1axis positioner maintenance manual [b-82545en 02]

7/25/2019 1axis Positioner Maintenance Manual [B-82545EN 02]

1/123

FANUC 1-Axis SERVO POSITIONER

M INTEN NCE M NU L

MECH NIC L UNIT


2/123

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and

understand the content.

This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller

labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.

No part of this manual may be reproduced in any form.

All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japans Foreign Exchange and

Foreign Trade Law. The export from Japan may be subject to an export license by the

government of Japan.

Further, re-export to another country may be subject to the license of the government of


3/123

B-82545EN/02 SAFETY PRECAUTIONS

1 SAFETY PRECAUTIONSFor the safety of the operator and the system, follow all safety

precautions when operating a robot and positioner and its peripheral

devices installed in a work cell.


4/123

SAFETY PRECAUTIONS B-82545EN/02

1.1 OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is very

dangerous to enter the operating space of the robot during automatic

operation, adequate safety precautions must be observed.

The following lists the general safety precautions. Carefulconsideration must be made to ensure operator safety.

(1) Have the robot system operators attend the training courses held

by FANUC.

FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot and positioner are stationary, it is possible

that the robot is still ready to move state and is waiting for a signal.

In this state, the robot is regarded as still in motion. To ensure

operator safety, provide the system with an alarm to indicate

visually or aurally that the robot is in motion.

(3) Install a safety fence with a gate so that no operator can enter the

work area without passing through the gate. Equip the gate with

an interlock that stops the robot when the gate is opened.

At this time, the positioner as well as the robot must be located

within the fence completely.

The controller is designed to receive this interlock signal. When the gate is

opened and this signal received, the controller stops the robot in an

emergency. For connection, see Fig.1.1 (a).

(4) Provide the peripheral devices with appropriate grounding (Class

1, Class 2, or Class 3).

(5) Try to install the peripheral devices outside the work area.(6) Draw an outline on the floor, clearly indicating the range of the

robot motion, including the tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with an

interlock to a visual or aural alarm that stops the robot and

positioner when an operator enters the work area.


5/123


(9) When adjusting each peripheral device independently, be sure to

turn off the power of the robot.

Note) Terminals FENCE1 and FENCE2are on the PC board in theoperator's panel.

Panel board

For R-J3iB CONTROLLER

EAS1

EAS1,EAS11, EAS2,EAS21 R-J3iC

Panel board Note) Terminals EAS1, 11 and EAS2, 21 are on the

PC board on the operators panel.

Refer to the R-30iA CONTROLLER


6/123


1.1.1 Operator Safety

The operator is a person who operates the robot system. In this sense, a

worker who operates the teach pendant is also an operator. However,

this section does not apply to teach pendant operators.

(1) When the robot and positioner do not need to operate, turn off the

power of the robot controller or press the emergency stop buttonbefore work.

(2) The operator must operate the robot system outside the work area

of the robot or positioner.

(3) Install a safety fence with a safety gate to prevent any worker other

than the operator from entering the work area unexpectedly and

also to prevent the worker from entering a dangerous area.

(4) Install an EMERGENCY STOP button within the operator's

reach.

The robot controller is designed to be connected to an external

EMERGENCY STOP button. With this connection, the controller stops the

robot operation when the external EMERGENCY STOP button is pressed.

See the diagram below for connection.

External EMERGENCYSTOP button Panel board

Note) Connect between EMGIN1 and EMGIN 2.

Terminals EMGIN1 and EMGIN2 are on the

Panel board.

Fig.1.1.1 (a) Connection Diagram for External Emergency Stop Switch

(For R-J3iB CONTROLLER)

External EMERGENCY STOP button

Panel board


7/123


1.1.2 Safety of the Teach Pendant Operator

When teaching the robot and positioner, the teach pendant operator

needs to enter the work area of the robot or positioner. The teach

pendant operator must give special consideration to safety.

(1) When it is not necessary to enter the work area of the robot or

positioner, perform work outside the work areas.(2) Before teaching work, check that the robot, positioner, and

peripheral device are not placed in a dangerous or abnormal state.

(3) When it is necessary to enter the work area of the robot or

positioner for teaching work, check the place and state of safety

apparatus such as the emergency stop button and dead man's

switch of the teach pendant.

The teach pendant supplied by FANUC is provided with a teach pendantenable switch and a deadman's switch in addition to the EMERGENCY STOP

button. The functions of each switch are as follows.

EMERGENCY STOP button : Pressing this button stops the robot in an

emergency, irrespective to the condition

of the teach pendant enable switch.

Deadman's switch : The function depends on the state of the

teach pendant enable switch.

When the enable switch is on - Releasing the finger from the dead man's

switch stops the robot in an emergency.When the enable switch is off-The deadman's switch is ineffective

NOTEThe deadman's switch is provided so that the robotoperation can be stopped simply by releasing fingerfrom the teach pendant in case of emergency.


8/123


(4) The teach pendant operator needs to exercise special caution to

prevent other people from entering the work area of the robot or

positioner.

NOTEIn addition to the above, the teach pendant enableswitch and the deadman's switch also have the

following function.By pressing the deadman's switchwhile the enable switch is on, the emergency stopfactor (normally the safety gate) connected to thecontroller is invalidated. In this case, it is possible foran operator to enter the fence during teach operationwithout pressing the EMERGENCY STOP button. Inother words, the system understands that thecombined operations of pressing the teach pendant

enable switch and pressing the deadman's switchindicates the start of teaching.The teach pendant operator should be well awarethat the safety gate is not functional under thiscondition and bear full responsibility to ensure that noone enters the fence during teaching.

(5) When entering the work area of the robot or positioner, the teach

pendant operator always needs to enable the teach pendant. In

particular, when the teach pendant enable switch is disabled, the

teach pendant operator needs to exercise caution to prevent the

robot from being started by an operator's panel other than the teach

pendant.

The teach pendant, operator panel, and peripheral device interface sendeach robot start signal. However the validity of each signal changes as

follows depending on the ON/OFF switch on the Teach pendant and the

three modes switch on the Operators panel and Remote condition on the

software.


9/123


(6) To start the robot by the operator's panel, confirm that there is no

people near the robot or positioner and that there is no

abnormality.

(7) When a program is completed, be sure to carry out a test run

according to the procedure below.

(a) Run the program for at least one operation cycle in the single

step mode at low speed.

(b) Run the program for at least one operation cycle in the

continuous operation mode at low speed.

(c) Run the program for one operation cycle in the continuous

operation mode at the intermediate speed and check that no

abnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in the continuous

operation mode at the normal operating speed and check that

the system operates automatically without trouble.

(e) After checking the completeness of the program through thetest run above, execute it in the automatic operation mode.

(8) While operating the system in the automatic operation mode, the

teach pendant operator should leave the robot work area.


10/123


1.1.3 Safety During Maintenance

For the safety of maintenance personnel, pay utmost attention to the

following.

(1) Except when specifically necessary, turn off the power of the

controller while carrying out maintenance. Lock the power switch,

if necessary, so that no other person can turn it on.(2) When disconnecting the pneumatic system, be sure to reduce the

supply pressure.

(3) Before the start of teaching, check that the robot and positioner

and its peripheral devices are all in the normal operating condition.

(4) When performing maintenance within the work area of the robot

or positioner with the power on, maintenance personnel needs to

indicate that maintenance is in progress and exercise caution to

prevent anyone from starting the robot accidentally.

(5) Do not operate the robot in the automatic mode while anybody is

in the robot work area.

(6) When it is necessary to maintain the robot alongside a wall or

instrument, or when multiple workers are working nearby, make

certain that their escape path is not obstructed.

(7) When a tool is mounted on the robot, or when any moving device

other than the robot is installed, such as belt conveyor, pay careful

attention to its motion.

(8) If necessary, have a worker who is familiar with the robot system

stand beside the operator's panel and observe the work being

performed. If any danger arises, the worker should be ready to

press the EMERGENCY STOP button at any time.

(9) When replacing or reinstalling components, take care to prevent

foreign matter from entering the system.

(10) When handling each unit or printed circuit board in the controller

during inspection, turn off the power of the controller and also turn

off the circuit breaker to protect against electric shock.(11) When replacing parts, be sure to use those specified by FANUC.

In particular, never use fuses or other parts of non-specified

ratings. They may cause a fire or result in damage to the

components in the controller.


