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Hyundai HX200L-2000 User's Manual

1. 1 32 1 11 3 Pneumatic and Hydraulic Systems 1 32 1 33 2 Specifications 2 1 2 1 Robot Machinery Part 2 2 2 2 Location of Robot Identification 2 3 2 9 Basic Specifications uos cerea 2 4 2 4 Robot Dimension Working Envelope 2 6 HY HEAVY INDUSTRIES CO LTD Contents 2 5 AXIs Identificati Nki ooo p pt ae eee NE Do Mea 2 11 2 6 Details of Wrist Axis Attachment 2 12 2 7 Details of Upper 1 ARM Attachment 2 13 2 8 Application Wiring and Inspection Wiring Diagram 2 14 2 8 1 Details of Customer Application Connectors 2 15 2 9 Restricting the Working Envelope eene 2 16 2 97 AXIS WARIS otio tee eet ei 2 16 3 Instructions 27 3 1 3 1 Robot Component Name pp 3 2 3 2 Location of Safety 3 3 3 3 How LO operate pp 3 4 3 3 1 Using a S 3 4 30 2 USING S OPKITETEUO Ko 3 6 SAP How to ISl ors
2. ge t 1 d d mr Fig 2 5 Robot Dimension and Working Envelope HX200L HYUNDAI HEAVY INDUSTRIES CO LTD 2 Specifications 3073 2 1186 851 2 Fig 2 6 Robot Dimension Working Envelope HX200L 2000 HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 3056 Fig 2 7 Robot Dimension and Working Envelope HX300L HYUNDAI un HEAVY INDUSTRIES CO LTD 2 5 Axis Identification Table 2 2 Axis Motion 2 Specifications Arm Swivel LFT S RHT S Arm Forward and Backward BWD H FWD H Arm Upward and Dow
3. 1 15 1 7 1 Safety Precautions for Robot Handling 1 15 1 7 2 Safety Precautions for Operating 1 18 1 7 3 Safety Precautions for Automatic 1 19 1 8 Safety Precautions for Access to Safety 1 20 1 9 Safety Precautions for Maintenance and Repair 1 21 1 9 1 Safety Precautions for Hi4a Controller Maintenance and Repair 1 21 1 9 2 Safety Precautions for Robot System amp Manipulator Maintenanace 1 22 1 9 3 Necessary Actions after Maintenance and Repair 1 23 1 10 Safety FUNCOMS m 1 24 1 10 1 Operating a Safety Circuit 1 24 1 10 2 Emergency 50 eaaa ea aa 1 26 1 10 3 Operating 2 gt 1 29 1 10 4 Connecting the Safety 1 29 1 10 5 Restricting the working lt 2 2 1 30 1 10 6 Monitoring Function mm 1 30 1 11 Safety Related to End 2 4044121 1 31 eee ene ene eee eee ee meer T 1 31 1 1 52 Tool uci
4. HM 1 0 056 0 AM LL 2 C HM lt eqni uonoeJuoo 19402 393 gt 9 lt 3Sd Buuepjos X lt LSH uzz 0 bse 0 AM 01 Bib 20 ide UG 0 bse 0 AM 6 221405 ul eJnsseJd 9 3939 il NG up o bseo M 181 ew 2 2 161 1 98 f oi va 2 Q3iHs 2 2 Q13lHS 2 F 795 TN 303 lt 08 0 f HM HM 9303093 GA GA N5 CSIXV 6U N rS 5 M N m 87 X 2 a X Z ve L 5 V3NO Cu6y 45 X 086 0795 12 0 uge z 198 X 0 0 95 old 2 lt C 6 a 1011 2 Q 13IHS 2 ni 303 oie 6969 i o 1SH H30800N3 28 8 3Sd 9 0d x 50 594 0 ng 2 E 2 87 tvd x 0 Evd Z3NO W212 c e 98 Y bse o ao A3ulOu UNO Fig 8 5 Encoder Wiring Connection No 2 HEAVY INDUSTRIES CO LTD HYUNDA 0 iring Internal W 8 YOLOSNNOO 13538 as su 7 5 zi Disu 4
5. y 1901002 8Jnss9Jd puo ajpung e u91 0 bssz AA 1121 eqni uonopJjuoo 13409 1 0 056 0 6 pjeius Buuepjos Jelly Z x 2 L z b S2 WNIWY31 18185 7 7 577 SINS Ol 01 Od 9 0 C n8 6 gt 66 87 gt gt 20 sev 0 9 4 90 x 0 Lev 90 9 aC Did G 20 ew M gt 99 9 Sev 99 9 2 vev Od 8y W gt gt 20 sev x G 20 2 C zev gt N9 0 N9 M VINO 6 303 6 8 01 oey 6 f 62v N8 UN 20 5 e 08 4 C 224 08 AN 9 9 92 oig 9 C Sev gt 9 e 9 N9 C 2 wo 0 e rr 7 ow TW 5 9 9 GN M 77 9A 801HNO 1001X038 oja A98l08 19 401705585 1808 921 TVNINH31 2 L 2 5 tiere 303 6 f oy 5 2 o 0 20 9 0 067 6 C 61v w 8 81 9 90 0 C LW 60 09 9 ew 9 N da sw 9 20 nv n n8 5 ely 0 2 21 N9 0 9 6 e gt 6 L ae HM 01 HM H 0 48 6 C 60v
6. Support center E 2 HX300 400 200L et shaft 2 5 9 R19 211011 00 500i 2000 300L Taper HHI Joint lower and D 4EA 4EA upper Link of 2 axis 2 R19 211041 00 2001 2000 3001 T Joint aper oint upper D 2 2EA x HX300 400 200L ARM in A2 200L 2000 300L HHI Support lower D Roller HX300 400 200L 4EA 4EA balance spring d 2 Bearing R15 211034 00 0 2000 300L shperical HHI Support upper D Roller HX300 400 200L 2EA 2EA balance spring bearin 2 9 R15 211035 00 2001 2000 3001 Wrist holder D Oil Seal 1EA cast iron R15 213181 00 HX300 400 300L holder W1 HHI Wrist holder D Oil Seal 1EA cast iron R15 233171 00 HX200 200L holder W1 HHI E HX300 400 200L oe d R15 211017 00 2001 2000 3001 HHI E HX300 400 200L KER T R15 210104 00 50i 2000 300L HHI Upper shaft of D V ring HX300 400 200L 2EA 2EA upper ARM in F A2 15 211205 001 200L 2000 300L 2 HYUNDAI HEAVY INDUSTRIES CO LTD Table 7 4 Spare Parts List IV HX200 HX200L 2000 HX300 HX300L HX400 HHI Case surface of D O ring 1 1EA axis B reduction R15 213091 00 HX300 400 300L gear HHI Case surface of D O ring 1 axis R1
7. 61 6 kgf m 70 kgf m Accuracy of position repeatability Ambient Temperature 0 40 273 313 K Relative humidity 20 85 RH Robot s Weight 2230 kg 2430 kg 2230 kg 2530 kg Index of working envelope 4 519 4 519 6 18 6 85 6 18 m HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 2 4 Robot Dimension and Working Envelope Fig 2 3 Robot Dimension and Working Envelope HX300 HYUNDAI HEAVY INDUSTRIES CO LTD 2 Specifications i POINT A FL INTERFERENCE RADIUS 2279 950 Fig 2 4 Robot Dimension Working Envelope HX400 25 HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 os
8. H aC Hm 9 80 Hm 0 Q x w 20 v 09 9 Hm 2 90 Hm 9 o 20 9 2 sov ore M O 46 Hm gt vOv gt 2 eov N9 o 2 Hm 2 20 20 Hm v lov a VOLBNO doDXost o 86 J9808 In 85 0308 OLOYNO a 1 Fig 8 7 Application Wiring Connection HEAVY INDUSTRIES CO LTD HYUNDAI 0 iring Internal W 8 N9 ug 0 0892 1 ALM VL bsSz ALM 1 joejuoo ul Jeplos 9 ejpung 9 2 TYNINH3D Bre WINES 61 ais mro m AN nN 8 Gn gt gt 146 Hf gt 9 51 man 01 gt gt 151 DT 8 1v8 arr 9 id an 5 7 NO w C arf 08 9 da ZLM Ses 9 9 T LLM 3 7 Ka ZLA ce gt oie A LA 3 3 zn 5 2 un y AES A y N fi n SS 34115882 11572 00 GON 99 1111 SINN LEX bS0 ZH3 09 ofd Fig 8 8 Application Wiring Connection No 2 HEAVY INDUSTRIES CO LTD HYUNDAI 5 c 9 D 2 4 9 Decommissioning HX200 HX200L 2000 HX300 HX300L 400 The robot is made up of several materials as shown in Table 9 1 Some of them should be properly arranged and sealed up to eliminate any bad influence on the human body or environ
9. Irregular twitching Note 4 Abnormal deviation Free fall of axis Overheating Incorrect action out of controll movement Note 1 Overload Phenomenon occurring when a load exceeds the rated motor load In specific thermal relay of circuit protector is tripped Note 2 Noise in operation Phenomenon which occurs vibration on operation Note 3 Staggering at stop Phenomenon which gives oscillating motion when the robot stops Note 4 Irregular twitching Phenomenon which gives sporadic twitching when the robot is not in motion HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 6 3 Diagnostics and Resolutions for Major Parts Failure 6 3 1 Fulcrum Bearings Vibration abnormal sound and overloads are observed when a fulcrum bearing is damaged When the Nut holding bearings becomes loose bearing play occurs It may damage the bearings Diagnostics Shake the 1 ARM and 2 ARM back and forth to check if bearing exhibits any play In case of using a Chain block check the bearings for the play with the 1 ARM and 2 ARM posture maintaining and without any overload to the reduction gear 2 Check to see if the robot touched other peripheral equipment before the malfunction B Resolution D Replace the bearing A Chain Block is needed to lift and hang the robot ARM Contact our service office for any difficulties
10. 1 17 Table 2 1 Basic Specifications for 2 4 Table 2 2 AXIS i e unte i D eR SU alate canine saves 2 11 Table 3 1 Components Name ppp 3 2 Table 3 2 Allowable load 3 11 Table 3 3 Allowable Load 3 11 Table 3 4 Allowable Moment 3 12 Table 4 1 Inspection 5 4 2 Table 4 2 Inspection Items and 4 3 Table 4 3 Inspection part for main 4 5 Table 6 1 Trouble phenomenon and 6 3 Table 6 2 Motor Weighs 6 10 Table 6 3 Necessary 6 12 Table 6 4 Necessary 6 12 Table 6 5 Reset connectors corresponding to 5 6 17 Table 6 6 Data range after 6 20 Table 7 1 Spare Parts EISE T ue eto tp te tto Nt itecto 7 2 Table 7 2 Spare Parts List ll eee e etes 7 4 Table 7 3 Spare Parts List 1l sce esee ere ero ee rero 7 5 Table 7 4 Spare Parts List 7 6 T ble 7 5 Spare Pars List NC oie couse ces ec 7 7 Table 9
11. 9 mm 7 lt 1100 BJ3 e 960 50 CNBAR ui r HX300 MB4 A HX300 RST A_ t 1 JCNRS 12XKV0 3sq HX300 F4 A 150 CNBA C E E HIGO0 LBt 6 A D 12XKV0 3sq CNBAG CNRSTI 6 15 HX300 MB5 00 5 300 1100 CNu47 v6 lk C 22 g 1200 12 014 A g 0300 0864 E ETFE 11 5 35 b p H 3B 0 3sqX5P CNR04 46P g 30 2 5a 24 26 2 300 a 700 960 300 LLL OC m 60 zi amp s e 1 A HX300 12 4 WerF 0 5sqk2 Er 600 CNLSI 1 HX300 L1 A J VCTF 05sqke 7 t L 300 4 ji 00 2 HX300 J3 H1 A ROIREV SB 0 3sq1 0P C EE 700 64 300 13 2 ROIREY SB 0 39940 740 000 A2 spring l spring f Li 350mm 201 370mm WATER IN TUBE lt gt WATER IN TUBE n 2 WATER DUT TUBE x P3 WATER TUBE 300 700 51 spring Fig 5 2 Wiring connection diagram HX300 400 200L 200L 2000 300L 5 21 HYUNDA HEAVY INDUSTRIES CO LTD Oo prar Rem o E ty 6 Trobleshooting 1X200 HX200L 2000 HX300 HX300L HX400 6 1 Troubleshooting Procedure If a failure occurs during robot s operation but it does not stem from the controller it must be caused by damage on machine parts The way to troubleshoot as quick and easy as p
12. HYUNDAI 6 4 HEAVY INDUSTRIES CO LTD 6 Trobleshoot ing 6 3 2 Reduction Gear Vibration and abnormal sound will be occurred when a reduction gear is damaged In this case it causes overload and abnormal deviation disturbing normal operation Sometimes overheating may result The robot may also become completely immovable or a position offset error may occur Main Axes S H V When turning ON OFF the brake release switch of axis H and axis V be sure to take necessary precautions to prevent the ARM from dropping and then switch the brake release ON OFF B Diagnostics D Check out any vibration abnormal sound or overheating of the reduction gear when the robot is in operation 2 Check out any play and abrasion in the reduction gear And check if any abnormality is felt by hand when shaking 1st ARM back and forth with the brake release switch of axis S ON 3 Check if peripheral equipment has been contacted with the robot before the abnormality Damage may occur to the reduction gear due to the contacting impact B Resolution CD Replace the reduction gear A chain block is needed to lift and hang the robot ARM Contact our service office for any difficulties Wrist Axes R2 B R1 When turning ON OFF the brake release switch be sure to take necessary precautions to prevent the ARM from dropping and then switch the brake release ON OFF B Diagnostics D Check out any vibration abnorm
13. HHI LIS 355 15 12 TEL 041 576 4294 5 FAX 041 576 4296 SASSAL SSS 415 2 EL 062 363 5272 FAX 062 363 5273
14. varning personnel and damage to equipment The special attention must be paid to the operation and handling Indicate the compulsory measures that should be Mandatory performed i y Prohibited Indicate the prohibited actions and or operations that should not be performed HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 1 4 2 Safety Nameplate Identification plates warning label and safety symbols are attached to the robot and to the inside and outside of control panel The designation labels and cable Mark for wire harness between the robot and control panel and the cables inside outside of control panel are provided All of these plates labels symbols and marks constitute safety relevant parts of the robot and the control panel They must remain attached to the robot manipulator and control panel at their clearly visible positions all the time for the safety and their full performance The painted markings on the floor and signs indicating dangerous zones must be clearly distinguished in form color and style from other markings on the machine near the robot system or inside the plant facilities where the robot system is installed clearly visible identification plates warning labels safety symbols It is forbidden to remove cover paint over by way of spoiling the designation labels and cable marks HYUNDAI HEAVY INDUSTRIES CO LTD 1 Safety 1 5 De
15. 1SUNO 5 2 b ng 0 AM 1211 gt gt HM AM LL 29 T HM lt SSW gt vy n8 lt 36 eqn UolloeJluoo 194025 lt 4 189 01 bm 303 HM 91 0 082 0 AM 161 Jedle6o 5 9 up o bse O M 8 JOB UOD ui ensseJd 9 3239 X JA SC 16 9 7 2 24 2 2 qns 4 2 00 oa 5 x bd c GA e No 20 x c Qu T Ter 2 8 7 Ew i 99751599 98 X 09270785 1300 687 8 60765 13808 old 9 e o c LLI p HW oig 581 D 2 Q I3IHS 2 2 1 5 2 LL uu OA mH ry M 8 5 018 gt wo WO V HM 9 e 930309 9 m G3 6 G3 NO NO X 90 90 ng ng 08 ne ne E 9 LT j T 8 V Usg E cq ds 866 55 8 aeo ugs z 28245 X bse 0 85 0 HX200 HX200L 2000 HX300 HX300L HX400
16. 7 1 8 Internal Wiring Diagram 8 1 Manipulator CorfiguballOEl cue peer a 8 2 9 2 Wirlng 8 3 MR HY Hl HEAVY INDUSTRIES CO LTD Contents List of Figures Fig 1 1 Recommended Size for Fence and Gate Hole Square Gate 1 8 Fig 1 2 Recommended Size for Fence and Gate Hole Slot 1 8 Fig 1 3 Placement of Peripheral Equipment and Operator 1 10 Fig 1 4 Space for robot installation itor 1 14 Fig 1 5 Robots Safety 1 24 Fig 1 6 Emergency Stop pp 1 27 Fig 1 7 Emergency Stop Connection of External System 1 28 Flg 2 1 Robot Machinery 2 2 2 2 Fig 2 2 The location of identification 2 3 Fig 2 3 Robot Dimension and Working Envelope HX300 2 6 Fig 2 4 Robot Dimension and Working Envelope HX400 2 7 Fig 2 5 Robot Dimension and Working Envelope HX200L 2 8 Fig 2 6 Robot Dimension and Working Envelope HX200L 2000 2 9 Fig 2 7 Robot Dimension and Working Envelope HX300L 2 10 Fig 2 8 Robot Dimension and Axis HX300 400 200L 200L 2000 300L 2 11 Fig 2 9 Details of Wrist Axis Attachment Surface HX300 400 300L 2 12 Fig 2 10 Detail
17. 20 gt gt wW lt lt m oU Hr Sz 99 wi 97 lt lt en oer Hd f d lt lt ZEM Gar zem e TEM SIXV A 99 cence 855 ZEA G 56 I7 dd oa gt gt 4 ace E ui aoo Ten 587 tgo tz fr 9 2 VNIWH31 555 NS 5 ia 5 Da lt lt oa IN EZM om 9 ZZM o SIXV H gt 3 onm ZZA 08 n IZA een a lt lt zen o gt zano 120 Lo 2 9 2 WNIWH31 5 9 NS S181 oe m 29 ST og 74 iva og HOLOW Za Lay de vis gt Da gt N SIXV S am lt gt 0 ZA 6 oi B ein 06 a zin 09 oa Iw 1 X05 2 H3 00 Z HWE 9 1 313 12 0902 95 09 LOBNO Fig 8 2 Motor and Brake wiring connection No 1 HEAVY INDUSTRIES CO LTD HYUNDAI HX200 HX200L 2000 HX300 HX300L HX400 5 9 2 TWNINY3L 9 2 TVNINH3D 5 os li Ws ane 9 oa gt 9 LOHNO L 9 5z gt gt eqni 19402 ts Duuepios JAY e eR IWN
