Denso VS-G Series Installation & Maintenance Manual
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Denso VS-G Series Installation & Maintenance Manual

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ROBOT
Vertical articulated
VS-G SERIES
INSTALLATION & MAINTENANCE GUIDE

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Summary of Contents for Denso VS-G Series

  • Page 1 ROBOT Vertical articulated VS-G SERIES INSTALLATION & MAINTENANCE GUIDE...
  • Page 2 Copyright © DENSO WAVE INCORPORATED, 2005-2008 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 Series Model Mini-sized, vertical articulated VS-6556G (6-axis type)

  • 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 1. Introduction This section provides safety precautions to be observed for the 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 type 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 3.3 Control devices The robot controller, teach pendant and mini-pendant should be installed outside the robot's restricted space and in a place where outside the robot's you can observe all of the robot’s movements and operate the restricted space 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 3.9 Setting-up a safety A safety fence should be set up so that no one can easily enter 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 3.11 No robot modification Never modify the robot unit, robot controller, teach pendant or 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 4.5 Release of residual air Before disassembling or replacing pneumatic parts, first release 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 DENSO Robot uses lithium batteries. 8. Battery Recycling 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 ..................39 2.4 CALSET................................59 2.4.1 What Is CALSET?............................59 2.4.2 Precautions about CALSET for the VS-G Series ..................59 2.4.3 Preparation for CALSET ..........................61 2.4.4 Mounting the CALSET Jig........................... 63 2.4.5 What Is a CALSET Position? ........................67 2.4.6 CALSET Procedure............................
  • Page 18 Chapter 3 Maintenance and Inspection ........................77 3.1 Maintenance & Inspection Intervals and Purposes ..................... 77 3.1.1 Precautions for installation and maintenance of robots for cleanroom type..........77 3.2 Daily Inspections..............................79 3.2.1 Check Items..............................79 3.3 Quarterly Inspections ............................80 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" and that the surrounding environment of the location where the robot is to be used meets the specifications as described below.

  • Page 20: Installation Environment Of The Robot Unit

    1.1.4 Installation Environment of the Robot Unit The installation requirements for the robot unit are listed on the next page. Prepare a highly rigid mount by referring to the figure on page 4. Caution: Do not electric-weld the equipment including the robot. A large current may flow through the motor encoder or robot controller resulting in a failure.
  • 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

    Mounting the Robot Unit Caution Before handling or installing the robot unit, be sure to read SAFETY PRECAUTIONS, "Installation Precautions." 1.2.1 Caution in Floor-mount Installation of the Dust- & Splash-proof Type of Robot Units For the dust- & splash-proof type of robot units, the drain-bolt (M3 x 8 mm) is screwed onto the rear side of the robot unit as shown in the figure below.

  • Page 23: Transporting The Robot Unit

    1.2.2 Transporting the Robot Unit (1) Precautions in transporting the robot The VS-G series weighs approximately 36 kg (80 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 24 (2) Transporting the robot unit Procedure Explanatory Illustration Before transportation, 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 25 Procedure Explanatory Illustration As shown at right, place a waste cloth on the second arm and pass the wire through the two eyebolts. Hoisting the Robot Unit Worker A: Remove the four bolts while supporting the robot unit to prevent it from getting overturned.

  • Page 26: Securing The Robot Unit

    "Transporting the Robot Unit." (5) Secure the robot unit to the mount with four bolts and plain washers. ⋅ Bolt: M10 × 30 mm (strength class: 12.9) ⋅ Tightening torque: 70 ±14 Nm Bolt Positions for Securing the Robot Unit (VS-G series)

  • Page 27: Grounding The Robot Unit

    NOTE: Use a dedicated grounding wire and grounding electrode. Do not share them with any other electric power or power equipment such as a welder. Grounding the Robot Unit (VS-G series) Installing the Robot Controller For the installing procedures of the robot controller, refer to the RC7M CONTROLLER MANUAL, Section 6.2 "Installing the Robot Controller."...

  • Page 28: Moving Each Axis With Motor Power Off In Emergency Stop

    Moving Each Axis with Motor Power OFF in Emergency Stop The table below shows which axes have a brake in the VS-G series of robot units. The brake releasing operation on UL-Listed robot units is different from that on other types.