11/123


1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

1.2.1 Precautions in Programming

(1) Use a limit switch or other sensor to detect a dangerous condition

and, if necessary, design the program to stop the robot when the

sensor signal is received.(2) Design the program to stop the robot when an abnormal condition

occurs in any other robots or peripheral devices, even though the

robot itself is normal.

(3) In a system in which the robot or positioner operates in sync with

peripheral devices, exercise caution against mutual interference.

(4) The interlock between the robot and peripheral devices is

necessary to check the states of all devices in the system using the

robot or positioner, so that the robot and positioner can be stoppedas needed.

1.2.2 Precautions for Mechanism

(1) Keep the component cells of the robot system clean, and operate

the robot in an environment free of grease, water, and dust.

(2) Employ a limit switch or mechanical stopper to limit the robot

motion so that the robot and the positioner do not come intocontact with its peripheral devices or tools.


12/123


1.3 SAFETY OF THE ROBOT MECHANISM

1.3.1 Precautions in Operation

(1) When operating the robot or positioner in the jog mode, keep an

appropriate speed so that the operator can take a responsive action

in any eventuality.(2) Before pressing the jog key, be sure to understand in advance how

the robot or positioner operates by the key.


(1) When the work areas of robots overlap, make certain that the

motions of the robots do not interfere with each other.

(2) Be sure to specify a certain work origin in a motion program forthe robot or positioner and make sure that the motion program

starts from and ends at the origin. This makes it clear at a glance

whether the robot has completed work.

1.3.3 Precautions for Mechanisms

(1) Clean the inside of the work area of the robot or positioner to

eliminate the effect of oil, water, and dust.


13/123


1.4 SAFETY OF THE END EFFECTOR


(1) To control the pneumatic, hydraulic and electric actuators,

carefully consider the necessary time delay after issuing each

control command up to actual motion and ensure safe control.(2) Provide the end effector with a limit switch, and control the robot

system by monitoring the state of the end effector.

1.5 SAFETY IN MAINTENANCE

(1) Never enter the work area of the robot or positioner during

operation. When entering the work area of the robot or positionerfor inspection or maintenance, turn off the power.

(2) If it is necessary to enter the robot work area with the power turned

on, first press the EMERGENCY STOP button on the operator's

box.

(3) When replacing or reinstalling components, take care to prevent

foreign matter from entering the system. When replacing the parts

in the pneumatic system, be sure to reduce the pressure in the

piping to zero by turning the pressure control on the air regulator.(4) When handling each unit or printed circuit board in the controller

during inspection, turn off the power of the controller and turn off

the circuit breaker to protect against electric shock.

(5) When replacing parts, be sure to use those specified by FANUC.

In particular, never use fuses or other parts of non-specified

ratings. They may cause a fire or result in damage to the

components in the controller.

(6) Before restarting the robot, be sure to check that no one is in the

robot work area and that the robot and its peripheral devices are all

in the normal operating state.


14/123


1.6 WARNING LABEL

(1) Greasing and degreasing label

Fig. 1.6 (a) Greasing and Degreasing Label

DescriptionWhen greasing and degreasing, observe the instructions indicated on

this label.

1) When greasing, be sure to keep the grease outlet open.

2) Use a manual pump to grease.

3) Be sure to use a specified grease.

CAUTION

See section I 3.1 GREASE REPLACEMENT for

explanations about specified greases, the amount ofgrease to be supplied, and the locations of greaseand degrease outlets for individual models.


15/123


(2) Step-on prohibitive label

Fig. 1.6 (b) Step-on Prohibitive Label

DescriptionDo not step on or climb the robot or controller as it may adversely affect

the robot and positioner and you may get hurt if you lose your footing as

well.

(3) High-temperature warning label


16/123


17/123


>600kg

>600kg

>450kg

Fig. 1.6 (e) Transportation label (1000kg load capacity type)

DescriptionWhen transporting the positioner, observe the instruction on the

transportation label. The above label includes the followinginstructions.

1) Using a crane

Use a crane having a load capacity of 5880 N (600 kg) or

greater.

Use one sling having a withstand load of 5880 N (600 kgf) or

greater. Use two M16 eyebolts with a withstand load of 4410 N (450

kgf) or greater. (The eyebolts are attached during shipment.)

WARNINGWh t l i tt h d th t f


18/123


19/123

B-82545EN/02 PREFACE

PREFACE

This manual describes maintenance and connection work for the servo

positioner. Before replacing parts, check the specifications of the

mechanical unit.

Model name Mechanical unit specification No.

1-Axis Servo Positioner (300kg) A05B-1220-J101

1-Axis Servo Positioner (1000kg) A05B-1220-J102

OSHINO-MURA.YAMANASHI PREF.JAPAN

(3)(2)

(4)

(1)

WEIGHT

(5)

TYPE

NO.DATE


20/123

PREFACE B-82545EN/02

Specification

Item Specifications

Motion range 740(-370to +370) 12.9 rad (-6.45 rad to +6.45 rad)

Continuous rotation is available.

Maximum operation

speed

160/sec 2.79 rad/sec 120/sec 2.09 rad/sec

Max. load capacity 300 kg 1000 kg

Allowable load

moment

36 kgf .m 353 N .m 160 kgf .m 1,568 N .m

Allowable bending

moment250 kgf .m 2450 N .m 2100 kgf .m 20,580 N .m

Allowable load inertia 2,350 kgf .cm .s2 240 kg .m

2 4,700 kgf .cm .s

2 460 kg .m

2

Drive method Electric servo drive by AC servo motor

Weight About 85 kg About 280kg

Follower unit (option)

weight

About 40 kg -

Installationenvironment

Ambient temperature : 0 - 45C

Ambient humidity : Normally: 75%RH or less

: Short time 95%RH or less

(within 1 month)

(No dew or frost allowed)

Vibration : 0.5G (4.9m/s2) or less

* A follower unit (A05B-1220-J151) is available as an option for

300kg load capacity type.

Dust-proof/drip performance

Normal specification

MECHANICAL UNIT IP54

CAUTIONDefinition of IP 54

5=Dust-tight4=Protection from water immersion

Performance of resistant chemicals and resistant solvents

(1) The positioner (including severe dust/liquid protection model)

b d i h h f ll i li id b h i f h


21/123

B-82545EN/02 PREFACE

RELATED MANUALS For the FANUC Robot series, the following manuals areavailable:

Safety handbook B-80687EN

All persons who use the FANUC Robot and system

designer must read and understand thoroughly this

handbook

Intended readers :

All persons who use FANUC Robot, system designer

Topics :

Safety items for robot system design, operation, maintenance

Setup and Operations

manual

LR ARC TOOL

B-82094EN

LR HANDLING TOOL

B-81524EN

Intended readers :

Operator, programmer, maintenance person, system

designer

Topics :

Robot functions, operations, programming, setup, interfaces,

alarms

Use :

Robot operation, teaching, system design

R-J3iB Mate

controller

Maintenance manual

B-81525EN

B-81525EN-1

(European specification)

Intended readers :

Maintenance person, system designerTopics :

Installation, connection to peripheral equipment, maintenance

Use :

Installation, start-up, connection, maintenance


manual

SPOT TOOL

B-81464EN-1

HANDLING TOOLB-81464EN-2

ARC TOOL

B-81464EN-3

Intended readers :


designer

Topics :

Robot functions, operations, programming, setup, interfaces,alarms

Use :

Robot operation, teaching, system design

R-J3iB controller

Maintenance manual

B-81465EN

B-81465EN-1

Intended readers :

Maintenance person, system designer

Topics :

Installation, connection to peripheral equipment, maintenance

Use :

Installation, start-up, connection, maintenance


manual

SPOT TOOL+

B-82594EN-1

HANDLING TOOL

Intended readers :


designer

Topics :