18. 200 Oko PES C A E 566 680 890 183 L B mm jl 400 600 800 1000 1200 op 215 oa ex Distance from the center of Fig 3 8 Wrist Axis Torque Mapping HX300 300L LRi mm ED OXIS 1 gt gt 5 om center of n CO 2 Rus C ERR AA All 500571 666 edo doo 333 LB mm EN AS 400 600 800 1000 1200 1400 Q Jistance from the center of 5 N m Fig 3 9 Wrist Axis Torque Mapping HX400 HYUNDAI HEAVY INDUSTRIES CO LTD Tipe Lr1 mm 3 Instructions 1200 pa 166 150 S PAS 1 400 S SN 250 00Lee oe Pay c N S l c AINA 200 We x 1 amp 6 866 l 00 600 Yan X Genter T Lb mm Rotation Center ne Fig 3 10 Wrist Axis Torque Mapping HX200L 3 15 HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 3 6 Recommended Standy Posture Selecting a good standby posture can save energy and reduce motor temperature If the tool is positioned as the figure below the load on H and V axes may be minimized In case that the posture shown belo
19. 8 FON sy 9z HM 0 056 0 AM LL d S SIXy S HM lt SSW n8 lt 3Sd 52 9 9120056 0 310 GY ISH 2270 0560 M 01 eqni uoloejluoo 19409 a HM wg 0 bse 0 AM 161 Jouje50 2 ayy afi TW up o bse o AM 8 221409 ui 3939 ejpung X O m ISTNO 2 09 02050 0 3101 2 gt 39N 6 UE NE qais f a 303 a 4 35 wed gt A9 2158 e e ISW dadooN3 NO 4 id SIXV H z 2 n8 gt gt W lt lt P Qu zad TA 2 4 H Nun Na wy zd o 140 6 59 46 X 09 0 9S A3dl0d Ww o 5 161 8 0 f 191 19139 ais 2 5 75 303 zi org i364 ai 09 LISY 4 i ISW e gt gt 0 d G 359 AG gt No 15d X gt 50 194 a 184 X 0 o 18 gt 4 X di 9 wy x gt gt vOUNO ofa HEAVY INDUSTRIES CO LTD HYUNDAI Fig 8 4 Encoder wiring Connection No 1 HX200 HX200L 2000 HX300 HX300L HX400
20. LTD 6 Trobleshoot ing 6 5 Encoder Zero Setting It is necessary to reset the origin when encoder data has been corrupted due to some problems and when the motor is replaced Level and Block is adopted as the position setting method for each axis The origin must be set in order of axis 4 5 and 6 considering axis interference of the wrist due to its structural characteristic A Warning In this work there is a part performing the state of motor ON Therefore this work must be performed in pairs One must always be ready to activate an emergency stop The other must perform the work quickly but carefully An escape route should be determined before starting work 6 15 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 6 5 1 Zero Setting CD Put the controller into TEACH mode and select MOTORS ON If you cannot select MOTOR On due to abnormality set the origin position of the robot by using the brake release switch 2 Move respective axes to the basic posture then set them by the scale mark 3 Reset the Encoder Refer to 6 5 2 Encoder Reset for the method of encoder reset 4 Correct the encoder Refer to Hi4a Controller Operation Manual 5 Confirm that there is no problem in robot motion HYUNDAI em HEAVY INDUSTRIES CO LTD 6 Trobleshoot ing 6 5 2 Encoder Reset D 2 5 Turn the controller power ON for 3 minutes and then turn it OFF Take off
21. 2 and 3 can also be restricted by means of mechanical stopper Operation Mode Selection ANSI RIA R15 06 1999 The robot must be operated either manually or automatically In a manual mode the robot must be operated only by using the teach pendant m HY HEAVY INDUSTRIES CO LTD 1 6 Installation Safety Fence HX200 HX200L 2000 HX300 HX300L HX400 Install safety fence against the possible collision between the robot and workers so that no worker may approach the robot When operators or other personnel enter the robot s working envelope by accident it may cause an accident Install the safety fence to stop the robot when one who intends to replace for TIP DRESSING or TIP replacement or to inspect welding equipment opens the fence gate and approaches the equipment during operation 1 5m 60 Min 0 3m 12 Max 20 4 9 1 875 4 9 1 875 Fig 1 1 Recommended Size for Fence and Gate Hole Square Gate m if AW VA Jg AWA Al gt ra 7 TR A e EC E z o 2520 2 UE Lo V ET ry iz wey AE VPE 4 9cm 1 875 Max Fig 1 2 Recommended Size for Fence and Gate Hole Slot Gate Install the safety fence to cover the robot s working e
22. 5 11 5 1 7 Bearing Joint Parts pp 5 13 AHY HEAVY INDUSTRIES CO LTD 5 1 8 A1 Frame Gear BOX pe 5 14 5 1 9 Wrist Gear BOX qu 5 15 5 2 Battery Replacement pp 5 16 5 2 1 Instructions for Battery SlOrage pp 5 18 5 3 Wiring tte ete tales ete tears 5 19 5 3 1 Wiring Connection 5 20 6 Troubleshooting 6 1 6 1 Troubleshooting Procedure pp 6 2 6 2 Trouble Symptoms and Possible 6 3 6 3 Diagnostics and Resolutions for Major Parts Failure 6 4 6 3 1 Fulcrum Bearirigs e echas pe utetur tek en uu es ue UIS 6 4 5 3 2 REGUCION Gel 6 5 0 3 3 Brake9 robe NEMINEM ee 6 7 BiG As iue das iue iussus 6 8 APR 6 9 5 4 Motor oo poder poe pt used ee pi une 6 10 6 4 1 Necessary Tools and dnte tret HEISE 6 12 6 4 2 How to Replace 6 13 6 5 Encoder Zero 6 15 SEWING MO E 6 16 0 5 2 Encoder Reset eee teen eb e ibt i E eee 6 17 6 5 3 Confirming the 6 19 6 5 4 Encoder Calibration Data input and Selection 6 20 7 Recommended Spare Farts 2
23. 8 1 Details of Customer Application Connectors Encoder Connector CONNECTOR lt 1 gt CONNECTOR lt 2 gt CONNECTOR lt 3 gt Fig 2 13 Details of Application Connector Encoder D CABLE SPECIFICATION 0 3sq 40pcs 2 CONNECTOR TYPE Receptacle lt 1 gt CA3102A32A10PX CNR10 2 MS3102A24 28S CNR10A 3 MS3102A24 28SX CNR10B CONNECTOR TYPE Plug lt 1 gt CA3106B32A10S CNR10 lt 2 gt MS3106B24 28P CNR10A lt 3 gt MS3106B24 28PX CNR10B Power Connector CONNECTOR lt 5 gt Fig 2 14 Details of Application Connector Power CABLE SPECIFICATION 2 0sq 11pcs 5 CONNECTOR TYPE Receptacle 4 MS3102A20 18P CNR20 5 MS3102A20 29S CNR30 8 CONNECTOR TYPE Plug 4 MS3106B20 18S CNR20 5 MS3106B20 29P CNR30 245 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 2 9 Restricting the Working Envelope When installing the robot take into account that the working envelope can be adjusted freely within the entire working envelope In case of possible collision between the robot and peripheral equipment the working envelope must be limited mechanically and by means of software Following instructions explain how to install switches or additional stoppers for setting the working envelope of main axes This is an optional part 2 9 1 Axis 1 Axis S By adding one more mechanical stopper the working envelope of the 1st axis can be limite
24. Floor Type H 0 Shelf Type Remove the grease outlet plug Inject the grease into the grease inlet using a grease gun Y Grease type Molywhite REOO Amount of grease 1 600cc The grease replacement is complete when new grease appears in the outlet port The new grease can be distinguished from the old one by color Move the H Axis for a few minutes to eject the old grease and then add grease until the new grease appears in the outlet port Wipe the outlet port with a cloth and attach the plug with seal tape HY 5 5 HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 5 1 3 V Axis Reduction Gear Grease outlet Plug PT1 8 Grease inlet Grease nipple A PT1 8 Attention If grease is added without removing the outlet plug it cause damage to the seal of reduction gear and grease will go inside the motor and may damage it It is absolutely necessary to remove the plug m Grease Replenishment C Make the V Axis Arm horizontal for ground V 0 Floor Type V 90 Shelf Type 2 Remove the grease outlet plug 3 Inject the grease into the grease inlet using a grease gun Grease type Molywhite REOO Amount of grease 300cc 4 Wipe the outlet port with a cloth and attach the plug with seal tape HYUNDAI HEAVY INDUSTRIES CO LTD 5 Maintenance m Grease Replacement D 2 3 Make the V Axis Arm horizontall for ground V 0 Floor Type V 90 Shelf Ty
25. Standby 3 16 Fig 4 1 Inspection Part for Main Bolts HX300 400 300L 4 6 Fig 4 2 Abnormal Backlash Inspecting 4 7 Fig 4 3 Cable Inspection Parts HX300 400 200L 200L 2000 300L 4 9 Fig 5 1 Explains of internal wiring pp 5 20 Fig 5 2 Wiring connection diagram HX300 400 200L 200L 2000 300L 5 21 Fig 6 1 How to prevent dropping of ARM Axis H amp 6 11 AHY HEAVY INDUSTRIES CO LTD IV Fig 6 2 Encoder Reset coser ether 6 18 Fig 8 1 Manipulator 8 2 Fig 8 2 Motor and Brake wiring connection 1 8 3 Fig 8 3 Motor and Brake wiring connection 2 8 4 Fig 8 4 Encoder wiring Connection 1 8 5 Fig 8 5 Encoder Wiring Connection 2 8 6 Fig 8 6 Encoder Wiring Connection 3 8 7 Fig 8 7 Application Wiring Connection 1 8 8 Fig 8 8 Application Wiring Connection 2 8 9 List of Tables Table 1 1 Safety marking 4 1 5 Table 1 2 State of robot
26. emergency exit or safe place considering that the robot may unexpectedly rush at you HYUNDAI m HEAVY INDUSTRIES CO LTD 1 Safety 1 9 Safety Precautions for Maintenance and Repair 1 9 1 Safety Precautions for Hi4a Controller Maintenance and o Repair 1 Maintenance and repair of the robot must be performed by the personnel who was duly trained in the special maintenance training course and has a good knowledge of maintenance 2 Perform your work following the maintenance procedures for controller 3 Perform your maintenance and repair in a safe way by securing emergency exit or safe place 4 Before the daily maintenance repair or changing parts be sure to power down In addition post a warning sign Do Not Input Power up the primary power so that other operators may not input power by accident 5 When changing parts be sure to use the specified ones 6 Be sure to power down when opening the Hi4a controller door 7 Before performing wait for three minutes after power down 8 Do not touch the heat sink and regeneration resistor of servo amp because they generate an intense heat 9 After completing maintenance Be sure to close the door completely after checking if tools or other things are still remained in the Hi4a controller m HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 9 2 Safety Precautions for Robot System amp Manipulator Maintenanace 1 Refer to
27. etc can be connected to the safety electric circuit in accordance with applied standard for the emergency stop circuit Emergency stop connection of the external system SEQUENCE BOARD BD461 Emergency Stop eel 1LED OPERATIONAL PANEL gt Emergency Stop Switch CNOP 5 1 P1 24V EMST1A CNOP 17 EMST1A Do EMST1B CNOP 18 EMST1B EMST2A CNOP 19 EMST2A Ly Emergency Stop Channel 2 LED EMST2B CNOP 20 EMST2B TEACHING PENDANT 1 0 CNRTP Emergency Stop Switch EMSTOP EMST1B A1 CNTPS K x I ta EMST1C B1 L EMST2B A2 M lt m EMST2C B2 N Es EXTERNAL SYSTEM Emergency Stop Switch EMST1C m EMST1 To M1 0V LIBENTI JM que se prts tll EMST2C TBEXT EMsT2E 1 24 __ ESOUT1 L eems UR CH ESOUT2 6 7 S RUN CHAIN Fig 1 7 Emergency Stop Connection of External System When using the emergency stop of the external system connect the Terminal No 1 ES1 amp No 2 M1 0V Common or No 3 ES2 amp No 4 P1 24V Common of the terminal block of BD461 to the external emergency stop line and you must open JP1 or JP2 At this time the emergency stop must be connected to be Normal On and it must be check for proper operation dur
28. its length of 3 5m 2EA and 3 3m 2EA Insert a protective hose or the proper location of protective hose m HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 3 3 2 Using Forklift Truck Loading Capacity minimum 3ton Fig 3 5 How to Transport Using Forklift Truck HX300 400 200L 200L 2000 300L Forklift may be used for transporting the robot manipulator The bracket for the forklift transporting as an option is provided Follow the instruction for safety Make each model taken a basic posture referring to the Figure Before forking fasten each bracket for forklift to the left and right side of 2 Frame with 4 pieces of M12 bolts and flat washer Transport at low speed Follow the safety regulations A attention Do lean against the robot manipulator during transporting Check the robot manipulator not to collide against the ground while getting on and off Follow the safety regulations during forklifting and transporting HYUNDAI HEAVY INDUSTRIES CO LTD 3 Instructions 3 4 How to Install A NOTE Before starting to unpack and install the robot read the safety regulations and other instructions very carefully A Warning The installation shall be made by qualified installation personnel and should conform to all national and local codes When unpacking the robot check if it has
29. not short positive and negative terminals of battery Do not expose batteries to high temperature or flame HYUNDAI 5 1 7 HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 5 2 1 Instructions for Battery Storage CD Do not keep the batteries at a high temperature and humidity Keep it in the well ventilating place without dew condensation 2 Keep it in a normal temperature at relatively constant temperature 20 15 and at relative humidity of less than 70 3 Check the battery storage every six months and manage them with first in first out HYUNDAI m HEAVY INDUSTRIES CO LTD 5 Maintenance 5 3 Internal Wiring Replacement cycle of internal wiring depends on follows Continuous operation Y Operating speed Atmosphere environment Inspect on a regular basis every three months and check any damage on the cables or cable protect spring If any damage replace it Replace the cable every 16 000 operating hours regardless of working condition Attention Y As all the wires are flexible type do not use any wires other than specified one Wiring replacement must be done by unit Do not use any Cable protective spring and Hose that have external damage as they may cause future problems When purchasing robot cables make inquiry of our service office about wiring type Specify the length of wiring for connecting the robot with the controller 5 19 HY
