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Okura Yusoki A Series Maintenance Manual

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Robot Manual
UL-MAI-11
Maintenance
Okura Yusoki Co., Ltd.

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Summary of Contents for Okura Yusoki A Series

  • Page 1 Robot Manual UL-MAI-11 Maintenance Okura Yusoki Co., Ltd.
  • Page 2 UL(11) Updating history Version Content Page (Date) 10 (2005.1.31) Newly released Header addition All pages 1-4,5 2-6,12 Expression and figurechange 10 (2005.3.31) 4-2,3 Gap of page by content addition 4-4 - 4-8 Date update Last page Addition of Updating history This page 1-5, 2-7, 2-13 Change in content of periodic maintenance and...
  • Page 3 UL(11) Updating history Version Content Page (Date) This page Addition of Updating history Reconstruction of Page 1-2, 1-7, 1-8, Addition of model A1800 2-2,2-17,2-18 2-3, 2-5, Change Model of Key Controller Parts 11(2009.01.28) 1-5,1-6,1-9, Chage Statemant of “ 1.2.Periodic Maintenance and Inspection“...
  • Page 4 Thank you for purchasing a model from the Okura Robot Palletizer A series. This manual is a guidebook to help you safely and correctly use your A Series Robot Palletizer. It should be useful not only to beginners who are using an Okura Palletizer for the first time, but also to experienced users, who can use this Manual to reconfirm their knowledge.

  • Page 5: Table Of Contents

    UL(11) Table of Contents 1. ROBOT ..................1-1 1.1. Robot Main Unit .................. 1-2 1.2. Periodic Maintenance and Inspection ..........1-5 1.3. Inspection Contents ................1-6 1.4. Reference Materials Concerning Maintenance........1-11 2. CONTROLLER ................2-1 2.1. Controller Internal Component Arrangement Diagram ....... 2-2 2.2.

  • Page 7: Robot

    UL(11) 1.Robot...

  • Page 8: Robot Main Unit

    11(2009.01.28) UL(11) 1.1. Robot Main Unit A1800   Parts list of robot main unit Name Model Servo motor (T-axis) SGMPH04 Servo motor (D-axis) SGMGH55 Servo motor (O-axis) SGMGH55 Servo motor (R-axis) SGMGH55 A type,M6×1.0 Grease nipple Harness Limit Switch D4D-1A32R...
  • Page 9 UL(11) A1600 III Parts list of robot main unit Name Model Servo motor (T-axis) SGMPH04 Servo motor (D-axis) SGMGH55 Servo motor (O-axis) SGMGH55 Servo motor (R-axis) SGMGH55 B type,M6×1.0 Grease nipple Harness Limit Switch D4D-1A32R...
  • Page 10 UL(11) A700II Parts list of robot main unit Name Model Servo motor (T-axis) TS4609 Servo motor (D-axis) TS4836 Servo motor (O-axis) TS4836 Servo motor (R-axis) TS4836 B type,M6×1.0 Grease nipple Harness Limit Switch D4D-1A32R...

  • Page 11: Periodic Maintenance And Inspection

    This section gives the periodic maintenance and inspection schedule, and explains inspection contents. 1.2.1.Inspection Types and Items For an Okura A series Robot Palletizer, there are the following four types of inspection: 3 basic types and overhaul. Inspection type Explanation...

