Okura Yusoki Co., Ltd. Robot Manual Maintenance UL-MAI-11
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Okura Yusoki Co., Ltd.
Robot Manual
Maintenance
UL-MAI-11
UL(11)
Updating history
Version (Date)
Content Page
10 (2005.1.31) Newly released Header addition All pages
Expression and figurechange 1-4,5 2-6,12 4-2,3
Gap of page by content addition 4-4 - 4-8
10 (2005.3.31)
Date update Last page Addition of Updating history This page
Change in content of periodic maintenance and inspection
1-5, 2-7, 2-13
Power lock fastening torque change (A1600III) 1-6 Figure sharpening 2-2, 2-4 Addition of expression the battery -> the brand new battery
2-10
10 (2006.7.31)
Date update Last page
10(2006.11.01)
Addition of Updating history Encoder battery type change(A700III) Correction of error expression Date update
This page 2-11,2-13 2-12 Last page
10(2007.9.1) Addition of Updating history Addition of 2 Page “2.3.5 Fuse Replacement” Date update
This page 2-14,15 Last page
10(2007.11.22)
Addition of Updating history Correction Key Controller Parts
NFB1 --- From “50AT” To “30AT” Change Model of Key Controller Parts “NFB3” Change Model of Key Controller Parts “C1,C5” Change Model of Key Controller Parts “SVC” Addition of Fuse Replacement of TBR2 Date update
This page 2-3 2-3, 2-5 2-3, 2-5 2-3, 2-5 2-15 Last page
10(2008.06.13)
Addition of Updating history Change Model of Key Controller Parts Chage Statemant of “2.3.3 battery Replacement” Change Screen of ”Operation ready condition” Date update
This page 2-3, 2-5 From 2-10 to 2-14 4-4 Last page
10 (2008.08.06) Addition of Updating history Chage Statemant of “2.3.3 battery Replacement” Date update
This page 2-13,2-14 Last page
10 (2008.10.02) Addition of Updating history Chage Statemant of “2.3.5 Fuse Replacement” Date update
This page 2-18 Last page
UL(11)
Updating history
Version (Date)
Content Page
11(2009.01.28)
Addition of Updating history Reconstruction of Page Addition of model A1800 Change Model of Key Controller Parts Chage Statemant of “ 1.2.Periodic Maintenance and Inspection“ Chage Statemant of “ 2.2.Periodic Maintenance and Inspection“ Date update
This page TOC 1-2, 1-7, 1-8, 2-2,2-17,2-18 2-3, 2-5, 1-5,1-6,1-9, 1-10,1-11 2-6 2-7,2-10, 2-12,2-16 Last page
UL(11)
Introduction Thank you for purchasing a model from the Okura Robot Palletizer A series. This manual is a guidebook to help you safely and correctly use your A Series Robot
Palletizer. It should be useful not only to beginners who are using an Okura Palletizer for the first time, but also to experienced users, who can use this Manual to reconfirm their knowledge. Please read this Manual carefully and use the Palletizer with a clear understanding of its content.
Definition of Operator
Important! Definition of operator: Only AUTHORIZED PERSONNEL can operate the robot. The definition of “AUTHORIZED PERSON” is described below: The only personnel that can operate the robot and/or robot system, are those who have enough knowledge or experience of robot operation and have also been trained to operate the robot. They must also have been authorized by the employer.
UL(11)
Table of Contents
1. ROBOT .......................................................................................1-1 1.1. Robot Main Unit .................................................................................. 1-2 1.2. Periodic Maintenance and Inspection ................................................. 1-5 1.3. Inspection Contents ........................................................................... 1-6 1.4. Reference Materials Concerning Maintenance................................... 1-11
2. CONTROLLER .............................................................................2-1 2.1. Controller Internal Component Arrangement Diagram ....................... 2-2 2.2. Periodic Maintenance and Inspection ................................................. 2-6 2.3. Inspection Contents ........................................................................... 2-8
3. TROUBLESHOOTING ..................................................................3-1 3.1. Cases Where There is an Error Message ............................................. 3-2 3.2. Cases Where There is No Error Message............................................. 3-2
4. MAINTENANCE MENU.................................................................4-1 4.1. Menu structure ................................................................................... 4-2 4.2. Ordinary maintenance menu .............................................................. 4-3
UL(11)
1-1
1.Robot
UL(11)
1-2
1.1. Robot Main Unit A1800
Parts list of robot main unit
No. Name Model
1 Servo motor (T-axis) SGMPH04
2 Servo motor (D-axis) SGMGH55
3 Servo motor (O-axis) SGMGH55
4 Servo motor (R-axis) SGMGH55
5 Grease nipple A type,M6×1.0
6 Harness
7 Limit Switch D4D-1A32R
2
3
6
4
5
1
7
11(2009.01.28)
UL(11)
1-3
A1600 III
Parts list of robot main unit
No. Name Model
1 Servo motor (T-axis) SGMPH04
2 Servo motor (D-axis) SGMGH55
3 Servo motor (O-axis) SGMGH55
4 Servo motor (R-axis) SGMGH55
5 Grease nipple B type,M6×1.0
6 Harness
7 Limit Switch D4D-1A32R
2
3
1
4
5
6
7
UL(11)
1-4
A700II
Parts list of robot main unit
No. Name Model
1 Servo motor (T-axis) TS4609
2 Servo motor (D-axis) TS4836
3 Servo motor (O-axis) TS4836
4 Servo motor (R-axis) TS4836
5 Grease nipple B type,M6×1.0
6 Harness
7 Limit Switch D4D-1A32R
3
2
1
4
5
6
7
UL(11)
1-5
1.2. Periodic Maintenance and Inspection This section gives the periodic maintenance and inspection schedule, and explains inspection contents.