Robot functions operations programming setup interfaces

R-30iA controller


22/123


23/123

B-82545EN/02 TABLE OF CONTENTS

TABLE OF CONTENTS

SAFETY PRECAUTIONS............................................................................s-1

PREFACE....................................................................................................p-1

I MAINTENANCE

1 CONFIGURATION ..................................................................................3

2 PREVENTIVE MAINTENANCE...............................................................5

2.1 DAILY INSPECTION ..................................................................................... 6

2.2 QUARTERLY INSPECTION..........................................................................8

2.3 ONE-AND HALF-YEAR PERIODIC INSPECTION (5,760 hours).................. 8

2.4 THREE-YEAR PERIODIC INSPECTION (11,520 hours) .............................. 8

2.5 MAINTENANCE TOOLS ............................................................................... 9

3 PERIODIC MAINTENANCE..................................................................11

3.1 GREASE REPLACEMENT.......................................................................... 12

3.2 PROCEDURE FOR RELEASING THE GREASE RESIDUAL PRESSURE 143.3 BATTERY REPLACEMENT ........................................................................ 15

4 TROUBLESHOOTING ..........................................................................17

4.1 GENERAL ...................................................................................................18

4.2 PROBLEMS AND CAUSES......................................................................... 19

4.3 BACKLASH MEASUREMENT..................................................................... 26

4.4 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS .................... 28

5 ADJUSTMENTS....................................................................................29

5.1 REFERENCE POSITION AND MOVING RANGE....................................... 30

5.2 MASTERING ............................................................................................... 32


24/123

TABLE OF CONTENTS B-82545EN/02

6.2 REPLACING THE REDUCER ..................................................................... 53

6.3 SEALANT APPLICATION............................................................................ 55

7 PIPING AND WIRING ...........................................................................57

7.1 WIRING DIAGRAMS ................................................................................... 58

7.2 CABLING (WHEN THE HARTING CONNECTOR OPTION IS SELECTED)59

8 CABLE REPLACEMENT......................................................................60

8.1 REPLACING CABLES................................................................................. 61

II CONNECTION

1 POSITIONER OUTLINE DRAWING .....................................................65

1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM........................ 66

2 MOUNTING DEVICES ON THE POSITIONER.....................................68

2.1 POSITIONER LOAD CONDITION............................................................... 69

3 TRANSPORTATION AND INSTALLATION .........................................71

3.1 TRANSPORTATION.................................................................................... 72

3.2 STORING THE POSITIONER.....................................................................74

3.3 INSTALLATION ........................................................................................... 75

3.4 MAINTENANCE CLEARANCE.................................................................... 80

3.5 ASSEMBLING THE POSITIONER FOR INSTALLATION ........................... 82

3.6 INSTALLATION CONDITIONS.................................................................... 83

APPENDIX

A SPARE PARTS LISTS ..........................................................................87

B CONNECTION DIAGRAMS 89


25/123

I. MAINTENANCE


26/123


27/123

B-82545EN/02 MAINTENANCE 1.CONFIGURATION

1 CONFIGURATIONFig. 1 shows the configuration of the mechanical unit.

The axis drive mechanism is configured in such a way that the flange

base is rotated by reducing the rotation speed of an AC servo motor

with a reducer.

The flange base is supported on the base through the reducer.

Motor

Reducer

Flange

Base


28/123

1.CONFIGURATION MAINTENANCE B-82545EN/02

SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS

Table 1 (a) Motor

Specification Name Load capacity

A06B-0235-B605#S000 iS8/4000 300kg

A06B-0265-B605#S000 iS22/4000 1000kg

Table 1 (b) Reducer

Specification Weight Load capacity

A97L-0218-0805#37 19.5 kg 300kg

A97L-0218-0819 91kg 1000kg

Table 1(c) Gear

Specification Name Load capacity

A290-7216-X212 Center gear 300kg

A290-7220-X111 Input gear 300kg


29/123

B-82545EN/02 MAINTENANCE 2.PREVENTIVE MAINTENANCE

2 PREVENTIVE MAINTENANCEDaily inspection, periodic inspection, and periodic maintenance can

keep the performance of the positioner stable for a long period of time.

NOTEThe annual operating time of the 1-axis servopositioner is assumed to be 3840 hours.When using the positioner beyond this annualoperating time, correct the maintenance frequency

in this chapter, which is determined on assumptionthat the positioner is used for 3860 hours per year,and perform maintenance as appropriate.


30/123

2.PREVENTIVE MAINTENANCE MAINTENANCE B-82545EN/02

2.1 DAILY INSPECTION

Clean and maintain each robot component during everyday system

operations. At the same time, check the components to see if there is a

crack or break in them. Also check and maintain the following items as

required.

a) Before automatic operation

No. Inspection item Inspection procedure

1 Pneumatic

pressure check

Make a pneumatic pressure check,

using the three-piece pneumatic

option shown in Fig. 2.1.

If the measured pneumatic

pressure does not fall in the range

between 0.5 and 0.7 MPa (5 and 7

kg/cm2), make adjustments, using

the regulator pressure setting

handle.

2 Check on the

amount of oil

mist

Put the pneumatic pressure system

in operation and check the amount

of oil dripping. If the measured

amount of oil dripping does not

meet the rating (one drop/10 to 20

seconds), make adjustments, usingthe oil adjustment knob. The oiler

becomes empty after 10 to 20 days

of normal operation.

3 Check on the

amount of oil

Check to see if the amount of oil in

the three-piece option is within the

rated level shown in Fig. 2.1.

4

For

machines

with a

three-piece

pneumatic

option

Check for

leakage from the

piping

Check to see if a joint or hose leaks.

If you find a problem, tighten the

joint or replace any defectivecomponent.

5 Whether cables are abnormal

Mechanical unit

See Chapter 8.

6 Battery voltage check Make sure that when the power is

turned on, the BLAL alarm has not


31/123



9 Reliable operation of peripheral

equipment

Check to see if the machine

operates exactly according to

directions from the robot and

peripheral equipment.

10 Check on the operation of the

brake.

See Section 4.2.

Fig. 2.1 Three-piece pneumatic option

b) After automatic operation

Once you are finished with automatic operation, bring the

positioner to its reference position, and turn it off.


1 Component cleaning

and inspection

Clean and maintain each component. At the

same time, check the components to see if

there is a crack or break in them.


32/123


2.2 QUARTERLY INSPECTION

Inspect the following items at regular intervals of about three months.

Increase the locations and the frequency of inspection if necessary (or

960 hours operating).


1 Loose connector Check that the motor connectors or other

connectors are not loose.

2 Loose bolt Check that the cover retaining bolts or

external bolts are not loose. In particular,

check the following three points.

1 axis positioner, Follower unit base fixing

bolts

Bolts fixing jigs to the flange surface

motor cover retaining bolts

3 Debris removal Remove any spatter, debris, and dust fromthe mechanical unit.

2.3 ONE-AND HALF-YEAR PERIODIC INSPECTION(5,760 hours)

Perform the following inspection/maintenance item at regular intervals

of about one year and half (or 5,760 hours operating).


1 Battery replacement Replace the battery in the mechanical

unit. (See Section 3.3.)

2.4 THREE-YEAR PERIODIC INSPECTION (11,520 hours)Perform the following inspection/maintenauce item at regular intervals

of three year.


33/123


2.5 MAINTENANCE TOOLS

You should have the following instruments and tools ready for

maintenance.

a) Measuring instruments

Instrument Condition Use

Dial gauge 1/100mm For positioning precision and

backlash measurement

Calipers 150mm

b) Tools

Phillips screwdrivers (large, medium, and small sizes)

Flat-blade screwdrivers (large, medium, and small sizes)

Box wrenches (M3 to M6)

Allen wrenches (M3 to M20)Torque wrench See Table 2.6.

Long T wrenches (M5, M6 and M8)

Adjustable wrenches (medium and small sizes)

Pliers

Long-nose pliers

Cutting pliers

Both-ended wrench

Grease gunC-ring pliers

Flashlight

Seal tape

Loctite No. 242, 262, 675

Sling

Gear puller

NOTEPrepare torque wrenches that enable the torquevalues indicated in Table 2.5 to be set.

NOTE


34/123


Table 2.5

Bolt size Torque setting value

M3 1.3 Nm (13 kgfcm)

M4 4 Nm (41 kgfcm)

M5 9 Nm (92 kgfcm)

M6 15.6 Nm (159 kgfcm)

M8 37.2 Nm (380 kgfcm)

M10 73.5 Nm (750 kgfcm)M12 128.4 Nm (1310 kgfcm)

M14 204.8 Nm (2090 kgfcm)

M16 318.5 Nm (3121 kgfcm)


35/123

B-82545EN/02 MAINTENANCE 3.PERIODIC MAINTENANCE

3 PERIODIC MAINTENANCE


36/123

3.PERIODIC MAINTENANCE MAINTENANCE B-82545EN/02

3.1 GREASE REPLACEMENT

The grease for the reducers needs to be replaced every three years or

11,520 hours in the procedure shown below. For greasing points, see

Figs. 3.1 (a) and (b).

