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(Arm Setup, Maintenance) BFP-A8175-A (10.01)

1. No Parts to be Qiling method Lubrication oil Lubrication interval Cover toremove lubricated E Default charge amount maker Lubrication amount guide RH 5AH series 1 axis reduc paces 6 000Hr Ji cover Hon gears Grease nipple Harmonic grease SK 1A J2 axis reduc WC 610 Only addition lii 6 000Hr 2 1 Japan Harmonic Systems tion gears 2g No 2 arm cover U 3 Shaft Wipe the old grease and Marutenpu PS No 2 Every 100km movement paint KYODO YUSHI CO LTD lg RH 10AH 15AH series 1 A ae Grease kal J1 cover reduction gears Grease nipple 3g A Harmonic grease SK 1A J2 axis WA 610 Only addition 6 000Hr 2 Japan Harmonic Systems reduction gears 2g No 2 arm cover U 3 Shaft Wipe the old grease and Marutenpu PS No 2 Every 100km movement paint KYODO YUSHI CO LTD lg The grease nipple position is shown in Fig 5 13 The lubrication specifications for each place are shown in Table 5 4 When lubricating remove the covers that need to be taken off by refer to Fig 5 3 Installing removing the cover 5 54 Maintenance and inspection procedures JMaintenance and Inspection Caution The brands of grease given in Table 5 4 are those filled when the robot is shipped The lubrication time is a cumulative value of the operation at the maximum speed If the operation has been sus pended or if the designated speed is slow the lubrication time can be le
2. 1 Is there any abnormal motion or abnormal noise when the power is Follow the troubleshooting section turned ON During operation try running with an original program 1 Check whether the movement points are deviated Follow the troubleshooting section Check the following points if there is any deviation 1 Are any installation bolts loose 2 Are any hand installation section bolts loose 3 Are the positions of the jigs other than the robot deviated 4 If the positional deviation cannot be corrected refer to Trou bleshooting check and remedy 2 Is there any abnormal motion or abnormal noise Follow the troubleshooting section Visual 5 42 Inspection items 5 2 2 Periodic inspection Carry out periodic inspection with the procedures given in Table 5 2 Table 5 2 Periodic inspection items details 5Maintenance and Inspection Procedure Inspection item details Remedies Monthly 160 hr inspection items 1 Are any of the bolts or screws on the robot arm loose Securely tighten the bolts 2 Are any of the connector fixing screws or terminal block terminal Securely tighten the screws screws loose 3 Remove the cover at each section and check the cables for Check and eliminate the cause wear damage and adherence of foreign matter If the cables are severely damaged contact the Mitsubishi Service Department 3 month 500 hr insp
3. J3 axis Fig 2 12 JOINT jog operation Confirming the operation 2 19 2Unpacking to Installation TEEN z Base coordinate system reference origin X X Z While maintaining the posture of the end axis the robot moves straight along the base coordinate system The end axis rotates Fig 2 13 XYZ jog operation MITSUSEHI End axis Tool coordinate X While maintaining the posture of the end axis the robot moves straight along the tool coordinate system The end axis changes directions while maintainingits position Fig 2 14 TOOL jog operation 2 20 Confirming the operation 2Unpacking to Installation Base coordinate system reference origin X Z The robot moves straight along the base coordinate system The direction of the end axis is not maintained during this type The direction of the end axis changes At this time the end axis position will change Fig 2 15 3 axis XYZ jog operation Vertical N ma Radius Z With an arc using the end axis position as the center of the Z axis the robot moves over the arc expands and contracts in the radial direction and moves vertically At this time the posture of the end axis is maintained The direction is changed while maintaining the end axis position Fig 2 16 CYLINDER jog operation Confirming the operation 2 21 2Unpacking to Installation 1 JOINT
4. key and move the cursor to the J1 input position 4 Input the J1 value in the same manner as above 5 Input the J2 J3 and J4 values in the same manner 6 After inputting all of the values press the INP key The origin set ting confirmation screen will appear 7 Press 1 B P and INP key to end the origin setting Setting the origin 2 17 2Unpacking to Installation lt gt 9 gt Moving the cursor O O Press the T and gt keys O Inputting characters O O Hold down the CHAR key and press the key with the character to be input on the lower right Three characters will scroll each time the character key is pressed OS Correcting an input O O After returning one character by pressing the DEL key input the character again 6 Installing the J1 cover Return the J1 cover removed in section Page 14 1 Confirming the origin data on page to its original position This completes the setting of the origin with the origin data input method to do so could lead to the robot moving because of incorrect operations or to phys ical damage or personal injury AN WA RNING Always remove and install the cover with the controller power turned OFF Failure O If the origin input data is incorrect O O If the origin input data is incorrect the alarm No 1760 origin setting data illegal will occur when origin data input In this case reconfirm the value input for the origin data
5. 30 50 70 100 When the MOVE keys are pressed the override XYZ LOW will decrease in the reverse order The currently X 134 50 ster ah set speed will appear on the upper right of the Y 220 00 MOVE Forw eackvo screen Set the override to 10 here for confirma Z 280 00 Set the speed tion work Moving along the base coordinate system STEP Z ster 22 MOVE 8 ax Eo EARE F SPACE PAR 1 x Y se x a 91 z a T 93 STEP ad 4 ster f xy MOVE 4 MNO Y The direction of the end axis will not change O When the robot is in the transportation posture 94 gt Moving along the X axis When the MOVE X J 1 keys are pressed the robot will move along the X axis plus direction When the MOVE X J 1 keys are pressed the robot will move along the minus direction Moving along the Y axis When the MOVE Y J2 keys are pressed the robot will move along the Y axis plus direction When the MOVE Y J2 keys are pressed the robot will move along the minus direction Moving along the Z axis When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed the robot will move along the minus direction There are directions from which linear movement is not possible from the transportation posture In this case an will appear o
6. Table 5 1 Daily inspection items details Procedure Inspection item details Remedies Before turning power ON Check the following items before turning the power ON 1 Are any of the robot installation bolts loose Securely tighten the bolts Visual 2 Are any of the cover tightening screws loose Securely tighten the screws Visual 3 Are any of the hand installation bolts loose Securely tighten the bolts Visual 4 Is the power supply cable securely connected Securely connect Visual 5 Is the machine cable between the robot arm and controller Securely connect securely connected Visual 6 Are there any cracks foreign contamination or obstacles on the Replace with a new part or take remedial measures robot and controller cover 7 Is any grease leaking from the robot arm After cleaning replenish the grease Visual Note Grease component may leak out in RH SAHC SA as well In this case wipe away the grease there is no need to replenish the grease 8 Is there any abnormality in the pneumatic system Are there any Drain the drainage and remedy the air leaks replace air leaks drain clogging or hose damage Is the air source normal the part Visual 9 Are there any cracks or foreign particles on the bellows Replace with a new bellows only for clean and protrction specification Visual After turning the power ON Turn the power ON while monitoring the robot
7. By using the REMOVE T B switch the T B can be installed and removed while the controller s control power is ON However in this procedure the teaching pendant will be installed with the control power OFF Refer to the separate Controller setup basic operation and maintenance for details on installing the teaching pendant with the control power ON 1 Installing with the control power OFF Display LCD ENABLE DISABLE switch 1 Confirm that the controller s power supply switch is OFF ENO A 2 Connect the T B connector to the RS 422 T B connector on the controller N 3 Do not pull the cable with force or bend it excessively as s r oy IN N Emergency stop switch the cable could break or the connector could be damaged a jay Ni Bak 4 Confirm that the REMOVE T B switch on the side of the Bia controller is not depressed is projected Bs amp Ts operation keys 5 Set the T B ENABLE DISABLE switch to DISABLE Appearance of teaching pendant REMOVE T B switch Connector Ki 1 i A ae Teaching pendant T B Fig 2 9 Installing the T B control power OFF REMOVE T B switch lt gt 4 When using the robot with the T B this switch is used to invalidate the emergency stop from the T B This is also used to install the T B with turning the controller s power supply ON Setting the origin 2 13 2Unpacking to Installation 2 3 2 Setting the origin with the
8. will occur Once the alarm occurs replace all batteries in the robot arm and controller as soon as possible Lithium batteries type AGBAT and ER6 are used in both the controller and robot arm The battery replacement procedures are as follow 1 Replacing the robot arm battery Don t disconnect connector etc While replacing the battery the encoder position A CAUTION data is saved by the power supplied from the controller Thus if the cable connec tion is incomplete the encoder position data will be lost when the controller power is turned OFF Several batteries are used in the robot arm but replace all old bat teries with new batteries at the same time 7 i Installation screw x 2 2 Battery cover Fig 5 14 Replacing the battery 1 Confirm that the robot arm and controller are connected with a cable 2 Turn the controller control power ON The position data is retained by the power supplied from the controller while replacing the battery Thus if the cable is not connected correctly or if the controller power is OFF the position data will be lost 3 Press the emergency stop button to set the robot in the emergency stop state This is a measure for safety and must always be carried out 4 Remove the two installation screws 1 and remove the battery cover 2 5 Remove the old battery from the holder and disconnect the lead connector 6 Insert the new battery into the holder and connect the lead connector R
9. 4 to the GR7 connector in the No 2 arm of the robot Then connect the GR8 plug coming from the No 4 solenoid valve 4 to the GR8 connector in the No 2 arm of the robot The connection correspondence after installation is as shown in Table 3 1 Table 3 1 Solenoid valve ports and hoses Correspondence of couplings and hand ports Hand Hand port Solenoid valve port Solenoid valve used OPEN A Hand 1 1 st row CLOSE B OPEN A Hand 2 2 nd row CLOSE B OPEN A Hand 3 3 rd row CLOSE B OPEN A Hand 4 4 th row CLOSE B 3 34 Installing the solenoid valve set general enveronment specifications Sinstalling the option devices 2 RH 10AH 15AH 1N VD01 VD01E VD02 VD02E VD03 VD03E VD04 VD04E iili T 3 No 3 solenoid valve 4 No 4 solenoid valve 2 No 2 solenoid valve Naco M4 X 101 1 No 1 solenoid valve CN i Naco a ra 14 P round head screw We 4 places AIR IN1 AIR IN2 AIR IN3 gt E 941 A3 B port ei 4 GR1 GR3 Electrical wiring opening grommet mad as ra mad aa a Hand input connector GR2 GR4 AIR OUT3 AE Ari E k i n n saa AIR OUT2 When using one row When using two row solenoid valve solenoid valve GR5 GR7 A 5 a E ee ees When using three row When using four row solenoid valve solenoid valve Connector connection inside the No 2 arm Fig 3 2 Solenoid valve installation procedures RH 1
10. The currently set speed will appear on the upper right of the screen Set the override to 10 here for confirmation work Moving along the X axis When the MOVE X J 1 keys are pressed the robot will move along the X axis plus direction When the MOVE X J 1 keys are pressed the robot will move along the minus direction Moving along the Y axis When the MOVE Y J2 keys are pressed the robot will move along the Y axis plus direction When the MOVE Y J2 keys are pressed the robot will move along the minus direction Moving along the Z axis When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed the robot will move along the minus direction QO Jog mode will change when only XYZ key is pressed again O O When the MOVE XYZ keys are pressed and then only the XYZ key is pressed the upper left display will change in the order of XYZ gt XYZ456 CYLNDER Each jog mode can be selected The end axis posture cannot be maintained with 3 axis XYZ jog O O With 3 axis XYZ jog the end axis posture orientation is not maintained when moving linearly in the X Y or Z axis direction Use XYZ 2 28 Confirming the operation jog to maintain the posture 2Unpacking to Installation Changing the direction of the end axis Rotating around the Z axis When t
11. 15AH series 25 lt 1 gt M4 set screws x 2 10 Top bellows D cut surface ae Details of D cut surface Liquid gasket coating position No 2 arm cover U 4 M3 x 8 screw Section A Fig 5 11 Replace the top bellows CAUTION Replace the bellows in a place where there is no risk of contamination by dust and oil mist If it must be replaced in a dust filled area be sure to remove as much dust as possible in advance before replacing it 5 52 Maintenance and inspection procedures JMaintenance and Inspection 2 How to Replace the Bottom Bellows Refer to Fig 5 12 and replace the bottom bellows 1 Turn off the robot controller s power supply 2 Remove the installation screws three M4 screws of the No 2 arm cover L lt 3 gt 3 Loosen the two M4 set screws installed beside the part lt 4 gt 30 mm above from the bottom edge of the ball screw and remove the bottom bellows from the No 2 arm cover L 4 Remove the screws four M3 x 8 screws of installation part lt 5 gt of the bellows and remove the bellows 5 Install the new bellows four M3 x 8 screws Tightening torque 0 8Nm 6 Align part lt 4 gt to 30 mm above the bottom edge of the ball screw and tighten the M4 set screws two pieces adjusting to the D cut surface 7 Install the No 2 arm cover L lt 3 gt with the M4 screws three pieces 8 Fill the clearance between part
