1. Manuals
  2. Brands
  3. Hyundai Manuals
  4. Robotics
  5. HX200L
  6. Maintenance manual

Hyundai HX200L Maintenance Manual

Manipulator
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Hyundai Robot
HX300060301MME2
Manipulator Maintenance Manual
- HX200L , HX200L-2000,
- HX300 , HX300L,
- HX400

Advertisement

Table of Contents
loading

Related Manuals for Hyundai HX200L

Summary of Contents for Hyundai HX200L

  • Page 1 Hyundai Robot HX300060301MME2 Manipulator Maintenance Manual - HX200L , HX200L-2000, - HX300 , HX300L, - HX400...
  • Page 2 It may not be provided to the third party, nor used for any other purposes. HHI reserves the right to modify without prior notification. Printed in Korea - Oct. 2005. 1st Edition Copyright ⓒ 2005 by Hyundai Heavy Industries Co., Ltd.

  • Page 3: Table Of Contents

    Contents 1. Safety 1. Safety.................... 1-1 1.1. Introduction .................... 1-2 1.2. Relevant Safety Regulations ..............1-4 1.3. Safety Training..................1-4 1.4. Safety Related Nameplate..............1-5 1.4.1. Safety Marking..................1-5 1.4.2. Safety Nameplate ................1-6 1.5. Definition of Safety Functions ..............1-7 1.6.
  • Page 4 Contents 2.5. Axis Identification................. 2-11 2.6. Details of Wrist Axis Attachment Surface ..........2-12 2.7. Details of Upper 1 ARM Attachment Surface........2-13 2.8. Application Wiring and Inspection Wiring Diagram ......2-14 2.8.1. Details of Customer Application Connectors........2-15 2.9. Restricting the Working Envelope............2-16 2.9.1.
  • Page 5 5.1.8. A1 Frame - Gear Box................ 5-14 5.1.9. Wrist - Gear Box ................5-15 5.2. Battery Replacement ................5-16 5.2.1. Instructions for Battery Storage............5-18 5.3. Internal Wiring..................5-19 5.3.1. Wiring Connection Diagram .............. 5-20 6. Troubleshooting 6. Trobleshooting................6-1 6.1.
  • Page 6 Fig 2.8 Robot Dimension and Axis [HX300/400/200L/200L-2000/300L] ..2-11 Fig 2.9 Details of Wrist Axis Attachment Surface : [HX300/400/300L] ..2-12 Fig 2.10 Details of Wrist Axis Attachment Surface : [HX200L] ....2-12 FIg 2.11 Details of Upper 1st ARM Attachment Surface......2-13 Fig 2.12 Application Wiring and Inspection Wiring Diagram ......
  • Page 7 Fig 6.2 Encoder Reset Connector.............. 6-18 Fig 8.1 Manipulator Configuration..............8-2 Fig 8.2 Motor and Brake wiring connection No.1 ......... 8-3 Fig 8.3 Motor and Brake wiring connection No.2 ......... 8-4 Fig 8.4 Encoder wiring Connection No.1 ............. 8-5 Fig 8.5 Encoder Wiring Connection No.2............. 8-6 Fig 8.6 Encoder Wiring Connection No.3.............
  • Page 9 1. Safety 1. Safety Safety...

  • Page 10: Introduction

    1. Safety HX200/HX200L-2000/HX300/HX300L/HX400 1.1. Introduction The main purpose of this chapter is to describe the safety precautions for users and operators who repair and manipulate the industrial robot. This manual describes safety precautions for robot manipulator and controller, in comply with the requirement of ANSI/RIA R15.06-1999, Standard for Safety, Industrial Robots, and qualified with safety regulations.
  • Page 11 1. Safety It is applied to the 6-axis industrial robot used by installing on the surface of wall or plane (axes addable). It is also appropriate for controlling operation in the dotted section or consecutive section. Major application is Spot welding Handling Assembly Application such as Sealing...

  • Page 12: Relevant Safety Regulations

    HX200/HX200L-2000/HX300/HX300L/HX400 1.2. Relevant Safety Regulations The robot is designed as per ISO10218.Jan. 1992 , safety standards for industrial robots, and furthermore in comply with ANSI/RIA 15.06-1999 regulations. 1.3. Safety Training All the personnel who intend to teach, operate or inspect the robot must be trained in an approved robotic operation and safety training course before start-up.

  • Page 13: Safety Related Nameplate

    1. Safety 1.4. Safety Related Nameplate 1.4.1. Safety Marking For the purpose of effective safety instructions, the following safety symbols are used in this manual. Table 1-1 Safety marking Symbols Descrptions Indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury to Warning personnel and damage to equipment.

  • Page 14: Safety Nameplate

    HX200/HX200L-2000/HX300/HX300L/HX400 1.4.2. Safety Nameplate Identification plates, warning label and safety symbols are attached to the robot and to the inside and outside of control panel. The designation labels and cable Mark for wire harness between the robot and control panel, and the cables inside/outside of control panel are provided.

  • Page 15: Definition Of Safety Functions

    1. Safety 1.5. Definition of Safety Functions Emergency Stop Function - IEC 204-1,10,7 There is one emergency stop button on the controller and teaching pendant respectively. If necessary, additional emergency buttons should be able to connected to the robot's safety chain circuit. The emergency stop function, which overrides all other robot controls, stops all moving parts by disconnecting power supply, and removes drive power to prevent the use of other dangerous functions controlled by the robot.

  • Page 16: Installation

    HX200/HX200L-2000/HX300/HX300L/HX400 1.6. Installation 1.6.1. Safety Fence Install safety fence against the possible collision between the robot and workers, so that no worker may approach the robot .When operators or other personnel enter the robot's working envelope by accident, it may cause an accident. Install the safety...
  • Page 17 1. Safety ② The safety fence should be a fixed type in principle, using harmless materials that do not have any broken surface or projecting part. ③ Install the safety fence with an entrance gate, and register the safety plug at the gate so that it does not open unless pulling the plug out.

