Denso VM-G Series Installation & Maintenance Manual
  1. Manuals
  2. Brands
  3. Denso Manuals
  4. Robotics
  5. VM-G Series
  6. Installation & maintenance manual
Denso VM-G Series Installation & Maintenance Manual

Denso VM-G Series Installation & Maintenance Manual

Robot vertical articulated
Hide thumbs
Table of Contents

Advertisement

Quick Links

ROBOT
Vertical articulated
VM-G SERIES
INSTALLATION & MAINTENANCE GUIDE

Advertisement

Table of Contents
loading

Related Manuals for Denso VM-G Series

Summary of Contents for Denso VM-G Series

  • Page 1 ROBOT Vertical articulated VM-G SERIES INSTALLATION & MAINTENANCE GUIDE...
  • Page 2 Copyright © DENSO WAVE INCORPORATED, 2005-2010 All rights reserved. No part of this 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 mentioned are trademarks or registered trademarks of their...

  • Page 3: Preface

    Preface Thank you for purchasing this high-speed, high-accuracy assembly robot. Before operating your robot, read this manual carefully to safely get the maximum benefit from your robot in your assembling operations. Robot series and/or models covered by this manual Model Remarks Series (Max.

  • Page 4: How The Documentation Set Is Organized

    & inspection procedures. STARTUP HANDBOOK Introduces you to the DENSO robot system and guides you through connecting the robot unit and controller with each other, running the robot with the teach pendant, and making and verifying a program. This manual is a comprehensive guide to starting up your robot system.

  • Page 5: How This Book Is Organized

    How this book is organized This book is just one part of the robot documentation set. This book consists of SAFETY PRECAUTIONS, chapters one through three. SAFETY PRECAUTIONS Defines safety terms and related symbols and provides precautions that should be observed. Be sure to read this section before operating your robot.

  • Page 7: Safety Precautions

    The maximum distance that the robot, end-effector, and workpiece can travel after the software motion limits are set defines the boundaries of the motion space of the robot. (The "motion space" is DENSO WAVE-proprietary terminology.) Operating space: Refers to the portion of the restricted space that is actually used while performing all motions commanded by the task program.
  • Page 8 This section provides safety precautions to be observed for the 1. Introduction robot system. The installation shall be made by qualified personal and should confirm to all national and local codes. 2. Warning Labels The robot unit and controller have warning labels. These labels alert the user to the danger of the areas on which they are pasted.
  • Page 9 SAFETY PRECAUTIONS 3. Installation Precautions 3.1 Insuring the proper installation environment The standard and cleanroom types have not been designed to For standard type and withstand explosions, dust-proof, nor is it splash-proof. cleanroom type Therefore, it should not be installed in any environment where: (1) there are flammable gases or liquids, (2) there are any shavings from metal processing or other conductive material flying about,...
  • Page 10 The robot controller, teach pendant and mini-pendant should be 3.3 Control devices installed outside the robot's restricted space and in a place outside the robot's where you can observe all of the robot’s movements and operate restricted space the robot easily. Pressure gauges, oil pressure gauges and other gauges should 3.4 Positioning of gauges be installed in an easy-to-check location.
  • Page 11 SAFETY PRECAUTIONS A safety fence should be set up so that no one can easily enter 3.9 Setting-up a safety the robot's restricted space. fence (1) The fence should be constructed so that it cannot be easily moved or removed. (2) The fence should be constructed so that it cannot be easily damaged or deformed through external force.
  • Page 12 Never modify the robot unit, robot controller, teach pendant or 3.11 No robot modification other devices. allowed If your robot uses welding guns, paint spray nozzles, or other 3.12 Cleaning of tools end-effectors requiring cleaning, it is recommended that the cleaning process be carried out automatically.
  • Page 13 SAFETY PRECAUTIONS 4. Precautions Touching the robot while it is in while Robot is operation can lead to serious Warning Running injury. Please ensure the fol- lowing conditions maintained that cautions listed from Section 4.1 and onwards are followed when any work is being performed.
  • Page 14 4) Implementation of measures for noise prevention 5) Signaling methods for workers of related equipment 6) Types of malfunctions and how to distinguish them Please ensure "working regulations" are appropriate to the robot type, the place of installation and to the content of the work. Be sure to consult the opinions of related workers, engineers at the equipment manufacturer and that of a labor safety consultant when creating these "working regulations".
  • Page 15 SAFETY PRECAUTIONS Before disassembling or replacing pneumatic parts, first release 4.5 Release of residual air any residual air pressure in the drive cylinder. pressure 4.6 Precautions for test Whenever possible, have the worker stay outside of the robot's restricted space when performing test runs. runs (1) At start-up 4.7 Precautions for...
  • Page 16 Industrial Robots and Robot Systems--General Safety Requirements ISO10218-1: 2006 Robots for industrial environments--Safety requirements--Part 1: Robot NFPA 79: 2002 Electrical Standard for Industrial Machinery 8. Battery Recycling DENSO Robot uses lithium batteries. Discard batteries according to your local and national recycling law.