30. robot s working envelope 6 System provider must ensure that all the circuits utilizing emergency stop function perfectly perform in a safe way 7 For the immediate emergency stop install emergency stop button within the accessible distance for the operator Technical Safety Precautions 1 Eliminate any interference with peripheral equipment considering the dimension and working envelope 2 Avoid such places for installing which is directly exposed to the sun extremely humid contaminated by oil or chemicals and containing a large amount of metal powder and explosive gas HYUNDAI HEAVY INDUSTRIES CO LTD 1 Safety 3 Install at the ambient temperature ranged 0 45 C 4 Secure sufficient space for the easier disassembly and maintenance 5 Install safety fence with a gate and prohibit any person from entering the robot s working envelope 6 Remove any obstacles out of the robot s working envelope 7 Take a special measure considering thermodynamics of controller if the robot is installed near the heating elements or places exposed directly to the sun 8 Take a special measure if the robot is installed in a place of abundant dust such as metal powder in the air 9 Install the robot not to transmit welding electric current In other word insulate SPOT GUN with from the robot s wrist 10 Grounding is very critical in preventing electric shock and malfunction caused by noise and thus i
31. 1 31 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 1 11 2 Tool Workpiece 1 It must be possible to replace tools such as milling cutters in a safe manner Make sure that safety devices are working correctly until the cutters stop rotating 2 Grippers must be designed to keep in gripping workpiece securely even though a power failure or a control failure takes place It must be possible to release workpiece from the gripper in a manual mode 1 11 3 Pneumatic and Hydraulic Systems 1 The special safety regulations will apply to pneumatic and hydraulic systems 2 Since residual energy of pneumatic and hydraulic systems can be still remaining even after the robot stops particular care and attention must be paid by users Internal pressure of equipment must be removed whenever starting the repair work for pneumatic and hydraulic systems HYUNDAI m HEAVY INDUSTRIES CO LTD 1 Safety 1 12 Liabilities The robot system has been built in accordance with the latest technical standards and approved safety rules Nevertheless the serious accidents such as death or personal injury still may take place due to the collision between the robot system and peripheral equipment The robot system must be used by operator who has a full technical knowledge on its designated use and also pay his close attention to the possible dangers and risks involved in its operation The use of robot system is subject
32. 1 Materials of each 9 2 AHY v HEAVY INDUSTRIES CO LTD 4 1 Safety HX200 HX200L 2000 HX300 HX300L 400 1 1 Introduction The main purpose of this chapter is to describe the safety precautions for users and operators who repair and manipulate the industrial robot This manual describes safety precautions for robot manipulator and controller in comply with the requirement of ANSI RIA R15 06 1999 Standard for Safety Industrial Robots and qualified with safety regulations The technical description and installation method of robot system is presented in detail at the specifications regarding installation of robot manipulator and controller Every operator who installs replaces adjusts manipulates maintains and repairs must read thoroughly and fully understand the manipulation and maintenance manual in particular the special attention must be paid to the WARNING symbol the most important marking related to the safety Installation replacement adjustment manipulation maintenance and repair of robot system must be performed by the personnel who was duly trained for these purposes following the indicated operating procedure This company is planning and carrying out the relevant training such as maintenance repair and manipulation for the above operations so robot users make sure that robot operators should get the relevant training And make sure tha
33. 200L 2000 Less than 200kg 200kgf A Allowable Load Torque Table 3 3 Allowable Load Torque HX300 300L Less than 1668N m 170kgf m bess m N m 62 HX400 Less than 1960N m 200kgf m Less 5 N m 50 HX200L 200L 2000 Less than 1290N m 132kgf m Less 40 HYU 3 1 1 HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 A Allowable Moment of Inertia Table 3 4 Allowable Moment of Inertia HX300 300L 150kg m 15 3kgf m s 30 kg m 3 1 kgf m s HX400 120 kg m 12 2 kgf m s2 50 kg m 5 1 kgf m s 58 8 kg m 6 0 HX200L 200L 2000 117 6 kg m 12 0 kgf m s kgf m s Loads must be kept below maximum conditions shown in Fig 3 8 Fig 3 10 Fig 3 8 and Fig 3 10 show the possible range in which a point load can be positioned assuming the attached load is a particle However as the actual load End Effector is not a particle calculate and evaluate the moment of inertia on each axis The following exmple shows moment of inertia calculation assuming the attached load is a particle Example An attached load weight is 200Kg with the HX300 Model Allowable position of the center of gravity from the center of R1 axis CD Allowable position of the center of gravity from the center of Axis R1 lt Allowable Torque Load Weight LR1 687 N m 200Kgx9 8 m s 0 35 m 2 Allowable position of the center of gravity from the allo
34. HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 5 3 1 Wiring Connection Diagram Refer to Fig 5 1 for part symbols of the internal wiring JUNCTION BOX CONNECTOR BJ2 CONNECTOR BJ1 BR E HX300 J2 MB1 A 5 E S Axis MOTOR Brake HX300 J2 MB1 A i i REVISION CODE A B C Axis No 1 S Axis 2 H Axis 3 V Axis 4 R2 Axis 5 B Axis 6 R1 Axis For COMPONENT H 1 CNR10A 2 CNR20A 3 CNR20B 4 CNR30A COMPONENT MB Motor Brake E Encoder L Limit switch H Application Connector JUNCTION PART J1 BJ1 J2 BJ2 J3 BJ3 ROBOT TYPE Fig 5 1 Explains of internal wiring HYUNDAI ve HEAVY INDUSTRIES CO LTD 5 Maintenance BJ1 BJ2 1100 1600 AIR TUBE 2 AIR TUBE 2 700 960 450 480 680 se SI AIR TUBE 1 at E AIR TUBE 1 ma 700 650 RENE HX300 J2 H3 4 HX300 J3 H3 A 2 054 ETFEM 114 Li TES 1043 E EA 900 _ 1000 22 108 4 2 0sq 14 TFE ROIREV SB 0 3sqX5P OR LJ 51 spring 49202
35. HHI Reduction 1EA 1EA Axis B gear R13 223101 00 HX400 RV HHI Reduction 1 TEA Axis R1 gear R13 213102 00 HX300 300L RV Reduction 1EA TEA Axis R1 gear R13 223102 00 HX400 RV HHI Reduction 1 Axis R2 R13 232052 00 HX200 200L RV HHI Reduction 1EA 1EA Axis B gear R13 233101 00 HX200 200L RV HHI Reduction 1 TEA Axis R1 gear R13 233102 00 HX200 200L HYUNDAI 7 3 HEAVY INDUSTRIES CO LTD Table 7 2 Spare Parts List HX200 HX200L 2000 HX300 HX300L HX400 HEAVY INDUSTRIES CO LTD Teijin seiki Gr ase HX300 400 200L 16kg S H V axis 200L 2000 300L ICAN reduction gear Moly white REOO Shell R2 B R1 axis HX300 400 200L 16kg 200L 2000 300L CAN Al ia 0769 Bearing of each vania axis 5 Replace every 2 HX300 400 200L 3EA 3EA years HX300 LB 200L 2000 300L regardless of 4 6 operating hours HHI Wrist ass y 1EA 1EA R12 217013 00 HX300 400 300L HHI Wrist ass y 1EA 1EA R12 237014 00 HX200 200L Cable from BJ1 to main axis ASS 1EA 1EA motor and HX300 400 200L right left side of 200L 2000 300L robot Axis A2 Wiring Cable from ASS Y 4EA 1EA right left side of robot to each HX300 400 200L HX300 J3 A 200L 2000 300L wrist axis motor 7 Recommended Spare Parts Table 7 3 Spare Parts List
36. Hyundai Robot HX300060301MME2 Manipulator Maintenance Manual HX200L HX200L 2000 HX300 HX300L HX400 HYU HEAVY INDUSTRIES CO LTD The information presented in the manual is the property of HHI Any copy or even partial is not allowed without prior written authorization from HHI It may not be provided to the third party nor used for any other purposes HHI reserves the right to modify without prior notification Printed in Korea Oct 2005 1st Edition Copyright 2005 by Hyundai Heavy Industries Co Ltd X Contents CENE WOM 1 2 1 2 Relevant Safety Regulations 44 4 22 1 4 DEVE iem UH c 1 4 1 4 Safety Related _ __ 1 5 1 4 1 Safety 1 5 1 4 2 1 6 1 5 Definition of Safety Functions pp 1 7 1 6 Installation REN DD Ee 1 8 126 Safety 1 8 1 6 2 Placement of Robot amp Peripheral Equipment 1 10 Tab ssdTrstalling the 1 12 1 6 4 Space for Robot 1 14 1 7 Safety Operation for Robot
37. IWHSL 90 51 97 9 0 9 uz o bso z 3413 141 Ld 9va o uz 0 bso z 3313 9 wae ND 0 0862 AIM S 08 eva 20 0 0 9 aro 9 2 54 m 9 NS 19 lt va 19 B 651 ova bia 9 9 YOLOW Je TIM oig ZIM e 19M oa we 19M SIXV 1H a caf 0 as 19A oig IANI 19 7 0 4 zon eon uj 19N om V oa 19n u95833j13S3NT 11 05072 44 00 9 2 94 9 NS C 9 9 951 a YSL oig 197 HOLOIN 1 LJ om zm 9 ISM SMENO 08 im e 9 SIXV 9 2 ISA oa SAdNO ISA gt P 0 1 a zen a isn XV SAND 8 Cue e 3 414 11 9802 09 9 2 WNIWH31 NS C 9 9 19 lt vel m Osce 001 85 lt v8 og 9 4 HOLON qoe e os om zm 9 VEN wc N SIXV ZH om 9 oa a a 4 0 vanno in 99 XJ L 9 LEX bSQ2 H3 09 dgzdju99 L 3 31 82 0072 13 00 08 Fig 8 3 Motor and Brake wiring connection No 2 8 4 HEAVY INDUSTRIES CO LTD HYUNDAI 0 iring Internal W
38. L 2000 HX300 HX300L HX400 Q Placement of Robot amp Peripheral Equipment 1 Make sure that the power supply is off before operating when connecting the primary power of controller or peripheral equipment There is a possible danger of electric shock because the high voltage such as 220V and 440V is used as its primary power 2 Post a sign No enter during operation up the safety fence gate and inform the operators of its purport 110 cm 44 Min d Operator M Controller 3 T nterlocked Barrier Guard 7 Restricted 7 Maximum 5 Safeguarded space Space space Fig 1 3 Placement of Peripheral Equipment and Operator 3 Arrange such devices as controller interlock panel and other manipulation panels to be handled outside of the safety fence 4 When installing operation stand install the emergency stop button on the stand Make sure that the stand stops in an emergency wherever the robot is handled HYUNDAI HEAVY INDUSTRIES CO LTD 1 Safety 5 Make sure that the robot manipulator and the wiring and piping of controller interlock panel and timer should not be placed in the way of operator s working range so that they would not be directly stepped by FORK LIFT There is a possible dang
39. Manual mode Maximum speed is 250mm s In a manual mode by means of workers selection workers may enter the safeguared area Auto mode The robot can be operated via remote controller All safety devices such as safety door safety mats etc are activated No one may enter the safety device area of rotbot 1 10 6 Monitoring Function 1 Motor monitoring function Motors are protected against overload by means of onboard sensors 2 Volatge Monitoring Function For the protection of the servo amp module turns off the power switch when the voltage is too low or too high HYUNDAI m HEAVY INDUSTRIES CO LTD 1 Safety 1 11 Safety Related to End Effectors 1 11 1 Gripper 1 When a gripper is used to grip a workpiece there should be safety precautions for unexpected dropping of the loaded workpiece 2 When any end effectors or devices are installed on the robot arm use the required size and piece of bolt and securely fasten as per the required torque using torque wrench Do not use the bolt which has rust or dirt on its surface 3 End effector must be designed and manufactured not to exceed the maximum allowable load at the wrist of robot Even though power or air supply stops the gripped workpiece must not be dropped from the gripper In order to remove any risks and problems which may cause personal injury and or physical damage the sharp edge and projecting part of end effector must be made dull and smooth
40. Replace the servo amp board BD440 to check errors Resolution D If cabling turns out to be in good condition withouth any damage replace the encoder 2 If there is no error after replacing the servo amp board BD440 replace the servo amp board im HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 6 4 Motor Replacement A Warning When motor is separated the ARM will drop due to its built in brakes inside the motor for holding robot s posture Take necessary precautions such as fixing A2 FRAME with 2nd ARM by using 20 250 bolts or lifting and hanging the ARM by using crane as shown in the Figure in order to prevent such dropping Do not hold the ARM in your hand In case of contacting the motor right after it stops ensure the motor temperature Motor weights are listed as follows Be careful when dealing with the motor Table 6 2 Motor Weight HX300 400 200L 200L 2000 300L 27 kg 10 7 kg HYUNDAI um HEAVY INDUSTRIES CO LTD 6 Trobleshoot ing m ae pps mmeg ma i WF 7 dii LOIN i Fig 6 1 How to prevent dropping of ARM Axis 8 A Warning In this work there is a part performed with the motor ON Therefore perform the work in pairs An observer must always be ready to activate an emergency stop The other perform the work quickly and carefully An escape route should be determined before starting
41. STRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 6 8 9 8 1 0 83Kgfm 128 4N m 13 Kgfm De M1235 128 4N m 13 1Kgfm 23 12 65 AN 128 4N m 13 1Kgfm NY 12 12 25 128 4 N m 13 IKgfm 2x4 M12x40 128 4N ml13 1Kgfm 5 m _ 1 H Fig 4 1 Inspection Part for Main Bolts HX300 400 300L HYUNDAI m HEAVY INDUSTRIES CO LTD 4 Inspection 4 4 Inspection of Wrist Backlash Check a diversion by forcing the end effector End Effector spot gun hand device etc which is attached to the vertical hem of Wrist in the direction of back and forth right and left and up and down End Effector Fig 4 2 Abnormal Backlash Inspecting Directions E HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 4 5 Inspection Internal Wiring Flexible cables are used for internal wiring of robot manipulator However when an internal cable is broken or crushed the robot may malfunction Therefore regular inspection is required When operating in the working envelope according to following inspection conditions inspection must be completed in advance 4 5 1 The Conditions of Safety Inspection When performing the operating work such as teachin