  • Page 18: Placement Of Robot & Peripheral Equipment

    HX200/HX200L-2000/HX300/HX300L/HX400 1.6.2. Placement of Robot & Peripheral Equipment (1) Make sure that the power supply is off before operating, when connecting the primary power of controller or peripheral equipment. There is a possible danger of electric shock because the high voltage such as 220V and 440V is used as its primary power.
  • Page 19 1. Safety (5) Make sure that the robot manipulator and the wiring and piping of controller, interlock panel, and timer should not be placed in the way of operator's working range so that they would not be directly stepped on by FORK and LIFT.

  • Page 20: Installing The Robot

    HX200/HX200L-2000/HX300/HX300L/HX400 1.6.3. Installing the Robot Install the robot as per the planning and layout which has been previously reviewed and studied for its optimized performance and functionality. In case of poor conditions for robot installation, the serious problems can take place, including error...
  • Page 21 1. Safety (3) Install at the ambient temperature ranged 0~45℃. (4) Secure sufficient space for the easier disassembly and maintenance. (5) Install safety fence with a gate, and prohibit any person from entering the robot's working envelope. (6) Remove any obstacles out of the robot’s working envelope. (7) Take a special measure, considering thermodynamics of controller, if the robot is installed near the heating elements or places exposed directly to the sun.

  • Page 22: Space For Robot Installation

    HX200/HX200L-2000/HX300/HX300L/HX400 1.6.4. Space for Robot Installation Install robot after securing sufficient space for maintaining the robot manipulator, Hi4a controller, and other peripheral equipment. Install the robot manipulator and controller, securing space for installation as per the guideline as described in the figure below.

  • Page 23: Safety Operation For Robot Handling

    1. Safety 1.7. Safety Operation for Robot Handling Follow the safety instructions to prevent any accidents. Don't modify nor ignore safety devices or circuits at any time, and be careful of electric shock. All the normal operations in an automatic mode must be performed outside of the safety fence.
  • Page 24 HX200/HX200L-2000/HX300/HX300L/HX400 (9) Operators must pull the safety plug out, and enter the safety fence with the plug. (10) Do not use any devices causing noise in and around the teaching area. (11) Handle the teaching pendant button, while checking the teaching point with your naked eyes, and do not handle it just relying on your sense.

  • Page 25: Table 1-2 State Of Robot Stop

    1. Safety Table 1-2 State of robot stop State of Robot Drive Power Access Pause (Minor failure, Pause switch) Emergency stop (Major failure, Emergency stop switch, Safety gate) Input signal standby of peripheral equipment (START INTERLOCK) Playback Completion Standby Even in the accessible state of robot, be watchful against any possible sudden movement of robot.

  • Page 26: Safety Precautions For Operating Test

    HX200/HX200L-2000/HX300/HX300L/HX400 1.7.2. Safety Precautions for Operating Test In case of operating test, errors in design or teaching and inferiority in manufacturing are possibly seen in the entire system such as teaching program, jig, and sequence. Thus, be more careful and safe in case of operating test. Accidents may occur by these combined causes.

  • Page 27: Safety Precautions For Automatic Operation

    1. Safety 1.7.3. Safety Precautions for Automatic Operation (1) While posting a sign [Do Not Enter During Operation] up the safety fence gate, ask the operators not to enter during operation. If the robot stops, you may enter the safety fence under your full understanding of the situation. (2) Be sure to check if any operators are inside of the safety fence when starting the automatic operation.

  • Page 28: Safety Precautions For Access To Safety Fence

    HX200/HX200L-2000/HX300/HX300L/HX400 1.8. Safety Precautions for Access to Safety Fence Robots are very powerful and heavy even at its low speed. When entering the safety fence, one must observe the relevant safety regulations of its pertinent country. The operators always must be aware of the unexpected movements of robot. Robots are able to move fast shortly after being stopped.

  • Page 29: Safety Precautions For Maintenance And Repair

    1. Safety 1.9. Safety Precautions for Maintenance and Repair 1.9.1. Safety Precautions for Hi4a Controller Maintenance and Repair (1) Maintenance and repair of the robot must be performed by the personnel who was duly trained in the special maintenance training course and has a good knowledge of maintenance.

  • Page 30: Safety Precautions For Robot System & Manipulator Maintenanace

    HX200/HX200L-2000/HX300/HX300L/HX400 1.9.2. Safety Precautions for Robot System & Manipulator Maintenanace (1) Refer to the safety precautions for Hi4a controller maintenance and repair. (2) Perform your maintenance and repair for the robot system and manipulator, following the indicated procedures. (3) Be sure to disconnect the primary power of controller. Post the warning sign [Do not input power] up the primary power to prevent other workers from connecting the power.

  • Page 31: Necessary Actions After Maintenance And Repair

    1. Safety 1.9.3. Necessary Actions after Maintenance and Repair (1) Check if the cables or parts of controller are properly connected. (2) After maintenance is completed, carefully check that no tools are left around or inside of the controller and manipulator. Make sure that the door is firmly closed.

  • Page 32: Safety Functions

    HX200/HX200L-2000/HX300/HX300L/HX400 1.10. Safety Functions 1.10.1. Operating a Safety Circuit Contactor MSHP1 Contactor MSHP2 Drive Unit & & Interlocking Operating Operating mode selector mode selector Man1 Man2 Auto1 Auto2 Limit switch AUTO Mode Safeguard Computer General Safeguard Commands TP EN Enabling device in T/P Emergency stop switch Fig 1.5 Robot’s Safety Circuit...
  • Page 33 1. Safety MOTORS OFF mode indicates that drive power is removed from the robot's motors and the brakes are applied. The status of the switches is displayed on the teach pendant. (Refer to the I/O monitoring screen of "SERVICE" menu, 『Hi4a controller operation manual』.) Safety circuit The emergency stop buttons on the controller panel and on the teaching pendant and...

