Osacom 8700 Controller (Same as Inst &Amp; Maint (1l4000b-9)

June 1997

No.1

L4000B -9

C O N T R O L L E R

~stributor I' you do not understand

We really appreciate you to purchase our products.

There are some mistakes on this manual, and the following list describes the corrections of the

mistakes. We apologize for any inconvenience this clerical error has caused and will do our best to see that such errors do not occur.

TABLE 0.0.0.1 List of Errata (113) Page 1-16 1-17 1-17 1-18 1-21 1-24 1-25 2-8 2-10 2-25 Mistakes

5. The location of breaker in the control unit is shown in Fig.=

____

Braker Handle

2. The Control units contains many ...

of them while is ON may

...

needs to be opened with the

...

...

of a failure, never any of ... 5. Ensure that the ground of each of

is ...

3. Connect connectors

are all the same type connectors but have ...

1. Connect connector CN16 of Teaching box to CN16

2. Connect optical fiber

connector to IC124 of !$jg&

m.

(1) Operation Status (LED

...

4.

...

OC LED of also

...

5. Overvoltage of main power supply

The main power supply is ... .

... deceleration is

w .

ELED502's Status]

ON indicates Voltage Drop (below

[2nd bit's Function When ON]

... SW1 on

m,

causing

...

Section 1.2.1 Fig.1.2.2.1 Inthe WARNING 1.2.3 1.3.1 1.3.2 1.3.3 2.3.2 Table 2.4.2.1 LED GREEN RED

@

@ Table 2.8.2.1 Table 2.8.3.1 Corrections

5. The location of breaker in the control unit is shown in Fig.=

Handle

2. The Control units contains many

...

of them while is ON may

...

needs to be opened with the ...

...

of a failure, never

@&&

any of

...

5. Ensure that the ground of each of

is

...

3. Connect connectors

are all the same type connectors but have ... 1. Connect connector CN16 of

Teaching box to C N l 6

pJ

-.

2. Connect optical fiber connector to lC124 of

A Board

(1) Operation Status (LED

...

4. ... OC LED of also ... 5. Overvoltage of main power supply

The main power supply is ... . ... deceleration is

w .

[LED5023 Status]

ON indicates Voltage Drop (below 3>vJ$J.

[2nd bit's Function When ON]

TABLE 0.0.0.1 List of Errata (213) ry contact (Relay CR22) MRON

m,

DC24V ... and the 5-15 - 5-20 5-42 2nd Item of

-1

5th Item of

-1

Line 3 of (2) Check

connection and connect it properly. LED 100 on Motion control board OFF(0N in the condition.)

...

be also displayed for

&

failures.)

Check

connection and connect it properly. LED 100 on Motion Control board OFF(0N in the condition.)

TABLE 0.0.0.1 List of Errata (313) Correction Switch box Motion control board or Servo Control board Reduce the voltage Reduce the load [Part] Memory lithium [I te mf [Item] [Item] [Remarks]

... voltage range by the

Page 5-49 5-54 5-55 6-2 7-4 7-6 7-1 0 7-18 7-34 7-36 7-38 7-40 A l - 1 A1-3 Section

. 2nd, 3rd, 5th

and 6th items of

p a K

Cause1

5th and 10th items of

/Action/

6th and 8th items of

/Possible

Cause1

4th item of

/Action]

9th item of

-1

Ref No.9 in 6.4 List of In- spection Items Ref No.

a

-2 Ref No.

@

Ref. No. Ref No.

@

in TABLE 1.1.1.1 Line 3 Mistakes Switch Box Motion control board or Servo Control board

fi?ilur

Reduce the voltage Reduce the

a

load [Part] Memory lithium [Item] [Item] [Item] [Remarks]

This instruction manual describes instruction of installation and maintenance f o r Manipulator, ROBOT CONTROL UNIT and its peripheral equipments such as the Teach Pendant, Operation Box and so on.

Read and understand the entire contents of this manual, with special emphasis on the safety devices throughout the manual, before installing, operating o r maintaining the Manipulator, Robot Control Unit, and its peripheral equipments. These equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are f o r use only by

persons trained and experienced in the safe operation of the above mentioned equipments. Do not allow untrained persons t o install, operate, or maintain these equipments.

Contact your distributor i f you do not fully understand these instructions.

Following Instruction manuals are provided f o r these equipments. These instruction manuals shall be referred where necessary in accordance with installation, operation and maintenance.

Model GOlS Model VOlS Model VlOS Model V20S Model V40S Model WOl S OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 INDUSTRIAL ROBOT MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR CONTROLLER TEACH l NG

INTERFACE WITH JIG OPTION

SAFETY WARNING

TRAINING COURSES

The equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are f o r use only by persons trained and experienced in the safe operation of the above mentioned equipments.

Therefore, DAIHEN Corporation provides various training courses such as the SAFETY,

OPERATION, MAINTENANCE and so on.For the details, contact your distributor o r DAIHEN Corporation.

1

LIMITED

WARRANTY

/

DAIHEN Corporation warrants this equipment against defects in parts and workmanship, which have occurred under the appropriate service and maintenance conditions including the periodic inspection described in the manual, f o r shorter period of either 14 months after B/L date of shipment f r o m Japan, o r 2000 hours actual working time f r o m the date of delivery of equipment t o the original user.

This warranty shall be invalidated by any abuse, misuse, misapplication o r improper

installation of the original user. DAIHEN, a t its option, will repair o r replace any equipments during the warranty period, which DAIHEN, upon inspection, shall determine t o be defective in material and/or workmanship.

The foregoing shall constitute the sole remedy any breach of DAIHEN's warranty. DAIHEN MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, EXCEPT AS

PROVIDED HEREIN, INCLUDING WITHOUT LIMITATION THEREOF, WARRANTIES AS TO MARKETABILITY, MERCHANTABILITY, FOR A PARTICULAR PURPOSE OF USE, OR AGAINST INFRINGEMENT OF A N Y PATENT.IN NO EVENT SHALL DAIHEN BE L I A B L E FOR A N Y DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF A N Y NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY DEFECTIVE PRODUCT OR THE USE OF

I

SAFETY

WARNING

/

THE FOLLOWING ROBOTIC SAFETY SHALL BE KEPT STRICTLY.IF NOT, SERIOUS PERSONAL I N J U R Y OR LOSS OF L I F E IS CAUSED.

A.

GENERAL INFORMATION AND SAFETY

19.11

General

Information presented in this section and on various labels, tags, and plates on the unit pertains t o equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed f o r the safe and effective use of this equipment.

A.2 Safety

The installation, operation, maintenance, and troubleshooting of arc welding robots require practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is t o be installed, operated, and maintained only b y qualified persons in accordance with the safety standard which is applied f o r your country such as ANSI/RIA document, "American National Standard F o r Industrial Robots Systems

-

Safety Requirements" and all other safety material found in this Section and throughout the entire manual. I n addition, follow all other codes as applicable t o the application. See A r c Welding Safety Precautions Sections in the welding power supply Owner's Manual f o r safety precautions regarding the operation of arc welding power supplies and welding equipment.

B.

SAFETY

ALERT

SYMBC)L AND SIGNAL

WORDS

The following safety alert symbol and signal words are used throughout this manual t o call attention t o and identify different levels of hazard and special instructions.

This safety alert symbol is used with the signal words WARNING and CAUTION t o call attention t o the safety statements.

WARNING statements identify procedures o r practices which must be followed t o avoid serious personal injury o r loss of life.

CAUTION statements identify procedures o r practices which must be followed t o avoid minor personal injury o r damage t o this equipment.

IMPORTANT statements identify special instructions necessary f o r the most efficient operation o f this equipment.

C.

G E N E R A L S A F E T Y R E Q U I R E M E N T S

Read, understand and comply with the following safety rules a t robot maintenance. 1 KEEP OUT of robot working envelope when main power is on.

2 STAY ALERT when near robot.

3 KEEP INFORMED about status of robot and general working conditions.

4 H A V E A N EMERGENCY STOP BUTTON I N H A N D whenever you are near the robot. 5 UNDERSTAND A N D BE F A M I L I A R WITH ROBOTIC MOVEMENTS.

