fanuc RJ3iB Maintenance Manual

FANUC Robotics R-J3iB Controller ARC Mate 120iB, 120iB/10L M-16iB/20, M-16iB/10L Maintenance Manual

MARMI120I07021E REV. A

B–81765EN/01

This publication contains proprietary information of FANUC Robotics North America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics North America, Inc.

FANUC Robotics North America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 48309–3253

The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC Robotics North America, Inc, 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 KARELâ programming language, INSIGHTâ 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 radio frequency 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 its headquarters in Rochester Hills, Michigan. For additional information contact

FANUC Robotics North America, Inc. Training Department 3900 W. Hamlin Road

Rochester Hills, Michigan 48309-3253

www.fanucrobotics.com

Send your comments and suggestions about this manual to:

product.documentation@fanucrobotics.com

The information illustrated or contained herein is not to be reproduced, copied, translated into another language, or transmitted in whole or in part in any way without the prior written consent of FANUC Robotics North America, Inc.

AccuStatâ, ArcToolâ, DispenseToolâ, FANUC LASER DRILLâ, KARELâ, INSIGHTâ, INSIGHT IIâ, PaintToolâ, PaintWorksâ, PalletToolâ, SOCKETSâ, SOFT PARTSâ SpotToolâ, TorchMateâ, and YagToolâ are Registered Trademarks of FANUC Robotics.

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

AccuAirÔ AccuCalÔ AccuChopÔ AccuFlowÔ AccuPathÔ AccuSealÔ ARC MateÔ ARC Mate Sr. Ô ARC Mate System 1Ô ARC Mate System 2Ô ARC Mate System 3Ô ARC Mate System 4Ô ARC Mate System 5Ô ARCWorks ProÔ AssistToolÔ AutoNormalÔ AutoTCPÔ BellToolÔ BODYWorksÔ Cal MateÔ Cell FinderÔ Center FinderÔ Clean WallÔ CollisionGuardÔ DispenseToolÔ F-100Ô F-200iÔ FabToolÔ FANUC LASER DRILLÔ FlexibellÔ FlexToolÔ HandlingToolÔ HandlingWorksÔ INSIGHTÔ INSIGHT IIÔ IntelliTrakÔ Integrated Process SolutionÔ Intelligent Assist DeviceÔ IPC -Integrated Pump ControlÔ IPD Integral Pneumatic DispenserÔ ISA Integral Servo ApplicatorÔ ISD Integral Servo DispenserÔ Laser Mate System 3Ô Laser Mate System 4Ô LaserProÔ LaserToolÔ LR ToolÔ MIG EyeÔ MotionPartsÔ NoBotsÔ Paint StickÔ PaintProÔ PaintTool 100Ô PAINTWorksÔ PAINTWorks IIÔ PAINTWorks IIIÔ PalletMateÔ PalletMate PCÔ PalletTool PCÔ PayloadIDÔ RecipToolÔ RemovalToolÔ Robo ChopÔ Robo SprayÔ S-420iÔ S-430iÔ ShapeGenÔ SoftFloatÔ SOFÔ PARTSÔ SpotTool+Ô SR MateÔ SR ShotToolÔ SureWeldÔ SYSTEM R-J2 ControllerÔ SYSTEM RJ3 ControllerÔ SYSTEM R-J3iB ControllerÔ TCP MateÔ TurboMoveÔ TorchMateÔ visLOCÔ visPRO-3DÔ visTRACÔ WebServerÔ WebTPÔ YagToolÔ

Conventions

This manual includes information essential to the safety of personnel, equipment, software, and data. This information is indicated by headings and boxes in the text.

WARNING

Information appearing under WARNING concerns the protection of personnel. It is boxed and in bold type to set it apart from other text.

CAUTION

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

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

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Safety-1

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 best be 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 Robotic 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.

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.