  • Page 34: Emergency Stop

    HX200/HX200L-2000/HX300/HX300L/HX400 1.10.2. Emergency stop An emergency stop should be activated when people or equipment is located at the dangerous area. The emergency stop buttons are located both on the control panel and on the teaching pendant. All safety control devices such as emergency stop buttons on the control panel must be located outside the working envelope and easily accessible at any time.
  • Page 35 1. Safety (1) Emergency stop for control panel and teach pendant (Basic) The emergency stop switch is on the control panel and teach pendant of the controller. Emergency stop switch Fig 1.6 Emergency Stop 1-27...

  • Page 36: Fig 1.6 Emergency Stop

    HX200/HX200L-2000/HX300/HX300L/HX400 (2) Emergency stop of external system External emergency stop device (button etc.) can be connected to the safety electric circuit in accordance with applied standard for the emergency stop circuit. ▶ Emergency stop connection of the external system SEQUENCE BOARD(BD461)

  • Page 37: Operating Speed

    1. Safety 1.10.3. Operating Speed To teach the robot, the operating mode switch must be in a MANUAL mode. Then the maximum speed of robot is limited to 250mm/s.. 1.10.4. Connecting the Safety Devices External safety devices such as light beams, light curtains, safety plug, and safety mats which can be adapted by the system builder execute interlocking the controller by way of connecting with safety circuit within the controller.

  • Page 38: Restricting The Working Envelope

    HX200/HX200L-2000/HX300/HX300L/HX400 1.10.5. Restricting the working Envelope When the robot is not necessary to reach certain area for specific applications, working envelope of the robot can be limited to secure the sufficient safety working area. This will reduce the damage or loss in case of robot's collision with external safety devices such as safety fence, etc..

  • Page 39: Safety Related To End Effectors

    1. Safety 1.11. Safety Related to End Effectors 1.11.1. Gripper (1) When a gripper is used to grip a workpiece, there should be safety precautions for unexpected dropping of the loaded workpiece. (2) When any end effectors or devices are installed on the robot arm, use the required size and piece of bolt, and securely fasten as per the required torque using torque wrench.

  • Page 40: Tool / Workpiece

    HX200/HX200L-2000/HX300/HX300L/HX400 1.11.2. Tool / Workpiece (1) It must be possible to replace tools such as milling cutters in a safe manner. Make sure that safety devices are working correctly until the cutters stop rotating. (2) Grippers must be designed to keep in gripping workpiece securely even though a power failure or a control failure takes place.

  • Page 41: Liabilities

    1. Safety 1.12. Liabilities The robot system has been built in accordance with the latest technical standards and approved safety rules. Nevertheless, the serious accidents such as death or personal injury still may take place due to the collision between the robot system and peripheral equipment.
  • Page 42 HX200/HX200L-2000/HX300/HX300L/HX400 Users must take the full responsibility for any accident caused by their negligence or non-observance of these instructions. The manufacturer will not take any liabilities and responsibilities for any damages or losses caused by the misuse or malfunction of such equipment which is not included in the contract between manufacturer and user and provided by user, or such equipment which is installed around the robot system arbitrarily by the user.

  • Page 43: Specifications

    2. Specifications 2. Specifications Specifications...

  • Page 44: Robot Machinery Part

    2. Specifications HX200/HX200L-2000/HX300/HX300L/HX400 2.1. Robot Machinery Part HX300 * - * Specification No. Robot TYPE Rated Payload Series Name FIg 2.1 Robot Machinery Part...

  • Page 45: Location Of Robot Identification Plate

    Model Name : HX165 Serial Number Year of Manufacture : Weight(Net) Manufactured by Hyundai Heavy Industries Co., Ltd. 1, CHEONHA-DONG, DONG-KU, ULSAN CITY, 682-792, KOREA Tel : 82-52-230-7901 Home page : www.hhi.co.kr Fax : 82-52-230-7920 Made in Korea Fig 2.2 The location of identification plate...

  • Page 46: Basic Specifications

    HX200/HX200L-2000/HX300/HX300L/HX400 2.3. Basic Specifications Table 2-1 Basic Specifications for Models Item Specification HX200L Model HX300 HX400 HX200L HX300L -2000 Construction Articulated Degree of freedom Drive system AC servo system ±3.142 rad (±180°) Swivel For/ +1.31 ~ -1.31 rad (+75°~ -75°) Backward +0.52 ~ -2.18 rad (+30°~ -125°)
  • Page 47 2. Specifications Item Specification HX200L Model HX300 HX400 HX200L HX300L -2000 1960 N·m 1290 N·m 1668 N·m 1668N·m R2 Rotation 2 (170 kgf·m) (200 kgf·m) (131.5 kgf·m) ((170kgf·m) Wrist 1960 N·m 1290 N·m 1668 N·m 1668N·m Bending Torque (170 kgf·m) (200 kgf·m)

  • Page 48: Robot Dimension And Working Envelope

    HX200/HX200L-2000/HX300/HX300L/HX400 2.4. Robot Dimension and Working Envelope Fig 2.3 Robot Dimension and Working Envelope : [HX300]...

  • Page 49: Fig 2.4 Robot Dimension And Working Envelope : [Hx400]

    2. Specifications Fig 2.4 Robot Dimension and Working Envelope : [HX400]...

  • Page 50: Fig 2.5 Robot Dimension And Working Envelope : [Hx200L]

    HX200/HX200L-2000/HX300/HX300L/HX400 Fig 2.5 Robot Dimension and Working Envelope : [HX200L]...

  • Page 51: Fig 2.6 Robot Dimension And Working Envelope : [Hx200L-2000]

    2. Specifications 2000 1490.8 1186 3250.3 Fig 2.6 Robot Dimension and Working Envelope : [HX200L-2000]...

  • Page 52: Fig 2.7 Robot Dimension And Working Envelope : [Hx300L]

    HX200/HX200L-2000/HX300/HX300L/HX400 Fig 2.7 Robot Dimension and Working Envelope : [HX300L] 2-10...

