture block B Locations of Mechanical Stops in the
35. e that you want to set Stopper bolt 24 Secure fixture block A to the plate with two hexagonal socket head STEP 2 bolts Make a pair of assemblies Fixture block A Hex socket head bolt M8x16 Strength class 12 9 Tightening torque 36 7 2 Nm Turn the assemblies made in Step 2 upside down Secure two STEP 3 mechanical stops to each of those assemblies with two hexagonal socket head bolts for determining the desired motion space Mechanical stops Hex socket head bolt M8x16 Strength class 12 9 Tightening torque 20 4 Nm 25 Temporarily secure one of the assemblies made in Step 3 to the side of STEP 4 the 1st axis with hexagonal socket head bolts Temporarily tighten bolts In the same way as in Step 4 temporarily secure the other one of the STEP 5 assemblies to the opposite side Temporarily tighten bolts Link the assemblies together that you have temporarily secured in STEP 6 Steps 4 and 5 using fixture block B and two hexagonal socket head bolts After that firmly tighten the hexagonal socket head bolts on fixture blocks A that have been temporarily tightened in Steps 4 and 5 Fixture block B Tightening torque 36 7 2 Nm 26 2 Software motion limits and Set RANG values If you perform CALSET with the mechanical stop parts prepared by the customer being mounted a mechanical end change requires RANG value change and CALSET In this case the position repeatability depe
36. e window appears asking you whether you want to execute CALSET eae Set CALSET OO ufs 34 Press OK STEP 22 The message window appears informing you that CALSET is completed STEP 23 Press OK Caution After CALSET is completed move the 1st axis over the full stroke in the manual mode speed 10 or less to confirm that the positive direction and negative direction software motion limits function properly If they are valid the axis stops just before the mechanical end and ERROR6071 appears In the following cases reset the bolt positions the positive direction software motion limits the RANG values and the negative direction software motion limits to the original settings and repeat the procedure from the beginning 1 The software motion limits do not function when the axis is near a mechanical end and another error 6111 6121 or 6171 occurs 2 A software motion limit error ERROR6071 occurs although the axis is not near a mechanical end 35 4 Changing set negative direction software motion limits NLIMs The set negative direction software motion limits NLIMs must be changed whenever the negative direction mechanical ends are changed Change the set negative direction software motion limits PLIMs according to steps 1 through 10 described below STEP 1 l Turn the power switch of the robot controller to ON STEP 2 l Set the mode selector switch of the teach pendant to MANUAL Press F2 Ar
37. ection software motion limit 90 3 When the positive direction mechanical ends are B and the negative direction mechanical ends are A change Positive direction software motion limit 90 RANG value obtained in Checking the set RANG value Negative direction software motion limit 0 4 When the positive direction mechanical ends are A and the negative direction mechanical ends are the permanent mechanical ends change Positive direction software motion limit 46 RANG value obtained in Checking the set RANG value 5 When the positive direction mechanical ends are the permanent mechanical ends and the negative direction mechanical ends are B change Negative direction software motion limit 136 29 3 Changing positive direction software motion limits PLIMs and RANG values The set positive direction software motion limits PLIMs and RANG values must be changed whenever the positive direction mechanical ends are changed If the following case the RANG values change and the CALSET are necessary after a mechanical end change If you perform the CALSET for the robot with the mechanical stop parts prepared by you when the CALSET becomes necessary Example Exchanging the motor In this case the position repeatability is depended on the mechanical stop parts prepared by you And also you need to note down the new RANG values and CALSET values The initial RANG values and CALSET values at the time of deliv
38. ed in it applies as is Specify the software motion limit that corresponds to the mechanical stop end position actually selected referring to the above manual 57 3 3rd axis Mechanical End Positions The 3rd axis mechanical end positions available are shown below Note Mounting the 3rd axis mechanical stop limits the workable angle of the 3rd axis so that the 3rd axis cannot move up to the factory default angle Observe the following 1 The 3rd axis cannot move overriding 150 in the positive direction so set the positive direction software motion limit for the 3rd axis in the negative side than 150 2 In the VS 6556G series mounting the 3rd axis mechanical stop limits the workable angle of the 3rd axis so that the 3rd axis cannot move overriding 25 20 on the UL Listed models in the negative direction Set the negative direction software motion limit for the 3rd axis in the positive side than 25 20 In the VS 6577G series the 3rd axis cannot move overriding 65 in the negative direction Set the negative direction software motion limit for the 3rd axis in the positive side than 65 Be careful with the design of the mechanical stop Depending upon the shape of the mechanical stop prepared by the customer the axis may hit the mechanical stop before the software motion limit described above is activated VS 6556G VS 6577G Motion range software motion limit value The table below lists the 3rd axis mot
39. ediately upon detection of a such as teaching malfunction and perform any other necessary measures 1 Check for any damage to the sheath or cover of the external wiring or to the external devices 2 Check that the robot is functioning normally or not any unusual noise or vibration during operation 3 Check the functioning of the emergency stop device 4 Check there is no leakage of air or oil from any pipes 5 Check there are no obstructive objects in or near the robot s restricted space SAFETY PRECAUTIONS 4 5 Release of residual air pressure 4 6 Precautions for test runs 4 7 Precautions for automatic operation 4 8 Precautions in repairs Before disassembling or replacing pneumatic parts first release any residual air pressure in the drive cylinder Whenever possible have the worker stay outside of the robot s restricted space when performing test runs 1 At start up 4 Stay out of the safeguarded space with a safety fence when starting the robot in particular take extra caution in Internal automatic operation Before starting the robot check the following items as well as setting the signals to be used and perform signaling practice with all related workers 1 Check that there is no one inside the safeguarded space with a safety fence 2 Check that the teach pendant and tools are in their designated places 3 Check that no lamps indicating a malfunction on the robot or related equ
40. elease the brake and bring the axis into contact with the mechanical stop e The VS G series can release the brake of the specified axis e Brake equipped version of the VS G series Each of the 2nd through 6th axes has a brake e None brake version of the VS G series Only the 2nd to 4th axes have brakes e UL Listed robot units of the VS G series All axes have brakes When releasing brakes be careful about the robot motion Releasing brakes causes the robot arm to move by its own weight After CALSET confirm in the manual mode that each axis stops at the software motion limit before coming into contact with the mechanical end In automatic operation start to run the robot at low speed Ensuring safety gradually increase the speed It makes adjustment easy Position related data in some programs made before CALSET may vary somewhat after CALSET For models having no mechanical stop on the 4th axis When rotating the 4th axis with the brake released take care not to let the 4th axis override the motion limit initial setting of the software motion limit Rotating it beyond the motion limit will cause the brake even released to be locked turning the motor off Be careful with arms that may rotate by gravity after brakes are released depending upon the robot posture and hand position If the RANG values have not been changed after a mechanical end change remove the changed mechanical end s before performing CALSET 62
