fanuc R-30iB Maintenance Manual

FANUC

R-30iB Mate CONTROLLER

Robot

series

MAINTENANCE MANUAL

MARETIBCN01121E REV. A

This publication contains proprietary information

of FANUC Robotics America Corporation furnished for

customer use only. No other uses are authorized

without the express written permission of

FANUC Robotics America Corporation.

FANUC Robotics America Corporation

Rochester Hills, Michigan 48309–3253

3900 W. Hamlin Road

B-83525EN/01

Copyrights and Trademarks

This new publication contains proprietary information of FANUC Robotics America Corporation furnished for customer use onl y . No othe r uses are authorized without the express written permission of FANUC Robotics America Corporation.

The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics America Corporation, hereinafter referred to as FANUC Robotics, reserves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations.

FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC Robotics' products and/or systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL® programming language, INSIGHT® vision equipment, and special tools.

FANUC Robotics recommends that only persons who have been trained in one or more approved FANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC Robotics' products and/or systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.

WARNING

This equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at the company's world headquarters in Rochester Hills, Michigan. For additional information contact

FANUC Robotics America Corporation Training Department 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253

www.fanucrobotics.com

For customer assistance, including Technical Support, Service, Parts & Part Repair, and Marketing Requests, contact the Customer Resource Center, 24 hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers should call 011-1-248-377-7159.

Send your comments and suggestions about this manu a l to:

product.documentation@fanucrobotics.com

The information illustrated or contained herein is not to be reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics America Corporation.

AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®, SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered Trademarks of FANUC Robotics.

FANUC Robotics reserves all proprietary rights, including but not limited to trademark and trade name rights, in the follow ing names:

AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™, AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™, ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™, ARC Mate System 5™, ARCWorks Pro™, AssistTool™, AutoNormal™, AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™, Center Finder™, Clean Wall™, DualARM™, LR Tool™, MIG Eye™, MotionParts™, MultiARM™, NoBots™, Paint Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks II™, PAINTWorks III™, PalletMate™, PalletMate PC™, PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™, Robo Chop™, Robo Spray™, S-420i™, S-430i™, ShapeGen™, SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3 Controller™, SYSTEM R-J3iB Controller™, SYSTEM R-J3iC Controller™, SYSTEM R-30iA Controller™, SYSTEM R-30iB Controller™, TCP Mate™, TorchMate™, TripleARM™, TurboMove™, visLOC™, visPRO-3D™, visTRAC™, WebServer™, WebTP™, and YagTool™.

FANUC CORPORATION 2013

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

•

All specifications and designs are subject to change without notice.

3 by FANUC Robotics America Corporation

Patents

One or more of the following U.S. patents might be related to the FANUC Robotics products described in this manual.

FANUC Robotics America Corporation Patent List

4,630,567 4,639,878 4,707,647 4,708,175 4,7 08,580 4,942,539 4,984,745 5,238,029 5,239,739 5,272,805 5,293,107 5,2 93,911 5,331,264 5,367,944 5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092 6,064,168 6,070,109 6,086,294 6,122,062 6,1 47,323 6,204,620 6,243,621 6,253,799 6,285,920 6,313,595 6,325,302 6,3 45,818 6,356,807 6,360,143 6,378,190 6,385,508 6,425,177 6,477,913 6,4 90,369 6,518,980 6,540,104 6,541,757 6,560,513 6,569,258 6,612,449 6,7 03,079 6,705,361 6,726,773 6,768,078 6,845,295 6,945,483 7,149,606 7,1 49,606 7,211,978 7,266,422 7,399,363