  • Page 53: Axis Identification

    2. Specifications 2.5. Axis Identification Table 2-2 Axis Motion Axis Name Operation Teaching Pendant Button Arm Swivel LFT(S+) RHT(S-) Arm Forward and Backward BWD(H+) FWD(H-) Arm Upward and Downward UP(V+) DOWN(V-) Wrist Rotation2 Rx+(R2+) Rx-(R2-) Wrist Bend Ry+(B+) Ry-(B-) Wrist Rotation1 Rz+(R1+) Rz-(R1-) DOWN...

  • Page 54: Details Of Wrist Axis Attachment Surface

    P.C.D. 125. Fig 2.9 Details of Wrist Axis Attachment Surface : [HX300/400/300L] Ø10H7 D.P.16 6-M10 TAP D.P.13(PCD 125) 6-M10 TAP D.P.14(PCD 160) 2-Ø10H7 D.P.16 Fig 2.10 Details of Wrist Axis Attachment Surface : [HX200L] 2-12...

  • Page 55: Details Of Upper 1 St Arm Attachment Surface

    2. Specifications 2.7. Details of Upper 1 ARM Attachment Surface There is a Tap in upper 1 ARM to attach peripheral equipment. ▦ Attach peripheral equipment within the range marked as [Attention] Attach peripheral equipment to the upper side of the 1st ARM, or to only one side of upper axis V.

  • Page 56: Application Wiring And Inspection Wiring Diagram

    HX200/HX200L-2000/HX300/HX300L/HX400 2.8. Application Wiring and Inspection Wiring Diagram There are air unit and connector to connect the additional equipment to the robot manipulator. Application connectors are indicated as follows. [Note] Max air pressure of air connection : 7bar (7.1 kgf/cm , 101 psi) Fig 2.12 Application Wiring and Inspection Wiring Diagram...

  • Page 57: Details Of Customer Application Connectors

    2. Specifications 2.8.1. Details of Customer Application Connectors [Encoder Connector] CONNECTOR<1> CONNECTOR<2> CONNECTOR<3> Fig 2.13 Details of Application Connector (Encoder) ① CABLE SPECIFICATION : 0.3sq * 40pcs ② CONNECTOR TYPE(Receptacle) <1> CA3102A32A10PX(CNR10) <2> MS3102A24-28S(CNR10A) <3> MS3102A24-28SX(CNR10B) ③ CONNECTOR TYPE(Plug) <1> CA3106B32A10S(CNR10) <2>...

  • Page 58: Restricting The Working Envelope

    HX200/HX200L-2000/HX300/HX300L/HX400 2.9. Restricting the Working Envelope When installing the robot, take into account that the working envelope can be adjusted freely within the entire working envelope. In case of possible collision between the robot and peripheral equipment, the working envelope must be limited mechanically and by means of software.

  • Page 59: Instructions

    3. Instructions 3. Instructions Instructions...

  • Page 60: Robot Component Name

    3. Instructions HX200/HX200L-2000/HX300/HX300L/HX400 3.1. Robot Component Name The following [Fig 3.1] and [Fig 3.2] show and name each component of the robot. Fig 3.1 Identification of Robot Components Table 3-1 Components name Component Name Component Name BASE BODY WRIST A2 FRAME...

  • Page 61: Location Of Safety Nameplate

    3. Instructions 3.2. Location of Safety Nameplate In order to prevent any accidents, safety marking plates such as [Fig 3.2] is attached to the robot. Do not remove or replace it unneccessarily. HYUNDAI ALVANIA 0769 GREASE 5cc Every 12 months WARNING HANDLING WIRES(4 pcs) Length : 3.5m...

  • Page 62: How To Operate

    HX200/HX200L-2000/HX300/HX300L/HX400 3.3. How to operate 3.3.1. Using Crane 4 Handling Wires Length : 3.5 M 4 Handling Wires Length : 3.5 M Hose for Hose for protection protection 4-M24 4-M24 EYE BOLT EYE BOLT Fig 3.3 How to Transport: Using crane [HX300/400]...

  • Page 63: Fig 3.4 How To Transport: Using Crane [Hx200L/300L]

    3. Instructions Fig 3.4 How to Transport: Using crane [HX200L/300L] The following lifting instructions are valid for a "naked" robot. If additional equipment is put on the robot, the center of gravity may change and make lifting dangerous. Never walk under the robot.

  • Page 64: Using Forklift Truck

    HX200/HX200L-2000/HX300/HX300L/HX400 3.3.2. Using Forklift Truck Loading Capacity minimum 3ton Fig 3.5 How to Transport : Using Forklift Truck [HX300/400/200L/200L-2000/300L] Forklift may be used for transporting the robot manipulator. The bracket for the forklift transporting, as an option, is provided. Follow the instruction for safety.

  • Page 65: How To Install

    3. Instructions 3.4. How to Install NOTE: Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully.. Warning: The installation shall be made by qualified installation personnel and should conform to all national and local codes. When unpacking the robot, check if it has been damaged during transporting or unpacking.

  • Page 66: Installating The Robot Manipulator

    HX200/HX200L-2000/HX300/HX300L/HX400 3.4.2. Installating the Robot Manipulator The manipulator must be firmly fixed with eight M20 bolts. Note that all eight bolts must be used. Bolts : M20*65 of higher(12.9) SOCKET HEAD BOLT Washer : OD = 44mm, ID = 25mm, T = 4mm...

  • Page 67: Dimension Of Installation Surface

    3. Instructions 3.4.3. Dimension of Installation Surface Fix the swivel base for robot's installation. Refer to [Fig 3.6] for the dimension. [HX300/400/200L/300L] [HX130/165,HX130S/165S] [HX300/400] Fig 3.6 Dimension of Robot Installation...

  • Page 68: Accuracy Of Installation Surface

    HX200/HX200L-2000/HX300/HX300L/HX400 3.4.4. Accuracy of Installation Surface The degree of flatness for the four attachment plate surfaces should safisty the specification. Use a shim, if necessary. The rest of the surface must be flat within ±2mm. ■ Cautions (1) The flatness of mounting plate must be within 1.0 mm.