12. AN CAUTION Before using this method the origin must be set with the origin data input method jig method or mechanical stopper method The procedure for setting the origin with the user origin method is explained below This operation is carried out with the teaching pendant Set the MODE switch on the front of the controller to TEACH and set the ENABLE DISABLE switch on the teaching pendant to ENABLE to enable the teaching pendant The operation method is shown below When setting the origin for the first time using this method carry out the operations in order from step 1 For the second and following time move the robot arm to the user origin position with jog operation and accurately posi tion all axes Then start the procedure from step 4 1 Determine the user origin position Move the robot to the position to be set as the origin with jog operation Refer to Page 19 2 4 Confirming the operation for details on the jog operation AN CAUTION This position is left as a guideline to position all axes with jog operation when setting the origin again with this method 2 Enter the JOINT jog mode and display the joint coordinates on the teaching pendant screen Record the value of the axis for which the origin is to be set 3 Input the value recorded in the user designated origin parameter USERORG The parameter details and input methods are described in the separate Instruction Manual Detailed Expla
13. BU160C366G52 J2 axis 1 6 BU149C707G63 J3 axis 1 7 BU160C366G54 J4 axis 1 8 Reduction gears BKO FA0530H12 J1 axis 1 Mitsubishi Electric 9 BKO FA0530H11 J2 axis 1 10 Top bellows BU223C263G51 J3 axis 1 clean and protrction specification 11 Bottom bellows BU160C561G51 J3 axis 1 clean and protrction specification 12 kli ji a protrction specification An needed 13 Norseal V714 3 2t x 5mm Installation area a each cover An needed clean and protrction specification RH 10AH 15AH series 1 Timing belt 666 3GT 12 J3 axis RH 10AH55 70 85 1 2 681 3GT 12 J3 axis RH 15AH85 1 3 540 3GT 6 J4 axis motor side 1 4 471 3GT 15 J4 axis shaft side 1 5 AC servo motor BU160B378G51 Jl axis 1 6 BU160B365G52 J2 axis 1 7 BU160C379G51 J3 axis 1 8 BU160C366G54 J4 axis RH 10AH55 70 85 1 9 BU160C422G54 J4 axis RH 15AH85 1 Mitsubishi Electric 10 Reduction gears BKO FA0530H13 J1 axis RH 10AH55 70 1 11 BKO FA0530H14 J1 axis RH 10AH85 15AH85 1 12 BKO FA0530H12 J2 axis 1 10 Top bellows BU223C265G51 J3 axis protrction specification 1 11 Bottom bellows BU160C562G51 J3 axis protrction specification 1 12 Liguid gasket 41212 Bellows protrction specification An needed 13 Norseal V714 3 2t x 5mm Ingtallation laad each cover An n eded protrction specification Note Confirm the robot arm serial No and contact the dealer for the type Maintenance parts 5 57 5Maintenance and Inspection 5 5 Resetting the origin The origin is se
14. Make sure that if the safety fence entrance door is opened during automatic operation the door is locked or that the robot will automatically stop Failure to do so could lead to personal injuries Never carry out modifications based on personal judgments or use non designated maintenance parts Failure to observe this could lead to faults or failures When the robot arm has to be moved by hand from an external area do not place hands or fingers in the openings Failure to observe this could lead to hands or fingers catching depending on the posture Do not stop the robot or apply emergency stop by turning the robot controller s main power OFF If the robot controller main power is turned OFF during automatic operation the robot accuracy could be adversely affected WARNING For using RH 5AH 10AH 15AH While pressing the brake releasing switch on the robot arm beware of the arm which may drop with its own weight Dropping of the hand could lead to a collision with the peripheral eguipment or catch the hands or fingers Revision history Date of print BFP No Details of revisions 2001 09 06 BFP A8175Z First print 2001 09 25 BFP A8175 Formal style 2001 10 22 BFP A8175 A The explanation of the RH 5AH series was added Error in writing correction H Introduction Thank you for purchasing the Mitsubishi industrial robot This instruction manual explains procedures to be taken for unpacking
15. No 2 arm cover U 1 a Hexagonal socket head cap screws 10 M4 x 10 RH 5AH series 11 M4 x 10 RH 10AH 15AH series 2 No 2 arm cover L 1 a Hexagonal socket head cap screws 3 M4 x 10 3 J1 cover 1 b Truss head screws 3 M4 x 8 4 Base cover 1 b Truss head screws 2 M4 x 8 1 Referring to Fig 5 3 remove the covers 2 Table 5 3 lists the names of the covers and installation screws 3 Lower the J4 axis shaft using jog operations before removing the No 2 arm cover U 4 When reattaching the covers after a maintenance inspection proceed in the reverse order of their removal Note Sealant is applied to the cover joint surface of the protrction specification and clean specification models Be sure to replace the sealant if it has been dislocated and bent or crushed and does not return to its original shape Use liquid gasket and Norseal in Page 57 Table 5 6 Spare parts list Moreover in the case of protrction specification and clean specification models it is necessary to remove the top and bottom bellows See Section Page 52 5 3 4 Replacing Bellows for details on how to remove them Maintenance and inspection procedures 5 45 5Maintenance and Inspection 5 3 3 Inspection maintenance and replacement of timing belt This robot uses a timing belt for the drive conveyance system of the pitch axis Compared to gears and chains the timing belt does not require lubricati
16. Origin jig Pinhole No 1 arm RH 10AH 15AH series Origin jig Pinhole Move the cursor lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 10000000 ORIGIN NOT DEF B C INP 95 J6 EXE Designate the origin setting axis 1 DEF ABC lt MECHA gt SET ORIGIN OK 1 1 EXECUTE J5 gt EXE Set the origin 1 DER lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 10000000 ORIGIN COMPLETED OS Origin setting axis designation O O 1 Move the J1 axis slowly toward the front using both hands Align the pinhole of the No 1 arm and the pinhole at the base section feed through the origin jig into the pinholes and fas ten 2 Press the key The cursor will move to SET AXIS 3 Designate the axis for which the origin is to be set Set 1 for the 1 axis and set 0 for the other axes Then press INP key Next a confirmation screen will appear 4 Press the 1 and INP keys The origin posture will be set 5 Setting of the origin is completed 6 Refer to Page 70 5 5 4 Recording the origin data in this manual and record the origin data on the origin data seal Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 Resetting the
17. Page 70 5 5 4 Recording the origin data in SET AXIS 11110000 this manual and record the origin data on the origin ORIGIN COMPLETED data seal OS Releasing the brakes O O To release the brakes move the cursor to the BRAKE axis No with the or gt key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately OS Origin setting axis designation O O Move the cursor to the SET AXIS axis No in the origin setting with the lt or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 Resetting the origin 5 63 5Maintenance and Inspection 5 5 2 Jig method The method for setting the origin with the transportation jig is explained below This operation is carried out with the T B Set the MODE switch on the front of the controller to TEACH and set the T B ENABLE DISABLE switch to ENABLE to validate the T B The following operation is carried out while lightly pressing the T B deadman switch lt MENU gt lt MAINT gt 1 TEACH 2 RUN 1 PARAM 2 INIT 3FILE 4 MONI 3BRAKE 4ORIGIN 1 Press the 5 key on the
18. and Inspection 2 J1 axis origin setting lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF B 95 Designate the origin setting axis 1 DEE Move the cursor lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 10000000 ORIGIN NOT DEF B m jae Designate the origin setting axis 1 DEF 0 ABC lt MECHA gt SET ORIGIN OK21 1 EXECUTE B INP J5 gt EXE 1 DEF Set the origin lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 10000000 ORIGIN COMPLETED O gt Origin setting axis designation O O 1 With both hands slowly move the J1 axis in minus direction and contact the mechanical stopper 2 Press the key The cursor will move to SET AXIS 3 Designate the axis for which the origin is to be set Set 1 for the 1 axis and set 0 for the other axes Then press INP key Next a confirmation screen will appear 4 Press the 1 and INP keys The origin posture will be set 5 Setting of the origin is completed 6 Refer to Page 70 5 5 4 Recording the origin data in this manual and record the origin data on the origin data seal Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 Resetti
19. instruction manuals 1 2 Safety Precautions 1Before starting use Always read the following precautions and the separate Safety Manual before starting use of the robot to learn the required measures to be taken Z CAUTION A CAUTION Z WARNING Z CAUTION Z DANGER Z CAUTION Z CAUTION Z CAUTION All teaching work must be carried out by an operator who has received special training This also applies to maintenance work with the power source turned ON Enforcement of safety training For teaching work prepare a work plan related to the methods and procedures of oper ating the robot and to the measures to be taken when an error occurs or when restart ing Carry out work following this plan This also applies to maintenance work with the power source turned ON Preparation of work plan Prepare a device that allows operation to be stopped immediately during teaching work This also applies to maintenance work with the power source turned ON Setting of emergency stop switch During teaching work place a sign indicating that teaching work is in progress on the start switch etc This also applies to maintenance work with the power source turned ON Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact of the operator and robot Installation of safety fence Establish a set signaling method to the related operators for startin
20. key and display a 0 5 60 Resetting the origin JMaintenance and Inspection 4 J3 and J4 axis origin setting Origin settings for the J3 and J4 axes must be performed at the same time lt MECHA gt 12345678 BRAKE 00000000 1 Press the 0 key twice and then press the 1 SET AXIS 11110000 key 1 will display at the 3 position to set the ORIGIN NOT DEF B brake release J5 2 Confirm the axis for which the brakes are to be Designate the origin setting axis J DEE released 3 One worker must securely support the J3 axis shaft with both hands 4 While holding down the deadman switch hold down the MOVE X keys The brakes will be released while the keys are held down 5 With both hands slowly move the J3 axis in Upward direction plus and contact the mechanical stopper J3 J3axis shaft CAUTION For safety purposes the step for releasing the brakes must be carried out by two workers One worker must operate the T B and the other must support the J3 axis shaft Be careful when releasing the brakes since the J3 axis may fall off by its dead load depending on the weight of the tool CAUTION If the T B X key or the deadman switch is released the brakes will be applied immediately 6 Hold the J4 axis with your hand and rotate it slowly to match the i alignment marks Alignment marks Alignment marks J3 View A 4 4 Generarl environment Prote
21. manual Always contact your dealer when parts are needed CAUTION The origin of the machine system could deviate when this work is carried out Review of the position data and re teaching will be required 5 3 1 Robot arm structure An outline structure drawing is shown in Fig 5 2 Each part is as shown below 9 Timing belt 8 J3 axis motor 4 ei ji 5 J4 axis motor No 2 arm cover U ma th A SJ 3 J2 axis motor pa No 2 arm 10 Ball screw spline Ht ly a 2 Reduction gears L no Hei mA No 2 arm cover L S 7 7 s V No 1 arm T Timing belt Ed 4 Reduction gears 6 Timing belt e me Base N E N 1 J1 axis motor Fig 5 2 Outline structure drawing of robot arm Common to all type 5 44 Maintenance and inspection procedures JMaintenance and Inspection 5 3 2 Installing removing the cover a a PoP 1 No 2 arm cover U 3 J1 cover 2 No 2 arm cover L 4 Base cover J4 axis shaft Fig 5 3 Installing removing the cover Table 5 3 Cover names No Cover name Q ty Installation bolt name Remarks d
22. menu screen and dis 5 MAINT 6 SET 5 POWER play the maintenance screen 6 J6 5 STU Display the maintenance screen lt MAINT gt lt ORIGIN gt 1 PARAM 2 INIT 1 DATA 2 MECH 3 BRAKE 4 ORIGIN gt 3 JIG 4 ABS 2 Press the 4 key on the maintenance screen 5 POWER 5 USER and display the origin setting method selection screen 7 J2 4 MNO Display the method selection screen lt ORIGIN gt lt MECHA gt 1 DATA 2 MECH mi SERVO OFF 3 JIG 4 ABS OK 1 3 Press the 3 key and select the jig method 5 USER 1 EXECUTE Then press the 1 key and the INP key to turn the servo OFF ie Next release the brakes of all axes move the 4 3 JKL 1 ver EXE arms manually with both hands and fasten them Select the jig method with the origin jigs Origin setting can be performed only for the axes you wish to set instead of setting the origin for all axes Go to the appropriate section that describes the origin setting and perform the necessary origin setting A CAUTION At this point release the brakes and move the J3 axis shaft with both hands To ensure safety the brake release procedure described below should always be done by two persons 5 64 Resetting the origin JMaintenance and Inspection 1 J1 axis origin setting lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF B J5 1 DEF Designate the origin setting axis RH 5AH series