Robots are unique industrial devices and can present unexpected hazards t o personnel because of their movements.Unpredictable robot motion can occur in even the best designed areas of operation.

6 NEVER STAND with your back toward the robot.

7 NEVER PLACE yourself between robot work stations i f more than one w o r k station is used.

8 THOROUGHLY T R A I N A L L PERSONNEL in robot operation and safety

9 READ robot safety regulation of the country installed robot and PUT INTO EFFECT it.

10 DO NOT REMOVE, DESTROY, OR COVER the WARNING and CAUTION labels on Robot Control Unit and Manipulator.

D.

SAFETY REQU l REMENTS

FOR

l

NSTALLATlON (Figure D-I)

The robot cell requires initial safety conditions that are vital f o r both personnel and equipment.

Make safety provisions p a r t of the basic cell design.lmplement the following during installation:

1 Brightly m a r k floor with distinctive areas identifying Zones 1 and 2 on Figure D-1. 2 Route all cables and hoses so that they will not be damaged and will not clutter the

cell floor space.

3 Protect welding system components f r o m spatter, slag, heat, and the general welding environment by locating equipment t o minimize exposure.

4 I f any welding components must be located in a high-exposure area, provide proper '

guards o r shields t o minimize d i r t and spatter.

5 Consider all necessary jig requirements t o include turntables, sliding trays, etc., that will become a p a r t of the application so that the operator does not have t o enter the w o r k envelope(Zone 1).

6 Install pressure-sensitive floor mats, proximity devices, limit switches, light curtains, etc., t o suit the application and number of work stations so that Emergency Stop will occur i f there is any instruction o r violation of the robot w o r k envelope.

7 lnstall chain fences and light batteries around other cell portions that are not t o be violated.

9 Provide proper Electrostatic Discharge(ESD) protection f o r electronic components in Robot Control Unit and Teach Pendant.

10 M A I N T A I N SAFE INTEGRITY OF CELL A T A L L TIMES.

Zone

3

Zone 1

-

Robot Work Envelope(Area) Zone 2 - Operator Work Area

Zone 3 - Outer Area of Robotic Cell

I M P O R T A N T : See Instruction manual " M A N I P U L A T O R " f o r vertical space requirements o f robot.

E,

OPERATOR SAFETY

REQUIREMENT

Provide proper ventilation f o r welding areas.Supply fresh a i r i f required o r use approved breathing device.

Wear approved head and body protection (this includes, but is not limited to, protective headgear, gloves, and safety shoes).

Install approved filter lens into welding helmet t o protect eyes f r o m arc rays. Press an EMERGENCY STOP button before entering robot area.

Stay alert f o r unexpected robot motion o r movement.

Provide arc guard curtains o r shields around the welding area so that arc rays do not injure operator o r other personnel.

Keep robotic cell clean, neat, and orderly.

Close and secure all access doors and panels on components.

Unless i t is specifically necessary t o enter the working area of robot system, t o avoid accident, no worker including the operator should enter the working area of robot system.

When entering the working area of the robot system f o r teaching the robot, be sure t o check the location and condition of the safety devices such as the EMERGENCY STOP button and DEADMAN SWITCH on the Teach Pendant. And place the EMERGENCY STOP button within the operator's reach f o r the robot should malfunction.

The robot is keeping the safety speed sufficiently during the teaching mode, however, there is a possibility that the operator is caught in the robot by slow speed.To avoid injury, pay attention t o the following:

a) Space requirement f o r the robotic system cell must allow sufficient area t o include installing robot system components, movement around the work envelope by one o r more operators into and out of the cell.

b) The operator should always have some predetermined escape place.

c) Never block the escape place of the operator by the other person o r something. d) I f the operator o r the other worker realize the operator's danger, press the

EMERGENCY STOP button immediately.

e) A t the worst, it means that i f the operator was caught in the robot, take the following procedure.

1) Press the Emergency Stop button immediately.

2) T u r n o f f the primary power switch of the Robot Control Unit.

3) To avoid fall the robot arm, l i f t the 2nd and 3rd axis of robot by wire ropes.

4) T u r n on the primary power switch of the Robot Control Unit again. (DO NOT TURN ON THE SERVO POWER.)

5) To release the brake, connect pin No. 1 and pin No.2 of terminal block on the Interlock Board by jumping wire. For search the location of pins, see

following Figure E-1.

6 ) To escape the person who was caught in the robot, move the robot a r m (the Axis 2).

7) Disconnect the jumping wire, after person escaped.

While operating the system in the automatic operation mode, operator should leave the working area of the robot system.

F.

SAFETY PROCEDURES DURING TEACHING (PROGRAMMING)

Teaching (programming) often requires the operator t o enter the robot w o r k envelope. As a result, always do the following during teaching procedures:

1 Move robot slowly (see instruction manual "TEACHING"

-

Teaching f o r speed entry information).

2 Always assign and position a watchperson, with an Emergency Stop button in hand, t o present and ready during teaching operations.

3 I f jig motion was programmed t o operate f r o m external output control, the jig could energize during teaching.Be careful and alert f o r jig motion.

G.

SAFETY

CHECKS AFTER ENTERING A PROGRAM

1 Have all unauthorized persons leave robotic cell.

2 Check the operation of all warning devices, such as lamps o r horns.

3 Check and be sure that the robot moves normally through its program sequences using the block operation mode(either step or continuous).

4 Check movement of all jigs, and be sure their operation is normal. 5 Check f o r proper operation of EMERGENCY STOP buttons.

.

SAFETY PROCEDURES BEFORE

AUTOMAT96

OPERATION

Before starting automatic robot operation, do the following:

1 Verify the correct program number allocation is assigned t o the appropriate Starting Box(es).

2 Have all unauthorized persons leave the robotic cell area.

3 Close and secure all gates and guard doors, and energizedight fences, barriers, and curtains as applicable f o r the entire specific cell.

4 Place all jigs in their normal, start-work positions.

5 Place the robot in the axes origin o r work origin position as required f o r the operation. 6 Remove all tools f r o m the robot work envelope.

7 Place welding workpiece(s) into proper position(s). 8 Place all equipment switches in the proper positions.

I.

SAFETY PROCEDURES

DURING

AUTOMATIC

OPERATION

During automatic operation, do the following:

1 Turn o f f main power o r press an EMERGENCY STOP button BEFORE entering the robot work envelope.Entry may be required f o r nozzle, tip, wire, o r gas adjustments o r replacements.

DO NOT ENTER WORK ENVELOPE UNLESS A N EMERGENCY STOP BUTTON IS PRESSED !

2 Be alert f o r jig movement initiated by an external control signal during operation. 3 Do not allow unauthorized persons t o operate controls.

4 I f t w o o r more Starting Boxes are used, be sure that the operators fully understand all procedures and cooperate with each other.

5 Press an EMERGENCY STOP button i f any problem occurs.

6 Since this an arc welding operation, protect operator(s) f r o m arc rays, fumes, and hot parts.

7 Be sure that the Automatic mode can only be selected a t a safe location outside the work envelope.

J.

SAFETY PROCEDURES

AT

END OF

WORK

1 Place robot welding torch into an area from which movement t o axes origin o r w o r k origin positions is possible without striking any objects.This may require manual operation with Teach Pendant.

2 Press an EMERGENCY STOP button t o t u r n o f f robot Servo power.

3 Turn off welding power source and all associated equipment. This includes jig power supplies as applicable.

4 Place line disconnect switches f o r Robot Control Unit and welding power supply in the OFF positions.

5 Allow robot and all equipment t o cool. 6 Clean robot, jigs, and entire cell area.

7 Install protective covers over all equipment AFTER proper cooling has occurred t o reduce dust and d i r t entry.

I(.

SAFETY

PROCEDURES DURING

INSPECTION,

MA1NTEMANCEf

ADJUSTMENT, AND SERVICING PROCEDURES

Since these procedures can involve entering the robot work envelope and may require that the main power and servo power are turned on, be sure t o always do the following during any maintenance, adjustment, o r repair procedures:

1 Train all service personnel in the functions, operations, and jig movements of the specific robotic cell.

2 Allow only trained and qualified persons t o service the robot.

3 Always assign and position a watchperson, with an EMERGENCY STOP button in hand, t o be present and ready during any servicing o r adjustment procedures.