  • Page 69: Allowable Load Of Wrist Axis

    Table 3-2 Allowable load weight Robot Model Allowable Laod Weight HX300/300L Less than 300kg(300kgf) HX400 Less than 400kg(400kgf) Less than 200kg(200kgf) HX200L/200L-2000 Allowable Load Torque Table 3-3 Allowable Load Torque Allowable Load Torque Robot Model R2 Axis B Axis R1 Axis Rotation...

  • Page 70: Table 3-4 Allowable Moment Of Inertia

    HX200/HX200L-2000/HX300/HX300L/HX400 Allowable Moment of Inertia Table 3-4 Allowable Moment of Inertia Allowable Load Torque Robot Model R2 Axis B Axis Rotation R1 Axis Rotation Rotation 150kg·m²(15.3kgf·m·s²) 30 kg·m²(3.1 kgf·m·s²) HX300/300L 120 kg·m²(12.2 kgf·m·s²) 50 kg·m²(5.1 kgf·m·s²) HX400 58.8 kg·m²(6.0 HX200L/200L-2000 117.6 kg·m²(12.0 kgf·m·s²)
  • Page 71 3. Instructions Allowable position of the center of gravity from the center of Axis B (The center of B axis is on the same axis of this robot, and the value of the allowable load torque and allowable moment of inertia of B and R2 axes are the same.

  • Page 72: Fig 3.8 Wrist Axis Torque Mapping:[Hx300/300L]

    HX200/HX200L-2000/HX300/HX300L/HX400 ■ Torque Map Fig 3.8 Wrist Axis Torque Mapping:[HX300/300L] Fig 3.9 Wrist Axis Torque Mapping : [HX400] 3-14...

  • Page 73: Fig 3.10 Wrist Axis Torque Mapping : [Hx200L]

    3. Instructions Fig 3.10 Wrist Axis Torque Mapping : [HX200L] 3-15...

  • Page 74: Recommended Standy Posture

    HX200/HX200L-2000/HX300/HX300L/HX400 3.6. Recommended Standy Posture Selecting a good standby posture can save energy and reduce motor temperature. If the tool is positioned as the figure below, the load on H and V-axes may be minimized. In case that the posture shown below might not be attained due to the limited space and time caused by peripheral equipment or cycle times, then contact our company.

  • Page 75: Inspection

    4. Inspection 4. Inspection Inspection...

  • Page 76: Inspection Item And Period

    4. Inspection HX200/HX200L-2000/HX300/HX300L/HX400 This chapter provides the instructions for regular inspection and overhaul necessary for the prolonged lifetime of robot performance. 4.1. Inspection Item and Period Inspection is positively necessary to continue and maintain the high performance of robot for long-term operation.

  • Page 77: Table 4-2 Inspection Items And Periods

    4. Inspection 4.2. Inspection Item and Period Table 4-2 Inspection Items and Periods Inspection Intervals Inspection Inspection Standards Remark Items method Daily mothns year Robot Manipulator and Axes common Examine dirt and ○ Cleaning dust with naked eyes Examine any cable damages Examine cable fixing bracket tightening...
  • Page 78 HX200/HX200L-2000/HX300/HX300L/HX400 Inspection Intervals Inspection Inspection Standards Remark Items method Daily mothns year Axix S, H, V Check the abnormal Reduction sound ○ gear Check the shaking(vibrating) Axis R2, B, R1 Check the abnormal Reduction ○ sound gear Check the vibrating...

  • Page 79: Inspection Of Main External Bolts

    4. Inspection 4.3. Inspection of Main External Bolts The recommended bolt torque is shown in [Fig 4.1]. Apply the appropriate torque, where required, using the torque wrench and place the paint marking where the check-up is completed Table 4-3 Inspection part for main bolts Inspection parts Inspection parts H &...
  • Page 80 HX200/HX200L-2000/HX300/HX300L/HX400 Fig 4.1 Inspection Part for Main Bolts [HX300/400/300L]...

  • Page 81: Inspection Of Wrist Backlash

    4. Inspection 4.4. Inspection of Wrist Backlash Check a diversion by forcing the end-effector (End Effector : spot gun, hand device, etc.), which is attached to the vertical hem of Wrist, in the direction of back and forth, right and left, and up and down. Fig 4.2 Abnormal Backlash Inspecting Directions...

  • Page 82: Inspection Internal Wiring

    HX200/HX200L-2000/HX300/HX300L/HX400 4.5. Inspection Internal Wiring Flexible cables are used for internal wiring of robot manipulator. However, when an internal cable is broken or crushed, the robot may malfunction. Therefore, regular inspection is required. When operating in the working envelope according to following inspection conditions, inspection must be completed in advance.

  • Page 83: Inspection Part

    4. Inspection 4.5.2. Inspection Part Inspection part Fig 4.3 Cable Inspection Parts : [HX300/400/200L/200L-2000/300L]...

  • Page 85: Maintenance

    5. Maintenance 5. Maintenance Maintenance...

  • Page 86: Grease Replenishment/Replacement

    5. Maintenance HX200/HX200L-2000/HX300/HX300L/HX400 5.1. Grease Replenishment/Replacement Attention If greasing is performed incorrectly, the internal pressure of the grease bath may suddenly increase, possibly causing damage to the seal, which would in turn lead to grease leakage and abnormal operation. When performing greasing, therefore, observe the following cautions.

  • Page 87: S-Axis Reduction Gear

    5. Maintenance 5.1.1. S-Axis Reduction Gear Attention If grease is added without removing the outlet plug, the grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug. ■ Grease Replenishment ① Remove the grease outlet plug. ②...

  • Page 88: H-Axis Reduction Gear

    HX200/HX200L-2000/HX300/HX300L/HX400 5.1.2. H-Axis Reduction Gear Attention If grease is added without removing the outlet plug, it cause damage to the seal of reduction gear and grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug.
  • Page 89 5. Maintenance ■ Grease Replacement ① Make the H-Axis Arm vertical for ground.(H:90°-Floor Type, H:0°-Shelf Type ) ② Remove the grease outlet plug. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 1,600cc ④...