23. monthly inspection add the following inspection items every three months estimated at 500 Hr operation hours O Hn Monthly inspection Monthly inspection 500 H Monthly inspection 3 month inspection Monthly inspection Monthly inspection 1000H Monthly inspection 3 month inspection 6 month inspection Daily inspection Monthly inspection Monthly inspection 1500H Monthly inspection 3 month inspection Monthly inspection Monthly inspection 2000H Monthly inspection 3 month inspection 6 month inspection Yearly inspection Operating time lt Guideline for inspection period gt For one shift 8 Hr day X 20 days month X 3 months approx 500 Hr 10 Hr day X 20 days month X 3 months approx 600 Hr For two shifts 15 Hr day X 20 days month X 3 months approx 1000 Hr Caution When using two lines the 3 month inspection 6 month inspection and yearly inspection must be carried out when half the time has passed Fig 5 1 Inspection schedule Maintenance and inspection interval 5 41 5Maintenance and Inspection 5 2 Inspection items The inspection items for the robot arm are shown below Also refer to section 5 Maintenance and inspection in the Controller setup basic operation and maintenance manual and inspect the controller 5 2 1 Daily inspection items Carry out the daily inspections with the procedures given in Table 5 1
24. to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 5 62 Resetting the origin JMaintenance and Inspection 5 All axis origin setting 1 Perform origin settings for the J1 J2 J3 and J4 axes by refer to Page 59 2 J1 axis origin setting Page 60 3 J2 axis origin setting Page 61 4 J3 and J4 axis origin setting Origin setting operations will be performed with other axes later At this point you only need to release the brakes to make each axis touch the mechanical stopper or to align the marks 2 The robot should look like the diagram at left once all procedures are complete Ir RPL l Move the cursor lt MECHA gt 12345678 3 Press the key to move the cursor to SET AXIS BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF BN 1 8 INP 4 Select the axis whose origin is to be set Designate the origin setting axis 1 E TR E E Set 1 to 4 of SET AXIS to 1 and then press the INP key A confirmation screen will be displayed lt MECHA gt SET ORIGIN 5 Press the 1 and INP keys OK21 The origin posture will be set 1 EXECUTE EXE Set the origin DEE 6 Setting of the origin is completed lt MECHA gt 12345678 BRAKE 00000000 7 Refer to
25. upper and lower cardboard boxes together using a cutter or similar tool See a of Fig 2 2 3 Pull out the upper box and place it vertically on the floor surface see b of Fig 2 2 At this point be sure to support the robot by hand so that it does not roll 4 Remove the cushioning material from the left side as seen from the front of the robot see c of Fig 2 2 Support the robot so that it does not roll 5 Remove the robot from the cushioning material see d of Fig 2 2 CAUTION When repackaging the robot in the cardboard box always use the fixtures 2 6 Installation 2Unpacking to Installation 2 RH 10AH 15AH series Wooden frame Robot arm NCAUTION Always unpack the robot at a flat place The robot could tilt over if unpacked at an unstable place Fig 2 2 Unpacking the robot arm The robot is shipped from the factory in wooden frame packing Handle the robot arm according to 2 2 2 Transportation procedures on page 8 The unpacking process is shown below 1 Place the wooden frame on a level floor surface 2 Remove the nails fastening the wooden frame 3 Remove the wooden frame and cushioning material 4 Remove the four bolts connecting the sleeper and the base unit i CAUTION When repackaging the robot in the wooden frame always use the fixing plate Installation 2 7 2Unpacking to Installation 2 2 2 Transportation procedures 1 RH 5AH series Transportation by
26. x e act 99 z Moving along the Z axis a on When the MOVE Z J3 keys are move J e mi pressed the robot will move along the Z The direction of the end axis will not change axis plus direction of the tool coordinate system When the MOVE Z J3 keys are pressed the robot will move along the minus direction lt gt 9 When the robot is in the transportation posture gt 4 gt There are directions from which linear movement is not possible from the transportation posture In this case an 9 will appear on the T B screen and the robot will not move Refer to section Page 22 1 JOINT jog oper ation on page and move the robot to a position where linear movement is possible and then carry out TOOL lt gt 9 9 When an M appears on the T B screen display lt gt 4 gt If the robot is moved outside the movement area with any of the axes an will appear In this case move the axis in the opposite direction TOOL LOW In the example on the left further linear movement in the same direction is not possible EX 360 00 BAY 280 00 MZ 170 00 2 26 Confirming the operation 2Unpacking to Installation Rotating the end axis Rotating around the Z axis When the MOVE C J4 keys are pressed the Z axis will rotate in the plus direction of the tool coordinate system When the MOVE C J4 keys are pressed the Z axis will rotate in the minus direction z 1 2 Ha T
27. 04 VD04E Bracket 11 B port 13 B port 7 7 B port 14 P round head screw Fa M3 x 25 7 we AIR INI 2 No 2 Solenoid valve AIR IN2 GR2 AIR IN3 z 3 No 3 Solenoid valve a d GRI GR3 A A A ii Electrical wiring opening grommet Hand input connector AIR OUT3 AIR OUT1 When using one row When using two row AIR OUT2 solenoid valve solenoid valve ED GR5 GR7 M 4 GR6 GR8 4 2 XY 2 racket When using three row When using four row solenoid valve solenoid valve Connector connection inside the No 2 arm Fig 3 1 Solenoid valve installation procedures RH 5AH Fig 3 1 shows the solenoid valve installation procedures and the solenoid valve connector connection procedures The installation procedures are as follow This work must be carried out with the controller power turned OFF 1 Attach the bracket with the two screws 15 provided M4 x 10 to the hole at the back of the No 2 arm of the robot Attach the solenoid valve to the bracket with the two screws 14 provided M3 x 25 2 Connect the quick coupling port P 5 for the solenoid valve and either AIR OUT1 or AIR OUT2 of the rear end of the No 2 arm with the air hose on the primary air supply side 6 provided by the customer 3 Connect the air hose on the primary air supply side 6 provided by the customer to either AIR IN1 or AIR IN2 of the rear section of the base unit 4 Connect t
28. 0AH 15AH Fig 3 1 shows the solenoid valve installation procedures and the solenoid valve connector connection procedures The installation procedures are as follow This work must be carried out with the controller power turned OFF 1 Attach the bracket with the two screws 15 provided M4 x 10 to the hole at the back of the No 2 arm of the robot Attach the solenoid valve to the bracket with the four screws 14 provided M4 x 45 2 Connect the quick coupling port P 5 for the solenoid valve and either AIR OUT1 or AIR OUT2 of the rear end of the No 2 arm with the air hose on the primary air supply side 6 provided by the customer 3 Connect the air hose on the primary air supply side 6 provided by the customer to either AIR IN1 or AIR IN2 of the rear section of the base unit 4 Connect the secondary piping couplings 6 to 13 and the hand provided by the customer to the second ary piping air hose provided by the customer at about the 1 200 mm position 5 Connect the GR1 plug coming from the No 1 solenoid valve 1 to the GR1 connector in the No 2 arm of the robot The cover U of the No 2 arm must be removed before performing connections Pierce through the center area of the electrical wiring opening grommet with a knife to let the connector on the solenoid valve side feed through Repeat when necessary Installing the solenoid valve set general enveronment specifications 3 35 Slnstalling the option devices Conn
29. 1 and then press the INP BRAKE 00000000 key A confirmation screen will be displayed SET AXIS 11110000 E B INP ORIGIN NOT DEF J ws 48 e Designate the origin setting axis 1 DEF 0 ABC lt MECHA gt 5 Press the 1 and INP keys SET ORIGIN The origin posture will be set XN OK 1 i B INP d EXECUTE s Set the origin DF 6 Setting of the origin is completed lt MECHA gt 12345678 7 Refer to Page 70 5 5 4 Recording the origin data in BRAKE 00000000 i Ta ay this manual and record the origin data on the origin data SET AXIS 11110000 seal ORIGIN COMPLETED O Releasing the brakes O O To release the brakes move the cursor to the BRAKE axis No with the or gt key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately OS Origin setting axis designation O O Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 5 68 Resetting the origin JMaintenance and Inspection 5 5 3 User origin method
30. 2 18 Setting the origin 2Unpacking to Installation 2 4 Confirming the operation In this section the robot will be moved manually using the T B to confirm that the operation is correct Moving the robot manually is called jog operation This operation includes the JOINT jog that moves each axis the XYZ jog that moves along the base coordinate system the TOOL jog that moves along the tool coordinate system and the CYLNDER jog that moves along the circular arc This operation is carried out while pressing the deadman switch on the back of the T B AN CAUTION The robot will move during this operation Make sure that there are no operators near the robot and that there are no obstacles such as tools in the robot operation range AN CAUTION To immediately stop the robot release the deadman switch on the back of the T B The servo power will turn OFF and the robot will stop The robot will also stop if the EMG STOP switch emergency stop switch on the front of the T B or the EMG STOP switch emergency stop on the front of the controller is pressed AN CAUTION Confirm that the origin has been set If the origin has not been set will appear at the current position display on the teaching pendant the JOINT jog oper ation will take place in any jog mode selected Refer to Page 13 2 3 Setting the origin on page for details on setting the origin J4 axis J2 axis C j 5 J1 axis MITSUBE
31. 3a or more If the installation surface is rough the contact with the table will be poor and positional deviation could occur when the robot moves 4 When installing use a common table to prevent the position of the devices and jigs subject to robot work from deviating 5 The installation surface must have sufficient strength to withstand the arm reaction during operation and resistance against deformation and vibration caused by the static dynamic load of the robot arm and peripheral devices etc 6 After installing the robot remove the self supporting plate suspension fitting and fixing plate refer to Fig 2 3 and Fig 2 4 NCAUTION When installing the robot secure enough space behind the robot for future maintenance to allow the connection of cables and the replacement of the backup battery 2 10 Installation 2Unpacking to Installation 2 2 4 Grounding procedures 1 Grounding methods 1 There are three grounding methods as shown in Fig 2 6 c but the dedicated grounding Fig 2 6 a should be used for the robot arm and control Controller Controller Controller and and and r i Robot arm ane i Robot arm an a Robot arm efsonal ler when possible Refer to the separate Con computer computer computer troller Setup Basic Operation and Maintenance Q for details on the controller grounding 2 Use Class D grounding grounding resistance 1009 or less EEE Dedicated groun
32. 5 21 4 15 1 J2 127 5 111 4 105 1 J 3 Notel 84 5mm 84 5mm 84 5mm J4 Not fixed Not fixed Not fixed Note1 The bottom surface of the shaft will interfere with the floor if the J3 axis is lowered down to the upper mechanical stopper Position the axes as indicated when transporting the robot Installation 2 9 2Unpacking to Installation 2 2 3 Installation procedures RH 5AH series Installation reference surface 6 3a lt 2 gt 4 M8 x 40 N Hexagon socket bolts gt Four positions o o Spring washer ol WO Plain washer i lt 1 gt 4 69 Installation holes Maintenance space Installation dimension details of X X RH 10AH 15AH series Installation reference surface 6 3a 122 240 200 lt 2 gt 4 M12 x 45 Hexagon socket bolts Four positions Spring washer N Plain washer N N A lt 1 gt 4 6 16 Installation holes gl Installed using M12 x 45 provided Maintenance space Installation dimension details of X X Fig 2 5 Installation dimensions 1 The robot installation surface has been machine finished Use the installation holes lt 1 gt opened at the four corners of the base and securely fix the robot with the enclosed installation bolts lt 2 gt 2 Install the robot on a level surface 3 It is recommended that the surface roughness of the table onto which the robot is to be installed by 6
33. ABLE MELCO TOKYO NAGOYA WORKS 1 14 YADA MINAMI 5 HIGASHI KU NAGOYA JAPAN OCT 2001 MEE Printed in Japan on recycled paper Specifications are subject to change without notice
34. D01E VD02 VD02E VD03 VD03E VD04 VD04E 3 2 Installing the solenoid valve set protection enveronment specifications 3 3 Installing the pneumatic hand interface ccscsccssssssessssssessecssseessseessessssesssneersnecssecessesssneessecessseessseessesenee 3 4 Hand output cable 1N GR35S ee 3 5 Installing the hand input cable GA 110350 and hand curl tut e 1E ST040 C PIB Basie MAO raisal ENTE AEE eH RCO a 5 1 5 Maintenance and Inspection spection kama 5 1 Maintenance and i 5 3 2 Installing removing the cover 5 3 3 Inspection maintenance and rep pa Timing belt replacement period mi k kk and replacement of J3 axis timing belt i t of J4 axis timing bel a befala position and specifications mrs ese to the es J2 axis 1 Replacing iia ahei arm qe FE 5 4 Maintenance parts 5 se ting the origin wees 55 2 Jie t ku i Da J1 6Appendix AA App F Appendix 1 Tiguration Tl een H 1Before starting use 1 Before starting use This chapter explains the details and usage methods of the instruction manuals the basic terminology and the safety precautions 1 1 Using the instruction manuals 1 1 1 The details of each instruction manuals The contents and purposes of the documents enclosed with this product are shown below Use these documents according to the application For special specifications a separate instruction manual describing the