4 Determine in advance i f the procedure(s) requires an energized robot.When power is not required, t u r n it off.

5 Determine in advance i f the procedure can be done outside the w o r k envelope.Always w o r k outside the robot w o r k envelope whenever possible.

6 T u r n o f f o r disable all jig(s) and external equipment not required f o r the specific procedure.

7 Provide proper Electrostatic Discharge (ESD) protection f o r circuit boards in Robot Control Unit and Teach Pendant.

8 When the procedure is finished, always correctly, securely, and carefully reconnect any wires and reinstall necessary hardware, plugs, covers, and panels.

L. ARC WELDING SAFETY PROCEDURES

Read and understand, and comply with all safety rules a t beginning of welding power supply manual in addition t o the following before beginning arc welding operations.

1 Prevent electric shock as follows:

1) I N S T A L L A N D GROUND all equipment according t o national, regional, and local codes.

2) DO NOT TOUCH live electrical parts.

3) WEAR D R Y INSULATING GLOVES A N D CLOTHING; be sure gloves have no holes. 4) DISCONNECT INPUT POWER before installing, inspecting, maintaining, servicing

any equipment.

2 Provide proper protection f r o m fumes and gases as follows: 1) KEEP YOUR HEAD out of the fumes.

2) USE FORCED EXHAUST VENTILATION a t the arc. 3) VENTILATE CELL t o prevent build-up of fumes and gases.

4) I f ventilation is inadequate, USE APPROVED BREATHING DEVICE.

5)

READ A N D FOLLOW WARNING LABELS on all containers of welding materials. 6) Before use, READ A N D UNDERSTAND the manufacture's instructions, Material

3 Protect eyes and skin f r o m arc rays ; protect ears f r o m noise as follows:

1) WEAR PROPERLY FITTING WELDING HELMET with proper shade of filter lens (See ANSI 249.1).

2) INSTALL ARC PROTECTIVE CURTAINS between operator and the arc. 3) WEAR PROPER SAFETY GLASSES in work area a t all times.

4) WEAR PROPER EAR PROTECTION,

5) WEAR PROPER BODY PROTECTION t o include woolen clothing, flame-proof apron and gloves, leather leggings, high boots and leather a r m and shoulder gauntlets.

4 Prevent fire and burns cause by hot metal, spatter, slag, and arc sparks as follows: 1 ) KEEP F L A M M A B L E MATERIALS out of the robotic cell.

2) Have operator(s) keep their sleeves, pockets, and collars down and buttoned as applicable. Wear pants without cuffs.

3) WATCH f o r fire.

4) Have a fire extinguisher nearby, and know how t o use it. 5) Allow equipment and work t o cool before handling.

5 Protect compressed gas cylinders f r o m excessive heat, mechanical shocks, and arcs as follows:

1) FASTEN CYLINDERS SECURELY so they cannot fall (use insulated chain o r equivalent).

2) INSULATE CYLINDERS f r o m mounts so that they are never grounded o r p a r t of an electrical circuit.

3) KEEP CYLINDERS A W A Y f r o m the welding arc and other heat sources. 4) LOCATE CYLINDERS A W A Y f r o m personnel and vehicle traffic patterns. 6 Provide impact protection t o all persons in the cell as follows:

1) ALWAYS WEAR PROPER PROTECTIVE HEADGEAR, such as safety helmet, when in the robotic cell.

2) WEAR SHATTER-RESISTANT SAFETY GLASSES a t all times when in the robotic cel I.

7 Since magnetic fields from high currents can affect pacemaker operation, have wearers consult their doctor before going near arc welding operations.

8 TURN OFF robot and welding power source input power before entering w o r k envelope o r working on welding power source.

9 Prevent EMC (Electro-Magnetic Compatibility) noise caused by welding arc as follows:

1) KEEP PRECISION DEVICES A W A Y from the welding arc.

M. WARNING LABELS

DO NOT REMOVE, DESTROY, o r COVER the following labels on the Robot Control Unit and Manipulator.

I f following labels become d i r t y or peeled off, order spare ones immediately.

The locations of these labels are shown in the instruction manual "MANIPULATOR" and "CONTROLLER".

KEEP

OUT

OF

ROBOT

AREA

WHEN

MAIN POWER

IS

ON.

A

WARNING

I

Keep out of robot area

w h e n m a i n power

is

on.

Read Instruction

c t i o n Manual carefully.

@ Always wear dry insulating gloves.

o Insulate yourself f r o m the work and the ground.

O D o not touch live electrical parts.

Keep your head out of the fumes.

@ Ventilate area, or use a breathing device.

@ D o not w e l d near flammable material.

@ W a t c h for fire; keep extinguisher nearby.

9 D o not locate unit over combustible surfaces.

N O I S E c a n d a m a g e h e a r i n g .

Wear welding helmet w i t h correct filter.

a Read and follow thts label and the lnsrrucrlon M a n u a l carefully

r Insulate yourself from the w o r k and the ground.

r D o not touch live electrical pans

*

K e e p a w a y f r o m rnovlng parts.

@ Keep hands, loose clothing, and tools a w a y d u r i n g operation.

*

Keep a w a y f r o m pinch points during operatton.

@ K n o w and understand equrprnent operation before

0 A l w a y s w e a r dry insulating gloves

s Insulate yourself from the work and the ground.

8 D o not touch live electrical parts. Disconnect ~ n p u t power before servicing

@Do not touch live electrical

@Disconnect all power

before installing or servicing.

@Multiple sources of voltage

may exist inside this

@ K e e p out of robot area when main power is on.

@ D o not locate this device in robot work area.

a

WARNING

E L E C T R I C S H O C K c a n kill.

(D D o not touch live electrical parts.

Read this label and Instruction Manual carefully. O Disconnect all power before installing or servicing. @ Only qualified persons are to install. operate. or service this equipment according to all codes and employer's safety practices.

.Wear dry insulating gloves and body protection. @ D o not locate over combustible surfaces. @ Keep all panels, covers, and guards securely in

place.

eB For protection against fire hazard.

Replace only w i t h the same type and rating of fuse.

-

NC8052

1

A

WARNING

s Read manual for connection procedures.

@ Connect grounding conductor and input conductors to proper terminals inside unit-grounding conductor first.

ee Be sure grounding conductor goes t o a proper earth ground and has less than 100 ohms of resistance.

Doublecheck grounding conductor, input voltage, and frequency before applying power.

Contents

Chapter1 Installation

1 1 Configuration ... 1 . 2

1.1.1 CO~/MAG welding ~ ~standard configuration b ~ t 1- 2

1.1 . 2 optional ~ ~... ~ i ~ ~ ~ 1-14 ~ t

1.2 Connecting primary power Supply ... 1 - 16

1

.

2

.

1 Connecting primary power Cable 1-16

1 2.2 opening control u n i t D~~~ ... 1 - 17 1 2 3 Grounding

_{. .}

... 1 - 18 1 3 External Connection ... 1 - 20

1.3.1 Connecting Control Cable 1,2, 3 (BIRBX-1005/BIRBX-8005) 1 - 21

1

.

3.2 connecting

hi^^

B~~ ... _1-24

1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface

(BBWF-0105) 1 -25

1.3.4 connecting operation panel ... 1 - 27 1 .3. 5 Connecting Starting Box ... _1-28

1

.

3.6 Connecting Miscellaneous Option 1-29

1 4 placing printed ~~~~d~ ... 1 - 30

1

.

4. 1 connecting ~~i~ processor ~~~~d 1-30

1 4 2 placing Servo Control Boards 1-31

1 4 3 placing Motion Control Board

_{. .}

1-31

1.4.4 Placing I/() Management Board ... _1-31

Chapter2 Internal Configuration of Control Unit

2 1 ~~i~ P~~~~~~~~ ~~~~d ~ 3 7 0 0 ~ 2- 5

2.1.1 Functions ... 2 - 5

2

.

1

.

