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Mitsubishi Electronics RV

1. IE ea 7g 2 Setting the parameters 1 Change the values of the first element J1 axis minus side and second element J1 axis plus side of the joint operating range parameter MEJAR Set the value to the angle corresponding to the position where the operating range change stopper was inserted in 1 Setting the robot arm above Refer to the separate Instruction Manual Detailed Explanation of Functions and Operations for details on changing the parameter 2 When completed changing the parameters turn the controller power OFF and ON Move the waist axis to the operating range limit with JOINT jog operation and confirm that the limit over occurs and the robot stops at the angle changed for both the sides This completes setting the parameters and the changing of the operating range Changing the operating range 3 317 4Basic operations 4 Basic operations The basic operations from creating the program to automatic operation are explained in section 4 Basic operations in the From Controller Setup to Maintenance manual Refer that manual as necessary 4 38 Maintenance and Inspection 5 Maintenance and Inspection The maintenance and inspection procedures to be carried out to use the robot for a long time without trouble are described in this chapter The types and replacement methods of consumable parts are also explained 5 1 Maintenance and inspection interval Maintenance and inspection
2. Visual After turning the power ON Turn the power ON while monitoring the robot 1 Is there any abnormal motion or abnormal noise when the power is Follow the troubleshooting section turned ON During operation try running with an original program 1 Check whether the movement points are deviated Follow the troubleshooting section Check the following points if there is any deviation 1 Are any installation bolts loose 2 Are any hand installation section bolts loose 3 Are the positions of the jigs other than the robot deviated 4 If the positional deviation cannot be corrected refer to Troubleshooting check and remedy 2 Is there any abnormal motion or abnormal noise Follow the troubleshooting section Visual 5 40 Jnspection items 5 2 2 Periodic inspection Carry out periodic inspection with the procedures given in Table 5 2 5Maintenance and Inspection Table 5 2 Periodic inspection items details Procedure Inspection item details Remedies Monthly inspection items 1 Are any of the bolts or screws on the robot arm loose Securely tighten the bolts 2 Are any of the connector fixing screws or terminal block terminal Securely tighten the screws screws loose 3 Remove the cover at each section and check the cables for wear Check and eliminate the cause damage and adherence of foreign matter If the cables are severely damaged contact the Mitsubi
3. N CAUTION N CAUTION N CAUTION CAUTION N WARNING N CAUTION N CAUTION 1 4 Safety Precautions Use the robot within the environment given in the specifications Failure to do so could lead to a drop or reliability or faults Temperature humidity atmosphere noise envi ronment etc Transport the robot with the designated transportation posture Transporting the robot in a non designated posture could lead to personal injuries or faults from drop ping Always use the robot installed on a secure table Use in an instable posture could lead to positional deviation and vibration Wire the cable as far away from noise sources as possible If placed near a noise source positional deviation or malfunction could occur Do not apply excessive force on the connector or excessively bend the cable Failure to observe this could lead to contact defects or wire breakage Make sure that the workpiece weight including the hand does not exceed the rated load or tolerable torque Exceeding these values could lead to alarms or faults Securely install the hand and tool and securely grasp the workpiece Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation Securely ground the robot and controller Failure to observe this could lead to mal functioning by noise or to electric shock accidents Indicate the operation state during robot operation Failure to i
4. N CAUTION N GAUTION N CAUTION ANWARNING N CAUTION N CAUTION Use the robot within the environment given in the specifications Failure to do so could lead to a drop or reliability or faults Temperature humidity atmosphere noise environ ment etc Transport the robot with the designated transportation posture Transporting the robot in a non designated posture could lead to personal injuries or faults from dropping Always use the robot installed on a secure table Use in an instable posture could lead to positional deviation and vibration Wire the cable as far away from noise sources as possible If placed near a noise source positional deviation or malfunction could occur Do not apply excessive force on the connector or excessively bend the cable Failure to observe this could lead to contact defects or wire breakage Make sure that the workpiece weight including the hand does not exceed the rated load or tolerable torque Exceeding these values could lead to alarms or faults Securely install the hand and tool and securely grasp the workpiece Failure to observe this could lead to personal injuries or damage if the object comes off or flies off during operation Securely ground the robot and controller Failure to observe this could lead to malfunc tioning by noise or to electric shock accidents Indicate the operation state during robot operation Failure to indicate the state could lead to operators app
5. A CAUTION Take special care to the leading of the connection cable If the cable is pulled with force or bent excessively wires could break or the connector could be damaged Installation 2 11 2Unpacking to Installation 2 3 Setting the origin The origin is set so that the robot can be used with a high accuracy After purchasing the robot always carry out this step before starting work This step must also be carried out if the combination of robot and controller being used is changed There are several methods for setting the origin but the origin data input method will be explained here Refer to 5 5 Resetting the origin on page 53 for the other methods The teaching pendant is required for this operation Caution If the origin data at shipment is erased due to out of battery it is necessary to set the origin again Refer to 5 5 Resetting the origin on page 53 and reset the origin using the jig method or ABS origin method 2 3 1 Installing the teaching pendant T B By using the REMOVE T B switch the T B can be installed and removed while the controller s control power is ON However in this procedure the teaching pendant will be installed with the control power OFF Refer to the separate Controller setup basic operation and maintenance for details on installing the teaching pendant with the control power ON 1 Installing with the control power OFF Display LCD ENABLE DISABLE switch 1 Confi
6. Solenoid valve installing the option devices 8 When you have completed the installation reinstall the No 2 arm cover B lt 2 gt to its original position and be careful not to entangle the cables when you do so The connections after the installation appear as in Table 3 1 for single type valves hand 2 is not applicable Table 3 1 Solenoid valve ports and hoses Correspondence of couplings and hand ports Hand Hand port Solenoid valve port Solenoid valve used OPEN Hand 1 First set CLOSE B OPEN A Hand 2 Second set CLOSE B OPEN A Hand 3 Third set CLOSE B OPEN A Hand 4 Fourth set CLOSE B Installing the solenoid valve set 1S VD01 02 VD02 02 VD03 02 VD04 02 3 33 3Installing the option devices uc A M gest 3 2 Installing the hand input cable The procedure for installing the hand input cable is as follows Conduct work by referring to Fig 3 1Solenoid valve installation procedures on page 31 and Fig 3 4Installing the hand input cable on page 34 below This work must be carried out with the controller power turned OFF X4 Socket bolts M4 X 8 4 bolts Grommet Remove Remove Grommet lt 3 gt No 2 arm cover C Fig 3 4 Installing the hand input cable 1 Remove the hexagon socket bolts five M4 x 10 and truss screw three M3 x
7. When the MOVE A J4 keys are pressed the J4 axis will rotate in the plus direction When the MOVE A J4 keys are pressed Rotate in the minus direction When the MOVE B J5 keys are pressed the J5 axis will rotate in the plus direction When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE C J6 keys are pressed the J6 axis will rotate in the plus direction When the MOVE C J6 keys are pressed Rotate in the minus direction 2 28 Confirming the operation 2Unpacking to Installation 5 CYLNDER jog operation Select the cylindrical jog mode CYLNDER LOW Press the MOVE XYZ keys and then press R 134 50 XYZ only the XYZ key CYLNDER will appear at the T 220 00 M upper left of the screen Z 280 00 CYLNDER jog mode Each time the MOVE keys are pressed the Set the jog speed override will increase in the order of LOW HIGH CYLNDER LOW gt 3 gt 5 gt 10 30 50 70 100 When the MOVE 7 keys are pressed the override will R 134 50 T 422000 step 4l t decrease in the reverse order The currently set Z 4280 00 M TONES MOVE FORWD BACKWD speed will appear on the upper right of the screen Set the override to 10 here for confirmation work Moving along an arc centering on the Z axis STEP Z e 8 Y TZ u1 Radius Control point The directi
8. Hold down the CHAR key and press the key with the character to be input on the lower right Three characters will scroll each time the character key is pressed Q O Correcting an input O O After returning one character by pressing the DEL key input the character again 6 Installing the shoulder coverB Return the shoulder coverB removed in section 1 Confirming the origin data on page 13 to its original position This completes the setting of the origin with the origin data input method Always remove and install the cover with the controller power turned OFF Failure AN WARNING to do so could lead to the robot moving because of incorrect operations or to physical damage or personal injury Q O If the origin input data is incorrect O O If the origin input data is incorrect the alarm No 1760 origin setting data illegal will occur when origin data input In this case reconfirm the value input for the origin data Setting the origin 2 17 2Unpacking to Installation 2 4 Confirming the operation In this section the robot will be moved manually using the T B to confirm that the operation is correct Moving the robot manually is called jog operation This operation includes the JOINT jog that moves each axis the XYZ jog that moves along the base coordinate system the TOOL jog that moves along the tool coordinate system and the CYLNDER jog that moves along the circular arc This operation is carried out
9. RUN PR gt INIT 1 Press the 5 key on the Menu screen to select 3 FILE 4 MONI 3 BRAKE 4 ORIGIN LE eer oen 5 MAINT 6 SET 5 POWER fs Select the maintenance screen en lt MAINT gt lt ORIGIN gt 1 PARAM 2 INIT 1 DATA 2 MECH 2 Press the 4 key to select the Origin Setting 3 BRAKE 4 ORIGIN gt 3 JIG 4 ABS screen 5 POWER 5 USER y J2 Select the Origin Setting screen A MNO lt ORIGIN gt lt TOOL gt Ge ne P x e 3 Press the 3 key to select the jig method Then 5 USER i 1 EXECUTE press the 1 key and the INP key to turn the servo OFF Z B INP Then cancel the brake of each axis move the ET EE arm with both hands and secure it with the OP jig AN CAUTION At this point release the brakes and move the arm with both hands To ensure safety the brake release procedure described below should always be done by two persons 5 54 Resetting the origin 5Maintenance and Inspection 1 J1 axis origin setting lt TOOL gt 12345678 1 Move the J1 axis slowly toward the front using BRAKE 00000000 both hands Align the pinhole of the No 1 arm SET AXIS 11110000 E and the pinhole at the base section feed ORIGIN NOT DEF J5 through the origin jig 8 into the pinholes and Designate the origin setting axis 1 DEF fasten mm Ss L EI L b Pinhole J1 axis Diagram of the robot viewed from the to 2 Press the key The cursor w