35. If placed near a noise source positional deviation or malfunction could occur Do not apply excessive force on the connector or excessively bend the cable Failure to observe this could lead to contact defects or wire breakage Make sure that the workpiece weight including the hand does not exceed the rated load or tolerable torque Exceeding these values could lead to alarms or faults Securely install the hand and tool and securely grasp the workpiece Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation Securely ground the robot and controller Failure to observe this could lead to mal functioning by noise or to electric shock accidents Indicate the operation state during robot operation Failure to indicate the state could lead to operators approaching the robot or to incorrect operation When carrying out teaching work in the robot s movement range always secure the priority right for the robot control Failure to observe this could lead to personal inju ries or damage if the robot is started with external commands Keep the jog speed as low as possible and always watch the robot Failure to do so could lead to interference with the workpiece or peripheral devices After editing the program always confirm the operation with step operation before starting automatic operation Failure to do so could lead to interference with periph eral devices because of prog
36. LE DISABLE switch to ENABLE to validate the T B Move the J4 axis to the upper end with jog operation beforehand 1 Select the T B lt MENU gt lt MAINT gt A 1 TEACH 2 RUN 1 PARAM 2 INIT 1 Press the 5 key on the menu screen and dis 3 FILE 4MONI 3BRAKE 4 0RIGIN play the maintenance screen 5 MAINT 6 SET 5 POWER FC J6 5 STU Display the maintenance screen lt MAINT gt lt ORIGIN gt 1 PARAM 2 INIT 1DATA 2 MECH 2 Press the 4 key on the maintenance screen 3 BRAKE 4 ORIGIN gt 3 JIG 4 ABS and display the origin setting method selection 5 POWER 5 USER sereen Y J2 4 MNO Display the method selection screen lt ORIGIN gt lt MECHA gt 1 DATA 2 MECH id aa OFF 3 Press the 2 key and select the jig method 3 JIG 4 ABS os 1 Then press the 1 key and the INP key to 5 USER EXECUTE turn the servo OFF NB Securely fix the transportation jig A to the base gt 0 ExE with the fixing bolts M4 X 12 2 bolts in this Select the jig method al 1 DEF state When setting the origin all axes can be set or only random axes can be set The methods corresponding to the axes to be set are described below so select the corresponding explanation and set the origin The brakes are released here and the J3 axis shaft is moved with both hands AN CAUTION For safety purposes the brakes must be released by two workers 5 58 Resetting the origin JMaintenance
37. Lower to the upper machine stopper Lower to the upper machine stopper J4 Not fixed Not fixed Not fixed 2 8 Installation 2Unpacking to Installation 2 RH 10AH 15AH series Transporting with a crane Brake release switch No 1 arm Suspension fitting A Fixing plate A Cushioning material for ball screws Suspension fitting C Fixing plate B on other side lt RH 10AH55 Fig 2 4 Transportation of robot arm RH 10AH70 85 RH 15AH85 Brake release switch Cushioning material zg for ball screws Fixing plate B 4 Suspension fitting B Fixing plate A 1 Suspension fitting A Self supporting plate 1 Hook the wires to each of the four eyebolts attached to the suspension fitting Make sure the bolts are securely hooked 2 Lift with a crane to transport the robot to the designated location 3 Be careful not to subject the robot to physical shock during transport 4 After installing the robot refer to Page 10 Installation procedures remove the wires the wire hooks the robot will stand by itself as shown in Fig 2 4 the self supporting plate suspension fitting A and B and fix ing plate A B and C NCAUTION When transporting a robot always attach four wires NCAUTION To reattach the fixing plate again set the axes ofthe robot to the positions according to the table below Axis RH 10AH55 RH 10AH70 RH 10AH85 RH 15AH85 J1 37
38. MITSUBISHI Mitsubishi Industrial Robot RH 5AH 10AH 15AH Series INSTRUCTION MANUAL ROBOT ARM SETUP amp MAINTENANCE MELIFA E P A817 5 A S AN Safety Precautions Always read the following precautions and the separate Safety Manual before starting use of the robot to learn the required measures to be taken 24 ZS CAUTION ZS CAUTION WARNING ZS CAUTION WARNING N CAUTION Zi CAUTION ZS CAUTION All teaching work must be carried out by an operator who has received special training This also applies to maintenance work with the power source turned ON Enforcement of safety training For teaching work prepare a work plan related to the methods and procedures of oper ating the robot and to the measures to be taken when an error occurs or when restart ing Carry out work following this plan This also applies to maintenance work with the power source turned ON Preparation of work plan Prepare a device that allows operation to be stopped immediately during teaching work This also applies to maintenance work with the power source turned ON Setting of emergency stop switch During teaching work place a sign indicating that teaching work is in progress on the start switch etc This also applies to maintenance work with the power source turned ON Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact of the operator an
39. N for RH 5AH or 45N for RH 10AH 15AH using the push pull gauge and tighten the J4 axis motor installation screws 1 6 The position could deviate after the belt is replaced Confirm that the position has not deviated If deviated refer to Page 58 5 5 Resetting the origin and reset the origin position Fig 5 7 J4 axis timing belt tension 1 Remove the bracket attached vertically on the shaft fastening area Fig 5 8 J4 axis timing belt tension 2 5 50 Maintenance and inspection procedures JMaintenance and Inspection 4 Timing belt tension RH 5AH series f Pressing force s Span d Slack Pressing force f N J3 351 3GT 6 159 25 2 Belt type Span s mm Slack d mm J4 Motor side 453 3GT 6 79 1 2 2 JA Shaft side 303 3GT 12 75 1 2 4 Fig 5 9 Belt tension RH S5AH series RH 10AH 15AH series f Pressing force s Span Belt type Span s mm Slack d mm Pressing force f N Remarks 666 3GT 12 239 3 7 RH 10AH55 70 85 681 3GT 12 238 3 7 RH 15AH85 J4 Motor side 540 3GT 6 134 2 1 JA Shaft side 471 3GT 15 107 1 7 Fig 5 10 Belt tension RH 10AH 15AH series The timing belt can satisfactorily convey the drive and keep a durable force only when it has an adequate tension The belt tension should not be too tight or too lose Instead it should be adjusted to a degree that elas
40. and replacement of J3 axis timing belt 7 Shaft 6 Shaft inatallation screw 1 J3 motor inatallation screw 4 Timing pulley Bottom of the J3 motor 2 Timing belt 5 Timing pulley Bottom of the shaft 7 Shaft X 2 Timing belt Fig 5 4 Inspection maintenance and replacement of J3 axis timing belt H Inspecting the J3 axis timing belt 1 Confirm that the robot controller power is OFF 2 Refer to Fig 5 3 and remove the No 2 arm cover U 3 Visually confirm that the symptoms indicated in 1 Timing belt replacement period have not occurred with the timing belt 4 Check the belt tension as shown in 4 Timing belt tension on page 51 Lightly press the center of the belt and confirm that the value of belt slack is in following RASSAA iti Force to press the belt apprpx 2N Flexure approx 2 5mm RH 10AH 15AH Force to press the belt apprpx 4N Flexure approx 3 7mm H Adjusting the J3 axis timing belt 1 Carry out steps 1 and 2 indicated in W Inspecting the J3 axis timing belt above 2 Lightly loosen two J3 motor installation screws 1 for RH 5AH or three J3 motor installation screws 1 for RH 10AH 15AH Be careful not to overly loosen the screws 3 While checking the tension of the timing belt 2 move the J3 motor 3 in the directions of the arrows indi cated in the figure above Lightly press the center of the belt and confirm that the value of belt sla
41. ata on the origin data seal Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 5 66 Resetting the origin JMaintenance and Inspection 3 J3 and J4 axis origin setting Origin settings for the J3 and J4 axes must be performed at the same time The method of origin setting is the same as the mechanical stopper method Refer to Page 61 4 J3 and J4 axis origin setting perform the reguired origin setting operations Resetting the origin 5 67 5Maintenance and Inspection 4 All axis origin setting RH 5AH series 1 Perform origin settings for the J1 J2 J3 and J4 axes by refer to Page 59 2 J1 axis origin setting Page 66 2 J2 axis origin setting Page 67 3 J3 and J4 axis origin setting Origin setting operations will be per formed with other axes later At this point you only need to release the brakes to make each axis touch the mechanical stopper or to align the marks 2 The robot should look like the diagram at left once all procedures are complete RH 10AH 15AH series a 3 Press the key to move the cursor to SET AXIS Move the cursor 4 Select the axis whose origin is to be set lt MECHA gt 12345678 Set 1 to 4 of SET AXIS to
42. ations Slnstalling the option devices 3 2 Installing the solenoid valve set protection enveronment specifications RH 5AH series 1A VD01M 01 VD01ME 01 VD02M 01 VD02ME 01 VD03M 01 VD03ME 01 VD04M 01 VD04ME 01 RH 10AH 15AH series 1A VD01M 02 VD01ME 02 VD02M 02 VD02ME 02 VD03M 02 VD03ME 02 VD04M 02 VD04ME 02 Solenoid valve box In the solenoid valve box Two pieces on opposite sides Support for solenoid valve box Example of RH 5AH Fig 3 3 Solenoid valve installation procedures Fig 3 3 shows how to install the solenoid valve set and how to connect the solenoid valve connector The sole noid valve must be installed in the solenoid valve box Turn the power supply to the controller off when performing this operation Turn off the power supply when performing this operation 1 Install the solenoid valve in the solenoid valve box using the two M3 x 25 screws provided 2 Perform the wiring and piping using the same installation procedure as described in steps 2 to 5 of Section 1 RH 5AH 1E VD01 VD01E VD02 VD02E VD03 VD03E VD04 VD04E on page 33 3 Install the solenoid valve box and support for the solenoid valve box using eight M3 x 8 screws At this point pull out the wiring and piping of the solenoid valve from the bottom of the box so that they do not overlap Confirm that the wiring and piping are clamped with sealant 4 Return the plugs GR1 to 8 inside the wiring port at the rear of robot s N
43. ck is in following RHZSA Hissini Force to press the belt approx 2N Flexure 2 5mm RH 10AH 15AH Force to press the belt approx 4N Flexure 3 7mm 4 The belt tension will increase when moved in the direction of arrow a and will decrease when moved in the direction of arrow b 5 If the belt is loosened too much when adjusting the tension causing it to come off the timing pulleys 4 and 5 or if the belt and pulley teeth engagement is deviated the machine system s origin will deviate 6 After adjusting securely tighten the J3 motor installation screws 1 Improper tightening can cause the belt to loosen with vibration Maintenance and inspection procedures 5 47 5Maintenance and Inspection H Replacing the J3 axis timing belt 1 Fig 5 4 shows the methods for inspecting adjusting and replacing the timing belt 2 Move the robot posture with the teaching pendant so that the J3 axis contacts the mechanical stopper of upside The J3 axis brakes must be released 3 Turn off the controller power 4 Be careful not to let the timing pulley 4 on the J3 axis motor move while the belt is being changed 5 If the pulley 4 and 5 position relation deviates the position could deviate 6 Loosen the J3 motor installation screws 1 to lift the J3 motor 3 upward and remove the timing belt 2 from the timing pulley 4 7 Loosen the shaft installation screws 6 to lift the shaft upward and remove the timing bel
44. completes the setting of the origin with the user origin method 9 Press the 1 key and then the INP key The origin will be set 5 5 4 Recording the origin data When the origin has been set with the mechanical stopper method or jig method record that origin data on the origin data label With this the origin can be set with the origin data input method the next time Confirm the origin data on the teaching pendant screen origin data input screen The origin data label is enclosed with the arm or attached on the back of the J1cover The teaching pendant operation method and J1cover removal method for confirming the origin data is the same as the methods for setting the origin with the origin data input method Refer to Page 14 2 3 2 Setting the origin with the origin data input method and write the origin data displayed on the teaching pendant onto the origin label 1 Confirming the origin data label Remove the Jicover Refer to Page 45 5 3 2 Installing removing the cover and remove the J1cover 2 Confirming the origin data Confirm the value displayed on the teaching pendant s Origin Data Input screen Refer to Page 14 2 3 2 Setting the origin with the origin data input method 5 Inputting the origin data and display the Origin Data Input screen on the teaching pendant display screen 3 Recording the origin data Write the origin data displayed on the teaching pendant to the origin