Remove the seal bolts and plugs of the grease outlets shown in

Figs. 3.1(a) and (b). Attach the grease nipple supplied with the positioner.

Apply the grease specified in Table 3.1(a) and (b) until the old

grease is replaced and the new grease is output from the grease

outlets. Use grease outlet 1 shown in Figs. 3.1 (a) and (b). Only

when grease outlet 1 cannot be used due to the installation state of

the jig, use grease outlet 2. At this time, confirm that the same

amount of the old grease as that of applied grease has been output

to prevent the grease bath from overflowing. After applying grease, release the residual pressure in the grease

bath as instructed by the procedure in Section 3.2.

CAUTIONWhen reusing a grease nipple once used, windsealing tape around the screw.

Table 3.1 (a) Grease to be replaced at regular intervals of three years

(11,520 hours) (300kg load capacity)

Specified grease

Kyodo Yushi

Amount of grease

to be appliedGun tip

pressure

Positioner

posture when

greased

Reducer VIGOGREASE RE0

(Specification:

A98L-0040-0174)

About 980 ml 0.1 MPa or less

(NOTE)

Grease outlet 1

is used : 0

Grease outlet 2

is used : free

NOTE When using a hand pump, apply grease approximately once per

two seconds.Table 3.1 (b) Grease to be replaced at regular intervals of three years

(11,520 hours) (1000kg load capacity)

A t f P iti


37/123


2

1

Fig. 3.1 (a) Grease inlet and outlet ( 300kg load capacity)

2

1

Fig. 3.1 (b) Grease inlet and outlet ( 1000kg load capacity)

Plug for grease inlet

Seal bolt for grease outlet 2Seal bolt for grease outlet 1

Plug for grease inlet

Seal bolt for grease outlet 2Seal bolt for grease outlet 1


38/123


CAUTIONIf you grease incorrectly, the pressure in the greasebath will increase, leading to a broken seal, which willeventually cause grease leakage or malfunction.When greasing, be sure to follow the cautions statedbelow.1 Before starting greasing, open the grease outlets

(remove bolts and the like from the grease outlets).2 Using a manual greasing pump, grease gently and

slowly.3 Avoid using a pneumatic pump driven from a factory

pneumatic line as much as possible.Even when using a of Table 3.1 (a) and (b) lessduring application of grease.

4 Be sure to use the specified grease. Otherwise,

damage to reducers or a similar abnormality mayoccur.

5 After applying grease, release the residual pressurewithin the grease bath as described in theprocedure in Section 3.2.

6 Wipe off any grease from the floor and positionercompletely, so no one will slip on it.

3.2 PROCEDURE FOR RELEASING THE GREASE RESIDUALPRESSURE

After applying grease, to release residual pressure from the grease bath,

perform a repetitive operation with a motion angle of at least 60 degreesand OVR100% for 10 minutes or more while leaving the grease inlets

and outlets open.

Under the grease inlets and outlets, attach bags for collecting grease so

that grease does not spatter when it comes out of the inlets or outlets.

If the above operation cannot be performed due to the environment of


39/123


3.3 BATTERY REPLACEMENT

A backup battery is used to keep the reference-position data for the

positioner.

The battery needs to be replaced at regular intervals of one year and half.

Follow this procedure for battery replacement.

This section describes the battery replacement procedure to followwhen the HARTING connector option is selected. Replace the battery

on the controller side when the HARTING connector option is not

selected.

1) Keep the power turned on.

Press the EMERGENCY STOP button of the robot to keep robot

and positioner from moving.

CAUTIONBe sure to turn on the power. If the battery isreplaced when the power is off, the current positioninformation is lost, so that mastering becomesnecessary.

2) Uncap the battery case.3) Take out the battery from the battery case.

4) Insert a new battery into the battery case while paying attention to

the polarity of the battery.

5) Cap the battery case.


40/123


Cap

Battery specifications: A98L-0031-0005

(1.5V size-D 4 pcs)

Battery case

Fig. 3.3 (b) Battery replacement 2


41/123

B-82545EN/02 MAINTENANCE 4.TROUBLESHOOTING

4 TROUBLESHOOTING


42/123

4.TROUBLESHOOTING MAINTENANCE B-82545EN/02

4.1 GENERAL

The source of mechanical unit problems may be difficult to locate

because of overlapping causes. Problems may become further

complicated, if they are not corrected properly. Therefore, it is

necessary to keep an accurate record of problems and to take proper

corrective actions.


43/123


4.2 PROBLEMS AND CAUSES

Table 4.2(a) shows the main mechanical unit problems and their causes.

If a cause of remedy is unclear, please contact your FANUC service

representative.

Table 4.2 (a) Problems and causes

Symptom Description Cause Measure-The base lifts off the floor plate

as the positioner operates.

-There is a gap between the

base and floor plate.

-A base retaining bolt is loose.

[Base fastening]

-It is likely that the positioner base is

not securely fastened to the floor plate.

-Probable causes are a loose bolt, an

insuffcient degree of surface flatness,

or foreign material caught.

-If the positioner is not securely

fastened to the floor plate, the base lifts

the floor plate as the positioner

operates, allowing the base and floor

plates to strike each other wihich, in

turn, leads to vibration.

-If a bolt is loose, apply loctite

and tighten it to the appropriate

torque.

-Adjust the floor plate surface

flatness to within the specified

tolenrance.

-If there is any foreign matter

between the base and floor

plate, remove it.

-The rack or floor vibrates

during operation of the

positioner.

[Rack or floor]

-It is likely that the rack or floor is not

suffciently rigid.

-If the rack or floor is not sufficiently

rigid, reaction from the positioner

deforms the rack or floor, leading to

vibration.

-Reinforce the rack or floor to

make it more rigid.

-If it is impossible to reinforce

the rack or floor, modify the

robot control program; doing so

might reduce the amount of

vibration.

Vibration

Noise

(Continued)

-Vibration becomes more

serious when the positioner

adopts a specific posture.

-If the operating speed of the

positioner is reduced, vibration

stops.

-Vibration is most noticeablewhen the positioner is

accelerating.

[Overload]

-It is likely that the load on the

positioner is greater than the maximum

rating.

-It is likely that the positioner control

program is too demanding for the

positioner hardware.-It is likely that the ACCELERATION

value is excessive.

-Check the maximum load that

the positioner can handle once

more. If the positioner is found

to be overloaded, reduce the

load, or modify the positioner

control program.

-Vibration in a specific portioncan be reduced by modifying

the robot control program while

slowig the positioner and

reducing its acceleration (to

minimize the influenece on the


44/123


Symptom Description Cause MeasureVibration

Noise

(Continued)

-Vibration was first noticed after

the positioner collided with an

object or the positioner was

overloaded for a long period.

-The grease has not been

exchanged for a long period.

[Broken gear, bearing, or reducer]

- It is likely that collision or overload

applied an excessive force on the drive

mechanism, thus damaging the

geartooth surface or rolling surface of a

bearing, or reducer.

- It is likely that prolonged use of the

positioner while overloaded caused

fretting of the gear tooth surface or

rolling surface of a bearing, or reducer

due to resulting metal fatigue.

- It is likely that foreign matter caught in

a gear, bearing, or within a reducer

caused damage on the gear tooth

surface or rolling surface of the

bearing, or reducer.

- It is likely that, because the greasehas not been changed for a long

period, fretting occurred on the gear

tooth surface or rolling surface of a

bearing, or reducer due to metal

fatigue.

These factors all generate cyclic

vibration and noise.

-Remove the motor, and

replace the gear , the bearing,

and the reducer. For the spec.

of parts and the method of

replacement, contact FANUC.

-Using the positioner within its

maximum rating prevents

problems with the drive

mechanism.

-Regularly changing the grease

with a specified type can help

prevent problems.


45/123


Symptom Description Cause MeasureVibration

Noise

(Continued)

-The cause of problem cannot

be identified from examination

of the floor, rack, or mechanical

section.

[Controller, cable, and motor]

-If a failure occurs in a controller circuit,

preventing control commands from

being supplied to the motor normally,

or preventing motor information from

being sent to the controller normally,

vibration might occur.