1.2.1.Inspection Types and Items For an Okura A series Robot Palletizer, there are the following four types of inspection: 3 basic types and overhaul.
No. Inspection type Explanation 1 Routine
inspection Routine inspection items
2 A inspection Perform every 1000 hours of operation 3 B inspection Perform every 10000 hours of operation 4 C inspection Perform every 20000 hours of operation
1. Inspection Schedule
Generally, the inspection schedule follows the cycles given below.
Operation time per day, and number of years Hours of
operation Routine
inspection A
inspection B
inspection C
inspection 8hours 16hours 24hours
1000 О 2000 О 1year 3000 О 4000 О 2years 1year 5000 О 6000 О 3years 1year 7000 О 8000 О 4years 2years 9000 О 10000 О О 5years 11000 О 12000 О 6years 3years 2years 13000 О 14000 О 7years 15000 О 16000 О 8years 4years 17000 О 18000 О 9years 3years 19000 О 20000
Routine
Insp
ection
О О О 10years 5years 3.3years
11(2009.01.28)
UL(11)
1-6
1.2.2.Inspection Items Periodic maintenance and inspection is divided into 4 levels, including overhaul, and the inspection contents at each level is as given in the following Table.
Inspection item Inspection contents
Routine
A
B
C
1 Routine inspection
Inspection for harness damage and
interference etc.
Check for abnormal noise and vibration during operation.
O
2 Hand
Inspection for hand rattling.
Check whether hand orientation is horizontal.
Lubrication of hand bearing section.
O
3 Electrical equipment Inspection for harness damage and kinking. O
4 Bearing lubrication Lubrication of R-axis bearing. O
5 Reduction gear grease replacement
Grease replacement. O
6 Parts replacement Replacement of standard replacement parts. O
1.3. Inspection Contents
1.3.1.Routine inspection Follow the instructions described in the Daily Service manual.
1.3.2.Hand The explanation here concerns standard hands for bags and cases.
Hand rattle
1. Check the fingers so that they are oriented correctly and securely fastened.
2. Check the actuator (air cylinder etc.) so that they are securely fastened and have no abnormal wear.
3. Check the harnesses so that they have no damages.
4. Check the air cylinder so that there are no loose nuts on the flow controls.
5. Check bolts so that they are securely fastened.
6. Check the frame for signs of cracking.
1
2 3
4, 5
4
11(2009.01.28)
UL(11)
1-7
Hand level The robot hand may deviate from horizontal if it touches or collides with stacked articles due to a programming mistake etc. This is because the hand incorporates a design feature to absorb the impact of the collision and minimize damage. A700III/ A1600III features as follows, The following explains how to recover when the hand deviates from horizontal.
1. Remove the plate of the wrist link lever.(See diagram at right)
2. Loosen the internal power lock screws, M8-30L 6 (in case A700III) M8-22L 11 (in case A1600III) in alternating diagonal fashion a little at a time. (Screws need only to be loosened to the point where the hand inclination can be corrected.)
3. Place a level on the top surface of the hand, and level the hand while checking the level reading. (Check that the hand mounted to the T-axis output shaft is horizontal.)
4. Using a torque wrench and proceeding in alternating diagonal fashion at a torque, 14.8 N-m (150kgf-cm) (in case A700 III) 23.5 N-m (240kgf-cm) (in case A1600III)
5. Raise the torque to 37.0 N-m (380kgf-cm) (in case A700III) 34.5 N-m (352kgf-cm) (in case A1600III) 40.2 N-m (410kgf-cm) (in case A1600III-W) Tighten in alternating diagonal fashion. Repeat this a few times. (at least 3 times) If there is reason for concern about corrosion, prevent bolt rusting by filling between the power lock and cover with grease.
Hand lubrication ( only for hands with LM guide) Open the hand palm, and use a grease gun to supply grease (Albania No.2, Showa Shell Petroleum) to the grease nipple on LM guide bearing case.). After lubricating, open and close the hand a few times, and lubricate again. Moreover, please wipe off the grease adhering to the rail etc.
11(2009.01.28)
Caution
The hand might incline further in
procedure 2. Please work in the
situation the hand is supported,.
Plate
A
UL(11)
1-8
Caution
The hand might incline further in
procedure 1. Please work in the
situation the hand is supported.
(A)
A1800 features as follows,
1. Loosen 10-bolts (M8 x 45L) in part (A) until just enough to get T axis back to level.,
2. Place a level on the top surface of the hand, and level the hand while checking the level reading. (Check that the hand mounted to the T-axis output shaft is horizontal.)
3. Using a torque wrench and proceeding in alternating diagonal fashion at a torque, 14.8 N-m (151kgf-cm)
4. Raise the torque to
29.0 N-m (296kgf-cm)
Tighten in alternating diagonal fashion. Repeat this a few times.
Hand lubrication ( only for hands with LM guide) Open the hand palm, and use a grease gun to supply grease (Albania No.2, Showa Shell Petroleum) to the grease nipple on LM guide bearing case.). After lubricating, open and close the hand a few times, and lubricate again. Moreover, please wipe off the grease adhering to the rail etc.
11（2009.01.28）
UL(11)
1-9
1.3.3. Electrical equipment Harnesses (Cables and air hoses)
1. Check that there is no looseness of harness connectors, no cable damage or kinking, no interference with the robot and peripheral equipment, no disconnection of connectors and no looseness of terminal block screws. Tighten if necessary.
2. Remove the cover on robot base and check the harness inside. Check that there is no damage, kinking. If there were any trouble, contact our service section.
