Horizontal Articulated Robot – IX Series Wall-Mounting Type, Arm Length 300/350 IX-TNN-3015, IX-TNN-3515 (Wall-Mounting) IX-UNN-3015, IX-UNN-3515 (Inverse) Operation Manual Fifth Edition
Please Read Before Use Thank you for purchasing an IAI product. This operation manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product. The CD or DVD that comes with the product contains operation manuals for IAI products.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Table of Contents Safety Guide ······················································································································1 Caution in Handling ···········································································································8 1. Names of Robot Parts ································································································9 1.1 1.2 1.3 1.4 2.
8. Warranty ·················································································································· 70 8.1 8.2 8.3 8.4 8.5 8.
Safety Guide “Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it before the operation of this product. Safety Precautions for Our Products The common safety precautions for the use of any of our robots in each operation. No.
No. 2 2 Operation Description Transportation 3 Storage and Preservation 4 Installation and Start Description When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.
No. 4 Operation Description Installation and Start Description (2) Cable Wiring Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool. Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error.
No. 4 5 4 Operation Description Installation and Start Teaching Description (4) Safety Measures When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. When the product is under operation or in the ready mode, take the safety measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot’s movable range.
No. 6 7 Operation Description Trial Operation Automatic Operation Description When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.
No. 8 9 6 Operation Description Maintenance and Inspection 10 Modification and Dismantle Disposal 11 Other Description When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Perform the work out of the safety protection fence, if possible.
Alert Indication The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the Instruction Manual for each model. Level Degree of Danger and Damage Danger This indicates an imminently hazardous situation which, if the product is not handled correctly, will result in death or serious injury.
Caution in Handling 1. Make sure to attach the vertical articulated robot properly by following this operation manual. Using the product with the vertical articulated robot not being certainly retained or affixed may cause abnormal noise, vibration, malfunction or shorten the product life.
1 Names of Robot Parts Name of Each Part 1. Names of Robot Parts 1.1 (1) Wall-Mounting Specification ALM (Alarm indicator) U-cable (outside robot) PG cable (outside robot) 4 user piping (black, red, white; 3 locations) Brake power cable (outside robot) User connector Spacer for user BK SW (Brake-release switch) Mechanical stopper for arm 2 M cable (outside robot) Air tubes (4: 3 pcs.
1.
1.2 Moving Direction 1.
1. Names of Robot Parts 1.3 Labels The following labels are attached on the robot and controller. Be sure to observe the instructions and cautions written on the labels to ensure the correct use of the robot/controller.
1.4 Label Positions 1.
1.
2 2.1 Transportation and Handling Handling of the Carton x If the carton is heavy, one operator should not attempt to carry it alone. x Place the carton on a level surface if it is to be left there for a while. x Do not climb upon the carton. x Do not place on the carton any heavy object that may cause the carton to deform, or an article whose shape allows a load to be concentrated at one point. 2.
2.3 Handling of Individual Components 2. Transportation and Handling The robot and controller are supplied as a set. Your robot cannot be used with the controller supplied with another robot. When handling multiple robots, be careful not to lose their correct parings with the controllers. When unpacking or moving the machine, do not lift the robot directly by the rotational axis or flexible tube. (It may cause machine problems due to deformation, disconnection, etc.) 2.
2.5 Transporting the Robot When transporting the robot, affix the arms using the supplied arm fixing plate and arm support plate. Additionally, wrap the cables around the upper section and secure them with gummed tape or other means. Arm support plate Arm fixing plate Danger Warning z If the arms and cables remain free, the arms may turn unexpectedly and pinch a hand, or a person may be tripped by the trailing cables. z Do not attempt to carry the robot by hand, as it may injure the back.
3 Installation Environment and Storage Environment 3.1 Installation Environment 3.
4 How to Install Shown below is how to install SCARA Robot. 4.1 Installation Posture : Available s : Not available Horizontally Oriented Mount Ceiling-Mount s 4.
4.2 4.1 Structure of Mounting Wall The movement range of the wall-mounting type covers up to the rear of the base. However, due to its special installation specification (mounting on a wall), the range of movement may be limited significantly depending on the structure of the wall on which the robot is mounted. 130q 130q 120q 120q R300 R134.6 Mounting wall R125 260 130 or more 69.9q R125 Line of interference with base 69.