41. emergency stop NWarning Performing the brake release operation drops the arm Make sure beforehand that the release operation will not cause bodily injuries or equipment damages Moving the axes in an emergency stop AX How to move the axes iS VS G VS G W VS G B VS G BW VS GW UL itane Move the robot arm by Move the robot arm by hand Select the target axis with the axis hand selector and then move the axis ond axig Release the brake with Release the brake with the by hand while holding down the Nd AXIS 8 teach pendant or teach pendant or brake release switch mini pendant and then mini pendant and then move For details refer to Section 1 6 move the robot arm by the robot arm by hand Releasing Brakes on UL Listed hand For details refer to the Robot Units SETTING UP MANUAL Chapter 5 Commands Assigned to Function Keys of ts me Topotarm DY the Teach Pendant and i Chapter 6 Using the Mini Pendant 3rd axis motor cover rear side 4th axis J4 re 4th axis cover Second arm cover Brake release switch Motor ON lamps 2nd axis motor cover rear side Axis selector 7 positions off 1 to 6 UL Listed 10 1 6 Releasing Brakes on UL Listed Robot Units The brake release operation on UL Listed robot units is different from that on other types The UL Listed robot units have the axis selector and the brake release switch on the base for brake releasing NOTE On robot units exc
42. ept UL Listed ones the teach pendant or mini pendant is used to release brakes Refer to the SETTING UP MANUAL Chapter 5 Commands Assigned to Function Keys of the Teach Pendant and Chapter 6 Using the Mini Pendant Warning 1 Before pressing the brake release switch make sure that there is no danger that dropping the arm will cause bodily injuries or equipment damage Pressing the switch releases the brake of the selected axis dropping the arm depending upon the axis 2 Do not turn the axis selector with the brake release switch being pressed 3 To prevent an unintended brake release usually set the axis selector to OFF STEP 1 Turn the power switch of the robot controller to ON NOTE Check that the motor ON lamps are not lit motor power OFF STEP 2 Select the target axis to release its brake with the axis selector Press the brake release switch Only when the switch is being pressed STEP 3 the brake of the selected axis is released Brake release switch Motor ON lamps Axis selector 7 positions off 1 to 6 11 1 7 Locking Out the Power Switch Lock out the power switch during maintenance and inspection jobs using a commercially available padlock according to the following procedure Step 11 Check that the power switch of the robot controller is turned OFF Power OFF Remove the lockout bar provided on the robot controller Step 2
43. ery from the plant are saved in the initialization floppy disk Change the set positive direction software motion limits PLIMs and RANG values according to steps 1 through 24 described below Changing Positive Direction Software Motion Limits PLIMs STEP 1 i Turn the power switch of the robot controller to ON STEP 2 l Set the mode selector switch of the teach pendant to MANUAL Press F2 Arm on the top screen STEP 3 The Current Robot Position window appears Press F12 Aux STEP 4 The Maintenance Functions Arm window appears H g m wm eem Jint noroi tz Maintenance Functions Arm 2 2 2l M Space RANG Brake CALSET LF1 LF2 LF3 LFG e o a ENC inf ENC rst ENC set CF18 CF11 CF12 Cancel Close this window C 30 Press F1 M Space STEP 5 The Motion Space Software motion limit window appears as shown below M g cx m sem Joint noroi w Motion Space Software motion limit 179 000 Software motion limit J2 135 000 Software motion limit GJ1 Software motion limit J3 165 000 Software motion limit J4 185 000 Software motion limit amp J5 120 000 Cancel OK F5 Change the selection go A Back Next Jump To Change Using the jog dial or cursor keys select the Software motion limit J1 deg field STEP 6 Press F5 Change The numeric keypad appears STEP 7 Using the numeric keys enter the
44. eten 5a Pei7t Us oe HS AIH ol SA7 B A ANHEE RBENRERPUEN Post a notice showing axes names and moving directions in a visible location on the robot unit The posted moving directions should match the actual directions No posting or wrong direction posting may result in bodily injuries or property damages due to incorrect operation SAFETY PRECAUTIONS 4 Precautions AN Touching the robot while it is in while Robot is Warning operation can lead to serious WARNING Running injury Please ensure the fol lowing conditions are maintained and that the cautions listed from Section 4 1 and onwards are followed when any work is_ being TROEN WWARBANCASE performed Risk of injury Do not enter restricted space Untallgefahr Nicht die Sperrzone betreten B59 Pot GE 7H Ast AA Yo EAH LA AMEER AREA A AR el Mah Do not enter the robot s restricted space when the robot is in operation or when the motor power is on As a precaution against malfunction ensure that an emergency stop device is activated to cut the power to the robot motor upon entry into the robot s restricted space When it is necessary to enter the robot s restricted space to perform teaching or maintenance work while the robot is running ensure that the steps described in Section 4 3 Ensuring safety of workers performing jobs within the robot s restricted space are taken 4 1 Creation of working When entering the robot s restricted
45. g teaching or making any changes always save the programs and data onto floppy disks Making back ups will help you recover if data stored in the robot controller is lost due to the expired life of the back up battery 3 Write the names of each of the floppy disks used for storing task programs to prevent incorrect disks from loading into the robot controller Store the floppy disks where they will not be exposed to dust humidity and magnetic field which could corrupt the disks or data stored on them T Safety Codes The safety standards relating to robot systems are listed below As well as observing the safety precautions given in this manual ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system Standards Title ANSI RIA R15 06 1999 Industrial Robots and Robot Systems Safety Requirements ANSI UL1740 1998 Safety for Robots and Robotic Equipment CAN CSA 2434 03 Industrial Robots and Robot Systems General Safety Requirements ISO10218 1 2006 Robots for industrial environments Safety requirements Part 1 Robot NFPA 79 2002 Electrical Standard for Industrial Machinery 8 Battery Recycling DENSO Robot uses lithium batteries Discard batteries according to your local and national recycling RA eS Ete as el ic EU Contents PROT ACC S E E EE E E A E E A A E A A ATE i How the documentation Set 18 OF Gani Ze sisses aa eaaa a E
46. g torque 9 8 Nm 20 42 Reference Drawing of Part A 21 39 v ay 74 81 74 6 6 DIA DRILL 120 30 15 65 174 225 Material A201 7 T4 43 2 7 gt D LO lt z o oe e e y y y 2 9 DIA DRILL N 10 30 Reference Drawing of Part B M8 18 DEPTH 24 STARTING HOLE DEPTH M6 11 DEPTH 18 STARTING H LE DEPTH Material A201 7 T4 Reference Drawing of Part C iy y ae a i 3X9 DIA DRILL 14 J a 7 o O Z r ii Ak et N J 7 YJ L Pe go F ee oe a SS e UUU melaa et Ld ri os Oat a 50 3 P 134 209 163 sss SSS Se 200 Material A201 7 T4 44 3 2 3rd axis Mechanical End Change VS6556G 1 Outline The 3rd axis mechanical end can be changed by mounting a mechanical stop to the undedicated internal threads as shown below The mechanical stop and the related parts should be prepared by the customer Example of 3rd axis Mechanical End Configured on the Robot Unit VS6556G Positions of Undedicated Internal Threads to be used for 3rd axis mechanical end change 2 undedicated internal threads Example of 3rd axis Mechanical End Configured on the Robot Unit Stay for 3rd axis mechanical end 2 spacers Stay for 3rd axis mechanical end Six sets of bolts and nuts M8x35