FANUC CORPORATION Patent List

4,571,694 4,626,756 4,700,118 4,706,001 4,7 28,872 4,732,526 4,742,207 4,835,362 4,894,596 4,899,095 4,920,248 4,9 31,617 4,934,504 4,956,594 4,967,125 4,969,109 4,970,370 4,970,448 4,9 79,127 5,004,968 5,006,035 5,008,834 5,063,281 5,066,847 5,066,902 5,0 93,552 5,107,716 5,111,019 5,130,515 5,136,223 5,151,608 5,170,109 5,1 89,351 5,267,483 5,274,360 5,292,066 5,300,868 5,304,906 5,313,563 5,3 19,443 5,325,467 5,327,057 5,329,469 5,333,242 5,337,148 5,371,452 5,3 75,480 5,418,441 5,432,316 5,440,213 5,442,155 5,444,612 5,449,875 5,4 51,850 5,461,478 5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,4 85,552 5,486,679 5,489,758 5,493,192 5,504,766 5,511,007 5,520,062 5,5 28,013 5,532,924 5,548,194 5,552,687 5,558,196 5,561,742 5,570,187 5,5 70,190 5,572,103 5,581,167 5,582,750 5,587,635 5,600,759 5,608,299 5,6 08,618 5,624,588 5,630,955 5,637,969 5,639,204 5,641,415 5,650,078 5,6 58,121 5,668,628 5,687,295 5,691,615 5,698,121 5,708,342 5,715,375 5,7 19,479 5,727,132 5,742,138 5,742,144 5,748,854 5,749,058 5,760,560 5,7 73,950 5,783,922 5,799,135 5,812,408 5,841,257 5,845,053 5,872,894 5,8 87,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082 5,983,744 5,9 87,591 5,988,850 6,023,044 6,032,086 6,040,554 6,059,169 6,088,628 6,0 97,169 6,114,824 6,124,693 6,140,788 6,141,863 6,157,155 6,160,324 6,1 63,124 6,177,650 6,180,898 6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011 6,236,896 6,250,174 6,278,902 6,279,413 6,2 85,921 6,298,283 6,321,139 6,324,443 6,328,523 6,330,493 6,340,875 6,3 56,671 6,377,869 6,382,012 6,384,371 6,396,030 6,414,711 6,424,883 6,4 31,018 6,434,448 6,445,979 6,459,958 6,463,358 6,484,067 6,486,629 6,5 07,165 6,654,666 6,665,588 6,680,461 6,696,810 6,728,417 6,763,284 6,7 72,493 6,845,296 6,853,881 6,888,089 6,898,486 6,917,837 6,928,337 6,9 65,091 6,970,802 7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,1 43,100 7,149,602 7,131,848 7,161,321 7,171,041 7,174,234 7,173,213 7,1 77,722 7,177,439 7,181,294 7,181,313 7,280,687 7,283,661 7,291,806 7,2 99,713 7,315,650 7,324,873 7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488 7,386,367 7,464,623 7,447,615 7,445,260 7,4 74,939 7,486,816 7,495,192 7,501,778 7,502,504 7,508,155 7,512,459 7,5 25,273 7,526,121

Conventions

WARNING

Information appearing under the "WARNING" caption concerns the protection of personnel. It is boxed and bolded to set it apart from the surrounding text.

CAUTION

Information appearing under the "CAUTION" caption concerns the protection of equipment, software, and data. It is boxed and bolded to set it apart from the surrounding text.

Note Information appearing next to NOTE concerns related information or useful hints.

Original Instructions

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

• 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 Japan’s “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 the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice.

The products in this manual are manufactured under strict quality control. However, when using any of the products in a facility in which a serious accident or loss is predicted due to a failure of the product, install a safety device.

In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as “impossible”.

Safety

FANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner, employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace.

The appropriate level of safety for your application and installation can be best determined by safety system professionals. FANUC Robotics therefore, recommends that each customer consult with such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC Robotics systems.

According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic system and to be aware of the recommended operating procedures for your particular application and robot installation.

Ensure that the robot being used is appropriate for the application. Robots used in classified (hazardous) locations must be certified for this use.

FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC Robotics training course and become familiar with the proper operation of the system. Persons responsible for programming the system–including the design, implementation, and debugging of application programs–must be familiar with the recommended programming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance of safety in the workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:

 The safety of people and equipment  Use of safety enhancing devices  Techniques for safe teaching and manual operation of the robot(s)  Techniques for safe automatic operation of the robot(s)  Regular scheduled inspection of the robot and workcell  Proper maintenance of the robot

Safety

Keeping People Safe

The safety of people is always of primary importance in any situation. When applying safety measures to your robotic system, consider the following:

 External devices  Robot(s)  Tooling  Workpiece

Using Safety Enhancing Devices

Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices:

 Safety fences, barriers, or chains  Light curtains  Interlocks  Pressure mats  Floor markings  Warning lights  Mechanical stops  EMERGENCY STOP buttons  DEADMAN switches

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal, state, and local laws, regulations, and guidelines that pertain to safety.

 Sponsor your personnel for training in approved FANUC Robotics training course(s)

related to your application. Never permit untrained personnel to operate the robots.

 Install a lockout device that uses an access code to prevent unauthorized persons

from operating the robot.