42. X300 400 200L shaft and base R15 210108 00 2001 2000 300 body in 51 HHI Axis 51 D O ring 2EA 2EA and output HX300 400 200L R15 210114 00 200L 2000 300L shaft Assemble HHI surface of D O ring 1EA 1EA reduction gear HX300 400 200L shaft and base R15 210115 00 72001 2000 300L body in S1 HHI S1 part between HX300 400 200L 15 211116 00 200L 2000 300L reduction gear HHI 51 motor base D O ring 1EA 1EA 209 motor HX300 400 200L R15 210110 00 2001 2000 300L surface 7 7 HEAVY INDUSTRIES CO LTD Internal wiring is shown connection diagram per unit and thus utilize it to inspect and replace the wiring 8 1 Manipulator Configuration Fig 8 1 Manipulator Configuration HYUNDAI 85 HEAVY INDUSTRIES CO LTD lagram D Ir ing Internal W 8 8 2 Wiring Diagram week o eqni uonoejuoo NO 0 08521 ADI v JOLY e 9 16 2 080 3413 9 uge z bso z 3413 2 9 uz obso z 3413 1 9 2 9 lt lt Wo 52 aa tel 295 251 5
43. YU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 9 Operators must pull the safety plug out and enter the safety fence with the plug 10 Do not use any devices causing noise in and around the teaching area 11 Handle the teaching pendant button while checking the teaching point with your naked eyes and do not handle it just relying on your sense 12 Do not work with your back against the robot and always pay attention to the robot s movement 13 teaching check and examine carefully under your feet In particular in high teaching for more than 2M secure a safe zone on which you may step before teaching 14 Instructions for any abnormal operations IN CD Press immediately the emergency stop button when any abnormal operations are found 2 Be sure to check if the relevant equipment is stopped when checking the abnormality in an emergency stop 3 In case that the robot stops automatically due to power failure investigate possible causes and take actions after confirming that the robot completely stops 4 In case of malfunction of emergency stop devices immediately disconnect the main power and investigate possible causes to take necessary actions 5 Investigation of the failure must be conducted only by a designated person For the re operation after emergency stop operators must clarify the cause of failure and take necessary actions and then operate the robot again following the pr
44. able load of bolts The repeated tensile load per bolt Approximately 8820 900 Kgf HYUNDAI HEAVY INDUSTRIES CO LTD HX130 165 HX130S 165S 3 4 3 Dimension of Installation Surface Fix the swivel base for robot s installation Refer to Fig 3 6 for the dimension MW 2 UT NN 2 Y TM N 3 Instructions HX300 400 200L 300L 4 M24 TAP Fig 3 6 Dimension of Robot Installation HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 3 4 4 Accuracy of Installation Surface The degree of flatness for the four attachment plate surfaces should safisty the specification Use a shim if necessary The rest of the surface must be flat within 2mm m Cautions 1 The flatness of mounting plate must be within 1 0 mm 2 The flatness of attachment plate surface for the 4 points must be within 1 0 mm 0 5 mm Fig 3 7 Accuracy of Installation surface HYUNDAI HEAVY INDUSTRIES CO LTD 3 Instructions 3 5 Allowable Load of Wrist Axis The load which will be applied to the mechanical interface of robot s wrist axis is restricted by allowable weight allowable load torque and allowable moment of inertia A Allowable Maximum Pay Load Weight Table 3 2 Allowable load weight HX300 300L Less than 300kg 300kgf HX400 Less than 400kg 400kgf HX200L
45. al sound or overheating of the reduction gear when the robot is in operation Check out any play in the reduction gear by shaking the End Effector such as spot gun and hand devices etc back and forth Turn motors off with the brake release switch ON and check that the axis can be rotated by hand If not the reduction gear is in bad condition Check if peripheral equipment has been contacted with the robot before the abnormality Damage may occur to the reduction gear due to the contacting impact e ew ss HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 Resolution D Replace the reduction gear 2 Replace the entire wrist section The replacement of entire wrist should be a quick and reliable resolution as it takes time and necessary equipment for reduction gear replacement HYUNDAI T HEAVY INDUSTRIES CO LTD 6 Trobleshoot ing 6 3 3 Brakes In case of brakes failure each axis possibly drops with the motors OFF Or in reverse brakes possibly operate even with the motors ON The latter causes overload and noise AN When intending to operate the entire robot without the motors ON operate it with the brake release switch ON Before turning the switch ON take necessary precautions to prevent the ARM from dropping as the robot ARM will drop by gravity B Diagnostics CD Check if the brake can be heard in operation by turning the brake release switch ON OFF altern
46. alibrations which determines encoder data from basic posture of the robot The number of pulses per revolution of the currently used encoder data is 8192bit irrespective of the robot model The current value of encoder displays what is added by compensation value to the actual encoder value In other word the difference between the current value of encoder and the absolute compensation value of encoder is real encoder value After reset the actual encoder value is classified as what it becomes less than 1 revolution and as what it becomes less than minus 1 revolution depending on the robot model Follow the procedure below to confirm the encoder has been successfully reset CD Connect the encoder connectors of motors and turn controller power Select Encoder Calibration in a constant setting mode and select Encoder Calibration Data Input at the next display The encoder calibration value for each axis is displayed in left side and the present encoder value in right side 2 Move the cursor to the encoder calibration value of axis that were reset and press 01 3 Confirm that the present encoder value is within the range of 0 8192 If not reset the encoder again A Warning After connecting the motor the following errors may occur according to the discharge of electricity of the encoder internal capacitor E0107 Encoder error Poor bit sequence e W1014 Voltage drop of encoder battery In this case turn controlle
47. and out using their hands through the safety fence It could be a cause of accident associated with compressing or amputating HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 Qs Installing the Robot Install the robot as per the planning and layout which has been previously reviewed and studied for its optimized performance and functionality In case of poor conditions for robot installation the serious problems can take place including error of relative position between robot and workpiece during operation bad performance quality of robot caused by vibration shortening lifetime and cause of serious accidents Thus pay attention to the following precautions when installing the robot General Safety Precautions 1 Design and install the robot system properly in compliance with laws regulations and safety requirements valid in the country where the robot system is installed 2 All the workers for the robot system must have the complete knowledge on the information specified in the application and supplementary manual and proficiently operate and handle the industrial robot 3 Installation workers of robot must follow the safety instructions and apply them to the installation when they face any safety problems 4 System provider must ensure that all the circuits utilizing safety functions perfectly perform in a safe way 5 Install main power supply to be disconnected from outside of the
48. arting to grease remove the plug from the grease outlet 2 Whenever possible avoid using a compressed air pump powered by the factory air supply If the use of a compressed air pump is unavoidable restrict the greasing pressure less than 7bar 7kgf cm 3 Use grease only of the specified type If not may damage the reduction gear or lead to other problems 4 After greasing confirm that no grease is leaking from the grease outlet and that the grease bath is not pressurized then re attach the plug in the grease outlet 5 To prevent accidents caused by slipping completely remove any excess grease from the floor or robot 6 When an ambient temperature is more than 40 C be sure to shorten the period of replenishment in half m Periodic Replenishment Replacement Lubrication Cycle Y Grease Replenishment 6 000 hours Y Grease Replacement 12 000 hours HYUNDAI HEAVY INDUSTRIES CO LTD 5 Maintenance 5 1 1 S Axis Reduction Gear 62 LN Grease outlet Plug PT1 8 Grease inlet Grease nipple A PT3 8 Attention If grease is added without removing the outlet plug the grease will go inside the motor and may damage it It is absolutely necessary to remove the plug m Grease Replenishment CD Remove the grease outlet plug 2 Inject the grease into the grease inlet using a grease gun Y Grease type Molywhite REOO Y Amount of grease 500cc 3 Attach the
49. ately with the motors OFF If not heard the vrake cable may be broken When operating the brake release switch ON OFF be careful of ARM dropping The brake release switch is located on the panel in the controller cabinet door B Resolution CD If cables turn out to be good condition replace the motor HY 6 7 HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 6 3 4 Motor Motor failure causes abnormal operation of robot such as staggering at stop irregular twitching and noise in operation Besides It may cause overheating and abnormal sound Check the reduction gear and fulcrum bearing as well in order to determine which part causes the abnormality It is because that similar phenomenon is observed when the reduction gear is damaged Diagnostics CD Check for overheating and abnormal sound B Resolution CD Replace the motor HYUNDAI a HEAVY INDUSTRIES CO LTD 6 Trobleshoot ing 6 3 5 Encoder Position offset malfunction and out of control movement as well as staggering at stop irregular twitching may occur when the Encoder is in bad condition This case has nothing to do with such phenomena as mechanical abnormal sound overheating and vibration Diagnostics CD Check for any encoder data failure 2 Use reference pins and blocks to check the positional data is correct at pin position 3 Check for any irregular variations in the encoder data when moving each robot axis 4
50. aused by their negligence or non observance of these instructions The manufacturer will not take any liabilities and responsibilities for any damages or losses caused by the misuse or malfunction of such equipment which is not included in the contract between manufacturer and user and provided by user or such equipment which is installed around the robot system arbitrarily by the user User must take the full liabilities and responsibilities for any risks and damages caused by such equipment HYUNDAI HEAVY INDUSTRIES CO LTD 7 c 5 O Q 70 4 2 Specifications HX200 HX200L 2000 HX300 HX300L HX400 23 2 1 Robot Machinery Part HX300 EN Specification No Robot TYPE Rated Payload Series Name Flg 2 1 Robot Machinery Part HYUNDAI HEAVY INDUSTRIES CO LTD 2 Specifications 2 2 Location of Robot Identification Plate The model name serial number and manufacturing date of robot are written down in the name plate The name plate is located in the rear of axis H in the ARM gt HYUNDAI HEAVY INDUSTRIES CO LTD Product Name Robot Mnipulator Model Name HX165 Serial Number Year of Manufacture Weight Net Kg Manufactured by Hyundai Heavy Industries Co Ltd 1 CHEONHA DONG DONG KU ULSAN CITY 682 792 KOREA Tel 82 52 230 7901 Fax 82 52 230 7920 Home page wwwhhi co kr Made in Ko
51. been damaged during transporting or unpacking In addition strictly keep the following installation instructions because installation method and foundation are very important to maintain a good robot performance 3 4 1 Operating Conditions 1 Ambient temperature should range from 0 to 45 2 Ambient humidity should range from 20 to 85 RH without dew condensation 3 Less dust oil or moisture 4 No flammable corrosive liquid or GAS 5 No impact and shacking 6 No electrical noise generator near the robot 7 If the robot is not immediately installed keep it a dry area at an ambient temperature between 15 and 40 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 3 4 2 Installating the Robot Manipulator The manipulator must be firmly fixed with eight M20 bolts Note that all eight bolts must be used Bolts M20 65 of higher 12 9 SOCKET HEAD BOLT Washer OD 44mm ID 25mm T 4mm Tightening Torque 314Nm The stiffness of the foundation must be designed to minimize the influence of the dynamic behavior of the robot In case of installing the robot on the floor where the concrete thickness is more than 200mm remove unevenness and cracks on the floor and then fix the mounting plate with M20 Anchor Bolts If the thickness of concrete is less than 200mm the foundation work is required Thus inspect the foundation before robot installation Allow
52. d by 15 If the 1st STOPPER BLOCK and STOPPER are deformed due to a great impact they must be replaced HYUNDAI HEAVY INDUSTRIES CO LTD 4 3 Instructions HX200 HX200L 2000 HX300 HX300L HX400 3 1 Robot Component Name The following Fig 3 1 and Fig 3 2 show and name each component of the robot df A BIN TERR z 15 a a q a d 22 10 A a 2 0 2 4 Fig 3 1 Identification of Robot Components Table 3 1 Components name 1 BASE BODY 9 WRIST 2 A2 FRAME 10 R2 axis Motor 3 279 ARM 11 B axis Motor 4 HINGE 12 R1 axis Motor 5 LINK 13 V axis Motor 6 BALANCE SPRING 14 H axis Motor 7 1 FRAME 15 S axis Motor 8 1 ARM 16 S axis Limit Switch HYUNI CO LTD 3 2 3 Instructions 3 2 Location of Safety Nameplate In order to prevent any accidents safety marking plates such as Fig 3 2 is attached to the robot Do not remove or replace it unneccessarily HYUNDAI WARNING Fig 3 2 Location of Safety Nameplat
