Denso VS-6556G, Installation & Maintenance Manual

Page 1: ...ROBOT Vertical articulated VS 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: ...ed VS G Models configured with RC7M controller VS 6556G 6 axis type VS 6556E GM 5 axis type NOTE 1 Model names listed above apply to the models of robot systems The model names of robot units are foll...

Page 4: ...Designer User s Manual SUPPLEMENT WINCAPSII GUIDE Provides instructions on how to use the teaching system WINCAPSII which runs on the PC connected to the robot controller for developing and managing...

Page 5: ...ting your robot Chapter 1 Installing Robot Components Provides information about physical site planning installation procedures and engineering design notes for hands Chapter 2 Customizing Your Robot...

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Page 7: ...ed by the manufacturer plus the space which can be swept by the end effector and the workpiece Quoted from the ISO 10218 1 2006 Restricted space Refers to the portion of the maximum space restricted b...

Page 8: ...Risk of injury Never enter the restricted space Except HM HM Label 2 For UL Listed robot units only Risk of injury This label alerts the user that pressing the brake release switch could drop the arm...

Page 9: ...and the wrist of the VM VS G W are an IP65 equivalent dust and splash proof structure Note that the robot controller is not a dust or splash proof structure Therefore when using the robot controller i...

Page 10: ...istance The grounding resistance of the robot power supply should not be more than 100 3 7 Positioning of emergency stop switches Emergency stop switches should be provided in a position where they ca...

Page 11: ...n interlock that ensures the emergency stop device operates automatically if it is opened or removed 2 Post a warning notice at the entrance exit of the fence stating In operation Entry forbidden or W...

Page 12: ...ation should be assured for safe robot operation 3 14 Protection from objects thrown by the end effector If there is any risk of workers being injured in the event that the object being held by the en...

Page 13: ...the robot s restricted space to perform teaching or maintenance inspections set working regulations for the following items and ensure workers adhere to them 1 Operating procedures required to run the...

Page 14: ...unction 1 Ensure an overseer is placed in a position outside the robot s restricted space and one in which he she can see all robot movements and that he she is devoted solely to that task c An emerge...

Page 15: ...the robot or related equipment are lit 2 Check that the display lamp indicating automatic operation is lit during automatic operation 3 Steps to be taken when a malfunction occurs Should a malfunction...

Page 16: ...isks used for storing task programs to prevent incorrect disks from loading into the robot controller 4 Store the floppy disks where they will not be exposed to dust humidity and magnetic field which...

Page 17: ...cy Stop 10 1 6 Releasing Brakes on UL Listed Robot Units 11 1 7 Locking Out the Power Switch 12 Chapter 2 Customizing Your Robot 13 2 1 What Is Customization 13 2 2 Modifying Software Motion Limits to...

Page 18: ...4 3 Replacing the Memory Backup Battery 86 3 4 4 Setting the Next Battery Replacement Date 86 3 5 Supplies and Tools for Maintenance 87 3 6 Replacing Fuses and Output ICs 87 3 7 Checking the Odometer...

Page 19: ...between 0 C and 40 C during operation Keep the ambient humidity at 90 or below to prevent dew condensation 1 1 2 Vibration Do not install the robot in an environment where it will be exposed to exces...

Page 20: ...llation type Floor mount or Overhead mount Ambient 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...

Page 21: ...t or slightly modify the robot speed Robot Mount Example for Floor mount 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 top p...

Page 22: ...ot units the drain bolt M3 x 8 mm is screwed onto the rear side of the robot unit as shown in the figure below At the floor mount installation remove the drain bolt shown in the figure below before in...

Page 23: ...hould wear helmets safety shoes and gloves during transport Caution Pass the hoisting wires through the specified eyebolts as illustrated below Passing them through other sections may drop the robot u...

Page 24: ...manually moving the second third and fourth axes When unpacked first the robot is in the transport position so this job is not required Fifth axis J5 90 2 Disconnect the robot control cable air piping...

Page 25: ...it to the target site 7 Worker B Put the robot unit down in the target position Worker A Temporarily secure the robot unit with four bolts 8 Secure the robot unit according to the instructions in Sect...

