YAMAHA SINGLE-AXIS ROBOT. User s Manual ENGLISH. E21-Ver. 1.17

Transcription

1 YAMAHA SINGLEAXIS ROBOT User s Manual ENGLISH E E1Ver. 1.17

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3 Before using the singleaxis robot FLIPX series (Be sure to read the following notes.) Thanks for your purchasing YAMAHA singleaxis robot FLIPX series. Before using this robot, read the following notes and set the origin position. The "X" series singleaxis and XY robots use absolute position detectors that do not require returntoorigin after turning on the controller power. However, when the controller power is turned on in the following cases, returntoorigin must be performed just the very first time. (1) When robot cable was first connected after delivery from YAMAHA. () When robot cable was disconnected from the controller and then reconnected. () When no absolute battery is connected. (4) When a motor or cable was replaced. At this point, any of the following errors is issued immediately after controller power is turned on, but this is not a malfunction. The controller will operate normally by restarting. When using ERCD, ERCX, SRCX, DRCX, TRCX or SR1 controllers: 15 : FEEDBACK ERROR : ABS.BAT.LVOLTAGE 4 : ABS.DATA.ERROR...etc. When using RCX14 or RCX controllers: : ABS.battery wire breakage 17.9 : Resolver disconnected during power off 17.9 : Position backup counter overflow : ABS.battery low voltage...etc.

4 Setting the origin position [1] When using a linear movement robot Applicable robots: All "X" series singleaxis robots except singleaxis rotary movement robots (see []) Linear movement axes (X, Y, Z axes) of "X" series Cartesian robots The above robots use the stroke end origin detection method. The motor side stroke end is set as the origin at the factory prior to shipping Set the origin position while referring to the following section in the robot controller user's manual. When using ERCD controller: See "8.1 Performing returntoorigin" in Chapter 8 of the "HPB Operation Guide" section. When using ERCX, SRCX, DRCX or TRCX controllers: See "911 Returntoorigin by the search method" in Chapter 9. When using SR1 controller: See "9.1.1 Returntoorigin by the search method" in Chapter 9 of the "HPB Operation Guide" section. When using RCX14 or RCX controllers: See "11.8 Absolute reset" in Chapter 4. CAUTION Avoid changing the origin position to the nonmotor side. Changing the origin position to the nonmotor side may cause a positional shift or robot breakdowns, and is also dangerous in some cases. If the origin position must be changed, please consult our sales office or dealer. [] When using a rotary movement robot Applicable robots: R5/R10/R0 ("X" series singleaxis robots) RF (R axis of "X" series Cartesian robots SXYx/MXYx) RL/RH (R axis of "X" series Cartesian robots HXYx) RM/RS (R axis of "X" series Cartesian robots ZRM/ZRS) On the above robots, the customer should set the origin at the desired position. Move the robot to the desired position and set it as the origin while referring to the following section in the robot controller use's manual. When using ERCX, SRCX, DRCX or TRCX controllers: See "91 Returntoorigin by the mark method" in Chapter 9. When using SR1 controller: See "9.1. Returntoorigin by the mark method" in Chapter 9 of the "HPB Operation Guide" section. When using RCX14 or RCX controllers: See "11.8 Absolute reset" in Chapter 4. After setting the origin position, affix the stickers (triangular stickers supplied with the robot) to both the tool side and workpiece side so that they can be used as the alignment marks. Use these marks as the reference position the next time the origin must be set.

5 Introduction The YAMAHA FLIPX series is a family of singleaxis industrial robots that use the absolute positioning method as a standard feature to improve ease of use, resistance to environmental conditions and maintenance work. A wide varaiety of product lineup allows you to select the desired robot model that best matches your application. This instruction manual describes the safety measures, handling, adjustment and maintenance of FLIPX series robots for correct, safe and effective use. Be sure to read this manual carefully before installing the robot. Even after you have read this manual, keep it in a safe and convenient place for future reference. This instruction manual should be used with the robot and considered an integral part of it. When the robot is moved, transferred or sold, send this manual to the new user along with the robot. Be sure to explain to the new user the need to read through this manual. Specifications of robot models other than standard models may be omitted in this manual if they are common to those of standard models. In this case, refer to the specifications of standard models. For details on specific operation and programming of the robot, refer to the separate YAMAHA Robot Controller User s Manual. NOTES The contents of this manual are subject to change without prior notice. Information furnished by YAMAHA in this manual is believed to be reliable. However, if you find any part unclear or inaccurate in this manual, please contact YAMAHA sales office or dealer. YAMAHA MOTOR CO., LTD. IM Operations

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7 Contents Chapter 1 About Safety 11 Safety Information Essential Caution Items Special Training for Industrial Robot Operation Robot Safety Functions Safety Measures for the System Trial Operation Work Within the Safeguard Enclosure Automatic Operation Adjustment and Inspection Repair and Modification Warranty Chapter Installation and Connections 1 Checking the product... Moving the robot... 4 Robot Installation Conditions Installation environments... 5 Installation base Installing the robot T T T9/T9H F F14/F14H F17/F R5/R10/R B10/B14/B14H F0N Protective bonding Connections Connecting the robot cables Changing the cable routing direction (F Type)... 6 Changing the cable routing direction (B Type) Changing the motor orientation (B type) User wiring... 8

8 7 Setting the operating conditions Payload Maximum speed setting Duty Chapter Adjusting the robot 1 Attaching the upper cover (B10/B14/B14H)... Adjusting the timing belt tension (B10/B14/B14H) Adjusting the drive belt tension... 5 Reference: Adjusting drive belt tension with a tension meter... 6 Adjusting the speed reduction belt tension... 7 Reference: Adjusting speed reduction belt tension with a tension meter... 8 Installing and removing the cover (F0N) Stroke cover... 9 Belt cover Motor cover Adjusting the timing belt tension (F0N)... 1 Chapter 4 Periodic Inspection 41 Before beginning work Periodic inspection Daily inspection Threemonth inspection Sixmonth inspection Threeyear inspection Applying grease Applying grease (T6/T7 type) Applying grease (T9/F types) Applying grease (B type) Adjusting and replacing a loose shutter Replacing the shutter (T6) Adjusting shutter looseness (T6) Replacing the motor Replacing the motor (B10/B14/B14H) Replacing the motor (F0N) Replacing the drive belt (B10/B14/B14H) Replacing the speed reduction belt (B10/B14/B14H) Replacing the slider Replacing the slider (B10/B14/B14H) Replacing the slider (F0N)... 41

9 Chapter 5 Specifications 51 Robot specifications T T T T9H F F F14H F F F0N R R R B B B14H AC servo motor termination (T/F Type) AC servo motor termination (R/B Type, F0N) Robot cables Chapter 6 Troubleshooting Appendix 61 Positioning error Feedback error About machine reference... iii Equation of moment of inertia calculation... iv

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11 Chapter 1 About Safety 11 Safety Information Essential Caution Items Special Training for Industrial Robot Operation Robot Safety Functions Safety Measures for the System Trial Operation Work Within the Safeguard Enclosure Automatic Operation Adjustment and Inspection Repair and Modification Warranty... 11

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13 Chapter 1 About Safety 11 Safety Information Industrial robots are highly programmable, mechanical devices that provide a large degree of freedom when performing various manipulative tasks. To ensure correct and safe use of YAMAHA industrial robots, carefully read this manual and make yourself well acquainted with the contents. FOLLOW THE S, CAUTIONS AND INSTRUCTIONS INCLUDED IN THIS MANUAL. Failure to take necessary safety measures or mishandling due to not following the instructions in this manual may result in trouble or damage to the robot and injury to personnel (robot operator or service personnel) including fatal accidents. Warning information in this manual is shown classified into the following items. DANGER Failure to follow DANGER instructions will result in severe injury or death to the robot operator, bystanders or persons inspecting or repairing the robot. Failure to follow instructions could result in severe injury or death to the robot operator, bystanders or persons inspecting or repairing the robot. CAUTION Failure to follow CAUTION instructions may result in injury to the robot operator, bystanders or persons inspecting or repairing the robot, or damage to the robot and/ or robot controller. NOTE Explains the key point in the operation in a simple and clear manner. Refer to the instruction manual by any of the following methods to operate or adjust the robot safely and correctly. 1. Operate or adjust the robot while referring to the printed version of the instruction manual (available for an additional fee).. Operate or adjust the robot while viewing the CDROM version of the instruction manual on your computer screen.. Operate or adjust the robot while referring to a printout of the necessary pages from the CD ROM version of the instruction manual. It is not possible to list all safety items in detail within the limited space of this manual. So it is essential that the user have a full knowledge of basic safety rules and also that the operator makes correct judgments on safety procedures during operation. This manual and warning labels supplied with or affixed to the robot are written in English. If the robot operator or service personnel does not understand English, do not permit that person to handle the robot. 1

