IAI America IX-UNN3515 User Manual
Horizontal Articulated Robot – IX Series
Wall-Mounting Type, Arm Length 300/350
IX-TNN-3015, IX-TNN-3515 (Wall-Mounting)
IX-UNN-3015, IX-UNN-3515 (Inverse)
Operation Manual Fifth Edition
Please Read Before Use
Thank you for purchasing an IAI product.
This operation manual explains the handling methods, structure and maintenance of this product, among
others, providing the information you need to know to use the product safely.
Before using the product, be sure to read this manual and fully understand the contents explained herein
to ensure safe use of the product.
The CD or DVD that comes with the product contains operation manuals for IAI products.
When using the product, refer to the necessary portions of the applicable operation manual by printing
them out or displaying them on a PC.
After reading the operation manual, keep it in a convenient place so that whoever is handling this product
can reference it quickly when necessary.
[Important]
The product cannot be operated in any way unless expressly specified in this operation
manual. IAI shall assume no responsibility for the outcome of any operation not specified
herein.
Information contained in this operation manual is subject to change without notice for the
purpose of product improvement.
This operation manual is original.
If you have any question or comment regarding the content of this manual, please contact
the IAI sales office near you.
Unauthorized use or reproduction of this operation manual, whether in whole or in part, is strictly
prohibited.
CE Marking
If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual
(ME0287) that is provided separately.
Table of Contents
Safety Guide ······················································································································1
Caution in Handling ···········································································································8
1. Names of Robot Parts ································································································9
1.1 Name of Each Part ·······················································································································9
1.2 Moving Direction ·························································································································11
1.3 Labels ·········································································································································12
1.4 Label Positions ···························································································································13
2. Transportation and Handling ··················································································· 15
2.1 Handling of the Carton ················································································································15
2.2 Packing Condition of the Robot ··································································································15
2.3 Handling of Individual Components ····························································································16
2.4 Checking after Unpacking ··········································································································16
2.5 Transporting the Robot ···············································································································17
3. Installation Environment and Storage Environment ················································ 18
3.1 Installation Environment ·············································································································18
3.2 Installation Platform ····················································································································18
3.3 Storage Environment ··················································································································18
4. How to Install ··········································································································· 19
4.1 Installation Posture ·····················································································································19
4.2 Structure of Mounting Wall ·········································································································20
4.3 Installing the Robot ·····················································································································21
4.4 Connecting the Controller ···········································································································22
4.5 Checking after Installation ··········································································································24
5. Precautions for Use ································································································· 25
5.1 Reference Acceleration/Deceleration Settings ···········································································25
5.2 Tools ···········································································································································27
5.3 Carrying Load ·····························································································································28
5.4 User Wiring and Piping ···············································································································29
6. Inspection/Maintenance ·························································································· 31
6.1 Inspection/Maintenance ··············································································································31
6.2 How to Check/Adjust Belt Tension ······························································································33
6.3 Battery Replacement ··················································································································40
6.4 Absolute Reset Procedure ··········································································································42
7. Speci cations ·········································································································· 59
7.1 Speci cation Table ······················································································································59
7.2 External Dimensions ···················································································································63
7.3 Robot Operation Area ·················································································································67
7.4 Wiring Diagram ···························································································································68
7.5 230V Circuit Components ···········································································································69
8. Warranty ·················································································································· 70
8.1 Warranty Period ··························································································································70
8.2 Scope of Warranty ······················································································································70
8.3 Honoring the Warranty ················································································································70
8.4 Limited Liability ···························································································································70
8.5 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications ·····71
8.6 Other Items Excluded from Warranty ·························································································71
Change History ··············································································································· 72
Safety Guide
“Safety Guide” has been written to use the machine safely and so prevent personal injury or property
damage beforehand. Make sure to read it before the operation of this product.
Safety Precautions for Our Products
The common safety precautions for the use of any of our robots in each operation.
No.
1 Model
Operation
Description
Selection
Description
This product has not been planned and designed for the application where
high level of safety is required, so the guarantee of the protection of
human life is impossible. Accordingly, do not use it in any of the following
applications.