Safety-2

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CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Keeping People and Equipment Safe

Using Safety Enhancing Devices

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

The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:

· People

· External devices

· Robot(s)

· Tooling

· Workpiece

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:

Setting Up a Safe Workcell

· Safety fences, barriers, or chains

· Light curtains

· Interlocks

· Pressure mats

· Floor markings

· Warning lights

· Mechanical stops

· EMERGENCY STOP buttons

· DEADMAN switches

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.

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Safety-3

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.

· Never rely on software as the primary safety element.

· 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.

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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.

· 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.

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Safety-5

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.

Staying Safe During Automatic Operation

- 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.

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

· Make sure all safety provisions are present and active.

· 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.

Safety-6

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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 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:

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Safety-7

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.

· 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.

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.

Safety-8

MARMI120I07021E REV

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.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

· 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.

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.

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Mechanical Safety Precautions

Safety-9

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.

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 software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE

Operating Safety Precautions

Programming Safety Precautions

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

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.

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.

Safety-10

MARMI120I07021E REV

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 personal 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.

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.

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

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Safety-11

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.

· 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 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.

Safety-12

MARMI120I07021E REV

Overtravel by robot axes is prevented by software limits. All of

· the major and minor axes are governed by software limits. 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 SCC 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.

WARNING

· 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.

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Safety-13

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.

Staying Safe While Operating Paint Application Equipment

· 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.

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.

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· 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.

· No smoking.

Staying Safe During Maintenance

· 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.

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.

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Safety-15

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.

· 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.

B–81765EN/01

PREFACE

This manual explains the maintenance and connection procedures for the mechanical units (R–J3iB controller) of the following robots. Before replacing the parts, determine the specification number of the mechanical unit.:

Model name Abbreviation

FANUC Robot ARC Mate 120iB ARC Mate 120iB A05B–1216–B201

FANUC Robot M–16iB/20 M–16iB/20 A05B–1216–B202

FANUC Robot ARC Mate 120iB/10L

FANUC Robot M–16iB/10L M–16iB/10L A05B–1216–B302

ARC Mate 120iB/10L

Mechanical unit

specification No.

A05B–1216–B301

p–1

PREFACE

PRODUCTION

MONTH

(1)

(3)

(4)

(2)

OSHINO–MURA, YAMANASHI PREF. JAPAN

TYPE NO. DATE

TOTAL WEIGHT WITH CONTROLLER : (5) kg TOTAL WEIGHT WITHOUT CONTROLLER : (6) kg

No. (1) (2) (3) (4) (5)

CONTENTS MODEL TYPE No. DATE

FANUC Robot ARC Mate 120iB A05B–1216–B201 220 kg

YEAR AND

MONTH

LETTERS

FANUC Robot M–16iB/20 A05B–1216–B202

FANUC Robot ARC Mate 120iB/10L

A05B–1216–B301

SERIAL

NO.

FANUC Robot M–16iB/10L A05B–1216–B302

B–81765EN/01

WEIGHT

(Without controller)

220 kg

Positon of label indicating mechanical unit specification number

p–2

B–81765EN/01

Specifications

PREFACE

Item

M–16iB/20

ARC Mate 120iB

M–16iB/10L

ARC Mate 120iB/10L

Type Articulated type Controlled axes 6 axes (J1, J2, J3, J4, J5, J6) Installation Floor, Upside–dowm (Wall & Angle mount) (Note 1) Motion range

J1 axis 340° (5.93rad) J2 axis 250° (4.36rad) J3 axis 460° (8.03rad) 455° (7.94rad) J4 axis 400° (6.98rad) J5 axis 280° (4.89rad) J6 axis 900° (15.71rad)

Maximum speed

J1 axis 165°/s (2.88rad/s) J2 axis 165°/s (2.88rad/s) J3 axis 175°/s (3.05rad/s) J4 axis 350°/s (6.11rad/s) J5 axis 340°/s (5.93rad/s)