3. Purchase of spare Harness between T Axis with hand is recommended. The Harness is included in the articles of consumption because it is influenced by environment such as the dust existence, the rotation frequency and the operation angle of the hand.
1.3.4.Bearing lubrication R-axis bearing
1. Move to the stroke end by operating in teach mode. Lock out and tag out the robot.
2. Using a grease gun, supply grease (Alvania No.2, Shell Petroleum) from the grease nipple. (about 10 pumps)
3. After lubrication, operate through the full stroke a few times. Then move to the opposite stroke end, lock out and tag out the robot.
4. Lubricate again at this point.
5. After lubrication, operate through the full stroke a few times.
* See Lock out and Tag out procedure in safety manual.
11(2009.01.28)
UL(11)
1-10
1.3.5.Reduction gear grease replacement Reduction gears are parts which might be replaced at B and C level inspection depending on wear.
Note B and C inspection are conducted in accordance with an agreement by Okura Service Co., Ltd.
1.3.6.Limit Switch R axis limit switch In the layout for which the revolution angle of R axis exceeds 260 degrees, please operate a limit switch manually and check the thing of an "emergency stop" out of which an error message comes. In addition, after the above-mentioned check should cancel operation of a limit switch with the reset button (blue) in a limit switch main part.
1.3.7.Parts replacement Standard Replacement Parts The following are standard replacement parts, which are replaced at C inspection (20000 hours inspection) No. Parts name Parts code location When to replace 1
Robot internal wiring
From robot base to robot hand
Recommend replacing wiring inside robot base if R Axis rotation angle is 180 degree or more. Recommend replacing wiring between robot and hand if T Axis rotation angle is 180 degree or more.
2
Servo motor See robot main part list
Recommend to replace servo motor if ambient temperature is close to 40 degree because electrical parts in encoder could be damaged.
３ Bearing All Axis Recommend to replace Bearing if it could be damaged.
４ R axis Cooling Fan (Only A1800)
109R1224M102
Rotor Recommend to replace fan.
11（2009.01.28）
UL(11)
1-11
1.4. Reference Materials Concerning Maintenance
1.4.1.Maintenance Parts The lubricants recommended here are designed to meet the demands of robot
operation, compliment scheduled maintenance, and maximize the useful service life of the equipment. No. Name/Model Qty. Area used 1 Lithium-based soap type grease #2 1kg Hand ,R-Axis bearing
1.4.2.Lubricant List
No. Lubrication point Lubricant grease type
Recommended grease brand
Appropriate amount /time
1 End Effector
(Linear Bearings/Varies)
2 R-Axis Turntable Bearing
Double Cross Roller Bearing
Lithium-based soap type grease #2
Albania No. 2
(Showa Shell)
40g
100gx2times
3
*)
Gear Reducers For Each Axis Only recommended type
Moly-white
(Kyodo Yushi)
See the table below
*)Replace grease for No.3 at overhaul. Amount of grease needed for reduction gear
Axis Model
R D O T
A1600III A1800
1920 1850 1850 120
A700III 1200 1000 1000 105 Units: cc
11（2009.01.28）
UL(11)
1-12
Material Size
Type
1.4.3.Bolt Fastening Torque Units:N·m (kgf-cm)
Allen bolt
S C M 4 3 5
M 5 7.0 (71.4) M 6 14.8 (151) M8 37.0 (378) M10 74.0 (755) M12 128 (1306)
[106 (1082)] M14 206 (2100)
[172 (1750)] M16 314 (3200) M18 [363 (3700)] M20 617 (6300)
Power lock A1600III:34.5 (352) A1600III-W:40.2 (410) A1800:29.0(296)
Figures inside the parenthesis [ ] indicate the bolt for reduction gear.
1.4.4.Parts supply assurance After shifting to robot new model, present model robot parts are continuing to supply for 10 years. And Okura repairs robot for 10 years. After those 10 years, Okura repair robot and supply robot parts as far as Okura can deal with.
11（2009.01.28）
UL(11)
2-1
2.Controller
UL(11)
2-2
FRONT VIEW BACK VIEW
LEFT VIEW RIGHT VIEW
2.1. Controller Internal Component Arrangement Diagram
2.1.1.A1600III A1800
The diagram here shows the arrangement of parts inside the robot controller. Please correlate these with the table on the following page.
11（2009.01.28）
UL(11)
2-3
Key Controller Parts (A1600Ⅲ A1800)
Parts No. Name Model NFB0 Circuit breaker NF-SFW 3P 70AT NFB1 Circuit breaker SA53RCUL/30 3P 30AT NFB2 Circuit breaker EA32AC 2P 3AT NFB3 Circuit breaker FAZ-D6/2-RT 2P 6A SP1 Surge protector R･A･V-801BXZ-4 NF1 Noise filter MBS-1340-33 NF2 Noise filter MBW-1203-22 CP1,2 Circuit protector CP31TM/2 1P 2A F1,2 Fuse CR2LS-50G/UL 50A TR1 Transformer STN0.5-S004 MC1,2 Magnetic contactor SC-N2/G MC3 Magnetic contactor SC-N1/G D1,2,3 Diode V03C D5,6 Diode RM3C VR1,2 Surge Killer ENE471D-14A VR3,4 Surge Killer ENE431D-20A RF Diode bridge RJDIO002 C1,5 Capacitor LQR2G392MSEG C2,3,4 Capacitor CD16-E2GA472MYNS RGT IGBT Module 2MBI100N-060 IPM IGBT Module 6MBP200RA060 CRS Current sensor HS-U100V4B15 FAN1,2,3,4 Fan MU1238A-12B FAN5,6 Fan MU1238A-12B Rs1 Resistance GG Type 40W 20Ω Rs2 Resistance GG Type 40W 30Ω Rs3,4,5,6,7,8 Resistance SMRK500W 500W 1.5Ω RC101 Host CPU board RC101 RC102 72I/O board RC102 RC103 Servo CPU board RC103 RC105 Servo power board RC105 RC106B Safety relay board RC106B RC107 200A Current board RC107 RC108 20A Current board RC108 TP Touch panel UG330H-SS4 RMC1,2 Safety relay G7SA-3A1B RBR Power relay G7J-4A-B-KM MR1 Terminal relay G6B-47BND SVC Receptacle WCF1041B TES Thermal sensor OHD3-100B AVR1 Switching regulator ZWQ80-5225 AVR2 Switching regulator ZWS100AF-24/J BAT BATTERY ER6K-♯17-A
11（2009.01.28）
UL(11)
2-4
LEFT VIEW RIGHT VIEW
FRONT VIEW BACK VIEW
2.1.2.A700III
The diagram here shows the arrangement of parts inside the robot controller. Please correlate these with the table on the following page.
