Intelligent Actuator IX Series Operation Manual

Horizontal articulated robot, wall-mounting type, arm length 300/350

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Horizontal Articulated Robot – IX Series

Wall-Mounting Type, Arm Length 300/350

IX-TNN-3015, IX-TNN-3515

(Wall-Mounting)

IX-UNN-3015, IX-UNN-3515

(Inverse)

Operation Manual Fifth Edition

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Summary of Contents for Intelligent Actuator IX Series

Page 1 Horizontal Articulated Robot – IX Series Wall-Mounting Type, Arm Length 300/350 IX-TNN-3015, IX-TNN-3515 (Wall-Mounting) IX-UNN-3015, IX-UNN-3515 (Inverse) Operation Manual Fifth Edition...
Page 3 Please Read Before Use Thank you for purchasing an IAI product. This operation manual explains the handling methods, structure and maintenance of this product, among others, providing the information you need to know to use the product safely. Before using the product, be sure to read this manual and fully understand the contents explained herein to ensure safe use of the product.
Page 4 CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Page 5: Table Of Contents
Table of Contents Safety Guide ······················································································································1 Caution in Handling ···········································································································8 Names of Robot Parts ································································································9 Name of Each Part ·······················································································································9 Moving Direction ························································································································· 11 Labels ·········································································································································12 Label Positions ···························································································································13 Transportation and Handling ··················································································· 15 Handling of the Carton ················································································································15 Packing Condition of the Robot ··································································································15 Handling of Individual Components ····························································································16 Checking after Unpacking ··········································································································16 Transporting the Robot ···············································································································17...
Page 6 Warranty ·················································································································· 70 Warranty Period ··························································································································70 Scope of Warranty ······················································································································70 Honoring the Warranty ················································································································70 Limited Liability ···························································································································70 Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications ·····71 Other Items Excluded from Warranty ·························································································71 Change History ··············································································································· 72...
Page 7: Safety Guide
Safety Guide “Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it before the operation of this product. Safety Precautions for Our Products The common safety precautions for the use of any of our robots in each operation. Operation Description Description...
Page 8 Operation Description Description Transportation When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers.
Page 9 Operation Description Description Installation (2) Cable Wiring and Start Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool. Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around.