J6 axis 520°/s (9.08rad/s) Max. load capacity at wrist 20kg 10kg Max. load capacity on J3 catting 12kg Allowable load moment at wrist

Allowable load inertia at wrist

J4 axis 39.2N·m

(4.0kgf·m)

J5 axis 39.2N·m

(4.0kgf·m)

J6 axis 19.6N·m

(2.0kgf·m)

J4 axis 0.88kg·m2

(9.0kgf·cm·s

J5 axis 0.88kg·m2

(9.0kgf·cm·s

J6 axis 0.25kg·m2

(2.5kgf·cm·s

22.0N·m

(2.2kgf·m)

22.0N·m

(2.2kgf·m)

9.8N·m

(1.0kgf·m)

)

0.63kg·m2

(6.4kgf·cm·s

0.63kg·m2

(6.4kgf·cm·s

0.15kg·m2

(1.5kgf·cm·s

)

) Drive method Electric servo drive by AC servo motor Repeatability "0.08mm "0.10mm Weight of mechanical unit 220kg Installation environment Ambient temperature : 0 – 45°C

Ambient humidity : Normally :75%RH or less

: Short time 95%RH or less

(within 1 month) (No dew or frost allowed)

Height : Up to 1,000 meters above the sea level

requires, no particular provision for attitude.

Vibration : 0.5G (4.9m/s

) or less

Required facilities (when no option is provided) Average power consumption: 1.0 kW

Input power supply capacity: 3.0 kVA

NOTE

1 Under the installation condition within ( ), the J1 and J2 axis motion range will be limited.

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PREFACE

B–81765EN/01

Dust–proof/waterproof performance of M–16iB/20/10L

Normal specification

Wrist+J3 arm IP67

Other part IP54

NOTE

Definition of IP code

Definition of IP 67

6=Dust–tight 7=Protection from water immersion

Definition of IP 54

5=Dust–protected 4=Protection from splashing water

Performance of resistant chemicals and resistant solvents

(1) The robot (including severe dust/liquid protection model) cannot be

used with the following liquids because there is fear that rubber parts (packing, oil seal, O ring etc.) will corrode.

(a) Organic solvents (b) Coolant including chlorine / gasoline (c) Amine washing lotion (d) Acid, alkali and liquid causing rust (e) Other liquids or solutions, that will harm NBR

(2) When the robots work in the environment, using water or liquid,

complete draining of J1 base must be done. Incomplete draining of J1 base will make the robot break down.

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B–81765EN/01

PREFACE

RELATED MANUALS

Safety handbook B–80687EN

All persons who use the FANUC Robot and system designer must read and understand thoroughly this handbook

R–J3iB controller Setup and Operations

manual

SPOT TOOL

B–81464EN–1

HANDLING TOOL

B–81464EN–2

ARC TOOL

B–81464EN–3

SEALING TOOL

B–81464EN–4

Maintenance manual

B–81465EN

B–81465EN–1 (European specification)

Mechanical unit Maintenance manual

FANUC Robot, ARC Mate 120iB, M–16iB B–81765EN

For the FANUC Robot series, the following manuals are available:

Intended readers : All persons who use FANUC Robot, system designer Topics : Safety items for robot system design, operation, maintenance

Intended readers : Operator, programmer, maintenance person, system designer Topics : Robot functions, operations, programming, setup, interfaces, alarms Use : Robot operation, teaching, system design

Intended readers : Maintenance person, system designer Topics : Installation, connection to peripheral equipment, maintenance Use : Installation, start–up, connection, maintenance

Intended readers : Maintenance person, system designer Topics : Installation, connection to the controller, maintenance Use : installation, start–up, connection, maintenance

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B–81765EN/01

SAFETY s–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREFACE p–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I. MAINTENANCE

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

1.1 J1–AXIS DRIVE MECHANISM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 J2–AXIS DRIVE MECHANISM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 J3–AXIS DRIVE MECHANISM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 J4–AXIS DRIVE MECHANISM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 J5– AND J6–AXIS DRIVE MECHANISMS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 SPECIFICATIONS OF THE MAJOR MECHANICAL UNIT COMPONENTS 10. . . . . . . . . . . . . . .