4.2 4.3 Installing the Robot x The base mounting surface has two Ø8H10 reference holes. Use these holes to prevent the machine from dropping during installation and also as guides for rough positioning. (To determine the precise position of the robot, use the base reference surface as a guide.) x When installing the robot, support it with the base and arm 1 with arms 1 and 2 extended, and affix onto the mounting surface.
4.4 Connecting the Controller The controller connection cables are attached on the robot (standard cable: 5 m, to air-tube joint: 150 mm). Pay attention to the following items when connecting the controller: Connect to the robot of the serial number specified on the robot designation label provided on the front panel of the controller. 4. How to Install Robot designation label Robot serial number Connect the cables securely after confirming that they are free from damage or bent connector pins.
Output voltage: 24 VDC r 10% Current capacity: 20 to 30 W 4. How to Install M cable 24 VDC power supply for brake (provided by user) PG cable Tool, control unit, etc. (provided by user) U cable (cable for user wiring) BK power cable Standard cable length: 5 m 150 mm 4, quick joint (3 pcs.) To air tube (provided by user) Warning z Before connecting or disconnecting a cable, always turn off the power to the controller.
4.5 4.4 Checking after Installation Once the robot has been installed, check the following items: 4. How to Install x Visually check the robot, controller and cables for dents and other abnormalities. x Confirm that the cables are connected properly and that the connectors are inserted securely. Warning z Failure to perform these checks may result in a malfunctioning robot or a damaged controller or robot.
5 5.1 Precautions for Use Reference Acceleration/Deceleration Settings 5. Precautions for Use Acceleration/deceleration (%) Use the robot based on appropriate acceleration/deceleration settings by referring to the following graph: (1) PTP operations (Use the ACCS/DCLS instructions of the SEL language for setting.
(2) CP operations (Use the ACC/DCL instructions of the SEL language for setting.) Arm length 300 Reference acceleration/deceleration settings for CP operation Arm length 300 Reference acceleration/deceleration settings for CP operation 1.6 Acceleration/deceleration (G) 5. Precautions for Use Acceleration/deceleration (G) 1.6 1.2 0.8 Reference range of maximum setting 0.4 Reference range for continuous operation setting 0 1.2 Reference range of maximum setting 0.
5.2 Tools The tool mounting part must have sufficient strength and rigidity, along with adequate fastening power to prevent positional shift. It is recommended that a tool be installed over a split ring, span ring or other appropriate part. A sample configuration of tool installation is given below. If the tool interferes with peripheral equipment, decrease the soft limit to reduce the operation area. D-cut surface Center of axis 1 (rotational axis) Tool Span ring, etc.
5.3 Carrying Load Load capacity Rated load capacity: 1 kg Maximum load capacity: 3 kg Load’s permissible moment of inertia 0.015 kgm (both rated and maximum) 5. Precautions for Use Load offset (from the center of axis 4 (rotational axis)) 40 mm or less Center of axis 4 (rotational axis) Load’s center of gravity 40 mm or less Caution z Set appropriate acceleration/deceleration according to the mass of the positioning precision and moment of inertia.
5.4 User Wiring and Piping The robot comes with standard cables and tubes that the user can use in a desired wiring/piping configuration. Air tubes Quick joint 4 (4: 3 pcs.) (white) M cable BK SW (outside robot) Brake-release switch Quick joint 4 (red) ALM (alarm indicator) U cable User connector Quick joint 4 (black) Brake power cable (outside robot) Spacer for user part installation Panel Rear panel User connector Rated voltage Permissible current Conductor size and number of wires Other 3.
The robot comes with a 15-pin plug for the D-sub connector for user wiring. Solder a user-supplied cable to the D-sub connector (plug), attach the supplied hood, and then connect to the user connector (socket). Use a shielded cable with an outer diameter of 11 or less. To turn on the indicator, the user must configure a dedicated circuit that uses the controller I/O output signal, etc.
6 Inspection/Maintenance 6.1 Inspection/Maintenance Your horizontal articulated robot must be inspected daily and on a regular basis to ensure safe, efficient operation. Perform the necessary inspections after confirming the maintenance/inspection items required for your IAI robot, as defined in this section. The following items must be adjusted at our factory.
6.1.1 Daily Inspection Check the following items daily before and after operating the robot. Observe the precautions for work near the robot and for inspection/maintenance/adjustment operations when carrying out each check. Check location Safety cage Robot Cables 6. Inspection/Maintenance Emergency-stop switch 6.1.2 Description Correct the deformation or positional shift of the cage. Confirm that the interlock mechanism is operating properly. Check the robot mounting bolts for looseness.