UL(11)
2-5
Key Controller Parts (A700Ⅲ) Parts No. Name Model
NFB0 Circuit breaker NF-SFW 3P 50AT NFB1 Circuit breaker SA53RCUL/15 3P 15AT NFB2 Circuit breaker EA32AC 2P 3AT NFB3 Circuit breaker FAZ-D6/2-RT 2P 6A SP1 Surge protector R･A･V-801BXZ-4 NF1 Noise filter MBS-1320-33 NF2 Noise filter MBW-1203-22 CP1,2 Circuit protector CP31TM/2 1P 2A F1,2 Fuse CR2LS-20G/UL 20A TR1 Transformer STN0.5-S004 MC1,2 Magnetic contactor SC-N1/G MC3 Magnetic contactor SC-4-1/G D1,2,3 Diode V03C D5,6 Diode RM3C VR1,2 Surge Killer ENE471D-14A VR3,4 Surge Killer ENE431D-20A RF Diode bridge RJDIO002 C1 Capacitor LQR2G392MSEG C2,3,4 Capacitor CD16-E2GA472MYNS RGT IGBT Module 2MBI100N-060 IPM IGBT Module 6MBP100RA060-05 FAN1,2,3,4 Fan MU1238A-12B FAN5,6 Fan MU1238A-12B Rs1 Resistance GG Type 40W 40Ω Rs2 Resistance GG Type 100W 150Ω Rs3,4,5 Resistance SMRK500W 500W 5Ω RC101 Host CPU board RC101 RC102 72I/O board RC102 RC103 Servo CPU board RC103 RC104 100A Current board RC104 RC105 Servo power board RC105 RC106B Safety relay board RC106B RC110 20A Current board RC110 TP Touch panel UG330H-SS4 RMC1,2 Safety relay G7SA-3A1B RBR Power relay G7J-4A-B-KM MR1 Terminal relay G6B-47BND SVC Receptacle WCF1041B TES Thermal sensor OHD3-100B AVR1 Switching regulator ZWQ80-5225 AVR2 Switching regulator ZWS100AF-24/J BAT BATTERY ER6K-♯17-A
11（2009.01.28）
UL(11)
2-6
2.2. Periodic Maintenance and Inspection
2.2.1.Inspection Types and Items
For Okura A series robot palletizer, there are the following four levels of inspection:
No. Level Explanation 1 Routine Routine inspection items 2 A Perform every 1000 hours of operation 3 B Perform every 10000 hours of operation 4 C Perform every 20000 hours of operation
Inspection Schedule Generally the inspection schedule follows the cycle given below:
Operation time per day, and number of years Hours of
operation Routine
inspection
A
inspection
B
inspection
C
inspection 8hours 16hours 24hours
1000 О 2000 О 1year 3000 О 4000 О 2years 1year 5000 О 6000 О 3years 1year 7000 О 8000 О 4years 2years 9000 О 10000 О О 5years 11000 О 12000 О 6years 3years 2years 13000 О 14000 О 7years 15000 О 16000 О 8years 4years 17000 О 18000 О 9years 3years 19000 О 20000
Routine
Insp
ection
О О О 10years 5years 3.3years
11（2009.01.28）
UL(11)
2-7
2.2.2. Inspection Items
Inspection contents at each level are as given in the following table.
Inspection item Inspection contents
Routine
A
B
C
1.Routine inspection
Inspection for harness damage and interference etc. Check for controller lamp operation Check for abnormal noise and vibration during operation
O
2.Controller
Air filter cleaning Fan operation check Inspection for connector looseness
O
３.Battery replacement
Replacement in case of abnormal messages (warning, abnormality) or 2 years after exchanging the batteries
O
４.Parts replacement Replacement of standard replacement parts
O
B inspection is not done in the model described to this manual.
11（2009.01.28）
UL(11)
2-8
2.3. Inspection Contents
2.3.1.Routine inspection Follow the instructions described in the Daily Service manual.
2.3.2.Controller Function check of emergency stop switches
1. Remove the teaching pendant from the controller. And turn On the main power supply.
2. Turn the motor power ON.
3. Press emergency stop switch on the controller panel.
4. Check that motor power will turn OFF and error message will be displayed on the touch panel screen.
5. Attach the teaching pendant to the controller and do the same function check to the emergency switch on the teaching pendant.