Page 26: ...rive the internally threaded positioning pin into the 6H7 hole NOTE Be sure to drive the knock pins It can minimize positional deviations that may be caused by the removal installation of the robot un...

Page 27: ...wer or power equipment such as a welder Grounding the Robot Unit VS G series 1 3 Installing the Robot Controller For the installing procedures of the robot controller refer to the RC7M CONTROLLER MANU...

Page 28: ...ws how to move each axis with the motor power being OFF when the robot is in an emergency stop Warning Performing the brake release operation drops the arm Make sure beforehand that the release operat...

Page 29: ...essing the brake release switch make sure that there is no danger that dropping the arm will cause bodily injuries or equipment damage Pressing the switch releases the brake of the selected axis dropp...

Page 30: ...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 31: ...et 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 of the e...

Page 32: ...ftware motion limit is set If the robot reaches a software motion limit during manual or automatic operation an error message will be displayed error code starting from 6070 the first digit represents...

Page 33: ...series Robot model 1st axis 2nd axis 3rd axis 4th axis 5th axis 6th axis Positive direction 170 135 166 190 120 360 VS 6556G See NOTE Negative direction 170 100 max 119 max 190 120 360 Positive direct...

Page 34: ...ng of the end effector becomes taut as the robot runs then change the software motion limits to make the motion space smaller as shown in the lower figure on this page NOTE When changing software moti...

Page 35: ...surement If the operating space is too small the robot may seem to become inoperable 2 2 5 Procedure for Changing the Software Motion Limits Described below is the procedure for changing the software...

Page 36: ...ss the SHIFT key and then press F12 Maint F12 The Maintenance Functions Arm window will appear STEP 5 Press F1 M Space on the Maintenance Functions Arm window The Motion Space window will appear as sh...

Page 37: ...be set on the line of the item selected in the Motion Space window If two or more items must be changed repeat Steps 5 and 6 STEP 7 Press OK in the Motion Space Software motion limit window STEP 8 Tu...

Page 38: ...he robot power is turned ON 4 If the robot is collided with the mechanical stopper the robot will stop by detecting the collision but the mechanical stopper may be broken When the robot is collided wi...

Page 39: ...A 2 pieces Fixture block B 1 piece Plate 2 pieces The figures on the following pages show the reference drawings of those mechanical stop parts Referring to those drawings you should prepare mechanica...

Page 40: ...axis Material A2017 Note 1 Unless otherwise specified corners should be C0 1 to C0 5 Mechanical Stop VS G series For 1st axis Material S45C Note 1 Unless otherwise specified corners should be C0 1 to...

Page 41: ...ied corners should be C0 1 to C0 5 Fixture Block B VS G series For 1st axis Material S45C Note 1 Unless otherwise specified corners should be C0 1 to C0 5 Note 2 and are arbitrary angles In the above...

Page 42: ...d change requires RANG value change and CALSET In this case the position repeatability depends on the mechanical stop parts prepared by the customer The initialization floppy disk holds the factory de...

Page 43: ...th two hexagonal socket head bolts Make a pair of assemblies STEP 3 Turn the assemblies made in Step 2 upside down Secure two mechanical stops to each of those assemblies with two hexagonal socket hea...

Page 44: ...Step 4 temporarily secure the other one of the assemblies to the opposite side STEP 6 Link the assemblies together that you have temporarily secured in Steps 4 and 5 using fixture block B and two hexa...

Page 45: ...nce angle or ready angle The RANG value checking procedure is given below The relationship between each mechanical end position and software motion limits is shown in the table on page 29 Change the s...

Page 46: ...P 4 Gently bring the 1st axis of the robot into contact with the newly set positive direction mechanical end STEP 5 Check the value in J1 box that appears when the 1st axis is in contact with the mech...

Page 47: ...tion software motion limit 0 RANG value obtained in Checking the set RANG value 2 When the positive direction mechanical ends are the permanent mechanical ends and the negative direction mechanical on...

Page 48: ...ability is depended on the mechanical stop parts prepared by you And also you need to note down the new RANG values and CALSET values The initial RANG values and CALSET values at the time of delivery...

Page 49: ...elect the Software motion limit J1 deg field STEP 7 Press F5 Change The numeric keypad appears STEP 8 Using the numeric keys enter the positive direction software motion limit value then press OK The...