  • Page 17: Table Of Contents

    2.3.2 2nd-axis and 3rd-axis Mechanical Ends Change ..................48 2.4 CALSET................................54 2.4.1 What Is CALSET?............................54 2.4.2 Precautions about CALSET for the VM-G Series ..................54 2.4.3 Preparation for CALSET ..........................56 2.4.4 Mounting the CALSET Jig........................... 58 2.4.5 What Is a CALSET Position? ........................61 2.4.6 CALSET Procedure............................
  • Page 18 Chapter 3 Maintenance and Inspection ........................70 3.1 Maintenance & Inspection Intervals and Purposes ..................... 70 3.1.1 Precautions for installation and maintenance of robots for cleanroom use ..........71 3.2 Daily Inspections..............................72 3.2.1 Check Items..............................72 3.3 Quarterly Inspections ............................73 3.3.1 Check Items..............................

  • Page 19: Chapter 1 Installing Robot Components

    Chapter 1 Installing Robot Components Preparing a Proper Environment for Installation Before installing the robot unit and robot controller, confirm that the operating environment is in conformity with each item of SAFETY PRECAUTIONS, "Installation Precautions". Also, take proper measures to protect the components from vibration. In an inappropriate environment, the robot will not operate to its full capacity or performance, components may not last long, and unexpected failure may result.
  • Page 20 Installation Requirements for the Robot Unit Item Environments and Conditions Flatness of the mount 0.1/500 mm (See the upper figure on the next page.) Rigidity of the mount Use steel materials. (See the figure on the next page.) Installation type Floor-mount or Overhead-mount During operation : 0 to 40C Ambient temperature...
  • Page 21 100 × 100 pipe 500 or more Caution (1) When the robot operates at high speed, the robot mount undergoes large reaction forces. The mount must be rigid enough so that it will not vibrate or be displaced due to reaction forces. It is also advisable to mechanically join the robot mount with heavy equipment.

  • Page 22: Mounting The Robot Unit

    1.2.1 Transporting the Robot Unit (1) Precautions in transporting the robot The VM-G series weighs approximately 88 kg (193 lbs). Use a crane suitable for the robot weight. Have at least two workers handle this job. Workers should wear helmets, safety shoes, and gloves during transport.
  • Page 23 (2) Transporting the robot unit Procedure Explanatory Illustration Before transportation, VM6083G/VM60B1G set the robot in a transport position as shown at right by manually moving the second, third and fourth axes. When unpacked first, the robot is in the transport position, so this job is not required.
  • Page 24 Procedure Explanatory Illustration As shown at right, VM6083G/VM60B1G place a waste cloth on the second arm and pass the wire through the two eyebolts. Wire (Belt sling) Waste cloth Eyebolts Robot unit mounting bolts Hoisting the Robot Unit Worker A: Remove the four bolts while supporting the robot unit to prevent it from...

  • Page 25: Securing The Robot Unit

    1.2.2 Securing the Robot Unit (1) Drill four bolt holes (M12) 15-mm deep or more in the robot mount where the robot unit is to be secured, according to the dimensions shown below. Reference plane Front Connector side Reference  plane (for mounting M12 bolt) Bolt Positions for Securing the VM-6083G/VM-60B1G...

