Denso VM-6083G Installation & Maintenance Manual Download

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iii

How this book is organized

This book is just one part of the robot documentation set. This book consists of SAFETY PRECAUTIONS,
chapters one through three.

SAFETY PRECAUTIONS

Defines safety terms and related symbols and provides precautions that should be observed. Be sure to
read this section before operating your robot.

Chapter 1 Installing Robot Components

Provides information about physical site planning, installation procedures, and engineering-design notes
for hands.

Chapter 2 Customizing Your Robot

Describes how to customize your robot--defining the software motion space and restricted space,
CALSETing, and setting control set of motion optimization.

Chapter 3 Maintenance and Inspection

Describes the regular maintenance and inspections necessary for maintaining the performance and
functions of your robot.

Summary of Contents for VM-6083G

Page 1: ...ROBOT Vertical articulated VM G SERIES INSTALLATION MAINTENANCE GUIDE...

Page 2: ...is publication may be reproduced in any form or by any means without permission in writing from the publisher Specifications are subject to change without prior notice All products and company names m...

Page 3: ...Series Floor mount Overhead mount Remarks Max reach nickname VM G Medium sized vertical articulated VM 6083G VM 60B1G Same as left Same as left VM1000 VM1300 NOTE 1 Model names listed above apply to...

Page 4: ...nel Designer User s Manual SUPPLEMENT WINCAPSIII GUIDE Provides instructions on how to use the programming support tool WINCAPSIII which runs on the PC connected to the robot controller for developing...

Page 5: ...ting your robot Chapter 1 Installing Robot Components Provides information about physical site planning installation procedures and engineering design notes for hands Chapter 2 Customizing Your Robot...

Page 6: ......

Page 7: ...ed by the manufacturer plus the space which can be swept by the end effector and the workpiece Quoted from the ISO 10218 1 2006 Restricted space Refers to the portion of the maximum space restricted b...

Page 8: ...Risk of injury Never enter the restricted space Except HM HM Label 2 For UL Listed robot units only Risk of injury This label alerts the user that pressing the brake release switch could drop the arm...

Page 9: ...and the wrist of the VM VS G W are an IP65 equivalent dust and splash proof structure Note that the robot controller is not a dust or splash proof structure Therefore when using the robot controller i...

Page 10: ...ce The protective grounding resistance of the robot power supply should not be more than 100 3 7 Positioning of emergency stop switches Emergency stop switches should be provided in a position where t...

Page 11: ...n interlock that ensures the emergency stop device operates automatically if it is opened or removed 2 Post a warning notice at the entrance exit of the fence stating In operation Entry forbidden or W...

Page 12: ...nt that the object being held by the end effector is dropped or thrown by the end effector consider the size weight temperature and chemical nature of the object and take appropriate safeguards to ens...

Page 13: ...the robot s restricted space to perform teaching or maintenance inspections set working regulations for the following items and ensure workers adhere to them 1 Operating procedures required to run the...

Page 14: ...unction 1 Ensure an overseer is placed in a position outside the robot s restricted space and one in which he she can see all robot movements and that he she is devoted solely to that task c An emerge...

Page 15: ...ignated places 3 Check that no lamps indicating a malfunction on the robot or related equipment are lit 2 Check that the display lamp indicating automatic operation is lit during automatic operation 3...

Page 16: ...isks used for storing task programs to prevent incorrect disks from loading into the robot controller 4 Store the floppy disks where they will not be exposed to dust humidity and magnetic field which...

Page 17: ...utions When Designing the End effectors 21 1 5 Locking Out the Power Switch 22 Chapter 2 Customizing Your Robot 23 2 1 What Is Customization 23 2 2 Modifying Software Motion Limits to Define New Motio...

Page 18: ...3 Replacing the Memory Backup Battery 81 3 4 4 Setting the Next Battery Replacement Date 81 3 5 Supplies and Tools for Maintenance 82 3 6 Replacing Fuses and Output ICs 82 3 7 Checking the Odometer a...

Page 19: ...power off during transportation ERROR 2AF1 Encoder reference position error may occur If the ERROR 2AF1 occurs when turning the robot controller ON at first after purchasing the robot refer to the ERR...

Page 20: ...ransportation 75 or less No dew condensation allowed Vibration During operation 4 9 m s 2 0 5G or less During storage and transportation 29 4 m s 2 3G or less Altitude During operation 1 000 m or less...

Page 21: ...t or slightly modify the robot speed Robot Mount Example for Floor mount Strut Mounting face 350 350 20 or more 100 100 t6 0 square steel pipe Caution 1 When the robot operates at high speed the top p...

Page 22: ...kers handle this job Workers should wear helmets safety shoes and gloves during transport Caution Pass the hoisting wires through the specified eyebolts as illustrated below Passing them through other...

Page 23: ...ansport Position Axis Angle First axis J1 0 Second axis J2 90 Third axis J3 165 Fourth axis J4 90 or 90 Fifth axis J5 90 or 90 2 Disconnect the robot control cable air piping and user signal cables fr...

Page 24: ...Worker B Put the robot unit down in the target position Worker A Temporarily secure the robot unit with four bolts 8 Secure the robot unit according to the instructions in Section 1 2 2 Securing the R...

Page 25: ...hey can minimize positional deviations when you remove and reinstall the robot unit for maintenance 3 Set the robot unit into place on the robot mount NOTE When transporting the robot unit follow the...

Page 26: ...the robot Fasten the wiring to the mounting face or beam so that the weight of the cables will not be directly applied to the connectors Overhead mount Frame The figure below shows an example of over...

Page 27: ...shown on pages 11 through 14 The customer should prepare them as required Example of Suspension Jigs A and B Example of Suspension Jig C Bolt tightening torque for M12 130 26 Nm Bolt tightening torque...