2. PREVENTIVE MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 DAILY INSPECTION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 QUARTERLY INSPECTION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 YEARLY INSPECTION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 ONE– AND HALF–YEAR PERIODIC INSPECTION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 THREE–YEAR PERIODIC INSPECTION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 MAINTENANCE TOOLS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. PERIODIC MAINTENANCE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 GREASING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 GREASE REPLACEMENT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 REPLACING THE BATTERIES 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TROUBLESHOOTING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 OVERVIEW 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 TROUBLES AND CAUSES 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. ADJUSTMENTS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 REFERENCE POSITION AND MOVING RANGE 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 MASTERING 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 General 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Resetting Alarms and Preparing for Mastering 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 Mastering to a Fixture (Master Position Master) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.4 Zero Position Mastering 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.5 Quick Mastering 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.6 Single Axis Mastering 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.7 Mastering Data Entry 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.8 Confirming Mastering 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 J5–AXIS GEAR BACKLASH ADJUSTMENTS 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 BRAKE RELEASE 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contents

B–81765EN/01

6. COMPONENT REPLACEMENT AND ADJUSTMENTS 55. . . . . . . . . . . . . . . . . . . . .

6.1 REPLACING THE J1–AXIS MOTOR

6.2 REPLACING THE J1–AXIS REDUCER 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 REPLACING THE J2–AXIS MOTOR

6.4 REPLACING THE J2–AXIS REDUCER 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 REPLACING THE J3–AXIS MOTOR

6.6 REPLACING THE J3–AXIS REDUCER 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 REPLACING THE J4–AXIS MOTOR

6.8 REPLACING THE J4–AXIS GEARBOX 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 REPLACING THE J5–AXIS MOTOR

6.10 REPLACING THE J5–AXIS GEAR 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 REPLACING THE J6–AXIS MOTOR

60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AND REDUCER 76. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. PIPING AND WIRING 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 PIPING DRAWING 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 WIRING DIAGRAMS 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 CABLE MOUNTING DIAGRAM 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. CABLE REPLACEMENT 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 CABLE DRESSING 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 REPLACING CABLES 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II. CONNECTION

1. ROBOT OUTLINE DRAWING AND OPERATION AREA DIAGRAM 99. . . . . . . . . .

1.1 OUTLINE DRAWING AND OPERATION AREA DIAGRAM 100. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. MOUNTING DEVICES ON THE ROBOT 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 WRIST SECTION END EFFECTOR MOUNTING SURFACE 107. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 WRIST LOAD CONDITIONS 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 DEVICE MOUNTING SURFACES 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 SETTING THE SYSTEM VARIABLES FOR SHORTEST–TIME CONTROL 114. . . . . . . . . . . . . . .

2.5 END EFFECTOR AIR PIPING 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 END EFFECTOR INPUT SIGNALS (RDI/RDO) 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 CONNECTOR SPECIFICATIONS 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TRANSPORTATION AND INSTALLATION 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 TRANSPORTATION 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 STORING THE ROBOT 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 INSTALLATION 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 MAINTENANCE CLEARANCE 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 ASSEMBLING THE ROBOT FOR INSTALLATION 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 AIR PIPING 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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B–81765EN/01

3.7 INSTALLATION CONDITIONS 134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

APPENDIX

A. SPARE PARTS LISTS 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. INTERNAL MECHANICAL UNIT CONNECTION DIAGRAMS 143. . . . . . . . . . . . . . .

C. PERIODIC INSPECTION TABLE 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D. MOUNTING BOLT TORQUE LIST 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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I. MAINTENANCE

+ 150 hidden pages