14 Chapter 1 About Safety 1 Essential Caution Items Particularly important cautions for handling or operating the robot are described below. In addition, safety information about installation, operation, inspection and maintenance is provided in each chapter. Be sure to comply with these instructions to ensure safe use of the robot. (1) Observe the following cautions during automatic operation. Install a safeguard (protective enclosure) to keep any person from entering within the movement range of the robot and suffering injury due to being struck by moving parts. Install a safety interlock that triggers emergency stop when the door or panel is opened. Install safeguards so that no one can enter inside except from doors or panels equipped with safety interlocks. The warning labels 1 (Fig. 11) are supplied with the robot and should be affixed to conspicuous spots on doors or/ panels equipped with safety interlocks. DANGER Serious injury or death will result from impact with moving robot. Keep outside of guard during operation. Lock out power before approaching robot. () Use caution to prevent hands or fingers from being pinched or crushed. Warning labels (Fig. 1) are affixed to the robot. Moving parts can pinch or crush. Keep hands away from robot arms. DANGER Serious injury or death will result from impact with moving robot. Keep outside of guard during operation. Lock out power before approaching robot. Moving parts can pinch or crush. Keep hands away from robot arms. Fig. 11 Warning label 1 Fig. 1 Warning label 14

15 Chapter 1 About Safety () Follow the instructions on listed on warning labels and in this manual. Be sure to read the warning labels and this manual carefully and make sure you thoroughly understand their contents before attempting installation and operation of the robot. Before starting robot operation, be sure to reread the procedures and cautions relating to your work as well as descriptions in this chapter (Chapter 1, Using the Robot Safely ). Never install, adjust, inspect or service the robot in any manner that does not comply with the instructions in this manual. The warning labels (Fig. 1) are supplied with the robot and should be affixed to the robot or conspicuous spots near the robot. Improper installation or operation can result in serious injury or death. Read the user s manual and all warning labels before operation. Improper Installation or operation can result in serious injury or death. Read user's(owner's) manual and all warning labels before operation. Fig. 1 Warning label (4) Do not use the robot in environments containing inflammable gas, etc. This robot was not designed for operation in environments where inflammable or explosive substances are present. Do not use the robot in environments containing inflammable gas, dust or liquids. Explosions or fire might otherwise result. (5) Do not use the robot in locations possibly subject to electromagnetic interference, etc. Avoid using the robot in locations subject to electromagnetic interference, electrostatic discharge or radio frequency interference. Malfunctions might otherwise occur. 15

16 Chapter 1 About Safety (6) Use caution when releasing the brake of a vertical use robot. The vertical axis will slide down when the brake is released, causing a hazardous situation. Press the emergency stop button and prop up the vertical axis with a support stand before releasing the brake. Be careful not to let your body get caught between the vertical axis and installation base when releasing the brake to perform direct teach. (7) Provide safety measures for end effector (gripper, ad9). End effectors must be designed and manufactured so that they create no hazards (for example, a workpiece that comes loose) even if power (electricity, air pressure, etc.) is shut off or power fluctuations occur. If there is a possible danger that the object gripped by the end effector may fly off or drop, then provide appropriate safety protection taking into account the object size, weight, temperature and chemical properties. (8) Use caution when removing the motor. (Vertical use robots) The vertical axis will slide down when the motor is released, causing a hazardous situation. Turn off the robot controller and prop up the vertical axis with a support stand before removing the motor. Be careful not to let your body get caught between the vertical axis parts and installation base. (9) Take the following safety precautions during inspection of controller. When you need to touch the terminals or connectors on the outside of the controller during inspection, always first turn off the controller power switch and also the power source in order to prevent possible electrical shock. Never touch any internal parts of the controller. Refer to the YAMAHA Robot Controller User s Manual for precautions on handling the controller. 16

17 Chapter 1 About Safety (10) Consult us for corrective action when the robot is damaged or malfunctions occur. If any part of the robot is damaged or any malfunction occurs, continuing the operation may be very dangerous. Please consult your YAMAHA sales office or dealer for corrective action. Damage or Trouble Damage to machine harness or robot cable Damage to exterior of robot Abnormal operation of robot (positioning error, excessive vibration, etc.) Zaxis brake trouble Possible Danger Electrical shock, malfunction of robot Flying outwards of damaged parts during robot operation Malfunction of robot Dropping of load (11) Use caution not to touch the controller rear panel cooling fan. Bodily injury may occur from coming into contact with the cooling fan while it is rotating. When removing the fan cover for inspection, first turn off the controller and make sure the fan has stopped. (1) Be careful not to touch the motor or speed reduction gear casing when hot. The motor and speed reduction gear casing are extremely hot after automatic operation, so burns may occur if these are touched. Before handling these parts during inspection or servicing, turn off the controller, wait for a while and check that the part has cooled. (1) Do not remove, alter or stain the warning labels. If warning labels are removed or difficult to see, then essential precautions might not be taken, resulting in accidents. Do not remove, alter or stain the warning labels on the robot. Do not allow the warning labels to be hidden by devices installed onto the robot by the user. Provide proper lighting so that the symbols and instructions on the warning labels can be clearly seen even from outside the safeguard enclosure. 17

18 Chapter 1 About Safety (14) Protective bonding Be sure to ground the robot and controller to prevent electrical shock. (15) Be sure to make correct parameter settings. CAUTION The robot must be operated with correct tolerable moment of inertia and acceleration coefficients according to the manipulator tip mass and moment of inertia. If these are not correct, drive unit service life may end prematurely, and damage to robot parts or residual vibration during positioning may result. (16) Do not use the robot for tasks requiring motor thrust. CAUTION Avoid using the beltdriven type robots for tasks which utilize motor thrust (pressfitting, burr removal, etc.). These tasks may cause malfunctions in the robot. 18

19 Chapter 1 About Safety 1 Special Training for Industrial Robot Operation Companies or factories using industrial robots must make sure that every person, who handles the robot such as for teaching, programming, movement check, inspection, adjustment and repair, has received appropriate training and also has the skills needed to perform the job correctly and safely.since the FLIPX series robots fall under the industrial robot category, the user must observe local regulations and safety standards for industrial robots, and provide special training for every person involved in robotrelated tasks (teaching, programming, movement check, inspection, adjustment, repair, etc.). 19

20 Chapter 1 About Safety 14 Robot Safety Functions (1) Overload detection This function detects an overload applied to the motor and shuts off the servo power. () Overheat detection This detects an abnormal temperature rise in the controller driver and shuts off the servo power. If an overload or overheat error occurs, take the following measures. 1. Insert a timer in the program.. Reduce the acceleration coefficient. () Soft limits Soft limits can be set on each axis to limit the working envelope in manual operation after returntoorigin and during automatic operation. Note: The working envelope is the area limited by soft limits. (4) Mechanical stoppers If the servo power is suddenly shut off during highspeed operation by emergency stop or safety functions, these mechanical stoppers prevent the axis from exceeding the movement range. No mechanical stopper is provided on the rotating axis. Note: The movement range is the area limited by mechanical stoppers. Axis movement will not stop immediately after the servo power supply is shut off by emergency stop or other safety functions. (5) Vertical axis brake An electromagnetic brake is installed on the vertical use robot to prevent the vertical axis from sliding down when servo power is turned off. This brake is working when the controller is off or the vertical axis servo power is off even when the controller is on. The vertical axis brake can be released by means of the programming box or by a command in the program when the controller is on. The vertical axis will slide down when the brake is released, creating a hazardous situation. Press the emergency stop button and prop the vertical axis with a support stand before releasing the brake. Use caution not to let your body get caught between the vertical axis and installation base when releasing the brake to perform direct teach. 110

21 Chapter 1 About Safety 15 Safety Measures for the System Since the robot is commonly used in conjunction with an automated system, dangerous situations are more likely to occur from the automated system than from the robot itself. Accordingly, appropriate safety measures must be taken on the part of the system manufacturer according to the individual system. The system manufacturer should provide a proper instruction manual for safe, correct operation and servicing of the system. 16 Trial Operation After making installations, adjustments, inspections, or maintenance or repairs to the robot, make a trial run using the following procedures. (1) If a safeguard enclosure has not yet been provided right after installation of the robot, rope off or chain off around the movement area of the manipulator in place of the safeguard, and observe the following points. 1.Use sturdy, stable posts which will not fall over easily..the rope or chain should be easily visible by everyone around the robot..place a sign to keep the operator or other personnel from entering the movement range of the manipulator. () Check the following points before turning on the controller. 1.Is the robot securely and correctly installed?.are the electrical connections to the robot correct?.are items such as air pressure correctly supplied? 4.Is the robot correctly connected to peripheral equipment? 5.Have safety measures (safeguard enclosure, etc.) been taken? 6.Does the installation environment meet the specified standards. () After the controller is turned on, check the following points from outside the safeguard enclosure. 1.Does the robot start and stop as intended? Can the operation mode be selected correctly?.does each axis move as intended within the soft limits?.does the end effector move as intended? 4.Are the signal transmissions to the end effector and peripheral equipment correct? 5.Does emergency stop work? 6.Are the teaching and playback functions normal? 7.Are the safeguard enclosure and interlock working as intended? 8.Does the robot move correctly during automatic operation? 111