 Use anti–tie–down logic to prevent the operator from bypassing safety measures.

 Arrange the workcell so the operator faces the workcell and can see what is going on

inside the cell.

 Clearly identify the work envelope of each robot in the system with floor markings,

signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling attached to the wrist flange that extend this range.

 Position all controllers outside the robot work envelope.

Safety

 Never rely on software or firmware based controllers as the primary safety element

unless they comply with applicable current robot safety standards.

 Mount an adequate number of EMERGENCY STOP buttons or switches within easy

reach of the operator and at critical points inside and around the outside of the workcell.

 Install flashing lights and/or audible warning devices that activate whenever the robot

is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise level at the end–use application.

 Wherever possible, install safety fences to protect against unauthorized entry by

personnel into the work envelope.

 Install special guarding that prevents the operator from reaching into restricted areas

of the work envelope.

 Use interlocks.  Use presence or proximity sensing devices such as light curtains, mats, and

capacitance and vision systems to enhance safety.

 Periodically check the safety joints or safety clutches that can be optionally installed

between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system, and help to minimize damage to the tooling and robot.

 Make sure all external devices are properly filtered, grounded, shielded, and

suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI), radio frequency interference (RFI), and electro–static discharge (ESD).

 Make provisions for power lockout/tagout at the controller.  Eliminate pinch points. Pinch points are areas where personnel could get trapped

between a moving robot and other equipment.

 Provide enough room inside the workcell to permit personnel to teach the robot and

perform maintenance safely.

 Program the robot to load and unload material safely.  If high voltage electrostatics are present, be sure to provide appropriate interlocks,

warning, and beacons.

 If materials are being applied at dangerously high pressure, provide electrical

interlocks for lockout of material flow and pressure.

Staying Safe While Teaching or Manually Operating the Robot

Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules:

 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught

in moving machinery.

 Know whether or not you are using an intrinsically safe teach pendant if you are

working in a hazardous environment.

iii

Safety

 Before teaching, visually inspect the robot and work envelope to make sure that no

potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These include tooling attached to the wrist flange that extends this range.

 The area near the robot must be clean and free of oil, water, or debris. Immediately

report unsafe working conditions to the supervisor or safety department.

 FANUC Robotics recommends that no one enter the work envelope of a robot that is

on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards are in place, check the teach pendant DEADMAN

switch for proper operation, and place the robot in teach mode. Take the teach

pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only the person with the teach pendant should be in the work envelope.

WARNING

Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch, for any operational convenience. Deactivating a safety device is known to have resulted in serious injury and death.

 Know the path that can be used to escape from a moving robot; make sure the escape

path is never blocked.

 Isolate the robot from all remote control signals that can cause motion while data is

being taught.

 Test any program being run for the first time in the following manner:

WARNING

Stay outside the robot work envelope whenever a program is being run. Failure to do so can result in injury.

- Using a low motion speed, single step the program for at least one full cycle.

- Using a low motion speed, test run the program continuously for at least one

full cycle.

- Using the programmed speed, test run the program continuously for at least

one full cycle.

 Make sure all personnel are outside the work envelope before running production.

Staying Safe During Automatic Operation

Advise all personnel who operate the robot during production to observe the following rules:

 Make sure all safety provisions are present and active.

Safety

 Know the entire workcell area. The workcell includes the robot and its work

envelope, plus the area occupied by all external devices and other equipment with which the robot interacts.

 Understand the complete task the robot is programmed to perform before initiating

automatic operation.

 Make sure all personnel are outside the work envelope before operating the robot.  Never enter or allow others to enter the work envelope during automatic operation of

the robot.

 Know the location and status of all switches, sensors, and control signals that could

cause the robot to move.

 Know where the EMERGENCY STOP buttons are located on both the robot control

and external control devices. Be prepared to press these buttons in an emergency.

 Never assume that a program is complete if the robot is not moving. The robot could

be waiting for an input signal that will permit it to continue its activity.

 If the robot is running in a pattern, do not assume it will continue to run in the same

pattern.

 Never try to stop the robot, or break its motion, with your body. The only way to

stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to

 Turn off power at the controller.  Lock out and tag out the power source at the controller according to the policies of

your plant.

 Turn off the compressed air source and relieve the air pressure.  If robot motion is not needed for inspecting the electrical circuits, press the

EMERGENCY STOP button on the operator panel.

 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught

in moving machinery.