Page 10 Operation Description Description Installation (4) Safety Measures and Start When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. When the product is under operation or in the ready mode, take the safety measures (such as the installation of safety and protection fence) so that nobody can enter the area within the robot’s movable range.
Page 11 Operation Description Description Trial Operation When the work is carried out with 2 or more persons, make it clear who is to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.
Page 12 Operation Description Description Maintenance When the work is carried out with 2 or more persons, make it clear who is and Inspection to be the leader and who to be the follower(s) and communicate well with each other to ensure the safety of the workers. Perform the work out of the safety protection fence, if possible.
Page 13 Alert Indication The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the Instruction Manual for each model. Level Degree of Danger and Damage Symbol This indicates an imminently hazardous situation which, if the Danger Danger product is not handled correctly, will result in death or serious injury.
Page 14: Caution In Handling
Caution in Handling 1. Make sure to attach the vertical articulated robot properly by following this operation manual. Using the product with the vertical articulated robot not being certainly retained or affixed may cause abnormal noise, vibration, malfunction or shorten the product life.
Page 15: Names Of Robot Parts
Names of Robot Parts Name of Each Part (1) Wall-Mounting Specification PG cable ALM (Alarm indicator) (outside robot) U-cable (outside robot) ‡4 user piping (black, red, white; 3 locations) Brake power cable (outside robot) User connector Spacer for user M cable (outside robot) Mechanical BK SW (Brake-release switch) stopper for arm 2...
Page 16 (2) Inverse Specification IX-UNN Arm 1 End cover (arm 1) Mechanical stopper for Axis 1 axis 3 (vertical axis) Arm 2 Reference Mechanical stopper for arm 1 surface Reference surface Axis 2 Cover (arm 2) Base Axis 3 (vertical axis) Panel Ball screw spline shaft...
Page 17: Moving Direction
Moving Direction Arm 2 Axis 3 Axis 1 Axis 2 Arm 1 Axis 4 Wall-mounting specification Axis 4 Arm 1 Axis 3 Axis 2 Axis 1 Arm 2 Inverse specification...
Page 18: Labels
Labels The following labels are attached on the robot and controller. Be sure to observe the instructions and cautions written on the labels to ensure the correct use of the robot/controller. (1) Labels on the Robot Prohibition of entry into Warning on handling of Warning against the operation area...
Page 19: Label Positions
Label Positions Label Positions on the Robot IX-TNN……15 Warning against (Wall-Mounting) electric shock CE-Certified robot (Provided only for CE-certified models) View B Warning on handling of the vertical axis Robot serial number View A (Inverse) Warning on handling Robot serial number of the vertical axis View A CE-Certified robot...
Page 20 Label Positions on the Controller Controller serial number Other than CE-certified specification Specification of connected robot CE-certified specification Caution/warning on controller handling...
Page 21: Transportation And Handling
Transportation and Handling Handling of the Carton Each robot is packed with a controller prior to shipment. When transporting the carton containing the robot and controller, observe the following items and be careful not to drop the carton or apply impact due to forcible contact: x If the carton is heavy, one operator should not attempt to carry it alone.
Page 22: Handling Of Individual Components
Handling of Individual Components The robot and controller are supplied as a set. Your robot cannot be used with the controller supplied with another robot. When handling multiple robots, be careful not to lose their correct parings with the controllers. When unpacking or moving the machine, do not lift the robot directly by the rotational axis or flexible tube.
Page 23: Transporting The Robot
Transporting the Robot When transporting the robot, affix the arms using the supplied arm fixing plate and arm support plate. Additionally, wrap the cables around the upper section and secure them with gummed tape or other means. Use a dolly, forklift or other appropriate equipment for transportation. When transporting the robot, move it slowly by maintaining balance and safeguarding against vibration or impact.