10. RV 6SL f Truss screw M4 X 8 4 g Truss screw M4 X 8 5 h Truss screw M3 X 10 2 i Flat head screw M4 xX 8 4 1 Refer to Fig 5 3 and remove the cover 2 The names of the covers are given in Table 5 3 and a list of the cover installation screws is given in Table 5 4 3 There are some covers that may be difficult to remove due to the robot posture In this case change the robot posture with jog operation and then remove the cover 4 When attaching the cover after maintenance and inspection use the detaching procedure in reverse The part Nos and symbols in Table 5 3 and Table 5 4 correspond to Fig 5 3 Maintenance and inspection procedures 5 45 5Maintenance and Inspection 5 3 3 Inspection maintenance and replacement of timing belt This robot uses a timing belt for the drive conveyance system of the J5 axis Compared to gears and chains the timing belt does not require lubrication and has a low noise However if the belt usage method and tension adjust ment are inadequate the life could drop and noise could be generated Sufficient aging to remove the initial elon gation of the belt and adjustment of the belt tension have been carried out before shipment from the factory However depending on the robot working conditions elongation will occur gradually over a long time The tension must be confirmed during the periodic inspection The timing belt must be replaced in the following cases 1 Timi
11. 3 2 Installing removing J5 Z21J Z the cover on page 44 remove the J6 A12 Z0 shoulder coverB and confirm the value Method E E N SP E Ne E N SP SP The value given in the default setting O AlphabetO 0 Zero column is the origin settings set with the Note Meanings of symbols in method column calibration jig before shipment E Jig method N Not used SP Not used Fig 2 8 Origin data label an example N WARNING Always install remove the cover with the controller control power turned OFF Failure to do so could lead to physical damage or personal injury should the robot start moving due to incorrect operations 2 Turning ON the control power AN CAUTION Confirm that there are no operators near the robot before turning the power ON 1 Turn the controller POWER switch ON The control power will be turned ON and L1 100 will appear on the STATUS NUMBER display on the front of the controller Setting the origin 2 13 2Unpacking to Installation 3 Preparing the T B STATUS NUMBER S 1E DISABLE ENABLE Next prepare to use the T B 1 Set the MODE switch on the front of the controller to TEACH 2 Set the T B ENABLE DISABLE switch to ENABLE The menu selection screen will appear The following operations are carried out with the T B Q O Operating from the T B O O Always set the MODE switch mode selection key switc
12. E 1 Slowly rotate the J4 axis to the plus direction oe with both hands Align the pinholes of the No 2 Designate the origin setting axis arm and elbow feed through the origin jig 6 into the pinholes and fasten Pinhole J4 axis RPL 1 Move the cursor lt TOOL gt 12345678 2 Press the key The cursor will move to BRAKE 00000000 SET AXIS SET AXIS 00010000 B C INP ORIGIN NOT DEF cs us aca Designate the origin setting axis 1 DEF VO ABG 3 Designate the axis for which the origin is to be set Set 1 for the 4 axis and set 0 for the other axes Then press INP key Next a confirmation screen will appear lt TOOL gt SET ORIGIN OK 1 1 EXECUTE E 4 Press the 1 and INP keys Set the origin 1 DEF The origin posture will be set lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 00010000 ORIGIN COMPLETED 5 Setting of the origin is completed 6 Refer to 5 5 4Recording the origin data on page 65 in this manual and record the origin data on the origin data seal OS Origin setting axis designation G4 Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 5 58 Resetting the origin 5Maintenance and Inspection 5 J5 axis
13. If the origin is not to be set press the 0 key and display a 0 Resetting the origin 5 59 5Maintenance and Inspection 6 J6 axis origin setting lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN ae DEF B 1 Slowly move the J6 axis with both hands and align the ABS mark of the wrist housing with the Designate the origin setting axis oe ABS mark of the hand mounting flange Bolt M5 2 bolts Prepared by customer AN CAUTION The J6 axis dose not have a mechanical stopper When setting the origin position do not rotate the axis more than themotion range 200 deg RPL Move the cursor 2 Press the key The cursor will move to SET AXIS lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 00000100 3 Designate the axis for which the origin is to be ORIGIN NOT DEF Mud set Set 1 for the 6 axis and set 0 for the ad toe Ee Ed EXE other axes Then press INP key Next a confirmation screen will appear B J5 J6 1 DEF 0 ABC TOOL SET ORIGIN OK 1 4 Press the 1 and INP keys 1 EXECUTE The origin posture will be set Set the origin Urs lt TOOL gt 12345678 5 Setting of the origin is completed BRAKE 00000000 SET AXIS 00000100 ORIGIN COMPLETED 6 Refer to 5 5 4Recording the origin data on page 65 in this manual and record the origin data on the origin data seal OS Origin setting axis
14. are divided into the inspections carried out daily and the periodic inspections carry out at set intervals Always carry these out to prevent unforeseen trouble to maintain the product for a long time and to secure safety 1 Inspection schedule In addition to the monthly inspection add the following inspection items every three months estimated at 500 Hr operation hours O Hr Monthly inspection Monthly inspection 500 Hr Monthly inspection 3 month inspection Monthly inspection S Monthly inspection Pe o 2 1000 Hq 2 Monthly inspection 3 month inspection 6 month inspection gt Monthly inspection Monthly inspection 1500 H Monthly inspection 3 month inspection Monthly inspection Monthly inspection 2 OO O H Monthly inspection 3 month inspection 6 month inspection Yearly inspection 6000H Monthly inspection 3 month inspection 6 month inspection Yearly inspection 3 year inspection Operating time lt Guideline for inspection period gt For one shift 8 Hr day X 20 days month X 3 months approx 500 Hr 10 Hr day X 20 days month X 3 months approx 600 Hr For two shifts 15 Hr day X 20 days month X 3 months approx 1000 Hr Caution When using two lines the 3 month inspection 6 month inspection and yearly inspection must be carried out when half the time has passed Fig 5 1 Inspection schedule Maintenance and inspection interval
15. arm structure An outline structure drawing is shown in Each part is as shown below 1 The J1 axis rotation is driven by the J1 axis motor lt 1 gt and reduction gears lt 2 gt arranged in the base Non excitation magnetic brakes are mounted in the Jlaxis motor 125 2 The J2 axis rotation is driven by the J2 axis motor X3 and reduction gears lt 4 gt arranged in the shoulder Non excitation magnetic brakes are mounted in the J2 axis motor 37 3 The J3 axis rotation is driven by the J3 axis motor 5 and reduction gears lt 6 gt arranged in the shoulder Non excitation magnetic brakes are mounted in the J3 axis motor 55 4 The J4 axis rotation is driven by the J4 axis motor lt 7 gt and reduction gears lt 8 gt arranged in the elbow block Non excitation magnetic brakes are mounted in the J4 axis motor lt 7 gt 5 The rotation of the J5 axis motor 9 arranged in the forearm is conveyed to the reduction gears lt 11 gt via the timing belt lt 10 gt to rotate the wrist housing and following parts Non excitation magnetic brakes are mounted in the J5 axis motor 9 6 The rotation of the J6 axis is driven by the J6 axis motor lt 12 gt arranged in the wrist housing and the reduc tion gears lt 13 gt Non excitation magnetic brakes are mounted in the J6 axis motor lt 12 gt 5 42 Maintenance and inspection procedures Maintenance and Inspection 8 gt J6 axis lt 7 gt J4 axis motor EO axis motor reduction
16. gear lt 9 gt J5 axis motor F Elbow Fore arm lt 12 gt J6 axis motor lt 13 gt J6 axis reduction gear lt 6 gt J3 axis reduction gear Upper arm lt 2 gt J1 axis reduction gear lt 3 gt J2 axis motor lt 4 gt J2 axis reduction gear lt 1 gt J 1 axis motor Fig 5 2 Outline structure of robot arm Maintenance and inspection procedures 5 43 5Maintenance and Inspection 5 3 2 Installing removing the cover f T f 6 No 2 arm cover C a 3 No 1 arm cover Fig 5 3 Installing removing the cover AN CAUTION Check to see that the packing has not been peeled off when the cover was mounted removed If it has been peeled off report to dealer If the cover is used with the packing peeled off oil mist and others may enter inside the arm and cause a breakdown 5 44 Maintenance and inspection procedures Table 5 3 Cover names 5Maintenance and Inspection No Cover names Qty Remarks 1 Bottom plate 1 2 Shoulder cover B 1 3 No 1 arm cover 1 4 Shoulder cover 2 5 Elbow cover A 1 6 No 2 arm cover C 1 7 No 2 arm cover A 1 8 No 2 arm cover B 1 9 Wrist cover 1 Table 5 4 Cover installation screw list No Installation screw name Q ty Remarks a Socket bolt M4 x 8 8 b Socket bolt M4 x 10 10 c Socket bolt M4 x 30 4 d Socket bolt M4 X 55 8 e Truss screw M4 X 8 8 RV 6S 10
17. lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 00100000 B C INP ORIGIN NOT DEF ld Ge Designate the origin setting axis 1 DEF DABG lt TOOL gt SET ORIGIN OK 1 B INP 1 EXECUTE Set the origin 1 DEF lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 00100000 ORIGIN COMPLETED OS Origin setting axis designation G4 1 Slowly rotate the J3 axis to the plus direction with both hands Align the pinholes of the No 1 and No 2 arm feed through the origin jig 8 into the pinholes and fasten 2 Press the key The cursor will move to SET AXIS 3 Designate the axis for which the origin is to be set Set 1 for the 3 axis and set 0 for the other axes Then press INP key Next a confirmation screen will appear 4 Press the 1 and INP keys The origin posture will be set 5 Setting of the origin is completed 6 Refer to 5 5 4Recording the origin data on page 65 in this manual and record the origin data on the origin data seal Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 71 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 Resetting the origin 5 51 5Maintenance and Inspection 4 J4 axis origin setting lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN ee DEF
18. origin setting lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 11110000 1 Slow he J5 axis in the di fol ORIGIN NOT DEF B owly rotate the ane in the neehion of plus d 90 with both hands Align the pinholes of the DEF Designate the origin setting axis No 2 arm and wrist housing feed through the origin jig 6 into the pinholes and fasten Pinhole J5 axis RPL 1 Move the cursor lt TOOL gt 12345678 2 Press the key The cursor will move to BRAKE 00000000 SET AXIS SET AXIS 00001000 B C INP ORIGIN NOT DEF ws 4 ue Be Designate the origin setting axis 1 DEF VO ABG 3 Designate the axis for which the origin is to be set Set 1 for the 5 axis and set 0 for the other axes Then press INP key Next a confirmation screen will appear TOOL SET ORIGIN OK 1 1 EXECUTE E 4 Press the 1 and INP keys Set the origin 1 DEF The origin posture will be set lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 00001000 ORIGIN COMPLETED 5 Setting of the origin is completed 6 Refer to 5 5 4Recording the origin data on page 65 in this manual and record the origin data on the origin data seal Q9 O Origin setting axis designation OO Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen
19. the shoulder coverB 2 Confirming the origin data Confirm the value displayed on the teaching pendant s Origin Data Input screen Refer to 2 3 2Setting the origin with the origin data input method 5b Inputting the origin data and display the Origin Data Input screen on the teaching pendant display screen 3 Recording the origin data Write the origin data displayed on the teaching pendant to the origin data label attached to the back of the shoul der coverB Refer to Fig 2 8Origin data label an example on page 13 and Fig 2 9Correspondence of origin data label and axis on page 16 for details on the origin data label 4 Installing the cover Install the shoulder coverB removed in step 1 Confirming the origin data label above Refer to 5 3 2Installing removing the cover on page 44 and replace the shoulder coverB This completes the recording of the origin data Resetting the origin 5 65 6Appendix 6 Appendix Appendix 1 Configuration flag The configuration flag indicates the robot posture For the 6 axis type robot the robot hand end is saved with the position data configured of X Y Z A B and C However even with the same position data there are several postures that the robot can change to The posture is expressed by this configuration flag and the posture is saved with FL1 in the position constant X Y Z A B C FL1 FL2 The types of configuration flags are shown below 1 RIGHT