  • Page 29: Releasing Brakes On Ul-Listed Robot Units

    Releasing Brakes on UL-Listed Robot Units The brake release operation on UL-Listed robot units is different from that on other types. The UL-Listed robot units have the axis selector and the brake release switch on the base for brake releasing. NOTE: On robot units except UL-Listed ones, the teach pendant or mini-pendant is used to release brakes.

  • Page 30: 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 31: 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 32: 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 33: Factory Defaults Of Software Motion Limits

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

  • Page 34: Changing Software Motion Limits

    NOTE: When changing software motion limits, always make the new motion space smaller than the motion space defined by initial settings. VS-G Series Example 1: Changing Software Motion Limits [VS-G series] Example 2: Changing Software Motion Limits [VS-G series]...

  • Page 35: Precautions When Changing The Software Motion Limits

    2.2.4 Precautions When Changing the Software Motion Limits (1) The software motion limits are invalid until CAL is completed. (2) Confirm the operating space of the robot in the actual working environment. Set the software motion limits using the correct unit of measurement. If the operating space is too small, the robot may seem to become inoperable.
  • Page 36 Press the SHIFT key and then press [F12 Maint.]. STEP 4 The Maintenance Functions (Arm) window will appear. Press [F1 M Space] on the Maintenance Functions (Arm) window. STEP 5 The Motion Space window will appear as shown below.
  • Page 37 Select the item to be modified, then press [F5 Change]. STEP 6 The numeric keypad will appear as shown below. Enter a desired value using the numeric keys, then press OK. The new value will be set on the line of the item selected in the Motion Space window.

  • Page 38: Changing The Mechanical End

    Changing the Mechanical End This section describes the procedures of changing the mechanical ends of the 1st-axis to 3rd-axis for the VS-G 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 39: 1St-Axis Mechanical End Change

    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 VS-G series so that the stroke of the 1st axis will be ±170°.
  • Page 40 VS-G series (For 1st-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 C0.5. Fixture Block A...
  • Page 41 VS-G series (For 1st-axis) Material: S45C (Note 1) Unless otherwise specified, 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) α and β are arbitrary angles. (In the above sample, mechanical stop positions A and B are 5°...
  • Page 42 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 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 angle.
  • Page 43 Secure fixture block A to the plate with two hexagonal socket-head STEP 2 bolts. (Make a pair of assemblies.) Turn the assemblies made in Step 2 upside down. Secure two STEP 3 mechanical stops to each of those assemblies with two hexagonal socket-head bolts for determining the desired motion space.
  • Page 44 Temporarily secure one of the assemblies made in Step 3 to the side of STEP 4 the 1st axis with hexagonal socket-head bolts. In the same way as in Step 4, temporarily secure the other one of the STEP 5 assemblies to the opposite side.
  • Page 45 (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 46 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. STEP 5 Check the value in J1 box that appears when the 1st axis is in contact with the mechanical end in Step 4.
  • Page 47 Mechanical End Positions and Set Software Motion Limits Positive-direction mechanical end Negative-direction mechanical end A’ B’ A’ B’ Positive-direction software -136 motion limit Negative-direction software motion limit Caution: If you set mechanical ends (in addition to the permanent mechanical end), set the software motion limits 5° inside from the mechanical ends (RANG value).
  • Page 48 (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. Note: If the following case, the RANG values change and the CALSET are necessary after a mechanical end change.
  • Page 49 Press [F1 M Space.]. STEP 5 The Motion Space (Software motion limit) window appears as shown below. 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 the positive-direction software motion STEP 8 limit value, then press OK.
  • Page 50 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 51 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 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.
  • Page 52 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 53 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 54 (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. STEP 1 Turn the power switch of the robot controller to ON. STEP 2 Set the mode selector switch of the teach pendant to MANUAL.
  • Page 55 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 56 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 57: 2Nd-Axis And 3Rd-Axis Mechanical Ends Change