  • Page 90: V-Axis Reduction Gear

    HX200/HX200L-2000/HX300/HX300L/HX400 5.1.3. V-Axis Reduction Gear Attention If grease is added without removing the outlet plug, it cause damage to the seal of reduction gear and grease will go inside the motor and may damage it. It is absolutely necessary to remove the plug.
  • Page 91 5. Maintenance ■ Grease Replacement ① Make the V-Axis Arm horizontall for ground. (V:0°-Floor Type, V:-90°-Shelf Type ) ② Remove the grease outlet plug. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 1,600cc ④...

  • Page 92: R2-Axis Reduction Gear

    HX200/HX200L-2000/HX300/HX300L/HX400 5.1.4. R2-Axis Reduction Gear Attention Do not inject excessive grease. The excessive grease would cause an abnormal operation. ■ Grease Replenishment ① Prepare a grease nipple A-PT1/4. ② Remove the grease outlet plug. ③ Remove the grease inlet plug and install grease nipple A-PT1/4.

  • Page 93: B-Axis Reduction Gear

    5. Maintenance 5.1.5. B-Axis Reduction Gear Attention Do not inject excessive grease. The excessive grease would cause an abnormal operation. ■ Grease Replenishment ① Prepare a grease nipple A-PT1/8 and then Make the R2-Axis 0°degree. ② Remove the grease inlet plug and install grease nipple A-PT1/8. ③...
  • Page 94 HX200/HX200L-2000/HX300/HX300L/HX400 ■ Grease Replacement ① Prepare a grease nipple A-PT1/8 and then Make the R2-Axis 0°degree. ② Remove the grease inlet plug and install grease nipple A-PT1/8. ③ Make the R2-Axis -90°degree and then Remove the grease outlet plug. ④ Inject the grease into the grease inlet using a grease gun.

  • Page 95: R1-Axis Reduction Gear

    5. Maintenance 5.1.6. R1-Axis Reduction Gear Attention Do not inject excessive grease. The excessive grease would cause an abnormal operation. ■ Grease Replenishment ① Remove the grease outlet plug. ② Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 200cc ③...
  • Page 96 HX200/HX200L-2000/HX300/HX300L/HX400 ■ Grease Replacement ① Remove the grease outlet plug. ② Inject the grease into the grease inlet using a grease gun. Grease type : Molywhite RE00 Amount of grease : 435cc ③ The grease replacement is complete when new grease appears in the outlet port.

  • Page 97: Bearing Joint Parts

    5. Maintenance 5.1.7. Bearing Joint Parts ■ Grease Replenishment ① Prepare a grease nipple A-PT1/8. ② As necessary, remove grease inlet plug and install grease nipple A-PT1/8. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Alvania0769 Amount of grease : 3cc ④...

  • Page 98: A1 Frame - Gear Box

    HX200/HX200L-2000/HX300/HX300L/HX400 5.1.8. A1 Frame - Gear Box ■ Grease Replenishment ① Prepare a grease nipple A-PT1/8. ② Remove the grease outlet plug. ③ Remove the grease inlet plug and install grease nipple A-PT1/8. ④ Inject the grease into the grease inlet using a grease gun.

  • Page 99: Wrist - Gear Box

    5. Maintenance 5.1.9. Wrist - Gear Box ■ Grease Replenishment ① Prepare a grease nipple A-PT1/8. ② Remove the grease inlet plug and install grease nipple A-PT1/8. ③ Inject the grease into the grease inlet using a grease gun. Grease type : Alvania0769 Amount of grease : 30cc ④...

  • Page 100: Battery Replacement

    HX200/HX200L-2000/HX300/HX300L/HX400 5.2. Battery Replacement The position data of each axis is preserved by the backup batteries. The batteries need to be replaced every two years. To replace batteries observe the following procedure. ① Keep the power on. Press the Emergency Stop button to prohibit the robot motion.
  • Page 101 5. Maintenance Attention Do not dipose the batteries. Dispose of the battery with industrial waste acoording to the laws and other rules in the country where the controller is installed. Do not recharge the batteries, otherwise batteries may result in exploding or everheating.

  • Page 102: Instructions For Battery Storage

    HX200/HX200L-2000/HX300/HX300L/HX400 5.2.1. Instructions for Battery Storage ① Do not keep the batteries at a high temperature and humidity. Keep it in the well-ventilating place without dew condensation. ② Keep it in a normal temperature, at relatively constant temperature(20±15 ) ℃...

  • Page 103: Internal Wiring

    5. Maintenance 5.3. Internal Wiring Replacement cycle of internal wiring depends on follows. Continuous operation Operating speed Atmosphere/environment Inspect on a regular basis,every three months and check any damage on the cables or cable protect spring. If any damage, replace it. Replace the cable every 16,000 operating hours regardless of working condition.

  • Page 104: Wiring Connection Diagram

    HX200/HX200L-2000/HX300/HX300L/HX400 5.3.1. Wiring Connection Diagram Refer to [Fig 5.1] for part symbols of the internal wiring. JUNCTION BOX CONNECTOR CONNECTOR HX300-J2-MB1-A S-Axis MOTOR Brake HX300 - J2 - MB1 - A REVISION CODE(A, B, C... ) Axis No.(1: S-Axis, 2:H-Axis,3:V-Axis,4: R2-Axis, 5:B-Axis,6:R1-Axis) For COMPONENT "H"(1: CNR10A, 2:CNR20A,3:CNR20B,4:CNR30A)

  • Page 105: Fig 5.2 Wiring Connection Diagram : [Hx300/400/200L/200L-2000/300L]

    5. Maintenance Fig 5.2 Wiring connection diagram : [HX300/400/200L/200L-2000/300L] 5-21...

  • Page 107: Trobleshooting

    6. Trobleshooting 6. Trobleshooting ting Trobleshoo...

  • Page 108: Troubleshooting Procedure

    6. Trobleshooting HX200/HX200L-2000/HX300/HX300L/HX400 6.1. Troubleshooting Procedure If a failure occurs during robot's operation, but it does not stem from the controller, it must be caused by damage on machine parts. The way to troubleshoot as quick and easy as possible should be to diagnose the problem. In addition, it is necessary to determine which parts cause the problem.