20. unstable place c Fig 2 1 Unpacking the robot arm The robot is shipped from the factory in cardboard and wooden frame packing Always refer to Fig 2 1 and unpack the robot Handle the robot arm according to 2 2 2 Transportation procedures Transporting with a crane The unpacking process is shown below 1 Using a knife etc slit the tape lt 1 gt fixing the upper lid 2 of the cardboard box Fig 2 1 a 2 Pull the upper lid X2 of the cardboard box off with both hands Fig 2 1 b 3 Remove the hexagon socket bolts 3 four positions connecting the sleeper and the base unit Fig 2 1 c 4 This completes the unpacking Fig 2 1 c 2 6 Installation 2Unpacking to Installation 2 2 2 Transportation procedures Transporting with a crane Fixing plate o o eo Suspension fitting Hexagon socket bolt four M10 x 25 four spring washers for M10 yo Front Side Fig 2 2 Transportation procedures transporting with a crane 1 Attach the suspension fittings to the left and right sides of the shoulder section and securely fix with bolts four M10 x 25 four spring washers for M10 At this time fix two of the suspension fitting s three holes at the side closest to the robot front 2 Catch wires in the eye bolts installed on the suspension fittings and quietly suspend the arm 3 At this time make sure that the wires etc do not interfere with the robot arm or cove
21. while maintaining the flange surface position the flange surface posture changes Fig 2 12 TOOL jog operation Confirming the operation 2 19 2Unpacking to Installation Control point The axis moves straight along the base coordinate system At this time the flange surface posture is not maintained Also the flange surface posture changes The flange surface position changes at this time Fig 2 13 3 axis XYZ jog operation Radius Control point The current position is set as the arc centering on the Z axis and the axis moves along that arc expands and contracts in the radius direction and moves vertically At this time the flange surface posture is maintained Also while maintaining the flange surface position the flange surface posture changes Fig 2 14 CYLINDER jog operation 2 20 Confirming the operation 2Unpacking to Installation 1 JOINT jog operation Select the JOINT jog mode Press the MOVE JOINT keys to select the JOINT LOW JOINT jog mode JOINT will appear at the upper Ji 34 50 JOINT left of the screen J2 420 00 UP J3 80 00 JOINT jog mode Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH Set the jog speed 3 5 gt 10 30 50 70 100 When the MOVE keys are pressed the JOINT LOW override will decrease in the reverse order Ji 34 50 STEP a The curre
22. while pressing the deadman switch on the back of the T B AN CAUTION The robot will move during this operation Make sure that there are no operators near the robot and that there are no obstacles such as tools in the robot operation range N CAUTION To immediately stop the robot release the deadman switch on the back of the T B The servo power will turn OFF and the robot will stop The robot will also stop if the EMG STOP switch emergency stop switch on the front of the T B or the EMG STOP switch emergency stop on the front of the controller is pressed AN WARNING Confirm that the origin has been set If the origin has not been set X will appear at the current position display on the teaching pendant the JOINT jog oper ation will take place in any jog mode selected Refer to 2 3 Setting the origin on page 12 for details on setting the origin J3 axis Jo axis QQ Pe ML C T J6 axis J2 axis Each axis moves independently Fig 2 10 JOINT jog operation 2 18 Confirming the operation 2Unpacking to Installation Control point While maintaining the flange surface posture the axis moves straight along the base coordinate system Also while maintaining the flange surface position the flange surface posture changes Fig 2 11 XYZ jog operation EZ Control point While maintaining the flange surface posture the axis moves straight along the tool coordinate system Also
23. 5 39 5Maintenance and Inspection 5 2 Inspection items The inspection items for the robot arm are shown below Also refer to section 5 Maintenance and inspection in the Controller setup basic operation and maintenance manual and inspect the controller 5 2 1 Daily inspection items Carry out the daily inspections with the procedures given in Table 5 1 Table 5 1 Daily inspection items details Procedure Inspection item details Remedies Before turning power ON Check the following items before turning the power ON 1 Are any of the robot installation bolts loose Securely tighten the bolts Visual 2 Are any of the cover tightening screws loose Securely tighten the screws Visual 3 Are any of the hand installation bolts loose Securely tighten the bolts Visual 4 Is the power supply cable securely connected Securely connect Visual 5 Is the machine cable between the robot and controller securely Securely connect connected Visual 6 Are there any cracks foreign contamination or obstacles on the robot Replace with a new part or take remedial measures and controller cover 7 Is any grease leaking from the robot arm After cleaning replenish the grease Visual 8 Is there any abnormality in the pneumatic system Are there any air Drain the drainage and remedy the air leaks replace leaks drain clogging or hose damage Is the air source normal the part
24. 8 that hold the No 2 arm cover B lt 2 gt and then remove both the No 2 arm cover B 2 2 Remove the socket bolts lt 4 gt four M4 x 8 that hold the No 2 arm cover C lt 3 gt or the solenoid valves lt 5 gt and then remove the No 2 arm cover C lt 3 gt or the solenoid valves lt 5 gt 3 If you are not using the spare line ADD stored in a coil in section A shown in Fig 3 1 remove it The spare line is connected to a connector inside section A 4 The hand input cable can be installed to both the No 2 arm cover C lt 3 gt and the solenoid valves 55 5 Remove one of the two grommets on either the No 2 arm cover C lt 3 gt or the solenoid valves 5 After removing the grommet peal off the sealing material left on the hole section of the plate 6 After removing the lock nut attached to the hand input cable feed the connector side of the hand input cable with a cable clamp through the hole on the plate Replace the removed lock nut in position and fasten it securely 7 Connect the connectors of HC1 and HC2 stored in section A shown in Fig 3 1 to HC1 and HC2 of the hand input cable 8 Mount the No 2 arm cover C lt 3 gt or the solenoid valves lt 5 gt to section A shown in Fig 3 1 When mounting be careful not to damage the sponge sealing material attached to the opening of section A 9 When you have completed the installation reinstall the No 2 arm cover B lt 2 gt to its original positio
25. E C J6 keys are pressed Rotate in the minus direction Q When alarm No 5150 occurs O O If alarm No 5150 ORIGIN NOT SET occurs the origin has not been set correctly Reconfirm the value input for the origin data OS Tool length OO The default tool length is Omm and the control point is the center of the end axis After installing the hand set the correct tool length in the parameters Refer to the separate manual Detailed Explanation of Functions and Operations for details 2 26 Confirming the operation 2Unpacking to Installation 4 3 axis XYZ jog operation Select the 3 axis XYZ jog mode sade LOW Press the MOVE XYZ keys and then X 134 50 xyz xyz press only the XYZ key XYZ456 will appear X 220 00 E y at the upper left of the screen Z 280 00 3 axis XYZ jog mode Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH gt 3 gt 5 gt 10 gt 30 gt 50 70 gt Set the jog speed XYZ456 LOW 100 When the MOVE keys are pressed X 134 50 the override will decrease in the reverse order Y 220 00 ster im us The currently set speed will appear on the Z 280 00 Set the soeed MOVE J Ed BELY upper right of the screen Set the override to 10 here for confirmation work Moving along the base coordinate system TZ step Z ec Ls MOVE 8 oy TZ The flange position does change W
26. F inputting the origin data will appear OK aie INE E 1 EXECUTE N oer PE lt DATA gt D 000000 1 000000 000000 3 000000 000000 9 000000 000000 OS Selecting a menu C9 The menu can be selected with one of the following methods A Press the numeral key for the No of the item to be selected B Using the and 1 keys etc move the cursor to the item to be selected and then press the INP key Setting the origin 2 15 2Unpacking to Installation T B screen lt DATA gt D _D_ 1 J1 _J2_ 3 J3 _J4 J Jo _J6_ 5 Inputting the origin data Origin data label D J1 J2 J3 J4 J5 J6 Input the value confirmed in section 1 Confirming the origin data on page 13 The correspondence of the origin data label value and axis to be input is shown in Fig 2 9 Fig 2 9 Correspondence of origin data label and axis The method for inputting the origin data is explained below The value shown in Fig 2 8will be input as an example XT B screen lt DATA gt D WD0000 1 000000 000000 3 000000 000000 5 000000 000000 _ Keys used lt paTa gt D visboo 1 000000 000000 3 000000 000000 5 000000 000000 _ lt DATA gt D VI S29 1 b0000 000000 3 000000 000000 5 000000 000000 J d lt DATA gt D VI S29 1 A B amp 8F GHSY5 3 H 7 2H BEL DATA D ifj00000 1 000000 000000 3 000000 000000 Gas 5 000000 000000
27. If a word is enclosed in brackets or a box in the text this refers to a key on JOINT the teaching pendant This indicates to press the B key while holding down the A key In this example the Forward key is pressed while holding down the X Y key 7 FORWD X A B This indicates to hold down the A key press and release the B key and then press the C key In this example the Step Move key is held down the Condition key is pressed and released and the Replace key is pressed STEP MOVE H CONDI IRPL 17 A B C TYB This indicates the teaching pendant 1 2 Using the instruction manuals 1 2 Safety Precautions Before starting use Always read the following precautions and the separate Safety Manual before starting use of the robot to learn the required measures to be taken N CAUTION N CAUTION N WARNING N CAUTION N DANGER N CAUTION N CAUTION N CAUTION All teaching work must be carried out by an operator who has received special training This also applies to maintenance work with the power source turned ON Enforcement of safety training For teaching work prepare a work plan related to the methods and procedures of oper ating the robot and to the measures to be taken when an error occurs or when restart ing Carry out work following this plan This also applies to maintenance work with the power source turn
28. J6 axis ot 1 Confirming the origin data 2 Confirming the origin data 3 Recording the origin data Installing the cover ppendix 66 Appendix 66 Before starting use 1 Before starting use This chapter explains the details and usage methods of the instruction manuals the basic terminology and the safety precautions 1 1 Using the instruction manuals 1 1 1 The details of each instruction manuals The contents and purposes of the documents enclosed with this product are shown below Use these documents according to the application For special specifications a separate instruction manual describing the special section may be enclosed Safety Manual Explains the common precautions and safety measures to be taken for robot handling system design and manufacture to ensure safety of the operators involved with the robot Standard Explains the product s standard specifications factory set special specifications option Specifications configuration and maintenance parts etc Precautions for safety and technology when incorporating the robot are also explained Robot Arm Setup amp Maintenance Explains the procedures required to operate the robot arm unpacking transportation installation confirmation of operation and the maintenance and inspection procedures Controller Setup Basic i Explains the procedures required to operate the controller unpacking transportation installati
29. LEFT Q is center of J5 axis rotation in comparison with the plane through the J2 axis vertical to the ground RIGHT LEFT FL 1 Flag 1 amp BOOOO OOOO0 T 1YO RIGHTY LEFT Note amp B is shows the binary Rotation center a Fig 6 1 Configuration flag RIGHT LEFT 2 ABOVE BELOW Q is center of J5 axis rotation in comparison with the plane through both the J3 and the J2 axis FL 1 Flag 1 amp BOOOO 0000 T 1 O ABOVEY BELOW Rotation center Note amp B is shows the binary ER J2 axis Rotation center Z Fig 6 2 Configuration flag ABOVE BELOW Appendix 66 Configuration flag 6Appendix 3 NONFLIP FLIP 6 axis robot only This means in which side the J6 axis is in comparison with the plane through both the J4 and the J5 axis J4 axis FL 1 Flag 1 amp BOOOO OOOO T 1YO NONFLIPY FLIP Note amp B is shows the binary NON FILIP J6 axis flange surface Fig 6 3 Configuration flag NONFLIP FLIP Configuration flag Appendix 67 sfa MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100 8310 TELEX J24532 CABLE MELCO TOKYO NAGOYA WORKS 1 14 YADA MINAMI 5 HIGASHI KU NAGOYA JAPAN MAY 2004 MEE Printed in Japan on recycled paper Specifications are subject to change without notice