6.1.3 Yearly Inspection Check the following items on the robot every year. Observe the precautions for work near the robot and for inspection/maintenance/adjustment operations when carrying out each check. Check location Ball-screw spline * Harmonic speed reducer Description Check the shaft for looseness. (Contact IAI if an abnormality is found.) Change the grease. (Contact IAI.
6.2.2 Removing the Cover (1) With arms 1 and 2 extended as illustrated below, remove the four low-head cap screws [2] and six countersunk head screws [1] one by one. (2) Lift the panel and remove the motor connectors (M, PG and BK) from the back of the panel. (Do not cause the wires to be pulled with excessive force when lifting the panel.) (3) Lift the cover upward and remove. 6.
6.2.3 Checking the Belt Tension Timing belt for vertical axis 6. Inspection/Maintenance Timing belt for rotational axis 6.2.4 Checking the Belt Tension for the Vertical Axis Using a push-pull gauge, push the timing belt for vertical axis with a force of 300 gf and measure the amount of deflection. If the deflection is 2.4 mm, the belt tension is normal. If the deflection is not 2.4 mm, adjust the tension by referring to 6.2.6, "Adjusting the Belt Tension for the Vertical Axis.
6.2.5 Checking the Belt Tension for the Rotational Axis 6. Inspection/Maintenance Using a push-pull gauge, push the timing belt for vertical axis with a force of 300 to 400 gf and measure the amount of deflection. If the deflection is 0.7 mm, the belt tension is normal. If the deflection is not 0.7 mm, adjust the tension by referring to 6.2.7, “Adjusting the Belt Tension for the Rotational Axis.” Push-pull gauge Deflection (0.
6.2.6 (1) (2) (3) (4) (5) Adjusting the Belt Tension for the Vertical Axis Loosen the four M5 bolts [1] slightly, making sure the fastened points do not become overly loose. Loosen the lock nut [2], and then turn the adjuster bolt [3] to tension the belt. Check the belt tension by referring to “Checking the Belt Tension for the Vertical Axis.” Tighten the M5 bolts [1] loosened in step 1 (tightening torque: 7.6 Nm) and tighten the lock nut [2].
6.2.7 Loosen the two M4 bolts [1] slightly, making sure the fastened points do not become overly loose. Move the rotational-axis motor [2] to tension the belt. Check the belt tension by referring to 6.2.5, “Checking the Belt Tension for the Rotational Axis.” Tighten the bolts [1] loosened in step 1 (tightening torque: [1] 3.7 Nm). Check the belt tension again by referring to 6.2.5, “Checking the Belt Tension for the Rotational Axis.” (If the deflection has changed, perform the adjustment again.
6.2.8 Installing the Cover (1) Install the cover and connect the motor connectors extending from the rotary joint. (2) Affix the panel using the six countersunk head screws [1] by paying attention not to cause the wires to rest on top of one another. (Place the wires neatly in the upper space without letting them rest on top of one another. Do not forcibly tighten the screws with the panel still floating.) (3) Tighten the four low-head cap screws [2]. Panel Rotary joint 6.
6.3 Battery Replacement 6.3.1 Preparation The following items are required when replacing the batteries: x Hex wrench (2.5 mm) x New dedicated batteries for IX AB-3 (4 pieces) 6. Inspection/Maintenance Before replacing the batteries, turn off the power to the controller, control panel and other relevant units. Warning Caution z Performing inspection or maintenance without fully understanding the details of work may result in a serious accident.
6.3.2 Battery Replacement Procedure (1) Remove the six low-head cap screws [1] and remove the rear panel (base). (2) Remove the batteries from the battery holder. (3) Remove the battery connectors and connect new batteries. x After removing the old batteries, quickly connect new batteries (roughly within 1 to 2 minutes x number of batteries). x If new batteries are not connected for a longer period, the rotation data will be lost and an absolute reset will become necessary.
6.4 Absolute Reset Procedure 6.4.1 Preparation for Absolute Reset The following jig is required when performing an absolute reset: x Absolute reset adjustment jig (type: JG-2) 6. Inspection/Maintenance Connect the cables for the robot, controller and PC, so the robot can be operated from the PC. Before commencing the work, always confirm that the emergency-stop switch is functioning properly.