47. he 1st axis over the full stroke in the manual mode speed 10 or less to confirm that the positive and negative direction software motion limits function properly If they are valid the axis stops just before the mechanical end and ERROR6071 appears In the following cases reset the bolt positions the positive direction software motion limits the RANG values and the negative direction software motion limits to the original settings and repeat the procedure from the beginning 1 The software motion limits do not function when the axis is near a mechanical end and another error 6111 6121 or 6171 occurs 2 A software motion limit error ERROR6071 occurs although the axis is not near a mechanical end 38 2 3 2 2nd axis and 3rd axis Mechanical Ends Change 1 What is the 2nd axis and 3rd axis Mechanical Ends Change At the time of delivery from the factory mechanical ends are preset so that the workable angle of the 2nd axis and 3rd axis will be as listed in the table below factory default Note The limit to the workable angle of the robot is defined by the software motion limit The software motion limit is set inside the mechanical end positions Workable angle at shipping for VS G series Workable angle for the 2nd axis Workable angle for the 3rd axis VS 6556G series 135 100 166 119 Changing the mechanical ends of the 2nd axis and 3rd axis by adding mechanical stoppers is called a mech
48. he mounting face or beam so that the weight of the cables will not be directly applied to the connectors T Functional ground Grounding conditions seac ioue ominas Working space etc Z 0 1 500 20 or more 1000 or less 100 x 100 pipe 500 or more Caution 1 When the robot operates at high speed the robot mount undergoes large reaction forces The mount must be rigid enough so that it will not vibrate or be displaced due to reaction forces It is also advisable to mechanically join the robot mount with heavy equipment 2 Some mounts may produce a resonance sound howling If this sound is loud increase the rigidity of the mount or slightly modify the robot speed Robot Mount Example for Floor mount square steel pipe Caution 1 When the robot operates at high speed the top plate structure undergoes large reaction forces Design the vibration proof mount so that the top plate will not vibrate due to reaction forces Also design the top plate structure so that it separates from other top plate structures in the equipment 2 Some mounts may produce a resonance sound howling If this sound is loud increase the rigidity of the mount or slightly modify the robot speed Robot Mount Example for Overhead mount 1 2 Mounting the Robot Unit caution Before handling or installing the robot unit be sure to read SAFETY PRECAUTIONS Installation Precautions Caution in Floor mount Ins
49. iacad i ssteecncanncceeincdnad ananassae caved tuniteat icra S 9 1 5 Moving Each Axis with Motor Power OFF in Emergency Stop ccccccccseesssesssessssessesseseseseeseeeeseseseeseeeeeens 10 1 6 Releasing Brakes on UL Listed Robot Units ccc ccccecesceseessseessessssesssssssssssssssssssssssseeeseeeeseeeesseseeeeeeeeeeentaaas 11 7 Lockne Outihe Power SWC hessian anina a a a atananaasauahay 12 Chapter 2 Customizino YOUr IR ODOL sscssssasisscssscesstsctascsconednossascatecsdsoantasastenacssensoannoscovaunansa tances aaa oo nan koia as 13 Ze MaE Custom ZANO Aa a AE ean T uammtouuitiembedanaeee 13 2 2 Modifying Software Motion Limits to Define New Motion Space cccccccccccccccccccececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 14 221l What Isa Software Monon Limit enisieniipnni ea A a A E aL 14 2 2 2 Factory Defaults of Software Motion Limits ccccccccsecccceececccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 15 2 2 3 Changing Software Motion LIMH S coenssireriennsosei ii naren a a E a a a E 16 2 2 4 Precautions When Changing the Software Motion Limits 00 0 cccccccccccssccccccceeceeceeeeeceeeeeeeeeeeceeeeeeeseseeeees t7 2 2 5 Procedure for Changing the Software Motion Limits 00 0 ccccccccccceccccccececeeceeeeeeeeeeeeseeeeeeeeeeeeseseeeseeeeeess 17 2 Chaneine the Mechanical Endeo seran ee dace A A 20 Aal Wsteaxis Mechanical End EHanpe sscan n e a a e a a 21 2 35 2 2nd axis and 3rd axis Mecha ical Ends Cha
50. ialization Floppy DISk orasini coarse tee a cae d cea E le ae th aalaet acct 95 Chapter 1 Installing Robot Components 1 1 Preparing a Proper Environment for Installation Before installing the robot unit and robot controller confirm that the operating environment is in conformity with each item of SAFETY PRECAUTIONS Installation Precautions and that the surrounding environment of the location where the robot is to be used meets the specifications as described below Also take proper measures to protect the components from vibration In an inappropriate environment the robot will not operate to its full capacity or performance components may not last long and unexpected failure may result 1 1 1 Ambient Temperature and Humidity Keep the ambient temperature between 0 C and 40 C during operation Keep the ambient humidity at 90 or below to prevent dew condensation 1 1 2 Vibration Do not install the robot in an environment where it will be exposed to excessive vibration or impact Caution When the excessive vibration is added to the robot unit at power off during transportation ERROR 2AF1 Encoder reference position error may occur If the ERROR 2AF1 occurs when turning the robot controller ON at first after purchasing the robot refer to the ERROR CODE TABLES or contact our Robot Service Section 1 1 3 Connecting the Robot Unit and Robot Controller Before delivery the robot unit and the robot controller are c
51. ion range when a positive or negative direction mechanical stop is mounted at each of the mechanical end positions available o e 7 Co T o 3rd axis Mechanical End Positions Available 58 2 4 CALSET 2 4 1 What Is CALSET Calibrating the relationship between position related information recognized by the robot controller and the actual position of the robot unit is called CALSET CALSET must be performed when the motor is replaced or when the encoder backup battery goes dead and the position related data retained in the encoder is lost as a result After CALSET is completed the calibrated data of the robot unit will be stored in the robot controller This data is called CALSET data which is different on each robot This robot has been CALSET before delivery and the CALSET data is stored in the floppy disks that come with the robot unit Therefore even if the memory backup battery in the robot controller dies so that the CALSET data is lost you do not need to CALSET the robot Just reload the CALSET data from the floppy disks 2 4 2 Precautions about CALSET for the VS G Series For models having no mechanical stop on the 4th axis Robots in the VS G series have no mechanical stop on the 4th axis If the 4th axis CALSET position is wrongly set by one rotation 360 while CALSET is being carried out the internal wiring may be caught in the crank and broken To carry out CALSET with a robot with no 4th axis
52. ipment are lit Check that the display lamp indicating automatic operation is lit during automatic operation Steps to be taken when a malfunction occurs Stop the robot s operation by activating the emergency stop device when it is necessary to enter the safeguarded space with a safety fence to perform emergency maintenance in the case of malfunction of the robots or related equipment Take any necessary steps such as posting a notice on the start switch to indicate work is in progress to prevent anyone from accessing the robot Do not perform repairs outside of the designated range Under no circumstances should the interlock mechanism be removed When opening the robot controller s cover for battery replacement or any other reasons always turn the robot controller power off and disconnect the power cable Use only spare tools specified in this manual 5 Daily and Periodical 1 Be sure to perform daily and periodical inspections Before In tion starting jobs always check that there is no problem with the ll robot and related equipment If any problems are found take any necessary measures to correct them 2 When carrying out periodical inspections or any repairs maintain records and keep them for at least 3 years 6 Management of 1 Carefully handle and store the Initial settings floppy disks packaged with the robot which store special data Floppy Disks exclusively prepared for your robot 2 After finishin
