Denso HS-G Series, Installation & Maintenance Manual

Page 1: ...ROBOT Horizontal articulated HS G SERIES INSTALLATION MAINTENANCE GUIDE...

Page 2: ...is publication may be reproduced in any form or by any means without permission in writing from the publisher Specifications are subject to change without prior notice All products and company names m...

Page 3: ...ount Overhead mount Overall arm length HS G Small sized horizontal articulated HS 4535 G HS 4545 G HS 4555 G HSS 4545 G HSS 4555 G 350 mm 450 mm 550 mm NOTE 1 Model names listed above apply to the mod...

Page 4: ...ical site planning installation procedures and engineering design notes for hands Chapter 2 Customizing Your Robot Describes how to customize your robot defining the software motion space and restrict...

Page 5: ...and Mechanical Stoppers for Wiring or Piping 14 1 4 4 Piping of Source Air 15 1 5 Installing the Flange Kit Option 16 1 6 Engineering design Notes for Robot Hands 16 1 7 Moving Each Axis with Motor P...

Page 6: ...Replacing the Encoder Backup Battery 46 3 5 3 Replacing the Memory Backup Battery 50 3 5 4 Setting the Next Battery Replacement Date 50 3 6 Supplies for Maintenance 51 3 7 Replacing Fuses and Output...

Page 7: ...ed failure may result 1 1 1 Ambient Temperature and Humidity Keep the ambient temperature between 0 C and 40 C during operation Keep the ambient humidity at 90 or below to prevent dew condensation 1 1...

Page 8: ...ient temperature During operation 0 to 40 C During storage and transportation 10 to 60 C Humidity During operation 90 or less No dew condensation allowed During storage and transportation 75 or less N...

Page 9: ...nt or slightly modify the robot speed Robot Mount Sample for Floor mount Type Strut Mounting face 350 350 20 or more 100 100 t6 0 square steel pipe Caution 1 When the robot operates at high speed the...

Page 10: ...gives the typical installation procedure assuming that you have set up the robot mount bed and prepared robot mounting bolt holes in it If you have not done it yet first read Section 1 2 3 Securing t...

Page 11: ...his job should be handled by two workers Caution 1 Do not hold the robot at sections other than those specified below The plastic cover could easily break 2 Before starting transportation make sure th...

Page 12: ...by at least two persons including a qualified operator for sling crane and forklift operation 3 Be sure to put on a helmet safety shoes and gloves Step 1 When unpacked the overhead mount robot unit i...

Page 13: ...r connector HSS G Step 3 Load the eyes of the belt sling on the hook of the crane Example of HSS G series Step 4 Remove the four bolts and release the robot unit from the pallet Caution When worker A...

Page 14: ...unit with the crane Caution Before starting this job make the work floor clear of obstacles HSS G Step 6 If the crane hoists the robot unit until it may be turned upside down stop the crane and have t...

Page 15: ...ead mount frame Secure the robot unit with four mounting bolts temporarily HSS G Step 8 Firmly secure the robot unit referring to Section 1 2 3 Securing the Robot Unit For HSS G Series Tightening torq...

Page 16: ...o that the pin becomes oriented as shown below 3 Drive an internally threaded positioning pin into the hole HS HSS G 6H7 dia Caution Never skip this step These dowel pins can minimize the risk of misa...

Page 17: ...se a dedicated grounding wire and grounding electrode Do not share them with other power facilities or welding machines HS HSS G Grounding the Robot Unit 1 3 Installing the Robot Controller For the in...

Page 18: ...aft The Z axis shaft has a hollow through which you may make wiring and piping from the hand control signal connector CN21 or air piping joints on the top of the 2nd arm In this wiring and piping chec...

Page 19: ...iven below set up a stay Note Maintenance and inspection of the robot unit sometimes requires removing and installing the covers Mount the stays for wiring and piping so that they will not interfere w...

Page 20: ...r securing a stay that clamps wiring or piping Doing so may result in the following problems The CALSET initial position will be deviated when CALSET is performed software limits will become invalid t...

Page 21: ...pped with four air pipes two of 4 mm and two of 6 mm in diameter for controlling hands The maximum of the source air pressure is listed below Apply dry air to the robot unit Maximum of source air pres...

Page 22: ...e flange so that the setscrew becomes aligned with the flat section of the T axis shaft 4 Gradually tighten the setscrew until it comes into contact with the flat section of the T axis shaft and the f...