Function check of the safety door switch
1. Remove the teaching pendant from the controller. And turn On the main power supply.
2. Turn the motor power ON
3. Open the safety door switch.
4. Check that motor power will turn OFF and error message will be displayed on the touch panel screen.
5. Attach the teaching pendant to the controller and do the same function check to the safety door switch.(with mode selection [Auto] )
6. Check that motor power will turn OFF and error message will be displayed on the touch panel screen.
7. Attach the teaching pendant to the controller and do the same function check to the safety door switch.(with mode selection [Manu] )
8. Check that no error message will be displayed on the touch panel screen and motor power is still On.
UL(11)
2-9
Function check on the intrusion detection switch If the system has intrusion detection switch, do the function check on the switch.
Air filter cleaning Clean the air filters at the side and back of the controller (Blow with air). (For the location of air filters, see controller appearance section in this manual) If filters are clogged, temperature inside the panel will rise abnormally, and trouble will result. cover air filter
PC board Check that boards inside the controller are dusty etc., and clean as necessary (blow with air --Approx. 2 Kgf/cm2).
Note If dry air is unavailable, blow off dust with contact cleaner.
Fan Operation Inspection Check that the fans at the side and back of the controller work normally when NFB0 is turned ON. If there is a flow of air when you touch with your hand outside or the cover, the fan is normal. (Do this after filter cleaning) If a fan is defective, it must be replaced immediately.
Screw Looseness Inspection Check for loose mounting screws for each part and each terminal, and tighten as necessary.
Connector Inspection Check that each connector inside the controller is securely connected
Air filter
Cover
UL(11)
2-10
2.3.3.Battery
● Memory Backup Battery When the error message “ 70. Battery voltage drop” appears, or 2 years after exchanging the battery, replace the battery.
Explanation Program data and other data in memory are maintained by the memory backup battery.
Important! If no batteries (either of the two) are connected while the main breaker is off (or during power failure), all data in the memory will be lost. Be sure to perform replacement according to the following way.
If the battery voltage is dropped,data in the memory will be lost by the main breaker off. Then buck up for recovery by OXPA-Qm/OXPA-PLC is recomenned in battery replacement. If the data in the memory is lost, then recover the memory data and setup “Hour-meter revision” of the touch panel after the battery replacement.
Battery Type: ER6K-#17-A (Hitachi-Maxell)
Battery Mounting Position The battery is mounted at the position shown in the diagram below on the CPU board inside the controller.
CN１１ CN 10
Memory Backup Battery
CPU board (RC101)
11（2009.01.28）
UL(11)
2-11
Before replacement
When message about battery is displayed, Refer to "About battery voltage low message (Page 2-15)" before replacement.
１．Check the battery manufacturer's safety instructions about the battery handling and scrapping.
２． Marking to the old battery is recommended for reliable replacement.
(＊）The consumption of new battery capacity
The consumption of new battery capacity is occurred when connecting with an empty battery and new battery. This consumption is prevented by the empty battery separating immediately after the new battery connection. This case is assumed that the influence on the backup time is a range of error.
Replacement Procedure
1. Turn OFF the main breaker.
2. Leave the battery to be replaced as is, and connect the brand new battery to the empty connector (CN10 or CN11).
3. Remove the old battery from the connector. （Within 5 seconds from new battery connection（＊））
4. Fasten the new battery to horizontal with the bracket.
5. Turn ON the main breaker.
After replacement
1. Check that the “Battery Voltage Low” error is reset.
2. Operate "Touch panel operation when batteries are replaced"(Page 2-14)
- Check the “Battery” display on automatic mode screen. Blue: normal Red: battery alarm
10 (2008.06.13)
UL(11)
2-12
● Encoder Memory Backup Battery Replacement When the error message “Encoder Battery Voltage Drop” appears, or 2 years after exchanging the battery, replace the battery.
Explanation Okura robot palletizers employ absolute encoders. Encoder memory backup batteries are necessary so that absolute encoders can retain position information even during a power failure.
Important!
If no batterｙ for encoders is connected or battery voltage is dropped while the main breaker is off (or during power failure), position information in the encoder will be lost. Be sure to perform replacement according to the following way.
Replacement work in the robot origin position is recommended for recovery of replacement error. If the data in the encoder memory is lost, Operate an origin storing after battery replacement. (Refer to the “Installation and Adjustment” Manual)
Battery Type: ER6K-#17-A (Hitachi Maxell) A1600III ER6K-#17-4 (Hitachi Maxell) A700III
Battery Mounting Position Inside robot base (See diagram)
Note
Because the harness leads to the cover, the cover cannot be separated from the base.
Battery
11（2009.01.28）
UL(11)
2-13
BAT-C1: Battery Connection Cable “BAT-C1” is setting for “replacement procedure A” in the robot base. If "BAT-C1" is connected, select "Replacement Procedure A".If "BAT-C1" is not connected, select "Replacement Procedure B".
Before replacement
When message about battery is displayed, Refer to "About battery voltage low message (Page 2-15)" before replacement.
１．Check the battery manufacturer's safety instructions about the battery handling and scrapping.
２． Marking to the old battery is recommended for reliable replacement.
3． Operate the robot origin position. Record the present position of the robot for the checking of the "After replacement". （Refer to the “Operation” Manual ）
(＊）The consumption of new battery capacity
The consumption of new battery capacity is occurred when connecting with an empty battery and new battery. This consumption is prevented by the empty battery separating immediately after the new battery connection. This case is assumed that the influence on the backup time is a range of error.
Replacement Procedure A（With Cable “BAT-C1“）
1. Turn OFF the main breaker.
2. Remove the cross recessed screw（M6-10L） for mounting the cover, and separate the cover form the base.（Confirm the connection of "BAT-C1". If "BAT-C1" is not connected, mount the cover, select "Replacement Procedure B".）
3. Remove the dust proof cap.
4. Leave the battery to be replaced as is, and connect the brand new battery to the empty connector.
5. Remove the old battery from the connector. （Within 5 seconds from new battery connection（＊3））
6. Connect the dust proof cap to the empty connector.
7. Mount the cover.
8.Turn ON the main breaker.