53. ling fan filters in the robot controller m Replacement of encoder backup batteries m Replacement of controller memory backup batteries m Inspection of timing belts m Replacement of controller fuses m Replacement of controller output ICs 17 CAUTION 1 When transporting or maintaining the cleanroom type of robot units take care not to apply an impact or shock to the cover section specified below An impact or shock applied to the cover section or the resulting deformed cover section may deteriorate the cleanliness performance No impact or shock is allowed on this cover section 78 3 2 Daily Inspections 3 2 1 Check Items Before starting operation every day check the items listed in the table below Daily Inspections Table Check Controller Gion What to do Power Note 1 LCD on the teach 3 pendant Connectors CN1 to Engage the CN10 on the robot l No looseness parts properly controller and their OPE vipua disengagement or dirt and clean mating parts them Cables connected to CN1 to CN10 on the robot controller and robot s external cables Free of damage or Repair or gouges replace Repair or Visually Properly displayed replace Visually Should light REPaArOT replace Visually i Should work properly Repar or Note 2 replace ee ie tess ue TRA TODO SNOL Repair or z EMERGENCY STOP come to an P pendant or the mini replace button emergency stop Visually Pilot lamps on the robo
54. listed in the upper table on this page and inspect the timing belts for the 5th and 6th axes shown in the lower table on this page during biannual inspection and maintenance Caution 1 The battery used in this device may present a risk of fire or chemical burn if mistreated Do not recharge disassemble heat above 100 C 212 F or incinerate 2 Dispose of used battery promptly Keep away from children Do not disassemble and do not dispose of in fire Backup Battery Types 4 Encoder backup battery pon UD ME PORNON CARDI i ae Toog Section 3 4 2 the servomotor encoder unit Back up programs In the robot Memory backup battery parameters and CAL data Section 3 4 3 The position data of the encoder built in the servomotor is stored in the internal memory of the encoder Programs parameters CAL data etc are stored in the internal memory of the robot controller The backup battery for each memory retains the above data while the power to the robot controller is turned OFF However these batteries have a limited lifetime and must therefore be replaced regularly NOTE If two years elapse from replacement of either backup battery the Time to change controller backup battery message will appear on the teach pendant N Caution Without replacing the backup _ batteries important robot specific data stored in each memory will be lost Biennial Inspection Table VS G series Power Timing belts on
55. ll strike against those eyebolts 1 2 3 Securing the Robot Unit 1 Drill four bolt holes M10 20 mm deep or more and two dowel pin holes 04 H7 for diamond shaped pin and o6H7 for internally threaded positioning pin 10 mm deep or more in the robot mounting position where the robot unit is to be secured according to the dimension in the figure below 2 Drive the diamond shaped pin into the 4H7 hole so that it orients as shown below 3 Drive the internally threaded positioning pin into the o6H 7 hole NOTE Be sure to drive the knock pins It can minimize positional deviations that may be caused by the removal installation of the robot unit for maintenance or the vibration during operation 4 Set the robot unit into place on the robot mount When transporting the robot unit follow the instructions given in Section 1 2 2 Transporting the Robot Unit 5 Secure the robot unit to the mount with four bolts and plain washers Bolt M10 x 30 mm strength class 12 9 Tightening torque 70 14 Nm 200 160 2 6H7 80 6640 05 Reference hole b Connector sid LO i lt 4 12 hole For M10 Diamond shaped pin Bolt Positions for Securing the Robot Unit VS G series 1 2 4 Grounding the Robot Unit Ground the grounding terminal of the robot unit with a wire of 5 5 mm or more NOTE Use a dedicated grounding wire and grounding electrode Do not share them wi
56. m on the top screen STEP 3 The Current Robot Position window appears 2 a wm sosm Joint wotol 1 Current Robot Position J r je fe P J T x J2 4 B J5 J6 0 00 J Cancel Close this window a Press F12 Maint STEP 4 The Maintenance Functions Arm window appears G m 8 co vm e Joint woro i z Maintenance Functions Arm 2 4 2 Z M Space RANG Brake CALSET CF1 F2 F3 F6 o o 2 ENC inf ENC rst ENC set F19 F11 F12 Cancel Close this window CE 36 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 Press F1 M Space The Motion Space Software motion limit window appears G 2 wm sosm Joint woto 1 Motion Space Software motion limit 170 000 Software motion limit J2 Software motion limit J3 Software motion limit J1 Software motion limit J4 185 000 Software motion limit J5 122 800 Cancel OK F5 Change the selection oe Using the jog dial or cursor keys select the Software motion limit J1 deg field Press F5 Change The numeric keypad appears limit value then press OK The screen returns to the Motion Space Software motion limit window Using the numeric keys enter a negative direction software motion l Press OK 37 STEP 1 0 Turn the power switch of the robot controller to OFF Caution After changing the software motion limit s move t
57. nd axis mechanical end can be changed by mounting a mechanical stop and a mechanical stop bolt with washer to the internal threads dedicated to 2nd axis mechanical end change as shown below The mechanical stop and the related parts should be prepared by the customer 2nd axis mechanical stop Secured with five hex socket head bolts M6x30 Strength class 12 9 Tightening torque 10 2 Nm 2nd axis mechanical stop bolt and washer mounted in one of the 5 internal threads provided Hex socket head bolt M6x10 Strength class 12 9 Tightening torque 10 2 Nm Example of 2nd axis Mechanical End Configured on the Robot Unit 53 2 Items to be Prepared by the Customer for 2nd axis Mechanical End Change Shown below are the items to be prepared by the customer for 2nd axis mechanical end change Items for 2nd axis Mechanical End Change To be prepared by the customer Reference Drawings Specifications 2nd axis mechanical stop 5x11 DIA 6 DEEP SF Unit mm Material A2017 Unit mm e Five hex socket head bolts M6x30 Strength class 12 9 for securing a mechanical stop e One hex socket head bolt M6x10 Strength class 12 9 as a mechanical stop bolt 3 2nd axis Mechanical End Positions The 2nd axis mechanical end positions available are shown in the VS G Series INSTALLATION amp MAINTENANCE GUIDE The 2nd axis motion range defined in it applies as is Specify the software motion limit that corresponds t
58. nds on the mechanical stop parts prepared by the customer The initialization floppy disk holds the factory defaults of the initial RANG values and CALSET values After performing CALSET the customer needs to manage the RANG values and CALSET values modified STEP 1 STEP 2 The set software motion limits and RANG values must be changed whenever the mechanical end positions are changed A RANG is the angle that determines the relationship between the reference position of the robot and the mechanical ends and is also called a reference angle or ready angle The RANG value checking procedure is given below The relationship between each mechanical end position and software motion limits is shown in the table on page 29 Change the set software motion limits PLIMs and RANG values according to the procedures given in 3 Changing positive direction software motion limits PLIMs and RANG values and 4 Changing the negative direction software motion limits NLIMs Checking the set RANG values After mounting the mechanical stop parts check the RANG values according to the procedure below The RANG values that you check here should be entered in the procedure of 3 Changing positive direction software motion limits PLIMs and RANG values and 4 Changing the negative direction software motion limits NLIMs When you use the permanent mechanical end this checking job is not required Turn the power switch of the