1) Medical equipment used to maintain, control or otherwise affect human
life or physical health.
2) Mechanisms and machinery designed for the purpose of moving or
transporting people (For vehicle, railway facility or air navigation facility)
3) Important safety parts of machinery (Safety device, etc.)
Do not use the product outside the specifications. Failure to do so may
considerably shorten the life of the product.
Do not use it in any of the following environments.
1) Location where there is any inflammable gas, inflammable object or
explosive
2) Place with potential exposure to radiation
3) Location with the ambient temperature or relative humidity exceeding
the specification range
4) Location where radiant heat is added from direct sunlight or other large
heat source
5) Location where condensation occurs due to abrupt temperature
changes
6) Location where there is any corrosive gas (sulfuric acid or hydrochloric
acid)
7) Location exposed to significant amount of dust, salt or iron powder
8) Location subject to direct vibration or impact
For an actuator used in vertical orientation, select a model which is
equipped with a brake. If selecting a model with no brake, the moving part
may drop when the power is turned OFF and may cause an accident such
as an injury or damage on the work piece.
1
No.
Operation
Description
Description
2 Transportation When carrying a heavy object, do the work with two or more persons or
utilize equipment such as crane.
When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
When in transportation, consider well about the positions to hold, weight
and weight balance and pay special attention to the carried object so it
would not get hit or dropped.
Transport it using an appropriate transportation measure.
The actuators available for transportation with a crane have eyebolts
attached or there are tapped holes to attach bolts. Follow the instructions
in the instruction manual for each model.
Do not step or sit on the package.
Do not put any heavy thing that can deform the package, on it.
When using a crane capable of 1t or more of weight, have an operator
who has qualifications for crane operation and sling work.
When using a crane or equivalent equipments, make sure not to hang a
load that weighs more than the equipment’s capability limit.
Use a hook that is suitable for the load. Consider the safety factor of the
hook in such factors as shear strength.
Do not get on the load that is hung on a crane.
Do not leave a load hung up with a crane.
Do not stand under the load that is hung up with a crane.
3 Storage and
Preservation
The storage and preservation environment conforms to the installation
environment. However, especially give consideration to the prevention of
condensation.
Store the products with a consideration not to fall them over or drop due to
an act of God such as earthquake.
4 Installation
and Start
(1) Installation of Robot Main Body and Controller, etc.
Make sure to securely hold and fix the product (including the work part). A
fall, drop or abnormal motion of the product may cause a damage or injury.
Also, be equipped for a fall-over or drop due to an act of God such as
earthquake.
Do not get on or put anything on the product. Failure to do so may cause
an accidental fall, injury or damage to the product due to a drop of
anything, malfunction of the product, performance degradation, or
shortening of its life.
When using the product in any of the places specified below, provide a
sufficient shield.
1) Location where electric noise is generated
2) Location where high electrical or magnetic field is present
3) Location with the mains or power lines passing nearby
4) Location where the product may come in contact with water, oil or
chemical droplets
2
No.
Operation
Description
4 Installation
and Start
Description
(2) Cable Wiring
Use our company’s genuine cables for connecting between the actuator
and controller, and for the teaching tool.
Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not
coil it around. Do not insert it. Do not put any heavy thing on it. Failure to
do so may cause a fire, electric shock or malfunction due to leakage or
continuity error.
Perform the wiring for the product, after turning OFF the power to the unit,
so that there is no wiring error.
When the direct current power (+24V) is connected, take the great care of
the directions of positive and negative poles. If the connection direction is
not correct, it might cause a fire, product breakdown or malfunction.
Connect the cable connector securely so that there is no disconnection or
looseness. Failure to do so may cause a fire, electric shock or malfunction
of the product.
Never cut and/or reconnect the cables supplied with the product for the
purpose of extending or shortening the cable length. Failure to do so may
cause the product to malfunction or cause fire.