22 Chapter 1 About Safety 17 Work Within the Safeguard Enclosure (1) Work within the safeguard enclosure When work is required inside the safeguard enclosure, always turn off the controller and place a sign indicating that the robot is being adjusted or serviced in order to keep any other person from touching the controller switch or operation panel, except for the following cases. 1) Soft limit settings ) Teaching For item 1), follow the precautions and procedure for each section. To perform item ), refer to the description in () below. () Teaching When performing teaching within the safeguard enclosure, comply with the instructions listed below. 1) Check or perform the following points from outside the safeguard enclosure. 1.Make sure that no hazards are present within the safeguard enclosure by a visual check..check that the programming box MPB, RPB or HPB operates correctly..check that no failures are found in the robot. 4.Check that emergency stop works correctly. 5.Select teaching mode and prohibit automatic operation. ) Never enter the movement range of the manipulator while within the safeguard enclosure. 18 Automatic Operation Automatic operation described here includes all operations in AUTO mode. (1) Check the following before starting automatic operation. 1. No one is within the safeguard enclosure.. The programming box and tools are in their specified locations.. The alarm or error lamps on the robot and peripheral equipment do not flash. 4. The safeguard enclosure is securely installed with safety interlocks actuated. () Observe the following during automatic operation or in cases where an error occurs. 1) After automatic operation has started, check the operation status and warning lamp to ensure that the robot is in automatic operation. ) Never enter the safeguard enclosure during automatic operation. ) If an error occurs in the robot or peripheral equipment, observe the following procedure before entering the safeguard enclosure. 1.Press the emergency stop button to set the robot to emergency stop..place a sign on the start switch, indicating that the robot is being inspected in order to keep any other person from touching the start switch and restarting the robot. 19 Adjustment and Inspection Do not attempt any installation, adjustment, inspection or maintenance unless it is described in this manual. 110 Repair and Modification Do not attempt any repair, parts replacement and modification unless described in this manual. These works require technical knowledge and skill, and may also involve work hazards. 11

23 Chapter 1 About Safety 111 Warranty The YAMAHA robot and/or related product you have purchased are warranted against the defects or malfunctions as described below. Warranty description Warranty Period : If a failure or breakdown occurs due to defects in materials or workmanship in the genuine parts constituting this YAMAHA robot and/or related product within the warranty period, then YAMAHA will repair or replace those parts free of charge (hereafter called "warranty repair"). : The warranty period ends when any of the following applies: (1) After 18 months (one and a half year) have elapsed from the date of shipment () After one year has elapsed from the date of installation () After,400 hours of operation Exceptions to the Warranty : This warranty will not apply in the following cases: (1) Fatigue arising due to the passage of time, natural wear and tear occurring during operation (natural fading of painted or plated surfaces, deterioration of parts subject to wear, etc.) () Minor natural phenomena that do not affect the capabilities of the robot and/or related product (noise from computers, motors, etc.). () Programs, point data and other internal data that were changed or created by the user. Failures resulting from the following causes are not covered by warranty repair. 1) Damage due to earthquakes, storms, floods, thunderbolt, fire or any other natural or manmade disasters. ) Troubles caused by procedures prohibited in this manual. ) Modifications to the robot and/or related product not approved by YAMAHA or YAMAHA sales representatives. 4) Use of any other than genuine parts and specified grease and lubricants. 5) Incorrect or inadequate maintenance and inspection. 6) Repairs by other than authorized dealers. YAMAHA MOTOR CO., LTD. MAKES NO OTHER EXPRESS OR IMPLIED WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. THE WARRANTY SET FORTH ABOVE IS EXCLUSIVE AND IS IN LIEU OF ALL EXPRESSED OR IMPLIED WARRANTIES, INCLUDING WAR RANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR WAR RANTIES ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE. YAMAHA MOTOR CO., LTD. SOLE LIABILITY SHALL BE FOR THE DELIVERY OF THE EQUIPMENT AND YAMAHA MOTOR CO., LTD. SHALL NOT BE LIABLE FOR ANY CON SEQUENTIAL DAMAGES (WHETHER ARISING FROM CONTRACT, WARRANTY, NEG LIGENCE OR STRICT LIABILITY). YAMAHA MOTOR CO., LTD. MAKES NO WARRANTY WHATSOEVER WITH REGARD TO ACCESSORIES OR PARTS NOT SUPPLIED BY YAMAHA MOTOR CO., LTD. 11

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25 Chapter Installation and Connections 1 Checking the product... Moving the robot... 4 Robot Installation Conditions Installation environments... 5 Installation base Installing the robot T T T9/T9H F F14/F14H F17/F R5/R10/R B10/B14/B14H F0N Protective bonding Connections Connecting the robot cables Changing the cable routing direction (F Type)... 6 Changing the cable routing direction (B Type) Changing the motor orientation (B type) User wiring Setting the operating conditions Payload Maximum speed setting Duty... 40

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27 Chapter Installation and Connections 1 Checking the product After unpacking, make sure that all components and accessories are included (as specified in your order). Also check the product for any damage on the exterior which might have occurred during transportation. If there are any missing parts or damage due to transportation, please notify your YAMAHA sales office or dealer immediately. Example Controller: SR1 Robot: B10, B14 or B14H Product name Qty Singleaxis robot 1 SR1 1 Robot cable 1 I/O connector 1 Battery 1 Battery attachment 1set Warning label 1 (Danger label) 1 Affix to a conspicuous spot in the system. Warning label (Warning label) 1 Affix to a conspicuous spot in the system. Belt tension adjusting bolt 1 See page 5. Cover seal (long stroke model only) See page 40. HPB 1 Option POPCOM 1 Option SD memory card 1 Option

28 Chapter Installation and Connections Moving the robot Using a hoist, carrying cart (dolly) or forklift is recommended for moving a singleaxis robot or controller. Use sufficient caution when moving robot models with a long stroke or designed for large payload, since they are heavy. Moving the robot RCX14 Serious injury may occur if the robot falls and pins someone under it. Use a hoist and rope with carrying capacity strong enough to support the robot weight. Make sure the rope stays securely on the hoist hook. Remove all loads attached to the robot manipulator end. If any load is still attached, the robot balance might shift while being carried, and the robot topple over causing accidents. Always wear a safety helmet, shoes and gloves during work. When moving the robot by equipment such as a forklift that requires a license, only properly qualified personnel may operate such equipment. The equipment and tools used for moving the robot should be serviced daily. CAUTION When moving or carrying the robot by hand, avoid placing the hand and fingers on the shutter of the robot. Pressing down on the shutter, even by a little force, may cause the shutter to warp or deform, resulting in a premature life end of the related parts. 4

29 Chapter Installation and Connections Robot Installation Conditions 1 Installation environments Be sure to install the robot in the following environments. Items Allowable ambient temperature Allowable ambient humidity Altitude Ambient environments Vibration Working space Specifications 0 to 45 C 5 to 85% RH (non condensation) 0 to 0 meters above sea level Avoid installing near water, cutting water, oil, dust, metallic chips and organic solvent. Avoid installation near corrosive gas and corrosive materials. Avoid installation in atmosphere containing inflammable gas, dust and liquid. Avoid installation near objects causing electromagnetic interference, electrostatic discharge and radio frequency interference. Do not subject to impacts or vibrations. Allow sufficient space margin to perform jobs (teaching, inspection, repair, etc.) For detailed information on how to install the robot controller, refer to the separate YAMAHA Robot Controller User s Manual. Avoid installing the robot in locations where the ambient conditions may exceed the allowable temperature or humidity, or in environments where excessive moisture, corrosive gases, metallic powder or dust are generated. Malfunctions, failures or short circuits may otherwise result. This robot was not designed for operation in environments where inflammable or explosive substances are present. Do not use the robot in environments containing inflammable gas, dust or liquids. Explosions or fire could otherwise result. Avoid using the robot in locations subject to electromagnetic interference, electrostatic discharge or radio frequency interference. Malfunctions may otherwise occur. Do not use the robot in locations subject to excessive vibration. Robot installation bolts may otherwise become loose causing the manipulator to fall over. 5

30 Chapter Installation and Connections Installation base To mount the robot, use an installation base that satisfies the following conditions. 1) The installation base is subjected to a great deal of stress while the robot is in operation. Prepare a sufficiently rigid and stable installation base, taking into account the robot weight including the end effector (gripper) and workpiece. CAUTION If the installation base is not sufficiently rigid and stable, vibration (resonance) may occur during operation, causing adverse effects on the robot work. ) The installation base surface must be machined within a flatness of ±0.05mm/500mm. CAUTION The robot positioning accuracy might decrease if the installation surface precision is insufficient. Good example Installation base Bad example Installation base ) Use an installation base of sufficient size to match the robot body so that the robot can be installed with the specified number of bolts. Avoid installing the robot with less than the specified number of bolts or installing the robot closer to one end as shown at the lower right. CAUTION Using less than the specified number of bolts to install the robot may cause vibration and poor positioning accuracy. NOTE Refer to the external view and dimensions for each robot model shown in 4.1 Robot specifications for machining dimensions and positions of screw holes. Ensure that the controller is off before connecting the robot cable to the controller. 6