59. ng with external devices system and user input output signals and I O circuits ERROR CODE TABLES List error codes that will appear on the teach pendant or mini pendant if an error occurs in the robot system These tables also provide detailed description and recovery ways OPTIONS MANUAL Describes the specifications installation and use of optional devices For the extension board conveyer tracking board refer to the OPTIONS MANUAL SUPPLEMENT 1l How this book is organized This book is just one part of the robot documentation set This book consists of SAFETY PRECAUTIONS chapters one through three SAFETY PRECAUTIONS Defines safety terms and related symbols and provides precautions that should be observed Be sure to read this section before operating your robot Chapter 1 Installing Robot Components Provides information about physical site planning installation procedures and engineering design notes for hands Chapter 2 Customizing Your Robot Describes how to customize your robot defining the software motion space and restricted space CALSETing and setting control set of motion optimization Chapter 3 Maintenance and Inspection Describes the regular maintenance and inspections necessary for maintaining the performance and functions of your robot lli SAFETY PRECAUTIONS SAFETY PRECAUTIONS Be sure to observe all of the following safety precautions Strict observance of these warning and cauti
60. nge ierse ioo aa ara assasi 39 DA CALSE DT i A A N 59 2E What ISC ALSE T eee re ee mn E E 59 2 4 2 Precautions about CALSET for the VS G Series so scsciss so side Mariveabbeusdeseneadeadends denied ieadiddaeeeldcasaeewese 59 24 3 Preparation tor CALSE T secnm s E 61 DAA Mounin ehe CALSE TI i caked coms iartas a a 63 ZA Whats a C AL SE ROSON spuna iced acini arniaad Sasuubea iat aldol uats Aauededemdddiindeniad mamas 67 DAO CO Alam I Proc cure sists s ccstenkaacantievnglavoaaodithnens A 68 2 5 Setting Control Sector Moun Opiniao sree it a a E eae AAA 75 26 Setting Ropot Installation Condilons ueerassi a a a a a a Galen ae 76 Chapter 3 Maintenance and Inspection sess scciescsssswasss sassansessswasssssedanspecssissdsvonsesncwassesesdossebassioss ssdsvouscsnstisssesesslonsebaswsesssdcvess 77 3 1 Maintenance Inspection Intervals and PUurpOses ssii 2 ccascax cacdosedcanhaxes eeacded sammazeadaeseded daubacen AR 77 3 1 1 Precautions for installation and maintenance of robots for cleanroom tyPe cccccccccccccccseceeeeeeeeeeeeeeeeeeees 77 ZA Daly Inspec Uon 4 5ai5 tee yan eee A Ete SS ae Se Thales eee ta tae 79 Sed C NECK NEMS ee eat E A E I E A E A vassals 79 J Quarter INS DECH OMS saien EA OA A EAE EO 80 DD le Check CIS enina a O 80 3 3 2 Cleaning the Cooling Fan Filters in the Robot Controller ccc ccccccccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeeeeess 80 JA YBieniiall NSPE CONS east eee aie rete eee esse
61. o the mechanical stop end position actually selected referring to the above manual 54 3 2nd axis Mechanical End Positions The 2nd axis mechanical end positions available are shown below Note Mounting the 2nd axis mechanical stop limits the workable angle of the 2nd axis so that the 2nd axis cannot move up to the factory default angle Observe the following 1 The 2nd axis cannot move overriding 60 in the negative direction so set the negative direction software motion limit for the 2nd axis in the positive side than 60 2 In the VS 6556 series mounting the 2nd axis mechanical stop limits the workable angle of the 3rd axis so that the 3rd axis cannot move overriding 100 30 on the UL Listed models in the negative direction Set the negative direction software motion limit for the 3rd axis in the positive side than 100 30 Be careful with the design of the mechanical stop Depending upon the shape of the mechanical stop prepared by the customer the axis may hit the mechanical stop before the software motion limit described above is activated Motion range software motion limit value The table below lists the 2nd axis motion range when a positive or negative direction mechanical stop is mounted at each of the mechanical end positions available Stop bolt position Positive direction Negative direction 42 76 2nd axis Mechanical End Positions Available 99 4 2 3rd axis Mechanical End Ch
62. obot posture 15 2 2 3 Changing Software Motion Limits If the robot interferes with any other device change the software motion limits to make the motion space smaller as shown in the upper figure on this page If the air piping or wiring of the end effector becomes taut as the robot runs then change the software motion limits to make the motion space smaller as shown in the lower figure on this page NOTE When changing software motion limits always make the new motion space smaller than the motion space defined by initial settings E VS G Series Motion range after change Motiion range before change Restricted range Positive direction software motion limit 1st axis after change Sonne motorn Wat Mechanical end Example 1 Changing Software Motion Limits VS G series Positive direction software motion limit set at delivery 6th axis 360 Hand Motion range T i after change Air piping wiring Motion range set at delivery T Positive direction software motion limit 6th axis after change Note The figure shows the hand turning 180 Example 2 Changing Software Motion Limits VS G series 16 2 2 4 Precautions When Changing the Software Motion Limits 1 The software motion limits are invalid until CAL is completed 2 Confirm the operating space of the robot in the actual working environment Set the
63. on which is set by a CALSET jig See Section 2 4 4 Position S f 2nd axis io N A comedo side CALSET Positions VS G series Caution for using customized mechanical ends If the RANG values have not been changed after a mechanical end change remove the changed mechanical end s before performing CALSET Refer to the CAUTIONS AT CHANGING THE MECHANICAL ENDS on page 18 67 2 4 6 CALSET Procedure 2 4 6 1 CALSETing a Single Axis CALSETing a specified single axis only is called single axis CALSET Perform single axis CALSET if the motor of an axis is replaced so that the axis must be CALSET or if some axes cannot be moved to the CALSET positions mechanical stop positions at any given time because of interference between the robot unit and its surrounding facilities NOTE Step 1 is required for CALSETing the 4th and 6th axes and Step 2 is for CALSETing the 6th axis When CALSETing any other axes skip to Step 3 STEP 1 Mount the CALSET jig according to Section 2 4 2 1 Mounting the CALSET Jig Required for CALSETing the 4th and 6th axes STEP 2 Fully turn the oth axis to its turning end in the positive direction Required for CALSETing the 6th axis CALSET jig Turn the 5th axis to its turning end Turn the power switch of the robot controller to ON STEP 3 Set the mode selector switch of the teach pendant to MANUAL STEP 4 Press MOTOR to turn ON the power to the mot