 If power is needed to check the robot motion or electrical circuits, be prepared to

press the EMERGENCY STOP button, in an emergency.

 Be aware that when you remove a servomotor or brake, the associated robot arm will

fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:

 Never enter the work envelope while the robot or a program is in operation.  Before entering the work envelope, visually inspect the workcell to make sure no

potentially hazardous conditions exist.

Safety

 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught

in moving machinery.

 Consider all or any overlapping work envelopes of adjoining robots when standing in

a work envelope.

 Test the teach pendant for proper operation before entering the work envelope.  If it is necessary for you to enter the robot work envelope while power is turned on,

you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately.

 Whenever possible, perform maintenance with the power turned off. Before you

open the controller front panel or enter the work envelope, turn off and lock out the 3–phase power source at the controller.

 Be aware that when you remove a servomotor or brake, the associated robot arm will

fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

WARNING

Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a

power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS PRESENT at the input side whenever the controller is connected to a power source. Turning the disconnect or circuit breaker to the OFF position removes power from the output side of the device only.

 Release or block all stored energy. Before working on the pneumatic system, shut

off the system air supply and purge the air lines.

 Isolate the robot from all remote control signals. If maintenance must be done when

the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this person.

 Make sure personnel cannot get trapped between the moving robot and other

equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked.

 Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot.

Make sure that such devices do not create pinch points that could trap personnel.

WARNING

Do not try to remove any mechanical component from the robot before thoroughly reading and understanding the procedures in the appropriate manual. Doing so can result in serious personal injury and component destruction.

Safety

 Be aware that when you remove a servomotor or brake, the associated robot arm will

fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

 When replacing or installing components, make sure dirt and debris do not enter the

system.

 Use only specified parts for replacement. To avoid fires and damage to parts in the

controller, never use nonspecified fuses.

 Before restarting a robot, make sure no one is inside the work envelope; be sure that

the robot and all external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe use of such devices.

Programming Safety Precautions

Implement the following programming safety measures to prevent damage to machine

tools and other external devices.

 Back–check limit switches in the workcell to make sure they do not fail.  Implement ‘‘failure routines” in programs that will provide appropriate robot actions

if an external device or another robot in the workcell fails.

 Use handshaking protocol to synchronize robot and external device operations.  Program the robot to check the condition of all external devices during an operating

cycle.

Mechanical Safety Precautions

Implement the following mechanical safety measures to prevent damage to machine tools and other external devices.

 Make sure the workcell is clean and free of oil, water, and debris.  Use

DCS (Dual Check Safety), software limits, limit switches, and mechanic

undesired m

ovement of the robot into the work area of machine tools and external devices.

hardstops to prevent

vii

Safety

KEEPING THE ROBOT SAFE

Observe the following operating and programming guidelines to prevent damage to the

robot.

Operating Safety Precautions

The following measures are designed to prevent damage to the robot during operation.

 Use a low override speed to increase your control over the robot when jogging the

robot.

 Visualize the movement the robot will make before you press the jog keys on the

teach pendant.

 Make sure the work envelope is clean and free of oil, water, or debris.  Use circuit breakers to guard against electrical overload.

Programming Safety Precautions

The following safety measures are designed to prevent damage to the robot during

programming:

 Establish interference zones to prevent collisions when two or more robots share a

work area.

 Make sure that the program ends with the robot near or at the home position.  Be aware of signals or other operations that could trigger operation of tooling

resulting in personal injury or equipment damage.

 In dispensing applications, be aware of all safety guidelines with respect to the

dispensing materials.

NOTE: Any deviation from the methods and safety practices described in this manual

must conform to the approved standards of your company. If you have questions, see your supervisor.

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personnel also must work inside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.

viii

Safety

Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.

CAUTION

Ensure that all ground cables remain connected. Never operate the paint robot with ground provisions disconnected. Otherwise, you could injure personnel or damage equipment.

Paint robots are operated in three modes:

 Teach or manual mode  Automatic mode, including automatic and exercise operation  Diagnostic mode

During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant.

In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds.

When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.

Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply strictly with the procedures in the manuals.

This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system.

The paint system includes the following safety features:

 Most paint booths have red warning beacons that illuminate when the robots are

armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are.

Safety

 Some paint booths have a blue beacon that, when illuminated, indicates that the

electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are.

 EMERGENCY STOP buttons are located on the robot controller and teach pendant.

Become familiar with the locations of all E–STOP buttons.

 An intrinsically safe teach pendant is used when teaching in hazardous paint

atmospheres.