45. ction and clean specifications OS Releasing the brakes O O To release the brakes move the cursor to the BRAKE axis No with the or key The brakes can be released only for the axis for which a 1 is displayed on the screen If the brakes are not to be released press the 0 key and display a 0 If the X key on the teaching pendant or the deadman switch is pressed while the brakes are released the brakes will be applied immediately Resetting the origin 5 61 5Maintenance and Inspection ig 7 Press the key The cursor will move to Move the cursor SET AXIS lt MECHA gt 12345678 BRAKE 00000000 8 Designate the axis for which the origin is to be SET AXIS 00110000 ja E Set 1 for the 3 and 4 axes and set 0 for the ORIGIN NOT DEF E el are Eaa J5 J6 EXE other axes Then press INP key Next a confir Designate the origin setting axis 1 DEF 0 ABC mation screen will appear lt MECHA gt SET ORIGIN 9 Press the 1 and INP keys OK2 1 The origin posture will be set 1 EXECUTE B INP J5 EXE Set the origin DEF lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 00110000 11 Refer to Page 70 5 5 4 Recording the origin ORIGIN COMPLETED data in this manual and record the origin data on the origin data seal 10 Setting of the origin is completed OS Origin setting axis designation O O Move the cursor
46. d robot gt Installation of safety fence Establish a set signaling method to the related operators for starting work and follow this method Signaling of operation start As a principle turn the power OFF during maintenance work Place a sign indicating that maintenance work is in progress on the start switch etc Indication of maintenance work in progress Before starting work inspect the robot emergency stop switch and other related devices etc and confirm that there are no errors Inspection before starting work The points of the precautions given in the separate Safety Manual are given below Refer to the actual Safety Manual for details ZS CAUTION A CAUTION A CAUTION CAUTION A CAUTION N CAUTION WARNING WARNING ZS CAUTION WARNING Zi CAUTION ZN CAUTION ZS CAUTION N CAUTION WARNING N CAUTION Use the robot within the environment given in the specifications Failure to do so could lead to a drop or reliability or faults Temperature humidity atmosphere noise environ ment etc Transport the robot with the designated transportation posture Transporting the robot in a non designated posture could lead to personal injuries or faults from dropping Always use the robot installed on a secure table Use in an instable posture could lead to positional deviation and vibration Wire the cable as far away from noise sources as possible If placed near a noise
47. data label attached to the back of the J1cover Refer to Page 14 Fig 2 10Origin data label an example and Page 17 Fig 2 11Correspondence of ori gin data label and axis for details on the origin data label 4 Installing the J1 cover Install the J1cover removed in step 1 Confirming the origin data label above Refer to Page 45 5 3 2 Installing removing the cover and replace the J1cover This completes the recording of the origin data 5 70 Resetting the origin GAppendix 6 Appendix Appendix 1 Configuration flag The configuration flag indicates the robot posture The robot hand end is saved with the position data configured of X Y Z A B and C However even with the same position data there are several postures that the robot can change to The posture is expressed by this configu ration flag and the posture is saved with FL1 in the position constant X Y Z A B C FL1 FL2 The types of configuration flags are shown below 1 RIGHT LEFT Indicates the location of the end axis relative to the line that passes through both the rotational center of the J1 axis and the rotational center of the J2 axis FL1 Flag 1 amp B0000 0000 T 1 0 RIGHT LEFT Note amp B is shows the binary Configuration flag Appendix 71 GAppendix Appendix 72 Configuration flag A MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100 8310 TELEX J24532 C
48. ding separated from the other devices should be used i gt aid a e iial Kk Et lll 3 Use a A W G 14 2mm2 or more stranded wire for the grounding wire The grounding point should be as close to the robot arm and controller as possi ble and the length of the grounding wire should be short Fig 2 6 Grounding methods 2 Grounding procedures 1 Prepare the grounding cable A W G 14 2mmZ2 or more and robot side installationscrew and washer 2 If there is rust or paint on the grounding screw section A remove it with a file etc M4 x 10 SW PW 3 Connect the grounding cable to the grounding screw section Robot grounding cable A W G 14 2mm2 or more Prepared by customer Fig 2 7 Connecting the grounding cable Installation 2 11 2Unpacking to Installation 2 2 5 Connecting with the controller RH 5AH series Robot arm Controller Motor power Li Motor signal CN2 Motor power cable 5m Motor signal cable 5m Fig 2 8 Connecting the machine cables RH 10AH 15AH series Controller Motor signal m Motor power 1 CN1 Motor power cable 5m Motor signal cable 5m Carry out the following procedure after installing the controller referring to the separate Controller Setup Basic Operation and Maintenance manual 1 Make sure that the power switch on the front of the controller is turned OFF 2 Connect the machine cable to t
49. e lead through to the outside Seal the grommet area with liquid sealant or similar mate rial 3 5 Installing the hand input cable 1A HC35C and hand curl tube 1E ST040 C The hand input cable and hand curl tube are used to connect to the hand and sensor manufactured by the cus tomer This option is not used for clean specification models There is a risk that dust will be generated by friction between the cables Examine the location of the cable clamp in order to reduce the friction as much as possible 3 38 Installing the pneumatic hand interface 4Basic operations 4 Basic operations The basic operations from creating the program to automatic operation are explained in section 4 Basic opera tions in the From Controller Setup to Maintenance manual Refer that manual as necessary 4 39 4Basic operations 4 40 JMaintenance and Inspection 5 Maintenance and Inspection The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are described in this chapter The types and replacement methods of consumable parts are also explained 5 1 Maintenance and inspection interval Maintenance and inspection are divided into the inspections carried out daily and the periodic inspections carry out at set intervals Always carry these out to prevent unforeseen trouble to maintain the product for a long time and to secure safety 1 Inspection schedule In addition to the
50. e of the movement area If moved outward an 4 will appear on the T B screen and the robot will not move 2 22 Confirming the operation 2Unpacking to Installation J3 axis jog operation STEP Z 1121 a MOVE 8 ay T J3 axis f When the MOVE Z J3 keys are pressed the J3 axis will rotate in the plus direction When the MOVE Z J3 keys are pressed Rotate in the minus direction J4 axis jog operation J4 axis STEP A STEP A eee e e 4 EE MOVE 2 i d i 5 MOVE 1 When the MOVE A J4 keys are pressed the J4 axis will rotate in the plus direction When the MOVE A J4 keys are pressed Rotate in the minus direction O When an M appears on the T B screen display O O If the robot is moved outside the movement area an 4 will appear In this case move the axis in the opposite direction JOINT LOW In the example on the left the J1 axis is at the limit of the plus side movement area F4J1 160 00 J2 20 00 J3 80 00 Confirming the operation 2 23 2Unpacking to Installation 2 XYZ jog operation Select the XYZ jog mode X Y Z LOW Press the MOVE XYZ keys to select the XYZ jog mode XYZ will appear at the upper left of X 134 50 GE the screen Y 220 00 Z 280 00 XYZ jog mode ae Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH Set the jog speed 3 5 10
51. ect the GR2 plug coming from the No 1 solenoid valve 1 to the GR2 connector in the No 2 arm of the robot In the case of a two sets valve 1N VD02 1N VDO2E also connect the GR3 plug coming from the No 2 solenoid valve 2 to the GR3 connector in the No 2 arm of the robot Then connect the GR4 plug coming from the No 2 solenoid valve 2 to the GR4 connector in the No 2 arm of the robot In the case of a three sets valve 1N VD03 1N VDO3E also connect the GR5 plug coming from the No 3 solenoid valve 3 to the GR5 connector in the No 2 arm of the robot Then connect the GR6 plug coming from the No 3 solenoid valve 3 to the GR6 connector in the No 2 arm of the robot In the case of a four sets valve 1N VD04 1N VD04E also connect the GR7 plug coming from the No 4 solenoid valve 4 to the GR7 connector in the No 2 arm of the robot Then connect the GR8 plug coming from the No 4 solenoid valve 4 to the GR8 connector in the No 2 arm of the robot The connection correspondence after installation is as shown in Table 3 1 Table 3 2 Solenoid valve ports and hoses Correspondence of couplings and hand ports Hand Hand port Solenoid valve port Solenoid valve used OPEN A Hand 1 1 st row CLOSE B OPEN A Hand 2 2 nd row CLOSE B OPEN A Hand 3 3 rd row CLOSE B OPEN A Hand 4 4 th row CLOSE B 3 36 Installing the solenoid valve set general enveronment specific
52. ection items 1 Is the timing belt tension abnormal If the timing belt is loose or too tense adjust it 2 It runs out of grease on the shaft Wipe the old grease off and lubricate 6 month 1 000 hr inspection items 1 Is the friction at the timing belt teeth severe If the teeth are missing or severe friction is found replace the timing belt Yearly 2 000 hr inspection items 1 Replace the backup battery in the robot arm Exchange it referring to Page 56 5 3 6 Replacing the backup battery 3 year 6 00 0 hr inspection items 1 Lubricate the grease at the harmonic reduction gears for J1 and J2 axis Lublicate it referring to Page 54 5 3 5 Lubrication Replace the bellows J3 axis only for clean and protrction specification Exchange it referring to Page 52 5 3 4 Replacing Bel lows Inspection items 5 43 5Maintenance and Inspection 5 3 Maintenance and inspection procedures The procedures for carrying out the periodic maintenance and inspection are described in this section Thoroughly read the contents and follow the instructions This work can be commissioned to the Mitsubishi Service Depart ment for a fee Never disassemble etc the parts not described in this manual The maintenance parts etc required for the user to carry out maintenance and inspection are described in Page 57 5 4 Maintenance parts of this
53. eplace all batteries with new ones at the same time 7 Carry out steps 4 to 6 in reverse to install the parts 8 Initialize the battery consumption time Always carry out this step after replacing the battery and initialize the battery usage time Refer to the sep arate Instruction Manual Detailed Explanation of Functions and Operations for details on the operation methods 5 56 Maintenance and inspection procedures 5 4 Maintenance parts JMaintenance and Inspection The consumable parts that must be replaced periodically are shown in Table 5 5 and spare parts that may be required during repairs are shown in Table 5 6 Purchase these parts from the dealer when required Some Mit subishi designated parts differ from the maker s standard parts Thus confirm the part name robot arm and con troller serial No and purchase the parts from the dealer Table 5 5 Consumable part list No Part name Type Usage place Q ty Supplier 1 Grease SK 1A Reduction gears of each axis An needed 2 Lithium battery A6BAT In base 4 ea Table 5 6 Spare parts list No Part name Type Usage place Q ty Supplier RH 5AH series 1 Timing belt 453 3GT 6 J3 axis 1 2 357 3GT 6 J4 axis motor side 1 3 303 3GT 12 J4 axis shaft side 1 4 AC servo motor BU160B365G51 J1 axis 1 5
54. ertically on the shaft fastening area Fig 5 5 J3 axis timing belt tension 5 48 Maintenance and inspection procedures JMaintenance and Inspection 3 Inspection maintenance and replacement of J4 axis timing belt Je 2 J4 axis motor 1 J4 axis installation screw Nhe ss id DTiming belt motor side 6 Timing pulley i ld NA ll 5 Timing pulley 1 4 E sy L ATN E A Aid ler Ed R A 9 Timing pulley Fa N X Ka E 3 Idler installation screw 10 b a 10 Timing belt gy Timing pulle shaft side na Fig 5 6 Inspection maintenance and replacement of J4 axis timing belt H Inspecting the J4 axis timing belt 1 Confirm that the robot controller power is OFF 2 Refer to Fig 5 3 and remove the No 2 arm cover U and No 2 arm cover L 3 Visually confirm that the symptoms indicated in 1 Timing belt replacement period have not occurred with the timing belt At two locations one at the first row and another at the second row 4 Check the belt tension as shown in 4 Timing belt tension on page 51 Lightly press the center of the belt and confirm that the value of belt slack is in following RH 5AH series Motor
55. firming the operation 2 25 2Unpacking to Installation 3 TOOL jog operation Select the TOOL jog mode Press the MOVE TOOL keys to select the TOOL LOW TOOL jog mode TOOL will appear at the upper X 134 50 TOOL left of the screen Y 220 00 B Z 280 00 TOOL jog mode Each time the MOVE keys are pressed the override will increase in the order of LOW gt HIGH Set the jog speed gt 3 gt 5 gt 10 gt 30 gt 50 gt 70 100 When the MOVE keys are pressed the override Legere g will decrease in the reverse order The currently Y 920 00 step set speed will appear on the upper right of the i NENE FORWO Bacwn screen Set the override to 10 here for confirma Z 280 00 Set the spee tion work Moving along the tool coordinate system Moving along the X axis Eaa When the MOVE X J 1 keys are ae pressed the robot will move along the X yai axis plus direction of the tool coordiate sys T tem When the MOVE X J 1 keys are pressed the robot will move along the minus direction Moving along the Y axis i r i When the MOVE Y J2 keys are pressed the robot will move along the Y li axis plus direction of the tool coordnate ster Z d F system SL a When the MOVE Y J2 keys are Y gt ster oy pressed the robot will move along the minus 7 e direction g TII