6.4.2 Starting the Absolute Reset Menu (1) Open the absolute reset window from the PC software. 6. Inspection/Maintenance (2) The absolute reset window opens. x One of three absolute reset screens—for arm 1, arm 2 and rotational axis + vertical axis—is displayed when a corresponding tab is clicked.
6.4.3 Absolute Reset Procedure for Arm 1 or 2 6. Inspection/Maintenance (1) Click the “Encoder Rotation Data Reset1” button. (2) Click the “Reset Controller Error” button.
(3) Click the “Servo ON” button. (5) Click the “Servo-OFF” button. 45 6. Inspection/Maintenance (4) Jog the arm to near the reference position (see reference position drawing in step 7), and click the “Jog end” button.
(6) Press the emergency-stop switch. 6. Inspection/Maintenance (7) Set an adjustment jig (pin) in arm 1 or 2 to fix the arm at the reference position. x Set the jig after confirming that the emergency-stop switch is pressed. x Set the jig after adjusting the arm to the reference position, using the positioning mark label as a guide. x Arm 1 has a cover (not arm 2), which is fixed with setscrews. Remove the setscrews and detach the cover before setting the jig.
(8) Click the “OK” button. 6. Inspection/Maintenance (9) Click the “Encoder Rotation Data Reset2” button.
(10) Remove the adjustment jig. x If you are working on arm 1, install the cover and secure it with the setscrews (not required for arm 2). (11) Release the emergency-stop switch. (12) Click the “OK” button. 6. Inspection/Maintenance x An arrow is shown next to the “Home pos. automatic update” button. Do not set this item. (In particular, be sure this item is not set when performing an absolute reset without using a jig).
6.4.4 Absolute Reset Procedure for the Rotational Axis + Vertical Axis (1) Click “Encoder Rotation Data Reset1” button. 6. Inspection/Maintenance (2) Click the “Reset Controller Error” button.
6. Inspection/Maintenance (3) Click the “Servo ON” button. (4) Click the “Temp. Standard posture standby” button. x The vertical axis returns to its home position. Exercise caution so as not to be injured by the axis during movement. (5) Jog the rotational axis to the reference position (see reference position drawing in step 8), and click the “Jog end” button.
(6) Click the “Servo-OFF” button. 6. Inspection/Maintenance (7) Press the emergency-stop switch.
(8) Affix the rotational axis at the reference position by setting the plate and pin of the adjustment jig as illustrated below. Set the jig after confirming that the emergency-stop switch is pressed. 1) Confirm that the rotational axis is roughly in the reference position. (Positioning marks for the rotational axis should align. With the wall-mounting specification, the D-cut surface should be on the right side when viewed from the front.
(9) Click the “OK” button. 6. Inspection/Maintenance (10) Click the “Encoder Rotation Data Reset2” button.
6. Inspection/Maintenance (11) Click the “Home pos. automatic update” button. (12) Remove the adjustment jig. (13) Release the emergency-stop switch. (14) Click the “OK” button.
(15) Click the “Servo ON” button. (17) Click the “Servo-OFF” button. 55 6. Inspection/Maintenance (16) Click the “Standard posture standby” button. x The vertical axis returns to its home position. Exercise caution so as not to be injured by the axis during movement.
6. Inspection/Maintenance (18) Click the “Encoder Rotation Data Reset3” button. (19) Click the “Home pos. automatic update” button, and then click “X” in the top right-hand corner to exit the absolute reset window. x Once the absolute reset is complete, be sure to write the flash ROM and reset the controller.
6.4.5 Writing the Flash ROM (1) Following an absolute reset of the rotational axis and vertical axis, the following screen opens when the absolute reset window is closed. Click the “Yes” button. x Clicking “Yes” writes the information in the flash ROM. x The flash ROM must also be written when home position automatic update has been performed for arm 1 or 2. 6. Inspection/Maintenance (2) When the writing of flash ROM is complete, the following screen is displayed. Click the “Yes” button.
6.4.6 Resetting the Controller 6. Inspection/Maintenance (1) Select “Software Reset” from the Controller menu on the tool bar. (2) Click the “Yes” button. The controller is reset and restarted.
7 Specifications 7.
7. Speci¿cations Item Operating environment Specifications Temperature: 0 to 40 C, humidity: 20 to 85%RH or less (non-condensing) 1,000 or less 71 20.