30. MITSUBISHI Mitsubishi Industrial Robot RV 6S Series INSTRUCTION MANUAL ROBOT ARM SETUP amp MAINTENANCE MIZLI A ENS BFP A8323 A E Supplemental Instruction Thank you for purchasing the Mitsubishi Industrial Robot MELFA Series This document additionally explains to the Mitsubishi Industrial Robot RV 6S Series INSTRUVTION MANUAL BFP A8323 Therefore check the content and use it together with your instruction manual 1 Outline When lubricating removal of the drain bolt or the plug is unnecessary The robot which is the target of these supplementary contents is shown below Target products The discrimination method Produced in September The DATE columns of the rated plate of the robot arm are all the robots after 2006 and afterwards 2006 09 Produced before August The robot by which the blue round sticker is stuck on the rated plate of the robot 2006 arm 2 Correction of the lubrication port Revision place P5 49 Fig 5 6 Lubrication positions 4 J4 axis lubrication port The drain bolt or the plug of all the axes were erased 5 J5 axis lubrication port 6 J6 axis lubrication port 1 EI Sj cn J 3 J3 axis VERENA lubrication port C e elo e uses 1 J1 axis 9 lubrication por
31. MOVE VA STEP EN PA J6 axis coe move b yz m J4 axis c wove Je OR MOVE 0 ABC STEP B move J ihe MOVE 6 WX E When the MOVE A J4 keys are pressed the J4 axis will rotate in the plus direction When the MOVE A J4 keys are pressed Rotate in the minus direction When the MOVE B J5 keys are pressed the J5 axis will rotate in the plus direction When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE C J6 keys are pressed the J6 axis will rotate in the plus direction When the MOVE C J6 keys are pressed Rotate in the minus direction Q O When an M appears on the T B screen display O O If the robot is moved outside the movement area an 4 will appear In this case move the axis in the opposite direction JOINT LOW E J1 160 00 J2 20 00 J3 80 00 In the example on the left the J1 axis is at the limit of the plus side movement area 2 22 Confirming the operation 2Unpacking to Installation 2 XYZ jog operation Select the XYZ jog mode Press the MOVE XYZ keys to select the XYZ XYZ LOW jog mode XYZ will appear at the upper left of X 134 50 XYZ the screen Y 220 00 Z 280 00 XYZ jog mode L Each time the MOVE keys are pressed the override will increase in the order of LOW HIGH Set the jog speed 85 10 30 50 70 100
32. Motor power cable 7m CN1 Motor signal cable 7m lt CR2B 574 controller Controller Robot arm Motor signal Motor power Motor power cable 5m Motor signal cable 5m Fig 2 6 Connecting the machine cables 2 10 Installation 2Unpacking to Installation Carry out the following procedure after installing the controller referring to the separate Controller Setup Basic Operation and Maintenance manual x Robot arm Connector on the robot arm side 1 Make sure that the power switch on the front of the controller is turned OFF 2 Connect the machine cable to its corresponding connector on the robot arm side 3 After connecting the connector insert the hook attached to the connector on the machine cable side to the rear of the projection of the robot arm connector to fix securely in place f you are using a CR2B 574 controller also connect the applicable connector on the controller side according to steps 2 and 3 above Minus screwdriver 4 To remove the cable insert a minus screwdriver into the hook while padding with a cloth and remove the cable by lifting the hook AN CAUTION The machine cable connectors are dedicated for the controller side and robot arm side so take special care when connecting If connected incorrectly the connector pins could bend or break Thus even if connected correctly the robot will not operate correctly creating a dangerous situation
33. U240C011G57 J3 axis 1 4 BU240C011G58 J4 axis 1 Mitsubishi Electric 5 BU240C010G53 J5 axis 1 6 BU240C010G54 J6 axis 1 7 Stopper BU224D594H01 Mechanical stoppers of the J1 to J3 2 per axis axes RV 6S RV 6SC 8 Reduction gears P961K000P68 J1 axis 1 9 P961K000P51 J2 axis 1 10 P961K000P72 J3 axis 1 Mitsubishi Electric 11 P961K000P63 J4 axis 1 12 P961K000P76 J5 axis 1 13 P961K000P75 J6 axis 1 RV 6SL RV 6SLC 14 Reduction gears P961K000P69 J1 axis 1 15 P961K000P53 J2 axis 1 16 P961K000P73 J3 axis 1 Mitsubishi Electric 17 P961K000P63 J4 axis 1 18 P961K000P76 J5 axis 1 19 P961K000P75 J6 axis 1 Note Confirm the robot arm serial No and contact the dealer for the type 5 52 Maintenance parts 5Maintenance and Inspection 5 5 Resetting the origin The origin is set so that the robot can be used with a high accuracy After purchasing the robot always carry out this step before starting work The origin must be reset if the combination of robot and controller being used is changed or if the motor is changed causing an encoder area The types of origin setting methods are shown in Table 5 8 Caution If the old battery is replaced because it has been used up it is necessary to set the origin again Reset the origin using the jig method or ABS origin method Table 5 8 Origin setting method No Method Explanation Remarks 1 Origin data input The origin data set as the default is input from The s
34. When the MOVE keys are pressed the override XYZ LOW will decrease in the reverse order The currently X 13450 ster set speed will appear on the upper right of the Y 220 00 MOVE FoRwo eackwo screen Set the override to 10 here for Z 280 00 Set the speed confirmation work Moving along the base coordinate system Tz TZ EA HZ STEP 4 ster o5 MOVE 3 JKL The direction of the frange will not change X When the MOVE X J1 keys are pressed the robot will move along the X axis plus direction When the MOVE X J1 keys are pressed Move along the minus direction When the MOVE Y J2 keys are pressed the robot will move along the Y axis plus direction When the MOVE Y J2 keys are pressed Move along the minus direction When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed Move along the minus direction O When the robot is in the transportation posture Q 4 There are directions from which linear movement is not possible from the transportation posture In this case an will appear on the T B screen and the robot will not move Refer to section 1 JOINT jog operation on page 21 and move the robot to a position where linear movement is possible and then carry out XYZ jog Q When an M appears on the T B screen display X 9 If the ro
35. adversely affected Do not turn off the main power to the robot controller while rewriting the internal information of the robot controller such as the program or parameters If the main power to the robot controller is turned off while in automatic operation or rewriting the program or parameters the internal information of the robot controller may be damaged 2 Unpacking to Installation 2 1 Confirming the product 2Unpacking to Installation The standard configuration of the robot arm part of the purchased product is shown in Table 2 1 Confirm the parts Users who have purchased optional products should refer to the separate Standard Specifications Table 2 1 Standard configuration No Part name Type Qty Remarks 1 Robot arm RV 6S series 1 unit 2 Guarantee card 1 copy 3 Installation bolts M8x40 4 pcs 4 Spring washer for installation bolts For M8 4 pcs 5 Plain washer for installation bolts For M8 4 pcs 6 Suspension fitting 2 pcs 7 Suspension fitting installation bolt 1 set This is installed in the robot arm 8 Fixing plates Thes at the time of shipment 9 Fixing plate installation bolt 1 set Confirming the product 2 5 2Unpacking to Installation 2 2 Installation 2 2 1 Unpacking Pull off lt 1 gt Tape lt 2 gt Upper lid Robot arm CAUTION Always unpack the robot at a flat place The robot could tilt over if unpacked at an
36. alves of three rows or more are used it is not possible to install a hand output cable separately because the hand output connectors 2 pcs in the forearm and the solenoid valves are already connected 5 Remove one of the two grommets on either the No 2 arm cover C lt 3 gt or the solenoid valves 5 After removing the grommet peal off the sealing material left on the hole section of the plate 6 After removing the lock nut attached to the hand output cable feed the connector side of the hand output cable with a cable clamp through the hole on the plate Replace the removed lock nut in position and fasten it securely 7 Connect the connectors of GR1 and GR2 stored in section A shown in Fig 3 1 to GR1 and GR2 of the hand output cable 8 Mount the No 2 arm cover C lt 3 gt or the solenoid valves lt 5 gt to section A shown in Fig 3 1 When mounting be careful not to damage the sponge sealing material attached to the opening of section A 9 When you have completed the installation reinstall the No 2 arm cover B lt 2 gt to its original position and be careful not to entangle the cables when you do so Installing the hand output cable 3 35 3Installing the option devices 3 4 Changing the operating range The operating range of the J1 axis can be changed to the range shown in Table 3 2 Option Table 3 2 Operating range alternative range Axis Standard Alternative
37. ance and Inspection 2 lt USER gt 12345678 lt USER gt 8 Press the Tke ee y and input 1 for the axis BRAKE 00000000 s neri TO ORIGIN for which the origin is to be set Press the INP RUM A 1 APRE key to display the Confirmation screen RPL B INP 1 J5 EXE Designate the origin setting axis J 1 DEF z lt USER gt lt USER gt 12345678 9 P the Ti k d then the INP key Th CHANGES TO ORIGIN p BRAKE 00000000 accen Md anairen sped NP dace OK 1 SET AXIS 11111100 1 EXECUTE ORIGIN NOT DEF B INP Set the origin 1 DEF This completes the setting of the origin with the user origin method 5 62 Resetting the origin 5Maintenance and Inspection 5 5 3 ABS origin method When the origin setting of the robot is performed for the first time this product records the angular position of the origin within one rotation of the encoder as the offset value If the origin setting is performed according to the ABS origin method this value is used to suppress variations in the origin setting operations and to reproduce the initial origin position accurately This operation is carried out with the teaching pendant Set the MODE switch on the front of the controller to TEACH and set the ENABLE DISABLE switch on the teaching pendant to ENABLE to enable the teaching pendant First set to the ABS mark arrow of the axis for which the origin is to be set with jog operatio
38. angle dus Angle 170 135 90 45 One of the points shown ded Insertion position None A B C on the left Ld Angle 170 135 90 45 One of the points shown Insertion position None a b c on the left Note The insertion position given in the table indicates the insertion position for the stopper Refer to Fig 3 6 The operating range is changed with robot arm settings and parameter settings 1 Setting the robot arm 1 Move the upper arm to the posture as shown in Fig 3 6 by jog operation 2 Turn OFF the controller power 3 By referring to Table 3 2 and Fig 3 6 insert the two stoppers M10 x 20 used to change the movement range of J1 axis at the angular position to be changed and fix securely by applying a clamping torque of 70 N mto86N m operating range change NCAUTION Do not remove the stopper for the standard specification of 170 degree shown in Fig 3 6 Type 1S DH 02 Specification Hexagon socket bolt 2 bolts M10 x 20 plating Strength classification 10 9 Detail of the stopper used to change the operating range of the J1 axis A Stopper for standard specification of 170 degree C M0 x 20 1 bolt Robot arm Fig 3 6 Installation of operating range change option 3 36 Changing the operating range Front of robot Jinstalling the option devices d
39. bot is moved outside the movement area with any of the axes an KH will appear In this case move the axis in the opposite direction XYZ LOW In the example on the left further linear movement in the same direction is not possible WAX 360 00 BAY 280 00 Eaz 170 00 Confirming the operation 2 23 2Unpacking to Installation Changing the flange surface posture 6 6 S z ove e Cs The flange position does not change When the MOVE A J4 keys are pressed The X axis will rotate in the plus direction When the MOVE A J4 keys are pressed Rotate in the minus direction When the MOVE B J5 keys are pressed The Y axis will rotate in the plus direction When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE C J6 keys are pressed The Z axis will rotate in the plus direction When the MOVE C J6 keys are pressed Rotate in the minus direction Q When alarm No 5150 occurs O O If alarm No 5150 ORIGIN NOT SET occurs the origin has not been set correctly Reconfirm the value input for the origin data Q O Tool length OO The default tool length is Omm and the control point is the center of the end axis After installing the hand set the correct tool length in the parameters Refer to the separate manual Detailed Explanation of Functions and Operations for details 2 24 Confirming the operation 2Un