Page 50: ...alues STEP 10 Press F2 RANG The RANG window appears as shown below F5 STEP 11 Press F5 Change The numeric keypad appears STEP 12 Using the numeric keys enter RANG values then press OK The screen retur...

Page 51: ...wer switch of the robot controller to ON STEP 16 Press F2 Arm on the top screen CALSET of the 1st Axis NOTE For UL Listed robot units release the brake on the 1st axis before CALSETing STEP 17 Press S...

Page 52: ...6 CALSET on the window in Step 18 The Set CALSET window appears STEP 20 Touch the J1 field and confirm that the mark turns green STEP 21 Press OK The message window appears asking you whether you want...

Page 53: ...valid the axis stops just before the mechanical end and ERROR6071 appears In the following cases reset the bolt positions the positive direction software motion limits the RANG values and the negativ...

Page 54: ...ed Change the set negative direction software motion limits PLIMs according to steps 1 through 10 described below STEP 1 Turn the power switch of the robot controller to ON STEP 2 Set the mode selecto...

Page 55: ...g dial or cursor keys select the Software motion limit J1 deg field STEP 7 Press F5 Change The numeric keypad appears STEP 8 Using the numeric keys enter a negative direction software motion limit val...

Page 56: ...stops just before the mechanical end and ERROR6071 appears In the following cases reset the bolt positions the positive direction software motion limits the RANG values and the negative direction soft...

Page 57: ...its to the positions inside the mechanical end positions And also if you change the RANG values required after a mechanical end change the CALSET must also be performed Note RANG refers to a reference...

Page 58: ...edicated internal threads D Go to 3 on page 3 For robot units without dedicated internal threads D Go to 4 on page 7 Locations of Internal Threads Dedicated to 2nd axis Mechanical End Change Locations...

Page 59: ...o 2nd axis mechanical end change as shown below The mechanical stop and the related parts should be prepared by the customer Example of 2nd axis Mechanical End Configured on the Robot Unit Hex socket...

Page 60: ...Material A2017 Unit mm Bolts Five hex socket head bolts M6x30 Strength class 12 9 for securing a mechanical stop One hex socket head bolt M6x10 Strength class 12 9 as a mechanical stop bolt 3 2nd axis...

Page 61: ...e 3rd axis cannot move overriding 100 30 on the UL Listed models in the negative direction Set the negative direction software motion limit for the 3rd axis in the positive side than 100 30 3 Be caref...

Page 62: ...own below The mechanical stop and the related parts should be prepared by the customer Example of 3rd axis Mechanical End Configured on the Robot Unit Secured with four hex socket head bolts M5x30 Str...

Page 63: ...her Material A2017 Unit mm Bolts Four hex socket head bolts M5x30 Strength class 12 9 for securing a mechanical stop One hex socket head bolt M5x10 Strength class 12 9 as a mechanical stop bolt 3 3rd...

Page 64: ...gative direction software motion limit for the 3rd axis in the positive side than 25 20 3 In the VS 6577G series the 3rd axis cannot move overriding 65 in the negative direction Set the negative direc...

Page 65: ...6G and 4 3 for the VS 6577G 4 1 2nd axis Mechanical End Change Common to VS 6566G and VS 6577G 1 Outline The 2nd axis mechanical end can be changed by mounting a mechanical stop to the undedicated int...

Page 66: ...xis mechanical stop consisting of Part A Part B and Part C The reference drawings of those parts are given on the following pages The mechanical stop is designed to set the 2nd axis motion range betwe...

Page 67: ...49 Reference Drawing of Part A Material A2017 T4...

Page 68: ...50 Reference Drawing of Part B Material A2017 T4 Reference Drawing of Part C Material A2017 T4...

Page 69: ...threads as shown below The mechanical stop and the related parts should be prepared by the customer Example of 3rd axis Mechanical End Configured on the Robot Unit VS6556G Positions of Undedicated In...

Page 70: ...is mechanical stop The reference drawings of the mechanical stop and the related parts are given on the following pages The 3rd axis mechanical stop is designed to set the 3rd axis motion range betwee...

Page 71: ...53 Reference Drawing of Stay for 3rd axis Mechanical End VS6556G Material A2017 T4...