2 Operation Status Indicator 2- 5

2.1.3 ~ ~~~i~ P~~~~~~~~ ~ ~~~~d l ... ~ ~ i ~ _{2- 6} ~ 2 2 ti^^ control ~~~~d ~ 3 7 0 0 ~ ... 2- 7

2 2.1 Functions 2 - 7

2.2.2 Operation Status Indicator ... _{2- 7}

2.3 1/0 Management Board L3700M (Standard) o r L4024M (Extension) ... 2- 8

2.3.1 Functions ... 2 - 8 2.3.2 operation status ~ ~ d... i ~ ~ t ~ ~ _{2- 8} 2.4 Servo Control Board (SCON) L4268R (or L4000R) and

position control ~~~~d (PCON) ~ 4 1 9 0 ~ ... 2- 9

2 4 1 Functions of Servo Control Board

_{. .}

2- 9

2.4.2 operation status ~ ~ dof

servo

i ~control ~~~~d ~ t ~... ~ ~ 2- 9

2

_{. .}

4 3 Switch Settings of Servo Control Board ... 2-11

2.4 4 jumper pin settings of

servo

control ~~~~d 2- 14

2.4.5 punctions of position control ~~~~d ... 2 - 16

2.4.7 switch settings of position control ~~~~d ... 2-16

2.5 Servo Driver Unit ~ 4 0 0 0 ~ (G01) ~ 4 0 0 1 Q (V01) ... 2-18 ,

2.5.1 ti^ ti^^^ 2 - 19

2 5 2 operation status ~

. .

~ d... i ~ ~ t ~ ~ ~ 2-19

2 6 Servo power Unit E5499A or E5787A 2-21

2 6 1 Functions

_{. .}

... 2-21

2.6.2 Operation Status Indicators ... _2-21

2 7 ~ ~~~~~d ~ 3 7 0 2 ~ ~ (or ~ 3 7 0 0 ~ ) k ~ l ~ ~ ~ 2 - 22

2 7 1

_{. .}

Functions 2 - 22

2 7 2

_{. .}

Connectors 2 - 22

2 7 3 switch settings

_{. .}

... 2-23

2.8 Interlock Board L3899Y ... 2-24

2.8.1 ~~~~~i~~~ 2 - 24

2.8.2 Operation Status Indicators ... _2-24

2 8 3 Switch Settings

_{. .}

2 - 25

2.8.4 Fuses and Connectors ... 2-27 2.8 5 Connecting Jig Terminals on Interlock Board ... 2-28

2 9 constant voltage power supply ~ - ~ 0 0 2 0 3 ... 2-30

2.9.1 ti^^^ 2 - 30

2

.

9.2 operation status indicators 2-30

...

2.10 Terminal Block Unit E5741A (Option) and Relay Unit E5685A (Option) 2-32

2 10.1 Functions of Terminal Block Unit 2 - 32

2.10.2 Connecting External Equipment (Jig, etc.) via Terminal Block Units ... 2-32

2.10.3 ti^^^ of R ~unit ] ... ~ ~ 2-35

2 . 10.4 connectors and J~~~~~ pins on ~~l~~ unit 2-36

...