 A DEADMAN switch is located on each teach pendant. When this switch is held in,

and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released or pressed harder during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E–STOP other robots.

WARNING

An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed robot.

 Overtravel by robot axes is prevented by software limits. All of the major and minor

axes are governed by software limits. DCS (Dual Check Safety), limit switches and hardstops also limit travel by the major axes.

 EMERGENCY STOP limit switches and photoelectric eyes might be part of your

system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SOC is in teach mode.

 When present, photoelectric eyes are sometimes used to monitor unauthorized

intrusion through the entrance/exit silhouette openings.

 System status is monitored by computer. Severe conditions result in automatic

system shutdown.

Staying Safe While Operating the Paint Robot

When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.

WARNING

Observe all safety rules and guidelines to avoid injury.

Safety

WARNING

Enclosures shall not be opened unless the area is known to be nonhazardous or all power has been removed from devices within the enclosure. Power shall not be restored after the enclosure has been opened until all combustible dusts have been removed from the interior of the enclosure and the enclosure purged. Refer to the Purge chapter for the required purge time.

 Know the work area of the entire paint station (workcell).  Know the work envelope of the robot and hood/deck and door opening devices.  Be aware of overlapping work envelopes of adjacent robots.  Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.  Know the location and status of all switches, sensors, and/or control signals that

might cause the robot, conveyor, and opening devices to move.

 Make sure that the work area near the robot is clean and free of water, oil, and debris.

Report unsafe conditions to your supervisor.

 Become familiar with the complete task the robot will perform BEFORE starting

automatic mode.

 Make sure all personnel are outside the paint booth before you turn on power to the

robot servo system.

 Never enter the work envelope or paint booth before you turn off power to the robot

servo system.

 Never enter the work envelope during automatic operation unless a safe area has been

designated.

 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught

in moving machinery.

 Remove all metallic objects, such as rings, watches, and belts, before entering a

booth when the electrostatic devices are enabled.

 Stay out of areas where you might get trapped between a moving robot, conveyor, or

opening device and another object.

 Be aware of signals and/or operations that could result in the triggering of guns or

bells.

 Be aware of all safety precautions when dispensing of paint is required.  Follow the procedures described in this manual.

Safety

Special Precautions for Combustible Dusts (Powder Paint)

When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot.

 Purge maintenance air should be maintained at all times, even when the robot power

is off. This will insure that dust can not enter the robot.

 A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed

to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. Do not energize the robot until you have performed the following steps.

1. Before covers are removed, the exterior of the robot should be cleaned to remove

accumulated dust.

2. When cleaning and removing accumulated dust, either on the outside or inside of the

robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken.

3. Thoroughly clean the interior of the robot with a lint free rag to remove any

accumulated dust.

4. When the dust has been removed, the covers must be replaced immediately.

5. Immediately after the covers are replaced, run a complete purge cycle. The robot can

now be energized.

Staying Safe While Operating Paint Application Equipment

When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.

WARNING

When working with electrostatic paint equipment, follow all national and local codes as well as all safety guidelines within your organization. Also reference the following standards: NFPA 33 Standards for Spray Application Using Flammable or Combustible Materials, and NFPA 70 National Electrical Code.

 Grounding: All electrically conductive objects in the spray area must be grounded.

This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers. Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms.

 High Voltage: High voltage should only be on during actual spray operations.

Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process.

 Avoid any accumulation of combustible vapors or coating matter.  Follow all manufacturer recommended cleaning procedures.  Make sure all interlocks are operational.

xii

Safety

 No smoking.  Post all warning signs regarding the electrostatic equipment and operation of

electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material.

 Disable all air and paint pressure to bell.  Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel should perform repair work on a robot.

 Paint robots operate in a potentially explosive environment. Use caution when

working with electric tools.

 When a maintenance technician is repairing or adjusting a robot, the work area is

under the control of that technician. All personnel not participating in the maintenance must stay out of the area.

 For some maintenance procedures, station a second person at the control panel within

reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards.

 Be sure all covers and inspection plates are in good repair and in place.  Always return the robot to the ‘‘home’’ position before you disarm it.  Never use machine power to aid in removing any component from the robot.  During robot operations, be aware of the robot’s movements. Excess vibration,

unusual sounds, and so forth, can alert you to potential problems.

 Whenever possible, turn off the main electrical disconnect before you clean the robot.  When using vinyl resin observe the following:

- Wear eye protection and protective gloves during application and removal.