  • Page 26: Overhead-Mounting The Robot

    100 × 100 × t6.0 (square steel pipe) Example of Overhead-mount Frame (VM-G series) Caution: When the robot is running at high speed, large reaction forces are exerted on the top plate structure. Take proper measures to protect the top plate from vibration caused by reaction forces.
  • Page 27 VM-6083G/VM-60B1G (1) Overhead-mount Suspension Jigs To mount the robot overhead, five types of jigs--suspension jigs A, B and C, two holders and two holder stopper plate--are required. The upper figures on this page show how to mount suspension jigs A and B, and the lower figure shows how to mount suspension jig C, holder and holder stopper plates.
  • Page 28 Suspension Jig A...
  • Page 29 Suspension Jig B...
  • Page 30 Suspension Jig C...
  • Page 31 NOTE 1) ALL CORNERS SHOULD FINE-CHAMFERED UNLESS OTHERWISE SPECIFIED. Holder 11 drill hole Holder Stopper Plate NOTE 1) ALL CORNERS SHOULD BE FINE-CHAMFERED UNLESS OTHERWISE SPECIFIED.
  • Page 32 (2) Overhead-mounting Example The basic procedure of overhead-mounting is given on the following pages. Follow the procedure to install the robot unit. Caution (1) Since the robot unit weighs approximately 88 kg (193 lbs), prepare a crane and a forklift with a lifting load of 0.5 ton or more.
  • Page 33 When unpacked, the robot unit is as shown below: STEP 1 Mount suspension jigs A and B using hexagon socket head bolts and plain STEP 2 washers. Hoisting bolts Suspension jig A Suspension jig B Jig mounting bolt M12×35 (hexagon socket head, strength class:12.9) and plain washer (JIS B1256, polished round 12) Bolt tightening torque : 130 ±26 Nm...
  • Page 34 Drive the hoisting (that come with the robot unit) into the suspension jigs. STEP 3 Pass a belt sling through each hoisting bolt, and put their eyes on the hook. STEP 4 Hook Belt sling Hoist the robot unit using a crane and move it to the position right above the STEP 5 suspension jig C.
  • Page 35 Slowly lower the hook of the crane until the robot unit turns upside down. STEP 6 Caution The robot unit will turn by its own weight as you lower the crane hook. This is not trouble, so do not touch the robot unit itself.
  • Page 36 On the other side, join suspension jigs B and C together using the other STEP 8 holder stopper plate in the same way as in Step 7. Suspension jig B Suspension jig A Holder stopper plate Suspension jig C Confirm that the robot unit is secured to the suspension jigs. STEP 9 STEP 10 Using a forklift, transport the robot unit fixed to suspension jigs to the robot...
  • Page 37 Using the forklift, set the robot unit fixed to suspension jigs in the specified STEP 11 position on the robot mount, then secure it to the robot mount with M1240 bolts (strength class: 12.9). Bolt tightening torque : 128 ±26 Nm M1240 (strength class: 12.9) While supporting the robot unit with the forklift, remove the bolts fastening STEP 12...
  • Page 38 Using the forklift, remove suspension jig C only from the robot unit. STEP 13 Suspension jig C Remove suspension jigs A and B from the robot unit. STEP 14 Suspension jig A Suspension jig B Confirm that the robot unit is secured to the robot mount. Then, the STEP 15 installation procedure is complete.

  • Page 39: Grounding The Robot Unit

    For the installing procedures of the robot controller, refer to the RC7M CONTROLLER MANUAL, Section 6.2 "Installing the Robot Controller.” Precautions When Designing the End-effectors Refer to the GENERAL INFORMATION ABOUT ROBOT for VM-G SERIES, Chapter 3, Section 3.5 "Precautions When Designing the End-effectors."...

  • Page 40: Locking Out The Power Switch

    Locking Out the Power Switch Lock out the power switch during maintenance and inspection jobs using 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 controller.

  • Page 41: Chapter 2 Customizing Your Robot

    Chapter 2 Customizing Your Robot What Is Customization? You may customize your robot by modifying or setting the following: - Software motion limits for defining motion space - Mechanical ends for defining restricted space - Control 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 of the end-effector wiring and...

  • Page 42: Modifying Software Motion Limits To Define New Motion Space

    Modifying Software Motion Limits to Define New Motion Space 2.2.1 What Is a Software Motion Limit? A limit to the operation range of the robot defined by the software is called a software motion limit. Software motion limits become valid after CAL of the robot has been completed and the robot has entered the range set by the limits.
  • Page 43 Motion range Software motion limit Mechanical end Restricted range NLIM (Negative-direction software motion limit) PLIM (Positive-direction software motion limit) Software Motion Limits and Mechanical Ends...