Page 24: Installation Environment And Storage Environment
Installation Environment and Storage Environment Installation Environment Install the robot in an environment that satisfies the following conditions: x Away from direct sunlight x Not subject to radiated heat from a high-capacity energy source such as a heat-treating furnace x Surrounding air temperature: 0qC to 40qC x Humidity: 85% or less (non-condensing) x Not exposed to corrosive or flammable gases x Not subject to impact or vibration...
Page 25: How To Install
How to Install Shown below is how to install SCARA Robot. Installation Posture : Available : Not available Horizontally Oriented Mount Wall-Mount Ceiling-Mount...
Page 26: Structure Of Mounting Wall
Structure of Mounting Wall The movement range of the wall-mounting type covers up to the rear of the base. However, due to its special installation specification (mounting on a wall), the range of movement may be limited significantly depending on the structure of the wall on which the robot is mounted.
Page 27: Installing The Robot
Installing the Robot x The base mounting surface has two Ø8H10 reference holes. Use these holes to prevent the machine from dropping during installation and also as guides for rough positioning. (To determine the precise position of the robot, use the base reference surface as a guide.) x When installing the robot, support it with the base and arm 1 with arms 1 and 2 extended, and affix onto the mounting surface.
Page 28: Connecting The Controller
Connecting the Controller The controller connection cables are attached on the robot (standard cable: 5 m, to air-tube joint: 150 mm). Pay attention to the following items when connecting the controller: Connect to the robot of the serial number specified on the robot designation label provided on the front panel of the controller.
Page 29 24 VDC r 10% Output voltage: Current capacity: 20 to 30 W M cable 24 VDC power supply for brake (provided by Tool, control PG cable user) unit, etc. (provided by user) U cable (cable for user wiring) BK power cable Standard cable length: 5 m 150 mm ‡...
Page 30: Checking After Installation
Checking after Installation Once the robot has been installed, check the following items: x Visually check the robot, controller and cables for dents and other abnormalities. x Confirm that the cables are connected properly and that the connectors are inserted securely. Warning z Failure to perform these checks may result in a malfunctioning robot or a damaged controller or robot.
Page 31: Precautions For Use
Precautions for Use Reference Acceleration/Deceleration Settings Use the robot based on appropriate acceleration/deceleration settings by referring to the following graph: (1) PTP operations (Use the ACCS/DCLS instructions of the SEL language for setting.) Reference acceleration/deceleration settings for PTP operation Reference range of maximum setting Reference range for continuous operation setting...
Page 32 (2) CP operations (Use the ACC/DCL instructions of the SEL language for setting.) Arm length 300 Arm length 300 Reference acceleration/deceleration Reference acceleration/deceleration settings for CP operation settings for CP operation Reference range of maximum setting Reference range of maximum setting Reference range for continuous operation setting Reference range for...
Page 33: Tools
Tools The tool mounting part must have sufficient strength and rigidity, along with adequate fastening power to prevent positional shift. It is recommended that a tool be installed over a split ring, span ring or other appropriate part. A sample configuration of tool installation is given below.
Page 34: Carrying Load
Carrying Load Load capacity Rated load capacity: 1 kg Maximum load capacity: 3 kg Load’s permissible moment of inertia 0.015 kg˜m (both rated and maximum) Load offset (from the center of axis 4 (rotational axis)) 40 mm or less Center of axis 4 (rotational axis) Load’s center of gravity 40 mm or less Caution...
Page 35: User Wiring And Piping
User Wiring and Piping The robot comes with standard cables and tubes that the user can use in a desired wiring/piping configuration. Air tubes Quick joint ‡4 Quick joint ‡4 (‡4: 3 pcs.) (red) (white) U cable M cable BK SW (outside robot) PG cable (alarm indicator)