53. e HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 3 3 How to operate 3 3 1 Using Crane 4 Handling Wires Length 3 5 M Y 4 Handling Wires Length 3 5M Hose for Hose for protection protection 2283 20 4 M24 EYE BOLT 4 M24 EYE BOLT LLL au r 4 1 3 Fig 3 3 How to Transport Using crane HX300 400 HYUNDA HEAVY INDUSTRIES CO LTD 3 4 3 Instructions AN 1 Z 62 574 4 4 M24 8 871 BO a 56 Fig 3 4 How to Transport Using crane HX200L 300L The following lifting instructions are valid for a naked robot If additional equipment is put on the robot the center of gravity may change and make lifting dangerous Never walk under the robot Pose the robot as shown in the Figure Mount four pieces of EYE BOLTS at the four parts of Base Body Hook 4 piece of wire hooks up with EYE BOLTS Use 4 piece of protective hose four parts 50cm to prevent damage Keep the safety regulations during Lifting process Weight of manipulator 2230kg HX300 200L 2430kg HX400 Minimum crane capacity 3 tons prevent damage of painting at the parts contacted with robot body Refer to Figures Use wire rope in
54. eal tape HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 5 2 Battery Replacement The position data of each axis is preserved by the backup batteries The batteries need to be replaced every two years To replace batteries observe the following procedure CD Keep the power on Press the Emergency Stop button to prohibit the robot motion Attention Replacing the batteries with the power supply turned off causes all current position data to be lost Therefore zeroing will be required again Dettach the battery bracket Take out the old batteries from the battery bracket Insert new batteries into it Pay attention to the direction of batteries DOY v Battery Spec ER6C AA 3 6V Y Manufacturer Maxell Reinstall the battery bracket u TEL n 1 ry EH rS 5 du 5 BATTERY BRACKEI HYUNDAI m HEAVY INDUSTRIES CO LTD Attention v lt lt lt lt lt 5 Maintenance Do not dipose the batteries Dispose of the battery with industrial waste acoording to the laws and other rules in the country where the controller is installed Do not recharge the batteries otherwise batteries may result in exploding or everheating Do not use any batteries other than the recommended one Change the batteries only with the specified one Do
55. ed spare Parts 4 7 Recommended Spare Parts HX200 HX200L 2000 HX300 HX300L HX400 The recommended spare parts for robot are as follows Please check robot serial number and manufacturing date when purchasing and contact our serive office Category Regular maintenance parts what is replaced regularly B Essential spare parts what is of high frequency C Essential component parts D Machine parts Table 7 1 Spare Parts List HHI Common B AC servo 3EA 1EA use for motor HX300 400 200L Axis S H R15 211007 00 200L 2000 and V Common HHI B AC servo 3EA 4EA use for motor Axis S H R15 331007 00 HX300L and V Common HHI B AC servo 3EA use for motor R13 212051 00 HX300 400 200L Axis R2 200L 2000 300L B and R1 RV HHI C Reduction 1EA 1EA Axis S gear R13 210101 00 HX300 400 200L 200L 2000 300L RV HHI C Reduction HX300 400 200L 1EA Axis gear 4 RIS EMOSP UU 2001 2000 3001 RV HHI C Reduction 1EA Axis V gear R13 21108V 00 HX300 400 200L 200L 2000 RV C Reduction 1EA 1EA Axis V gear R13 33108V 00 HX300L HYUNDAI 5 HEAVY INDUSTRIES CO LTD 7 Recommended Spare Parts RV HHI Reduction 1EA Axis R2 R13 212052 00 HX300 400 300L RV HHI Reduction 1EA Axis R13 213101 00 HX300 300L RV
56. ence during operating test Unexpected accidents are likely to occur because of its low reliability AHY HEAVY INDUSTRIES CO LTD 1 1 8 1 Safety Safety Precautions for Automatic Operation 1 While posting a sign Do Not Enter During Operation up the safety fence gate ask the operators not to enter during operation If the robot stops you may enter the safety fence under your full understanding of the situation 2 Be sure to check if any operators are inside of the safety fence when starting the automatic operation Operating without checking the presence of operators may cause a personal injury 3 Before starting the automatic operation check and confirm that the program number step number mode and starting selection are in the possible state for automatic operation If starting with the other programs or steps selected the robot could move in an unpredicted way and lead to an accident 4 Before starting the automatic operation check if the robot is properly located to get started Check whether the program number or step number is identical with the location of robot Even if it s all identical accidents are still possible to occur due to an abnormal movement when the robot is differently located 5 Be prepared to immediately press the emergency stop button when starting the automatic operation Immediately press the emergency stop button in case of robot s unexpected movements or emergency 6 Be sure t
57. er of accident if the workers are affected by electricity or the wiring is down 6 Place the controller interlock panel and handling stand within the sight of robotic performance It may cause a serious accident to operate the robot while the operator is working or the robot is malfunctioning in an invisible sight 7 Restrict the robot s working envelope by using soft limits and mechanical stopper if the necessary working envelope is narrower than the holding workable envelope It is possible to stop the robot in advance when it moves beyond its normal working envelope due to an abnormal condition Refer to the Robot Manipulator Maintenance Manual 8 Welding spatters directly on the operator or around him may cause burning or fire Install such devices as a glare shield or a cover in the full sight of robot s working envelope 9 Make sure that the device indicating the robot s running condition whether automatic or manual mode must be noticeable even in the far distance In the case of automatic start up warning with a buzzer or warning lamp is also valid 10 Make sure that there is no projecting part in the robot s peripheral equipment Cover it if necessary It usually may cause an accident if the operator comes in touch with it And it may lead a serious accident if the operator is astonished at the sudden movement of robot and conducts it 11 Don t make the system designed to allow the workers to carry the Work in
58. est one should be able to stop the robot with a teaching pendant or control panel When entering the working envelope through the safety gate take the teaching pendant with you so that other people may not operate the robot Make sure to post up the control panel a sign indicating the state of robot handling Read carefully and be aware of the follows when entering the working envelope 1 Do not enter the working envelope other than teaching person 2 Be sure to set the handling setting on teaching pendant to TEACHING LOCK 3 Operation set up mode of controller must be a manual mode in the control panel 4 Always wear the approved working suite Do not wear a loose clothes as you please 5 Do not wear gloves when handling Hi4a contoller 6 Do not leave innerwear such as underwear shirts or necktie out of the working suite 7 Do not wear personal accessories such as big earrings rings or necklaces 8 Make sure to wear safety shoes helmet and goggles and if necessary wear other self protective outfit such as safety gloves 9 Make sure that the emergency stop circuit is working correctly and in its proper function turns MOTORS OFF when pressing the emergency stop button in the control panel and teaching pendant before handling the robot 10 Make your posture face to face with the robot manipulator when performing your work 11 Follow the predetermined working procedure 12 Be prepared for
59. finition of Safety Functions Emergency Stop Function IEC 204 1 10 7 There is one emergency stop button on the controller and teaching pendant respectively If necessary additional emergency buttons should be able to connected to the robot s safety chain circuit The emergency stop function which overrides all other robot controls stops all moving parts by disconnecting power supply and removes drive power to prevent the use of other dangerous functions controlled by the robot Safety Stop Function ISO 10218 EN 775 6 4 3 When a safety stop circuit is provided each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit The robot should have a number of electrical input signals which can be used to connect external safety devices such as safety gates safety pads and safety lamps These signals allow the robot s safety functions to be activated by all equipment including peripheral equipment and the robot itself Speed Limiation Function ISO 10218 EN 775 3 2 17 In a manual mode the speed of robot is strictly limited to 250 mm per second as maximum The speed limitation applies not only to the TCT Tool Coordinate Time but to all parts of manual mode robot The speed of equipment mounted on the robot should be possibly monitored Restricting working Envelope ANSI RIA R15 06 1999 The working envelope of robot axes should be restricted using software limits Axis 1
60. g except shutting off driving source of industrial robot in the working envelope check the following articles before the work If abnormality is found correct the problem on the spot and then take necessary actions Check if the covered wire and sheathing are damaged or not Check if the manipulator can be operated or not Check emergency stop function HYUNDAI 7 HEAVY INDUSTRIES CO LTD 4 Inspection 4 5 2 Inspection Part _ UE NS MSS Fig 4 3 Cable Inspection Parts HX300 400 200L 200L 2000 300L 4 9 HYUNDAI HEAVY INDUSTRIES CO LTD G 4 5 Maintenance HX200 HX200L 2000 HX300 HX300L HX400 5 1 Grease Replenishment Replacement Attention If greasing is performed incorrectly the internal pressure of the grease bath may suddenly increase possibly causing damage to the seal which would in turn lead to grease leakage and abnormal operation When performing greasing therefore observe the following cautions CD Before st
61. gure below Install Hi4a controller outside of the safety fence in order to monitor the robot manipulator and to operate in a safe way Door Hi4a Controller P d 7 Me Mo y d SafetyFence a Minimum110 que Working Envelope Ae Minimum 110cm Working Envelope with Tool and Workpiece installed gt NOS NOS RAV T 1 en S 1 BAS SAS AS ASS Fig 1 4 Space for robot installation When installing be sure to make it easier to perform the maintenance when opening the Hi4a Controller door Secure the available space The controller power in the above Figure could change depending on the kind of controller HYUNDAI i HEAVY INDUSTRIES CO LTD 1 Safety 1 7 Safety Operation for Robot Handling Follow the safety instructions to prevent any accidents Don t modify nor ignore safety devices or circuits at any time and be careful of electric shock All the normal operations in an automatic mode must be performed outside of the safety fence Check the robot s working envelope if anyone is inside before operating Safety Precautions for Robot Handling 1 Do not handle the robot other than such personnel as operators handling the robot and other possible operators and supervisors who were designated as whom duly
62. he contactors is disconnected the robot will always return to MOTORS OFF mode HYUNDAI HEAVY INDUSTRIES CO LTD 1 Safety MOTORS OFF mode indicates that drive power is removed from the robot s motors and the brakes are applied The status of the switches is displayed on the teach pendant Refer to the I O monitoring screen of SERVICE menu 4 controller operation manual Safety circuit The emergency stop buttons on the controller panel and on the teaching pendant and external emergency stop buttons are included in the safety circuit of operation Users may install the safety devices safety plug safety stop device for safe place which are operated in the AUTO mode In a manual mode the signals of these safety devices are ignored You can connect the general safety stop devices that is active in all operating modes No one can enter the working envelope in an automatic operation mode due to the unconditional operation of the safety devices door safety mat safety plug etc These signals are also generated in a manual mode but the controller will keep the robot operating while ignoring the robot s teaching In this case maximum speed of robot is restricted to 250mm s Thus the purpose of this safety stop function is to secure the safe area around the manipulator while one approaches the robot for maintenance and teaching When the robot is stopped by a limit switch it can be moved from the position by jogging it
63. i Dad ENGL DUE Rue Dd ADU DX AINE DU D DU Quis 3 7 3 4 1 Operating 004 40444 1 3 7 3 4 2 Installating the Robot Manipulator 3 8 3 4 3 Dimension of Installation Surface 3 9 3 4 4 Accuracy of Installation 3 10 3 5 Allowable Load of Wrist 3 11 3 6 Recommended Standy 3 16 4 inspection 4 1 4 1 Inspection Item and 4 2 4 2 Inspection Item and 4 3 4 3 Inspection of Main External Bolts e 4 5 4 4 Inspection of Wrist Backlash iun aie 4 7 4 5 Inspection Internal Wiring pp 4 8 4 5 1 The Conditions of Safety Inspection 4 8 45 2 P 4 9 5 1 Grease 5 2 5 1 1 S Axis Reduction Gear nou oec cde pdt et podes 5 3 5 1 2 H Axis Reduction e tetto 5 4 5 1 3 Reduction Gear e e scott 5 6 5 1 4 R2 Axis Reduction Gear cere rete ce rex oet 5 8 5 1 5 B Axis 5 9 5 1 6 R1 Axis Reduction Gear