56. g work and follow this method Signaling of operation start As a principle turn the power OFF during maintenance work Place a sign indicating that maintenance work is in progress on the start switch etc Indication of maintenance work in progress Before starting work inspect the robot emergency stop switch and other related devices etc and confirm that there are no errors Inspection before starting work Safety Precautions 1 3 1Before starting use 1 2 1 Precautions given in the separate Safety Manual The points of the precautions given in the separate Safety Manual are given below Refer to the actual Safety Manual for details Z CAUTION Z CAUTION CAUTION ZS CAUTION ZS CAUTION CAUTION Z WARNING Z WARNING Z CAUTION Z WARNING Z CAUTION ZS CAUTION ZS CAUTION ZS CAUTION ZS WARNING Z CAUTION 1 4 Safety Precautions Use the robot within the environment given in the specifications Failure to do so could lead to a drop or reliability or faults Temperature humidity atmosphere noise envi ronment etc Transport the robot with the designated transportation posture Transporting the robot in a non designated posture could lead to personal injuries or faults from drop ping Always use the robot installed on a secure table Use in an instable posture could lead to positional deviation and vibration Wire the cable as far away from noise sources as possible
57. gt lt DATA D Wb0000 1 000000 000000 3 000000 000000 5000000 000000 lt DATA D W00000 1000000 000000 3 000000 000000 lt DATA gt D fP000 1 000000 000000 5 000000 000000 oaTa D vhboo 1 000000 000000 PSS 3 000000 000000 5 000000 000000 pos A J4 2 GHI lt DATAYD VI S29 1 050000 000000 3 000000 000000 5 000000 000000 lt DATAYD V S29 1 A B amp 8F GHSY5 3 H 7 2H B M1L 5 59A37 K8 amp 6P lt DATA gt D V S29 CHANGES TO ORIGIN oK 7 E us execute MM 1 oer AER 3 000000 000000 POS 4 Keys used B POS 45 5 000000 000000 CHAR INP EXE 1 Confirm that the cursor is at the D position on the T B display screen 2 Input the D value V S29 Inputting V Press the VWX key once while holding down the CHAR key V will appear so release the CHAR key V will be set Inputting 1 Press the key three times while holding down the CHAR key will appear so release the CHAR key will be set In the same manner while holding down the CHAR key press the key twice and the STU key once input S Release the CHAR key and press the 2 key input 27 and then the 9 key input 9 V S29 will appear at the D data on the teaching pendant screen 3 Press the
58. he MOVE C J4 keys are pressed the Z axis will rotate in the plus direction of the tool coordinate system When the MOVE C J4 keys are pressed the Z axis will rotate in the minus direction STEP MOVE The Position of the end axis will not change Confirming the operation 2 29 2Unpacking to Installation 5 CYLNDER jog operation Select the cylindrical jog mode oe EOW Press the MOVE XYZ keys and then press R 134 50 XYZ only the XYZ key CYLNDER will appear at the T 220 00 y upper left of the screen Z 280 00 CYLNDER jog mode 7 Each time the MOVE keys are pressed the Set the jog speed CYLNDER LOW override will increase in the order of LOW HIGH 3 5 10 gt 30 50 70 100 When R 134 50 the MOVE keys are pressed the override will T 220 00 step i decrease in the reverse order The currently set Z 280 00 elik i MOVE FORWD BACKWD speed will appear on the upper right of the screen f e e spee Moving along an arc centering on the Z axis E ove 3 Vertical my The direction of the end axis will not change 2 30 Confirming the operation Set the override to 10 here for confirmation work Moving along an arc Assuming that the current position is on an arc centering on the Z axis the robot moves along that arc When the MOVE Y J2 keys are
59. he Position of the end axis will not change lt gt When alarm No 5150 occurs O O If alarm No 5150 ORIGIN NOT SET occurs the origin has not been set correctly Reconfirm the value input for the origin data OS Tool length O O The default tool length is Omm and the control point is the center of the end axis After installing the hand set the correct tool length in the parameters Refer to the separate manual Detailed Explanation of Functions and Operations for details Confirming the operation 2 27 2Unpacking to Installation 4 3 axis XYZ jog operation Select the 3 axis XYZ jog mode XY2456 LOW Press the MOVE XYZ keys and then Aaa xyz xyz press only the XYZ key XYZ456 will appear Y ee A at the upper left of the screen Z 280 00 3 axis XYZ jog mode 7 Set the jog speed XYZ456 LOW X 134 50 Y 220 00 Z 280 00 re 7 OO Set the soeed Move E E Moving along the base coordinate system x Y Tx 1 Y H 91 i 4 e Z STEP z H 93 MOVE 3 JKL The direction of the end axis will not change ster X STEP Y 91 02 MOVE SPACE POR MOVE 4 mo ZX x a Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH gt 3 gt 5 10 gt 30 gt 50 gt 70 gt 100 When the MOVE keys are pressed the override will decrease in the reverse order
60. he robot arm and the corresponding connector on the controller CAUTION The machine cable connectors are dedicated for the controller side and robot arm side so take special care when connecting If connected incorrectly the connector pins could bend or break Thus even if con nected correctly the robot will not operate correctly creating a dangerous situation NCAUTION Take special care to the leading of the connection cable If the cable is pulled with force or bent excessively wires could break or the connector could be damaged NCAUTION Connect cables between devices in a place where there is no risk of contamination from dust and oil mist Also be sure to protect the robot arm s connector area from dust and oil mist when cables between devices are disconnected since contamination will cause failures in the robot 2 12 Installation 2Unpacking to Installation 2 3 Setting the origin The origin is set so that the robot can be used with a high accuracy After purchasing the robot always carry out this step before starting work This step must also be carried out if the combination of robot and controller being used is changed There are several methods for setting the origin but the origin data input method will be explained here Refer to Page 58 5 5 Resetting the origin on page for the other methods The teaching pendant is required for this operation 2 3 1 Installing the teaching pendant T B
61. he secondary piping couplings 6 to 13 and the hand provided by the customer to the second ary piping air hose provided by the customer at about the 800 mm position Installing the solenoid valve set general enveronment specifications 3 33 Slnstalling the option devices 5 Connect the GR1 plug coming from the No 1 solenoid valve 1 to the GR1 connector in the No 2 arm of the robot The cover U ofthe No 2 arm must be removed before performing connections Pierce through the center area of the electrical wiring opening grommet with a knife to let the connector on the solenoid valve side feed through Repeat when necessary Connect the GR2 plug coming from the No 1 solenoid valve 1 to the GR2 connector in the No 2 arm of the robot In the case of a two sets valve 1E VD02 1E VDO2E also connect the GR3 plug coming from the No 2 solenoid valve 2 to the GR3 connector in the No 2 arm of the robot Then connect the GR4 plug coming from the No 2 solenoid valve 2 to the GR4 connector in the No 2 arm of the robot In the case of a three sets valve 1E VD03 1E VDO3E also connect the GR5 plug coming from the No 3 solenoid valve 3 to the GR5 connector in the No 2 arm of the robot Then connect the GR6 plug coming from the No 3 solenoid valve 3 to the GR6 connector in the No 2 arm of the robot In the case of a four sets valve 1E VD04 1E VD04E also connect the GR7 plug coming from the No 4 solenoid valve
62. hed vertically to the shaft fastening area 3 Apply the specified amount of grease to the shaft If too much grease is applied grease may get scattered all over inside of the No 2 arm If the grease reaches the timing belt inside the No 2 arm the timing belt may deteriorate prematurely 4 Attach the covers in the reverse order of their removal In the case of protrction specification and clean specification models it is necessary to remove the top and bot tom bellows See Section Page 52 5 3 4 Replacing Bellows for details on how to remove them AN CAUTION Replace the bellows in a place where there is no risk of contamination by dust and oil mist If it must be replaced in a dust filled area be sure to remove as much dust as possible in advance before replacing it Maintenance and inspection procedures 5 55 5Maintenance and Inspection 5 3 6 Replacing the backup battery An absolute encoder is used for the position detector so the position must be saved with the backup battery when the power is turned OFF The controller also uses a backup battery to save the program etc These batter ies are installed when the robot is shipped from the factory but as these are consumable parts they must be replaced periodically by the user The guideline for replacing the battery is one year but this will differ according to the robot s usage state When the battery life nears the Battery cumulative time over alarm Alarm No 7520
63. installing servicing and inspecting the robot arm Always read through this manual before starting use to ensure correct usage of the robot No part of this manual may be reproduced by any means or in any form without prior consent from Mitsubishi The details of this manual are subject to change without notice The information contained in this document has been written to be accurate as much as possible Please interpret that items not described in this document cannot be performed Please contact your nearest dealer if you find any doubtful wrong or skipped point Copyright C 2001 MITSUBISHI ELECTRIC CORPORATION Contents 1 Before starting use instruction manua e details of each instruction manuals nbols used in instruction manual 1 1 Using tal 112 1 2 Safety Precautions 1 2 1 Precautions given in the siit Safety tuned 2 Unpacking to Installation EENE EN ainiti alaliiki astal ed 21 ie the k kk 2 RH 10AH 15AH series 2 2 2 JAA na ip FINS ac lth alee acta nicer acer eee ai 2 2 4 Grounding 0 2 Turning ON 3 Prapa 3 Installing the option devices eseserereerrrerererrererererrererereerereeeeeen AE ER a E EEEE 2 00 3 1 Installing the solenoid valve set usid enveronment aiia an A 1 RH 5AH 1E VD01 VD01E VD02 VD02E VD03 VD03E VD VDOME PERET 2 RH 10AH 15AH 1N VD01 V
64. ion 5 Plain washer for installation bolts For M8 4 pcs 6 Arm fixing plates 1 set For robot arm transportation 7 Arm fixing plate installation bolt 1 set RH 10AH 15AH series 1 Robot arm RH 10AH55 70 85 or Either RH 15AH85 series 1 unit 2 Guarantee card 1 copy 3 Installation bolts M12 x 45 4 pcs 4 Spring washer for installation bolts For M12 4 pcs For robot arm installation 5 Plain washer for installation bolts For M12 4 pcs 6 Fixing plate 1 set 7 Fixing plate installation bolts 1 set For robot arm transportation 8 Suspension fitting 1 set 9 Suspension fitting installation bolts 1 set Note The number 3 4 and 5 are in the attached plastic bag in the robot arm Confirming the product 2 5 2Unpacking to Installation 2 2 Installation 2 2 1 Unpacking 1 RH 5AH series tt Pull out vertically J a Robot arm CAUTION Always unpack the Fixing plate A robot at a flat place The robot could tilt over if unpacked at an unstable place Note The cushioning material will be required if the robot is transported again so save it in a safe place Fig 2 1 Unpacking the robot arm RH 5AH series The robot is shipped from the factory in cardboard packing Always refer to Fig 2 2 and unpack the robot Handle the robot arm according to 2 2 2Transportation procedures The unpacking process is shown below 1 Place the cardboard box on a flat floor surface 2 Cut the tapes holding the
65. jog operation Select the JOINT jog mode Press the MOVE JOINT keys to select the JOINT LOW JOINT jog mode JOINT will appear at the upper J1 34 50 JOINT left of the screen J2 20 00 move y J3 80 00 JOINT jog mode Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH Set the jog speed 3 gt 5 gt 10 30 50 70 100 When the MOVE keys are pressed the over JOINT LOW ride will decrease in the reverse order Ji 34 50 step The currently set speed will appear on the upper right J2 20 00 ls AMOVE FoRvi Backwo of the screen J3 80 00 et the spee Set the override to 10 here for confirmation work J1 axis jog operation i an 4 m al 1 x amp aaa x on 1 k i 01 MOVE SPACE PQR 4 When the MOVE X J1 keys are pressed the J1 axis will rotate in the plus direction When the MOVE X J1 keys are pressed Rotate in the minus direction J2 axis jog operation J2 axis wove he Sao C Grove 4 MNO 9 RK gt Li be When the MOVE Y J2 keys are pressed the J2 axis will rotate in the plus direction When the MOVE Y J2 keys are pressed Rotate in the minus direction When the robot is in the transportation posture O O The axes may be outside the movement area Move these axes toward the inner sid
66. lt 4 gt and the ball screw with the liquid gasket described in Page 57 Table 5 6 Spare parts list or similar material Note Check the condition of the sealant when installing the No 2 arm cover L onto No 2 arm Be sure to replace the sealant if it is dislocated and bent or crushed and does not return to its original shape Page 57 Table 5 6 Spare parts list provides a list of names of Norseal types Tr 4 M3 x 8 screw X lt 3 gt No 2 arm cover L 3 M4 screw I eut surface Bottom bellows Details of D cut surface Liguid gasket coating position Section B 5 12 Replace the bottom bellows AN CAUTION Replace the bellows in a place where there is no risk of contamination by dust and oil mist If it must be replaced in a dust filled area be sure to remove as much dust as possible in advance before replacing it Maintenance and inspection procedures 5 53 5Maintenance and Inspection 5 3 5 Lubrication 1 Lubrication position and specifications 4 J2 axis air inlet RH 5AH series 2 J2 axis lubrication port 3 Shaft lubrication 1 J1 axis lubrication port 5 J1 axis air inlet RH 10AH 15AH series 2 J2 axis lubrication port 3 Shaft lubrication 1391 axis lubrication port 5 J1 axis air inlet Fig 5 13 Lubrication positions Table 5 4 Lubrication specifications