Page 36 The robot comes with a 15-pin plug for the D-sub connector for user wiring. Solder a user-supplied cable to the D-sub connector (plug), attach the supplied hood, and then connect to the user connector (socket). Use a shielded cable with an outer diameter of ‡ 11 or less. To turn on the indicator, the user must configure a dedicated circuit that uses the controller I/O output signal, etc.
Page 37: Inspection/Maintenance
Inspection/Maintenance Inspection/Maintenance Your horizontal articulated robot must be inspected daily and on a regular basis to ensure safe, efficient operation. Perform the necessary inspections after confirming the maintenance/inspection items required for your IAI robot, as defined in this section. The following items must be adjusted at our factory. Do not disassemble the following components or cut cables at the user site: Disassembly of servo motor Disassembly of reduction gear unit...
Page 38 6.1.1 Daily Inspection Check the following items daily before and after operating the robot. Observe the precautions for work near the robot and for inspection/maintenance/adjustment operations when carrying out each check. Check location Description Correct the deformation or positional shift of the cage. Safety cage Confirm that the interlock mechanism is operating properly.
Page 39: How To Check/Adjust Belt Tension
6.1.3 Yearly Inspection Check the following items on the robot every year. Observe the precautions for work near the robot and for inspection/maintenance/adjustment operations when carrying out each check. Check location Description Ball-screw spline Check the shaft for looseness. (Contact IAI if an abnormality is found.) * Harmonic speed Change the grease.
Page 40 6.2.2 Removing the Cover (1) With arms 1 and 2 extended as illustrated below, remove the four low-head cap screws [2] and six countersunk head screws [1] one by one. (2) Lift the panel and remove the motor connectors (M, PG and BK) from the back of the panel. (Do not cause the wires to be pulled with excessive force when lifting the panel.) (3) Lift the cover upward and remove.
Page 41 6.2.3 Checking the Belt Tension Timing belt for vertical axis Timing belt for rotational axis 6.2.4 Checking the Belt Tension for the Vertical Axis Using a push-pull gauge, push the timing belt for vertical axis with a force of 300 gf and measure the amount of deflection.
Page 42 6.2.5 Checking the Belt Tension for the Rotational Axis Using a push-pull gauge, push the timing belt for vertical axis with a force of 300 to 400 gf and measure the amount of deflection. If the deflection is 0.7 mm, the belt tension is normal. If the deflection is not 0.7 mm, adjust the tension by referring to 6.2.7, “Adjusting the Belt Tension for the Rotational Axis.”...
Page 43 6.2.6 Adjusting the Belt Tension for the Vertical Axis (1) Loosen the four M5 bolts [1] slightly, making sure the fastened points do not become overly loose. (2) Loosen the lock nut [2], and then turn the adjuster bolt [3] to tension the belt. (3) Check the belt tension by referring to “Checking the Belt Tension for the Vertical Axis.”...
Page 44 6.2.7 Adjusting the Belt Tension for the Rotational Axis (1) Loosen the two M4 bolts [1] slightly, making sure the fastened points do not become overly loose. (2) Move the rotational-axis motor [2] to tension the belt. (3) Check the belt tension by referring to 6.2.5, “Checking the Belt Tension for the Rotational Axis.” (4) Tighten the bolts [1] loosened in step 1 (tightening torque: [1] 3.7 N˜m).
Page 45 6.2.8 Installing the Cover (1) Install the cover and connect the motor connectors extending from the rotary joint. (2) Affix the panel using the six countersunk head screws [1] by paying attention not to cause the wires to rest on top of one another. (Place the wires neatly in the upper space without letting them rest on top of one another.
Page 46: Battery Replacement
Battery Replacement 6.3.1 Preparation The following items are required when replacing the batteries: x Hex wrench (2.5 mm) x New dedicated batteries for IX AB-3 (4 pieces) Before replacing the batteries, turn off the power to the controller, control panel and other relevant units. Warning Caution z Performing inspection or maintenance without fully understanding the details of work may result in...
Page 47 6.3.2 Battery Replacement Procedure (1) Remove the six low-head cap screws [1] and remove the rear panel (base). (2) Remove the batteries from the battery holder. (3) Remove the battery connectors and connect new batteries. x After removing the old batteries, quickly connect new batteries (roughly within 1 to 2 minutes x number of batteries).