    Note: The limit to the workable angle of the robot is defined by the software motion limit. The software motion limit is set inside the mechanical end positions. Workable angle at shipping for VS-G series Model Workable angle for the 2nd-axis...
  • Page 58 [ 2 ] Locations of Internal Threads Dedicated to 2nd- and 3rd-axis Mechanical End Change Robot units may or may not have internal threads dedicated to mechanical end change, depending upon robot models. Check whether your robot unit has those internal threads, referring to the locations of dedicated internal threads shown below.
  • Page 59 [ 3 ] Mechanical End Change for Robot Units Having Dedicated Internal Threads [3-1] 2nd-axis Mechanical End Change (1) Outline The 2nd-axis mechanical end can be changed by mounting a mechanical stop and a mechanical stop bolt (with washer) to the internal threads dedicated to 2nd-axis mechanical end change as shown below.
  • Page 60 (3) 2nd-axis Mechanical End Positions The 2nd-axis mechanical end positions available are shown in the VS-G Series INSTALLATION & MAINTENANCE GUIDE. The 2nd-axis motion range defined in it applies as is. Specify the software motion limit that corresponds to the mechanical stop...
  • Page 61 (3) 2nd-axis Mechanical End Positions The 2nd-axis mechanical end positions available are shown below. Note: Mounting the 2nd-axis mechanical stop limits the workable angle of the 2nd axis so that the 2nd axis cannot move up to the factory default angle. Observe the following.
  • Page 62 [3-2] 3rd-axis Mechanical End Change (1) Outline The 3rd-axis mechanical end can be changed by mounting a mechanical stop and a mechanical stop bolt (with washer) to the internal threads dedicated to 3rd-axis mechanical end change as shown below. The mechanical stop and the related parts should be prepared by the customer.
  • Page 63 (3) 3rd-axis Mechanical End Positions The 3rd-axis mechanical end positions available are shown in the VS-G Series INSTALLATION & MAINTENANCE GUIDE. The 3rd-axis motion range defined in it applies as is. Specify the software motion limit that corresponds to the mechanical stop...
  • Page 64 (3) 3rd-axis Mechanical End Positions The 3rd-axis mechanical end positions available are shown below. Note: Mounting the 3rd-axis mechanical stop limits the workable angle of the 3rd axis so that the 3rd axis cannot move up to the factory default angle. Observe the following.
  • Page 65 [ 4 ] Mechanical End Change for Robot Unit Having No Dedicated Internal Threads For robot units having no internal threads dedicated to mechanical end change, use undedicated internal threads as shown below. The 2nd-axis mechanical stops for the VS-6556G and VS-6577G are of the same shape, so the description of mechanical end change in [4-1] is common to both models.
  • Page 69 [4-2] 3rd-axis Mechanical End Change (VS6556G) (1) Outline The 3rd-axis mechanical end can be changed by mounting a mechanical stop to the undedicated internal 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 Internal Threads (to be used for 3rd-axis mechanical end change)
  • Page 73 [4-3] 3rd-axis Mechanical End Change (VS6577G) (1) Outline The 3rd-axis mechanical end can be changed by mounting a mechanical stop to the undedicated internal 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 Threads (to be used for 3rd-axis mechanical end change)

  • Page 77: Calset

    Precautions about CALSET for the VS-G Series (For models having no mechanical stop on the 4th-axis) Robots in the VS-G series have no mechanical stop on the 4th-axis. If the 4th-axis CALSET position is wrongly set by one rotation (360°) while CALSET is being carried out, the internal wiring may be caught in the crank and broken.
  • Page 78 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.

  • Page 79: Preparation For Calset

    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 1st to 3rd and 5th axes On the 4th and 6th axes...
  • Page 80 • Brake-equipped version of the VS-G series: Each of the 2nd through 6th axes has a brake. • None-brake version of the VS-G series: Only the 2nd to 4th axes have brakes. • UL-Listed robot units of the VS-G series: All axes have brakes.

  • Page 81: 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 82 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 the 6th axis. Mounting a CALSET Jig (VS-G series)
  • Page 83 STEP 1 NOTE: After CALSETing, be sure to set the bolt back into place and torque it to 1.0 Nm ±20%. Removing the CALSET Bolt (VS-G series) STEP 2 Rotate the second arm to the position specified in the Step 4.
  • Page 84 TIP: The CALSET position of the 4th axis refers to the point where the notch of the second arm comes into contact with the head of the CALSET bolt by turning the second arm. Mounting the CALSET Bolt (VS-G series)

  • Page 85: What Is A Calset Position

    Turning end in the positive direction, which is set by a CALSET jig. (See Section 2.4.4.) 6th axis CALSET Positions (VS-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.