(3) Grounding
The grounding operation should be performed to prevent an electric shock
or electrostatic charge, enhance the noise-resistance ability and control
the unnecessary electromagnetic radiation.
For the ground terminal on the AC power cable of the controller and the
grounding plate in the control panel, make sure to use a twisted pair cable
with wire thickness 0.5mm
2
(AWG20 or equivalent) or more for grounding
work. For security grounding, it is necessary to select an appropriate wire
thickness suitable for the load. Perform wiring that satisfies the
specifications (electrical equipment technical standards).
Perform Class D Grounding (former Class 3 Grounding with ground
resistance 100: or below).
3
No.
4 Installation
Operation
Description
and Start
Description
(4) Safety Measures
When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
When the product is under operation or in the ready mode, take the safety
measures (such as the installation of safety and protection fence) so that
nobody can enter the area within the robot’s movable range. When the
robot under operation is touched, it may result in death or serious injury.
Make sure to install the emergency stop circuit so that the unit can be
stopped immediately in an emergency during the unit operation.
Take the safety measure not to start up the unit only with the power turning
ON. Failure to do so may start up the machine suddenly and cause an
injury or damage to the product.
Take the safety measure not to start up the machine only with the
emergency stop cancellation or recovery after the power failure. Failure to
do so may result in an electric shock or injury due to unexpected power
input.
When the installation or adjustment operation is to be performed, give
clear warnings such as “Under Operation; Do not turn ON the power!” etc.
Sudden power input may cause an electric shock or injury.
Take the measure so that the work part is not dropped in power failure or
emergency stop.
Wear protection gloves, goggle or safety shoes, as necessary, to secure
safety.
Do not insert a finger or object in the openings in the product. Failure to do
so may cause an injury, electric shock, damage to the product or fire.
When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
5 Teaching When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
Perform the teaching operation from outside the safety protection fence, if
possible. In the case that the operation is to be performed unavoidably
inside the safety protection fence, prepare the “Stipulations for the
Operation” and make sure that all the workers acknowledge and
understand them well.
When the operation is to be performed inside the safety protection fence,
the worker should have an emergency stop switch at hand with him so that
the unit can be stopped any time in an emergency.
When the operation is to be performed inside the safety protection fence,
in addition to the workers, arrange a watchman so that the machine can
be stopped any time in an emergency. Also, keep watch on the operation
so that any third person can not operate the switches carelessly.
Place a sign “Under Operation” at the position easy to see.
When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.
4
No.
Operation
Description
Description
6 Trial Operation When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
After the teaching or programming operation, perform the check operation
one step by one step and then shift to the automatic operation.
When the check operation is to be performed inside the safety protection
fence, perform the check operation using the previously specified work
procedure like the teaching operation.
Make sure to perform the programmed operation check at the safety
speed. Failure to do so may result in an accident due to unexpected
motion caused by a program error, etc.
Do not touch the terminal block or any of the various setting switches in
the power ON mode. Failure to do so may result in an electric shock or
malfunction.
7 Automatic
Operation
Check before starting the automatic operation or rebooting after operation
stop that there is nobody in the safety protection fence.
Before starting automatic operation, make sure that all peripheral
equipment is in an automatic-operation-ready state and there is no alarm
indication.
Make sure to operate automatic operation start from outside of the safety
protection fence.
In the case that there is any abnormal heating, smoke, offensive smell, or
abnormal noise in the product, immediately stop the machine and turn
OFF the power switch. Failure to do so may result in a fire or damage to
the product.
When a power failure occurs, turn OFF the power switch. Failure to do so
may cause an injury or damage to the product, due to a sudden motion of
the product in the recovery operation from the power failure.
5
No.
8 Maintenance
Operation
Description
and Inspection
Description
When the work is carried out with 2 or more persons, make it clear who is
to be the leader and who to be the follower(s) and communicate well with
each other to ensure the safety of the workers.
Perform the work out of the safety protection fence, if possible. In the case
that the operation is to be performed unavoidably inside the safety
protection fence, prepare the “Stipulations for the Operation” and make
sure that all the workers acknowledge and understand them well.