31 Chapter Installation and Connections 4 Installing the robot 41 T6 To install the T6 robot, tap holes into the installation base and secure the robot to the base with M4 bolts from inside of the robot frame. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method 1) Tap M4 holes into the installation base where the robot is to be secured. For hole pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) ) Remove the screws securing the side covers of the robot and remove the side covers (on both sides). If necessary, move the slider to a location where it does not block the installation holes on the bottom of the robot frame. Slider Shutter Side cover 7

32 Chapter Installation and Connections ) Secure the robot to the base with the specified bolts and torque. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M4 bolt, strength: 8.8T, length: longer than 0mm 0kgcm to 45kgcm M4 hex wrench Shutter CAUTION Be careful not to damage the shutter when tightening the bolts. Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. 4) Reattach the side covers after installing the robot. 8

33 Chapter Installation and Connections 4 T7 To install the T7 robot, tap holes into the installation base and secure the robot to the base with M4 bolts from inside of the robot frame. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method 1) Tap M4 holes into the installation base where the robot is to be secured. For hole pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) ) Remove the screws securing the side cover of the robot and remove the side cover (on one side). If necessary, move the slider to a location where it does not block the installation holes on the bottom of the robot frame. Side cover Slider ) Secure the robot to the base with the specified bolts and torque. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M4 bolt, strength: 8.8T, length: longer than 0mm 0kgcm to 45kgcm M4 hex wrench 9

34 Chapter Installation and Connections Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. 4) Reattach the side cover after installing the robot. Protective bonding Always ground the robot and controller unit to prevent electrical shock. Always use the ground terminal (M4 screw) on the robot unit to make ground connection. The ground terminal location is shown below. Ground terminal Robot cable CAUTION A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. Always turn off the power to the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019) 10

35 Chapter Installation and Connections 4 T9/T9H To install the T9/T9H robot, use either of the following two methods. Method A : Drill holes through the installation base and secure the robot to the base with M8 bolts from the bottom. (M8 tapped holes are already machined on the bottom of the robot frame.) Method B : Tap holes into the installation base and secure the robot to the base with M8 bolts from inside of the robot frame. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method A Drill holes through the installation base where the robot is to be secured. Then secure the robot with the specified bolts from the bottom. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M8 bolt, strength: 8.8T, length: installation base thickness + 1mm (maximum) 0kg cm to 70kg cm Installation base M8 bolt Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. Do not use a bolt longer than the specified length. A bolt that is too long will penetrate inside the robot frame and cause operating defects or malfunctions. 11

36 Chapter Installation and Connections Installation method B 1) Tap M6 holes into the installation base where the robot is to be secured. For hole pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) ) Remove the screws securing the side cover of the robot and remove the side cover (on one side). If necessary, move the slider to a location where it does not block the installation holes on the bottom of the robot frame, or else remove the upper cover. Side cover Slider ) Secure the robot to the base with the specified bolts and torque. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M6 bolt, strength: 8.8T, length: longer than 5mm kg cm to 10kg cm M6 hex wrench Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. 4) Reattach the side cover (and upper cover if removed) after installing the robot. 1

37 Chapter Installation and Connections Protective bonding Always ground the robot and controller unit to prevent electrical shock. Always use the ground terminal (M4 screw) on the robot unit to make ground connection. The ground terminal location is shown below. Ground terminal Robot cable CAUTION A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. Always turn off the power to the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019) 1

38 Chapter Installation and Connections 44 F10 To install the F10 robot, use either of the following two methods. Method A : Drill holes through the installation base and secure the robot to the base with M5 bolts from the bottom. (M5 tapped holes are already machined on the bottom of the robot frame.) Method B : Tap holes into the installation base and secure the robot to the base with M5 bolts from inside of the robot frame. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method A Drill holes through the installation base where the robot is to be secured. Then secure the robot with the specified bolts from the bottom. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M5 bolt, strength: 8.8T, length: installation base thickness + 9mm (maximum) 60kg cm to 90kg cm M5 bolt Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. Do not use a bolt longer than the specified length. A bolt that is too long will penetrate inside the robot frame and cause operating defects or malfunctions. CAUTION The robot frame is made of aluminum so be careful not to damage the screw threads when tightening the bolt. 14

39 Chapter Installation and Connections Installation method B 1) Tap M5 holes into the installation base where the robot is to be secured. For hole pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) ) Remove the screws securing the upper cover of the robot and remove the upper cover. If necessary, move the slider to a location where it does not block the installation holes on the bottom of the robot frame. Upper cover Slider ) Secure the robot to the base with the specified bolts and torque. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M5 bolt, strength: 8.8T, length: longer than 0mm 60kg cm to 90kg cm M5 hex wrench Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. 4) Reattach the upper cover after installing the robot. 15

40 Chapter Installation and Connections Protective bonding Always ground the robot and controller unit to prevent electrical shock. Always use the ground terminal (M4 screw) inside the robot unit to make ground connection. The ground terminal location is shown below. (When you remove the upper and lower covers for the motor and also the end plate, you will see the ground terminal as shown.) End plate Motor upper cover Ground terminal Motor lower cover CAUTION A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. Always turn off the power to the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019) 16

41 Chapter Installation and Connections 45 F14/F14H To install the F14/F14H robot, use either of the following two methods. Method A: Drill holes through the installation base and secure the robot to the base with M6 bolts from the bottom. (M6 tapped holes are already machined on the bottom of the robot frame.) Method B: Tap holes into the installation base and secure the robot to the base with M6 bolts from inside of the robot frame. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method A Drill holes through the installation base where the robot is to be secured. Then secure the robot with the specified bolts from the bottom. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M6 bolt, strength: 8.8T, length: installation base thickness + 10mm (maximum) is recommended* kg cm to 10kg cm * A bolt size of installation base thickness +0mm (maximum) can be used since the robot frame interior is hollow. Even in this case, the screw thread length that actually engages is 10mm. Installation base M6 bolt 17

42 Chapter Installation and Connections Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. Do not use a bolt longer than the specified length. A bolt that is too long will penetrate inside the robot frame and cause operating defects or malfunctions. CAUTION The robot frame is made of aluminum so be careful not to damage the screw threads when tightening the bolt. Installation method B 1) Tap M6 holes into the installation base where the robot is to be secured. For hole pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) ) Remove the screws securing the upper cover of the robot and remove the upper cover. If necessary, move the slider to a location where it does not block the installation holes on the bottom of the robot frame. Upper cover Slider 18

43 Chapter Installation and Connections ) Secure the robot to the base with the specified bolts and torque. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M6 bolt, strength: 8.8T, length: longer than 0mm kg cm to 10kg cm M6 hex wrench Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. 4) Reattach the upper cover after installing the robot. 19

44 Chapter Installation and Connections Protective bonding Always ground the robot and controller unit to prevent electrical shock. Always use the ground terminal (M4 screw) inside the robot unit to make ground connection. The ground terminal location is shown below. End plate Ground terminal Motor cable CAUTION A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. Always turn off the power to the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019) 0

45 Chapter Installation and Connections 46 F17/F0 To install the F17/F0 robot, tap holes into the installation base and secure the robot to the base with M8 bolts from inside of the robot frame. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method 1) Tap M8 holes into the installation base where the robot is to be secured. For hole pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) ) Remove the screws securing the upper cover of the robot and remove the upper cover. If necessary, move the slider to a location where it does not block the installation holes on the bottom of the robot frame. Upper cover ) Secure the robot to the base with the specified bolts and torque. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M8 bolt, strength: 8.8T, length: longer than 45mm (F17), longer than 50mm (F0) 0kgcm to 70kgcm M8 hex wrench 1

46 Chapter Installation and Connections Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. 4) Reattach the upper cover after installing the robot. Protective bonding Always ground the robot and controller unit to prevent electrical shock. Always use the ground terminal (M4 screw) inside the robot unit to make ground connection. The ground terminal location is shown below. End plate Ground terminal Motor cable CAUTION A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. Always turn off the power to the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019)

47 Chapter Installation and Connections 47 R5/R10/R0 To install the R5/R10/R0 robot, tap holes into the installation base and secure the robot to the base as shown below. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method Tap holes into the installation base where the robot is to be secured. For hole diameter and pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) M6 bolt Installation base M6 bolt Installation base