2.11 Charging Battery Unit W-LO0471 (Not mounted on IRBCX-532) 2-36

2 11

_{. .}

1 Functions ... 2-36

2.11.2

~~~~ifi~~t.~~~

2-36

2

.

11

.

3 Replacing Charging Battery Unit ... _2-36

2 12 M~~~~~ ~ ~~ 3 3 9 1 ~ t ... t ~ ~ ~ 2-37

2-12 1 ti^^^ ... 2-37

2

.

12

.

2 Specifications 2 - 37

2. 12 3 Replacing Memory Battery 2 - 37

2 13 Switch Box E5760 or E5809 ... 2-38

2.13 1 Functions ... 2-38

213.2 Fuse 2-38

2.14 ~ ~ ~~~~~~f~~~~~ i l iW - L O O ~ ~ O ~ ~ ~ 2 -40

2 14.1 ~~~~~i~~~ ... 2-40

2.15 Step-down Transformer (Option) 2 -40

2 . 15

.

1 T~~~~ of step-down ~~~~~f~~~~~~ 2-40

2. 15.2 connecting step-down ~~~~~f~~~~~ 2-41

2.15 3 voltage switching T~~~ of step-down ~~~~~f~~~~~ ... 2-42

2 16 power Unit E6029A 2 -45

2 16 1

_{. .}

Functions of power Unit 2-45

Chapter3 Peripheral Equipment of Robot Control Unit

3 1

hi^^

B~~ ... 3 - 2 3 1 1 ~~~~~i~~~

_{. .}

... 3 - 2

3.1.2 outside view of

hi^^

B~~ ... _{3 - 2}

3.1.3 Notes on Usage ... _{3 - 3}

3.1.4 Internal Configuration 3 - 3

3 2 Operation Panel . 3- 4

3.2.1 switches and ti^^^ ... _{3 - 4}

3 2 2 Outside View and Internal Circuit

_{. .}

... 3 - 5

3.3 Operation Box (Option) ... _{3 - 6}

3.3.1 switches and $'Unctions ... _{3 - 6}

3 3 2 Outside View and Internal Circuit

_{. .}

... 3 - 6

3 4 Starting Box (Option) ... 3 - 8

3.4.1 Switches and Functions ... _{3 - 8}

3

.

4

.

2 Connecting Starting Box 3- 9

3.4.3 Outside View and Internal Circuit ... _3-10

3 5 ~ ~~ ~ d i ~ ~ t ~ d b ~welding power t

supply

(option) ... 3-11

3.5.1 Notes on Using Robot Dedicated Welding Power Supply ... . 3-11

3.5.2 Outside View and Internal Configuration of Robot Dedicated

welding power supply 3-11

3 6 Welding Interface (Option) 3 - 12

3 6 1 Functions

_.

_.

3- 12

3.6.2 Description of parts 3-13

3 6 3 Printed Board E5624G

_{. .}

3- 13

3 6 4 External Connection

_{. .}

... 3-15

3.6.5 Operation Sequence 3-16

3 6 6 Internal Circuit

. .

... 3-18

3 7 External Storage (Option) ... 3-19

3 7 1 Specifications

_{. .}

3 - 1 g

3 7 2 Configuration of External Storage

_{. .}

3-20

3 7 3 Connecting External Storage

_.

_.

3 - 21

3.7.4 Notes on Handling External Storage ... 3-22

3.7.5 Notes on ~ ~ ~~l~~~~ ~d l ii ~~ ~k ~ 3-22

3 8 printer Interface Unit (option) 3-23

3 8 1 Functions

_{. .}

3 - 23

3 8 2 Configuration

. .

... 3-23

3 8 3 Connecting printer Interface Unit

. .

... 3-25

3

_{. . .}

8 3 1 When External Storage is not used 3-25 3.8.3.2 When External Storage is used ... _3-26

3 8 4 Connecting printer

_{. .}

' ... 3-26

Chapter4 Connecting Robot Peripheral Jig (External Axis)

4.1 T~~~~ of Robot peripheral ~i~~ 4 - 2 4.2 connecting peripheral ~i~ to ~ ~control unit b ~ ... t 4 - 3

4.2.1 system configuration ... 4 - 3

4.2.2 control cables for peripheral ~i~ 4 - 4

...

4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit 4- 5

4.3. 1 GOIS+ 1 Axis System 4 - 7

4 3 2 G01S+2 Axis System

_{. .}

... 4 - 9

4 3 3 ~ 0 1 ~ + 3

_{. .}

~~i~ system ... 4-11

4 3.4 VOlS+ 1 Axis System 4- 13

4 3 5 V01S+2 Axis System

_{. .}

... 4-15

4 3 6 VOlSS.3 Axis System

_{. .}

... 4-17

Chapter5 Troubleshooting

5 1 Symptoms 5 - 15

5 1 1 Nothing Appears on the Teaching Box

. .

... 5-15

5.1 2 The ~ ion the Teaching Box ~ ~ lIs Unsteady ~ ... ~ 5-16 5.1

.

3 initial Diagnosis Is ~~t completed ... 5-17

5 1 4 ?'he

. .

servo

power supply cannot B~ ~~~~~d ON ... 5-20 ...

5.1.5 The Servo Power Supply Is Shut OFF Immediately When Turned ON 5-21

5.1.6 Manual Manipulation Does Not Function ... 5-22

5.2 A Failure Code and A Failure Message Are Displayed ... 5-23

5.2.1 ~h~ ~ iof A ~~ ~... ~ i l l ~ ~ ~ ~ ~ _5-23

5 2 2 Logical Outputs for Failures

_{. .}

5-26

5.2.3 shock

sensor

5-27

5 2

_{. .}

4 Servo power shutoff 5 - 28

5 2 5

. .

software

~ i

,I

~ ~i software ~ i ~ i t ~i k~ ... 5-29

5 2 6 Overrun

_{. .}

... 5 - 31

5.2 7 ~ ~~ ~ ~i l ~~ ~ ~~ ~ 5 ~- 32 i ~ ~ ~ i ~ ~

5 2 8 Data Installation Failures

_{. .}

5 - 34

5.2.9 r \ / ~ ~ ~~ ~ ~i ~ l~ ~ ~ ~ ~ 5-36

5.2.10 setting E~~~~~ ... 5-37

5 2 11 ABSO Data Failure

. .

5 - 39

5 3 When Servo Failure Occurred ... 5-40

5 3 1 How To See the Servo Failure Display

. .

5-40

5.3.2 ~ ~ ~ ~ for b

servo

l ~ ~~ h~... ~ ~i t il ~ ~~ ~ ~ 5-46 ~

Chapter6 Periodic Inspection

6 1 Warranty period 6-1

6 2 periodic Inspection Schedule 6 - 1

6 3 Notes for Performing Periodic Inspection ... 6-2

Chapter7 P a r t s L i s t

7 1 IRBCX-422 Robot Control Unit ... 7 - 2

7 2 IRBCX-462 Robot Control Unit ... 7 - 4

7 3 IRBCX-512 Robot Control Unit ... 7 . 6 7.4 IRBCX-532 Robot Control Unit ... 7 - 8

7 5 IRBCX-541 Robot Control Unit ... 7-10

7 6 IRBCX-551 Robot Control Unit ... 7-12

7.7 BBOpX-3000 Operation panel ... _7-14

7.8 BBOP-3005 Operation Pane] 7-16

7.9 BBTBX-6008 Teaching Box ... _7-18

7.10 BBST-4005 Starting Box ... _7-20

7

.

11 BBWF-0105 welding Interface ... _7-22

7 12 BIRBX-1005 Control Cables 7 - 24

7 12 1 control cable 1 2 3

_.

_.

~ 0 1 ~ 0 1 ~ 0 1 ) ... 7-24

, > 9

7 12 2 cables

_{. .}

/ H~~~

7 - 24

7.12.3 Control Cable5 ( F o r Almega Auto 11% Robot Control Unit) ... 7-25

7 13 BIRBX-8005 Control Cables 7-26

7 13 1 Control Cable 1 2 3

. .

, , (For V10 ~ 2 0 ) 7-26

7.13 2 ~~~l control cable ( F~ 1 0 ~ ~ 2 0 ) ~ 7-27

9

7 14 BIRBX-6005 Control Cables 7-28

7 14 1 Control Cable 1 2 3 (For V40)

_{. .}

... 7-28

9 ,

7 14 2 ~~~l control cable

_{. .}

( F~ 4 0 ) ~ ~... 7-29

7 15 Robot Control Unit for External Axes ... 7-30

7 15 1 IRBCX-422-1 Robot Control Unit

_{. .}

7 - 30

7 15 2 IRBCX-422-2 Robot Control Unit

_{. .}

7-32

7 15 3 IRBCX-422-3 Robot Control Unit

_{. .}

7-34

7 15 4 IRBCX-512-1 Robot Control Unit

_{. .}

7-36

7 15

_{. .}

5 IRBCX-512-2 Robot Control Unit ... 7-38

7 15 6 IRBCX-512-3 Robot Control Unit

_.

_.

... 7-40 Chapter8 Electrical Connection Diagram

8 1 Electrical Diagram of Robot Control Unit IRBCX-422 462 ... 8 - 1

1

8 2 Electrical Diagram of Robot Control Unit IRBCX-512 ... 8 - 7

8 3 Electrical Diagram of Robot Control Unit IRBCX-541 ... 8-13

8.4 Electrical Diagram of Robot Control Unit IRBCX-551 ... 8-19

8.5 Internal Sequence Diagram of Robot Control Unit ... 8-25

8.6 Outside Dimensional Drawing of Robot Control Unit ... 8-33

8.6.1 IRBCX-422 462 512 541 551 ... 8-33

, t ' I

8 6 2 IRBCX-532

_{. .}

... 8-34

APPENDIX I-WELDING EQUIPMENTS

1.1 connecting ~ ~~ ~b d ~iWelding ~ t~ tpower ~ dSupply A l - 1

1

.

1.1 ~ ~connecting cable t ~ ~ ~ ~ l A l - 1

1 1.2 Connecting Cables A1 - 2

1.2 Connecting Welding Interface a n d Welding Power Supply A l - 3

1 . 2. 1 External Connecting Cable ... _{A l - 3}

1.2.2 Connecting Method of Cables A l - 4

1 3 TIG Interface E5743 ... A l - 6

1

.

3. 1 A~~~~~~~~~ of TIG interface A l - 6

1

.

3.2 setting J~~~~~ wires of TIG ~ ~ t ~ ~ f A l - 7 ~ ~ ~

1 . 3.3 Connecting TIG Interface A l - 7

1 4 Filler Wire Feed Control Unit EST56 A l - 8

1.4.1 Appearance of Filler Wire Feed Control Unit ... _{A l - 8}

1 4

_{. .}

2 Connecting Filler Wire Feed Control Unit ... A1 - 8

1 5 CUT Interface E5782 ... A l - 9

1

.

5. 1 Appearance of CUT Interface ... _{A l - 9}

1 .5.2 setting J~~~~~ wires of CUT interface ... _A1 - 10

1

.

5.3 connecting CUT ~ ~ t ~ ~ f ~ A1 ~- 10 ~

1

6

Weld Stick Detection Unit E5391 A1 -11

1 .6

.

1 Specifications of Weld Stick Detection Unit ... _Al-11

1.6 2 Functions of Weld Stick Detection Unit ... A1 - 12