Battery
Dust proof cap Robot internal wiring
10 (2008.08.06)
UL(11)
2-14
Replacement Procedure B（No Cable “BAT-C1“）
1. Turn ON the main breaker.
2. Remove the cross recessed screw（M6-10L） for mounting the cover, and separate the cover form the base.
3. Remove the battery from the connector, and replace with new battery.
4. Mount the cover.
After replacement
１．Check that the “Battery Voltage Low” error is reset.
２．Check the position of the robot is the same as the record of the "Before replacement ３．"
３. Operate the "Touch panel operation when batteries are replaced"(Page 2-15)
４． Check that the error message “Battery voltage drop” is not issued.
- Check the “Battery” display on automatic mode screen. Blue: normal Red: battery alarm
10 (2008.08.06)
UL(11)
2-15
●Touch panel operation when batteries are replaced After exchanging the batteries, the following operation is necessary in "Hour-meter revision" screen of the touch panel. The movement procedure to the screen is as follows. System entry menu -> Hour-meter revision 1) Press the Replace key.
The battery beginning of using day is updated at a present date. Press the replace key for the controller when you replace the memory backup battery. Press the replace key for the robot when you replace the encorder battery.
●About battery voltage low message There are two kinds of abnormal messages (warning and abnormality) due to the decrease of the battery. 1) Memory's battery low (encoder battery low)
It is warning that the battery longevity (two years from the use beginning) approaches. As for this message, it is possible to reset with the abnormal release button even if the batteries are not replaced, and operating the robot is also possible continuously. However, if operating is continued, the voltage drop (abnormality) occurs and the backup data will be lost. Please replace the batteries as soon as possible (within about one week) after displaying the message. - After abnormal release (After deleting the message), red is displayed to " Battery" of the automatic mode screen. - Please do not intercept controller's main power supply until the battery is replaced to make sure.
2) Battery voltage drop (encoder battery voltage drop)
It is shown that the battery voltage decreased. When a controller main power supply is intercepted, the backup data is lost though it is possible to operate continuously when the message is displayed while working (a controller main power supply is being turned on). Please do not intercept controller's power supply until the battery is replaced. When the message is displayed at the beginning of work (A controller main power supply is turned on), the backup data has already been lost.. It is not possible to operate until restoring it according to the backup data.
10 (2006.11.01)
UL(11)
2-16
2.3.4.Parts replacement Standard Replacement Parts
No. Parts name Parts code location When to replace
1
Memory backup battery
ER6K-#17-A
Inside controller, (in the duct above CPU board)
Every 2 years
2
Encoder backup battery
ER6K-#17-A (A1600III)
ER6K-#17-4 (A1700III)
In the robot base
Every 2 years
3 Switching Regulator
4 Fan 5 Capacitor
Recommend to replace every 7 years.
6 Board
7 Magnetic Contactor
Recommend to replace when Overload or Regenerative Error occurred frequently.
8 Relay
(See controller internal component arrangement diagram)
(See controller internal component arrangement diagram)
Depend on the contact condition.
9 Main power lamp
Inquiry to Okura Group
Controller panel
Depend on the brilliance check
11（2009.01.28）
UL(11)
2-17
2.3.5.Fuse replacement
Circuit ID Current Rating Voltage Rating DC BUS A1800 A1600III F1,F2 50A DC４００V A700III F1,F2 20A DC４００V RC105 F3 0.1A AC25０V Service Receptacle F4 2.0A AC125V
F1, F2
When fusion occurred to F1 or F2 Fuse, replace the fuse.
Explanation Fuse set on DC300V Power circuit line for Over Current Protection.
CAUTION Check the voltage between P300A and N300A in TBR3 terminal is 0V. Confirm capacitor discharged.
Fuse Type:
CR2LS-50G/UL(Fuji Electric) A1600III A1800 CR2LS-20G/UL(Fuji Electric) A700III
Fuse Mounting Position
Set on inside the robot controller. See 2.1.1 A1600III or See 2.1.2 A700III (2.1 Controller Internal Component Arrangement Diagram.)
Replacement Procedure
1. Turn Off the main breaker. 2. Remove the screws for mounting the cover, and separate the cover form the
controller without touching Terminal. 3. Check the voltage between P300A and N300A in TBR3 terminal is 0V. 4. Remove screw for mounting the fuse, and replace with a new fuse by screw for
mounting. 5. Mount the cover by the screws. 6. Turn On the main breaker, Check that the error message “Error No. 201: Servo
power voltage too low” and “Error No. 202: Servo power voltage too high” are not issued.
6mm
3mm
F1, F2 Normal After Fusion
11（2009.01.28）
UL(11)
2-18
F3
When fusion occurred to F3 Fuse, replace the fuse.
Explanation Fuse set on RC105 Circuit Board for Over Current Protection.
Fuse Type:
SS2-0.1AN1(SOC) Fuse Mounting Position
Set on RC105 Board. See 2.1.1 A1600III 1800 or See 2.1.2 A700III (2.1 Controller Internal Component Arrangement Diagram.)
Replacement Procedure
1. Turn Off the main breaker. 2. Remove the screws for mounting Servo Amp Box Metal Cover, and separate the
cover form the controller. 3. Open fuse cover, and replace with a new fuse. 4. Close the fuse cover. 5. Mount on Servo Amp Metal Cover by the screws. 6. Turn On the main breaker, Check that Display turn to Auto mode after pressing the
abnormal reset button.
TBR2
When fusion occurred to F4 Fuse, replace the fuse.