  • Page 109: Trouble Symptoms And Possible Causes

    6. Trobleshooting 6.2. Trouble Symptoms and Possible Causes As shown in [table 6-1], there may be many parts as the cause of one phenomenon. Refer to next page to determine which part is malfunction. Table 6-1 Trouble phenomenon and cause Defect parts Reduction Fulcrum...

  • Page 110: Diagnostics And Resolutions For Major Parts Failure

    HX200/HX200L-2000/HX300/HX300L/HX400 6.3. Diagnostics and Resolutions for Major Parts Failure 6.3.1. Fulcrum Bearings Vibration, abnormal sound and overloads are observed when a fulcrum bearing is damaged. When the Nut holding bearings becomes loose, bearing play occurs. It may damage the bearings.

  • Page 111: Reduction Gear

    6. Trobleshooting 6.3.2. Reduction Gear Vibration and abnormal sound will be occurred when a reduction gear is damaged. In this case, it causes overload and abnormal deviation disturbing normal operation. Sometimes overheating may result. The robot may also become completely immovable, or a position offset error may occur.
  • Page 112 HX200/HX200L-2000/HX300/HX300L/HX400 Resolution ① Replace the reduction gear. ② Replace the entire wrist section. (The replacement of entire wrist should be a quick and reliable resolution as it takes time and necessary equipment for reduction gear replacement)

  • Page 113: Brakes

    6. Trobleshooting 6.3.3. Brakes In case of brakes failure, each axis possibly drops with the motors [OFF]. Or, in reverse, brakes possibly operate even with the motors [ON]. The latter causes overload and noise. When intending to operate the entire robot without the motors [ON], operate it with the brake release switch [ON].

  • Page 114: Motor

    HX200/HX200L-2000/HX300/HX300L/HX400 6.3.4. Motor Motor failure causes abnormal operation of robot such as staggering at stop, irregular twitching and noise in operation. Besides, It may cause overheating and abnormal sound. Check the reduction gear and fulcrum bearing as well in order to determine which part causes the abnormality.

  • Page 115: Encoder

    6. Trobleshooting 6.3.5. Encoder Position offset, malfunction, and out of control movement as well as staggering at stop, irregular twitching may occur when the Encoder is in bad condition. This case has nothing to do with such phenomena as mechanical abnormal sound, overheating, and vibration Diagnostics ①...

  • Page 116: Motor Replacement

    HX200/HX200L-2000/HX300/HX300L/HX400 6.4. Motor Replacement Warning: When motor is separated, the ARM will drop due to its built-in brakes inside the motor for holding robot's posture. Take necessary precautions such as fixing A2 FRAME with 2nd ARM by using M20×250 bolts or lifting and hanging the ARM by using crane as shown in the Figure in order to prevent such dropping.
  • Page 117 6. Trobleshooting Fig 6.1 How to prevent dropping of ARM Axis H & V Warning: In this work, there is a part performed with the motor [ON]. Therefore, perform the work in pairs. An observer must always be ready to activate an emergency stop. The other perform the work quickly and carefully.

  • Page 118: Necessary Tools And Parts

    HX200/HX200L-2000/HX300/HX300L/HX400 6.4.1. Necessary Tools and Parts Table 6-3 Necessary Tools Axis Tool Name Part No.(Model) Remark Name M12 Torque wrench S, H, V (Lock type) Use torque wrench Torque wrench and extension on ( prepared by user) the market M8 Torque wrench (Lock type)

  • Page 119: How To Replace Motor

    6. Trobleshooting 6.4.2. How to Replace Motor (1) Put the controller into TEACH mode and select motors [ON]. When the motors [On] state cannot be obtained, check the respective ARM is firmly fixed while supporting it to prevent dropping. And then begin at step No.4. (2) The axis requiring motor replacement takes basic posture.
  • Page 120 HX200/HX200L-2000/HX300/HX300L/HX400 Warning Before encoder correction, check motor connections, with motors [ON], while pressing the Enable switch for 2~3 seconds. (13) Perform the encoder calibration about the axis whose motor is replaced. Refer to the chapter [Encoder Calibration] in the controller operating manual..

  • Page 121: Encoder Zero Setting

    6. Trobleshooting 6.5. Encoder Zero Setting It is necessary to reset the origin when encoder data has been corrupted due to some problems and when the motor is replaced. Level and Block is adopted as the position setting method for each axis. The origin must be set in order of axis 4, 5, and 6 considering axis interference of the wrist due to its structural characteristic.

  • Page 122: Zero Setting

    HX200/HX200L-2000/HX300/HX300L/HX400 6.5.1. Zero Setting ① Put the controller into TEACH mode and select [MOTORS ON]. If you cannot select MOTOR On due to abnormality, set the origin position of the robot by using the brake release switch. ② Move respective axes to the basic posture, then set them by the scale mark.

  • Page 123: Encoder Reset

    6. Trobleshooting 6.5.2. Encoder Reset ① Turn the controller power [ON] for 3 minutes, and then turn it [OFF]. ② Take off the rear cover of the robot. (Check the batteries/encoder backup batteries are well conneceted.) ③ Turn the controller power [ON]. ④...

  • Page 124: Fig 6.2 Encoder Reset Connector

    HX200/HX200L-2000/HX300/HX300L/HX400 Fig 6.2 Encoder Reset Connector 6-18...

  • Page 125: Confirming The Reset

    6. Trobleshooting 6.5.3. Confirming the Reset Warning This operation is used to verify an encoder reset was performed correctly. Note this procedure is different from『Encoder Calibration』which determines encoder data from basic posture of the robot. The number of pulses per revolution of the currently used encoder data is 8192bit irrespective of the robot model.