IX-TNN3515 (Arm Length 350, Wall-mounting) IX-UNN3515 (Arm Length 350, Inverse) Axis 4 (rotational axis) Positioning repeatability (*3) Axis 1 + Axis 2 Axis 3 (vertical axis) Axis 4 (rotational axis) Cycle time (*4) Load capacity Rated Maximum Push-in thrust Dynamic (*5) of axis 3 Static (*6) (vertical axis) Permissible moment of inertia Permissible load on axis 4 (*7) Permissible torque Tool allowable diameter (Note 6) Origin detection User wiring Alarm indicator (*8) User piping mm W degree mm degre
7. Speci¿cations Item Operating environment Specifications Temperature: 0 to 40 C, humidity: 20 to 85%RH or less (non-condensing) 1,000 or less 71 21.
7.
IX-TNN3515 (Arm Length 300) Arm 2 stopper 4 (Mechanical end) 4 - 9 16 counterbore, depth 0.5 (Opposite side of counterbore) 2 - 8H10 Tapped hole for peripheral installation (4-M4, depth 12) Same on opposite surface Reference surface Reference surface 4 (Mechanical end) 7.
IX-UNN3015 (Arm Length 300) T-slot for peripheral installation 4 (Mechanical end) Arm 2 stopper Arm 1 stopper Reference surface Tapped hole for peripheral installation (4-M4, depth 12) Same on opposite surface 4 (Mechanical end) 2 - 8H10 16 16h7 11 (inner diameter) 4 (white) quick joint 4 (red) quick joint ALM (*2) 35 BK SW Brake-release switch User connector 4 (black) quick joint User spacer Outer diameter 7, height 10, M4, depth 5 (*1) Detailed view of panel Detailed view
IX- UNN3515 (Arm Length 350) T-slot for peripheral installation Arm 1 stopper 16 Reference surface Reference surface 4 - 9 16 counterbore, depth 0.5 (Opposite side of counterbore) Tapped hole for peripheral installation (4-M4, depth 12) Same on opposite surface 2 - 8H10 4 (Mechanical end) 7.
7.3 Robot Operation Area IX-TNN3015 (Arm Length 300) IX-UNN3015 7.
68 U cable (outside robot) BK power cable (outside robot) PG cable (outside robot) M cable (outside robot) Cable fix cap (Capcon) Air joint, red (4) Air joint, white (4) Air joint, black (4) FG (To base) Board Servo motor for axis 1 (arm 1) Inside base Flexible cable U cable (inside robot) M cable (inside robot) PG ca ble (ou tsid e rob ot) Inside arm 2 FG (to D-sub housing) Electromagnetic brake for axis 4 (R-axis) Servo motor with brake for axis 4 (R-axis) Servo motor with brake for a
TS4606 N2032 E200 TS4606 N7032 E200 Axis 2 servo motor Axis 3 servo motor with brake Axis 4 servo motor M cable (inside robot) M cable (outside robot) 2 3 4 5 6 TS4602 N2032 E200 TS4607 N2027 E200 Axis 1 servo motor 1 Model number Code name No. /35 /35 IAI America, Inc. IAI America, Inc. Tamagawa Seiki Co.,Ltd. Manufacturer Remarks Used power line: Rated at 300 V, 80qC, AWG18 (0.89 mm2), Oil-proof cable, UL VW-1, c-UL FT-1 Used power line: Rated at 300 V, 105qC, AWG18 2 (0.
8. Warranty 8.1 Warranty Period One of the following periods, whichever is shorter: y 18 months after shipment from IAI y 12 months after delivery to the specified location y 2,500 hours of operation 8.2 Scope of Warranty Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: 7.
8.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications (1) If our product is combined with another product or any system, device, etc., used by the customer, the customer must first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc.
Change History Revision Date Change History April 2011 72 Description of Revision Third edition A page for CE Marking added March 2012 Fourth edition Introduction, Safety Symbols and Safety Precautions are deleted Pg. 1 to 7 Safety Guide added Pg. 8 Caution in Handling added Pg. 21 Brake voltage source capacity from 20W to 30W changed to 20W Pg. 31 Caution notes added telling to go to see the doctor to have an appropriate treatment when the grease got into an eye Pg.
Manual No.: ME3625-5A (August 2012) Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan TEL +81-54-364-5105 FAX +81-54-364-2589 website: www.iai-robot.co.jp/ Technical Support available in USA, Europe and China Head Office: 2690 W.