- Adequate ventilation is required. Overexposure could cause drowsiness or

skin and eye irritation.

- If there is contact with the skin, wash with water.

- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

 When using paint remover observe the following:

- Eye protection, protective rubber gloves, boots, and apron are required

during booth cleaning.

- Adequate ventilation is required. Overexposure could cause drowsiness.

- If there is contact with the skin or eyes, rinse with water for at least 15

minutes. Then seek medical attention as soon as possible.

- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.

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B-83525EN/01 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

Thank you for purchasing FANUC Robot. This chapter describes the precautions which must be observed to ensure the safe use of the robot. Before attempting to use the robot, be sure to read this chapter thoroughly.

Before using the functions related to robot operation, read the relevant operator's manual to become familiar with those functions.

If any description in this chapter differs from that in the other part of this manual, the description given in this chapter shall take precedence.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 WORKING PERSON

The personnel can be classified as follows.

perator:

Turns robot controller power ON/OFF

•

Starts robot program from operator’s panel

•

Programmer or teaching operator:

Operates the robot

•

Teaches robot inside the safety fence

•

Maintenance engineer:

Operates the robot

•

Teaches robot inside the safety fence

•

Maintenance (adjustment, replacement)

•

- An operator cannot work inside the safety fence.

- A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc..

- To work inside the fence, the person must be trained on proper robot operation.

During the operation, programming, and maintenance of your robotic system, the programmer, teaching operator, and maintenance engineer should take additional care of their safety by using the following safety precautions.

- Use adequate clothing or uniforms during system operation

- Wear safety shoes

- Use helmet

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SAFETY PRECAUTIONS B-83525EN/01

2 NOTATION OF “WARNING”, “CAUTION”

and “NOTE”

This manual contains safety precautions against injury and property damage. Those precautions are labeled ”Warning” or ”Caution,” according to the degree of importance. Supplementary explanation is given under ”Note.” Before starting to use a robot, carefully read the ”Warning,” ”Caution,” and ”Note.”

WARNING

Failure to follow the instruction given under ”Warning” can cause fatal or serious

injury to the user. This information is indicated in bold type in a box so that it can be easily distinguished from the main body of this manual.

CAUTION

Failure to follow the instruction given under ”Caution” can cause injury to the

user or property damage. This information is indicated in a box so that it can be easily distinguished from the main body of this manual.

NOTE

The information given under ”Note” is a supplementary explanation, which is

neither a warning nor a caution.

Carefully read and save this manual.

3 WORKING PERSON SAFETY

Working person 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. Careful consideration must be made to ensure working person safety.

(1) Have the robot system working persons attend the training courses held by FANUC.

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

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is

waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person 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 working person can enter the work area without passing

through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see Fig.3 (b).

Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).

(4)

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B-83525EN/01 SAFETY PRECAUTIONS

(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 when a working person enters the work area.

(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the

power of the robot.

The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot (10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation

with gloved fingers could cause an operation error.

(11) Programs, system variables, and other information can be saved on memory card or USB memories.

Be sure to save the data periodically in case the data is lost in an accident.

(12) The robot should be transported and installed by accurately following the procedures recommended

by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers.

(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.

Then, the speed should be gradually increased to check the operation of the robot.

(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the

same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation.

(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and

peripheral equipment can be adversely affected, or workers can be severely injured.

- Avoid using the robot in a flammable environment.

- Avoid using the robot in an explosive environment.

- Avoid using the robot in an environment full of radiation.

- Avoid using the robot under water or at high humidities.

- Avoid using the robot to carry a person or animal.

- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)

(16) After connecting the safety signals like external emergency stop signal and/or safety fence signal,

verify that,

󲸤All safety signals stop the robot as intended. 󲸤There is no mistake in connection of safety signals.