-If the pulse coder develops a fault,

vibration might occur because

information about the motor position

cannot be transferred to the controller

accurately.

-If the motor becomes defective,

vibration might occur because the

motor cannot deliver its rated

performance.

-If a connection cable between themhas an intermittent break, vibration

might occur.

-If the power cable has an intermittent

break, vibration might occur.

-If the power source voltage drops

below the rating, vibration might occur.

-If a robot control parameter is set to an

invalid value, vibration might occur.

-Refer to the Controller

Maintenance Manual for

troubleshooting related to the

controller and amplifier.

-Replace the pulse coder for

the motor, and check whether

the vibration still occurs.

-Also, replace the motor, and

check whether vibration still

occurs. For the method of

replacement, contact FANUC.

-Check that the positioner is

supplied with the rated voltage.

-Check whether the sheath of

the power cord is damaged. If

so, replace the power cord, and

check whether vibration stilloccurs.

-Check whether the sheath of

the cable connecting the

mechanical section

and controller is damaged. If

so, replace the connection

cable, and check whether

vibration still occurs.

-Check that the positionercontrol parameter is set to a

valid value. If it is set to an

invalid value, correct it. Contact

FANUC for further information if

necessary.


46/123


Symptom Description Cause Measure-There is some relationship

between the vibration of the

positioner and the operation of

a machine near the positioner.

[Noise from a nearby machine]

-If the positioner is not grounded

properly, electrical noise is induced on

the grounding wire, preventing

commands from being transferred

accurately, thus leading to vibration.

-If the positioner is grounded at an

unsuitable point, its grounding

potential becomes unstable, and noise

is likely to be induced on the grounding

line, thus leading to vibration.

-Connect the grounding wire

firmly to ensure a reliable

ground potential and prevent

extraneous electrical noise.

Vibration

Noise

(Continued)

-There is an unusual sound

after replacement of grease.


after a long period of time.


during operation at low speed.

-There may be an unusual sound when

using other than the specified grease.

-Even for the specified grease, there

may be an unusual sound during

operation at low speed immediately

after replacement or after a longperiod of time.

-Use the specified grease.

-When there is an unusual

sound even for specified

grease, perform operation for

one or two days on an

experiment. Generally, anusual sound will disappear.

-While the positioner is not

supplied with power, pushing it

with the hand causes part of the

mechanical unit to wobble.

-There is a gap on the mounting

surface of the mechanical unit.

[Mechanical section coupling bolt]

-It is likely that overloading or a

collision has loosened a mounting bolt

in the positioner mechanical section.

-Check that the following bolts

are tight. If any of these bolts is

loose, apply loctite and tighten

it to the appropriate torque.

-Motor retaining bolt

-Reducer retaining bolt

-Reducer shaft retaining bolt

-Base retaining bolt-End effecter retaining bolt

Rattling

-Backlash is greater than the

tolerance stated in the

applicable maintenance

manual.

(See Table 4.3 (b) and (c).)

[Increase in backlash]

-It is likely that excessive force applied

to the drive mechanism, due to a

collision or overloading, has broken a

gear or the inside of the reducer,

resulting in an increase in the amount

of backlash.

-It is likely that prolonged use in

overload conditions has caused the

tooth surfaces of a gear and the

reducer to wear out, resulting in an

increase in the amount of backlash.

It i lik l th t l d ith t

-Remove the motor, and check

whether any of its gears are

broken. If any gear is broken,

replace it.

-Check whether any other gear

of the drive mechanism is

damage. If there is no damage

gear, replace the reducer.

-If the reducer is broken, or if a

gear tooth is missing, replace

the relevant component. Also,

remove all the grease from the

b d h th i id f


47/123


Symptom Description Cause Measure-The ambient temperature of

the installation location

increases, causing

the motor to overheat.

-After a cover was attached to

the motor, the motor

overheated.

-After the robot control program

or the load was changed, the

motor

overheated.

[Ambient temperature]

-It is likely that a rise in the ambient

temperature or attaching the motor

cover prevented the motor from

releasing heat efficiently, thus leading

to overheating.

[Operating condition]

-It is likely that the positioner was

operated with the maximum average

current

exceeded.

-The teach pendant can be

used to monitor the average

current. Check the average

current when the robot control

program is running. The

allowable average current is

specified for the positioner

according to its ambient

temperature. Contact FANUC

for further information.

-Relaxing the positioner

control program and

conditions can reduce the

average current, thus

preventing overheating.

-Reducing the ambient

temperature is the most

effective means of preventing

overheating.

-Having the surroundings of

the motor well ventilated

enables the motor to release

heat efficiently, thus

preventing overheating. Using

a fan to direct air at the motor

is also effective.-If there is a source of heat

near the motor, it is advisable

to install shielding to protect

the motor from heat radiation.

-After a control parameter was

changed, the motor

overheated.

[Parameter]

-If data input for a workpiece is invalid,

the positioner cannot be accelerated

or decelerated normally, so the

average current increases, leading tooverheating.

-Input an appropriate

parameter as described in

CONTROLLER

OPERATORS MANUAL.

Motor

overheating

-Symptom other than stated

above

[Mechanical section problems]

-It is likely that problems occurred in

the mechanical unit drive mechanism,

th l i i l d th

-Repair the mechanical unit

while referring to the above

descriptions of vibration,

i d ttli


48/123


Symptom Description Cause MeasureGrease

leakage

-Grease is leaking from the

mechanical unit.

[Poor sealing]

-Probable causes are a crack in the

casting, a broken O-ring, a damaged

oil seal, or a loose seal bolt.

-A crack in a casting can occur due to

excessive force that might be caused

in collision.

-An O-ring can be damaged if it is

trapped or cut during disassembling or

re-assembling.

-An oil seal might be damaged if

extraneous dust scratches the lip of

the oil seal.

-A loose seal bolt and grease nipple

might allow grease to leak along the

threads.

-If a crack develops in the

casting, sealant can be used

as a quick-fix to prevent

further grease leakage.

However, the component

should be replaced as soon as

possible, because the crack

might extend.

-O-rings are used in the

locations listed below.

-Motor coupling section

-Reducer (case and shaft)

coupling section

-Oil seals are used in the

locations stated below.

-Inside the reducer

-Seal bolts and nipples are

used in the locations stated

below.

-Grease drain inlet and outlet

Axis rotation -An axis rotates because the

brake does not function.

-An axis rotates gradually when

it should be at rest.

[Brake drive relay and motor]

-It is likely that brake drive relay

contacts are stuck to each other to

keep the brake current flowing, thus

preventing the brake from operating

when the motor is deenergized.-It is likely that the brake shoe has

worn out or the brake main body is

damaged, preventing the brake from

operating efficiently.

-It is likely that oil or grease has

entered the motor, causing the

brake to slip.

-Check whether the brake

drive relay contacts are stuck

to each other. If they are found

to be stuck, replace the relay.

-If the brake shoe is worn out,

if the brake main body isdamaged, or if oil or grease

has entered the motor,

replace the motor.

-The positioner operates at a

point other than the taughtposition.

-The repeatability is not within

the tolerance.

[Mechanical section problems]

-If the repeatability is unstable,probable causes are a failure in the

drive mechanism or a loose bolt.

-If the repeatability becomes stable it

is likely that a collision imposed an

i l d l di t li i

-If the repeatability is unstable,

repair the mechanical sectionby referring to the above

descriptions of vibration,

noise, and rattling.

-If the repeatability is stable,

t th t ht

Displacement


49/123


Symptom Description Cause MeasureDisplacement

(Continuted)

-Displacement occurred after a

parameter was changed.

[Parameter]

-It is likely that the mastering data was

rewritten in such a way that

the positioner origin was shifted.

-Re-enter the previous

mastering data, which is

known to be correct.

-If correct mastering data is

unavailable, perform

mastering again.

BZAL alarm

occured

-BZAL is displayed on the

controller screen

-The voltage of the memory backup

battery may be low.

-The pulse coder cable may be

defected.

-Replace the battery.

-Replace the cable.

Troubles

related to arc

welding

-Starting of an arc is not good.

-An arc is unstable.

-Beads are irregular.

-The welding ground cable may be

loosened or broken(NOTE).

-Tighten the connection part of

the ground cable.

-Replace the ground cable.