48 Chapter Installation and Connections M5 or M6 bolt Installation base Bolt Tightening torque Hex sockethead M5 or M6 bolt, strength: 8.8T, length: installation base thickness + 1mm (maximum) M5: 60kgcm to 90kgcm M6: kgcm to 10kgcm Protective bonding Always ground the robot and controller unit to prevent electrical shock. Always use the ground terminal (M4 screw) inside the robot unit to make ground connection. The ground terminal location is shown below. Ground terminal (M4 screw) A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. 4

49 Chapter Installation and Connections Always turn off the power to the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019) Origin position The FlipX series uses the absolute method so performing returntoorigin is not necessary after the power is turned on. However, data containing the origin position may be lost if the absolute battery is removed from the controller or the battery dies. When this happens, origin return (or origin reset) must be performed after the battery is reconnected. The R5, R10 and R0 robots utilize the mark method (refer to controller manual) that does not use sensors. Use a triangular seal enclosed in the package to affix it at the desired position, and perform origin return (or origin reset). When the next time origin return is required, this seal can be used as the matching mark to ensure reproducibility. We recommend affixing the seal as far away from the R5, R10 and R0 shaft center as possible to achieve high reproducibility. 5

50 Chapter Installation and Connections 48 B10/B14/B14H Always turn off the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Drill holes through the installation base where the robot is to be secured. Then secure the robot with the specified bolts from the bottom. The bolts and tightening torque are shown below. Robot model Bolt Tightening torque B10 Hex sockethead M5 bolt Strength: 8.8T 60kg. cm to 90kg. cm Length: installation base thickness + 10mm (maximum) B14, B14H Hex sockethead M6 bolt Strength: 8.8T kg. cm to 10kg. cm Length: installation base thickness + 10mm (maximum) Installation base M5 bolt (B10), M6 bolt (B14, B14H) Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. Do not use a bolt longer than the specified length. A bolt that is too long will penetrate inside the robot frame and cause operating defects or malfunctions. CAUTION The robot frame is made of aluminum so be careful not to damage the screw threads when tightening the bolt. 6

51 Chapter Installation and Connections 49 F0N To install the F17/F0 robot, tap holes into the installation base and secure the robot to the base with M8 bolts from inside of the robot frame. Always turn off the power to the controller before installing the robot. Serious accidents might occur if the robot starts to operate during installation. Installation method 1) Tap M8 holes into the installation base where the robot is to be secured. For hole pitch, see the external view and dimensions in 5.1 Robot Specifications of Chapter 5.) ) Remove the screws securing the upper cover of the robot and remove the upper cover. If necessary, move the slider to a location where it does not block the installation holes on the bottom of the robot frame. ) Secure the robot to the base with the specified bolts and torque. The bolts and tightening torque are shown below. Bolt Tightening torque Hex sockethead M8 bolt, strength: 8.8T, length: longer than 45mm (F17), longer than 50mm (F0) 0kgcm to 70kgcm 7

52 Chapter Installation and Connections Be sure to tighten the bolt to the correct torque. The wrong torque may not only cause robot position errors but also lead to serious accidents. 4) Reattach the upper cover after installing the robot. Refer to Chapter Installing and removing the cover (F0N), and install the cover. Protective bonding Always ground the robot and controller unit to prevent electrical shock. A grounding terminal (M4 screw) is provided inside the cable box, so always ground the unit. The position of the grounding terminal is shown below. Cable box Cable carrier Robot cable Ground terminal CAUTION A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. Always turn off the power to the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019) 8

53 Chapter Installation and Connections 5 Protective bonding Always ground the robot and controller unit to prevent electrical shock. Always use the ground terminal (M4 screw) of the robot unit to make ground connection. The ground terminal location is shown below. Robot cable Ground terminal CAUTION A secure ground connection (less than ohm resistance to ground) is recommended. Use electrical wire thicker than AWG14 (mm ) as the ground wire. Always turn off the controller before making the ground connection. Provide a terminal marked PE as the protective conductor for the entire system, and connect it to an external protective conductor. Also securely connect the ground terminal on the robot frame to the protective conductor. (Symbol 417IEC5019) 9

54 Chapter Installation and Connections 6 Connections 61 Connecting the robot cables Connect the robot cables to the mating connectors on the controller as shown. Refer to the SR1 robot controller user s manual for the controller connectors. Before connecting the cables, check that there are no bends or breaks in the robot cable connector pins and that the cables are not damaged. Bent or broken pins or cable damage may cause robot malfunctions. CAUTION After connecting the relay connectors on the robot cables, fit the connector hoods together securely. 0

55 Chapter Installation and Connections Robot cable connections Refer to 5 AC servo motor cable termination and 5 Robot cable when wiring the cables. SR1 HPB PWR ERR MOTOR U HPB V W I/O BAT AC IN L ROB I/O N L1 N1 Robot cable (power cable) RGEN SAFETY P N SHORT: ACV OPEN: ACV Singleaxis robot FLIPX series MO connector... Motor wire Robot cable (signal cable) ORG connector... Origin sensor wire (only robots with origin sensor) BK connector... Brake wire (only robots with brake) P connector... Resolver signal wire Hood *After making connections, fasten the hoods securely. System Configurations Servo control Resolver signal Motor power Robot controller SR1 U V W MOTOR AC IN PWR HPB I/O L N L1 N1 RGEN P BAT ROB I/O SAFETY Input 16 generalpurpose pins 7 custompurpose pins Output 16 generalpurpose pins custompurpose pins N SHORT: ACV OPEN: ACV Power supply AC~115/~0V ±10% ERR RSC communication control RSC or communication control (communication cable) I/O control (4V power supply builtin) SD memory card (option) Programming box HPB (option) PC External control (PLC) SD MEMORY CARD POPCOM communication software (option) Singleaxis robot FLIPX series The controller is supplied with the robot as a standard unit. The programming box HPB is optional. 1

56 Chapter Installation and Connections 6 Changing the cable routing direction (F Type) The cable in F type robots (F10, F14, F17, F0 series) can be run out (extracted) in any direction. Limits on wiring directions have been eliminated and vertical or horizontal installations are made possible for efficient use of space. Methods for changing the cable routing (extraction) direction are shown below. (The standard cable extraction slot is on the rear side when shipped from the factory.) Standard cable extraction direction 1) Remove the upper cover and motor endplate. (On the F10, remove both upper and lower motor covers and endplate.) ) Remove the robot cable from the endplate. ) Change the cable extraction (routing) direction. Top extraction : Clip the endplate cable installation slot with wire nippers or similar tool, fit a robot cable grommet into that slot and route the cable out through that slot. Side extraction : Fit a robot cable grommet into the side routing bracket and route the cable out through that slot. (Side extraction is not possible on the F10.) Cable routing bracket Top extraction Side extraction NOTE When routing the cable from the opposite side, you must change the clamping position of the cable routing bracket. (Change the ground wire installation position to the opposite side at this time.) 4) Reattach the endplate and upper cover (or motor upper and lower covers) back to their original positions.

57 Chapter Installation and Connections 6 Changing the cable routing direction (B Type) The cables in B type robots (B10, B14, B14H series) can be run out (extracted) in any direction. Limits on wiring directions have been eliminated so available space can be efficiently used. Methods for changing the cable routing (extraction) direction are shown below. When rotating 180 degrees 1) Remove the four screws securing the motor cover. ) Remove the motor cover and rotate it 180 degrees. Motor cover Rotate 180 degrees. ) Reattach the motor cover and tighten the four screws to secure the motor cover and cables.

58 Chapter Installation and Connections When rotating 90 degrees 1) Remove the four screws securing the motor cover and remove the motor cover. ) Remove the cables from the motor cover and trim the unused cable extraction slots with wire nippers or similar tool. ) Fit the robot cable grommets into the new cable extraction slots and route the cables out through those slots. Motor cover Grommet 4) Reattach the motor cover and tighten the four screws to secure the motor cover and cables. 4

59 Chapter Installation and Connections 64 Changing the motor orientation (B type) Always turn off the controller before beginning work. Serious accidents might occur if the robot starts to operate during work. Motor orientation in B type robots (B10, B14, B14H series) can be changed to use space more efficiently. If the motor case is hanging up on an object and hampers installation of the robot, use the following method to change the motor orientation. 1) Remove the screws securing the belt cover and remove the belt cover. ) Remove the motor plate bolts (4 pieces). Motor plate Motor plate bolt 5

60 Chapter Installation and Connections ) Detach the belt from the pulleys, change the motor orientation as desired and lightly tighten the motor plate bolts (4 pieces). Now shift the motor case towards the large pulley as shown by the arrow. Motor plate Motor plate bolt 4) First fit the belt onto the (small) motor pulley and then onto the large pulley. 6

61 Chapter Installation and Connections 5) Pull the motor in the direction that increases tension on the belt, and lightly tighten the motor plate bolts. Motor case Motor plate bolt 6) Adjust the belt tension. See Adjusting the speed reduction belt tension in Chapter. 7) Reattach the belt cover. CAUTION Check that the belt teeth correctly mesh with the large pulley teeth. A poor intermesh may cause positioning errors or shorten the belt service life. CAUTION Since a positional shift occurs after adjusting the belt tension, absolute reset, and the point data. 7