When the work is to be performed inside the safety protection fence,
basically turn OFF the power switch.
When the operation is to be performed inside the safety protection fence,
the worker should have an emergency stop switch at hand with him so that
the unit can be stopped any time in an emergency.
When the operation is to be performed inside the safety protection fence,
in addition to the workers, arrange a watchman so that the machine can
be stopped any time in an emergency. Also, keep watch on the operation
so that any third person can not operate the switches carelessly.
Place a sign “Under Operation” at the position easy to see.
For the grease for the guide or ball screw, use appropriate grease
according to the Instruction Manual for each model.
Do not perform the dielectric strength test. Failure to do so may result in a
damage to the product.
When releasing the brake on a vertically oriented actuator, exercise
precaution not to pinch your hand or damage the work parts with the
actuator dropped by gravity.
The slider or rod may get misaligned OFF the stop position if the servo is
turned OFF. Be careful not to get injured or damaged due to an
unnecessary operation.
Pay attention not to lose the cover or untightened screws, and make sure
to put the product back to the original condition after maintenance and
inspection works.
Use in incomplete condition may cause damage to the product or an injury.
* Safety protection Fence : In the case that there is no safety protection
fence, the movable range should be indicated.
9 Modification
and Dismantle
Do not modify, disassemble, assemble or use of maintenance parts not
specified based at your own discretion.
10 Disposal When the product becomes no longer usable or necessary, dispose of it
properly as an industrial waste.
When removing the actuator for disposal, pay attention to drop of
components when detaching screws.
Do not put the product in a fire when disposing of it.
The product may burst or generate toxic gases.
11 Other Do not come close to the product or the harnesses if you are a person
who requires a support of medical devices such as a pacemaker. Doing so
may affect the performance of your medical device.
See Overseas Specifications Compliance Manual to check whether
complies if necessary.
For the handling of actuators and controllers, follow the dedicated
instruction manual of each unit to ensure the safety.
6
Alert Indication
The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the
warning level, as follows, and described in the Instruction Manual for each model.
Level Degree of Danger and Damage Symbol
Danger
Warning
Caution
Notice
This indicates an imminently hazardous situation which, if the
product is not handled correctly, will result in death or serious injury.
This indicates a potentially hazardous situation which, if the product
is not handled correctly, could result in death or serious injury.
This indicates a potentially hazardous situation which, if the product
is not handled correctly, may result in minor injury or property
damage.
This indicates lower possibility for the injury, but should be kept to
use this product properly.
Danger
Warning
Caution
Notice
7
Caution in Handling
1. Make sure to attach the vertical articulated robot properly by following this operation
manual.
Using the product with the vertical articulated robot not being certainly retained or affixed may
cause abnormal noise, vibration, malfunction or shorten the product life.
8
1 Names of Robot Parts
1.1 Name of Each Part
(1) Wall-Mounting Specification
ALM (Alarm indicator)
4 user piping
(black, red, white; 3 locations)
User connector
Spacer for user
BK SW (Brake-release switch)
Mechanical stopper for
axis 3 (vertical axis)
U-cable (outside robot)
Mechanical
stopper for arm 2
1. Names of Robot Parts
PG cable
(outside robot)
Brake power cable
(outside robot)
M cable (outside robot)
Air tubes (4: 3 pcs.)
Wiring duct
Ball screw spline
shaft
Axis 3
(vertical axis)
Cover (arm 2)
Mechanical stopper for
axis 3 (vertical axis)
Axis 4
(R-axis)
Panel
Axis 2
Arm 2
Arm 1
Axis 1
Rear panel
(base)
Base
Mechanical stopper for arm 1
End cover (arm 1)
* The inverse specification is mounted upside down.