Page 48: Absolute Reset Procedure
Absolute Reset Procedure 6.4.1 Preparation for Absolute Reset The following jig is required when performing an absolute reset: x Absolute reset adjustment jig (type: JG-2) Connect the cables for the robot, controller and PC, so the robot can be operated from the PC. Before commencing the work, always confirm that the emergency-stop switch is functioning properly.
Page 49 6.4.2 Starting the Absolute Reset Menu (1) Open the absolute reset window from the PC software. (2) The absolute reset window opens. x One of three absolute reset screens—for arm 1, arm 2 and rotational axis + vertical axis—is displayed when a corresponding tab is clicked.
Page 50 6.4.3 Absolute Reset Procedure for Arm 1 or 2 (1) Click the “Encoder Rotation Data Reset1” button. (2) Click the “Reset Controller Error” button.
Page 51 (3) Click the “Servo ON” button. (4) Jog the arm to near the reference position (see reference position drawing in step 7), and click the “Jog end” button. (5) Click the “Servo-OFF” button.
Page 52 (6) Press the emergency-stop switch. (7) Set an adjustment jig (pin) in arm 1 or 2 to fix the arm at the reference position. x Set the jig after confirming that the emergency-stop switch is pressed. x Set the jig after adjusting the arm to the reference position, using the positioning mark label as a guide. x Arm 1 has a cover (not arm 2), which is fixed with setscrews.
Page 53 (8) Click the “OK” button. (9) Click the “Encoder Rotation Data Reset2” button.
Page 54 (10) Remove the adjustment jig. x If you are working on arm 1, install the cover and secure it with the setscrews (not required for arm 2). (11) Release the emergency-stop switch. (12) Click the “OK” button. x An arrow is shown next to the “Home pos. automatic update” button. Do not set this item. (In particular, be sure this item is not set when performing an absolute reset without using a jig).
Page 55 6.4.4 Absolute Reset Procedure for the Rotational Axis + Vertical Axis (1) Click “Encoder Rotation Data Reset1” button. (2) Click the “Reset Controller Error” button.
Page 56 (3) Click the “Servo ON” button. (4) Click the “Temp. Standard posture standby” button. x The vertical axis returns to its home position. Exercise caution so as not to be injured by the axis during movement. (5) Jog the rotational axis to the reference position (see reference position drawing in step 8), and click the “Jog end”...
Page 57 (6) Click the “Servo-OFF” button. (7) Press the emergency-stop switch.
Page 58 (8) Affix the rotational axis at the reference position by setting the plate and pin of the adjustment jig as illustrated below. Set the jig after confirming that the emergency-stop switch is pressed. Confirm that the rotational axis is roughly in the reference position. (Positioning marks for the rotational axis should align.
Page 59 (9) Click the “OK” button. (10) Click the “Encoder Rotation Data Reset2” button.
Page 60 (11) Click the “Home pos. automatic update” button. (12) Remove the adjustment jig. (13) Release the emergency-stop switch. (14) Click the “OK” button.
Page 61 (15) Click the “Servo ON” button. (16) Click the “Standard posture standby” button. x The vertical axis returns to its home position. Exercise caution so as not to be injured by the axis during movement. (17) Click the “Servo-OFF” button.
Page 62 (18) Click the “Encoder Rotation Data Reset3” button. (19) Click the “Home pos. automatic update” button, and then click “X” in the top right-hand corner to exit the absolute reset window. x Once the absolute reset is complete, be sure to write the flash ROM and reset the controller.
Page 63 6.4.5 Writing the Flash ROM (1) Following an absolute reset of the rotational axis and vertical axis, the following screen opens when the absolute reset window is closed. Click the “Yes” button. x Clicking “Yes” writes the information in the flash ROM. x The flash ROM must also be written when home position automatic update has been performed for arm 1 or 2.
Page 64 6.4.6 Resetting the Controller (1) Select “Software Reset” from the Controller menu on the tool bar. (2) Click the “Yes” button. The controller is reset and restarted.
Page 65: Speci¿ Cations
Specifications Specification Table IX-TNN3015 (Arm Length 300, Wall-mounting) IX-UNN3015 (Arm Length 300, Inverse) Item Specifications Type IX-TNN3015-**L-T1/ IX-UNN3015-**L-T1 Degree of freedom Four degrees of freedom Overall arm length Arm 1 length Arm 2 length Drive method Axis 1 (arm 1) AC servo motor + Speed reducer Axis 2 (arm 2) AC servo motor + Speed reducer...