NOTEArc welding troubles may be caused by a welding

unit such as a welding power supply or torch. Whena trouble occurs, see the manual of each unit to findthe cause.


50/123


4.3 BACKLASH MEASUREMENT

Measurement method1. Maintain the positioner in a specified posture. (See Fig. 4.3 (a))

2. Apply positive and negative loads to each axis as shown in Fig.

4.3(a).

3. Remove the loads and measure the displacement.

Apply positive and negative loads three times and then remove the

loads. Calculate the average of the displacements in the second and

third measurements as the backlash.

+10kg

+10kg

+10kg

0

-10kg

Stop position

-10kg

-10kg

L

L

L

L

Firtst step(Do not measure)

0kg

0kg

0kg

0kg

Second step(B =L + L )2 21

Third step

(B =L + L )3 43

1

2

3

4

Fig 4 3 (a) BAcklash Meas rement Method


51/123


Table 4.3 (a) Backlash measurement posture and measurement positionMeasured

postureMeasurement position (mm)

0 See fig 4.3(b)

Table 4.3 (b) Backlash allowable rattling of each axis

(300kg load capacity)

Angle conversion (arc-min) 2.5

Displacement conversion (mm) 0.127Distance from rotation center to

measurement position (mm)175

Table 4.3 (c) Backlash allowable rattling of each axis

(1000kg load capacity)

Angle conversion (arc-min) 2.5

Displacement conversion (mm) 0.164

Distance from rotation center to

measurement position (mm) 225

NOTEThe displacement conversion value indicates playin the direction of rotation from the center of the axisat the distance shown in brackets.

Backlashmeasurement position


52/123


4.4 COMPONENT REPLACEMENT AND ADJUSTMENT ITEMS

Adjustments are needed after a component is replaced.

The following table lists components and the adjustment items that

must be made after their replacement. After replacing a component,

make necessary adjustments according to this table.

Component replacement orfunction change

Adjustment item

Cable replacement Quick mastering

Battery replacement

(The battery should be replaced once

1.5 years.)

Replace the battery with the power

kept on.

No adjustment is needed.


53/123

B-82545EN/02 MAINTENANCE 5.ADJUSTMENTS

5 ADJUSTMENTSEach part of the mechanical units of a positioner is set to the best

condition before the positioner is shipped to the customer. Thecustomer does not need to make adjustments on the positioner when it isdelivered.If a mechanical unit of the positioner has a large backlash because of along-term use or component replacement, make adjustments accordingto this section.

5 ADJUSTMENTS


54/123

5.ADJUSTMENTS MAINTENANCE B-82545EN/02

5.1 REFERENCE POSITION AND MOVING RANGE

Zero point and software motion limits are provided for controlled axis.Exceeding the software motion limit of a controlled axis is calledovertravel (OT). Overtravel is detected at both ends of the motion limitfor each axis. The positioner cannot exceed the software motion limitunless there is a failure of the system causing loss of zero point position

or there is a system error.Fig. 5.1(a) shows the zero point and motion limit (stroke).

Fig. 5.1(b) shows the motion direction (+/).

+370

0

-370

(NOTE) There is not a mechanical stopper.

Fig. 5.1(a) Axis swiveling

C 5 ADJUSTMENTS


55/123


740(370)

+

-

Fig. 5.1(b) Axis motion direction

5 ADJUSTMENTS MAINTENANCE B 82545EN/02


56/123


5.2 MASTERING

Mastering methodThere are following five methods of mastering.

Table 5.2 Mastering method

Fixture position

mastering

This is performed using a mastering fixture before

the machine is shipped from the factory.Zero-position

mastering (eye mark

mastering)

This is performed with all axes set at the 0-degree

position. A zero-position mark (eye mark) is

attached to each positioner axis. This mastering is

performed with all axes aligned to their respective

eye marks.

Simplified mastering This is performed at a user-specified position. The

corresponding count value is obtained from the

rotation speed of the pulse coder connected to the

relevant motor and the rotation angel within one

rotation. simplified mastering uses the fact that

the absolute value of a rotation angel within one

rotation will not be lost.

One-axis mastering One-axis mastering is not used.

Mastering data entry Mastering data is entered directly.

Once mastering is performed, it is necessary to carry out positioning, or

calibration. Positioning is an operation is which the control unit readsthe current pulse count value to sense the current positon of the

positioner.

If the backup batteries for the pulse coder go dead during cablereplacement, simplified mastering can be performed, resetting the

positioner exactly to its initial position by calibration.If replacement of the motors, reducers, or other parts causes mechanical

changes in the phases of the pulse coder, simplified mastering cannot beperformed. In this case, perform fixture position mastering for accurateposition calibration.

CAUTION

B 82545EN/02 MAINTENANCE 5 ADJUSTMENTS


57/123


5.2.1 Resetting Alarms and Preparing for Mastering

Before performing mastering because a motor is replaced, it isnecessary to release the relevant alarm and display the positioningmenu.

Alarm displayedServo 062 BZAL or Servo 075 Pulse mismatch

Procedure1 Display the positioning menu by following steps 1 to 6.

1 Press the screen selection key.2 Press [0 NEXT] and select [6 SYSTEM].3 Press F1 [TYPE], and select [SYSTEM Variable] from the

menu.4 Place the cursor on $MASTER_ENB, then key in 1 and

press [ENTER].5 Press F1 [TYPE], and select[Mater/Cal] from the menu.6 Select the desired mastering type from the [Master/Cal]

menu.

2 Toreset the Servo 062 BZAL alarm, follow steps 1 to 5.1 Press the screen slelection key.2 Press [0 NEXT] and Select [6 SYSTEM].

3 Press F1 [TYPE], and select [Master/Cal] from the menu.4 Place the cursor on F3 RES_PCA, then press F4 [TRUE].5 Switch the controller power off and on again

3 To reset the Servo 075 Pulse mismatch alarm, follow steps 1 to3.1 When the controller power is switched on again, the message

Servo 075 Pulse mismatch appears again.2 Rotate the axis for which the message mentioned above has

appeared through 10 degrees in either direction.3 Pree [FAULT RESET]. The alarm is reset.

5 ADJUSTMENTS MAINTENANCE B-82545EN/02


58/123


5.2.2 Fixture position master

Fixture position mastering is performed using a mastering fixture. Thismastering is carried out in the predetermined fixture position.Fixture position mastering is accurate because a dedicated masteringfixture is used. Fixture position mastering is not required in dailyoperations because it is factory-performed.When mastering the positioner, arrange the positioner to meet the

following conditions.- Make the positioner mounting base horizontal.(Set the positioner mounting surface so that the levelness of theentire surface is 1 mm or less.)- Remove the hand and other parts form the wrist.- Set the positioner in the condition protected from an external

force.

CAUTIONBe extremely careful in moving the positioner duringmastering because an axis movement range is notchecked.



59/123

B 82545EN/02 MAINTENANCE 5.ADJUSTMENTS

Assembling mastering fixturesAttach the mastering fixture to the positioner as shown in Fig. 5.2.2 (a)to (e).

Remove the seal from the mastering fixture attaching surface.Be sure to restore the original condition after completion of mastering.

BOLTM5X16

CLAMPA290-7022-X954

DIAL GAUGEBOLTM8X20(2pcs)

PIN BA290-7220-X953

PIN AA290-7220-X954

BoltM10X20(2pcs)

PIN DA290-7220-X956

PIN CA290-7220-X955

Mastering fixture BA290-7220-X952

MASTERING FIXTURE AA290-7220-X951

Fig. 5.2.2 (a) Attaching the mastering fixture to the 1-axis positioner (300kg load capacity)



60/123

BOLTM8X20(2pcs)

PIN BA290-7220-X954

PIN AA290-7220-X953

MASTERING FIXTURE AA290-7220-X957

BOLTM5X16

CLAMPA290-7022-X954

Fig. 5.2.2 (c) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity)

BOLTM16X30(2)

MASTERING FIXTURE B

A290-7220-X958



61/123

Fig. 5.2.2 (d) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity)

THE DIRECTIONOF PIN O6 THE DIRECTION

OF PIN O10

Fig. 5.2.2 (e) Attaching the mastering fixture to the 1-axis positioner (1000kg load capacity)



62/123

Mastering 1 Press MENUS.2 Press NEXT and select SYSTEM.3 Press F1, [TYPE].4 Select Mater/Cal.