67. n the T B screen and the robot will not move Refer to section Page 22 1 JOINT jog operation on page and move the robot to a position where linear movement is possible and then carry out XYZ jog lt When an M appears on the T B screen display O O If the robot is moved outside the movement area with any of the axes an A will appear In this case move the axis in the opposite direction LOW In the example on the left further linear movement in the same direction is not possible 360 00 280 00 170 00 2 24 Confirming the operation 2Unpacking to Installation Changing the direction of the end axis Rotating around the Z axis When the MOVE C J4 keys are pressed the Z axis will rotate in the plus direction When the MOVE C J4 keys are pressed the Z axis will rotate in the minus A direction C J6 5 STU C STEP J6 0 ABC MOVE X Z The Position of the end axis will not change lt gt When alarm No 5150 occurs O O If alarm No 5150 ORIGIN NOT SET occurs the origin has not been set correctly Reconfirm the value input for the origin data OS Tool length O O The default tool length is Omm and the control point is the center of the end axis After installing the hand set the correct tool length in the parameters Refer to the separate manual Detailed Explanation of Functions and Operations for details Con
68. na tion of Functions and Operations Refer to that manual and input the user designated origin position 4 Next set the origin Ee 2 RUN aa Press the MENU key to display the Menu n i screen ip ka 3 BRAKE 4 ORIGIN 5 Press the 5 key to display the Maintenance E 5 POWER screen FC J6 Display the maintenance screen 5 STU A A E MECH 6 Press the 4 key to select the Origin Setting 3BRAKE 40RIGN P 3416 4ABS P 5 POWER 5 USER Y J2 Display the origin setting method selection screen 4 MNO lt ORIGIN gt lt USER gt M DATA 2MECH SERVO OFF 7 Press the 5 key to select the user origin 3 JIG 4 ABS gt OK method 5 USER 1 EXECUTE Then press 1 key and INP key to turn OFF i the servo C B J6 95 as 5 STU 1 DEF Select the origin method and servo OFF Resetting the origin 5 69 5Maintenance and Inspection lt USER gt 12345678 ae TO ORIGIN 8 Press the key and input 1 for the axis BRAKE 00000000 al OKA for which the origin is to be set Press the INP SET AXIS 11110000 i key to display the Confirmation screen ORIGIN NOT DEF 1 EXECUTE RPL B INP i IP J5 EXE Designate the origin setting axis J 1 DEF lt USER gt 12345678 BRAKE 00000000 gt ET AXIS 11110000 ORIGIN NOT DEF lt USER gt CHANGES TO ORIGIN OK21 1 EXECUTE B INP 15 EXE Set the origin 1 DEF This
69. ng method selection screen lt ORIGIN gt 1 DATA 2 MECH INP the data input method 3 JIG 4 ABS EXE The origin data input method will be selected and the screen for turning 9 USER Ji DEF OFF the servo power will appear 3 Press the 1 key on the origin setting method selection screen and select ja lt ORIGIN gt 4 Press the 1 and INP keys to turn OFF the servo power The screen for SERVO OFF inputting the origin data will appear OK Be INE E 1 EXECUTE MB Us cee EE lt DATA gt D 000000 1 000000 000000 3 000000 000000 9 000000 000000 OS Selecting a menu O O The menu can be selected with one of the following methods A Press the numeral key for the No of the item to be selected B Using the and 1 keys etc move the cursor to the item to be selected and then press the INP key 2 16 Setting the origin 2Unpacking to Installation 5 Inputting the origin data Origin data label D J1 J2 3 J4 J5 J6 T B screen lt DATA gt D D tJi 2 3 43 04 5 45 _J6_ Input the value confirmed in section Page 14 1 Confirming the origin data on page The correspondence of the origin data label value and axis to be input is shown in Fig 2 11 Fig 2 11 Correspondence of origin data label and axis The method for inputting the origin data is explained below The value shown in Fig 2 10 will be input as an exam ple lt T B screen
70. ng the origin 5 59 5Maintenance and Inspection 3 J2 axis origin setting lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 11110000 A 7 ORIGIN NOT DEF 5 1 With both hands slowly move the J2 axis in J5 plus direction and contact the mechanical Designate the origin setting axis VC stopper r F a e RP i i 2 Press the key The cursor will move to L Move the cursor SET AXIS lt MECHA gt 12345678 BRAKE 00000000 3 Designate the axis for which the origin is to be SET AXIS 01000000 set ORIGIN NOT DEF Ga an JE Set 1 for the 2 axis and set 0 for the other Desienate ka sei maa 1 ver lo asc EXE axes Then press INP key Next a confirmation screen will appear lt MECHA gt SET ORIGIN 4 Press the 1 and INP keys OK21 The origin posture will be set B INP 1 EXEGUTE f Set the origin 1 DEF lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 01000000 6 Refer to Page 70 5 5 4 Recording the origin ORIGIN COMPLETED data in this manual and record the origin data on the origin data seal 5 Setting of the origin is completed Origin setting axis designation O O Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0
71. ngthened in proportion Depending on the robot operation state the lubrication time will fluctuate so determine the time according to the state so that the grease does not run out The numbers in the Table 5 4 correspond to the supply positions in Fig 5 13 2 Lubrication method to the J1 J2 axis 1 Refer to the Page 45 Fig 5 3Installing removing the cover and remove the covers 2 Insert the grease shown in Table 5 4 using a grease gun from the lubrication grease nipple Add only the specified amount of grease Adding excess grease may cause grease to leak 3 Replace the covers with the removal procedure in reverse Note Sealant is applied to the cover joint surface of the protrction specification and clean specification models Be sure to replace the sealant if it has been dislocated and bent or crushed and does not return to its original shape Use liquid gasket and Norseal in Page 57 Table 5 6 Spare parts list Moreover in the case of protrction specification and clean specification models it is necessary to remove the top and bottom bellows See Section Page 52 5 3 4 Replacing Bellows for details on how to remove them 3 Lubrication method to the shaft 1 Refer to Page 45 Fig 5 Zinstalling removing the cover remove the No 2 arm cover U 2 Wipe the old grease off the shaft At this time wipe off the grease that has been scattered inside the No 2 arm cover U and the bracket attac
72. o 2 arm After placing the connector inside No 2 arm surround the grommet with silicon rubber 5 Install the solenoid valve box with the two M4 x 10 screws provided using the screw holes at the rear of robot s No 2 arm Caution The hand output cable is located outside the solenoid valve box at the time of shipping Even if this hand output cable will not be used place the GR1 to GR8 plugs inside the wiring port attach the supplied grommet and then fill the fringe of the grommet with silicon rubber Installing the solenoid valve set protection enveronment specifications 3 37 Slnstalling the option devices 3 3 Installing the pneumatic hand interface Refer to the separate Instruction Manual Controller setup basic operation and maintenance and install the pneumatic hand interface on the controller The pneumatic hand interface is mounted on the RZ 326 or RZ 327 card in the controller 3 4 Hand output cable 1N GR35S This hand output cable is used by the user to connect to the handle output connector on the rear of the robot arm Refer to section Page 33 1 RH 5AH 1E VD01 VD01E VD02 VD02E VD03 VD03E VD04 VDO4E on page Table 3 1 for the connection methods In the case of clean specification or protrction specification models after connecting the plugs GR1 to 8 inside the wiring port at the rear of robot s No 2 arm make a cut in the center of the wiring port grommet using a cutter or similar tool and let th
73. on and has a low noise However if the belt usage method and tension adjustment are inadequate the life could drop and noise could be generated Sufficient aging to remove the initial elongation of the belt and adjustment of the belt tension have been carried out before shipment from the factory However depending on the robot working conditions elongation will occur gradually over a long time The tension must be confirmed during the periodic inspection The timing belt must be replaced in the following cases 1 Timing belt replacement period The timing belt life is greatly affected by the robot working conditions so a set time cannot be given However if the following symptoms occur replace the belt 1 When cracks from at the base or back of the belt teeth 2 When the belt expands due to adherence of oil etc 3 When the belt teeth wear to approx half of the tooth width 4 When the belt teeth jump due to belt teeth wear 5 When the belt snaps AN CAUTION Due to the manufacturing of the timing belt initial wear will occur Wear chips may accumulate in the cover after approx 300 Hr of operating the robot but this is not a fault If the wear chips appear soon after wiping them off replace the belt AN CAUTION When the belt is replaced the machine system origin may deviate In this case the position data must be reviewed 5 46 Maintenance and inspection procedures JMaintenance and Inspection 2 Inspection maintenance
74. ons shown in Table 1 1 are used throughout this User s Manual Learn the meaning of these symbols before reading this instruction manual Table 1 1 Symbols in instruction manual Symbol Meaning Precaution indicating cases where there is a risk of operator fatality or seri AN DAN G E R ous injury if handling is mistaken Always observe these precautions to safely use the robot Precaution indicating cases where the operator could be subject to fatalities AN WA RNIN G or serious injuries if handling is mistaken Always observe these precautions to safely use the robot Precaution indicating cases where operator could be subject to injury or NCAUTIO N physical damage could occur if handling is mistaken Always observe these precautions to safely use the robot If a word is enclosed in brackets or a box in the text this refers to a key on JOINT the teaching pendant This indicates to press the B key while holding down the A key In this example the Forward key is pressed while holding down the X Y key FORWD X A B This indicates to hold down the A key press and release the B key and then press the C key In this example the Step Move key is held down the Condition key is pressed and released and the Replace key is pressed STEP MOVE COND I gt RPL 1 A B C TYB This indicates the teaching pendant 1 2 Using the
75. origin 5 65 5Maintenance and Inspection 2 J2 axis origin setting lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF M Designate the origin setting axis RH 5AH series No 2 arm Pinhole Origin jig RH 10AH 15AH series No 2 arm e A Origin jig RPL l Move the cursor lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 01000000 ORIGIN NOT DEF Designate the origin setting axis J5 96 DEF 0 ABC lt MECHA gt SET ORIGIN OK21 ie 2 B 1 EXECUTE ay es Set the origin J DEE lt MECHA gt 12345678 BRAKE 00000000 SET AXIS 01000000 ORIGIN COMPLETED OS Origin setting axis designation O O 1 Slowly rotate the J2 axis to 90 deg clockwise with both hands if RH 5AH series Slowly rotate the J2 axis to 0 deg with both hands if RH 10AH 15AH series Align the pinholes of the No 1 and No 2 arms feed through the origin jig into the pinholes and fasten 2 Press the key The cursor will move to SET AXIS 3 Designate the axis for which the origin is to be set Set 1 for the 2 axis and set 0 for the other axes Then press INP key Next a confirmation screen will appear 4 Press the 1 and INP keys The origin posture will be set 5 Setting of the origin is completed 6 Refer to Page 70 5 5 4 Recording the origin data in this manual and record the origin d
76. origin data input method 1 Confirming the origin data Origin data history table Origin Data History Serial No ES804008 The origin data to be input is noted in Date Default ae i the origin data sheet enclosed with the D V S29 arm or on the origin data history table J1 O6DTYY attached to the back side of the J1 J2 2 HL9X cover Refer to Fig 2 10 J 3 1CP55V J 4 T6IM Y Referring to Page 45 5 3 2 Installing J5 removing the cover on page remove J6 the J1 cover and confirm the value Method E E N SP E N E N SP SP The value given in the default setting 0 AlphabetO 0 Zero column is the origin settings set with the Note Meanings of symbols in method column calibration jig method before shipment E Jig method N Not used SP Not used Fig 2 10 Origin data label an example AN WARNING Always install remove the cover with the controller control power turned OFF Fail ure to do so could lead to physical damage or personal injury should the robot start moving due to incorrect operations 2 Turning ON the control power AN CAUTION Confirm that there are no operators near the robot before turning the power ON 1 Turn the controller POWER switch ON The control power will be turned ON and 1 100 will appear on the STATUS NUMBER display on the front of the controller 2 14 Setting the origin 2Unpacking to Installation 3 Preparing the T B TEE Ne
77. people Fixing plate A No 2 arm Fixing plate B Fig 2 3 Transportation of robot arm 1 The robot must be transported by two workers with putting the fixing plate A and B Place the robot on a dolly etc and move it to near the installation place Transporting the robot with the following grips should be limited to placing the robot on the frame or dolly and to positioning 2 When transporting the robot arm one person should hold the rear part of the base area A and another per son should hold the fixing plate A and No 1 arm B Never hold the robot from the left right side or the cover It may lead to accidents such as the cover drop ping off and the robot falling over causing damage 3 When transporting the robot do not apply force on the cover or apply a strong impact on the robot 4 Remove the fixtures after installing the robot NCAUTION have no grips NCAUTION shows the values listed in the table below CAUTION The robot must always be transported by two workers Failure to ob serve this could lead to falling over or dropping of the robot BU164D997H02 To prevent accidents do not hold the robot from the left right sides or hold covers that When installing the fixing tool again place the robot in the posture where each axis Axis RH 5AH35 RH 5AH45 RH 5AH55 J1 49 5 25 17 J2 139 5 115 107 J3 Lower to the upper machine stopper