  • Page 86: 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 87 Releasing brakes NOTE: For UL-Listed robot units, release brakes referring to Section 1.6 "Releasing Brakes for UL-Listed Robot Units" and then proceed to Step 15. Press the MOTOR key on the teach pendant to turn OFF the power to the STEP 7 motor.
  • Page 88 Confirm that there is no danger even if the arms fall as a result of released STEP 12 brakes. CAUTION: In the VS-G series, the brake of the specified axis is released. Press OK. STEP 13 The system message appears asking you whether you want to change the...
  • Page 89 Press OK. STEP 14 The system message appears informing that the brake is released and warning against drop of arms. CALSET.] STEP 15 Press the axis to be CALSET against the mechanical stop by hand. Press [F6 CALSET.]. STEP 16 The Set CALSET window appears.
  • Page 90 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 91 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 92 Caution: When removing the flange and cover, dusts inside robot may be splashed. Perform 5-axis or 6-axis CALSET according to the CALSET procedure described on “VS-G SERIES INSTALLATION & MAINTEANACE GUIDE”. Reinstall the flange and cover using three bolts. Bolt fixing torque: 1.57 Nm±20%...

  • Page 93: 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 94: 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 95: Chapter 3 Maintenance And Inspection

    Chapter 3 Maintenance and Inspection Maintenance & Inspection Intervals and Purposes Carry out the maintenance and inspection jobs show in the table below. 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 96 CAUTION (1) When transporting or maintaining 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 section may deteriorate the cleanliness performance.

  • Page 97: Daily Inspections

    Daily Inspections 3.2.1 Check Items Before starting operation every day, check the items listed in the table below. 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 98: Quarterly Inspections

    Normal Operation of Cooling Fan (VS-G) 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...

  • Page 99: Biennial Inspections

    Caution: Without replacing backup batteries, important robot-specific data stored in each memory will be lost. Biennial Inspection Table (VS-G series) Controller Check: How to check: Criterion What to do: Power...

  • Page 100: Replacing The Encoder Backup Battery

    3.4.2 Replacing the Encoder Backup Battery Replace the encoder backup battery according to the procedure below. STEP 1 Prepare a new set of 3 backup batteries for replacement. STEP 2 Turn the controller power OFF. Remove the cover from the robot unit. STEP 3 Cover Cover...
  • Page 101 Remove the dummy connector cap from the battery board. STEP 4 Dummy connector cap Connect a new battery (1st one) to the pin from which you have STEP 5 disconnected the dummy connector cap in Step 4. New backup battery Note: Do not disconnect old backup batteries before connecting a new one to the pin from which the dummy connector cap is removed.
  • Page 102 Disconnect the old backup battery that is right next to the new battery STEP 6 connected in Step 5, and then connect a new battery (2nd one). Old backup battery New backup battery 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).
  • Page 103 Remove the last old battery and connect the dummy connector cap STEP 8 disconnected in Step 4. Dummy connector cap Old backup battery STEP 9 Install the cover to the robot unit. Cover Cover Cover Cross pan-head screw Hex. socket-head bolt Standard type Dust-proof &...

  • Page 104: 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 105: Supplies And Tools For Maintenance

    Supplies and Tools for Maintenance The table below shows the supplies and tools for maintenance. Caution (1) The battery used in this device may present a risk of fire or chemical burn if mistreated. Do not recharge, disassemble, heat above 100°C (212°F), or incinerate. (2) Dispose of used battery promptly.

  • Page 106: 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 107 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 108: 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 109: 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 110: Resetting The User Counters Of The Controller On-Time And The Robot Running Time

    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 111 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: 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 113: 3.10 Using The Initialization Floppy Disk

    3.10 Using the Initialization Floppy Disk The initialization floppy disk (*.arm) stores arm data in WINCAPSII format. You transfer the stored arm data to the robot controller in these two steps: (1) Create a project by using the data stored in the floppy disk. (2) Transfer the trajectory generation file in the project to the robot controller.
  • Page 114 STEP 3 Select arm data. (1) Press the Details button to call up the window below. Browse button [Details window] (2) Press the Browse button in Arm Manager to call up the Open Project window. Select desired file in the floppy disk, then press the Open button. File "Vm-6083d.arm"...
  • Page 115 Transferring the 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. [Arm Manager window]...
  • Page 116 STEP 3 Data transmission (1) From the File menu of Arm Manager window, click Transfer command. 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.
  • Page 117 During data transfer, the following dialog is displayed. [Transfer 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. Turn the controller power off and then on. [Transfer completion message]...
  • Page 119 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.

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Vs-6556gVs-6577g

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