  • Page 44: Factory Defaults Of Software Motion Limits

    2.2.2 Factory Defaults of Software Motion Limits Table 4-1 lists the software motion limits that are set at the time of delivery. Factory Defaults of Software Motion Limits (VM-G series) Robot model 1st axis 2nd axis 3rd axis 4th axis...

  • Page 45: Changing Software Motion Limits

    2.2.3 Changing Software Motion Limits If the robot interferes with any other device, change the software motion limits to make the motion space smaller as shown by the upper figure on this page. If the air piping or wiring of the end-effector becomes taut as the robot runs, change the software motion limits to make the motion space smaller as shown by the lower figure on this page.

  • Page 46: Changing The Mechanical End

    Changing the Mechanical End This section describes the procedures of changing the mechanical ends from the 1st-axis to 3rd-axis on the VM-6083G/VM-60B1G series. CAUTIONS IN CHANGING THE MECHANICAL ENDS 1. When changing the mechanical ends, design the mechanical stoppers according to your usage and manufacture them.

  • Page 47: 1St-Axis Mechanical End Change

    2.3.1 1st-axis Mechanical End Change [ 1 ] What is the 1st-axis Mechanical End Change? At the time of delivery from the factory, mechanical ends are set in the VM-6083G/VM-60B1G series so that the stroke of the 1st axis will be ±170°. Changing the mechanical ends of the 1st axis by adding mechanical stops is called a mechanical end change.
  • Page 48 VM-6083G/VM-60B1G (For 1st-axis) 2-11 DRILL, 17.5 DIA x 10 DEEP SF Material: A2017 (Note 1) Unless otherwise specified, corners should be C0.1 to C0.5. Mechanical Stop VM-6083G/VM-60B1G (For 1st-axis) 2-11 DRILL, 17.5 DIA x 10.8 DEEP SF 2-13.5 DRILL, 20 DIA x 13 DEEP SF Material: S45C (Note 1) Unless otherwise specified, corners should be C0.1 to C0.5.
  • Page 49 VM-6083G/VM-60B1G (For 1st-axis) 4-11 DRILL, 17.5 DIA x 14 DEEP SF Material: S45C (Note 1) Unless otherwise specified, corners should be C0.1 to C0.5. Fixture Block B VM-6083G/VM-60B1G (For 1st-axis) Material: S45C (Note 1) Unless otherwise specified, corners should be C0.1 to C0.5. (Note 2) α...
  • Page 50 Precautions When Changing the Mechanical Ends After a mechanical end change, the software motion limits (PLIMs, NLIMs) must be changed. 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 angle that determines the relationship between the reference position of the robot and the mechanical ends, and is also called a ready...
  • Page 51 Secure fixture block A to the plate with two hexagonal socket-head STEP 2 bolts. (Make a pair of assemblies.) Plate Fixture block A Hex. socket-head bolt M10x25 (Strength class: 12.9) Tightening torque: 71 ±14.2 Nm STEP 3 Turn the assemblies made in Step 2 upside down. Secure two mechanical stops to each of those assemblies with two hexagonal socket-head bolts each for determining the desired motion space.
  • Page 52 Temporarily secure one of the assemblies made in Step 3 to the side of STEP 4 the 1st axis with hexagonal socket-head bolts. Temporarily tighten bolts. In the same way as in Step 4, temporarily secure the other one of the STEP 5 assemblies to the opposite side.
  • Page 53 Link the assemblies together that you have temporarily secured in STEP 6 Steps 4 and 5, using fixture block B and four hexagonal socket-head bolts. After that, firmly tighten the hexagonal socket-head bolts (on fixture blocks A) that have been temporarily tightened in Steps 4 and 5. Fixture block B...
  • Page 54 (2) Software motion limits and Set RANG values Note: If you perform CALSET with the mechanical stop parts (prepared by the customer) being mounted, a mechanical end change requires RANG value change and CALSET. In this case, the position repeatability depends on the mechanical stop parts prepared by the customer.
  • Page 55 Press [F2 Arm] on the top screen. STEP 3 The Current Robot Position window appears. Gently bring the 1st axis of the robot into contact with the newly set STEP 4 positive-direction mechanical end. Check the value in J1 box that appears when the 1st axis is in contact STEP 5 with the mechanical end in Step 4.
  • Page 56 Mechanical End Positions and Set Software Motion Limits Positive-direction mechanical end Negative-direction mechanical end A’ B’ A’ B’ Positive-direction software -33.75 -123.75 motion limit Negative-direction software 33.75 123.75 motion limit Caution: If you set mechanical ends (in addition to the permanent mechanical end), set the software motion limits 5°...
  • Page 57 (3) Changing positive-direction software motion limits (PLIMs) and RANG values The set positive-direction software motion limits (PLIMs) and RANG values must be changed whenever the positive-direction mechanical ends are changed. Change the set positive-direction software motion limits (PLIMs) and RANG values according to steps 1 through 23 described below.
  • Page 58 Press [F1 M Space.]. STEP 5 The Motion Space (Software motion limit) window appears as shown below. STEP 6 Using the jog dial or cursor keys, select the Software motion limit (+J1, deg) field. Press [F5 Change.]. STEP 7 The numeric keypad appears. Using the numeric keys, enter the positive-direction software motion STEP 8 limit value, then press OK.
  • Page 59 Changing Set RANG Values Press [F2 RANG.]. STEP 10 The RANG window appears as shown below. STEP 11 Press [F5 Change.]. The numeric keypad appears. Using the numeric keys, enter RANG values, then press OK. STEP 12 The screen returns to the RANG window.
  • Page 60 Press OK. STEP 13 The screen returns to the Maintenance Functions (Arm) window. Turn the power switch of the robot controller to OFF. STEP 14 Turn the power switch of the robot controller to ON. STEP 15 Press [F2 Arm] on the top screen. STEP 16 CALSET of the 1st Axis Press SHIFT.
  • Page 61 Press [F6 CALSET.] on the window in Step 18. STEP 19 The Set CALSET window appears. Touch the J1 field and confirm that the mark turns green. STEP 20 Press OK. STEP 21 The message window appears asking you whether you want to execute CALSET.
  • Page 62 Press OK. STEP 22 The message window appears informing you that CALSET is completed. Press OK. STEP 23 Caution: After CALSET is completed, move the 1st axis over the full stroke in the manual mode (speed = 10% or less) to confirm that the positive-direction and negative-direction software motion limits function properly.
  • Page 63 (4) Changing set negative-direction software motion limits (NLIMs) The set negative-direction software motion limits (NLIMs) must be changed whenever negative-direction mechanical ends changed. Change negative-direction software motion limits (PLIMs) according to steps 1 through 10 described below. Turn the power switch of the robot controller to ON. STEP 1 STEP 2 Set the mode selector switch of the teach pendant to MANUAL.
  • Page 64 Press [F1 M Space.]. STEP 5 The Motion Space (Software motion limit) window appears. Using the jog dial or cursor keys, select the Software motion limit (-J1, STEP 6 deg) field. Press [F5 Change.]. STEP 7 The numeric keypad appears. Using the numeric keys, enter a negative-direction software motion STEP 8 limit value, then press OK.
  • Page 65 Turn the power switch of the robot controller to OFF. STEP 10 Caution: After changing the software motion limit(s), move the 1st axis over the full stroke in the manual mode (speed = 10% or less) to confirm that the positive- and negative-direction software motion limits function properly.