AUTO

SYSTEM Master/Cal G2 JOINT 1 %

TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Calibrate key select? [NO]

[ TYPE ] YES NO

5 Release brake control, and jog the positioner into a posture formastering.See fig. 5.2.2 (f) and (g) for the mastering posture.

NOTEBrake control can be released by setting the systemvariables as follows:

$PARAM_GROUP.()SSV_OFF_ALL: FALSE$PARAM_GROUP.()SSV_OFF_ENB[*]: FALSE

(for all axes)After changing the system variables, switch thecontrol unit power off and on again.



63/123

6 Select 1 FIXTURE POSITION MASTER and Press F4, YES.

AUTO


TORQUE = [ON ]



3 QUICK MASTER



6 CALIBRATE

Robot Mastered! Mastering Data :

< 0.0000> < 90.0000> < 0.0000>

< 0.0000> < 0.0000> < 0.0000>

[ TYPE ] LOAD RES_PCA DONE

7 Select 6 CALIBRATE and press F4, YES. Mastering will beperformedAlternatively, switch the power off and on again. Switching the

power on always causes positioning to be performed.

AUTO

SYSTEM Master/Cal JOINT 1 %

TORQUE = [ON ]



3 QUICK MASTER





64/123

9 Restore brake control. Reset system variables$PARAM_GROUP.$SV_OFF_ALL and$PARAM_GROUP.$SV_OFF_ENB to their original values, andturn the power off and then back on.

10 After mastering, update the mastering data listed in thefactory-supplied data sheet with new mastering data($DMR_GROUP.$MASTER_COUN [*]).([*] is the axis number of the positioner.).

0

Fig. 5.2.2 (f) Mastering position (300kg load capacity)

Mastering posture



65/123

5.2.3Zero Position Mastering

Zero-position mastering is performed with axes set at the 0-degreeposition. A zero-position mark (eye mark) is attached to each positioneraxis. This mastering is performed with all axes set at the 0-degree

position using their respective eye marks.Zero-position mastering involves a visual check. It cannot be soaccurate. It should be used only as a quick-fix method.

Procedure Mastering to Zero Degrees

Step 1 Press MENUS.2 Select NEXT and press SYSTEM.3 Press F1, [TYPE].4 Select Master/Cal.

AUTO


TORQUE = [ON ]



3 QUICK MASTER



6 CALIBRATE

Calibrate zero position master key select? [NO]

[ TYPE ] YES NO

5 Release brake control, and jog the robot into a posture formastering See Fig 5 2 3 (a) and (b) for the mastering post re



66/123

6 Select Zero Position Master.

AUTO


TORQUE = [ON ]



3 QUICK MASTER



6 CALIBRATE

Robot Mastered! Mastering Data:

[ TYPE ] LOAD RES_PCA DONE

7 Press F4, YES. Mastering will be performed automatically.

Alternatively, turn the power off and then back on. Mastering isperformed.When the power is turned off and then back on, mastering isalways performed.

AUTO


TORQUE = [ON ]



3 QUICK MASTER




67/123

9 Reset the brake control release settings to the original state. Setsystem variables $PARAM_GROUP, $SV_OFF_ALL, and$SV_OFF_ENB to their original values, then turn off then back onthe power.

A

DETAIL A

Fig. 5.2.3 (a) Marking of the zero-degree for each axis (position mark) (300kg load capacity)

B



68/123

5.2.4Quick Mastering

Simplified mastering is performed at a user-specified position. Thecorresponding count value is obtained from the rotation speed of the

pulse coder connected to the relevant motor and the rotation anglewithin one rotation. Simplified mastering uses the fact that the absolutevalue of a rotation angle within one rotation will not be lost.Simplified mastering is factory-performed at the zero-degree position.

Do not change the setting unless there is a problem.If it is impossible to set the positioner at the position mentioned above,it is necessary to re-set the simplified mastering reference positionusing the following method. (It would be convenient to set up a markerthat can work in place of the position mark.)

CAUTION1 Simplified mastering can be used, if the pulse count

value is lost, for example, because a low voltage

has been detected on the backup battery for thepulse counter.

2 Simplified mastering cannot be used, after the pulsecoder is replaced or after the mastering data is lostfrom the robot control unit.

3 This operation cannot be performed if mastering datais lost as a result of mechanical disassembly ormaintenance. In this case, perform zero positionmastering or fixture position mastering to recoverthe mastering data.

Procedure Recording the Quick Master Reference Position

Step 1 Select SYSTEM.2 Select Master/Cal.

AUTO


TORQUE = [ON ]




69/123

3 Release brake control, and jog the positioner to the simplifiedmastering reference position.

Set quick master ref? [NO] 4 Move the cursor to SET QUICK MASTER REF and pressENTER. Press F4, YES.

Procedure Quick Mastering

Step 1 Display the Master/Cal screenAUTO

SYSTEM Master/Cal JOINT 1 %

TORQUE = [ON ]



3 QUICK MASTER



6 CALIBRATE

Robot Not Mastered!

Quick master? [NO]

[ TYPE ] YES NO

2 Release brake control, and jog the positioner to the simplifiedmastering reference position.

Quick master? [NO] 3 Move the cursor to QUICK MASTER and press ENTER. PressF4, YES. Quick mastering data is memorized.

4 Move the cursor to CALIBRATE and press ENTER. Calibrationis executed. Calibration is executed by power on again.

5 After completing the calibration, press F5, DONE.6 Restore brake control. Reset system variables

$PARAM GROUP.$SV OFF ALL and



70/123

5.2.6Mastering Data Entry Method

Step 1 Select [6 SYSTEM] and press ENTER.2 Select [Variable]. The system variable screen appears.

3 Change the mastering data.The mastering data is saved to the

$DMR_GRP().$MASTER_COUN system variable.(is the axisnumber of the positioner.)

4 Select $DMR_GRP. (* is the group number of the postioner.)

G2 1 %

$DMR_GRP[2] 1/25

1 $MASTER_DONE TRUE

2 $OT_MINUS [9] of BOOLEAN

[ ]

SYSTEM Variables JOINT



71/123

5 Select $MASTER_COUN, and enter the mastering data you haverecorded.

G2 1 %

$DMR_GRP[2].$MASTER_COUN 1/9

1 [1] 95678329

2 [2] 10223045

3 [3] 0

4 [4] 0

5 [5] 0

6 [6] 0

7 [7] 0

8 [8] 0

9 [9] 0

[ ]


TYPE

0

6 Press the previous page key.7 Set $MASTER_DONE to TRUE.

G2 1 %$DMR_GRP[2] 1/25

1 $MASTER_DONE TRUE

2 $OT_MINUS [9] of BOOLEAN

3 $OT_PLUS [9] of BOOLEAN

4 $MASTER_COUN [9] of INTEGER

5 $REF_DONE FALSE

6 $REF_POS [9] of REAL

7 $REF_COUNT [9] of INTEGER

8 $BCKLSH SIGN [9] f BOOLEAN




72/123

5.2.7 Confirming Mastering

1) Confirming that mastering was performed normallyUsually, positioning is performed automatically when the power isturned on. To confirm that mastering was performed normally,check that the current-position display matches the actual positionof the positioner, using this procedure.a) Replay the taught operation of the positioner to set zero

degrees, and visually check that the zero-degree positionmarks shown in Fig. 5.2.3 (a) and (b) are aligned.

b) Replay a specific portion of the program, and check that thepositioner has moved to the taught position.

2) Possible alarms in positioningThe following paragraphs describe alarms that may occur in

positioning and explain how to handle them.a) BZAL alarm

This alarm is raised if the voltage of the pulse coder backupbattery becomes 0V when the controller power is off.Mastering must be performed again because the counter has

already lost data.b) BLAL alarm

This alarm indicates that the voltage of the pulse coderbackup battery is too low to run the pulse coder. If this alarmis issued, replace the backup battery soon while keeping the

power on, and check whether the current-position data iscorrect, using a method described in item (1).

c) CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR,

and SPHAL alarmsIf any of these alarms is issued, contact your FANUC servicerepresentative. A motor may have to be replaced.

B-82545EN/02 MAINTENANCE6. COMPONENT REPLACEMENT AND

ADJUSTMENTS


73/123

6 COMPONENT REPLACEMENT ANDADJUSTMENTS

Adjustments are needed after a component is replaced.The following table lists components and the adjustment items that

must be made after the components are replaced. After replacing a

component, make necessary adjustments according to this table.