40. designation O O Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a OT This completes the setting of the origin with the jig method 5 60 Resetting the origin 5Maintenance and Inspection 5 5 2 User origin method AN CAUTION Before using this method the origin must be set with the other method The setting method is explained in 5 5 2User origin method on page 61 The procedure for setting the origin with the user origin method is explained below This operation is carried out with the teaching pendant Set the MODE switch on the front of the controller to TEACH and set the ENABLE DISABLE switch on the teaching pendant to ENABLE to enable the teaching pendant The operation method is shown below When setting the origin for the first time using this method carry out the operations in order from step 1 For the second and following time move the robot arm to the user origin position with jog operation and accurately posi tion all axes Then start the procedure from step 4 1 Determine the user origin position Move the robot to the position to be set as the origin with jog operation Refer to 2 4Confirming the opera tion on page 18 for details on the jog operation AN CAUTION Choose the user origin positi
41. e pressed Move along the minus direction Q When the robot is in the transportation posture O 4 There are directions from which linear movement is not possible from the transportation posture In this case an KA will appear on the T B screen and the robot will not move Refer to section 1 JOINT jog operation on page 21 and move the robot to a position where linear movement is possible and then carry out TOOL jog Q O When an M appears on the T B screen display O O If the robot is moved outside the movement area with any of the axes an FA will appear In this case move the axis in the opposite direction TOOL LOW In the example on the left further linear movement in the same direction is not possible ux 360 00 BAY 280 00 WAZ 170 00 Confirming the operation 2 25 2Unpacking to Installation Changing the flange surface posture The flange position does not change When the MOVE A J4 keys are pressed The X axis will rotate in the plus direction of the tool coordinate system When the MOVE A J4 keys are pressed Rotate in the minus direction When the MOVE B J5 keys are pressed The Y axis will rotate in the plus direction of the tool coordinate system When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE C J6 keys are pressed The Z axis will rotate in the plus direction of the tool coordinate system When the MOV
42. ed ON Preparation of work plan Prepare a device that allows operation to be stopped immediately during teaching work This also applies to maintenance work with the power source turned ON Setting of emergency stop switch During teaching work place a sign indicating that teaching work is in progress on the start switch etc This also applies to maintenance work with the power source turned ON Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact of the operator and robot Installation of safety fence Establish a set signaling method to the related operators for starting work and follow this method Signaling of operation start As a principle turn the power OFF during maintenance work Place a sign indicating that maintenance work is in progress on the start switch etc Indication of maintenance work in progress Before starting work inspect the robot emergency stop switch and other related devices etc and confirm that there are no errors Inspection before starting work Safety Precautions 1 3 I1 Before starting use 1 2 1 Precautions given in the separate Safety Manual The points of the precautions given in the separate Safety Manual are given below Refer to the actual Safety Manual for details N CAUTION N CAUTION N CAUTION N CAUTION CAUTION N CAUTION N WARNING N WARNING N CAUTION N WARNING
43. efault charge Lubrication Lubrication No Parts to be lubricated Cover to remove method maker amount interval amount 1 J1 axis reduction gears 60g 14g Shoulder cover B Grease 2 J2 axis reduction gears nipple 60g 14g No 1 arm cover WA 610 Grease 3 J3 axis reduction gears Harmonic grease SK 1A 40g 8g No 1 arm cover 6000Hr 4 J4 axis reduction gears Grease Japan Harmonic 16g 4g nipple Systems 5 J5 axis reduction gears WB 610 10g 2g Wrist cover 6 J6 axis reduction gears 10g 2g Wrist cover The grease nipple position is shown in Fig 5 6 The lubrication specifications for each place are shown in Fig 5 6 Caution The brands of grease given in Table 5 5 are those filled when the robot is shipped The lubrication time is a cumulative value of the operation at the maximum speed If the operation has been suspended or if the designated speed is slow the lubrication time can be lengthened in proportion The Lubrication interval in Table 5 5 is usually based on the three year inspection 8Hr x 20 days x 36 months 6000Hr Depending on the robot operation state the lubrication time will fluctuate so determine the time according to the state so that the grease does not run out With the maintenance forecast function of the personal computer support software option the guidance of lubrication time is calculated according to the operating environment of the customer The numbers in the corre
44. erformed Please contact your nearest dealer if you find any doubtful wrong or skipped point Copyright C 2003 MITSUBISHI ELECTRIC CORPORATION CONTENTS 1 Before starting use 1 1 1 1 Using the instru 1 1 1 1 1 The details of each instruction manuals is 1 1 2 Symbols used in instruction manual 1 2 1 2 Safety Precautions 1 3 1 2 1 Precautions giv 1 4 2 Unpacking to Installation 2 1 Confirmin ing the product 2 2 Installation 2i EE 2 2 1 Unpacking sU TEN 222 Transportation p proce Spi 2 2 3 Installation procedures ou ane Leas 225 5r Sapa ub ihe CST EDI BE oe EE ED RE E 2 3 Setting bi origin 2 4 Confirming the operation 1 JOINT jog operati 2 XYZ jog operation 3 3 TOOL lag Give ANGIE ui secs pc d e ee osi cte ie eae LL 4 3 axis XYZ jog oper m 5 CYLNDER jog operation 3 Installing the option devices xl 3 1 Installing the solenoid valve set 3 2 Installing the hand input cable 3 3 Installing the hand output cable 24 Changing the Operating PARSE iuga mec pe etr HERR TER GREG Gegee ed T GN SDN Sur soc UU Uu EE IL DL MID LM DM ML M d d ccc M 5 Maintenance and Inspection 5 1 Maintenance and inspection 5 2 Inspection i 533 np on ius hehe rd ee 0 Timing belt inni period 2 Lubrication method 5 3 5 Replacing the backup batt 1 Replacing the robot arm battery 6
45. etting method is explained in 2 3Setting the method the T B origin on page 12 2 Jig method The origin posture is set with the calibration jig The setting method is explained in 5 5 1Jig method on installed page 54 3 User origin method A randomly designated position is set as the Before using this method the origin must be set with the origin posture other method The setting method is explained in 5 5 2User origin method on page 61 4 ABS origin method This method is used when the encoder backup Before using this method the origin must be set with the data lost in the cause such as battery cutting other method with same encoder The setting method is explained in 5 5 3ABS origin method on page 63 Note Although OP setting by the mechanical stopper method can also be selected it is not recommended for this robot Please use one of the methods listed in Table 5 8 Resetting the origin 5 53 5Maintenance and Inspection 5 5 1 Jig method The procedure of setting the origin with the calibration jig is shown below This operation is carried out with the teaching pendant Set the MODE switch on the front of the controller to TEACH and set the ENABLE DISABLE switch on the teaching pendant to ENABLE to enable the teaching pendant The following operation is carried out while lightly pressing the deadman switch on the teaching pendant a 2
46. for ensuring the optimum functions of the robot Observe the following points when design ing 2 Install the robot on a level surface 3 It is recommended that the surface roughness of the table onto which the robot is to be installed by 6 3a or more If the installation surface is rough the contact with the table will be poor and positional deviation could occur when the robot moves 4 When installing use a common table to prevent the position of the devices and jigs subject to robot work from deviating 5 The installation surface must have sufficient strength to withstand the arm reaction during operation and resistance against deformation and vibration caused by the static dynamic load of the robot arm and peripheral devices etc 6 Remove the fixing plates after installing the robot 7 When the robot is installed by hanging from the ceiling or on the wall the MEGDIR parameter must be changed For more information about parameters and how to change the parameters refer to the separate Instruction Manual Detailed Explana tion of Functions and Opera tions 2Unpacking to Installation 2 2 4 Grounding procedures 1 Grounding methods Controller and Controller and Robot arm Robot arm Controller Robot arm and personal computer O O personal computer personal computer c Common grounding a Dedicated grounding b Common grounding Normal Optimum Good F
47. g belt replacement period have not occurred with the timing belt 4 Confirm that the belt tension is adjusted to slacken approx 2 3mm when the center of the belt is lightly pressed with a finger approx 1 3N as shown in Fig 5 5 Belt tension Wi Adjusting the J5 axis timing belt 1 Carry out steps 1 and 2 indicated in lil Inspecting the J5 axis timing belt above 2 Lightly loosen the two installation bolts lt 1 gt Do not loosen too much 3 Move the motor lt 3 gt in the directions of the arrows shown in Fig 5 4 using the tension adjustment screw while checking the tension of the timing belt 25 Lightly pushing the center of the belt with your finger approxi mately 1 3 N move the motor to the position where the belt flexes about 2 3 mm 4 The belt tension will increase when moved in the direction of arrow a and will decrease when moved in the direction of arrow b 5 If the belt is loosened too much when adjusting the tension causing it to come off the timing pulleys lt 4 gt and lt 5 gt or if the belt and pulley teeth engagement is deviated the machine system s origin will deviate 6 After adjusting securely tighten the two motor installation bolts lt 1 gt Improper tightening can cause the belt to loosen with vibration Wi Replacing the J5 axis timing belt 1 Fig 5 4 shows the methods for inspecting adjusting and replacing the timing belt 2 Move the robot posture with the teaching pendant
48. h on the front of the controller to TEACH and then set the T B ENABLE DISABLE switch to ENABLE When the T B is valid only operations from the T B are possible Operations from the controller or external signals will not be accepted Q When T B operations are mistaken 4 The displayed screen will return to the menu selection screen when the MENU key is pressed Carry out the operations again from this screen Operations can also be carried out again by setting the T B ENABLE DISABLE switch to DISABLE once and then setting to ENABLE 2 14 Setting the origin 2Unpacking to Installation 4 Selecting the origin setting method lt T B screen gt Keys used MENU 1 TEACH 2 RUN 1 Press the 5 key on the menu screen and display the maintenance screen 3FILE MONI Qe 9 MAINT 6 SET 3 8 TU J lt MAINT gt 3 1 PARAM 2INIT Y 3 BRAKE 4 ORIGIN 2 5 POWER J V4 mno 2 Press the 4 key on the maintenance screen and display the origin setting method selection screen lt ORIGIN gt 3 Press the 1 key on the origin setting method selection screen and select 1DATA 2 MECH N INP the data input method 3 JIG 4 ABS EXE The origin data input method will be selected and the screen for turning 9 USER JA DEF OFF the servo power will appear lt ORIGIN gt 4 Press the 1 and INP keys to turn OFF the servo power The screen for SERVO OF
49. has an adequate tension The belt tension should not be too tight or too lose Instead it should be adjusted to a degree that elasticity is felt when the belt is pressed with the thumb If the belt tension is too weak the belt loosening side will vibrate On the other hand if the belt tension is too strong a sharp sound will be heard and the belt tension side will vibrate The detailed adjustment tension is shown in Fig 5 5 Check and adjust with the belt pressing force f and the slack amount d between span s 5 48 Maintenance and inspection procedures Maintenance and Inspection 5 3 4 Lubrication 1 Lubrication position and specifications 4 J4 axis lubrication port J4 axis drain bolt M4 co 5 Jo axis J6 axis drain plug M3 lubrication port 6 J6 axis lubrication port N Jg Y 8 Le P J5 axis drain bolt m 3 J3 axis lubrication port J2 axis drain bolt M4 wi 1 J1 axis lubrication port p 2 J2 axis lubrication port J1 axis drain bolt M4 View from A Fig 5 6 Lubrication positions Maintenance and inspection procedures 5 49 5Maintenance and Inspection Table 5 5 Lubrication specifications T Oiling Lubrication oil D