  • Page 66: 2Nd-Axis And 3Rd-Axis Mechanical Ends Change

    Note: The limit to the workable angle of the robot is defined by the software motion limits. The software motion limits are set inside the mechanical end positions. Workable angle at shipping for VM-G series Model Workable angle for the 2nd-axis Workable angle for the 3rd-axis VM-6083G series +135°, -90°...
  • Page 67 [ 2 ] Reference Drawings of the 2nd-axis and 3rd-axis Mechanical Stops [2.1] Fixing plates for the 2nd-axis and 3rd-axis mechanical stoppers The VM-6083G/VM-60B1G series of robots has fixing plates to mount the 2nd- and 3rd-axis mechanical stoppers at the time of delivery from the factory.
  • Page 68 [2.2] Reference drawings of the 2nd- and 3rd-axis mechanical stoppers The reference drawings of the 2nd- and 3rd-axis mechanical stoppers for changing the mechanical ends are shown in the figure below. 2nd-axis mechanical stopper 3rd-axis mechanical stopper External appearance External appearance Reference drawing Reference drawing Fixing Bolt: Hex.
  • Page 69 [2.3] Examples of changing the mechanical ends by mechanical stoppers Using the mechanical stoppers prepared by the customer, the mechanical ends can be changed as follows. (1) Example of changing the 2nd-axis mechanical ends Explanation of changing the 2nd-axis mechanical ends Fixing Mechanical end positions position of...
  • Page 70 (2) Example of changing the 3rd-axis mechanical ends Explanation of changing the 3rd-axis mechanical ends Fixing Mechanical end positions position of mechanical Positive direction (+) Negative direction (-) stopper <Original mechanical end position> VM-6083G: +167° 46' <Original mechanical end position> VM-60B1G: +170°...
  • Page 71 [ 3 ] Changing the Mechanical Ends The procedure of changing the mechanical ends is as follows by using the mechanical stoppers described in [2.2]. Step 1 Prepare the mechanical stopper and fixing bolts described in [2.2]. (Manufactured by the customer). Step 2 Remove the 2nd-axis and 3rd-axis cover.