62 Chapter Installation and Connections 65 User wiring Cable carrier Observe the following precautions when using a cable carrier with the FLIPX series. CAUTION Use a cable carrier that maintains an R50 or larger cable bend diameter. When fitting the robot cables into the cable carrier, keep the space used within 0 percent of the total space including other cables and air hoses. Lay the cables and air hoses in rows inside the cable carrier so they do not cross each other. The cables and tubes inside the cable carrier will move during robot operation applying tension to both ends. Gently secure the cables to allow for some slack so a large amount of force is not applied to cable connector during robot movement. Breaks or electrical discontinuity may occur if the cables are fastened too tightly with snap bands or fastening ties so allow for some slack and gently secure the cables. NOTE Separating the robot cables from the user cables in the cable carrier with plate partitions (see drawing below) improves reliability and makes maintenance easier. Partitions Cross section view inside cable carrier Cable carrier Typical singleaxis robot using cable carrier 8

63 Chapter Installation and Connections 7 Setting the operating conditions 71 Payload Optimal acceleration for the YAMAHA Singleaxis robot FLIPX series is automatically determined by setting the controller payload parameters. Set the total weight of the workpiece and the end effectors such as grippers attached to the robot slider in the payload parameter as shown below. CAUTION Be sure to enter an accurate value when making this setting, since a mistake will cause troubles such as vibration or a shorter machine service life span. To set the payload parameter Use the following method when setting the payload parameter on a singleaxis robot controller (SR1). When setting this parameter on other controllers (RCX14, RCX) refer to their controller user's manuals. 1) Press F (SYS) on the initial menu screen. The SYS (system) mode screen appears. ) Press F 1 (PRM) to enter the parameter setting mode. The SYSPRM mode screen appears. ) Select the parameter group. Press F 1 (AXIS) to select the axis parameter. The current setting for PRM (Robot type) appears on the screen. 9

64 Chapter Installation and Connections 4) Display PRM11 (payload). Press the keys to scroll up or down the parameter list and select the parameter you want to set. 5) Set the parameter. Enter the parameter value with the number keys and press. The parameter setting range is shown on the bottom line of the screen. When setting is complete, the cursor moves back to the beginning of the parameter data. 7 Maximum speed setting In operation of a singleaxis robot with a long stroke ball screw, resonance of the ball screw may occur. In this case, the maximum speed must be reduced to an appropriate level. The maximum speed can be reduced by lowering the SPEED setting in automatic operation or by programming. Use the desired method that matches your application. For maximum speed setting versus the robot stroke length, see Chapter 4, "Specifications" If the maximum speed does not reach a hazardous level, reducing the speed is unnecessary even when a robot has a long stroke axis. CAUTION Do not operate the robot if the ball screw is vibrating. The ball screw may otherwise wear out prematurely. 7 Duty To achieve maximum service life for the YAMAHA singleaxis robots, the robot must be operated within the allowable duty (50%). The duty is calculated as follows: Operation time Duty (%) = Operation time + Nonoperation time If the robot duty is too high, an error such as "overload" or "overheat" occurs. In this case, increase the stop time to reduce the duty. 40

65 Chapter Adjusting the robot 1 Attaching the upper cover (B10/B14/B14H)... Adjusting the timing belt tension (B10/B14/B14H) Adjusting the drive belt tension... 5 Reference: Adjusting drive belt tension with a tension meter... 6 Adjusting the speed reduction belt tension... 7 Reference: Adjusting speed reduction belt tension with a tension meter... 8 Installing and removing the cover (F0N) Stroke cover... 9 Belt cover Motor cover Adjusting the timing belt tension (F0N)... 1

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67 Chapter Adjusting the robot 1 Attaching the upper cover (B10/B14/B14H) On robot models having a long stroke, a slider travel guide (U groove) is provided inside the upper cover. The slider must be aligned with this U groove when attaching the upper cover. CAUTION If the slider and upper cover alignment is poor, the slider may wear out prematurely. Insert the slider into the U groove correctly so that the slider is not worn away or damaged by the edge of the upper cover. 1) Turn off the controller. ) Insert the slider into the U groove provided along the center of the upper cover, while holding the upper cover in parallel with the robot movement axis. Slider travel guide (U groove) Slider ) Lightly tighten the four screws to temporarily secure the upper cover, move the slider table from the motor side all the way to the nonmotor side, and fully tighten the screws on the nonmotor side. Then move the slider table back to the motor side and fully tighten the two screws on the motor side to secure the upper cover. 4) Move the slider table by hand to check that it travels along the upper cover smoothly.

68 Chapter Adjusting the robot Adjusting the timing belt tension (B10/B14/B14H) The B10, B14 and B14H series robots use a timing belt to move the slider table. If the belt becomes slack, use the following procedure to apply belt tension. The motor and speed reduction gear casing are extremely hot after automatic operation, so burns may occur if these are touched. Before touching these parts, turn off the controller, wait for a while and check that the parts have cooled. Injury can occur if hands or fingers are squeezed between the drive pulley and belt. Always turn off the controller and use caution when handling these parts. CAUTION Since a positional shift occurs after adjusting the belt tension, absolute reset, and the point data. L/ L/ Slider table Pushpull scale Pushpull scale Slack Load Slack Load Pulley Belt Pulley Belt Pulley Fig. 1 Adjustment of speed reduction belt tension Fig. Adjustment of drive belt tension Belt 5 Pushpull scale 5 Stay Nut Hole 55 Nut Fig. Stay (example) Metal plate of.mm thick 4

69 Chapter Adjusting the robot 1 Adjusting the drive belt tension 1) Turn off the controller. ) Take off the end cover. ) Remove the screws securing the upper cover and remove the upper cover. CAUTION On robot models having a long stroke, the slider is fitted in the travel guide (U groove) inside the upper cover, so remove the upper cover by sliding it along the direction the robot moves. 4) Attach the belt tension adjusting bolt (supplied) as shown and loosen the eight bolts (4 bolts on each side) securing the belt stays. Then turn the belt tension adjusting bolt to apply tension. Tension adjusting bolt Belt stay bolt Belt stay 5) Move the slider by hand to a position at which the distance from the slider edge to the base block edge is 150mm. Apply a load to the belt at a position 115mm (B10) or 19mm (B14, B14H) away from the slider edge. 150mm L 5

70 Chapter Adjusting the robot 6) Lightly tighten the belt stay bolts and check the belt tension. The correct load and resulting slack to be applied to each robot are shown in Tables 1. When the load producing the specified slack is within this range, no adjustment is required. If not within this range, adjust the tension by repeating steps 4) and 5). Table 1 Load and slack for drive belt tension Robot model Load (N) Load (kgf) Slack (mm) B to to 0.6 B14, B14H 5.9 to to 0.7 7) Tighten the belt stay bolts and remove the belt tension adjusting bolt. 8) Reattach the upper cover and then the end cover. See 1 Attaching the upper cover in Chapter. Reference: Adjusting drive belt tension with a tension meter We recommend using a tension meter to adjust the belt tension more accurately. Recommended tension meter: U505 (Made by UNITTA) Measurement method To make the drive belt tension adjustment of step 5), pull the belt to a position where a load is to be applied and adjust the belt tension by measuring the frequency with the tension meter while referring to the table below. For details on how to use the tension meter, refer to the tension meter instruction manual. Robot model Tension (N) Frequency (Hz) Span length (mm) Belt width (mm) Unit mass (g/width [mm] _ length [m]) B10 17 to to B14, B14H 169 to to

71 Chapter Adjusting the robot Adjusting the speed reduction belt tension 1) Turn off the controller. ) Remove the belt cover. ) Apply a load shown in Table at the center between the two pulleys and measure the slack (or tension). When the slack is within the allowable range, no adjustment is required. If not within allowable range, adjust the tension (or slack) with the procedure below. Table Load and slack for speed reduction belt tension Robot model Load (N) Load (kgf) Slack (mm) B to to 0.7 B14,B14H 5.9 to to 0.7 4) If the belt tension must be adjusted, loosen the motor plate bolts. 7

72 Chapter Adjusting the robot 5) If the slack (or tension) measured in step is smaller than the range specified in Table, move the motor case in the direction that increases belt tension. If the slack or tension is greater than the range in Table, move in the direction that reduces belt tension. Then, temporarily retighten the motor plate bolts. Tension increases Tension reduces Motor plate bolts 6) Measure the belt tension again as in step ). When the load producing the specified slack (or tension) is within the allowable range in Table, no adjustment is required. If not within that range, adjust the tension (or slack) by repeating steps ) to 5). 7) Tighten the motor plate bolts securely. 8) Reattach the belt cover. Reference: Adjusting speed reduction belt tension with a tension meter We recommend using a tension meter to adjust the belt tension more accurately. Recommended tension meter: U505 (Made by UNITTA) Measurement method To make the drive belt tension adjustment of step ), pull the belt to a position where a load is to be applied and adjust the belt tension by measuring the frequency with the tension meter while referring to the table below. For details on how to use the tension meter, refer to the tension meter instruction manual. Robot model Tension (N) Frequency (Hz) Span length (mm) Belt width (mm) Unit mass (g/width [mm] _ length [m]) B10 44 to to B14, B14H 44 to to