Page 23: ...the motor power being OFF when the robot is in an emergency stop Note that moving the 3rd Z and 4th T axes requires releasing their brakes beforehand Warning Performing the brake release operation dro...

Page 24: ...F3 Brake on the teach pendant Enter the direct mode with the teach pendant and press the brake release switch Access F2 Arm F6 Aux F3 Direct on the teach pendant Note 1 For detailed procedures refer t...

Page 25: ...ng a commercially available padlock according to the following procedure Step 1 Check that the power switch of the robot controller is turned OFF Step 2 Remove the lockout bar provided on the robot co...

Page 26: ...ntrol set of motion optimization Robot installation conditions You are recommended to define new motion space and restricted space in order to prevent interference with other devices or entanglement o...

Page 27: ...tic operation an error message will be displayed error code starting from 607x where x represents the axis number and the robot will come to a stop The power to the motor will be also turned OFF if th...

Page 28: ...m 206 mm 206 mm 206 mm 3rd axis Negative direction 46 mm 74 mm 6 mm 114 mm 6 mm 114 mm Positive direction 360 4th axis Negative direction 360 2 HSS 4545 G Overhead mount type Overall arm length 450 mm...

Page 29: ...W HSS 45553 G W 3rd axis Z axis stroke 150 mm 200 mm 320 mm 150 mm 200 mm 320 mm Positive direction 155 1st axis Negative direction 155 Positive direction 145 2nd axis Negative direction 145 Positive...

Page 30: ...shown below Caution When changing software motion limits always take into account that the robot arm will motion within the range specified by the initial software motion limits Changing Software Mot...

Page 31: ...motion space may cause the robot unit to seem immovable 2 2 5 Procedure for Changing the Software Motion Limits Described below is the procedure for changing the software motion limits Step 1 Turn th...

Page 32: ...press F12 Maint F12 The Maintenance Functions Arm window will appear Step 5 In the Maintenance Functions Arm window press F1 M Space The Motion Space window will appear as shown below Select the item...

Page 33: ...e new value will be set on the line of the item selected in the Motion Space window If two or more items must be changed repeat Steps 6 and 7 Step 8 Press OK in the Motion Space window Step 9 Turn the...

Page 34: ...er changing the mechanical end the software motion limits PLIMs NLIMs should be changed not to interfere the mechanical end at the robot operation 3 When the robot has collided with a mechanical stopp...

Page 35: ...ALSET must be performed when any motor is replaced or when any encoder backup battery goes dead so that the position related data retained in the encoder is lost as a result After CALSET is completed...

Page 36: ...s into contact with the mechanical end 2 After CALSET confirm in the manual mode that each axis stops at the software motion limit before coming into contact with the mechanical end 3 In automatic ope...

Page 37: ...e axis As illustrated below the CALSET bolts are built in the robot unit so remove them and set them up into the specified positions After completion of CALSET put them back into place 1st axis Turnin...

Page 38: ...related with that of the 4th axis 1 Before performing the 3rd axis 4th axis CALSET move the 4th axis 3rd axis to the CALSET position 2 When performing the 3rd axis 4th axis CALSET perform the 4th axi...

Page 39: ...ep 4 The Brake release setting window appears as shown below Step 5 Select Brake released Step 6 Confirm that there is no danger even if the arm falls as a result of the brake being released Then pres...

Page 40: ...sking you whether you want to change the brake settings Press OK Step 8 The system message appears informing that the brake is released Press OK Step 9 Press the axis to be CALSET against the mechanic...

Page 41: ...5 Step 10 Press F6 CALSET The Set CALSET window appears as shown below Step 11 Press the axis number to be CALSET to turn it on green For other axes that are not to be CALSET turn it off black Press O...

Page 42: ...obot brake becomes activated Step 15 Turn the ROBOT STOP button to cancel robot stop Step 16 Press the MOTOR key to turn the motor ON Caution A motor lock overload error may occur just after the power...

Page 43: ...the teach pendant The single axis CALSET of the specified axis is completed 2 CALSET of All Axes The CALSET of all axes is called all axis CALSET The procedure is the same as that for single axis CAL...

Page 44: ...rmation see the PROGRAMMER S MANUAL I Section 4 7 Setting the Master Control Parameters in User Preferences For the setting procedure refer to the SETTING UP MANUAL Section 2 8 Setting the Master Cont...

Page 45: ...in the robot unit and the robot specific data programs parameters etc stored in the internal memory of the robot controller Caution Maintenance and inspection must be carried out by a trained worker...