  • Page 72: Calset

    CALSET the robot. Just reload the CALSET data from the floppy disks. 2.4.2 Precautions about CALSET for the VM-G Series (For models having no mechanical stop on the 4th-axis) Robots in the VM-6083G/VM-60B1G series launched have no mechanical stop on the 4th-axis.
  • Page 73 Checking of 4th-axis Position before Carrying Out CALSET (1) Manually move the 4th-axis section until the hand control signal connector comes to the upper side. (2) Dismount the cover from the second arm so that the internal wiring can be checked. The cover to dismount for each model is shown below: Hand control signal connector (CN21)

  • Page 74: Preparation For Calset

    5th axis against the mechanical stop since CALSET requires the positional relationship between the 5th and 6th axes. (2) If your model has no mechanical stop on the 4th axis (VM-G series) Press each of the 1st, 2nd, 3rd, and 5th axes manually against the associated mechanical stop and get the actual position.
  • Page 75 Caution (1) When CALSETing, move the axis to be CALSET in the vicinity of the mechanical stop, release the brake, and bring the axis into contact with the mechanical stop. • The VM-G series can release the brake of the specified axis. • On the VM-G series, the 2nd to 6th axes have brakes.

  • Page 76: Mounting The Calset Jig

    2.4.4 Mounting the CALSET Jig To CALSET the 6th axis on all models or the 4th axis on models having no mechanical stop, you need 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 77 (2) Mounting the CALSET jig on the 4th axis (which has no mechanical stop) As a CALSET jig, a special bolt (CALSET bolt) is provided inside the 3rd-axis motor cover in the robot unit. Remove the 3rd-axis motor cover and unscrew the CALSET bolt. STEP 1 NOTE: After CALSETing, be sure to set the bolt back into place and torque it to 1.0 Nm ±20%.
  • Page 78 Set the CALSET bolt to the end of the 3rd axis housing as shown below. STEP 4 Tightening torque of the CALSET bolt: 2.9 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.

  • Page 79: What Is A Calset Position

    3rd axis Front CALSET Positions (VM-G series) Caution for using customized mechanical ends: If the RANG values have not been changed after a mechanical end change, remove the changed mechanical end(s) before performing CALSET. (Refer to the "Precautions When Changing the...

  • Page 80: Calset Procedure

    2.4.6 CALSET Procedure 2.4.6.1 CALSETing a Single Axis CALSETing a specified single axis only is called single-axis CALSET. Perform single-axis CALSET if the motor of an axis is replaced so that the axis must be CALSET, or if some axes cannot be moved to the CALSET positions (mechanical stop positions) at any given time because of interference between the robot unit and its surrounding facilities.
  • Page 81 Press the MOTOR key on the teach pendant to turn OFF the power to the STEP 7 motor. Press [F2 Arm] on the teach pendant. STEP 8 Press the SHIFT key and [F12 Maint.]. STEP 9 Press [F3 Brake.]. STEP 10...
  • Page 82 Touch the axis number to be CALSET to select "Brake released" (green STEP 11 display). Confirm that there is no danger even if the arm falls as a result of released STEP 12 brakes. CAUTION: The brake of the specified axis has been released. Press OK.
  • Page 83 Press OK. STEP 14 The system 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. Press [F6 CALSET.]. STEP 16 The Set CALSET window appears. CALSET.]...
  • Page 84 Press the axis number to be CALSET to select CALSET (green display). STEP 17 Deselect CALSET (black display) for the other axes that are not required to be CALSET. Press OK. STEP 18 The system message appears asking whether you want to carry out CALSET and showing a caution that the robot reference position will change.
  • Page 85 Press the ROBOT STOP button. STEP 20 The robot brake becomes activated. Turn the ROBOT STOP button to cancel robot stop. STEP 21 STEP 22 Press the MOTOR to turn ON the power to the motor. Caution: A "motor lock overload" error may occur just after the power to the motor is turned ON.