64. ilized in adverse condition such as spot welding grinding etc perform the inspection more frequently to ensure proper reliability of the robot system Inspect all visible cabling and replace them if damaged Check the mechanical bumper devices for deformation and damage If the bumper or Dog is bent replace it immediately Check the tightening torque of main bolts as shown in Fig 4 1 Check the abnormal noise in an automatic or teaching mode in order to ensure the condition of power transmission such as motor reduction gear etc HYUNDAI 4 4 HEAVY INDUSTRIES CO LTD 4 Inspection 4 3 Inspection of Main External Bolts The recommended bolt torque is shown in Fig 4 1 Apply the appropriate torque where required using the torque wrench and place the paint marking where the check up is completed Table 4 3 Inspection part for main bolts 1 H amp V axis reduction gear case 10 R2 axis reduction gear attachment attachment 2 H amp V axis motor attachment 11 Wrist attachment 3 Hinge and Link attachment 12 B axis reduction gear attachment 4 Balance spring attachment 13 Wrist CAP attachment 5 R1 axis motor attachment 14 Wrist HOLDER attachment 6 R2 axis motor attachment 15 Wrist HOLDER attachment 7 B axis motor attachment 16 Wrist COVER attachment 8 1st ARM attachment 17 RI on 9 1st Link attachment 18 End effector attachment HYU HEAVY INDU
65. ing test run HYUNDAI nm HEAVY INDUSTRIES CO LTD 1 Safety 1 10 3 Operating Speed To teach the robot the operating mode switch must be in a MANUAL mode Then the maximum speed of robot is limited to 250mm s 1 10 4 Connecting the Safety Devices External safety devices such as light beams light curtains safety plug and safety mats which can be adapted by the system builder execute interlocking the controller by way of connecting with safety circuit within the controller These devices are used for safety device during execution of normal program in an automatic mode 4 29 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 1 10 5 Restricting the working Envelope When the robot is not necessary to reach certain area for specific applications working envelope of the robot can be limited to secure the sufficient safety working area This will reduce the damage or loss in case of robot s collision with external safety devices such as safety fence etc The movement of axes 1 2 and 3 of HR HX can be limited by means of mechanical stopper or electrical limit switches In this case the corresponding software limitation parameters must be also changed The movement of the three wrist axes if necessary can be also limited by the Main CPU Limitation of working envelope for all the axes could be carried out by the user The robot is delivered to customer as the status of full working envelope setting
66. let Plug P M B Grease inlet Grease nipple A PT1 8 m Grease Replenishment CD Prepare a grease nipple A PT1 8 2 As necessary remove grease inlet plug and install grease nipple A PT1 8 3 Inject the grease into the grease inlet using a grease gun Grease type Alvania0769 Amount of grease 4 Remove grease nipple A PT1 8 from grease inlet port 5 Reinstall the grease plugs with seal tape 5 13 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 5 1 8 A1 Frame Gear Box Grease outlet Plug PT1 8 Grease Inlet Plug PT1 8 m Grease Replenishment CD Prepare a grease nipple A PT1 8 2 Remove the grease outlet plug 8 Remove the grease inlet plug and install grease nipple A PT 1 8 4 Inject the grease into the grease inlet using a grease gun Grease type Alvania0769 Amount of grease 30cc 5 Remove grease nipple A PT1 8 from grease inlet port 6 Reinstall the grease plugs with seal tape HYUNDAI HEAVY INDUSTRIES CO LTD 5 Maintenance 5 1 9 Wrist Gear Box Grease inlet Plug PT1 8 m Grease Replenishment CD Prepare a grease nipple A PT1 8 2 Remove the grease inlet plug and install grease nipple A PT 1 8 3 Inject the grease into the grease inlet using a grease gun Grease type Alvania0769 Amount of grease 30cc Remove grease nipple A PT 1 8 from grease inlet port Reinstall the grease plugs with s
67. ment Table 9 1 Materials of each part Battery NiCad or Lithium Wiring Motor Copper Base body A2 frame Upper arm Link Hinge etc Cast Iron A1 pipe Steel Brakes Motors Samarium Cobalt or Neodymium Wiring Connectors Plastic Rubber Reduction gears Bearings Oil Grease Wrist cover etc Aluminum alloy cast HYUNDAI HEAVY INDUSTRIES CO LTD AHYUNDAI HEAVY INDUSTRIES CO LTD O Head Office 1 Jeonha Dong Dong Gu Ulsan Korea TEL 82 52 230 7901 Ex 11 FAX 82 52 230 7900 O Seoul Office 140 2 Gye Dong Jongno Gu Seoul Korea TEL 82 2 746 4711 5 FAX 82 2 746 4720 O Suwon Office 537 3 Yeongdeok Ri Giheung Eup Yongin Si Kyenggi Do Korea TEL 82 31 205 4713 FAX 82 31 205 3200 O Daegu Office 223 5 Bumeo 2 Dong Susung Gu Daegu Korea TEL 82 53 746 6232 Ex 3 FAX 82 53 746 6231 O Cheonan Office 355 15 Daga Dong Cheonan Chungnam Korea TEL 82 41 576 4294 Ex 5 FAX 82 41 576 4296 O Gwangju Office 415 2 Nongsung Dong Seo Gu Gwangju Korea TEL 82 62 363 5272 FAX 82 62 363 5273 A St 305 1 HA TEL 052 230 7901 11 FAX 052 230 7900 APA s 140 2 HA TEL 02 746 4711 5 FAX 02 746 4720 ASA BAS Sel 537 3 H1 TEL 031 205 4713 FAX 031 205 3200 o U ASA SAP 80 2 5 223 5 1 TEL 053 746 6232 3 053 746 6231 aot APA
68. nd Periods Robot Manipulator and Axes common 4 Inspection 1 Cleaning Examine dirt and dust with naked eyes 2 5 Inspection wiring Examine any cable damages Examine cable fixing bracket tightening bolts paint marking with naked eyes Examine any cable cover damages with naked eyes 3 Main bolts Examine paint marking with naked eyes Limit Switch Dog Check the ON OFF function of limit switch Check if the emergency stop lamp is on when the limit switch is ON 5 Motor Check the abnorma heating Check the abnorma sound 6 Check the ON OFF operation of brake release switch Note Turn the switch off in a second because the ARM of working axis may be dropped when the brake release switch is on When the brake release switch is OFF ARM of End Effect will not be dropped HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 Axix S H V Check the abnormal 7 Reduction sound gear Check the shaking vibrating Axis R2 B R1 Check the abnormal 8 Reduction ar sound 9 Check the vibrating End Effect Examine paint 9 tightening marking with naked bolts eyes there is any diversion by rotating should not feel 10 Diversion each axis to the right diversion by and reverse touch direction If the robot is ut
69. nstall as following instructions D Install an exclusive grounding terminal using class 3 or higher For the input voltage of 400V of higher use special class 3 or higher 2 Connect grounding line into the grounding bus bar inside of the control panel 8 In case of direct grounding on the floor by anchoring two point grounding both by robot manipulator and by controller can produce a ground loop and contrariwise cause abnormal operation In this case connect the grounding line to the base of robot manipulator and disconnect the second grounding point to the controller If the robot vibrates even after stopping double check the grounding status because the possible main causes could be an incomplete grounding or ground loop 4 In the use of internal transgun GUN there is a possible danger of dropping because the primary power cable is directly connected to the spot gun In this case directly connect the grounding line to the base of robot manipulator in order to prevent any electric shock and protect the control panel but do not connect it to the controller ium HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 1 6 4 Space for Robot Installation Install robot after securing sufficient space for maintaining the robot manipulator Hi4a controller and other peripheral equipment Install the robot manipulator and controller securing space for installation as per the guideline as described in the fi
70. ntactor MSHP2 Drive Unit gt MSHP1 MSHP2 m lt amp Interlocking gt amp Operating Operating mode selector mode selector Aaa A A Aa A LZ Man1 4 TIN 2 4 Autot a y d lm Auto2 ev 9 9 zz s 9 9 Lene 9 x of 9 15 Limit switch ASG AUTO Mode Safeguard Computer GSG General Safeguard Commands TP EN Enabling device in T P EM Emergency stop switch Fig 1 5 Robot s Safety Circuit The robot s safety system is based on a two channel safety circuit that is continuously monitored If an error is detected the power supply to the motors is disconnected and the motor brake is applied To return the robot to MOTORS ON mode the switches of two channel circuit must be connected If one of the two channel circuit switches shorts the contactor of motor will be disconnected leading to the application of brake and finally the robot will be stopped Furthermore when safety circuit is disconnected the interrupting call will be sent automatically to the controller to find out the possible reason for the interruption The safety control circuit of operation is based on dual safety electric circuit in which the controller and MOTORS ON mode are operated inteactively In order to be in MOTORS ON mode the safety circuit consisted of several swtiches must be all connected MOTORS ON mode indicates that drive power is supplied to the motors If one of t
71. nvelope and to secure enough space for teaching and maintenance working The safety fence should also be firmly installed so that it is hardly accessible and removable AHY HEAVY INDUSTRIES CO LTD 1 Safety 2 The safety fence should be a fixed type in principle using harmless materials that do not have any broken surface or projecting part 3 Install the safety fence with an entrance gate and register the safety plug at the gate so that it does not open unless pulling the plug out Interlock the robot to be MOTORS OFF when the safety plug is pulled out or wire the robot to be MOTORS OFF when the safety fence is open Refer to 11 Connecting the Other Signals Hi4a Controller Manual 4 When intending to operate the robot with the safety plug pulled out wire the robot as a low speed play mode Refer to 11 Connecting the Other Signals Hi4a Controller Manual 5 For immediate emergency stop install emergency stop button wihin operator s easily accessible distance 6 If the safety fence is not installed install other devices substituting for the safety plug in the whole place within the robot s working envelope such as photoelectric switch and mat switch These devices may stop the robot automatically when a person enters the working envelope 7 The robot s working envelope dangerous zone should be distinguished from other zones by painting its floor m HY HEAVY INDUSTRIES CO LTD HX200 HX200
72. nward UP V DOWN V R2 Wrist Rotation2 Rx R2 Rx R2 B Wrist Bend Ry B Ry B R1 Wrist Rotation1 Rz R1 Rz R1 NC Rr ie Y 1 Fig 2 8 Robot Dimension and Axis HX300 400 200L 200L 2000 300L 2 11 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 2 6 Details of Wrist Axis Attachment Surface When attaching the operating tool to the mechanical interface of robot s wrist flange fasten it with a bolt at P C D 125 Li FA 250h6 LE Li E N 6 Mle DP edcPCD 200 gt Fig 2 9 Details of Wrist Axis Attachment Surface HX300 400 300L 12 Q10H7 D P 16 M 6 M10 TAP qu D P 13 PCD 125 6 M10 2 10H7 D P 16 D P 14 PCD 160 Fig 2 10 Details of Wrist Axis Attachment Surface HX200L HYUNDAI HEAVY INDUSTRIES CO LTD 2 Specifications 2 7 Details of Upper 1 ARM Attachment Surface There is a Tap in upper 1 ARM to attach peripheral equipment Attach peripheral equipment within the range marked as Attention Attach peripheral equipment to the upper side of the 1st ARM or to only one side of upper axis V When attaching be sure to the center position
73. o detect any abnormalities by checking the route condition or sound of robot movement Sometimes the robot may be abnormally operated including a sudden break down However it will show give certain indication before the break down Understand the robot s normal condition well in order to catch the symptom in advance 7 When any abnormality is detected from the robot immediately stop and take proper actions on it Using the robot before any proper actions taken may cause an interruption of produce as well as serious failure leading to a very serious personal injury 8 When checking the robots movement after the proper actions taken for the abnormality do not operate the robot with operators inside of the safety fence Unexpected accidents are possibly to occur because its low reliability may cause another abnormality 24 HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 3 Safety Precautions for Access to Safety Fence Robots are very powerful and heavy even at its low speed When entering the safety fence one must observe the relevant safety regulations of its pertinent country The operators always must be aware of the unexpected movements of robot Robots are able to move fast shortly after being stopped The operators should know that the robot is able to move in a different route without any notice by means of external signals Thus when trying to stop the robot during teaching or operating t
74. of gravity should be located within the range marked as M Max weight on the 1 Frame 80kg Max weight the 1 ARM 80 0 2 T f LN LC is Moesia 4 M8 DP 12 Center range of gravity A1 FRAME Center range of gravity A1 ARM Flg 2 11 Details of Upper 1st ARM Attachment Surface HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 2 8 Application Wiring and Inspection Wiring Diagram There are air unit and connector to connect the additional equipment to the robot manipulator Application connectors are indicated as follows Note Max air pressure of air connection 7bar 7 1 kgf cm 101 psi Connector for users MS3102A24 2BS PF3 8 Air Out AIRT N N j CNR108 X y Connector 1 e 85 M83102A24 288X J ON 1 BN CNR30A Connector for users Optional MS3106B20 29P Y 0 y i _ users Optional CNR20 Connector for users Optional MS3102A24 118 Ec FO WO Fig 2 12 Application Wiring and Inspection Wiring Diagram HYUNDAI HEAVY INDUSTRIES CO LTD 2 Specifications 2