Explanation Fuse set on Receptacle line （between RX3 and RX3B） for Over Current Protection. The receptacle is at the right side of the controller.
Fuse Type:
UL CSA FGMA 2A 125V （FUJI TERMINAL INDUSTRY CO LTD） Fuse Mounting Position
Set on TBR2. See 2.1.1 A1600III/A1800 or See 2.1.2 A700III (2.1 Controller Internal Component Arrangement Diagram.)
Replacement Procedure
1. Turn Off the main breaker. 2. Open Fuse Block, and replace with a new fuse. 3. Close Fuse Block. 4. Turn On the main breaker,
Check the Receptacle voltage (100V).
11(2009.01.28)
Fuse Block
Open
Close
UL(11)
3-1
3.Troubleshooting Follow the next procedure for troubleshooting.
Check if there is an error message on display screen. If there is an error message on display screen, refer to cause and remedy of each error message on screen. For detail information, see “Operation manual, 4-1 error message”.
In case no error message appears No error message is issued for low urgent problem (Like burning out of an indicator lamp bulb) of mal-adjustment due to poor stacking form. For problems of this type, correctly determine the occurrence situation (when) and occurring phenomenon (what), and then select the pertinent item from the table below, and take measures. (See 3.2 Cases where there is no error message)
UL(11)
3-2
3.1. Cases Where There is an Error Message Please refer to “Operation manual”.
3.2. Cases Where There is No Error Message No error message is issued for low urgency problems. (Like burning out of an indicator lamp bulb) For problems of this type, correctly determine the occurrence situation (Problem) and then select the pertinent item from the table below, and take measures.
Problem
(Occurring Phenomenon)
Cause Remedy
Main power lamp doesnot light up
Burn out of main power supply lamp. Replace lamp.
Burn out of DC24V power supply (AWR2).
Replace AWR2.
Tripping of breaker (NFB1,NFB2). Switch on again.
Measure voltage at the load side terminals RX3 and SX3 of the noise filter(NF2).
Normal if within the range of AC 200V ±10%.
Correct supplied power.
Reconsider and modify transformer capacity and cable size.
Measure voltage on the secondary side (R,S,T) of the main NFB(NFB0).
Normal if within the range of ±10% of the rated voltage.
Correct supplied power.
Reconsider and modify transformer capacity and cable size.
Nothing appears on the touch panel screen.
Check the voltage on AVR2 (normal if 24V).
Replace AVR2 if the voltage is abnormal.
If the voltage is normal, replace touch panel.
Defective connection of connector. Check harness.
Check connector.
Turn on the main power and check if theletter [check] appears on touch panel.
Check the voltage on AVR1 (normal if 5V). Replace AVR1 if the voltage is abnormal.
Check DC24V power supply (AVR2). Replace AVR2. Motor power display lamp does not light up Burn out of indicator lamp bulb. Replace lamp bulb.
Motor power does not switch on
Check the motor power ON condition in maintenance mode menu.
If RC103 ON enable can not be turned on, turn off main power supply.
Defective magnet switch (MS1). Replace magnet switch (MS1).
Arm movement is not smooth
Check the weight parameters -Hand weight(system parameter) -Article weight(program parameter)
Input the correct value.
Acceleration time is too short. Basically input the value in the standardprogram
Time scaling parameter (program parameter) is too small.
Basically input 0 for the time scaling parameter. If having margin in motor torque, it can be turned down to –25.
Check if the mechanical parts are Replace the defective parts.
UL(11)
3-3
Problem
(Occurring Phenomenon)
Cause Remedy
vibrating.(bearing, reducer, motor)
Arm movement is slow Check the speed parameter (in step parameter)
Basically input 10
Stacking position is shifted
When creating program in OXPA, check system parameters (pallet station, hand )
Input the correct value
Check the T-axis 0 degree position. Set the end effector parallel to the robot arm in T-axis origin setting.
System does not proceed to the next step
Check the sequence command where the robot waiting.
- Parts layout in controller are explained in section 2.1. - System parameters are explained in Installation and Adjustment manual. - Step parameters are explained in Teaching manual.
UL(11)
4-1
4. Maintenance menu There is some useful information on maintenance menu in a touch panel.
UL(11)
4-2
4.1. Menu structure Maintenance menu is displayed by choosing "Maintenance mode" in main menu, and every maintenance menu can be operated.
4.1.1.Move to maintenance menu under operation Basically maintenance menu is selected only when a robot is stopped. To move to maintenance menu under operation, press the hidden key located below on the auto mode screen. * In the case of returning from maintenance menu, it returns to auto mode screen
instead of main menu screen.
System storage mode
Teaching mode
Maintenance mode
Basic menu
Automatic operation mode
Auto mode screen
Maintenance mode screen
Main menu
：under operation
：during stop
Auto mode screen (under operation)
Hidden key
UL(11)
4-3
4.2. Ordinary maintenance menu
4.2.1.Data memory content Internal data memory contents (data held for each program) and external data memory contents (D) can be checked and modified on this screen.
1. Internal data memory data held for each program. D 0 ：stacking layer D 1 ：stacking work D 2 ：grip quantity D 3 ：robot data D 12 ：stop position (for the 1st bag) D 13 ：stop position (for the 2nd bag) D 14 ：centering position D 15 ：pressing height D 4 ～ 11 ：universal
2. External data memory D 1000 ～ D 2999 ：user area D 5000 ～ D 5015 ：user area D 6000 ～ D 6127 ：system area * 1 D 7000 ～ D 7015 ：supervisor area * 1 (*1：Although the values other than a user area can also be changed, do not change basically.) ● Press [Dis Prog No.=] key and input the required program No. to change the program
No. of displayed internal data memory. ● Press [Dis Strt No.=] key and input the required program No. to change the program
No. of displayed external data memory. Press [Continuous start] key to set to continuous display.