73 Chapter Adjusting the robot Installing and removing the cover (F0N) 1 Stroke cover Removing the stroke cover 1) Remove the fixing screws (M4, panhead) on both ends. ) Place the table slide near the stroke end, and pull off the cover. Side cover Center cover Motor block Table slide End block Installing the stroke cover 1) Place the table slide near the stroke end, and pass the cover between the table slide and motor block. ) Fix the cover to the end block. At this time, move the table slide to the stroke center, and confirm that it does not interfere with the cover. If the table slide interferes with the cover, adjust by tightening the fixing screw. (Refer to following photographs.) When cover contacts table slide Tighten the cover fixing screw When cover contacts motor block Loosen the cover fixing screw 9

74 Chapter Adjusting the robot Belt cover Removing the belt cover 1) Loosen the hexagon bolts (M4, two bolts) on the front with a spanner or socket wrench. After removing the M4 screws on the top, pull the cover upward and off. (Refer to the following photograph.) M4 screw (two screws) M4 hexagon bolt (two bolts) Installing the belt cover 1) Fit the cover so that the notch on the cover passes between the hexagon bolts. Tighten the hexagon bolts with a spanner or socket wrench, and then fix from above with the M4 screws. 10

75 Chapter Adjusting the robot Motor cover Removing the motor cover 1) Cut the Insulocktie binding the motor cable with a pair of nippers, and remove. ) Remove the two M6 hexagon bolts, and pull the motor cover upward and off. (Refer to the following photograph.) Installing the motor cover 1) Insert the motor cover into the installation hole, and fix with two M6 hexagon bolts. ) Using the o5 hole open on the motor cover, fix the motor cable with an Insulocktie. 11

76 Chapter Adjusting the robot 4 Adjusting the timing belt tension (F0N) 1) Temporarily tighten the motor installation bolt. ) Remove the belt cover, and install the adjustment bolt (M5). Apply belt tension. (Refer to the following photograph.) ) Tighten the motor fixing bolt. 4) Place the measuring head of the tension meter near the belt, and flip the belt at the middle of the belt span with a hex wrench or similar tool. 5) Adjust the belt tension by measuring the frequency with the tension meter while referring to the table below. Recommended tension meter: U505 (made by UNITTA) Frequency (Hz) Tension (N) Tension (kg) Span length (mm) Belt unit weight (kg/m) 07 to to 98 9 to ) When the appropriate tension has been set, tighten the motor installation bolt, and measure the tension again. (Note that the tension will increase as the bolt is tightened.) 7) Remove the adjustment bolt, and install the belt cover. 1

77 Chapter 4 Periodic Inspection 41 Before beginning work Periodic inspection Daily inspection Threemonth inspection Sixmonth inspection Threeyear inspection Applying grease Applying grease (T6/T7 type) Applying grease (T9/F types) Applying grease (B type) Adjusting and replacing a loose shutter Replacing the shutter (T6) Adjusting shutter looseness (T6) Replacing the motor Replacing the motor (B10/B14/B14H) Replacing the motor (F0N) Replacing the drive belt (B10/B14/B14H) Replacing the speed reduction belt (B10/B14/B14H) Replacing the slider Replacing the slider (B10/B14/B14H) Replacing the slider (F0N)... 41

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79 Chapter 4 Periodic Inspection 41 Before beginning work Periodic inspection and maintenance are essential to ensure safe and efficient operation of YAMAHA robots. This chapter describes periodic inspection items and procedures for the FLIP X series. Before beginning work, read the precautions below and also in Chapter 1 About Safety and follow the instructions. DANGER If the inspection or maintenance procedure calls for operation of the robot, stay out of the working area of the robot during operation. Do not touch any parts inside the controller. Keep watching the robot movement and surrounding area so that the operator can press the emergency stop button if any danger occurs. When the robot does not need to be operated during adjustment or maintenance, always turn off the controller and the external switch board. Do not touch internal parts of the controller for 5 seconds after the controller has been turned off. Use only lubricant and greases specified by YAMAHA sales office or dealer. Use only parts specified by YAMAHA sales office or dealer. Take sufficient care not to allow any foreign matter to contaminate them during adjustment, parts replacement or reassembly. Do not modify any parts on the robot or controller. Modification may result in unsatisfactory specifications or threaten operator safety. When adjustment or maintenance is complete, retighten the bolts and screws securely. During robot adjustment or maintenance, place a sign indicating that the robot is being adjusted or serviced, to prevent others from touching the control keys or switches. Provide a lock on the switch keys or ask someone to keep watch as needed. 4

80 Chapter 4 Periodic Inspection When applying grease to the ball screws and linear guide, take the following precautions. Precautions when handling grease: Inflammation may occur if this gets in the eyes. Before handling the grease, wear your safety goggles to ensure the grease will not come in contact with the eyes. Inflammation may occur if the grease comes into contact with skin. Be sure to wear protective gloves to prevent contact with skin. Do not take orally or eat. (Eating will cause diarrhea and vomiting.) Hands and fingers might be cut when opening the container, so use protective gloves. Keep out of the reach of children. Do not heat the grease or place near an open flame since this could lead to sparks and fires. Emergency Treatment: If grease gets in the eyes, wash liberally with pure water for about 15 minutes and consult a physician for treatment. If grease comes in contact with the skin, wash away completely with soap and water. If taken internally, do not induce vomiting but promptly consult a physician for proper treatment. 44

81 Chapter 4 Periodic Inspection 4 Periodic inspection 41 Daily inspection Check the following points on a daily basis, before and after robot operation. Checkpoints Cables and shutter Ball screws and bearings Motor Check items Check for scratches, dents, and excessively tight bends. Check for unusual vibration and noise. Check for unusual vibration and noise, and for abnormal temperature rise. Notes Replace if necessary. See "44" in this chapter. 4 Threemonth inspection Check the following points every months and apply grease if needed. Checkpoints Check items Notes Ball screw, linear guide and ball bushing Shutter Check for dirt or grime. If dirt or grime is found, clean the part. Apply grease after cleaning. Apply grease if the items checked are dry or do not have enough grease. Recommended grease is as follows: Standard model: Use Alvania No. (Showa Shell), Daphne Eponex No. (Idemitsu) Clean room model: Use LG (NSK) Check for slack. Adjust if necessary. See "4" in this chapter. See "4" in this chapter. See "44" in this chapter. CAUTION Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw, linear guide and linear bushing shaft. 45

82 Chapter 4 Periodic Inspection 4 Sixmonth inspection Check the following points every six months, and make adjustments or apply grease if necessary. Checkpoints Check items Notes Main bolts and screws on robot Ball screw and linear guide Check for looseness. If loose, tighten. Check for looseness in the ball screw and linear guide. Tighten if necessary. Check for vibration during operation. Tighten drive section, and X and Y axis installation bolts if necessary. Check for wear and backlash. If any abnormality is found, contact YAMAHA sales office or dealer. If problem is not solved or wear and backlash are found, please contact us. Controller Lubrication of ball screw nut and linear guides Check for loose terminals. Check for loose connectors. Apply Alvania No. (Showa Shell), Daphne Eponex No. (Idemitsu Sekiyu) to the ball screw nut and linear guides. See "4" in this chapter Belt Check the timing belt for wear, cracks or cuts. Check the timing belt tension. (See Adjusting the timing belt tension in chapter.) Slider (Belt type or F0N) On robot models using a long stroke, check the slider inside the upper cover for abnormal wear or damage. (See 1 Attaching the upper cover in Chapter.) CAUTION Using a grease other than recommended by YAMAHA may shorten the service life of the ball screw, linear guide and linear bushing shaft. 44 Threeyear inspection Inspect the following points once every three years, and contact us if any problem is found. Set an earlier inspection interval if parts are subject to longterm or frequent usage. Checkpoints Check items Notes Ball screw nut sections and linear guides Check for wear and looseness in the ball screw, nut and linear guide. Contact us if trouble is found. 46

83 Chapter 4 Periodic Inspection 4 Applying grease 41 Applying grease (T6/T7 type) Follow these instructions when applying grease to the T6/T7 robot ball screws and linear guides during periodic maintenance. 1) Check that the controller power switch is turned off. ) Remove the screw securing the robot side covers and remove the side covers. ) Coat the ball screw and linear guides with grease by hand and move the slider back and forth to spread the grease. Ball screw Applying grease to the ball screw Linear guide Applying grease to the linear guide 4) Reattach the side covers. 47