Page 72: ...54 Reference Drawing of 3rd axis Mechanical Stop VS6556G Material A2017 T4 Reference Drawing of Spacer for 3rd axis Mechanical End VS6556G Material S45C...

Page 73: ...nternal threads as shown below The mechanical stop and the related parts should be prepared by the customer 3rd axis Mechanical Stop Mounted on the Robot Unit VS6577G Positions of Undedicated Internal...

Page 74: ...is mechanical stop The reference drawings of the mechanical stop and the related parts are given on the following pages The 3rd axis mechanical stop is designed to set the 3rd axis motion range betwee...

Page 75: ...57 Reference Drawing of 3rd axis Mechanical Stop VS6577G Material A5083P H32 Note The joint sections should be welded...

Page 76: ...58 Reference Drawing of Stay for 3rd axis Mechanical End VS6577G Material A2017BE T4 Reference Drawing of Spacer for 3rd axis Mechanical End VS6577G Material S45C...

Page 77: ...ta is stored in the floppy disks that come with the robot unit Therefore even if the memory backup battery in the robot controller dies so that the CALSET data is lost you do not need to CALSET the ro...

Page 78: ...the 4th axis section is at a designated position The hand control signal connector CN21 of the second arm comes to the upper side and the internal wiring is not caught in the crank at this time Check...

Page 79: ...e internal wiring may be caught in the crank and broken in such a case 2 4 3 Preparation for CALSET The VS G series has no mechanical stop on the 4th and 6th axes Mechanical Stops on Axes VS G On the...

Page 80: ...manual mode that each axis stops at the software motion limit before coming into contact with the mechanical end 4 In automatic operation start to run the robot at low speed Ensuring safety gradually...

Page 81: ...eed to mount the CALSET jig on the axis beforehand according to the procedure given in 1 below or 2 given later respectively To CALSET all axes including the above axes follow those procedures 1 and 2...

Page 82: ...flange as shown in the figure below TIP The CALSET position of the 6th axis refers to the point where the stopper pin shown in the figure below comes into contact with bolt A by turning the flange of...

Page 83: ...inside the 3rd axis motor cover in the robot unit STEP 1 Remove the 3rd axis motor cover and unscrew the CALSET bolt NOTE After CALSETing be sure to set the bolt back into place and torque it to 1 0...

Page 84: ...9 Nm 20 NOTE Be sure to use the CALSET bolt as a CALSET jig Using any other bolt will result in a positional error in CALSET TIP The CALSET position of the 4th axis refers to the point where the notch...

Page 85: ...g end in the positive direction 4th axis Turning end in the positive direction which is set by a CALSET jig See Section 2 4 4 counterclockwise end when viewed from the arm end 5th axis Turning end in...

Page 86: ...ep 2 is for CALSETing the 6th axis When CALSETing any other axes skip to Step 3 STEP 1 Required for CALSETing the 4th and 6th axes Mount the CALSET jig according to Section 2 4 2 1 Mounting the CALSET...

Page 87: ...Section 1 6 Releasing Brakes for UL Listed Robot Units and then proceed to Step 15 STEP 7 Press the MOTOR key on the teach pendant to turn OFF the power to the motor STEP 8 Press F2 Arm on the teach...

Page 88: ...n display STEP 12 Confirm that there is no danger even if the arms fall as a result of released brakes CAUTION In the VS G series the brake of the specified axis is released STEP 13 Press OK The syste...

Page 89: ...stem message appears informing that the brake is released and warning against drop of arms STEP 15 Press the axis to be CALSET against the mechanical stop by hand STEP 16 Press F6 CALSET The Set CALSE...

Page 90: ...display for the other axes that are not required to be CALSET STEP 18 Press OK The system message appears asking whether you want to carry out CALSET and showing a caution that the robot reference po...

Page 91: ...tle in the opposite direction of the mechanical end and turn ON the power again STEP 23 Move the CALSETed axis in the opposite direction from the mechanical end by the manual operation of the teach pe...

Page 92: ...is or 6 axis CALSET as follows 1 Before performing 5 axis or 6 axis CALSET remove the flange and cover Caution When removing the flange and cover dusts inside robot may be splashed 2 Perform 5 axis or...