  • Page 12: Inspection Contents

    11(2009.01.28) UL(11) 1.2.2.Inspection Items Periodic maintenance and inspection is divided into 4 levels, including overhaul, and the inspection contents at each level is as given in the following Table. Inspection item Inspection contents Inspection for harness damage and interference etc. 1 Routine inspection Check for abnormal noise and vibration during operation.
  • Page 13 11(2009.01.28) UL(11) Hand level The robot hand may deviate from horizontal if it touches or collides with stacked articles due to a programming mistake etc. This is because the hand incorporates a design feature to absorb the impact of the collision and minimize damage.
  • Page 14 11（2009.01.28） UL(11) A1800 features as follows, 1. Loosen 10-bolts (M8 x 45L) in part (A) until just enough to get T axis back to level., 2. Place a level on the top surface of the hand, and level the hand while checking the level reading.
  • Page 15 11(2009.01.28) UL(11) 1.3.3. Electrical equipment Harnesses (Cables and air hoses) Check that there is no looseness of harness connectors, no cable damage or kinking, no interference with the robot and peripheral equipment, no disconnection of connectors and no looseness of terminal block screws.
  • Page 16 11（2009.01.28） UL(11) 1.3.5.Reduction gear grease replacement Reduction gears are parts which might be replaced at B and C level inspection depending on wear Note B and C inspection are conducted in accordance with an agreement by Okura Service Co., Ltd. 1.3.6.Limit Switch R axis limit switch In the layout for which the revolution angle of R axis exceeds 260 degrees, please...

  • Page 17: Reference Materials Concerning Maintenance

    11（2009.01.28） UL(11) 1.4. Reference Materials Concerning Maintenance 1.4.1.Maintenance Parts The lubricants recommended here are designed to meet the demands of robot operation, compliment scheduled maintenance, and maximize the useful service life of the equipment. Name/Model Qty. Area used Lithium-based soap type grease #2 Hand ,R-Axis bearing 1.4.2.Lubricant List Lubrication point...
  • Page 18 11（2009.01.28） UL(11) 1.4.3.Bolt Fastening Torque Units:N·m (kgf-cm) Type Allen bolt Material S C M 4 3 5 Size 7.0 (71.4) 14.8 (151) 37.0 (378) 74.0 (755) 128 (1306) [106 (1082)] 206 (2100) [172 (1750)] 314 (3200) [363 (3700)] 617 (6300) Power lock A1600III:34.5 (352) A1600III-W:40.2 (410)

  • Page 19: Controller

    UL(11) 2.Controller...

  • Page 20: Controller Internal Component Arrangement Diagram

    11（2009.01.28） UL(11) 2.1. Controller Internal Component Arrangement Diagram 2.1.1.A1600III A1800 The diagram here shows the arrangement of parts inside the robot controller. Please correlate these with the table on the following page. BACK VIEW FRONT VIEW LEFT VIEW RIGHT VIEW...
  • Page 21 11（2009.01.28） UL(11) Key Controller Parts (A1600Ⅲ A1800) Parts No. Name Model NFB0 Circuit breaker NF-SFW 3P 70AT NFB1 Circuit breaker SA53RCUL/30 3P 30AT NFB2 Circuit breaker EA32AC 2P 3AT NFB3 Circuit breaker FAZ-D6/2-RT 2P 6A R･A･V-801BXZ-4 Surge protector Noise filter MBS-1340-33 Noise filter MBW-1203-22 CP1,2...
  • Page 22 UL(11) 2.1.2.A700III The diagram here shows the arrangement of parts inside the robot controller. Please correlate these with the table on the following page. BACK VIEW FRONT VIEW LEFT VIEW RIGHT VIEW...
  • Page 23 11（2009.01.28） UL(11) Key Controller Parts (A700Ⅲ) Parts No. Name Model NFB0 Circuit breaker NF-SFW 3P 50AT NFB1 Circuit breaker SA53RCUL/15 3P 15AT NFB2 Circuit breaker EA32AC 2P 3AT NFB3 Circuit breaker FAZ-D6/2-RT 2P 6A Surge protector R･A･V-801BXZ-4 Noise filter MBS-1320-33 Noise filter MBW-1203-22 CP1,2...

  • Page 24: Periodic Maintenance And Inspection

    11（2009.01.28） UL(11) 2.2. Periodic Maintenance and Inspection 2.2.1.Inspection Types and Items For Okura A series robot palletizer, there are the following four levels of inspection: Level Explanation Routine Routine inspection items Perform every 1000 hours of operation Perform every 10000 hours of operation...
  • Page 25 11（2009.01.28） UL(11) 2.2.2. Inspection Items Inspection contents at each level are as given in the following table. Inspection item Inspection contents Inspection for harness damage and interference etc. Check for controller lamp 1.Routine inspection operation Check for abnormal noise and vibration during operation Air filter cleaning Fan operation check...