Reference
surface
Reference
surface
9
(2) Inverse Specification IX-UNN
Mechanical stopper for
axis 3 (vertical axis)
1. Names of Robot Parts
Cover (arm 2)
Axis 3
(vertical axis)
Ball screw
spline shaft
Mechanical stopper for
axis 3 (vertical axis)
Arm 1
Arm 2
Panel
Axis 4
(R-axis)
Axis 2
Axis 1
End cover (arm 1)
Mechanical stopper for arm 1
Reference
surface
Base
Rear panel (base)
Wiring duct
Reference
surface
ALM (Alarm indicator)
4 user piping
(black, red, white; 3 locations)
User connector
Spacer for user part installation
BK SW
(Brake-release switch)
U-cable (outside robot)
Arm 2
(mechanical
stopper)
PG cable
(outside robot)
Brake power cable
(outside robot)
M cable (outside robot)
Air tubes (4: 3 pcs.)
10
1.2 Moving Direction
Arm 2
(-)
Axis 3
(+)
(-) (+)
Axis 4
(-) (+)
(-) (+)
Axis 2
1. Names of Robot Parts
Axis 1
Arm 1
(+)
Axis 3
(-)
Arm 2
Wall-mounting specification
Axis 4
(-) (+)
(-) (+)
Axis 2
Arm 1
(-) (+)
Axis 1
Inverse specification
11
1.3 Labels
The following labels are attached on the robot and controller. Be sure to observe the instructions and cautions
written on the labels to ensure the correct use of the robot/controller.
(1) Labels on the Robot
1. Names of Robot Parts
(2) Labels on the Controller
Caution/warning on
handling of the controller
Prohibition of entry into
the operation area
Robot serial number
Warning on handling of
the vertical axis
CE-certified robot
(Provided only for CE-certified models)
Designation of the connected robot
Warning against
electric shock
Controller serial number
(Other than CE-certified models)
Danger
x Failure to observe the cautionary information provided on the labels may result in serious injury or damage
to the robot.
12
Warning
Controller serial number
(CE-certified models)
Caution
1.4 Label Positions
A
Label Positions on the Robot
IX-TNN15
(Wall-Mounting)
Warning on handling
of the vertical axis
Warning against
electric shock
CE-Certified robot (Provided only
for CE-certified models)
Robot serial number
View
1. Names of Robot Parts
View B
(Inverse)
Warning on handling
of the vertical axis
(Provided only for CE-certified models)
CE-Certified robot
Warning against
electric shock
Robot serial number
View A
View B
13
Label Positions on the Controller
Controller serial number
Other than CE-certified specification
Caution/warning on controller handling
1. Names of Robot Parts
Specification of connected robot
CE-certified specification
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2 Transportation and Handling
A
2.1 Handling of the Carton
Each robot is packed with a controller prior to shipment.
When transporting the carton containing the robot and controller, observe the following items and be careful not
to drop the carton or apply impact due to forcible contact:
x If the carton is heavy, one operator should not attempt to carry it alone.
x Place the carton on a level surface if it is to be left there for a while.
x Do not climb upon the carton.
x Do not place on the carton any heavy object that may cause the carton to deform, or an article whose
shape allows a load to be concentrated at one point.
2.2 Packing Condition of the Robot
Robot
Controller, accessories and other
items (except for the robot)
2. Transportation and Handling
rm fixing plate
Warning
z The robot and controller are very heavy. When transporting the carton containing the robot and
controller, handle it with extra care so as not to drop the carton or apply impact due to forcible
contact, as it may cause injury or damage to the robot or controller.
z Serious injury may result if the carton is dropped onto a person during transportation.
z Never stand below the carton as it is hoisted.
z Use a carrier device with sufficient loading capacity.
z If a machine or method is used that requires specified skills, it must be operated/performed by a
person having the proper qualifications.
Caution
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2.3 Handling of Individual Components
The robot and controller are supplied as a set.
Your robot cannot be used with the controller supplied with another robot.
When handling multiple robots, be careful not to lose their correct parings with the controllers.
When unpacking or moving the machine, do not lift the robot directly by the rotational axis or flexible tube.
(It may cause machine problems due to deformation, disconnection, etc.)
2.4 Checking after Unpacking
After unpacking the carton, check the condition of the robot and other items contained in the carton.