50. hat may be applied to an installation stand Please use these values as reference when designing the installation stand 4 M8 X 40 hexagon socket bolt Four positions Spring washer Plain washer 2 6 holes 4 9 installation hole prepared holes for 8 positioning pins d fri i lo Robot front J 7 a N N um p 6 3a Installation 96 3 E 102 5 S HEN 205 E 115 140 Base bottom Fig 2 3 Installation dimensions Table 2 2 Magnitude of each reaction force Item Unit Value Tilt moment ML N m 892 Torsional moment Mr N m 892 Horizontal direction translation force Fy N 800 Vertical direction translation force Fy N 1 400 BFP A8323 A01 A E N Safety Precautions Always read the following precautions and the separate Safety Manual before starting use of the robot to learn the required measures to be taken J N CAUTION N CAUTION ANWARNING N CAUTION ANWARNING N CAUTION N CAUTION N CAUTION All teaching work must be carried out by an operator who has received special training This also applies to maintenance work with the power source turned ON Enforcement of safety training For teaching work prepare a work plan related to the methods and procedures of oper ating the robot and to the measures to be taken when an error occurs or when restart ing Ca
51. he peripheral device by drop or move by inertia of the arm Do not turn off the main power to the robot controller while rewriting the internal information of the robot controller such as the program or parameters If the main power to the robot controller is turned off while in automatic operation or rewriting the program or parameters the internal information of the robot controller may be damaged Revision history Date of Point Instruction Manual No Revision Details 2003 10 10 BFP A8323 First print 2004 05 20 BFP A8323 A Installing the hand input output cable was added Error in writing correction B Introduction Thank you for purchasing the Mitsubishi industrial robot This instruction manual explains procedures to be taken for unpacking installing servicing and inspecting the robot arm Always read through this manual before starting use to ensure correct usage of the robot No part of this manual may be reproduced by any means or in any form without prior consent from Mitsubishi The details of this manual are subject to change without notice An effort has been made to make full descriptions in this manual However if any discrepancies or unclear points are found please contact your dealer The information contained in this document has been written to be accurate as much as possible Please interpret that items not described in this document cannot be p
52. he setting of the origin with the ABS method 5 64 Resetting the origin 1 Press the 5 key on the Menu screen to select the Maintenance screen 2 Press the 4 key to select the Origin Setting screen 3 Press the 4 key to select the ABS method After that press the 1 key and INP key to turn the servo OFF 4 Press the key and input 1 for the axis to set the origin in SET AXIS Press the INP key to display the Confirmation screen 5 Press the 1 key and then press the INP key The origin will be set 5Maintenance and Inspection 5 5 4 Recording the origin data When the origin has been set with the jig method record that origin data on the origin data label With this the ori gin can be set with the origin data input method the next time Confirm the origin data on the teaching pendant screen origin data input screen The origin data label is enclosed with the arm or attached on the back of the shoulder coverB The teaching pendant operation method and shoulder coverB removal method for confirming the origin data is the same as the methods for setting the origin with the origin data input method Refer to 2 3 2Setting the origin with the origin data input method on page 13 and write the origin data displayed on the teaching pendant onto the origin label 1 Confirming the origin data label Remove the shoulder coverB Refer to 5 3 2Installing removing the cover on page 44 and remove
53. hen the MOVE X J1 keys are pressed the robot will move along the X axis plus direction When the MOVE X J1 keys are pressed Move along the minus direction When the MOVE Y J2 keys are pressed the robot will move along the Y axis plus direction When the MOVE Y J2 keys are pressed Move along the minus direction When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed Move along the minus direction 2 Jog mode will change when only XYZ key is pressed again 4 When the MOVE XYZ keys are pressed and then only the XYZ key is pressed the upper left display will change in the order of XYZ XYZ456 CYLNDER Each jog mode can be selected Q9 The flange surface end axis posture cannot be maintained with 3 axis XYZ jog 29 Q With 3 axis XYZ jog the flange surface end axis posture orientation is not maintained when moving linearly in the X Y or Z axis direction Use XYZ jog to maintain the posture Confirming the operation 2 27 2Unpacking to Installation Changing the flange surface posture J6 axis N STEP Ee EE J6 MOVE 5 STU STEP B Move Q5 STEP A MOVE 1 DEF 4 m UE C wove Jo 8 MOVE 0 ABC J5 axis STEP B move ES MOVE 6 Wx The flange position changes This is the same as the J4 J5 and J6 axis JOINT jog operation
54. ig 2 4 Grounding methods 2 Grounding procedures Robot arm M4 x 10 SW PW Robot grounding cable AWG 11 3 5mm or more Prepared by customer Fig 2 5 Connecting the grounding cable 1 There are three grounding methods as shown in Fig 2 4 but the dedicated grounding Fig 2 4 a should be used for the robot arm and controller when possible Refer to the separate Controller Setup Basic Operation and Maintenance for details on the controller grounding 2 Use Class D grounding grounding resistance 1009 or less Dedicated grounding separated from the other devices should be used 3 Use a AWG 11 3 5mm2 or more stranded wire for the grounding wire The grounding point should be as close to the robot arm and controller as possi ble and the length of the grounding wire should be short 1 Prepare the grounding cable AWG 1 1 3 5mm or more and robot side installation screw and washer 2 If there is rust or paint on the grounding screw section A remove it with a file etc 3 Connect the grounding cable to the grounding screw section AN CAUTION When installing the robot be sure to allocate a sufficient maintenance space for connecting the cables between devices and replacing a backup battery at the rear of the robot Installation 2 9 2Unpacking to Installation 2 2 5 Connecting with the controller lt CR3 535M controller Controller Robot arm on
55. ill move to RPL 5 SET AXIS Move the cursor lt TOOL gt 12345678 3 Designate the axis for which the origin is to be BRAKE 00000000 set Set 1 for the 1 axis and set 0 for the SET AXIS 10000000 other axes Then press INP key Next a ORIGIN NOT DEF ie confirmation screen will appear J5 J6 XE Designate the origin setting axis V DEF 0 ABC 4 Press the 1 and INP keys TOOL The origin posture will be set SET ORIGIN OK 1 1 EXECUTE Set the origin 1 DEF 5 Setting of the origin is completed lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 10000000 ORIGIN COMPLETED 6 Refer to 5 5 4Recording the origin data on page 65 in this manual and record the origin data on the origin data seal OS Origin setting axis designation G4 Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 Resetting the origin 5 55 5Maintenance and Inspection 2 J2 axis origin setting lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN ee DEF B 1 Slowly rotate the J2 axis in the direction of 22 minus 90 with both hands Align the pinholes es of the No 1 arm and shoulder feed through the origin jig 8 into the pinholes and fasten Desig
56. n This can be set for all axes simultaneously or each axis independently When setting the ABS mark always view the operations from the mark and set at the end of the triangular mark The positions where the ABS mark is attached are shown in Fig 5 28 Refer to 1 JOINT jog operation on page 21 for details on the jog operation ABS mark Fig 5 8 ABS mark attachment positions Resetting the origin 5 63 5Maintenance and Inspection The procedures for setting the origin with the ABS method are explained below 1 Select the T B lt MENU gt lt MAINT gt 1 TEACH 2 RUN 1 PARAM 2 INIT 3 FILE 4 MONI 3 BRAKE 4 ORIGIN 5 MAINT 6 SET 5 POWER 6 J6 Select the Maintenance screen BE lt MAINT gt lt ORIGIN gt 1 PARAM 2 INIT 1DATA 2 MECH 3 BRAKE 4 ORIGIN 3 JIG 4 ABS 5 POWER 5 USER Select the Origin Setting screen lt ORIGIN gt lt ABS gt 1DATA 2 MECH mi SERVO OFF 3 JIG 4ABS OK 1 5 USER 1 EXECUTE B Select the ABS method lt ABS gt SERVO OFF OK 1 1 EXECUTE lt ABS gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF RPL B INP 1 J5 EXE Execute the origin setting confirmation le DEE lt ABS gt lt ABS gt 12345678 SET ORIGIN b BRAKE 00000000 OK 1 SET JIG 11110000 1 EXECUTE ORIGIN NOT DEF B INP J9 L EXE KC E 1 DEF Execute the origin settin This completes t
57. n and be careful not to entangle the cables when you do so 3 34 Installing the hand input cable Jinstalling the option devices dg c _ eg 3 3 Installing the hand output cable The procedure for installing the hand output cable is as follows Conduct work by referring to Fig 3 1Solenoid valve installation procedures on page 31 and Fig 3 5Installing the hand output cable on page 35 below This work must be carried out with the controller power turned OFF lt 4 gt Socket bolts M4 X 8 4 bolts Grommet Remove p 3 No 2 arm cover C Cable clamp GR1 GR2 View D Fig 3 5 Installing the hand output cable 1 Remove the hexagon socket bolts five M4 x 10 and truss screw three M3 x 8 that hold the No 2 arm cover B lt 2 gt and then remove both the No 2 arm cover B 2 2 Remove the socket bolts lt 4 gt four M4 x 8 that hold the No 2 arm cover C lt 3 gt or the solenoid valves lt 5 gt and then remove the No 2 arm cover C lt 3 gt or the solenoid valves 52 3 If you are not using the spare line ADD stored in a coil in section A shown in Fig 3 1 remove it The spare line is connected to a connector inside section A 4 The hand output cable can be installed to both the No 2 arm cover C lt 3 gt and the solenoid valves lt 5 gt However if solenoid v
58. n the minus direction 2 30 Confirming the operation installing the option devices 3 Installing the option devices 3 1 Installing the solenoid valve set 18 VD01 02 VD02 02 VD03 02 VD04 02 Socket bolt M4 x 8 4 bolts Attached to the solenoid ud lt 4 gt Socket bolt M4 x 8 4 bolts lt 1 gt No 2 arm cover A No 1 solenoid valve No 2 solenoid valve No 3 solenoid valve No 4 solenoid valve GR8 Pei View B View C Fig 3 1 Solenoid valve installation procedures Installing the solenoid valve set 1S VD01 02 VD02 02 VD03 02 VD04 02 3 31 installing the option devices uc S S amm uix Fig 3 1 and Fig 3 2 shows the solenoid valve installation procedures and the solenoid valve connector connection procedures The installation procedures are as follow This work must be carried out with the controller power turned OFF 1 Remove the hexagon socket bolts five M4 x 10 and truss screw three M3 x 8 that hold the No 2 arm cover B X2 and then remove both the No 2 arm cover B 2 2 Remove the socket bolts lt 4 gt four M4 x 8 that hold the No 2 arm cover C lt 3 gt and then remove both the No 2 arm cover C 3 3 If you are not using the spare line ADD stored in a coil in section A shown in Fig 3 1 remove it The spare li
59. nate the origin setting axis RPL I Move the cursor lt TOOL gt 12345678 2 Press the key The cursor will move to BRAKE 00000000 SET AXIS SET AXIS 01000000 B G INP ORIGIN NOT DEF cs d ue ee Designate the origin setting axis 1 DEF VO ABC 3 Designate the axis for which the origin is to be set Set 1 for the 2 axis and set 0 for the other axes Then press INP key Next a confirmation screen will appear lt TOOL gt SET ORIGIN OK 1 1 EXECUTE E 4 Press the 1 and INP keys Set the origin 1 DEF The origin posture will be set lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 01000000 ORIGIN COMPLETED 5 Setting of the origin is completed 6 Refer to 5 5 4Recording the origin data on page 65 in this manual and record the origin data on the origin data seal Q9 O Origin setting axis designation O O Move the cursor to the SET AXIS axis No in the origin setting with the or gt key The origin is set only for the axis for which a 1 is displayed on the screen If the origin is not to be set press the 0 key and display a 0 5 56 Resetting the origin 5Maintenance and Inspection 3 J3 axis origin setting lt TOOL gt 12345678 BRAKE 00000000 SET AXIS 11110000 ORIGIN NOT DEF J5 1 DEF Designate the origin setting axis Pinhole J3 axis Move the cursor