78. pressed the robot will move along the arc in the plus direction When the MOVE Y J2 keys are pressed the robot will move in the minus direction Moving in the radial direction Assuming that the current position is on an arc centering on the Z axis the robot will expand and contract in the radial direction When the MOVE X J 1 keys are pressed the robot will expand in the radial direction When the MOVE X J 1 keys are pressed the robot will contract in the radial direction Moving along the Z axis When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed the robot will move along the minus direction 2Unpacking to Installation Changing the direction of the end axis Rotating around the Z axis When the MOVE C J4 keys are pressed the Z axis will rotate in the plus direction of the tool coordinate system When the MOVE C J4 keys are pressed the Z axis will rotate in the minus direction Vertical C 3 cou fa Lwove JH i The Position of the end axis will not change Confirming the operation 2 31 2Unpacking to Installation 2 32 Confirming the operation Sinstalling the option devices 3 Installing the option devices 3 1 Installing the solenoid valve set general enveronment specifications 1 RH 5AH 1E VD01 VD01E VD02 VD02E VD03 VD03E VD
79. ramming mistakes etc Make sure that if the safety fence entrance door is opened during automatic opera tion the door is locked or that the robot will automatically stop Failure to do so could lead to personal injuries Never carry out modifications based on personal judgments or use non designated maintenance parts Failure to observe this could lead to faults or failures When the robot arm has to be moved by hand from an external area do not place hands or fingers in the openings Failure to observe this could lead to hands or fingers catching depending on the posture Do not stop the robot or apply emergency stop by turning the robot controller s main power OFF If the robot controller main power is turned OFF during automatic operation the robot accuracy could be adversely affected 2 Unpacking to Installation 2 1 Confirming the product 2Unpacking to Installation The standard configuration of the robot arm part of the purchased product is shown in Table 2 1 Confirm the parts Users who have purchased optional products should refer to the separate Standard Specifications Table 2 1 Standard configuration No Part name Type Qty Remarks RH 5AH series 1 Robot arm RH 5AH35 45 55 series Either 1 unit 2 Guarantee card 1 copy 3 Installation bolts M8 x 40 4 pcs 4 Spring washer for installation bolts For M8 4 pcs For robot arm installat
80. row b 6 If the belt is loosened too much when adjusting the tension causing it to come off the timing pulleys 5 6 8 and 9 or if the belt and pulley teeth engagement is deviated the machine system s origin will deviate 7 After adjusting securely tighten the idler installation bolts 3 and J4 motor installation bolt 2 Improper tightening can cause the belt to loosen with vibration Maintenance and inspection procedures 5 49 5Maintenance and Inspection E Replacing the J4 axis timing belt 1 Fig 5 6 shows the methods for inspecting adjusting and replacing the timing belt 2 Turn off the controller power 3 To reduce dislocation try to keep the relative positions of the timing pulleys 5 6 8 and 9 as much as possible 4 Loosen the three idler installation screws 3 and the two J4 axis motor installation screws 1 to remove the timing belts 7 and 10 If the hand prevents the belts from being removed remove the hand when changing the belts 5 Perform tension adjustment according to steps 3 to 6 in I Adjusting the J4 axis timing belt and 4 Timing belt tension on page 51 For more accurate tension adjustment pull out the idler 4 with a force of 135N for RH 5AH or 115N for RH 10AH 15AH using the push pull gauge and then tighten the idler instal lation screws 3 as shown in Fig 5 7 The use of the method as shown in Fig 5 8 is recommended Push the J4 axis motor 2 with a force of 65
81. side Force to press the belt apprpx 2N Flexure 1 2mm Shaft side Force to press the belt apprpx 4N Flexure 1 2mm RH 10AH 15AH series Motor side Force to press the belt approx 2N Flexure 2 1mm Shaft side Force to press the belt approx 5N Flexure 1 7mm H Adjusting the J4 axis timing belt 1 Carry out steps 1 and 2 indicated in W Inspecting the J4 axis timing belt above 2 Slightly loosen the two J4 motor installation screws 1 and the three idler installation screws 3 Be care ful not to overly loosen the screws 3 While checking the tension of the timing belt shaft side 10 move the idler 4 in the directions of the arrows indicated in the figure above Lightly press down the center section of the belt with a force of about 4N for RH 5AH or about 5N for RH 10AH 15AH and then move the idler 4 so that the flexure of the tim ing belt 10 reaches about 1 2 mm for RH 5AH or about 1 7 mm for RH 10AH 15AH 4 While checking the tension of the timing belt motor side 7 move the J4 axis motor 2 in the directions of the arrows indicated in the figure above Lightly press down the center section of the belt with a force of about 2N and then move the J4 axis motor 2 so that the flexure of the timing belt 7 reaches about 1 2 mm for RH 5AH or about 2 1 mm for RH 10AH 15AH 5 The belt tension will increase when moved in the direction of arrow a and will decrease when moved in the direction of ar
82. source positional deviation or malfunction could occur Do not apply excessive force on the connector or excessively bend the cable Failure to observe this could lead to contact defects or wire breakage Make sure that the workpiece weight including the hand does not exceed the rated load or tolerable torque Exceeding these values could lead to alarms or faults Securely install the hand and tool and securely grasp the workpiece Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation Securely ground the robot and controller Failure to observe this could lead to malfunc tioning by noise or to electric shock accidents Indicate the operation state during robot operation Failure to indicate the state could lead to operators approaching the robot or to incorrect operation When carrying out teaching work in the robot s movement range always secure the pri ority right for the robot control Failure to observe this could lead to personal injuries or damage if the robot is started with external commands Keep the jog speed as low as possible and always watch the robot Failure to do so could lead to interference with the workpiece or peripheral devices After editing the program always confirm the operation with step operation before starting automatic operation Failure to do so could lead to interference with peripheral devices because of programming mistakes etc
83. special section may be enclosed Safety Manual Explains the common precautions and safety measures to be taken for robot handling system design and manufacture to ensure safety of the operators involved with the robot Standard Explains the product s standard specifications factory set special specifications option Specifications configuration and maintenance parts etc Precautions for safety and technology when incorporating the robot are also explained Robot Arm Setup amp Maintenance Explains the procedures required to operate the robot arm unpacking transportation installation confirmation of operation and the maintenance and inspection procedures Controller Setup Basic Explains the procedures required to operate the controller unpacking transportation installation confirmation of operation basic operation from creating the program to automatic operation and the maintenance and inspection procedures Operation and Maintenance Detailed Explanation of Functions and Explains details on the functions and operations such as each function and operation Operations commands used in the program connection with the external input output device and parameters etc Explains the causes and remedies to be taken when an error occurs Explanations are given for each error No Using the instruction manuals 1 1 1Before starting use 1 1 2 Symbols used in instruction manual The symbols and expressi
84. t 2 by lifting it from the bottom spline section Refer to Fig 5 4 8 Install a new timing belt on the timing pulleys 4 and 5 in the reverse order of the procedure described in steps 6 and 7 above 9 With the J3 axis touching the upper mechanical stopper hook the timing belt 2 around the timing pulleys 4 and 5 10 Perform tension adjustment according to steps 3 to 6 in M Adjusting the J3 axis timing belt and 4 Timing belt tension on page 51 For more accurate tension adjustment pull out the idler 4 with a force of 135N for RH 5AH or 115N for RH 10AH 15AH using the push pull gauge and then tighten the idler installation screws 3 as shown in Fig 5 7 The use of the method as shown in Fig 5 8 is recommended Push the J4 axis motor 2 with a force of 65N for RH 5AH or 45N for RH 10AH 15AH using the push pull gauge and tighten the J4 axis motor installation screws 1 11 For more accurate tension adjustment the use of the method as shown in Fig 5 5 is recommended Loosen the J3 motor installation screws 1 and then push the J3 motor 3 with a force of 65N for RH 5AH or 90N for RH 10AH 15AH using the push pull gauge 8 12 The position could deviate after the belt is replaced Confirm that the position has not deviated If deviated refer to Page 58 5 5 Resetting the origin and reset the origin position 8 Push pull gauge 1 J3 motor inatallation screw Remove the bracket attached v
85. t so that the robot can be used with a high accuracy After purchasing the robot always carry out this step before starting work The origin must be reset if the combination of robot and controller being used is changed or if the motor is changed causing an encoder area The types of origin setting methods are shown in Table 5 7 Table 5 7 Origin setting method No Method Explanation Remarks 1 Origin data input method The origin data set as the default is input from the T B The setting method is explained in Page 13 2 3 Setting the origin 2 Mechanical stopper method This origin posture is set by contacting each axis The setting method is explained in Page 58 against the mechanical stopper 5 5 1 Mechanical stopper method 3 Jig method The origin posture is set with the calibration jig The setting method is explained in Page 64 installed 5 5 2 Jig method 4 User origin method A randomly designated position is set as the origin pos Before using this method the origin must be ture set with the origin data input method or Mechanical stopper method or jig method The setting method is explained in Page 69 5 5 3 User origin method 5 5 1 Mechanical stopper method The method for setting the origin with the transportation jig is explained below This operation is carried out with the T B Set the MODE switch on the front of the controller to TEACH and set the T B ENAB
86. ticity is felt when the belt is pressed with the thumb If the belt tension is too weak the belt loosening side will vibrate On the other hand if the belt tension is too strong a sharp sound will be heard and the belt tension side will vibrate The detailed adjustment tension is shown in Fig 5 9 and Fig 5 10 Check and adjust with the belt pressing force f and the slack amount d between span s Maintenance and inspection procedures 5 51 5Maintenance and Inspection 5 3 4 Replacing Bellows 1 How to Replace the Top Bellows Refer to Fig 5 11 and replace the top bellows 1 Move the J3 axis to the position where the clamp ring becomes visible 2 Turn off the robot controller s power supply 3 Remove the clamp ring 4 Loosen the M4 set screws two pieces next to part lt 1 gt installed at the top of the ball screw and remove the top bellows from the No 2 arm cover U 5 Remove the screws four M3 x 8 screws of installation part lt 2 gt of the bellows and remove the bellows 6 Install the new bellows four M3 x 8 screws Tightening torque 0 8Nm 7 Align part lt 1 gt on the ball screw and tighten the M4 set screws two pieces adjusting to the D cut surface 8 Install the bellows on the No 2 arm cover U with clamp ring 9 Fill the clearance between part lt 1 gt and the ball screw with the liquid gasket described in Page 57 Table 5 6 Spare parts list or similar material RH 5AH series 6 20 A RH 10AH
87. xt prepare to use the T B 1 Set the MODE switch on the front of the controller to TEACH 2 Set the T B ENABLE DISABLE switch to ENABLE The menu selection screen will appear The following operations are carried out with the T B ENABLE DISABLE OS Operating from the T B O O Always set the MODE switch mode selection key switch on the front of the controller to TEACH and then set the T B ENABLE DISABLE switch to ENABLE When the T B is valid only operations from the T B are possible Operations from the controller or external sig nals will not be accepted O lt When T B operations are mistaken O O The displayed screen will return to the menu selection screen when the MENU key is pressed Carry out the operations again from this screen Operations can also be carried out again by setting the T B ENABLE DIS ABLE switch to DISABLE once and then setting to ENABLE Setting the origin 2 15 2Unpacking to Installation 4 Selecting the origin setting method lt T B screen gt Keys used lt MENU gt 1 TEACH 2 RUN 1 Press the 5 key on the menu screen and display the maintenance screen 3 FILE 4MONI 5 MAINT 6 SET 5 STU lt MAINT gt 1 PARAM 2 INIT 3 BRAKE 4 ORIGIN 7Y J2 5 POWER j 4 mo 2 Press the 4 key on the maintenance screen and display the origin setti

(Arm Setup, Maintenance) BFP-A8175-A (10.01)

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