1 .6. 3 Connecting Weld Stick Detection Unit ... _A1

- 13

1.7 Connection Examples of Various Welding Power Supplies ... A1-15

1

.

7. 1 C02/MAG/MIG Welding Power Supply ... A1 - 16

1.7.2 TIG Welding Power Supply ... A1-22

Contents

1 . 3 External Connection 1-20

... .

1.3.1 Connecting Control Cable 1,2, 3 (BIRBX-1005/BIRBX-8005) 1 - 21

1

.

3

.

2 connecting

hi^^

B~~ 1-24

1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface

(BBWF-0105) ... 1-25

1 3 4 Connecting Operation Panel

. .

... 1-27 1 3

_{. .}

5 Connecting Starting Box ... _1-28

1.

I n s t a l l a t i o n

W A K N l N t i

1. Before the installation and

connecting cables to the robot _{ELECTRIC SHOCK}

control unit, ensure that the switch

of the switchboard and the @ D o not touch live electrical

breaker in the control unit a r e _{installing or servicing.}

turned OFF s o that no voltage is ources of voltage

being impressed.

2. Install the robot control unit and its peripheral equipment such a s the welding power supply, the

starting box,and s o on out of the _{a8 Read instruction manual.}

action range of the robot. 3. To install the robot control unit,

the welding power supply and the likes on a high place such a s on a frame (over Zm),arrange a working floor just a s shown in Fig.l.1 .for easy adjustment and maintenance.

Fig.1 . l . Installation of robot control unit on high place

T O AVOID D A M A G E T O T H E R O B O T C O N T R O L UNIT, KEEP T H E AIR I N L E T A N D E X H A U S T

A

CAUTION

FAILURE T O CONNECT C N 4 7 T O BATTERIES will cause loss of absolute offset data. 0 Di~connscf input wwar before installing or servicing. C o n n e c t CN47 to bsttarics bafors using robot

CN47 is located on the Icfl rids of the main transformer.

0 P e r f o m absoluts o f b o t adjustment according to Inrtructioo Monval nftsr C N 4 7 is connectad.

0 Whon raplacing banariss, bs sure tho1 the control pawar is on.

.--...

A

L A U l I U N 5

1. Install the robot control unit over 20cm away from wall.

2. After completing the installation work, carry out the "Absolute Offset Setting"

Installation 1 - 1

described in the Instruction Manual "TEACHING", s o that the attitude of the manipulator and the position coordinate data of the robot control unit should coincide with each other.

"..",,

3. Keep the space for the cable connection on the side of Robot Control Unit over 30cm away from wall.

2 . 1

Configuration

1

.I

.1

COp/MAG Welding Robot Standard Configuration

1. ALMEGA GOlS Basic Configuration

@ ~ ~ ~... i ~ ~ l I R B - Q ~ ( G O ~ S ) ~ ~ t ~ ~_{Standard accessories}

Wrench

Clamping bolts

@ Control Unit IRBCX-422 1

(OSACOM SUPER 8700)

@) Teaching Box ... BBTBX-6008 _{1 (Cable 8m)} @ Operation Panel ... _{BBOPX-3000 1 (Optional)}

@ Control Cable 1 ,2,3 ... _{BIRBX-1005 lset (3 cables:5m length)}

(For Manipulator-Control Unit)

COu'MAG Welding Components

@ Robot Dedicated Welding Power Supply -.-- CPVAS-350 1

a

control cable 5 BWCB-5105 1 (Cable length 5m)

( F o r Control Unit-Robot Dedicated Welding Power Supply)

@ Wire Reel Stand L318H 1

0

~ ~ b l ~ ~ / BIRB-3005 ~ ~ ~lset ~ ~

1 Workpiece Side Welding Cable --.----.-..- L3442B (1) (Cable length 5m)

( F o r Welding Power Supply-Workpiece)

~ - ~~~~h side welding cable 2 ... L2527D (1) (Cable length 5m)

(For Welding Power Supply-Manipulator)

0 3 G~~ H~~~ ... L2527B _{(I) (Cable length 5m)}

@-4 control cable 4 ~ 3 3 9 2 ~ (1) (Cable length 5m)

(For Welding Power Supply-Manipulator)

2. ALMEGA WOlS Basic Configuration

a

~ ~ ~ i ~ ~ l 1 ~ ~ - 4 6 1 ~ t ~ 1 ~Standard accessories

(WOlS) * Wrench

Clamping bolts

@ Control Unit ... IRBCX-462 ₁

(OSACOM SUPER 8700)

@

hi^^

B~~ BBTBX-6008 1 (Cable 8m)

Operation panel BBopX-3000 1 (Optional)

@ Control Cable 1 2 3 , , ... BIRBX-1005 lset ( 3 cables:5m length)

(For Manipulator-Control Unit)

COdMAG Welding Components

@ Robot Dedicated Welding Power Supply .-- CPVAS-350 1

a

Control Cable 5 ... BWCB-5105 _{1 (Cable length 5m)}

(For Control Unit-Robot Dedicated Welding Power Supply)

@ Wire Reel Stand L318H 1

@ Wire Feed Unit L6065A 1

@ Cape Hanger ... _{L6058D 1}

Coaxial power Cable K2863A 1 (2.5m)

@ COz Welding Torch ... MTX-3502 1

@ Torch Attached Bracket ... L318G ₁

@ Torch Gauge Assembly ... L3382G 1

0

~ ~ b l ~ ~ / BIRB-3005 ~ ~ ~lset ~ ~

0 - 1 Workpiece Side Welding Cable -.--..--.--..--- L3442B (I) (Cable length 5m)

( F o r Welding Power Supply-Workpiece)

0 - 2 Torch Side Welding Cable -..--..-.---.--- L2527D (1) (Cable length 5m)

(For Welding Power Supply-Manipulator)

Q-3 G~~ H~~~ ... ~ 2 5 2 7 ~ _{(1) (Hose length 5m)}

0 - 4 control cable 4 ---.- ... ~ 3 3 9 2 ~ (1) (Cable length 5 5 m)

(For Welding Power Supply-Manipulator)

@ Gas Regulator ... 5092-320 _{1 (FCR-8033)} Q Conduit ... Z318D41 _{1 (3x1)}

3. ALMEGA VOlS Basic Configuration

a

Manipulator ... _{IRB-511 1 Standard accessories}

(VOlS) Clamping bolts

@ Control Unit ... IRBCX-512 ₁

(OSACOM SUPER 8700)

@ Teaching Box ... _{BBTBX-6008 1 (Cable 8 m )} @ operation panel ... BBOPX-3000 1 (Optional)

@ Control Cable 1 2 3 , , ... BIRBX-1005 Iset (3 cables:5 m length)

(For Manipulator-Control Unit)

C02/MAG Welding Components

@ Robot Dedicated Welding Power Supply .-- CPVAS-350 1

a

Control Cable 5 ... BWCB-5105 _{1 (Cable length 5 m )}

( F o r Control Unit-Robot Dedicated Welding Power Supply)

@ Wire Reel Stand L318H 1

@ Wire 'Feed Unit L3603A 1

@ Coaxial Power Cable ... K2364A _{1 (1.2m)}

C 0 2 Welding Torch MTXC-3501 1 (With shock sensor)

@) Torch Attached Bracket ... L6300B 1

@ Torch Gauge Assembly L6300C 1

@ G~~ ~ ~... ~ ~ 5092-320 l ~ ₁ t_(FCR-8033) ~ ~

@) Conduit ... Z318D41 _{1 (3m)} @ Cables/Hoses ... BIRB-3005 _lset

1 Workpiece Side Welding Cable ...-..-..--- L3442B (1) (Cable length 5m)

(For Welding Power Supply-Workpiece)

@-2 Torch Side Welding Cable .---.---... L2527D (I) (Cable length 5m)

( F o r Welding Power Supply-Manipulator)

@-3 G~~ H~~~ L2527B (1) (Hose length 5m)

@-4 Control Cable 4 ... L3392G _{(1) (Cable length 5m)}

4. ALMEGA VlOS Basic Configuration

@ ~ ~ ~ i IRB-541 ~ ( ~ 1 0 s ) 1 ~Standard accessories l ~ ~ ~ ~

Clamping bolts

@ Control Unit IRBCX-541 1

(OSACOM SUPER 8700)

@

hi^^

B~~ BBTBX-6008 1 (Cable 8m)

operation panel ... BBOPX-3000 1 (Optional)

@ Control Cable 1 2 3 , , ... BIRBX-8005 lset ( 3 cables:5 m length)

( F o r Manipulator-Control Unit)

COdMAG Welding Components

@ Robot Dedicated Welding Power Supply -. CPVAS-350 1

a

control cable 5 ... BWCB-5105 1 (Cable length 5m)

( F o r Control Unit-Robot Dedicated Welding Power Supply)

@ Wire Reel Stand ... L318H 1

@ Wire Feed Unit L3603A 1

0

coaxial power cable ... ~ 2 3 6 4 ~ 1 (1.2m)

0

COz Welding Torch MTXC-3501 1 (With shock sensor)

@ Torch Attached Bracket ... L3585p ₁

@) Torch Gauge Assembly L3585M 1

G~~ ~ ~ ~ ~ 5092-320 l ~ 1 t(FCR-8031) ~ ~

@ Conduit ... Z318D41 _{1 (3m)} @ ~ ~ b... l ~ ~ / BIRB-3005 ~ ~ ~_lset ~ ~

- 1 Workpiece Side Welding Cable .--.---.--.---.-- L3442B (1) (Cable length 5m)

(For Welding Power Supply-Workpiece)

- 2 Torch Side Welding Cable L2527D (1) (Cable length 5m)

(For Welding Power Supply-Manipulator)

@-3 G~~ H~~~ ... ~ 2 5 2 7 ~ _{(1) (Cable length 5m)}

0 4 Control Cable 4 ... _{L3392G (1) (Cable length 5m)}

5. ALMEGA V20S Basic Configuration

Manipulator ... IRB-551 0720s) 1 Standard accessories