Standard parts
Robot 1
2. Transportation and Handling
Controller 1
Operation manual for robot 1
Operation manual for controller 1
Accessories
D-sub connector 1
Hood set (for D-sub connector) 1
Caution label 2
Positioning label 1
PIO flat cable 1
Optional parts
PC software (type: IA-101-X-MW)
Floppy disk 2
PC connection cable 1
Hand-held emergency-stop switch 1
Operation manual for PC software 1
Absolute reset adjustment jig (type: JG-2)
Positioning jig for axes 1 and 2 (pin) 1
Positioning jig for axis 4 (plate) 1
Absolute-data backup battery (AB-3)
Caution
z Always operate the robot using the controller supplied with the robot in the same carton. Using
another controller may result in an unexpected operation, damaged motor or other problem.
z After unpacking, be sure to confirm the condition of the robot and other items contained in the
carton. Should you find a damaged or missing part, please contact IAI immediately.
Note
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2.5 Transporting the Robot
When transporting the robot, affix the arms using the supplied arm fixing plate and arm support plate.
Additionally, wrap the cables around the upper section and secure them with gummed tape or other means.
Use a dolly, forklift or other appropriate equipment for transportation. When transporting the robot, move it slowly
by maintaining balance and safeguarding against vibration or impact.
2. Transportation and Handling
Arm support plate
Arm fixing plate
Danger
z If the arms and cables remain free, the arms may turn unexpectedly and pinch a hand, or a
person may be tripped by the trailing cables.
z Do not attempt to carry the robot by hand, as it may injure the back. Additionally, an injury may
result if the robot is dropped onto the feet.
z Serious injury may result if a person is caught under a fallen robot during transportation.
z Never stand below the robot as it is hoisted.
z If a machine or method is used that requires specified skills, it must be operated/performed by a
person having the proper qualifications.
Warning
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3 Installation Environment and Storage Environment
3.1 Installation Environment
Install the robot in an environment that satisfies the following conditions:
x Away from direct sunlight
x Not subject to radiated heat from a high-capacity energy source such as a heat-treating furnace
x Surrounding air temperature: 0qC to 40qC
x Humidity: 85% or less (non-condensing)
x Not exposed to corrosive or flammable gases
x Not subject to impact or vibration
x Not exposed to a significant amount of electromagnetic waves, ultraviolet rays or radiation
x Sufficient space is available to ensure safety in teaching and maintenance/inspection operations
Generally, the robot must be installed where the operator need not wear protective gear in order to work.
3.2 Installation Platform
The platform on which to install the robot receives a significant reactive force. Be certain the platform has
sufficient rigidity to withstand the anticipated force.
x The surface on which the robot is fixed must have a thickness of 25 mm or more.
The levelness of the robot installation surface must be at least r0.05 mm.
x Drill M8 tapped holes into the installation surface of the platform. The effective threads must be 10 mm or
3. Installation Environment and Storage Environment
longer.
x The platform must have sufficient rigidity to withstand not only the weight of the robot but also the dynamic
moment of inertia that is generated when the robot is operated at maximum speed.
x Secure the platform to the floor or other rigid structure in a manner that prevents any movement due to
operation of the robot.
x The installation platform must allow the robot to be mounted on a level surface.
3.3 Storage Environment
The storage environment conforms to the installation environment. If the robot is to be stored for a prolonged
period of time, be sure the robot will not be exposed to dew condensation.
Unless otherwise specified, desiccant is not placed in the carton when shipped. If the robot is to be kept in an
environment subject to condensation, provide preventive measures from over the carton or directly to the robot
after unpacking.
The maximum storage temperature is 60qC for a short storage period. If the robot is to be stored for more than a
month, the surrounding air temperature should not exceed 50qC.
Danger
z Failure to provide a proper environment for installation and storage may shorten the service life of
the robot, reduce its operation accuracy, or cause a malfunction or failure.
z Never use the robot in a flammable atmosphere. The robot may explode or ignite.
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Warning
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