64. on indications are a MUST for preventing accidents which could result in bodily injury and substantial property damage Make sure you fully understand all definitions of these terms and related symbols given below before you proceed to the text itself A N WARNING Alerts you to those conditions which could result in serious bodily injury or death if the instructions are not followed correctly A N CAUTION Alerts you to those conditions which could result in minor bodily injury or substantial property damage if the instructions are not followed correctly Terminology and Definitions Maximum space Refers to the space which can be swept by the moving parts of the robot as defined by the manufacturer plus the space which can be swept by the end effector and the workpiece Quoted from the ISO 10218 1 2006 Restricted space Refers to the portion of the maximum space restricted by limiting devices i e mechanical stops that establish limits which will not be exceeded Quoted from the ISO 10218 1 2006 Motion space Refers to the portion of the restricted space to which a robot is restricted by software motion limits The maximum distance that the robot end effector and workpiece can travel after the software motion limits are set defines the boundaries of the motion space of the robot The motion space is DENSO WAVE proprietary terminology Operating space Refers to the portion of the restricted space that is actually use
65. onfigured as a set If you purchase two or more robot systems take care not to mistake each set when connecting robot units and controllers Caution The robot unit and robot controller in a set are given the same serial number 1 1 4 Installation Environment of the Robot Unit The installation requirements for the robot unit are listed on the next page Prepare a highly rigid mount by referring to the figure on page 4 caution Do not electric weld the equipment including the robot A large current may flow through the motor encoder or robot controller resulting in a failure If electric welding is required remove the robot unit and the robot controller from the equipment beforehand Installation Requirements for the Robot Unit ee Floor mount or Overhead mount Ambient temete During operation 0 to 40 C P During storage and transportation 10 to 60 C During operation 90 or less No dew condensation allowed Humidity During storage and transportation 75 or less No dew condensation allowed Vibration During operation 4 9 m s 0 5G or less During storage and transportation 29 4 m s 3G or less Altitude During operation 1 000 m or less Safe installation Refer to the SAFETY PRECAUTIONS 3 1 Insuring the proper environment installation environment e Sufficient service space must be available for inspection and disassembly e Keep wiring space 230 mm or more behind the robot and fasten the wiring to t
66. or STEP 5 Move the axis to be CALSET in the vicinity of the mechanical stop via the manual operation from the teach pendant STEP 6 68 Releasing brakes NOTE For UL Listed robot units release brakes referring to Section 1 6 Releasing Brakes on UL Listed Robot Units and then proceed to Step 15 STEP 7 Press the MOTOR key on the teach pendant to turn OFF the power to the motor STEP g l Press F2 Arm on the teach pendant STEP O Press the SHIFT key and F12 Maint STEP 4 0 Press F3 Brake 69 STEP 11 Touch the axis number to be CALSET to select Brake released green display STEP 4 2 Confirm that there is no danger even if the arms fall as a result of released brakes CAUTION In the VS G series the brake of the specified axis is released STEP 4 9 Press OK The system message appears asking you whether you want to change the brake settings DETERE Brake Release Settings ee h e System Message e J I IJ 70 STEP 1 A Press OK The system message appears informing that the brake is released and warning against drop of arms F6 CALSET STEP 1 5 l Press the axis to be CALSET against the mechanical stop by hand Press F6 CALSET STEP 1 6 The Set CALSET window appears 71 Press the axis number to be CALSET to select CALSET green display STEP 1 r Deselect CALSET black display for the other axes that are not required to be CALSET STEP 4 Q Press OK
67. ork Be sure to consult the opinions of related workers engineers at the equipment manufacturer and that of a labor safety consultant when creating these working regulations 4 2 Display of operation To prevent anyone other than the worker from accessing the start panel switch or the changeover switch by accident during operation display something to indicate it is in operation on the operation panel or teach pendant Take any other steps as appropriate such as locking the cover 4 3 Ensuring safety of When performing jobs within the robot s restricted space take workers performing any of the following steps to ensure that robot operation can be jobs within the robot s stopped immediately upon a malfunction restricted space 1 Ensure an overseer is placed in a position outside the robot s restricted space and one in which he she can see all robot movements and that he she is devoted solely to that task An emergency stop device should be activated immediately upon a malfunction Do not permit anyone other than the worker engaged for that job to enter the robot s restricted space 2 Ensure a worker within the robot s restricted space carries the portable emergency stop switch so he she can press it the emergency button on the teach pendant immediately if it should be necessary to do so 4 4 Inspections before Before starting work such as teaching inspect the following commencing work items carry out any repairs imm
68. robot controller to ON Set the mode selector switch of the teach pendant to MANUAL 2 Press F2 Arm on the top screen STEP 3 The Current Robot Position window appears Gently bring the 1st axis of the robot into contact with the newly set STEP 4 positive direction mechanical end Check the value in J1 box that appears when the 1st axis is in contact STEP 5 with the mechanical end in Step 4 The value is RANG value to be newly set Angle of the 1st axis J1 28 Mechanical End Positions and Set Software Motion Limits Positive direction mechanical end Negative direction mechanical end Positive direction software 0 46 as OO motion limit Negative direction software 46 136 motion limit Caution If you set mechanical ends in addition to the permanent mechanical end set the software motion limits 5 inside from the mechanical ends RANG value If the software motion limits are set merely less than 5 inside from the mechanical ends the robot may bump against the mechanical stops before it stops by software Examples 1 When the positive direction mechanical ends are A and the negative direction ones are the permanent mechanical ends change Positive direction software motion limit 0 RANG value obtained in Checking the set RANG value 2 When the positive direction mechanical ends are the permanent mechanical ends and the negative direction mechanical ones are B change Negative dir
69. s caught in the crank and becomes invisible in the left figure The figure below shows the crank at around 250 Internal wiring Cast crank 4 When the 4th axis section is not at the normal position manually move it to a designated position Preparation before carrying out CALSET is finished now NOTE If the step 2 4 2 is omitted the 4th axis CALSET position may be mistaken by one rotation 360 The internal wiring may be caught in the crank and broken in such a case 2 4 3 Preparation for CALSET The VS G series has no mechanical stop on the 4th and 6th axes Mechanical Stops on Axes VS G On the ist to 3rd and 5th axes On the 4th and 6th axes Mechanical stops provided No mechanical stops Press each of the ist 2nd 3rd and 5th axes manually against the associated mechanical stop and get the actual position Since the 4th and 6th axes have no mechanical stop you need to mount a CALSET jig to set a temporary mechanical end for CALSET Then press the 4th and 6th axes against those mechanical ends and get those positions When CALSETing the 6th axis you need to press also the 5th axis against the mechanical stop since CALSETing requires the positional relationship between the Sth and 6th axes 61 E Cautions at CALSET CALSET requires some space for bringing each axis into contact with the mechanical end Caution 1 When CALSETing move the axis to be CALSET in the vicinity of the mechanical stop r