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SAFETY PRECAUTIONS B-83525EN/01

󲩊󲩈󲨩 󲩈󲩭󲩤󲩫󲩝󲩛󲩧󲩜󲩝󲩪 󲩊󲩁󲨧󲩊󲩇󲨤󲩐󲩀󲨺󲩃󲨤󲩐󲩊󲩇󲩌

󲩊󲩅󲨩 󲩅󲩧󲩬󲩧󲩪󲨘󲩨󲩧󲩯󲩝󲩪󲨧󲩚󲩪󲩙󲩣󲩝

󲨽󲨹󲩊󲩌󲩀

󲩋󲩙󲩞󲩝󲩬󲩱󲨘󲩞󲩝󲩦󲩛󲩝

󲩁󲩦󲩬󲩝󲩪󲩤󲩧󲩛󲩣󲩡󲩦󲩟󲨘󲩜󲩝󲩮󲩡󲩛󲩝󲨘󲩙󲩦󲩜󲨘󲩫󲩙󲩞󲩝󲩬󲩱󲨘󲩨󲩤󲩭󲩟󲨘󲩬󲩠󲩙󲩬󲨘󲩙󲩪󲩝󲨘󲩙󲩛󲩬󲩡󲩮󲩙󲩬󲩝󲩜󲨘󲩡󲩞󲨘󲩬󲩠󲩝 󲩟󲩙󲩬󲩝󲨘󲩡󲩫󲨘󲩧󲩨󲩝󲩦󲩝󲩜󲨦

Fig.3 (a) Safety fence and safety gate

󲨽󲩥󲩝󲩪󲩟󲩝󲩦󲩛󲩱󲨘󲩫󲩬󲩧󲩨󲨘󲩚󲩧󲩙󲩪󲩜

󲨽󲨹󲩋󲨩󲨘

󲨽󲨹󲩋󲨩󲨩󲨘

󲨽󲨹󲩋󲨪󲨘

󲨽󲨹󲩋󲨪󲨩󲨘

ig.3 (b) Limit switch circuit diagram of the safety fence

(Note) Connect EAS1 and EAS11, EAS2 and EAS21. Terminals EAS1, EA11,EAS2,EAS21 are on the emergency sto board.

3.1 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) If you do not have to operate the robot, turn off the power of the robot controller or press the

EMERGENCY STOP button, and then proceed with necessary work.

(2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering

the work area unexpectedly and to prevent the worker from entering a dangerous area.

(4) Install an EMERGENCY STOP button within the operator’s reach.

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B-83525EN/01 SAFETY PRECAUTIONS

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external EMERGENCY STOP button is pressed. For connection, see Fir.3.1.

󲨽󲩰󲩬󲩝󲩪󲩦󲩙󲩤󲨘 󲨽󲩅󲨽󲩊󲨿󲨽󲩆󲨻󲩑󲨘 󲨘

󲩋

󲩌󲩇󲩈󲨘󲩚󲩭󲩬󲩬󲩧󲩦󲨘

󲨽󲩥󲩝󲩪󲩟󲩝󲩦󲩛󲩱󲨘󲩫󲩬󲩧󲩨󲨘󲩚󲩧󲩙󲩪󲩜

󲨽󲨽󲩋󲨩󲨘

󲨽󲨽󲩋󲨩󲨩󲨘

󲨽󲨽󲩋󲨪󲨘

󲨽󲨽󲩋󲨪󲨩󲨘

Fig. 3.1 Connection Diagram for External Emergency Stop Button

(Note) Connect EES1 and EES11, EES2 and EES21. Terminals EES1,EES11,EES2,EES21 are on the emergenc stop board.

3.2 SAFETY OF THE PROGRAMMER

While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the safety of the teach pendant operator especially.

(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal

operating condition.

(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and

other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area.

(4) The programmer must be extremely careful not to let anyone else enter the robot work area. (5) Programming should be done outside the area of the safety fence as far as possible. If programming

needs to be done in the area of the safety fence, the programmer should take the following precautions:

- Before entering the area of the safety fence, ensure that there is no risk of dangerous situations in the area.

- Be prepared to press the emergency stop button whenever necessary.

- Robot motions should be made at low speeds.

- Before starting programming, check the entire system status to ensure that no remote instruction to the peripheral equipment or motion would be dangerous to the user.

The operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence.

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SAFETY PRECAUTIONS B-83525EN/01

The teach pendant is provided with an enable/disable switch, DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY

PRECAUTIONS for detail of stop type) when pressed.

(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting

status. (a) Disable: The DEADMAN switch is disabled. (b) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the

operator presses the switch strongly.

Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or

presses the pendant strongly in case of emergency. The R-30iB Mate employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot stops immediately.

Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000 times per year.

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch of the operator panel, the teach pendant enable/disable switch and the remote condition on the software.