60. ndicate the state could lead to operators approaching the robot or to incorrect operation When carrying out teaching work in the robot s movement range always secure the priority right for the robot control Failure to observe this could lead to personal inju ries or damage if the robot is started with external commands Keep the jog speed as low as possible and always watch the robot Failure to do so could lead to interference with the workpiece or peripheral devices After editing the program always confirm the operation with step operation before starting automatic operation Failure to do so could lead to interference with periph eral devices because of programming mistakes etc Make sure that if the safety fence entrance door is opened during automatic opera tion the door is locked or that the robot will automatically stop Failure to do so could lead to personal injuries Never carry out modifications based on personal judgments or use non designated maintenance parts Failure to observe this could lead to faults or failures When the robot arm has to be moved by hand from an external area do not place hands or fingers in the openings Failure to observe this could lead to hands or fingers catching depending on the posture Do not stop the robot or apply emergency stop by turning the robot controller s main power OFF If the robot controller main power is turned OFF during automatic operation the robot accuracy could be
61. ne is connected to a connector inside section A Solenoid valve IP Cut to an appropriate length Connector storage position View from No 2 arm cover B side Fig 3 2 Solenoid valve installation diagram details 1 4 The length of the two air hoses 6 stored in section A is longer than necessary by assuming the use of a solenoid valve set not manufactured by Mitsubishi Cut off the air hoses to an appropriate length and connect them to the couplings 5 Of the two air hoses 6 the one marked with AIR IN is for connecting the quick coupling P port 6 of the solenoid valves and the other marked with RETURN is for connecting the quick coupling R port 7 of the solenoid valves 6 Using the screw holes of the No 2 arm cover C lt 3 gt mount the solenoid valves with the socket bolts four M4 x 8 attached to the solenoid valves When mounting the solenoid valves be careful not to damage the sponge sealing material attached to the opening of section A If the sealing material is damaged it may degrade the protection specification 7 Connect the connectors of GR1 to GR2 stored in section A to the plugs of GR1 to GR2 coming out of the solenoid valves Store the connectors near the location marked with O shown in Fig 3 2 Fig 3 2 shows a view when stored 3 32 Installing the solenoid valve set 1S VD01 02 VD02 02 VD03 02 VD04 02 No 2 arm Fig 3 3 Solenoid valve installation diagram details 2
62. ng belt replacement period The timing belt life is greatly affected by the robot working conditions so a set time cannot be given However if the following symptoms occur replace the belt 1 When cracks from at the base or back of the belt teeth 2 When the belt expands due to adherence of oil etc 3 When the belt teeth wear to approx half of the tooth width 4 When the belt teeth jump due to belt teeth wear 5 When the belt snaps AN CAUTION Due to the manufacturing of the timing belt initial wear will occur Wear chips may accumulate in the cover after approx 300 Hr of operating the robot but this is not a fault If the wear chips appear soon after wiping them off replace the belt AN CAUTION When the belt is replaced the machine system origin may deviate In this case the position data must be reviewed 5 46 Maintenance and inspection procedures 5Maintenance and Inspection 2 Inspection maintenance and replacement of J5 axis timing belt lt 3 gt Motor BS lt 1 gt Motor installation bolt M4 X 12 Socket bolt lt 5 gt Timing pulley lt 4 gt Timing pulley Fig 5 4 Inspection maintenance and replacement of J5 axis timing belt N Inspecting the J5 axis timing belt 1 Confirm that the robot controller power is OFF 2 Refer to 5 3 2Installing removing the cover on page 44 and remove the No 2 arm cover A 3 Visually confirm that the symptoms indicated in 1 Timin
63. ntly set speed will appear on the upper right s MS 4 MOVE FoR packwo of the screen et the spee Set the override to 10 here for confirmation work J1 axis jog operation EA C T STEP X sre ox MOVE SPACE PQR Ji axis When the MOVE X J1 keys are pressed the J1 axis will rotate in the plus direction When the MOVE X J1 keys are pressed Rotate in the minus direction J2 axis jog operation e STEP sy EA EA m MOVE 4 MNO J2 axis STEP Y step i MOVE 9 amp lt gt When the MOVE Y J2 keys are pressed the J2 axis will rotate in the plus direction When the MOVE Y J2 keys are pressed Rotate in the minus direction Q When the robot is in the transportation posture O 4 The axes may be outside the movement area Move these axes toward the inner side of the movement area If moved outward an FA will appear on the T B screen and the robot will not move Confirming the operation 2 21 2Unpacking to Installation J3 axis jog operation STEP Z step ez MOVE 8 Gy When the MOVE Z J3 keys are pressed the J3 axis will rotate in the plus direction When the MOVE Z J3 keys are pressed Rotate in the minus direction J4 J5 and J6 axis jog sp ie J6 MOVE 5 STU STEP B J5
64. on confirmation of operation basic operation from creating the program to automatic operation and the maintenance and inspection procedures Operation and Maintenance Detailed Explanation of Functions and Explains details on the functions and operations such as each function and operation Operations commands used in the program connection with the external input output device and parameters etc Explains the causes and remedies to be taken when an error occurs Explanations are given for each error No Using the instruction manuals 1 1 Before starting use 1 1 2 Symbols used in instruction manual The symbols and expressions shown in Table 1 1 are used throughout this instruction manual Learn the meaning of these symbols before reading this instruction manual Table 1 1 Symbols in instruction manual Symbol Meaning Precaution indicating cases where there is a risk of operator fatality or seri AN DAN G E R ous injury if handling is mistaken Always observe these precautions to safely use the robot Precaution indicating cases where the operator could be subject to fatalities AN WARNIN G or serious injuries if handling is mistaken Always observe these precautions to safely use the robot Precaution indicating cases where operator could be subject to injury or NCAUTIO N physical damage could occur if handling is mistaken Always observe these precautions to safely use the robot
65. on as the position where it doesn t move by the gravity This position is left as a guideline to position all axes with jog operation when setting the origin again with this method 2 Enter the JOINT jog mode and display the joint coordinates on the teaching pendant screen Record the value of the axis for which the origin is to be set 3 Input the value recorded in the user designated origin parameter USRORG The parameter details and input methods are described in the separate Instruction Manual Detailed Explana tion of Functions and Operations Refer to that manual and input the user designated origin position lt MENU gt lt MAINT gt 4 Next set the origin 1 TEACH 2 RUN 1 PARAM 2 INIT Press the MENU key to display the Menu 3 FILE 4 MONI 3 BRAKE 4 ORIGIN screen 5 MAINT 6 SET 5 POWER 5 Press the 5 key to display the Maintenance screen 3C J6 Display the maintenance screen 5 STU 6 Press the 4 key to select the Origin Setting lt MAINT gt lt ORIGIND screen 1 PARAM 2 INIT 1 DATA 2 MECH 3 BRAKE 4 ORIGIN gt 3 JIG 4 ABS 5 POWER 5 USER y J2 Display the origin setting method selection screen 4 MNO 7 Press the 5 key to select the user origin lt ORIGIN gt lt USER gt method 1 DATA2 MECH gt SERVO OFF Then press 1 key and INP key to turn OFF 3 JIG4 ABS OK the servo 5 USER 1 EXECUTE Resetting the origin 5 61 5Mainten
66. on of the frange will not change Assuming that the current position is on an arc centering on the Z axis the robot moves along that arc When the MOVE Y J2 keys are pressed the robot will move along the arc in the plus direction When the MOVE Y J2 keys are pressed Move in the minus direction When the MOVE X J1 keys are pressed the robot will expand in the radial direction When the MOVE X J1 keys are pressed Contract in the radial direction When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction When the MOVE Z J3 keys are pressed Move along the minus direction Confirming the operation 2 29 2Unpacking to Installation Changing the flange surface posture step C qwe MOVE o asc Z X srEP SA H 4 MOVE 2 GHI Control point The flange position does not change This is the same as the A B and C axis XYZ jog operation When the MOVE A J4 keys are pressed The X axis will rotate in the plus direction When the MOVE A J4 keys are pressed Rotate in the minus direction When the MOVE B J5 keys are pressed The Y axis will rotate in the plus direction When the MOVE B J5 keys are pressed Rotate in the minus direction When the MOVE C J6 keys are pressed The Z axis will rotate in the plus direction When the MOVE C J6 keys are pressed Rotates i
67. oue ls ve ODATASDOEboo0 1 000000 000000 TA 3 000000 000000 4 5 000000 000000 om 5 59A37 KBH amp 6P 2 GHI 9 amp O lt DATA gt D V S29 CHANGES TO ORIGIN B INP OK J5 EXE DEF Execute BIB 1 Confirm that the cursor is at the D position on the T B display screen 2 Input the D value V S29 Inputting V Press the VWX key once while holding down the CHAR key V will appear so release the CHAR key V will be set Inputting Press the key three times while holding down the CHAR key will appear so release the CHAR key will be set In the same manner while holding down the CHAR key press the key twice and the STU key once input S Release the CHAR key and press the 2 key input 2 and then the 9 key input 79 V S29 will appear at the D data on the teaching pendant screen 3 Press the key and move the cursor to the J1 input position 4 Input the J1 value in the same manner as above 5 Input the J2 J3 J4 J5 and J6 values in the same manner 6 After inputting all of the values press the INP key The origin setting confirmation screen will appear 7 Press 1 B P and INP key to end the origin setting 2 16 Setting the origin 2Unpacking to Installation Q O Moving the cursor O O Press the 1 1 1 e and keys Q O Inputting characters C
68. packing to Installation 3 TOOL jog operation Select the TOOL jog mode Press the MOVE TOOL keys to select the TOOL LOW TOOL jog mode TOOL will appear at the upper X 134 50 TOOL left of the screen Z 280 00 TOOL jog mode Each time the MOVE keys are pressed the override will increase in the order of LOW gt HIGH Set the jog speed gt 3 gt 5 gt 10 gt 30 gt 50 gt 70 100 When the MOVE keys are pressed the override uem ie will decrease in the reverse order The currently Y 1220 00 STEP af set speed will appear on the upper right of the i EE Fono BAckwDJ screen Set the override to 10 here for ee Oo Set the spee confirmation work Moving along the tool coordinate system X J1 SPACE POR n E Ne The direction of the frange will not change When the MOVE X J1 keys are pressed the robot will move along the X axis plus direction of the tool coordinate system When the MOVE X J1 keys are pressed Move along the minus direction When the MOVE Y J2 keys are pressed the robot will move along the Y axis plus direction of the tool coordinate system When the MOVE Y J2 keys are pressed Move along the minus direction When the MOVE Z J3 keys are pressed the robot will move along the Z axis plus direction of the tool coordinate system When the MOVE Z J3 keys ar
69. rm that the controller s power supply switch is OFF N 3 Eed 2 Connect the T B connector to the RS 422 T B connector on the controller 3 Do not pull the cable with force or bend it excessively as the cable could break or the connector could be damaged Emergency stop switch 4 Confirm that the REMOVE T B switch on the side of the l j j amp a controller is not depressed is projected S4 Hed Operation keys g a 5 Set the T B ENABLE DISABLE switch to DISABLE E Appearance of teaching pendant REMOVE T B switch Teaching pendant T B lt Figure shows the CR3 535M C N controller gt Fig 2 7 Installing the T B control power OFF O REMOVE T B switch O4 O When using the robot with the T B this switch is used to invalidate the emergency stop from the T B This is also used to install the T B with turning the controller s power supply ON 2 12 Setting the origin 2Unpacking to Installation 2 3 2 Setting the origin with the origin data input method 1 Confirming the origin data Origin data history table Origin Data History Serial No ES804008 Date Default The origin data to be input is noted in the origin data sheet enclosed with the arm B vise or on the origin data history table J 1 O6DTYY attached to the back side of the shoulder J2 2 HL9X coverB Refer to Fig 2 8 J 3 1CP55V J4 T6 M Y Referring to 5