Clamping bolts

@ Control Unit IRBCX-551 1

(OSACOM SUPER 8700)

@

hi^^

B~~

BBTBX-6008 1 (Cable 8 m )

@ operation panel BBOPX-3000 1 (Optional)

@ Control Cable 1 I2 3 , BIRBX-8005 lset (3 cables:5m length)

6. ALMEGA V40S Basic Configuration

a

~ ~ ~ IRB i - 531 ( ~ 4 0 ~ ) ~ 1 Standard accessories ~ l ~ ~ ~ ~

Clamping bolts

@ Control Unit ... IRBCX-532 ₁

(OSACOM SUPER 8700)

@

hi^^

B~~ . BBTBX - 6008 1 (Cable 8m)

a

operation panel ... BBOPX-~OOO 1 (Optional)

@ Control Cable 1 2 3 4 _{, , ,} ... BIRBX-f'j005 _{lset (4 cables:5 m length)}

1.1.2 Optional Equipments

The following Equipments a r e provided as options.

@ Teaching Box

@ Control Cable 1,2,3 (For Manipulator-Control Unit)

Model BBTBX-6015 a ) F o r VOlS,GOlS,WOlS Specifications Cable Length: 15m b) F o r VlOS,V20S Model

I

Specifications

BIRBX-8003

I

Cable Length: 3m

BIRBX-8010 Cable Length: lOm

BIRBX-8015

I

Cable Length:15m

c) F o r V40S (Control Cable 1,2,3,4)

@

Control Cable 5 (For Control Unit-Almega Auto

II

)

Model

I

Specifications

BWCB-5110

I

Cable Length: lOrn(Optica1 fiber)

@

Cables/Hose (For Control Unit-Almega Auto II )

BWCB-5115

I

Constructions

Cable Length: 15 m (Optical fiber)

Model --- - BIRB-3010 BIRB-3015 Specifications L3375T L3375V Control Cable 4 Workpiece Side Welding Cable Gas Hose L3375E L3375G Torch Side Welding Cable L3375L L3375N L3443B L3444B

Cable Length: lOm Cable Length: 15m

@

Tool Control Cable a ) F o r VlOS,V2OS b) F o r V40S Model BIRBX-9105 BIRBX-9110 BIRBX-9115 Specifications Cable Length: 5m

Cable Length: lOm Cable Length: 15m

0

Operation Box Model BIRBX-6105 BIRBX-6110 BIRBX-6115 Model Specifications Cable Length: 5m

Cable Length: lOm Cable Length: 15 m

I

Specifications

BBOPX-3005

I

Operation Box with 5m cable

BBOPX-3008

I

Operation Box with 8m cable

BBOPX-3015

~ ~storage t ~ ~ ~ ~ l E5777A

External Connecting Cable ... E5657L

Cable Assy(l) E5777K

Cable Assy(2) E5777 J

Interface printed Board E5657C

Accessories E5777N

@ Welding Interface E5624A

(For COz o r MAG Welding Power Unit expect CPVAS)

@ personal Computer Interface Cable E5623B

(For Personal Computer-Backplane board)

0

Terminal Block Unit E574 1 A

Q Relay u n i t E5685A

@ ~ ~ tTerminal Block Unit ~ ~ d ~ d ... E5766A

@ ~ ~ tRelay Unit ~ ~ d ~ d E5772A

Operation Box with 15m cable

Starting Box Installation 1 - 1 5 Model BBST-4005 BBST-4008 BBST-4015 Specifications Cable Length: 5m Cable Length: 8m Cable Length: 15m

1.2

Connecting Primary Power Supply

1.2.1 Connecting P r i m a r y Power Cable

1. Primary Power Supply

3 phase AC200V ( + l o % , - 15%), 50/60Hz

3KVA (GOl,WOl,VOl), 4kVA (VlO), 5kVA (V20), 7kVA (V40)

2. To primary power cable of 3 . 5 d min. x 3 wires,attach a M4 round crimpstyle terminal a t the control unit side.

CAUTION

Be sure that grounding is carried out a s a prevention against electric shock. F o r the grounding method, see1.2.3.

Fig. 1.2.1.1 Connecting Primary Power Cable 3. Install a nonfuse breaker (3 phase, 200V) on a leakage breaker between primary

power supply and control unit.

GO1

+

1-3 Axes

4. F o r wiring both control unit and welding power supply,in order t o reduce noise effects,install separately wiring t o primary power supply and grounding terminal.

5. The location of breaker in the control unit is shown in Fig.l.2.1.1.

6. Supply primary power t o each of control unit and welding power supply from its independent power supply

@

NOTE

1. This robot control unit is equipped with inverter circuit t o control AC servo motors. Therefore, if implying a leakage breaker,be sure t o specify a leakage breaker for inverter in order t o prevent its leakage current generated from the inverter circuit.

2. In the use of high sensitivity type of a leakage breakerjnstall one per control unit.In the case of the collective use among multiple control unit, install one middle sensitivity type leakage breaker for several control units.

1.2.2

Opening Control Unit Door

Door Key - t---7 1. Unlock the upper and lower

/

door keys. Use a minus

screwdriver.

Braker

.+

I

- 2. Turn the breaker handle to

"Open Reset" in the direction of the arrow in Fig.1.2.2.1 to

i

open the door.

At this moment,the primary

i

power of the control unit is

shut off.

//

Door Key

I

/---

Fig.1.2.2.1 Door of control unit

ELECTRIC SHOCK can kill.

* D o not touch live electrical parts.

@Disconnect all power before installing or servicing. .Multiple sources of voltage

m a y exist inside this enclosure.

If the door needs to be opened with the power ON,for example to check the control unit a t any occurrence of a failure, follow the procedures described below:

Fig. 1.2.2.2 Breaker handle

Unlock the upper and lower door keys. Use a minus screwdriver.

Turn "Release" button to the arrow shown in Fig.1.2.2.2 with a screwdriver,and you may open the door with the power ON.

WARNING

1. Voltage is impressed on the primary side of the breaker even after the breaker of the control unit is turned OFF. Therefore, in case of opening the door for maintenance, be sure to turn OFF the power source switch.

2. The control units contains many high-voltage components and touching any of them while powere is ON may cause electric shock. Therefore, if the door needs to be opened with the power ON, for example to check the control unit

a t any occurrence of a failure, never fouch any of components inside of the

unit.

1.2.3 Grounding

F o r a safety operation, install the grounding arrangement a s shown in Fig.1.2.3.1. 1. F o r the manipulator, use a MI2 t a p located a t the bottom of the body t o provide a n

independent ground with a grounding cable over 3.5d.

2. F o r the robot control unit,provide an independent ground with a grounding cable over 3.5mnT.

The grounding terminal of the control unit is located on the top and the bottom of the breaker.

3. F o r the welding power supply,provide a n independent ground with a grounding cable over 1 4 d .

4. Be sure t o apply ground resistance below 100 9 .

5. Ensure that the ground of each of 1,2,3,and 4 is separated from one another,as

shown in Fig.l.2.3.1,and never use them together with the grounding cable o r grounding pole from other electric power.

6. F o r the use of metallic conduit,duct and cable rack for wiring of grounding cables, follow the Electrical Installation Technical Standards in your country.

l r ~ s u l a t l n s P l a t e , M a n l F u l a t o r S l o e W s ! d i n g C a b l e ( A )

-

R o b o t C o n t r o l U n i t \ W e l r r i n g T o r c h - e x c e e d i n g 100Q) n o t l e s s t h a n 3 5mm2 ( w i t h i n :Onj Fig.1.2.3.1 Grounding

A

CAUTION \

Be sure of the danger of imperfect connection of, particularly, the workpiece side cable B, a s shown in Fig.1.2.3.2, which may cause a welding current to flow into the control unit through the motor frame, resulting in damage in the

control unit. Similarly, pay attention when using another welding power supply

[ r Read manual for connection procedures.

_I

A : Torch Side Welding Cable

B : W o r k Side Welding Cable

Fig. 1.2.3.2 Welding current flowing into control unit

e Connect grounding conductor and input conductors to proper terminals inside unit-grounding conductor first. e Be sure grounding conductor goes to

a proper earth ground and has less than 100 ohms of resistance. e Doublecheck grounding conductor.