Teach pendant

Mode

AUTO

mode

T1, T2

mode

T1,T2 mode: DEADMAN switch is effective.

enable/disable

switch

Off

Software

remote

condition

Local Not allowed Not allowed Not allowed

Remote Not allowed Not allowed Not allowed

Local Not allowed Allowed to start Not allowed

Remote Not allowed Not allowed Allowed to start

Local Allowed to start Not allowed Not allowed

Remote Allowed to start Not allowed Not allowed

Local Not allowed Not allowed Not allowed

Remote Not allowed Not allowed Not allowed

Teach pendant Operator panel Peripheral device

(6) To start the system using the operator’s panel, make certain that nobody is the robot work area and

that there are no abnormal conditions in the robot work area.

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

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 the test operation 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.

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B-83525EN/01 SAFETY PRECAUTIONS

3.3 SAFETY OF THE MAINTENANCE ENGINEER

For the safety of maintenance engineer personnel, pay utmost attention to the following.

(1) During operation, never enter the robot work area. (2) A hazardous situation may arise when the robot or the system, are kept with their power-on during

maintenance operations. Therefore, for any maintenance operation, the robot and the system should be put into the power-off state. If necessary, a lock should be in place in order to prevent any other person from turning on the robot and/or the system. In case maintenance needs to be executed in the power-on state, the emergency stop button must be pressed.

(3) If it becomes necessary to enter the robot operation range while the power is on, press the

emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly.

(4) When entering the area enclosed by the safety fence, the maintenance worker should check the entire

system to make sure that no dangerous situations are present. If the worker needs to enter the area of the fence while a dangerous situation exists, the worker should always take extreme care and check the current system status.

(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off

and the pressure in the piping should be reduced to zero.

(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal

operating condition.

(7) Do not operate the robot in the automatic mode while anybody is in the robot work area. (8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working

nearby, make certain that their escape path is not obstructed.

(9) 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.

(10) If necessary, have a worker who is familiar with the robot system stand beside the operator 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.

(11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an

accident may occur, causing damage to the robot and injury to the worker.

(12) When replacing or reinstalling components, take care to prevent foreign matter from entering the

system.

(13) When handling each unit or printed circuit board in the controller during inspection, turn off the

circuit breaker to protect against electric shock.

If there are two cabinets, turn off the both circuit breaker. (14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction

or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause a fire.

(15) When restarting the robot system after completing maintenance work, make sure in advance that

there is no person in the work area and that the robot and the peripheral devices are not abnormal.

(16) When a motor or brake is removed, the robot arm should be supported with a crane or other

equipment beforehand so that the arm would not fall during the removal.

(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent

dangerous falls.

(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated

state, the worker should wear heat-resistant gloves or use other protective tools.

- Servo motor

- Inside the controller

(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause

any danger.

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SAFETY PRECAUTIONS B-83525EN/01

(20) When a motor, decelerator, or other heavy load is handled, a crane or other equipment should be

used to protect maintenance workers from excessive load. Otherwise, the maintenance workers would be severely injured.

(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot

would be adversely affected. In addition, a misstep can cause injury to the worker.

(22) After the maintenance is completed, spilled oil or water and metal chips should be removed from the

floor around the robot and within the safety fence.

(23) When a part is replaced, all bolts and other related components should put back into their original

places. A careful check must be given to ensure that no components are missing or left unmounted.

(24) In case robot motion is required during maintenance, the following precautions should be taken :

- Foresee an escape route. And during the maintenance motion itself, monitor continuously the whole system so that your escape route will not become blocked by the robot, or by peripheral equipment.

- Always pay attention to potentially dangerous situations, and be prepared to press the emergency stop button whenever necessary.

(25) The robot should be periodically inspected. (Refer to the manual of the controller or mechanical

unit.) A failure to do the periodical inspection can adversely affect the performance or service life of the robot and also may cause an accident.

(26) After a part is replaced, a test operation should be given for the robot according to a predetermined

method. (See TESTING section of “Controller operator’s manual”.) During the test operation, the maintenance staff should work outside the safety fence.

4 SAFETY OF THE TOOLS AND

PERIPHERAL DEVICES

4.1 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) For a system in which the robot and its peripheral devices are in synchronous motion, particular care

must be taken in programming so that they do not interfere with each other.

(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect

the states of all devices in the system and can be stopped according to the states.

4.2 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) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid. (3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does

not strike against its peripheral devices or tools.

(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not

kept, unexpected troubles might occur.

• Use mechanical unit cable that have required user interface.

• Don’t add user cable or hose to inside of mechanical unit.

• Please do not obstruct the movement of the mechanical unit cable when cables are added to

outside of mechanical unit.

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