Page 93: ...Control Set of Motion Optimization The payload center of gravity is represented by the TOOL0 coordinate system see the figure below in the unit of mm The origin of the TOOL0 coordinate system is the...

Page 94: ...it is set for floor mount If you overhead mount your robot you need to change the installation settings For the setting procedure refer to the SETTING UP MANUAL Section 2 10 Setting the Robot Installa...

Page 95: ...eries as specified in Section 3 4 every two years To retain the robot specific data programs parameters etc stored in the internal memory of the robot controller and the position data stored in the el...

Page 96: ...the cleanroom type of robot 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 sectio...

Page 97: ...Repair or replace 5 Cooling fan in the robot controller ON Visually Note 2 Should work properly Repair or replace 6 EMERGENCY STOP button on the teach pendant or the mini pendant ON Press the EMERGENC...

Page 98: ...OFF Measure the tightening torque with a torque wrench No looseness Specified torque 110 22 Nm Tighten the bolts to the specified torque 2 Cooling fan filters in the robot controller OFF Visually No...

Page 99: ...rams parameters and CAL data In the robot controller Section 3 4 3 The position data of the encoder built in the servomotor is stored in the internal memory of the encoder Programs parameters CAL data...

Page 100: ...according to the procedure below STEP 1 Prepare a new set of 3 backup batteries for replacement STEP 2 Turn the controller power OFF STEP 3 Remove the cover from the robot unit Standard type Dust pro...

Page 101: ...to the pin from which you have disconnected the dummy connector cap in Step 4 Note Do not disconnect old backup batteries before connecting a new one to the pin from which the dummy connector cap is...

Page 102: ...STEP 7 Disconnect the old backup battery that is right next to the new battery connected in Step 6 and then connect a new battery 3rd one Note Be sure to replace all of three batteries with new ones...

Page 103: ...P 9 Install the cover to the robot unit Standard type Dust proof splash proof type Tightening torque Cross pan head screw 0 59 Nm Standard type Hex socket head bolt 2 0 Nm Dust proof splash proof type...

Page 104: ...nt date will also become incorrect 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 ap...

Page 105: ...type of controllers FS 1705W 1 Air filter set 410053 0110 For global type of controllers FS 1705 2 Memory backup battery 410076 0260 For RC7M controller 3 Fuse 1 3A 410054 0230 For LM13 for controlle...

Page 106: ...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 pressing F6 Reset...

Page 107: ...own below F5 Press F5 Odometer STEP 5 The Odometer window appears as shown below F6 In the above Odometer window the J1 through J6 are expressed in rpm If the Trip meter count exceeds the Interval val...

Page 108: ...ter to Zero STEP 1 Display the Odometer window as shown below Access F6 Set F6 Maint F5 Odometer from the top screen F6 Press F6 Reset STEP 2 The following message appears Press the OK button The trip...

Page 109: ...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 time counted after you reset the user...

Page 110: ...Cumu running Shows the total of the robot running time counted after you reset the user counter to zero Operation Shows the ON time of the robot controller counted after it is turned ON this time Run...

Page 111: ...93 STEP 2 The following system message appears Press the OK button The user counter of the controller ON time has been reset to zero...

Page 112: ...encoder backup batteries or Error 677 occurs due to a great impact applied to the robot when the power is off is any of 1 to 6 denoting the object axis This section describes how to reset encoders Fo...

Page 113: ...ed in the floppy disk 2 Transfer the trajectory generation file in the project to the robot controller Creating a project to be transferred STEP 1 Create a new project Start WINCAPSII From the File me...

Page 114: ...Open Project window Select desired file in the floppy disk then press the Open button Selecting a file 3 The screen will return to the Details window where you press OK button STEP 4 Create a project...

Page 115: ...e trajectory generation file STEP 1 Start of Arm Manager From System Manager run Arm Manager STEP 2 Connection with the robot controller Press the Connect button to connect with the robot controller A...

Page 116: ...d The Transfer Environment Table appears as shown below Transfer Environment Table 2 On the table shown above select the Trajectory and press the Transmit button 3 The following message appears Press...

Page 117: ...Trajectory Generation Table 4 Upon completion of transfer the following message appears Press OK The arm data stored in the initialization floppy disk has been transferred to the robot controller Tur...

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Page 119: ...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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