input voltage, and frequency before applying power.

1.3 External Connection

Notes on Connection

1. Before connecting cables t o the robot control unit,make s u r e t h a t the switch of the

switch board of the distribution panel and the breaker within the control unit a r e turned "OFF" s o t h a t n o voltage is being impressed.

2 . Make s u r e t h a t the connections (connectors and terminals) of cables and hoses a r e tightened.

3. Do not put a n y load on the cables.

4. Do not c r o s s various cables.

5. Do not install cables under the welding power supply.

6. Separately place the welding cables and other control cables without binding them up.

7. Cables may be installed inside the unit from both the right and left sides.Connect them in accordance with the description shown in the following pages.

8.

As f o r connecting t o the jig,refer t o "Interface with Jig" in the instruction manual.

G.B.

and servo driver as indicated

@Connect 6N67, CN68,

CN69,

CN70,

CN71

andCN72 of control cable. to Interlock Board

as following drawing.

@Connect 6N31, 6N32 and CN33 of starting

Box to Interlock Board as in the -Following

as positioner and slider. In case of a single

mechanism (one manipulator) system,

613169 and

6N72

are not connected.

@As for details of each cable connection,

Read Instruction Manuals.

1.3.1

Connecting Control Cable

1,2,3 (BIRBX-1005/BIRBX-8005)

The manipulator and the robot control unit a r e connected with 3 cables.

CNl ,connectors CN67, 68 and CN51-56.

(1) Connecting Control Cable 1

1. Connect cannon plug CN1 Connecting cannon plug

of Manipulator.

2. Connect connectors CN67

and CN68 t o CN67 and CN

*

Duct

68 of Interlock board

/

.

Servo

Driver

L C N I C o n t r o l C a b l e I respectively. Connect connectors CN51- 56 to CN51-56 a r e all the same type connectors but have different colors to identify each axis. After connection,be sure to check that they a r e all correctly connected. Place the cables connected to servo Drivers in the ducts located a t the right side and the upper part. Connect a grounding cable to a grounding plate mounted on the bottom of Control Unit.

Fig.l.3.1.1 Connecting Control Cable 1

CAUTION

_'I

1. Because this cable is a motor power cable,do not bind it with other signal cables.

2. Connector CN56 is for V01.

Therefore, if manipulator is GO1,this connector should not be connected.

L J

1

CN2,connectors CN7 and

1

(2)

Connecting Control Cable 2

CN2

C o n t

Connecting cannon plug

Fig.1.3.1.2 Connecting Control Cable 2

+

C a b l

1. Connect cannon plug CN2 t o CN2 of Manipulator. 2. Wire along the left side

and connect connector CN70 t o CN70 of Interlock Board. 3. Connect connector CN7 t o CN7 of Servo Control Board 1.

A

CAUTION

1. Since this cable is the signal cable for encoder, do not bind it with other motor cables and AC input cables.

2. Connectors of the same type as the connector CN70 a r e employed in CN5 in

SCON Board 1 and 2.

(3) Connecting Control Cable 3

Inter

Fa

l o c k

Connecting cannon plug CN3,connectors CN7 and CN71

f

G r o u n d i n g P1atcX3

+

1. Connect cannon plug CN3

t o CN3 of Manipulator.

2. Wire along the left side

and connect connector CN71 t o CN71 of Interlock Board.

3. Connect connector CN7 t o CN7 of Servo Control Board 2.

Fig.1.3.1.3 Connecting Control Cable 3

1 CAUTION ?

1. Since this cable is the signal cable for encoder, do not bind it with other motor cables and AC input cables.

2. Connectors of the same type a s the connector CN71 a r e employed in CN5 in SCON Board 1 and 2.

To avoid damage for printed circuit board, do not mis-connect.

"1.3.2 Connecting Teaching Box

Fig.1.3.2.1 Connecting Teaching Box

Connecting connector CN16 1. Connect connector CN16

of Teaching box to CN16 on the side of Control Unit.

1.3.3 Connecting Control Cable 5 (BWCB-5105) o r

Welding Interface (BBWF-0105)

1. Connect connector CN37 t o CN37 of Interlock Board. 2. Connect optical fiber

connector t o IC124 of Back plane.

Connecting connector CN37 and optical fiber connector

to

R o b o t W e l d i n g

P o w e r

SuPP l Y

or

*

W e l d i n g Interface

Fig. 1.3.3.1 Connecting Robot Dedicated Welding Power Supply

@

NOTE

I

Connect welding interface like control cable (BWCB-5105).

cover (Fig.a) and fiber cap (Fig.b).

(The unclean connection of optical fiber cable causes malfunction of the robot.)

Q a c k P l a n e

C o n n e c t o r C o v e r

(Fig. a) (Fig. b)

1.3.4 Connecting Operation Panel

1

Connecting connectors

I

*

Fig.1.3.4.1 Coilnecting Operation Panel

1. Connect connectors CN28 and CN31 t o CN28 a n d CN31 of Interlock Board respectively.

1.3.5

Connecting Starting

Box

(Note) Station Nos. and their corresponding Connector Nos. a r e a s follows: Connecting connector

CN3 1

( L e f t S i d e )

I

+

1. Connect connector CN31 of Starting Box to

CN32-CN36 of Interlock Board and Relay Unit

PCB5

(The

I n s i d e

o f

Door)

I

+ t o

S t a r t i n g

B o x

I

.3.6

Connecting Miscellaneous Options

1. Connect Line Master and Personal Computer t o the following connectors of Backplane board:

CN19 for Line Master

CN18 for Personal Computer

Fig. 1.3.6.1 Connecting Miscellaneous Options

CAUTION

Do not bind all these cables with motor cable.

1.4

Placing Printed Boards

Cautions on Placing Printed Boards

1. The printed b o a r d s connected t o Backplane Board a r e inserted in the slots.After insertion,in order t o prevent imperfect contact of the connector connection which may cause malfunction due t o vibration and shock,ensure t h a t the printed b o a r d s a r e

fixed with printed board metal fixing plates (2).

M a l n P r o c e s s o r Board

/

Motion Control Board

/I/O

M a n a g e m e n t Board

Fig.l.4.0.1 Fixing Printed Board

2. After placing the printed boards,be sure t o check t h a t the b o a r d s a r e all in the correct slots.Misplacing may damage a board.

1.4.1 Connecting M a i n Processor Board

Connect connectors J l , J 2 of Main Processor Board t o connectors 51-4 and 52-4 of Backplane Board.(See Fig.l.4.O.l)

1.4.2 Placing Servo Control Boards

1. Connect connector CN1 of Servo Control Board 1 to connector 52-2 of Backplane Board.(See Fig.l.4.O.l)

2. Connect connector CN1 of Servo Control Board 2 to connector 52-1 of Backplane Board.(See Fig.l.4.0.1)

1.4.3 Placing Motion Control Board

Connect connectors J1,52 of Motion Control Board of connectors 51-3,52-3 of Backplane Board.

1.4.4 Placing

1/0

Management Board

Connect connectors J1,J2 of I/O Management Board to connectors 51-5,5255 of

Backplane Board.

C h a p t e r

2

I n t e r n a l C o n f i g u r a t i o n o f

C o n t r o l U n i t

Contents

2.2 1 Functions ...

2 2 2 Operation Status Indicator

. .

...

2.3 1/0 Management Board L3700M (Standard) o r L4024M (Extension) ...

2 3.1 Functions ...

2 3 2 Operation Status Indicator

. .

...

2.4 Servo Control Board (SCON) L4268R (or L4000R) and

position Control Board (pCON) U1CjOS ...

2 4 1 Functions

. .

of Servo Control Board

2.4.2 Operation Status Indicators of Servo Control Board ... 2.4.3 switch settings of

servo

control ~~~~d ...

2

.

4

.

4 Jumper pin Settings of Servo Control Board

2 4 5 Functions

_{. .}

of position Control Board ...

2.4.6 Operation Status Indicators of Position Control Board ...

2 4 7 Switch Settings

_{. .}

of position Control Board ...