Replacement component Adjustment item

Motor (a) Mastering

Reducers (a) Mastering

NOTEBe very careful when dismounting and mounting theheavy components that are listed below.

Component Weight (about) Load capacity

Motor 10kg 300kg

Motor 22kg 1000kg

Reducer 20kg 300kgReducer 91kg 1000kg

Flange 16kg 300kg

Flange 28kg 1000kg

NOTEWhen applying LOCTITE to the important bolttightening points, make sure that it is applied to the

entire longitudinal portion in the engaging section ofthe female threads. If it is applied to the malethreads, the bolts may be loosened becausesufficient effects cannot be obtained. Remove thedust within the bolts and taps and wipe oil off the

MAINTENANCE B-82545EN/026. COMPONENT REPLACEMENT AND

ADJUSTMENTS


74/123

6.1 REPLACING THE MOTOR

In the case of 300kg load capacity1 Turn off the power to the controller.

2 Remove the four M812 bolts and remove the motor cover.

(Only when the motor cover option is selected)

3 After removing the battery box fixing plate while referencing Fig.

6.1 (b), remove the four M6

10 bolts and remove the connectorbox.

(Only when the HARTING connector option is selected)

4 Remove the motor connector.

5 Remove the four M820 motor mounting bolts and washer and

remove the motor.

6 Attach the input gear to a new motor, and reverse the removal

steps to mount the motor. Replace the O-rings with new ones, and

put the new O-rings in place. See Fig. 6.1 (a) for the tightening

torque and Loctite application.

7 Supply the grease bath with the specified grease as described in

Section 3.1.

8 Perform mastering while referencing Chapter 5.

Motor

O ring

NutLoctite 242Tightening Torque 16.7Nm

Washer

Motor cover(Motor cover option is selected)

Input Gear

C ring

Bearing

BoltM8X20,4pcs

Washer

BoltM8X12,4pcs(Harting connector option orMotor cover option is selected)

Connector box(Harting connector option is selected)


ADJUSTMENTS


75/123

BOLTM6X10,4pcs

PLATE FOR FIXATIONOF BATTERY BOX

BATTERY BOX

Fig. 6.1 (b) Removing the connector box (when the HARTING connector option is selected)

In the case of 1000kg load capacity

1 Turn off the power to the controller.

2 Remove the four M812 bolts and remove the motor cover.(Only when the motor cover option is selected)

3 After removing the battery box fixing plate while referencing Fig.

6.1 (b), remove the four M610 bolts and remove the connector

box.

(Only when the HARTING connector option is selected)

4 Remove the motor connector.

5 Remove the four M1230 motor mounting bolts and washer and

remove the motor.6 Attach the input gear to a new motor, and reverse the removal

steps to mount the motor. Replace the O-rings with new ones, and

put the new O-rings in place. See Fig. 6.1 (c) for the tightening

torque and Loctite application.


ADJUSTMENTS

D b lt


76/123

()

OS2

M12X30,4

M8X12,4()

C

242 118N.m

2423.2N.m

()

()

,4

Fig. 6.1 (c) Replacing the motor (1000kg load capacity)

Replacing parts (300kg load capacity)

Part name Specification

O-ring JB-OR1A-G105

Motor A06B-0235-B605#S000

Bearing A97L-0001-0195#06Z000A

Oil seal A98L-0040-0047#07010014

Replacing parts (1000kg load capacity)

Part name Specification

O-ring JB-OR1A-G125

Motor A06B-0265-B605#S000

Bearing A97L-0001-0196#09Z000A

Oil seal A98L-0040-0047#13016014

NOTEReplace the bearing or oil seal only when it isb k

NutLoctite 242Tightening Torque 3.2N.m

C ring

Washer

Washer 4 cs

Bearing

Input gear

Connector box(Harting connector optionis setected.)

Motor

Bolt M1230.4pcs

O ringAlvania rease S2

Draw bolt

Loctite 242Ti htenin Tor ue 118N.m

Bolt

M812.4pcs

Motor cover(Motor cover option isselected.

(Harting connector option ormotor cover option is selected.)

Plate for fixation of Battery Box

(Harting connector optionis setected.)


ADJUSTMENTS


77/123

6.2 REPLACING THE REDUCER

In the case of 300kg load capacity1 Remove the motor as section 6.1.

2 Remove the covers, bolts, insulators A and B, collars, flange, and

insulater in that order.

3 Pull the pipe out of the reducer.

4 Remove the 11 M10X45 bolts with washers that fasten the reducer

on the base, and remove the reducer.

5 Remove the gear.

6 Reverse the removal steps to mount a new reducer. Replace the

O-rings with new ones, and put the new O-rings in place. Be

careful not to damage the oil seal.See Fig. 6.2 (a) for the tightening torque and Loctite application.

7 Install the motor as section 6.1.


Section 3.1.

9 Perform mastering while referencing Chapter 5.

OS2

M10X45,11262 73.5Nm

OS2

M12X35,9262

128.4Nm

,3

,3

,9

B,9A

A,3

Bolt

M1045.11pcsLoctite 262Tightening Torque 73.5N.m

Reducer

Washer

Flange

Gear

Washer plate 3pcs

O ringAlvania grease S2


Bolt M1235.9pcsLoctite 262

Tightening Torque128.4N.m

collar 9pcs

Insulator B 9pcs(Insert after the insulator A.)

Base

Cover3pcs

Insulator A 3pcs


ADJUSTMENTS

In the case of 1000 kg load capacity


78/123

In the case of 1000 kg load capacity

1 Remove the motor as described in Section 6.1.

2 Remove the covers, bolts, washers, insulators A and B, flanges,

insulators C in that order.

3 Remove the 15 bolts (M16 50) that fix the reducer and base and

then remove the reducer and the components ahead of it.

4 Remove the 16 bolts (M12 85) and washers that secure the

reducer and adapter and remove the reducer from the adapter.

5 Apply sealant to a new reducer as described in Section 6.3 andassemble these components in the reverse order. Replace the

O-rings with new ones and put them in place. Be careful not to

damage the oil seal. For the tightening torque and the application

of LOCTITE, see Fig. 6.2 (b).

6 Mount the motor as described in Section 6.1.


Section 3.1.

8 Perform mastering as described in Chapter 5.

A,18

OS2

M12X85,16262128.4Nm

C

,18

M12X35,18262 128.4Nm

,18

B,18A

,16

M16X50,15 262Nm 318.5Nm

,15

Fig. 6.2 (b) Replacing the reducer (1000kg load capacity)

Bolt

M1650 15pcsLoctite 262NmTightening Torque318.5N.m

ReducerWasher 16pcs Flange

Insulator A 18 cs

AdapterWasher 15pcs


O ringAlvania grease S2Bolt M1285 16pcs

Loctite 262Tightening Torque128.4N.m

Insulator C

Insulator B 18pcs(Insert after the insulator A.)

Base

Cover18pcs

PipeWasher 18pcs

Bolt M1235 18pcs

Loctite 262

Tightening Torque

128.4N.m


ADJUSTMENTS


79/123

6.3 SEALANT APPLICATION

Washing and degreasing the surfaces to be sealed1 After dismounting the reducer from the arm, apply releasant

(Loctite Gasket Remover) to the arms surface from which the

reducer was dismounted, then wait until the sealant (Loctite 518)

becomes softened (for about 10 minutes). Remove the softened

sealant from the surface using a spatula.

2 Blow air onto the surface to be sealed to remove dust from the

tapped holes.

3 Sufficiently degrease the reducers surface to be sealed and the

arms surface to be sealed, using a cloth dampened with alcohol.

4 Polish the arm's surface to be sealed with an oil stone, and

degrease it with alcohol again.

NOTEOil may drip from the inside of the reducer. Afterdegreasing, make sure that no oil is dripping.

Applying sealant5 Make sure that the reducer and the arm are dry (with no alcohol

remaining). If they are still wet with alcohol, wipe them dry.

6 Apply sealant (Loctite 518) to the surfaces as Fig. 6.3.

Assembling7 To prevent dust from sticking to the portions to which sealant was

applied, mount the reducer as quickly as possible after sealant

ap

1axis positioner maintenance manual [b-82545en 02]

Documents