  • Page 86: Setting Control Set Of Motion Optimization

    Setting Control Set of Motion Optimization The optimum speed or acceleration will vary depending upon the payload and center of gravity of an end-effector or workpiece that is to be set at the end of the robot flange. Set the payload and center of gravity position of the end-effector or workpiece and the control set of motion optimization according to the payload and robot posture.

  • Page 87: Setting Robot Installation Conditions

    Y-axis positive direction (orientation vector) Z-axis positive direction (approach vector) X-axis positive direction (normal vector) Right Hand Coordinate System Setting Robot Installation Conditions The optimum operating conditions will differ depending on whether the robot is floor-mounted or overhead-mounted. When the robot leaves the factory, it is set for floor-mount. If you overhead-mount your robot, you need to change the installation settings.

  • Page 88: Chapter 3 Maintenance And Inspection

    Chapter 3 Maintenance and Inspection Maintenance & Inspection Intervals and Purposes The table below lists the intervals and purposes of maintenance & inspection. Caution: Before performing maintenance and inspection jobs, read the SAFETY PRECAUTIONS, "4. Precautions while Robot is Running" and "5. Daily and Periodical Inspections." Maintenance &...

  • Page 89: Precautions For Installation And Maintenance Of Robots For Cleanroom Use

    3.1.1 Precautions for installation and maintenance of robots for cleanroom use When carrying out installation, maintenance or inspection jobs of the cleanroom type in your cleanroom, be sure to follow your dust-proof job rules. If you remove the covers from the robot controller or robot unit, even the cleanroom type may scatter worn belt dust, piping grease, dust or dirt accumulating inside.

  • Page 90: Daily Inspections

    Daily Inspections 3.2.1 Check Items Before starting operations, check the items listed in the table below every day. Daily Inspections Table Controller What to do: Check: How to check: Criterion Power (Note 1) Connectors (CN1 to Engage the CN10 on the robot No looseness, parts properly Visually...

  • Page 91: Quarterly Inspections

    Quarterly Inspections 3.3.1 Check Items Check the items listed in the table below every three months. Quarterly Inspections Table Controller Check: How to check: Criterion What to do: Power Robot base Measure the No looseness. Tighten the bolts to mounting bolts tightening the specified Specified torque:...

  • Page 92: Biennial Inspections

    Biennial Inspection Table (VM-6083G/VM-60B1G) Controller Check: How to check: Criterion What to do: Power Timing belts on Visually No lack of teeth or Contact DENSO, the 5th and 6th excessive wear. Industrial Systems axes Product Division.

  • Page 93: Replacing The Encoder Backup Battery

    3.4.2 Replacing the Encoder Backup Battery Replace the encoder backup battery according to the procedure below. <Replacing procedure > Prepare a new set of 3 backup batteries for replacement. STEP 1 Note: Be sure to replace all of three batteries with new ones at one time. Turn the controller power OFF.
  • Page 94 Remove the hexagon socket-head bolts from the battery support plate. STEP 3 <Standard type (VM-6083G, VM-60B1G)> <Dust- & splash-proof type (VM-6083G-W, VM-60B1G-W)>...
  • Page 95 Pull out the battery support plate from the robot unit. STEP 4 Note: If the robot is the dust- & splash-proof type, replace the O-ring to the new ones. <Standard type ( VM-6083G ,VM-60B1G)> < Dust- & splash-proof type (VM-6083G-W, VM-60B1G-W) >...
  • Page 96 Remove the dummy connector cap from the battery board. STEP 5 Connect a new battery (1st one) to the pin from which you have STEP 6 disconnected the dummy connector cap in Step 5. Note: Do not disconnect old backup batteries before connecting a new one to the pin from which the dummy connector cap is removed.
  • Page 97 Disconnect the old backup battery that is left next to the new battery STEP 7 connected in Step 6, and then connect a new battery (2nd one). Disconnect the old backup battery that is left next to the new battery STEP 8 connected in Step 7, and then connect a new battery (3rd one).
  • Page 98 Remove the last old battery and connect the dummy connector cap STEP 9 disconnected in Step 5. Secure the battery support plate to the connector plate. STEP 10 Tightening torque: 1.6 ±0.3 Nm <Standard type (VM-6083D, VM-60B1D)> < Dust- & splash-proof type (VM-6083D-W, VM-60B1D-W) >...