70. service life will become short 84 Remove the last old battery and connect the dummy connector cap STEP 8 disconnected in Step 4 Dummy connector cap Old backup battery STEP O Install the cover to the robot unit Cover ie 7 f haa A Cover Cross pan head screw Hex socket head bolt Standard type Dust proof amp splash proof type Tightening torque Cross pan head screw 0 59 Nm Standard type Hex socket head bolt 2 0 Nm Dust proof splash proof type 85 3 4 3 Replacing the Memory Backup Battery For the replacing procedures of the memory backup battery refer to the RC M CONTROLLER MANUAL Section 6 5 Replacing the Memory Backup battery 3 4 4 Setting the Next Battery Replacement Date STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 After replacing the memory backup battery set the next battery replacement date from the teach pendant according to the following procedure NOTE This procedure cannot be performed with the operating panel NOTE Check that the system clock of the robot controller shows the correct date beforehand If it is incorrect the next replacement date will also become incorrect On the top screen of the teach pendant press F6 Set The Settings Main window appears Press F6 Maint in the Settings Main window The Maintenance menu appears In the top of the window the current setting is displayed The date entry areas show the default repla
71. software motion limits using the correct unit of measurement If the operating space is too small the robot may seem to become inoperable 2 2 5 Procedure for Changing the Software Motion Limits Described below is the procedure for changing the software motion limits STEP 1 f Turn the power switch of the robot controller to ON STEP 2 f Set the mode selector switch of the teach pendant to MANUAL STEP 3 Press F2 Arm on the top screen of the teach pendant The Current Robot Position window appears as shown in Step 4 17 STEP 4 STEP 5 Press the SHIFT key and then press F12 Maint Current Robot Position F12 The Maintenance Functions Arm window will appear Press F1 M Space on the Maintenance Functions Arm window The Motion Space window will appear as shown below Motion Space Software motion limit 170 0900 135 900 165 000 185 000 129 000 owaj 18 STEP 6 Select the item to be modified then press F5 Change The numeric keypad will appear as shown below i 2 wm som Joint woro 1 Change Limit Motion Space Software motion limit Software motion limit J1 Software motion limit J2 Software motion limit J3 Software motion limit J4 S ee o ee Software motion limit J5 A L CANCEL OK OK Take in new entry Cancel Discard new entry tur ey fT Enter a desired value using the numeric keys then press OK The ne
72. t controller Cooling fan in the robot controller Operate the safety The robot should door switch and open come to an the switch wiring door emergency stop Safety door Ropar gr replace Brake release switch on the UL Listed robot Check for looseness No looseness Tighten up Motor ON lamps on the UL Listed robot They should light Inspect and msveally when the motor is ON repair Some repair and replacement operations shown in What to do column may involve special work Contact the Robot Service Section The normal operation of the cooling fan is as shown in the figure on the next page 19 Air outlet Normal Operation of Cooling Fan VS G 3 3 Quarterly Inspections 3 3 1 Check Items Check the items listed in the table below every three months Quarterly Inspections Table Robot base Measure the No looseness Tighten the bolts to mounting bolts tightening the specified Specified torque torque 70414 Nm torque with a torque wrench Cooling fan filters OFF Visually No dust or dirt Clean the cooling in the robot fan filters Refer to controller Section 3 3 2 3 3 2 Cleaning the Cooling Fan Filters in the Robot Controller For the cleaning procedures of the air intake filter refer to the RC7M CONTROLLER MANUAL Section 6 4 Cleaning the Air Intake Filter 80 3 4 Biennial Inspections 3 4 1 Battery Replacement and Check Items Replace the two types of backup batteries
73. tallation of the Dust amp Splash proof Type of Robot Units For the dust amp splash proof type of robot units the drain bolt M3 x 8 mm is screwed onto the rear side of the robot unit as shown in the figure below At the floor mount installation remove the drain bolt shown in the figure below before installing the robot unit It will become a drain hole for the liquid caution At the overhead mount installation do not remove the drain bolt when installing the robot unit If you do so the robot failure may occur 1 2 1 Drain bolt M3x8mm Drain Bolt on the Dust amp Splash proof Type of Robot Units 1 2 2 Transporting the Robot Unit 1 Precautions in transporting the robot The VS G series weighs approximately 36 kg 80 Ibs Use a crane suitable for the robot weight Have at least two workers handle this job Workers should wear helmets safety shoes and gloves during transport Caution Pass the hoisting wires through the specified eyebolts as illustrated below Passing them through other sections may drop the robot unit resulting in a broken robot or bodily injuries Do not hold the first arm elbow either side of the 2nd arm 2nd axis cover or 3rd axis cover or apply force to any of them Wire Belt sling Waste cloth Eyebolts Robot unit mounting bolts Hoisting Points for Transportation VS G series 2 Transporting the robot unit Transport Position 1 Before transporta
74. tenance and Inspection 3 1 Maintenance amp Inspection Intervals and Purposes Carry out the maintenance and inspection jobs show in the table below N Caution Before performing maintenance and inspection jobs read the SAFETY PRECAUTIONS 4 Precautions while Robot is Running and 5 Daily and Periodical Inspections Maintenance amp Inspection Intervals and Purposes No Intervals Purposes Daily Perform inspection jobs specified In To use your robot safely section 3 2 every day before starting operations Quarterly Perform inspection jobs specified in To maintain the precision of the robot and section 3 3 every three months to prevent failures caused by overheat of the robot controller Biennial Replace backup batteries as To retain the robot specific data specified in Section 3 4 every two programs parameters etc stored in the years internal memory of the robot controller and the position data stored in the electronic absolute encoder build in the robot unit 3 1 1 Precautions for installation and maintenance of robots for cleanroom type When carrying out installation maintenance or inspection jobs of the cleanroom type in your cleanroom be sure to follow your dust proof job rules If you remove the covers from the robot controller or robot unit even the cleanroom type may scatter worn belt dust piping grease dust or dirt accumulating inside Jobs requiring special care m CALSET m Cleaning of coo
75. tening torque 9 8 Nm 20 49 2 Reference Drawings of 3rd axis Mechanical Stop VS6577G The figures below show the mechanical end configured with a 3rd axis mechanical stop The reference drawings of the mechanical stop and the related parts are given on the following pages The 3rd axis mechanical stop is designed to set the 3rd axis motion range between 128 in the positive direction and 14 5 in the negative direction 3rd axis Mechanical Stop Mounted on the Robot Unit VS6577G SPACER 2 M5 12DEEP es 1A W ae 50 Reference Drawing of 3rd axis Mechanical Stop VS65 77G _ u U on E T i o o 12 co SP 70 119 a 6 5 95 524 4 x 6 5dia drill A 1 172 67 374 Material A5083P H32 Note The joint sections should be welded 51 Reference Drawing of Stay for 3rd axis Mechanical End VS6577G 2x 5 5dia drill 60 HELI SERT 4 x M8 100 i 100Z 25 M8 1 251 5DS 15 02 SENE ee BA l me HELI SERT 2 x M8 ie M8 1 25 x 1 5DS E ho 2 ON j UJ l HELI SERT 12 i M6 1 0 x 2DS 70 From the reverse side 160 173 1 62 174 62 Material A2017BE T4 Reference Drawing of Spacer for 3rd axis Mechanical End VS6577G Material S45C 52 4 Changing the 2nd and 3rd axis Mechanical Ends for Robot Units Having Particular Internal Threads UL Listed Robot Units 4 1 2nd axis Mechanical End Change 1 Outline The 2