  • Page 26: Inspection Contents

    UL(11) 2.3. Inspection Contents 2.3.1.Routine inspection Follow the instructions described in the Daily Service manual. 2.3.2.Controller Function check of emergency stop switches Remove the teaching pendant from the controller. And turn On the main power supply. Turn the motor power ON. Press emergency stop switch on the controller panel.
  • Page 27 UL(11) Function check on the intrusion detection switch If the system has intrusion detection switch, do the function check on the switch. Air filter cleaning Clean the air filters at the side and back of the controller (Blow with air). (For the location of air filters, see controller appearance section in this manual) If filters are clogged, temperature inside the panel will rise abnormally, and trouble will result.
  • Page 28 11（2009.01.28） UL(11) 2.3.3.Battery ● Memory Backup Battery When the error message “ 70. Battery voltage drop” appears, or 2 years after exchanging the battery, replace the battery. Explanation Program data and other data in memory are maintained by the memory backup battery. Important! If no batteries (either of the two) are connected while the main breaker is off (or during power failure), all data in the memory...
  • Page 29 10 (2008.06.13) UL(11) Before replacement When message about battery is displayed, Refer to "About battery voltage low message (Page 2-15)" before replacement. １．Check the battery manufacturer's safety instructions about the battery handling and scrapping. ２． Marking to the old battery is recommended for reliable replacement. (＊）The consumption of new battery capacity The consumption of new battery capacity is occurred when connecting with an empty battery and new battery.
  • Page 30 11（2009.01.28） UL(11) ● Encoder Memory Backup Battery Replacement When the error message “Encoder Battery Voltage Drop” appears, or 2 years after exchanging the battery, replace the battery. Explanation Okura robot palletizers employ absolute encoders. Encoder memory backup batteries are necessary so that absolute encoders can retain position information even during a power failure.
  • Page 31 10 (2008.08.06) UL(11)   Robot internal wiring Dust proof cap Battery     BAT-C1: Battery Connection Cable “BAT-C1” is setting for “replacement procedure A” in the robot base. If "BAT-C1" is connected, select "Replacement Procedure A".If "BAT-C1" is not connected, select "Replacement Procedure B".  ...
  • Page 32 10 (2008.08.06) UL(11) Replacement Procedure B（No Cable “BAT-C1“） Turn ON the main breaker. Remove the cross recessed screw（M6-10L） for mounting the cover, and separate the cover form the base. Remove the battery from the connector, and replace with new battery. Mount the cover.
  • Page 33 10 (2006.11.01) UL(11) ●Touch panel operation when batteries are replaced After exchanging the batteries, the following operation is necessary in "Hour-meter revision" screen of the touch panel. The movement procedure to the screen is as follows. System entry menu -> Hour-meter revision 1) Press the Replace key.
  • Page 34 11（2009.01.28） UL(11) 2.3.4.Parts replacement Standard Replacement Parts Parts name Parts code location When to replace Inside controller, Memory backup ER6K-#17-A Every 2 years duct battery above board) ER6K-#17-A Encoder (A1600III) robot backup Every 2 years base ER6K-#17-4 battery (A1700III) Switching Recommend replace Regulator...
  • Page 35 11（2009.01.28） UL(11) 2.3.5.Fuse replacement Circuit Current Rating Voltage Rating DC BUS A1800 A1600III F1,F2 DC４００V A700III F1,F2 DC４００V RC105 0.1A AC25０V Service Receptacle F4 2.0A AC125V F1, F2 When fusion occurred to F1 or F2 Fuse, replace the fuse. Normal After Fusion F1, F2 Explanation...
  • Page 36 11(2009.01.28) UL(11) When fusion occurred to F3 Fuse, replace the fuse. Explanation Fuse set on RC105 Circuit Board for Over Current Protection. Fuse Type: SS2-0.1AN1(SOC) Fuse Mounting Position Set on RC105 Board. See 2.1.1 A1600III 1800 or See 2.1.2 A700III (2.1 Controller Internal Component Arrangement Diagram.) Replacement Procedure 1.