Page 66 c i f Operating Temperature: 0 to 40 C, humidity: 20 to 85%RH or Surrounding air temperature/humidity environment less (non-condensing) i t l Robot weight 20.8 Brake power source for main unit 24V DC ±10% 20W Power supply 230 V 50/60 Hz 5A Allowable supply voltage Controller fluctuation...
Page 67 IX-TNN3515 (Arm Length 350, Wall-mounting) IX-UNN3515 (Arm Length 350, Inverse) Item Specifications Type IX-TNN3515-**L-T1/ IX-UNN3515-**L-T1 Degree of freedom Four degrees of freedom Overall arm length Arm 1 length Arm 2 length Drive method Axis 1 (arm 1) AC servo motor + Speed reducer Axis 2 (arm 2) AC servo motor + Speed reducer Axis 3 (vertical axis)
Page 68 c i f Operating Temperature: 0 to 40 C, humidity: 20 to 85%RH or Surrounding air temperature/humidity environment less (non-condensing) i t l Robot weight 21.9 Brake power source for main unit 24V DC ±10% 20W Power supply 230 V 50/60 Hz 5A Allowable supply voltage Controller fluctuation...
Page 69: External Dimensions
External Dimensions IX-TNN3015 (Arm Length 300) Arm 2 stopper T-slot for peripheral installation <M3, M4> ‡ ‡1 6 counterbore, depth 0.5 (Opposite side of counterbore) ‡ 8H10 Tapped hole for peripheral Reference surface installation (4-M4, depth 12) Same on opposite surface Reference surface ‡16 Arm 1 stopper...
Page 70 IX-TNN3515 (Arm Length 300) Arm 2 stopper T-slot for peripheral installation <M3, M4> 4 - ‡9 ‡ 16 counterbore, depth 0.5 (Opposite side of counterbore) 2 - ‡8H10 Tapped hole for peripheral Reference surface installation (4-M4, depth 12) Same on opposite surface Reference surface Arm 1 stopper ‡16...
Page 71 IX-UNN3015 (Arm Length 300) T-slot for peripheral installation <M3, M4> Arm 2 stopper Arm 1 stopper Reference surface ‡ ‡1 6 counterbore, depth 0.5 Reference (Opposite side of counterbore) surface Tapped hole for peripheral installation (4-M4, depth 12) Same on opposite surface ‡...
Page 72 IX- UNN3515 (Arm Length 350) T-slot for peripheral installation <M3, M4> Arm 2 stopper Arm 1 stopper ‡16 Reference surface ‡ ‡1 Reference 6 counterbore, depth 0.5 surface (Opposite side of counterbore) Tapped hole for peripheral installation (4-M4, depth 12) Same on opposite surface ‡...
Page 73: Robot Operation Area
Robot Operation Area IX-TNN3015 (Arm Length 300) IX-UNN3015 Line of interference with base Pay attention not to contact with the mounting wall Operation/entry prohibited range Operation/entry prohibited range Movement range Mechanical stopper position IX-TNN3515 (Arm Length 350) IX-UNN3515 Line of interference with base Pay attention not to contact with the mounting wall...
Page 74: Wiring Diagram
Wiring Diagram...
Page 75: 230V Circuit Components
230-V Circuit Parts...
Page 76: Warranty
Warranty Warranty Period One of the following periods, whichever is shorter: y 18 months after shipment from IAI y 12 months after delivery to the specified location y 2,500 hours of operation Scope of Warranty Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or problem in question pertains to our product as delivered by us or our authorized dealer.
Page 77: Conditions Of Conformance With Applicable Standards/Regulations, Etc., And Applications
Conditions of Conformance with Applicable Standards/Regulations, Etc., and Applications (1) If our product is combined with another product or any system, device, etc., used by the customer, the customer must first check the applicable standards, regulations and/or rules. The customer is also responsible for confirming that such combination with our product conforms to the applicable standards, etc.
Page 78: Change History
Change History Revision Date Description of Revision April 2011 Third edition A page for CE Marking added March 2012 Fourth edition Introduction, Safety Symbols and Safety Precautions are deleted Pg. 1 to 7 Safety Guide added Pg. 8 Caution in Handling added Pg.
Page 80 Manual No.: ME3625-5A (August 2012) Head Office: 577-1 Obane Shimizu-KU Shizuoka City Shizuoka 424-0103, Japan TEL +81-54-364-5105 FAX +81-54-364-2589 website: www.iai-robot.co.jp/ Technical Support available in USA, Europe and China Head Office: 2690 W. 237th Street, Torrance, CA 90505 TEL (310) 891-6015 FAX (310) 891-0815 Chicago Office: 1261 Hamilton Parkway, Itasca, IL 60143 TEL (630) 467-9900 FAX (630) 467-9912 Atlanta Office: 1220 Kennestone Circle, Suite 108, Marietta, GA 30066...

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