84 Chapter 4 Periodic Inspection 4 Applying grease (T9/F types) Follow these instructions when applying grease to the ball screws and linear guides during periodic maintenance. On the T9 and F7 types, the grease can be applied to the nut of the ball screw by using the grease nipple. In this case, prepare a grease nipple (M6) before starting work. 1) Check that the controller power switch is turned off. ) Remove the screws securing the robot upper cover and remove the upper cover. ) Apply grease using either of the following methods. Method A: Coat the ball screw and linear guides with grease by hand and move the slider back and forth to spread the grease. Method B: Fit the grease nipple into the M6 tap hole on the flange of the ball screw nut. Supply grease to the grease nipple and move the slider back and forth to spread the grease. Flange of ball screw nut Slider M6 tap hole for grease nipple CAUTION Be sure to always remove the grease nipple after applying grease with method B. 4) Reattach the upper cover. 4 Applying grease (B type) Apply grease to the linear guide every months. Using the following grease gun and grease will ensure correct refills of grease. Grease gun model Nozzle type Grease : MG70 (made by THK) or equivalent : N type (made by THK) or equivalent : AFB grease (made by THK, 70 g cartridge) or equivalent 48

85 Chapter 4 Periodic Inspection 44 Adjusting and replacing a loose shutter 441 Replacing the shutter (T6) Use the following procedure when the T6 shutter must be replaced. 1) Check that the controller power switch is turned off. ) Remove the 4 screws securing the slider cover and take off the slider cover. M hex wrench ) Remove the screws securing the shutter. Remove the screws on the endplate side and the screws on the motor side. Endplate 4) Remove the shutter from the shutter guide and pass the new shutter through it. Shutter guide Shutter 49

86 Chapter 4 Periodic Inspection 5) Reinstall the shutter and the slider cover using the reverse of the above procedure. NOTE Do not fully tighten the screws to secure the shutter on the endplate side at this time. Fully tighten these screws after adjusting for shutter looseness in step 6. 6) Tighten the screws while pulling on the shutter with your fingers so that there is no looseness in the shutter. CAUTION Do not press down on the shutter with excessive force. Pressing down hard on the shutter may cause the shutter to warp. 44 Adjusting shutter looseness (T6) The shutter may elongate with continued use. In such cases, adjust as follows. 1) Slightly loosen the two screws securing the endplate side of the shutter. (Do not remove.) ) While pulling on the shutter with your fingers, tighten the screws so that there is no looseness. See step 6 of 441 Replacing the shutter (T6). 410

87 Chapter 4 Periodic Inspection 45 Replacing the motor 451 Replacing the motor (B10/B14/B14H) CAUTION Since a positional shift occurs after replacing the motor, returntoorigin must be performed again and the point data respecified. When removing the parts, check and mark the part positions versus each other so you can correctly reassemble the parts later. 1) Turn off the controller. ) Remove the belt cover. ) Remove the motor case and motor cover. Motor cover Motor case 4) Remove the four bolts installing the motor to the motor plate and remove the motor. 411

88 Chapter 4 Periodic Inspection 5) Loosen the two motor pulley set screws and remove the pulley from the motor shaft. 6) Fit the pulley onto the shaft of the new motor. The motor shaft has two flat faces. Insert the pulley so that the set screws make perpendicular contact with the flat faces of the motor shaft. (To make sure this is correct, tighten each set screw so their tips slightly protrude inwards about 0.1 to 0.mm and then insert the pulley onto the motor shaft.) 7) Install the motor to the motor plate. 8) Fit the belt onto the pulleys. 9) Adjust the belt tension. See Adjusting the timing belt tension in Chapter. 10)Reattach the motor case and cover. 11)Reattach the belt cover. 41

89 Chapter 4 Periodic Inspection 45 Replacing the motor (F0N) CAUTION Since a positional shift occurs after replacing the motor, returntoorigin must be performed again and the point data respecified. When removing the parts, check and mark the part positions versus each other so you can correctly reassemble the parts later. 1) Turn the controller power OFF. ) Remove the belt cover and motor cover. (Refer to Chapter Installing and removing the cover.) ) Open the cover of the box fixed onto the table slide, and disconnect the motor wiring connector. 4) Remove the motor installation bolts (M6: 4 bolts). Wiring box Motor cable Motor cover Motor installation bolt 5) Pull the belt off the pulley. (Refer to the following photograph.) Pulley Belt 6) Remove the motor. 41

90 Chapter 4 Periodic Inspection 7) Remove the fixing bolts (M6: four bolts) from the pulley connection boss, and pull the pulley off the motor. (Loosen the bolts while fixing the surface machined section of the boss with a pair of pliers, etc.) 4M6 Hexagon bolt Ring Boss 8 Pulley Motor 8) Replace the motor, and install the pulley onto the motor. (Refer to the drawing above.) Take care to the orientation and order of the rings at this time. 9) Install the motor onto the block. Temporarily tighten the fixing bolts. 10)Install the belt. Refer to Chapter 4 Adjusting the timing belt (F0N), and adjust the belt tension. 11)Install the motor cover and belt cover. 1)Connect the motor wiring connector, store inside the box, and install the cover. 414

91 Chapter 4 Periodic Inspection 46 Replacing the drive belt (B10/B14/B14H) CAUTION Since a positional shift occurs after replacing the belt, returntoorigin must be performed again and the point data respecified. When removing the parts, check and mark the part positions versus each other so you can correctly reassemble the parts later. 1) Remove the end cover on the nonmotor side and then remove the upper cover. (On robot models having a long stroke, remove the upper cover by sliding it along the axis of robot movement. This is required because the slider is fitted in the travel guide (U groove) inside the upper cover.) ) Remove the motor. (See the procedure in 45 Replacing the motor in Chapter 4.) It is unnecessary to remove the motor if installed horizontally or downwards. ) Remove the cover 1 shown in the photo. Cover 1 4) Remove the eight bolts (4 bolts on each side) securing the belt stays and remove the belt stays from the slider table. Slider table Belt stay bolt Belt stay 415

92 Chapter 4 Periodic Inspection 5) Remove the two center bolts on each of the belt stays and remove the belt from the stays. 6) Set the new belt along the robot axis as instructed below. 7) First route the belt edge onto the idle pulley and use a narrow rod or similar tool to push out the belt edge as shown. 8) Pass the belt through from the lower side of the slider table and route the belt edge under the drive pulley. Then, use a narrow rod or similar tool to make the belt edge face upwards. 416

93 Chapter 4 Periodic Inspection 9) Finally, while making the belt mesh between the drive pulley and drive pulley idler, turn the drive pulley so the belt comes out upwards. 10)Attach the belt stays to both ends of the belt. 11)Install the belt stays onto the slider table and lightly tighten the bolts to temporarily secure the stays. 1)Adjust the belt tension. (See the procedure explained in Adjusting the timing belt tension in Chapter.) 1)Reattach the upper cover. (See the procedure explained in 1 Attaching the upper cover in Chapter.) 14)Reattach the end cover. 417

94 Chapter 4 Periodic Inspection 47 Replacing the speed reduction belt (B10/B14/B14H) CAUTION Since a positional shift occurs after replacing the belt, returntoorigin must be performed again and the point data respecified. When removing the parts, check and mark the part positions versus each other so you can correctly reassemble the parts later. 1) Remove the belt cover. ) Remove the motor plate bolts (4 pieces). Motor plate bolt 418

95 Chapter 4 Periodic Inspection ) Bring the motor plate close to the large pulley and detach the belt from the pulleys. 4) First fit the new belt onto the motor pulley (small pulley) and then onto the large pulley. 5) Adjust the belt tension. (See the procedure explained in Adjusting the speed reduction belt tension in Chapter. 6) Reattach the belt cover. 419

96 Chapter 4 Periodic Inspection 48 Replacing the slider 481 Replacing the slider (B10/B14/B14H) 1) Turn off the controller. ) Remove the screws securing the upper cover and remove the upper cover by sliding it along the direction the robot moves. ) Remove the slider mounting bolts ( pieces). Slider mounting bolt 4) Replace the slider and lightly tighten the two bolts on the new slider. 5) Reattach the upper cover. (See the procedure explained in 1 Attaching the upper cover in Chapter. 6) Move the slider table back and forth along the axis a few times. 7) Remove the cover seal (1mm diameter) affixed to the upper cover on the nonmotor side. (A hole appears under the cover seal.) Move the slider to the point where you can see the slider mounting bolt through this hole. Cover seal Bolt tightening hole 8) Tighten the slider mounting bolts fully, then again shift the slider table 0mm to align the other bolt with the hole and fully tighten to secure the slider table. 9) Affix the new seal (supplied) to cover the hole. 40

97 Chapter 4 Periodic Inspection 48 Replacing the slider (F0N) 1) Turn the controller power OFF. ) Remove the top center cover. ) Remove the two slider installation bolts. Slider Installation bolt 4) Replace the slider and fix with the installation bolt. 5) Install the top center cover. Refer to Chapter Installing the cover. 41