75. oper procedure 15 Write out the operating rules proper to working details and installing location regarding the operation and handling method for the robot and the necessary actions for robot s any failure In addition it is recommended to operate the robot in accordance with the operating rules 16 Instructions when the robot stops Make sure not to approach the robot even when it seems to be stopped Most accidents occur from a sudden movement of robot which seemed to be stopped when one approaches it The conditions that the robot stops is as follows HYUNDAI um HEAVY INDUSTRIES CO LTD 1 Safety Table 1 2 State of robot stop Pause Minor failure Pause switch Emergency stop Major failure Emergency stop switch Safety gate Input signal standby of peripheral equipment START INTERLOCK Playback Completion Standby Even in the accessible state of robot be watchful against any possible sudden movement of robot Make sure to avoid approaching the robot without precautions for emergency under all circumstances Though the access during a pause is shown in the table as x allow the access to robot with the same precautions as teaching work if the entrance is open to take actions for minor failures i e malfunction caused by failure in arc nozzle contact and weldment detection 17 Clean up any split oil tools and impurities in the safety fence after completing robotic opera
76. ossible should be to diagnose the problem addition it is necessary to determine which parts cause the problem 1 Step 1 Which axis occurs the problem First of all check which axis causes the malfunction In case that it is hard to detect the problem check the following possible mechanical defaults 5 there any parts making noise 5 any parts generating an overheating 5 there any parts have a play or backlash 2 Step 2 Which parts have been damaged If the abnormal axes are determined investigate which parts cause trouble There could be many causes for one phenomenon Refer to Table 6 1 for the cause and phenomenon of the trouble 3 Step 3 Dealing with malfunction parts If the malfunction parts are confirmed conduct relevant repair procedure based on the chapter 6 3 Diagnostics and Resolutions for Major Parts Failure Contact our service office if you have any difficulties in dealing with problems HYUNDAI is HEAVY INDUSTRIES CO LTD 6 Trobleshoot ing 6 2 Trouble Symptoms and Possible Causes As shown in table 6 1 there may be many parts as the cause of one phenomenon Refer to next page to determine which part is malfunction Table 6 1 Trouble phenomenon and cause Overload Note1 Displacement Abnormal sound occurrence Noise in operation Note 2 Staggering at stop Note 3
77. ount of grease 1 100cc The grease replacement is complete when new grease appears in the outlet port The new grease can be distinguished from the old one by color Wipe the outlet port with a cloth and reinstall the inlet outlet plug with seal tape AHY HEAVY INDUSTRIES CO LTD 5 8 5 Maintenance 5 1 5 B Axis Reduction Gear Grease outlet Grease inlet Plug PT1 8 Attention Do not inject excessive grease The excessive grease would cause an abnormal operation m Grease Replenishment Prepare a grease nipple 1 8 and then Make the R2 Axis O degree Remove the grease inlet plug and install grease nipple A PT 1 8 Make the R2 Axis 90 degree and then Remove the grease outlet plug Inject the grease into the grease inlet using a grease gun Grease type Molywhite REOO Amount of grease 250cc 5 Wipe the outlet port with a cloth and reinstall the inlet outlet plugs with seal tape DOO m HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 m Grease Replacement Prepare a grease nipple A PT1 8 and then Make the R2 Axis O degree Remove the grease inlet plug and install grease nipple A PT 1 8 Make the R2 Axis 90 degree and then Remove the grease outlet plug Inject the grease into the grease inlet using a grease gun Y Grease type Molywhite REOO Amount of grease 950cc The grease replacement is complete when new grease appears in the outlet port The ne
78. outlet plug with seal tape m Grease Replacement CD Remove the grease outlet plug 2 Inject the grease into the grease inlet using a grease gun Grease type Molywhite REOO Amount of grease 3 650cc 3 The grease replacement is complete when new grease appears in the outlet port The new grease can be distinguished from the old one by color Move the S Axis for a few minutes to eject the old grease and then add grease until the new grease appears in the outlet port 5 Wipe the outlet port with a cloth and attach the plug with seal tape HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 5 1 2 H Axis Reduction Gear Grease outlet Plug PT1 8 Grease Inlet Grease Nipple 1 8 Attention If grease is added without removing the outlet plug it cause damage to the seal of reduction gear and grease will go inside the motor and may damage it It is absolutely necessary to remove the plug m Grease Replenishment CD Make the H Axis Arm vertical for ground H 90 Floor Type H 0 Shelf Type 2 Remove the grease outlet plug 3 Inject the grease into the grease inlet using a grease gun Grease type Molywhite REOO Y Amount of grease 300cc 4 Wipe the outlet port with a cloth and attach the plug with seal tape HYUNDAI 5 4 HEAVY INDUSTRIES CO LTD 5 Maintenance m Grease Replacement D 2 3 Make the H Axis Arm vertical for ground H 90
79. pe Remove the grease outlet plug Inject the grease into the grease inlet using a grease gun Y Grease type Molywhite 00 Amount of grease 1 600cc The grease replacement is complete when new grease appears in the outlet port The new grease can be distinguished from the old one by color Move the V Axis for a few minutes to eject the old grease and then add grease until the new grease appears in the outlet port Wipe the outlet port with a cloth and attach the plug with seal tape HY 5 7 HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 5 1 4 R2 Axis Reduction Gear Grease Outlet Plug PT1 4 Grease Inlet Nipple or Plug PT1 4 Attention Do not inject excessive grease The excessive grease would cause an abnormal operation m Grease Replenishment D 2 3 4 8 Prepare a grease nipple A PT 1 4 Remove the grease outlet plug Remove the grease inlet plug and install grease nipple A PT 1 4 Inject the grease into the grease inlet using a grease gun Y Grease type Molywhite REOO Amount of grease 250 Wipe the outlet port with a cloth and reinstall the inlet outlet plugs with seal tape m Grease Replacement DONO Prepare a grease nipple 1 4 Remove the grease outlet plug Remove the grease inlet plug and install grease nipple A PT 1 4 Inject the grease into the grease inlet using a grease gun Y Grease type Molywhite REOO Am
80. r power on for more than 10 minutes and reset encoder And then turn controller power once again and power ON It will be restored to normal condition m HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 6 5 4 Encoder Calibration Data input and Selection is necessary to compensate encoder data for the basic position of each axis Referto Encoder calibration in the Controller Manual for details Select Encoder calibration Position Rec in the mode of Constant Encoder Calibration Screen 08 09 05 Encoder offset 0 5 3 5 00400000 0 01 H 00400000 00400000 90 0 V 00400000 00400000 0 0 R2 00400000 2 00400000 0 0 Use Arrow key and press SET gt NEED Table 6 6 Data range after resettin All of Axes 0 8191 8192 1 Press SET key after moving the revolving bar into the desired location to set by using keys and the following message is displayed After axis Oper press REC ESC usable gt 2 Move the robot to the position that the origin pin becomes ON with axis operating button and press REC key 3 Press PF5 Complete to complete setting A Warning In case of encoder DATA compensation after replacing motor check if the motor power is on with the power HYUNDAI HEAVY INDUSTRIES CO LTD Recommend
81. rea Fig 2 2 The location of identification plate 25 HYUNDAI HEAVY INDUSTRIES CO LTD 2 3 Basic Specifications Table 2 1 Basic Specifications for Models HX200 HX200L 2000 HX300 HX300L HX400 Construction Articulated Degree of freedom 6 Drive system AC servo system 5 Swivel 3 142 rad 180 H For 1 31 1 31 rad 75 75 Backward Up o 4950 Max LH 0 52 2 18 rad 30 125 Working envelope R2 Rotation 2 6 283 rad 360 Wrist B Bending 2 094 rad 120 R1 Rotation 1 6 283 rad 360 S Swivel 1 658 rad s 95 s poe For 1 57 rad s Arm H Backward 1 658 rad s 95 s 90 s Up 1 483rad s MU V downward 1 658 rad s 95 s 85 s Speed R2 Rotation2 4 5 4 S 2 09 rad s 120 s 11 s Wrist B Bending 1 5 2 09 rad s 120 s j R1 Rotation 1 S S 3 14 rad s 180 s 1 2943 N 3924 N 2943 N Load Capacity 300 kg 400 kg 1962 N 200 kg 300 kg HYUNDAI 2 4 HEAVY INDUSTRIES CO LTD 2 Specifications 1668 1960 1290 1668N m R2 Rotation 2 170 kgfm 200 kgm 131 5 kgfm 170kgfm Wrist Bending 1668 Nm 1960 Nm 1290 1668N m Torque 9 170 kgfm 200 kgfm 131 5kgfm 170kgf m 687 823 604 6 687N m R1 Rotation 1 5 kgfm 84
82. reduction R13 213092 00 HX300 400 300L gear Bearing housing D O ring 1 1EA E 9 R13 213092 00 HX300 400 300L HHI Case surface of D O ring 1 axis B reduction R15 233117 00 HX200 200L gear HHI Case surface of D O ring 1EA axis R1 reduction R15 233176 00 HX200 200L gear Bearing housing in D O ring 1 EA 1EA e 9 15 233175 00 HX200 200L HHI Assemble surface D O ring 1 of frame and pipe 15 212072 00 300400 2001 in A1 200L 2000 300L HHI Case of Axis R2 D O ring 1EA 1EA reduction gear in R15 212075 00 HX300 400 300L A1 HHI Case of Axis R2 D O ring 1 1EA reduction gear in R15 232075 00 HX200 200L A1 HHI Case of Axis H and D O ring 2 EA 2EA V reduction gear in R15 211013 00 HX300 400 200L A2 200L 2000 300L HHI D O ring 2EA 2EA Motor Base in A2 R15 211020 00 HX300 400 200L 200L 2000 300L HEAVY INDUSTRIES CO LTD 7 6 Table 7 5 Spare Parts List V 7 Recommended Spare Parts V axis reduction D O ring 2EA 2EA gear output HX300 400 200L outlet R15 211021 00 2001 2000 300 HHI Balance spring D O ring 2EA 2EA pn R13 211022 00 4X300 400 200L 200L 2000 300L HHI A2 part between D O ring 1EA 1EA upper arm and HX300 400 200L collar 15 211027 00 200L 2000 300L Assemble HHI surface of D O ring 1EA 1EA reduction gear H
83. rinding For the other use than the above emergency application make a contact with our company to consult on the robot use and possible applications Invalid environment Our robot must not be used in a highly explosive environment and the areas contaminated by oil flammable materials or chemical materials Prohibited to be installed and manipulated m HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 1 2 Relevant Safety Regulations The robot is designed as 15010218 1992 safety standards for industrial robots and furthermore in comply with ANSI RIA 15 06 1999 regulations 1 3 Safety Training All the personnel who intend to teach operate or inspect the robot must be trained in an approved robotic operation and safety training course before start up The safety training course includes the following details Purpose and functions of safety devices Safety procedure to handle the robot Performance of robot or the robot system and possible hazards Tasks associated with any specific robot applications Safety concepts etc HYUNDAI 1 4 HEAVY INDUSTRIES CO LTD 1 Safety 1 4 Safety Related Nameplate 1 4 1 Safety Marking For the purpose of effective safety instructions the following safety symbols are used in this manual Table 1 1 Safety markin Indicate a potentially hazardous situation which if not avoided could result in death or serious injury to
84. s of Wrist Axis Attachment Surface HX200L 2 12 Fig 2 11 Details of Upper 1st ARM Attachment Surface 2 13 Fig 2 12 Application Wiring and Inspection Wiring Diagram 2 14 Fig 2 13 Details of Application Connector Encoder 2 15 Fig 2 14 Details of Application Connector 2 15 Fig 3 1 Identification of Robot 3 2 Fig 3 2 Location of Safety 3 3 Fig How to Transport Using crane 300 400 3 4 Fig 3 4 How to Transport Using crane HX200L 300L 3 5 Fig 3 5 How to Transport Using Forklift Truck HX300 400 200L 200L 2000 300L 3 6 Fig 3 6 Dimension of Robot 3 9 Fig 3 7 Accuracy of Installation surface 3 10 Fig 3 8 Wrist Axis Torque 3 14 Fig 3 9 Wrist Axis Torque Mapping 400 3 14 Fig 3 10 Wrist Axis Torque Mapping 2000 3 15 Fig 3 11 Recommended
85. seal due to the gear attached to the axis of motor 7 Detach the gear from the motor shaft not give excessive impact to the motor shaft 8 Assemble the gear after lightly applying grease to the shaft The bolt used to attach the gear to the shaft should be cleaned and removed of grease before using Apply loctite 243 to the screw part of the bolt and then tighten it using a torque wrench in a regular torque Besides slowly tighten the bolt in a symmetrical order 9 Assemble the motor on the robot after applying a small amount of grease to the lip of oil seal and applying a moderate amount of grease to the teeth of gear When assembly the main axis motor be sure not to damage the lip of oil seal 10 Connect the connector to the motor 11 When repalcing the axis H or V replenish the grease as the amount as it lost 12 Reset the encoder of the axis whose motor is replaced 6 13 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 A Warning Before encoder correction check motor connections with motors ON while pressing the Enable switch for 2 3 seconds 13 Perform the encoder calibration about the axis whose motor is replaced Refer to the chapter Encoder Calibration in the controller operating manual 14 Remove M20 bolt a supporting bolt for preventing possible dropping of axis H or V 15 Confirm that there is no error in robot s motion HYUNDAI m HEAVY INDUSTRIES CO