  • Page 126: Encoder Calibration(Data Input) And Selection

    HX200/HX200L-2000/HX300/HX300L/HX400 6.5.4. Encoder Calibration(Data input) and Selection IT is necessary to compensate encoder data for the basic position of each axis. Refer to 『Encoder calibration』in the Controller Manual for details. Select 『Encoder calibration (Position Rec)』in the mode of Constant. [Encoder Calibration Screen]...

  • Page 127: Recommended Spare Parts

    7. Recommended Spare Parts 7. Recommended Spare Parts Recommended Spare Parts...

  • Page 128: Table 7-1 Spare Parts Listⅰ

    HX200/HX200L-2000/HX300/HX300L/HX400 7. Recommended Spare Parts The recommended spare parts for robot are as follows. Please check robot serial number and manufacturing date when purchasing, and contact our serive office. [Category] A : Regular maintenance parts(what is replaced regularly) B : Essential spare parts (what is of high frequency)
  • Page 129 7. Recommended Spare Parts Manufacturer Per Unit Category Part Name Applicable Model Application Specification Use Rec. Reduction 1EA 1EA Axis R2 gear R13-212052-00 HX300/400/300L Reduction 1EA 1EA Axis B gear R13-213101-00 HX300/300L Reduction 1EA 1EA Axis B gear R13-223101-00 HX400 Reduction 1EA 1EA Axis R1...

  • Page 130: Table 7-2 Spare Parts Listⅱ

    HX200/HX200L-2000/HX300/HX300L/HX400 Table 7-2 Spare Parts ListⅡ Manufacturer Per Unit Caterogy Part Name Applicable Model Application Specification Rec. Teijin seiki HX300/400/200L 16kg S,H,V axis Grease /200L-2000/300L /CAN reduction gear Moly white RE00 R2,B,R1 axis Shell reduction grear HX300/400/200L 16kg Grease Gear and...

  • Page 131: Table 7-3 Spare Parts List Ⅲ

    7. Recommended Spare Parts Table 7-3 Spare Parts List Ⅲ Manufacturer Per Unit Category Part Name Applicable Model Application Specification Rec. Taper Support center Roller 2 EA shaft in A2 HX300/400/200L Bearing R15-211011-00 /200L-2000/300L Joint lower and Taper 4 EA upper Link of Bearing HX300/400/200L...

  • Page 132: Table 7-4 Spare Parts List Ⅳ

    HX200/HX200L-2000/HX300/HX300L/HX400 Table 7-4 Spare Parts List Ⅳ Part Name Manufacturer Per Unit Applicable Category Specificatio Application Model Dwg. No. Use Rec. Case surface of O-ring 1 EA axis B reduction gear R15-213091-00 HX300/400/300L Case surface of O-ring 1 EA axis R1 reduction...

  • Page 133: Table 7-5 Spare Parts List Ⅴ

    7. Recommended Spare Parts Table 7-5 Spare Parts List Ⅴ Part Name Manufacturer Per Unit Category Applicable Model Application Specification Dwg. No. Rec. V axis reduction O-ring gear output HX300/400/200L outlet R15-211021-00 /200L-2000/300L Balance spring O-ring ASS’Y in A2 HX300/400/200L R13-211022-00 /200L-2000/300L A2 part between...

  • Page 135: Internal Wiring Diagram

    8. Internal Wiring Diagram 8. Internal Wiring Diagram Internal Wiring Diagram...

  • Page 136: Manipulator Configuration

    HX200/HX200L-2000/HX300/HX300L/HX400 8. Internal Wiring Diagram Internal wiring is shown in a connection diagram per unit, and thus utilize it to inspect and replace the wiring. 8.1. Manipulator Configuration Fig 8.1 Manipulator Configuration...

  • Page 137: Fig 8.2 Motor And Brake Wiring Connection No.1

    8. Internal Wiring Diagram 8.2. Wiring Diagram Fig 8.2 Motor and Brake wiring connection No.1...

  • Page 138: Fig 8.3 Motor And Brake Wiring Connection No.2

    HX200/HX200L-2000/HX300/HX300L/HX400 Fig 8.3 Motor and Brake wiring connection No.2...

  • Page 139: Fig 8.4 Encoder Wiring Connection No.1

    8. Internal Wiring Diagram Fig 8.4 Encoder wiring Connection No.1...

  • Page 140: Fig 8.5 Encoder Wiring Connection No.2

    HX200/HX200L-2000/HX300/HX300L/HX400 Fig 8.5 Encoder Wiring Connection No.2...

  • Page 141: Fig 8.6 Encoder Wiring Connection No.3

    8. Internal Wiring Diagram Fig 8.6 Encoder Wiring Connection No.3...

  • Page 142: Fig 8.7 Application Wiring Connection No.1

    HX200/HX200L-2000/HX300/HX300L/HX400 Fig 8.7 Application Wiring Connection No.1...

  • Page 143: Fig 8.8 Application Wiring Connection No.2

    8. Internal Wiring Diagram Fig 8.8 Application Wiring Connection No.2...
  • Page 145 9. Decommissioning 9. Decommissioning Decommissioning...

  • Page 146: Table 9-1 Materials Of Each Part

    9. Decommissioning HX200/HX200L-2000/HX300/HX300L/HX400 The robot is made up of several materials as shown in [Table 9-1]. Some of them should be properly arranged and sealed up to eliminate any bad influence on the human body or environment. Table 9-1 Materials of each part...
  • Page 147 Head Office 1, Jeonha-Dong, Dong-Gu, Ulsan, Korea TEL : 82-52-230-7901 Ex 11 / FAX : 82-52-230-7900 Seoul Office 140-2, Gye-Dong, Jongno-Gu, Seoul, Korea TEL : 82-2-746-4711 Ex 5 / FAX : 82-2-746-4720 Suwon Office 537-3, Yeongdeok-Ri, Giheung-Eup, Yongin-Si, Kyenggi-Do, Korea TEL : 82-31-205-4713 / FAX : 82-31-205-3200 Daegu Office 223-5, Bumeo 2-Dong, Susung-Gu, Daegu, Korea...

This manual is also suitable for:

Hx300Hx400Hx200l-2000Hx300l

Table of Contents