  • Page 99: Replacing The Memory Backup Battery

    3.4.3 Replacing the Memory Backup Battery For the replacing procedures of the memory backup battery, refer to the RC7M CONTROLLER MANUAL, Section 6.5 "Replacing the Memory Backup battery.” 3.4.4 Setting the Next Battery Replacement Date After replacing the memory backup battery, set the next battery replacement date from the teach pendant, according to the following procedure.

  • Page 100: Supplies And Tools For Maintenance

    Supplies and Tools for Maintenance The table lists the supplies and tools for maintenance. Supplies and Tools for Maintenance Name Part No. Remarks 410053-0100 For standard type of controllers (FS-1705W) Air filter set 410053-0110 For global type of controllers (FS-1705) Memory backup battery 410076-0260 For RC7M controller...

  • Page 101: Checking The Odometer And Trip Meter

    Checking the Odometer and Trip Meter You may check the odometer and trip meter which count traversed distance of each axis in the Odometer window of the teach pendant. The access to the Odometer window is [F6 Set]—[F6 Maint.]—[F5 Odometer]. The Odometer window shows the following items: [Odometer] Shows the total distance of each axis traversed after the robot leaves the factory.
  • Page 102 STEP 4 The Maintenance menu appears as shown below. Press [F5 Odometer]. STEP 5 The Odometer window appears as shown below. In the above Odometer window, the J1 through J6 are expressed in rpm. If the Trip meter count exceeds the Interval value, the oil change prompt message will appear.

  • Page 103: Resetting The Trip Meter To Zero

    3.7.2 Resetting the Trip 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 meter has been reset to zero.

  • Page 104: Checking The Controller On-Time And The Robot Running Time And Resetting Their User Counters

    Checking the Controller ON-Time and the Robot Running Time and Resetting Their User Counters You may check the robot controller ON-time and the robot running time in the Total hours window of the teach pendant. The Total hours window shows the following items: [Total operation] Shows the grand total of the robot controller ON-time counted after the controller leaves the factory.
  • Page 105 STEP 2 The Total hours window appears as shown below. [Total operation] Shows the grand total of the robot controller ON-time counted after the controller leaves the factory. [Total running] Shows the grand total of the robot running time counted after the robot leaves the factory.

  • Page 106: Resetting The User Counters Of The Controller On-Time And The Robot Running Time

    3.8.2 Resetting the User Counters of the Controller ON-Time and the Robot Running Time STEP 1 Display the Total hours window as shown below. Access: [F6 Set]—[F6 Maint.]—[F1 Total h] from the top screen To reset the user counter of the controller ON-time (Cumu.operation), for example, press [F4 Cumu.
  • Page 107 The user counter of the controller ON-time has been reset to zero as shown below.

  • Page 108: Resetting Encoders

    Resetting Encoders You need to reset encoders and perform CALSET if: - Error 641* occurs due to run-down 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.

  • Page 109: 3.10 Using The Initialization Floppy Disk

    3.10 Using the Initialization Floppy Disk The initialization floppy disk (*.WAM) holds arm data exclusively prepared for your robot. If CALSET-related data in the robot controller is lost due to exhaustion of the memory backup battery, for instance, use the arm data held in the initialization floppy disk for recovery.
  • Page 110 STEP 2 Configuring communication options for transfer of arm data from WINCAPSIII to the robot controller Choose Tool | Option | Communication tab. Select "Data send setting: CALSET data" and press OK. Note: During ordinary operations, the "Data send setting: CALSET data" should be deselected.
  • Page 111 Please feel free to send your comments regarding any errors or omissions you may have found, or any suggestions you may have for generally improving the manual. In no event will DENSO WAVE INCORPORATED be liable for any direct or indirect damages resulting from the application of the information in this manual.

This manual is also suitable for:

Vm-6083gVm-60b1g

Table of Contents