70. roaching the robot or to incorrect operation When carrying out teaching work in the robot s movement range always secure the pri ority right for the robot control Failure to observe this could lead to personal injuries or damage if the robot is started with external commands Keep the jog speed as low as possible and always watch the robot Failure to do so could lead to interference with the workpiece or peripheral devices After editing the program always confirm the operation with step operation before starting automatic operation Failure to do so could lead to interference with peripheral devices because of programming mistakes etc Make sure that if the safety fence entrance door is opened during automatic operation the door is locked or that the robot will automatically stop Failure to do so could lead to personal injuries Never carry out modifications based on personal judgments or use non designated maintenance parts Failure to observe this could lead to faults or failures When the robot arm has to be moved by hand from an external area do not place hands or fingers in the openings Failure to observe this could lead to hands or fingers catching depending on the posture Do not stop the robot or apply emergency stop by turning the robot controller s main power OFF If the robot controller main power is turned OFF during automatic operation the robot accuracy could be adversely affected Moreover it may interfere with t
71. rry out work following this plan This also applies to maintenance work with the power source turned ON Preparation of work plan Prepare a device that allows operation to be stopped immediately during teaching work This also applies to maintenance work with the power source turned ON Setting of emergency stop switch During teaching work place a sign indicating that teaching work is in progress on the start switch etc This also applies to maintenance work with the power source turned ON Indication of teaching work in progress Provide a fence or enclosure during operation to prevent contact of the operator and robot Installation of safety fence Establish a set signaling method to the related operators for starting work and follow this method Signaling of operation start As a principle turn the power OFF during maintenance work Place a sign indicating that maintenance work is in progress on the start switch etc Indication of maintenance work in progress Before starting work inspect the robot emergency stop switch and other related devices etc and confirm that there are no errors Inspection before starting work The points of the precautions given in the separate Safety Manual are given below Refer to the actual Safety Manual for details N CAUTION AN CAUTION AN CAUTION AN CAUTION N CAUTION N CAUTION Z WARNING ANWARNING N GAUTION ANWARNING N GAUTION
72. rs Always place cloth etc at interfering places 4 When transferring to the installation place take care not to apply vibration or impact 5 After installing at the installation place remove the above suspension fittings 6 Always follow the above procedures and methods to transport the robot for secondary transportation such as when changing the installation position If the arm is directly suspended without using the specified suspension fittings or if it is suspended in the work posture the configuration devices could be damaged and the transportation workers will be subject to risk due to an inadequate center of gravity position Installation 2 7 2Unpacking to Installation 2 2 3 Installation procedures Four positions Spring washer Plain washer 4 9 installation hole 2 6 holes prepared holes for d 8 positioning pins T a a Tt Robot front N N GE 204 160 1 1 B 1 1 6 3a Installation 96 102 5 fee EE ss 205 115 140 6 3a Installation Base bottom Fig 2 3 Installation dimensions 2 8 Installation 1 The robot installation surface has been machine finished Use the installation holes 4 6 9 holes opened at the four corners of the base and securely fix the robot with the enclosed installa tion bolts M8 x 40 hexagon socket bolts Installation of the robot arm is a very important step
73. s carry out this step after replacing the battery and initialize the battery usage time Refer to the separate Instruction Manual Detailed Explanation of Functions and Operations for details on the opera tion methods Caution If the old battery is replaced because it has been used up it is necessary to set the origin again Refer to 5 5Resetting the origin on page 53 and reset the origin using the jig method or ABS origin method Maintenance and inspection procedures 5 51 5Maintenance and Inspection 5 4 Maintenance parts The consumable parts that must be replaced periodically are shown in Table 5 6 and spare parts that may be required during repairs are shown in Table 5 7 Purchase these parts from the dealer when required Some Mit subishi designated parts differ from the maker s standard parts Thus confirm the part name robot arm and con troller serial No and purchase the parts from the dealer Table 5 6 Consumable part list No Part name Type Usage place Q ty Supplier 1 Timing belt 393 3GT 4 J5 axis 1 M434N4 2 Grease SK 1A Reduction gears of each axis An needed Mitsubishi Electric 3 Lithium battery A6BAT In battery cover 5 Table 5 7 Spare parts list No Part name Type Usage place Q ty Supplier 1 AC servo motor BU240C011G55 J1 axis 1 2 BU240C011G56 J2 axis 1 3 B
74. shi Service Department 3 month inspection items 1 Is the timing belt tension abnormal If the timing belt is loose or too tense adjust it 6 month inspection items 1 Is the friction at the timing belt teeth severe If the teeth are missing or severe friction is found replace the timing belt Yearly inspection items 1 Replace the backup battery in the robot arm Exchange it referring to 5 3 5Replacing the backup battery on page 51 3 year inspe ction items 1 Lubricate the grease at the harmonic reduction gears for each axis Lublicate it referring to 5 3 4Lubrication on page 49 Inspection items 5 41 5Maintenance and Inspection 5 3 Maintenance and inspection procedures The procedures for carrying out the periodic maintenance and inspection are described in this section Thoroughly read the contents and follow the instructions This work can be commissioned to the Mitsubishi Service Depart ment for a fee Never disassemble etc the parts not described in this manual The maintenance parts etc required for the customer to carry out maintenance and inspection are described in 5 4Maintenance parts on page 52 of this manual Always contact your dealer when parts are needed A CAUTION The origin of the machine system could deviate when this work is carried out Review of the position data and re teaching will be required 5 3 1 Robot
75. so that the J5 axis may be downward Turn it to the direc tion of gravity 3 Make sure that the pulleys do not move while replacing the belt 4 If the pulley lt 4 gt and lt 5 gt position relation deviates the position could deviate 5 Make marks on the timing belt lt 2 gt and timing pulleys lt 4 gt and lt 5 gt with a felt tip pen as shown in Fig 5 4 so that the engagement of the timing belt lt 2 gt and timing pulleys lt 4 gt and lt 5 gt does not deviate 6 Loosen the two motor installation screws lt 1 gt and remove the belt 7 Copy the marks onto the new timing belt Make sure that both belts are tense when making the marks 8 Align the new timing belt with the marks on the timing pulleys lt 4 gt and lt 5 gt and install 9 Refer to steps 3 to 6 in W Adjusting the J5 axis timing belt and 3 Timing belt tension to adjust the tension 10 The position could deviate after the belt is replaced Confirm that the position has not deviated If deviated refer to 5 5Resetting the origin on page 53 and reset the origin position Maintenance and inspection procedures 5 47 5Maintenance and Inspection 3 Timing belt tension f Pressing force S Span d Slack Belt type Span s mm Slack d mm Pressing force f N 393 3GT 4 145 2 3 1 3 Fig 5 5 Belt tension The timing belt can satisfactorily convey the drive and keep a durable force only when it
76. spond to the supply positions in Fig 5 6 Avoid excessive lubrication since it may lead to grease leak Also the number of lubrications is limited to 3 times 2 Lubrication method 1 Set the robot to the posture shown in Fig 5 6 2 Refer to the 5 3 2Installing removing the cover on page 44 and remove the covers 3 Remove the drain bolt or plug 4 Insert the grease shown in Table 5 5 using a grease gun from the lubrication grease nipple 5 Install the drain bolt or plug 6 Replace the covers with the removal procedure in reverse 5 50 Maintenance and inspection procedures 5Maintenance and Inspection 5 3 5 Replacing the backup battery An absolute encoder is used for the position detector so the position must be saved with the backup battery when the power is turned OFF The controller also uses a backup battery to save the program etc These batteries are installed when the robot is shipped from the factory but as these are consumable parts they must be replaced periodically by the customer The guideline for replacing the battery is one year but this will differ according to the robot s usage state When the battery life nears the Battery cumulative time over alarm Alarm No 7520 will occur Once the alarm occurs replace all batteries in the robot arm and controller as soon as possible Lithium batteries type AGBAT and ERO are used in both the controller and robot arm 1 Replacing the robot arm battery Don
77. t 2 J2 axis lubrication port View from A BFP A8323 A01 A 3 Change of the lubrication method and notes Details of change and supplement A procedure and precautions applicable to the products affected by the change were added to 2 Lubrication method on P5 50 The procedure applicable to the products affected by the change is described below When lubricating all other products follow the original procedure specified in the instruction manual 1 Lubrication method of products affected by the change 1 Set the robot to the posture shown in Fig 5 6 2 Refer to the 5 3 2Installing removing the cover on page 44 and remove the covers 3 Insert the grease shown in Table 5 5 using a grease gun of manual type from the lubrication grease nipple 4 Replace the covers with the removal procedure in reverse 2 Precautions for lubrication Take note of the following points when lubricating all products regardless of whether or not they are affected by the change N CAUTION Use manual grease gun and inject grease with pressure 0 03Mpa or less Do not use the grease gun which derived by the factory air presser to avoid injecting by too high pressure BFP A8323 A01 A 4 Supplemental note for the installation surface receiving force Supplemental details Magnitude of each reaction force added to P2 8 2 2 3 Installation procedures Table 2 2 shows the maximum reaction force design values t
78. t disconnect connector etc While replacing the battery the encoder position AN CAUTION data is saved by the power supplied from the controller Thus if the cable connection is incomplete the encoder position data will be lost when the controller power is turned OFF Several batteries are used in the robot arm but replace all old batteries with new batteries at the same time lt 3 gt Connector box lt 2 gt Instal lation screw lt 1 gt Battery cover Lead connector Fig 5 7 Replacing the battery 1 Confirm that the robot arm and controller are connected with a cable 2 Turn the controller control power ON The position data is retained by the power supplied from the controller while replacing the battery Thus if the cable is not connected correctly or if the controller power is OFF the position data will be lost 3 Press the emergency stop button to set the robot in the emergency stop state This is a measure for safety and must always be carried out 4 Remove the two installation screws lt 2 gt and remove the battery cover lt 1 gt 5 The battery holder is located in the connector box lt 3 gt Remove the old battery from the holder and discon nect the lead connector 6 Insert the new battery into the holder and connect the lead connector Replace all batteries with new ones at the same time 7 Carry out steps 4 in reverse to install the parts 8 Initialize the battery consumption time Alway

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