4.2.2.Deviation trace Deviation of each axis is displayed. (Max value and current value)
● Press [Max val clear] key to clear Max value. (Max value is memorized even if the power is OFF.)
UL(11)
4-4
4.2.3.Acceleration and deceleration time
1. Last executed 12 steps trace data is displayed. (Displayed data are position, acceleration time, and deceleration time.) * System is set to continuous display.
4.2.4.Operation ready condition
1. Every condition that the motor power ON enabling and operation start enabling are fulfilled or not is displayed. In case all conditions are highlighted, a motor power or operation can be supplied. * In case motor power does not turn on or operation does not start, check the condition in this screen.
Lighting condition:
RBT->(M503E,Y2B): following three conditions are satisfied at the same time. - “Initial pulse” is lighting. - “No Error” is lighting. - “No Warning” is lighting. Initial pulse: Reading an initial pulse is correctly completed. No Error: M603C is OFF. No Warning: M603D is OFF.
RC103 ON ena: following two conditions are satisfied at the same time. - Emergency stop is not detected. - Either of “RBT->M503E” or “RBT->Y2B” is lighting.
2. Input-output signal ON/OFF state connected board (RC103) can be shown in this screen lower part.
(New screen) On and after SH ver2.08B.
10(2008.06.13)
UL(11)
4-5
4.2.5.Stacked counter revision
1. Pallet position counter initialization The counter values of the corresponding program are displayed while selecting the pallet No. to initialize.
● Press [Initialize Pallet Selected] key to initialize the counter value of displayed current program.
● In case [All] key is selected in pallet selection, the counter values of all pallet (1 - 6) are initialized.
●Press [Initialize All Programs] key to initialize the counter values of all program stored in robot counter.
2. Counter Revision Counter value of each program No. can be changed in this screen.
● Press [Prog No.=] key and input the program No. to revise the counter.
● Press [Change] to input the value to revise. ● Press [Enter] to execute the counter revision.
* To hold a count value not per pallet but per program, counter revision of the program which is not stacked is also possible. * In case of moving to maintenance menu under operation, this screen is not displayable.
UL(11)
4-6
4.2.6.I/O monitor Internal rly (data held for each program), external rly (X/Y/M) can be checked and modified on this screen.
1. Internal rly Rly held for every each program R0 ～ R7 : universal
2. External rly
X0 ～ X77 (h) *1
Y0 ～ Y5F (h)
M5000(h) ～ M504F (h)
M6000(h) ～ M64FF (h) *1
M7000(h) ～ M701F (h) *1
(Cannot change the values at *1 area.)
● Press [X],[Y],[M] to display rly. ● Press [Program No.=] key and input the required program No. to change the program
No. of displayed internal rly. ● Press [Display Start No.=] key and input the required program No. to change the
program No. of displayed external rly. ● Press [Monitor Status] key to update screen display automatically.
UL(11)
4-7
4.2.7.Executed sequence command
1. The executed robot seq uence is displayed to the 40 newest. * Screen display is updated automatically. ● Press the hidden key upper left on the screen to clear the data.
4.2.8.Setting of Timer value
1. For RP, stop position, centering position, and press height can be set up for every station.
● To set up th e value, select the location value of value with cursor key.
● Press [+],[-] to set up the timer value.
● Press [Start] or [Stop] to operate or stop a robot in this screen. (For adjustment)
* Since a setting value is memorized for every program, while a program changes, a timer value setup of a corresponded station will also change.
* In the case of moving to this screen during robot operation, be able to return to the last screen only after a robot is stopped.
* The set-up value is set to the next data area. It is reflected when [+] or [-] is pressed.
Station1 Station2 Station3 Station4 Stop position (1st) D6096 D6100 D6104 D6108 Stop position (2nd) D6097 D6101 D6105 D6109 Centering position D6098 D6102 D6106 D6110 Press height D6099 D6103 D6107 D6111
UL(11)
4-8
4.2.9.Conveyor information
1. Start, stop, and latch clearance of Built-in PLC can be carried out. ● Press [Change] key to change operation and stop of corresponded PLC. Password is required (For system registration). ● Press [Latch clearance] to carry out latch clearance of Built-in PLC (normally speed + high speed). (Notes : in the only case of a stop state, normally and high speed PLC can be clearable.)
4.2.10.IDNo - PrgNo. allocation IDNo-PrgNo. allocation screen displays only at the time of the starting mode from Exterior PLC (memory switch 1 -5 ON).
1. ID and program allocation for centronics communication can be shown and registered. ● Press [ALL change], all allocation of IDNo.1 to 127 is canceled. ●Press [Change], IDNo. allocation changed screen is displayed.
（IDNo. allocation Changed screen）
1.Input IDNo. with ten-key. In the case of inputting assigned IDNo., [Present PrgNo.] is displayed on a screen. After inputting IDNo., a cursor moves to the location automatically to input PrgNo.
* A cursor can be also moved manually by pressing [IDNo.] key or [PrgNo.] key.
2.Input PrgNo. with ten-key. Press [Chnge] key to cancel PrgNo. already assigned.
3.After inputting IDNo. or PrgNo., Press [Enter] key.
UL(11)
Robot manual
Maintenance
11 Version: 2009.01.2８
Robot Palletizer described in this manual is under production since Mar 2005.
<caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice.
Okura Yusoki Co., Ltd. 900 Furuouchi, Noguchi-cho, Kakogawa,
Hyogo 675-8675 Japan
Related Documents