Page 46: ...t units take care not to apply an impact or shock to the cover section specified below An impact or shock applied to the cover section or the resulting deformed cover section may deteriorate the clean...

Page 47: ...work properly Repair or replace 6 EMERGENCY STOP button on the teach pendant or the mini pendant ON Press the EMERGENCY STOP button The robot should come to an emergency stop Repair or replace 7 Safet...

Page 48: ...42 Normal Operation of Cooling Fan Example of HS G...

Page 49: ...tightening torque with a torque wrench No looseness Specified torque 70 14 Nm Tighten the bolts to the specified torque 2 Cooling fan filters in the robot controller OFF Visually No dust or dirt Clean...

Page 50: ...d Lubricants HS HSS G series No Lubrication points Lubricant type Lubricant amount Remarks Z axis shaft Epinoc AP1 2 to 3 cc Apply the grease to the whole Z axis shaft Example of HS G NOTE When applyi...

Page 51: ...tery type Used to Located Refer to 1 Encoder backup battery Back up the position data of the servomotor encoder In the robot unit Section 3 5 2 2 Memory backup battery Back up programs parameters and...

Page 52: ...iven below Step 1 Prepare two new backup batteries for replacement Step 2 Turn the controller power OFF Remove the cover from the robot unit Four hex socket head bolts M3x8 HS HSS G Step 3 NOTE On the...

Page 53: ...to the battery board from which you have disconnected the old one in Step 4 and then load it into the holder HS HSS G Step 5 NOTE Do not disconnect both of the current batteries at the same time Doin...

Page 54: ...e to the battery board from which you have disconnected the old one in Step 6 and then load it into the holder HS HSS G Step 7 NOTE Be sure to replace both of two batteries with new ones at one time O...

Page 55: ...he cover to the robot unit NOTE On the dust splash proof type or cleanroom type the cover has a packing for sealing Take care not to lose or pinch it Tightening toque Hex socket head bolt M3x8 1 6 0 3...

Page 56: ...t Step 1 On the top screen of the teach pendant press F6 Set The Settings Main window appears Step 2 Press F6 Maint in the Settings Main window The Maintenance menu appears Step 3 Press F4 Battery in...

Page 57: ...Epinoc Ap l 3 Encoder backup battery set 410679 0010 A set of two batteries HS E17500 410053 0100 For standard type of controllers FS 1705W 4 Air filter set 410053 0110 For global type of controllers...

Page 58: ...rsed after the robot leaves the factory You cannot reset the odometer Trip meter Shows the distance of each axis traversed after you reset the trip meter to zero You can reset the trip meter by pressi...

Page 59: ...Maintenance menu appears as shown below F5 Press F5 Odometer Step 5 The Odometer window appears as shown below F6 In the above Odometer window the J1 J2 and J4 are expressed in number of revolutions a...

Page 60: ...Meter to Zero Step 1 Display the Odometer window as shown below Access F6 Set F6 Maint F5 Odometer from the top screen Press F6 Reset Step 2 The following message appears Press the OK button The trip...

Page 61: ...time counted after the robot leaves the factory Cumu operation Shows the total of the robot controller ON time counted after you reset the user counter to zero Cumu running Shows the total of the robo...

Page 62: ...after the robot leaves the factory Cumu operation Shows the total of the robot controller ON time counted after you reset the user counter to zero Cumu running Shows the total of the robot running tim...

Page 63: ...ing Time Step 1 Display the Total hours window as shown below Access F6 Set F6 Maint F1 Total h from the top screen F6 To reset the user counter of the controller ON time Cumu operation for example pr...

Page 64: ...58 Step 3 The user counter of the controller ON time has been reset to zero as shown below...

Page 65: ...replacement of a motor DENSO preserves arm data configured at the time of shipment for 10 years If your arm data is lost contact your DENSO representative Note Arm data refers to CALSET and RANG valu...

Page 66: ...rom the controller for creating a new project Step 3 Following the project wizard enter the IP address and the desired backup file name Step 4 Select Receive data from the controller after creating th...

Page 67: ...ata has been backed up open the project data in WINCAPSIII and proceed to STEP 2 Start WINCAPSIII log on as a Programmer and create a project suitable for your robot model Choose Tool Arm parameters t...

Page 68: ...bot controller Choose Connect Transfer data to display the Transfer data window Select Parameters Arm parameters and Configuration CALSET then press Send Upon completion of transfer of the CALSET rela...

Page 69: ...ual is to provide accurate information in the handling and operating of the robot Please feel free to send your comments regarding any errors or omissions you may have found or any suggestions you may...

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