86. t the robot handling work should be carried out only by the operators who completed this training course The Users of HR and HX industrial robots have a responsibility under the safety relavant regulations valid in the country where the robot is installed and responsibility to properly design install and operate the safety devices to protect workers The dangerous zone of robot system that is the working range in which the robot tool and peripheral equipment are operated must be safeguarded to prevent workers or objects from entering the zone If a person or object should nevertheless enters the dangerous zone make sure that the robot system is immediately shut down by emergency stop system The operators of robot system have a responsibility to take all necessary steps to make correct installation examination and operation of the relevant safety devices This manual is provided for the utilization of HR and HX Series Manipulator models and Hi4a controller Valid application and invalid environment of HR and HX Series robots are as follows Application HYUNDAI HEAVY INDUSTRIES CO LTD 1 Safety It is applied to the 6 axis industrial robot used by installing on the surface of wall or plane axes addable It is also appropriate for controlling operation in the dotted section or consecutive section Major application is Spot welding Handling Assembly Application such as Sealing MIG MAG welding Palletizing G
87. the rear cover of the robot Check the batteries encoder backup batteries are well conneceted Turn the controller power ON After connecting the reset connector CNRST1 6 of the axis to reset with the plug located in the cover of the rear robot for 5 seconds pull the reset plug out Reset connectors of the respective axis should be connected for the reset work only Besides there is usually no connection in the reset connector Cover the rear of the robot 5 RST1 RST 1 lt RST 2 H RST2 RST 1 e RST 2 V RST3 RST 1 lt RST 2 R2 RST4 RST 1 lt RST 2 B RST5 RST 1 lt RST 2 R1 RST6 RST 1 lt RST 2 6 17 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 CNRST1 CONNECTER RST1 PSE MSE CNRST2 RST2 PSE MSE CNRST3 PSE MSE CNRST4 RST4 PSE MSE CNRST5 RSTS Encoder Wiring MBE CNRST6 RST6 PSE MSE CNRO4 Fig 6 2 Encoder Reset Connector HYUNDAI m HEAVY INDUSTRIES CO LTD 6 Trobleshoot ing 6 5 3 Confirming the Reset A Warning This operation is used to verify an encoder reset was performed correctly Note this procedure is different from Encoder C
88. the safety precautions for Hi4a controller maintenance and repair 2 Perform your maintenance and repair for the robot system and manipulator following the indicated procedures 3 Be sure to disconnect the primary power of controller Post the warning sign Do not input power up the primary power to prevent other workers from connecting the power 4 Make sure that the Arm is fixed and immovable before maintenance and repair since dropping or moving of the robot s Arm may cause a danger during maintenance and repair Refer to the Robot manipulator maintenance manual AHY HEAVY INDUSTRIES CO LTD 1 22 1 Safety Necessary Actions after Maintenance and Repair 1 Check if the cables or parts of controller are properly connected 2 After maintenance is completed carefully check that no tools are left around or inside of the controller and manipulator Make sure that the door is firmly closed 3 Do not turn on the power if any problems or critical failures are detected 4 Be sure that there is no one within the working envelope and that you are in a safe place before turning on the power 5 Turn on the main circuit breaker on the control panel 6 Check the current position and status of robot 7 Operate the manipulator at low speed 4 23 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 1 10 Safety Functions 1 10 1 Operating a Safety Circuit Contactor MSHP1 Co
89. tion Accidents such as conduction may occur in the working envelope contaminated by oil or scattered tools on its floor Make a habit of organizing and cleaning things up m HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 Safety Precautions for Operating Test In case of operating test errors in design or teaching and inferiority in manufacturing are possibly seen in the entire system such as teaching program jig and sequence Thus be more careful and safe in case of operating test Accidents may occur by these combined causes 1 Before handling check the stop buttons and signal functions to stop the robot 3 such aS emergency stop button or stop button And then check the abnormality detective movements Above all it is the most critical to check all the stop signals It would be the most important to stop the robot when any possible accidents are predicted In case of operating test start the robot at low speed approximately 20 30 in the variable speed function and repeat it more than one cycle to check the movements If any errors are found immediately correct them After then increase in speed 50 75 100 gradually and repeat more than one cycle respectively to check the movements Operating at high speed from the very beginning may cause a serious accident In case of operating test it is hard to predict what problems would happen Do not enter the safety f
90. to compliance with these operating instructions and the operation and maintenance manual supplied together with the robot system The safety related functions of robot system must not be used for any purposes other than safety When you use the robot system for any other or additional purposes than its designated usage you must review whether it is valid in accordance with design criteria The manufacturers cannot take any responsibility for any damage or loss which resulted from such misuse or improper use The users shall have the full responsibility for the risks caused by such misuse or improper use When you use and operate the robot system for its designated use you must have a good command of all the information contained at these operating instructions as well as the maintenance manual The robot system may not be put into operation until it is ensured that the functional machine or plant into which the robot system has been integrated conforms to the specifications of the EC directives 89 392 EWG dated 14 June 1989 and 91 368 EWG dated 20 June 1991 The following harmonized standards in particular were taken into account with regard to the safety of the robot system IEC 204 1 10 7 ISO 11161 3 4 ISO 10218 EN 775 6 4 3 ISO 10218 EN 775 3 2 17 ISO 10218 EN 775 3 2 8 ISO 10218 EN 775 3 2 7 HYU HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 Users must take the full responsibility for any accident c
91. trained in an approved robotic training course and become familiar enough with the proper operation of the safety and robotic functions 2 Be sure to wear helmets goggles and safety shoes 3 Perform the work in pairs One person must be ready to press the emergency stop button in an emergency while the other must perform his work quickly but carefully within the robot s working envelope Always check the escape route before working 4 Make sure that there is no one in the working envelope when the power source is on 5 Operations such as teaching must be performed outside of the robot s working envelope However if the operation is performed within the working envelope after stopping the robot enter the envelope with safety plug or key switch for converting to automatic mode Make sure that other operators do not change it into automatic mode by accident Also pay close attention to the specific direction of robotic movement in case of abnormal operation and malfunction 6 Supervisors should follow the instructions below CD Be located at a place where you could take an entire view of robot and commit yourself to monitoring 2 Press the emergency stop button immediately when abnormality is found 8 Anyone is forbidden to be near the operating area other than those who are engaged in the operation 7 In a manual mode the speed of teaching is limited to 250mm sec 8 In teaching post a sign Under Teaching ias H
92. w grease can be distinguished from the old one by color 6 Wipe the outlet port with a cloth and reinstall the inlet outletplug with seal tape DOO HYUNDAI m HEAVY INDUSTRIES CO LTD 5 Maintenance 5 1 6 R1 Axis Reduction Gear Grease outlet Plug PT1 4 gt Grease inlet Grease nipple A PT1 8 Attention Do not inject excessive grease The excessive grease would cause an abnormal operation m Grease Replenishment D Remove the grease outlet plug 2 Inject the grease into the grease inlet using a grease gun Grease type Molywhite REOO Amount of grease 200cc 3 Wipe the outlet port with a cloth and attach the outlet plug with seal tape HYUNDAI HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 m Grease Replacement CD Remove the grease outlet plug 2 Inject the grease into the grease inlet using a grease gun Y Grease type Molywhite REOO v Amount of grease 435cc 3 The grease replacement is complete when new grease appears in the outlet port The new grease can be distinguished from the old one by color 4 Wipe the outlet port with a cloth and attach the outlet plug with seal tape HYUNDAI Pu HEAVY INDUSTRIES CO LTD 5 Maintenance 5 1 7 Bearing Joint Parts Grease inlet Grease nipple A PT1 8 Grease inlet Grease nipple A PT1 8 Grease inlet Grease nipple A PT1 8 Grease in
93. w might not be attained due to the limited space and time caused by peripheral equipment or cycle times then contact our company Fig 3 11 Recommended Standby Posture HYUNDAI HEAVY INDUSTRIES CO LTD prar T Q 7 2 4 4 Inspection HX200 HX200L 2000 HX300 HX300L HX400 This chapter provides the instructions for regular inspection and overhaul necessary for the prolonged lifetime of robot performance 4 1 Inspection Item and Period Inspection is positively necessary to continue and maintain the high performance of robot for long term operation There are daily inspection and regular inspection Table 4 1 shows basic periods for regular inspections so inspectors should make an inspection according to the indicated periods And overhaul every 35 000 operating hours The inspection periods have been reviewed for SPOT Welding In case of high precision work such as handling it is recommended to inspect at the half intervals of that period as shown in Table 4 1 Table 4 1 Inspection Schedule 6 months 9 months 12 months 3 months 6 months 9 months 12 months 6 months 9 months 1 year 1 year amp 3 months 1 year amp 6 months 1 year amp 9 months 2 years AHY HEAVY INDUSTRIES CO LTD Daily Inspection 4 2 Inspection Item and Period Table 4 2 Inspection Items a
94. wable moment of inertia Lg lt Allowable moment of inertia Load Weight 30 kg m 200 kg 0 387 m gt 0 35 m 2 From the above result the maximum distance from the center of R1 axis becomes 0 35 m being restricted by the allowable moment of inertia HYUNDAI 235 HEAVY INDUSTRIES CO LTD 3 Instructions Allowable position of the center of gravity from the center of Axis The center of B axis is on the same axis of this robot and the value of the allowable load torque and allowable moment of inertia of B and R2 axes are the same Therefore if the allowable condition on the B axis is satisfied it guarantees to satisfy that on the R2 axis CD Allowable position of the center of gravity from the allowable torque Lg lt Allowable Torque Load Weight Lg 1668 200Kgx9 8 m s 0 851 2 Allowable position of the center of gravity from the allowable moment of inertia lt Allowable moment of inertia Load Weight 150 kg m 200 kg 0 866 m gt 0 851 m From above result the maximum distance from the center of B axis becomes 0 851m being restricted by the allowable moment of inertia 3 13 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 Torque Map c L Ri mm Oo 600 ur 466 50 3501 3 1 1 280 Y
95. with the operation key on the teaching pendant Refer to constant setting controller operation manual The safety circuits must never be by passed modified or changed in any way 4 25 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 1 10 2 Emergency stop An emergency stop should be activated when people or equipment is located at the dangerous area The emergency stop buttons are located both on the control panel and on the teaching pendant All safety control devices such as emergency stop buttons on the control panel must be located outside the working envelope and easily accessible at any time Status of Emergency stop When the button is pressed the robot will operate as follows Robot stops immediately in any cases Disconnect the servo system power Motor brake is activated Emergency stop message is displayed on screen For the emergency stop the following two methods can operated simultaneously Emergency stop for control panel and teach pendant is basic HYUNDAI Vo HEAVY INDUSTRIES CO LTD 1 Safety 1 Emergency stop for control panel and teach pendant Basic The emergency stop switch is on the control panel and teach pendant of the controller Emergency stop switch Fig 1 6 Emergency Stop 1 27 HY HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 2 Emergency stop of external system External emergency stop device button
96. work After replacing axis H or V ensure that M20 bolt for supporting ARM has been removed before operating the robot HYUNDAI 6 1 1 HEAVY INDUSTRIES CO LTD HX200 HX200L 2000 HX300 HX300L HX400 6 4 1 Necessary Tools and Parts Table 6 3 Necessary Tools Torque wrench prepared by user V M12 Torque wrench Lock type Use torque wrench R2 B R1 M8 Torque wrench Lock type M5 Torque wrench Lock type and extension on the market Table 6 4 Necessary parts main axes H V M20x250 Standard Dropping preventive bolt optional Wrist Axis R2 B R1 HY HEAVY INDUSTRIES CO LTD 6 12 6 Trobleshoot ing 6 4 2 How to Replace Motor 1 Put the controller into TEACH mode and select motors ON When the motors On state cannot be obtained check the respective ARM is firmly fixed while supporting it to prevent dropping And then begin at step No 4 2 The axis requiring motor replacement takes basic posture 3 In case of main axes S V Refer to Fig 6 1 Insert a supporting bolt to prevent ARM dropping In case of wrist axes R2 B R1 Set the origin by using SACLES 4 Turn the main power OFF with the controller power OFF 5 Disconnect the connector from the motor 6 Remove attachment bolts of motor and pull the motor out of robot When removing motors of axis H or V be sure not to damage the lip of oil

Hyundai HX200L-2000 User's Manual

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