  • Page 37: Troubleshooting

    UL(11) 3.Troubleshooting Follow the next procedure for troubleshooting. Check if there is an error message on display screen. If there is an error message on display screen, refer to cause and remedy of each error message on screen. For detail information, see “Operation manual, 4-1 error message”. In case no error message appears No error message is issued for low urgent problem (Like burning out of an indicator lamp bulb) of mal-adjustment due to poor stacking form.

  • Page 38: Cases Where There Is An Error Message

    UL(11) 3.1. Cases Where There is an Error Message Please refer to “Operation manual”. 3.2. Cases Where There is No Error Message No error message is issued for low urgency problems. (Like burning out of an indicator lamp bulb) For problems of this type, correctly determine the occurrence situation (Problem) and then select the pertinent item from the table below, and take measures.
  • Page 39 UL(11) Problem Cause Remedy (Occurring Phenomenon) vibrating.(bearing, reducer, motor) Arm movement is slow Check the speed parameter (in step Basically input 10 parameter) Stacking position is When creating program in OXPA, check Input the correct value shifted system parameters (pallet station, hand ) Check the T-axis 0 degree position.

  • Page 41: Maintenance Menu

    UL(11) 4. Maintenance menu There is some useful information on maintenance menu in a touch panel.

  • Page 42: Menu Structure

    UL(11) 4.1. Menu structure Automatic operation mode Teaching mode Basic menu System storage mode Maintenance mode Maintenance menu is displayed by choosing "Maintenance mode" in main menu, and every maintenance menu can be operated. 4.1.1.Move to maintenance menu under operation Basically maintenance menu is selected only when a robot is stopped.

  • Page 43: Ordinary Maintenance Menu

    UL(11) 4.2. Ordinary maintenance menu 4.2.1.Data memory content Internal data memory contents (data held for each program) and external data memory contents (D) can be checked and modified on this screen. 1. Internal data memory data held for each program. D 0 ：stacking layer D 1 ：stacking work D 2 ：grip quantity...
  • Page 44 10(2008.06.13) UL(11) 4.2.3.Acceleration and deceleration time Last executed 12 steps trace data is displayed. (Displayed data are position, acceleration time, and deceleration time.) * System is set to continuous display. 4.2.4.Operation ready condition Every condition that the motor power ON enabling and operation start enabling are fulfilled or not is displayed.
  • Page 45 UL(11) 4.2.5.Stacked counter revision Pallet position counter initialization The counter values of the corresponding program are displayed while selecting the pallet No. to initialize. ● Press [Initialize Pallet Selected] key to initialize the counter value of displayed current program. ● In case [All] key is selected in pallet selection, the counter values of all pallet (1 - 6) are initialized.
  • Page 46 UL(11) 4.2.6.I/O monitor Internal rly (data held for each program), external rly (X/Y/M) can be checked and modified on this screen. Internal rly Rly held for every each program R0 〜 R7 : universal External rly X0 〜 X77 (h) Y0 〜...
  • Page 47 UL(11) 4.2.7.Executed sequence command The executed robot seq uence is displayed to the 40 newest. * Screen display is updated automatically. ● Press the hidden key upper left on the screen to clear the data. 4.2.8.Setting of Timer value For RP, stop position, centering position, and press height can be set up for every station.
  • Page 48 UL(11) 4.2.9.Conveyor information Start, stop, and latch clearance of Built-in PLC can be carried out. ● Press [Change] key to change operation and stop of corresponded PLC. Password is required (For system registration). ● Press [Latch clearance] to carry out latch clearance of Built-in PLC (normally speed + high speed).
  • Page 49 <caution> Unauthorized reproduction of part or all of the content of this manual is forbidden. The content of this manual is subject to future change without prior notice.   Okura Yusoki Co., Ltd.  900 Furuouchi, Noguchi-cho, Kakogawa, Hyogo 675-8675 Japan...

This manual is also suitable for:

A1800A1600iiiA700iiA700iiiA1600iii-w

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