76. th any other electric power or power equipment such as a welder Grounding terminal M5 Functional ground 5 5mm or more Grounding the Robot Unit VS G series 1 3 Installing the Robot Controller For the installing procedures of the robot controller refer to the RC7M CONTROLLER MANUAL Section 6 2 Installing the Robot Controller 1 4 Cautions for Designing the Robot Hand Refer to the GENERAL INFORMATION ABOUT ROBOT for VP G SERIES Chapter 3 section 3 5 Precautions When Designing the End effectors 1 5 Moving Each Axis with Motor Power OFF in Emergency Stop The table below shows which axes have a brake in the VS G series of robot units The brake releasing operation on UL Listed robot units is different from that on other types Robot unit Axes with brake How to release brake With the teach pendant or mini pendant VS G l Without brake Vo Gy 2nd to 4th axes Access F2 Arm F12 Maint F3 Brake on the teach pendant For details refer to the SETTING UP MANUAL Chapter 5 Commands Assigned to Function Keys mane AME O OUK AES of the Teach Pendant and Chapter 6 Using the Mini Pendant With the brake release switch For details refer to Section 1 6 Releasing Brakes UL Listed VS GW UL All axes on UL Listed Robot Units Note The teach pendant or mini pendant cannot release the brakes The table below shows how to move each axis with the motor power being OFF when the robot is in an
77. the 6th axis flange Its Y component is in the direction from the flange center to the 5H7 pin hole orientation vector direction The Z component is in the vertical direction to the flange face across the flange center approach vector direction The X component is in the X axis direction of the right hand coordinate system normal vector direction with the orientation vector as the Y axis and the approach vector as the Z axis See the figure on the next page Orientati t Orientation vector Y axis rientation vector 5H7 pin hole Normal vector X axis xis flange 7 _ Approach vector Z axis Center of flange Approach vector TOOLO coordinate axis Position of payload center of gravity Xe Ye Ze Payload Center of Gravity 19 Y axis positive direction orientation vector Z axis positive direction lt approach vector X axis positive direction normal vector Right Hand Coordinate System 2 6 Setting Robot Installation Conditions The optimum operating conditions will differ depending on whether the robot is floor mounted or overhead mounted When the robot leaves the factory it is set for floor mount If you overhead mount your robot you need to change the installation settings For the setting procedure refer to the SETTING UP MANUAL Section 2 10 Setting the Robot Installation Condition and the PROGRAMMER S MANUAL Section 4 7 3 Setting Robot Installation Conditions 76 Chapter 3 Main
78. tion set the robot in a transport position as shown at right by manually moving the second third and fourth axes When unpacked first the robot is in the transport position so this job is not required Axis oge o O Fouthaxis J4 280 S Fifthaxs J5 80 Disconnect the robot control cable air piping and user signal cables from the robot unit When the robot unit is first unpacked this job is not required As shown at right mount the eyebolts When delivered the robot unit is packed with eyebolts attached so this job is not required Eyebolts Mounting Eyebolts As shown at right place a waste cloth on the second arm and pass the wire through the two eyebolts Belt sling Waste cloth Eyebolts Robot unit mounting bolts Hoisting the Robot Unit Worker A Remove the four bolts while supporting the robot unit to prevent it from getting overturned Worker B Operate the crane and move the robot unit to the target site Worker B Put the robot unit down in the target position Worker A Temporarily secure the robot unit with four bolts Secure the robot unit according to the instructions in Section 1 2 3 Securing the Robot Unit on the next page N Caution 1 Before transporting the robot check that the path to the target position is free of obstacles 2 Before running the robot unit be sure to remove the eyebolts Otherwise the robot arm wi
79. unning Time Display the Maintenance window as shown below Access F6 Set F6 Maint from the top screen 2 wm cos Joint woro 1 Maintenance o e lt a 2l Total h Yersion Date Battery Odometer F1 F2 F3 F4 F5 Cancel Close this window eo A Total h Version Date Battery Odometer Press F1 Total h 91 STEP 2 The Total hours window appears as shown below Total operation Total running Cumu operation Cumu running Operation Running Total hours anen Hon o SHIM L OHOn OO OHM OHM Shows the grand total of the robot controller ON time counted after the controller leaves the factory Shows the grand total of the robot running time counted after the robot leaves the factory Shows the total of the robot controller ON time counted after you reset the user counter to zero Shows the total of the robot running time counted after you reset the user counter to zero Shows the ON time of the robot controller counted after it is turned ON this time Shows the running time of the robot counted after the robot controller is turned ON this time 3 8 2 Resetting the User Counters of the Controller ON Time and the Robot Running Time STEP 1 Display the Total hours window as shown below Access F6 Set F6 Maint F1 Total h from the top screen Total hours O Tuon oH om pM OH OH 0O OWM OHM To reset the user
80. utline The 2nd axis mechanical end can be changed by mounting a mechanical stop to the undedicated internal threads as shown below The mechanical stop consists of three parts Part A Part B and Part C The mechanical stop and the related parts should be prepared by the customer Example of 2nd axis Mechanical End Configured on the Robot Unit Positions of Undedicated Internal Threads Example of 2nd axis Mechanical End to be used for 2nd axis mechanical end change Configured on the Robot Unit 3 gt 2 undedicated internal threads ES B Note for mounting Part B This face of Part A and that of Part B should be parallel with each other 41 2 Reference Drawings of 2nd axis Mechanical Stop The figures below show the mechanical end configured with a 2nd axis mechanical stop consisting of Part A Part B and Part C The reference drawings of those parts are given on the following pages The mechanical stop is designed to set the 2nd axis motion range between 67 5 in the positive direction and 50 in the negative direction 2nd axis Mechanical Stop Mounted on the Robot Unit i f pa ne EN A i o A U N P Secured with two hex socket head bolts M8X25 Strength ciass 12 9 Tightening torque 19 6 Nnm 20 Secured with three hex socket head bolts Secured with a hex socket head bolt M8X25 Strength class 12 9 M6X45 Strength class 12 9 Tightening torque 19 6 Nm 20 Tightenin
81. w value will be set on the line of the item selected in the Motion Space window If two or more items must be changed repeat Steps 5 and 6 STEP 7 i Press OK in the Motion Space Software motion limit window STEP 8 Turn OFF the power to the robot controller Caution The new software motion limit s specified for the motion space will take effect after the robot controller restarts and CAL is completed 19 2 3 Changing the Mechanical End This section describes the procedures of changing the mechanical ends of the 1st axis to 3rd axis for the VS G series A N CAUTIONS IN CHANGING THE MECHANICAL ENDS When changing the mechanical ends design the mechanical stoppers according to your usage and manufacture them After changing the mechanical end the software motion limits PLIMs NLIMs should be changed not to interfere the mechanical end at the robot operation The mechanical stoppers may not limit the workable area of the robot Therefore do not enter the robot s restricted space when the robot power is turned ON If the robot is collided with the mechanical stopper the robot will stop by detecting the collision but the mechanical stopper may be broken When the robot is collided with the mechanical stopper remove the mechanical stopper And inspect the robot and surrounding devices and repair them Do not re use the mechanical stoppers and re manufacture them The reference drawings described on this manual cannot b

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