Page 28: ...10 Suspension Jig A NOTE 1 BURRS NOT ALLOWED...

Page 29: ...11 Suspension Jig B NOTE 1 BURRS NOT ALLOWED...

Page 30: ...12 Suspension Jig C NOTE 2 ENTIRE SURFACE EXCEPT THREADS SHOULD BE PAINTED WITH SPECIFIED COLOR NOTE 1 BURRS NOT ALLOWED...

Page 31: ...13 Holder Holder Stopper Plate NOTE 1 ALL CORNERS SHOULD BE FINE CHAMFERED UNLESS OTHERWISE SPECIFIED 11 drill hole NOTE 1 ALL CORNERS SHOULD BE FINE CHAMFERED UNLESS OTHERWISE SPECIFIED...

Page 32: ...to install the robot unit Caution 1 Since the robot unit weighs approximately 88 kg 193 lbs prepare a crane and a forklift with a lifting load of 0 5 ton or more 2 The overhead mounting job must be pe...

Page 33: ...t suspension jigs A and B using hexagon socket head bolts and plain washers Bolt tightening torque 130 26 Nm Suspension jig A Suspension jig B Hoisting bolts Jig mounting bolt M12 35 hexagon socket he...

Page 34: ...unit into the suspension jigs STEP 4 Pass a belt sling through each hoisting bolt and put their eyes on the hook STEP 5 Hoist the robot unit using a crane and move it to the position right above the...

Page 35: ...so do not touch the robot unit itself STEP 7 Using the holder stopper plates attached to suspension jig C join suspension jigs B and C together Bolt tightening torque 71 14 2 Nm Holder stopper plate...

Page 36: ...the same way as in Step 7 STEP 9 Confirm that the robot unit is secured to the suspension jigs STEP 10 Using a forklift transport the robot unit fixed to suspension jigs to the robot mount Suspension...

Page 37: ...obot mount then secure it to the robot mount with M12 40 bolts strength class 12 9 Bolt tightening torque 128 26 Nm STEP 12 While supporting the robot unit with the forklift remove the bolts fastening...

Page 38: ...ig C only from the robot unit STEP 14 Remove suspension jigs A and B from the robot unit STEP 15 Confirm that the robot unit is secured to the robot mount Then the installation procedure is complete S...

Page 39: ...ower equipment such as a welder Grounding the Robot Unit VM 6083G VM 60B1G 1 3 Installing the Robot Controller For the installing procedures of the robot controller refer to the RC7M CONTROLLER MANUAL...

Page 40: ...ng a commercially available padlock according to the following procedure Step 1 Check that the power switch of the robot controller is turned OFF Step 2 Remove the lockout bar provided on the robot co...

Page 41: ...et of motion optimization Robot installation conditions You are recommended to define new motion space and restricted space in order to prevent interference with other devices or entanglement of the e...

Page 42: ...motion limit is set If the robot reaches a software motion limit during manual or automatic operation an error message will be displayed error code starting from 6070 the first digit represents the ax...

Page 43: ...Software Motion Limits and Mechanical Ends NLIM Negative direction software motion limit PLIM Positive direction software motion limit Software motion limit Mechanical end Restricted range Motion ran...

Page 44: ...eries Robot model 1st axis 2nd axis 3rd axis 4th axis 5th axis 6th axis Positive direction 170 135 165 185 120 360 VM 6083G See NOTE Negative direction 170 90 max 80 max 185 120 360 Positive direction...

Page 45: ...ler than the motion space defined by initial settings VM 6083G VM 60B1G Example 1 Changing Software Motion Limits VM 6083G VM 60B1G Example 2 Changing Software Motion Limits VM 6083G VM 60B1G Positive...

Page 46: ...o not enter the robot s restricted space when the robot power is turned ON 4 If the robot is collided with the mechanical stopper the robot will stop by detecting the collision but the mechanical stop...

Page 47: ...ieces Fixture block B 1 piece Plate 2 pieces The figures on the following pages show the reference drawings of those mechanical stop parts Referring to those drawings you should prepare mechanical sto...

Page 48: ...0B1G For 1st axis Material S45C Fixture Block A 2 11 DRILL 17 5 DIA x 10 DEEP SF Note 1 Unless otherwise specified corners should be C0 1 to C0 5 2 11 DRILL 17 5 DIA x 10 8 DEEP SF 2 13 5 DRILL 20 DIA...

Page 49: ...Block B VM 6083G VM 60B1G For 1st axis Material S45C Plate 4 11 DRILL 17 5 DIA x 14 DEEP SF Note 1 Unless otherwise specified corners should be C0 1 to C0 5 Note 1 Unless otherwise specified corners...

Page 50: ...l end change requires RANG value change and CALSET In this case the position repeatability depends on the mechanical stop parts prepared by the customer The initialization floppy disk holds the factor...

Page 51: ...p 2 upside down Secure two mechanical stops to each of those assemblies with two hexagonal socket head bolts each for determining the desired motion space Mechanical stops Hex socket head bolt M10x25...

Page 52: ...ne of the assemblies made in Step 3 to the side of the 1st axis with hexagonal socket head bolts STEP 5 In the same way as in Step 4 temporarily secure the other one of the assemblies to the opposite...

Page 53: ...have temporarily secured in Steps 4 and 5 using fixture block B and four hexagonal socket head bolts After that firmly tighten the hexagonal socket head bolts on fixture blocks A that have been tempor...

Page 54: ...nce angle or ready angle The RANG value checking procedure is given below The relationship between each mechanical end position and software motion limits is shown in the table on page 38 Change the s...

Page 55: ...P 4 Gently bring the 1st axis of the robot into contact with the newly set positive direction mechanical end STEP 5 Check the value in J1 box that appears when the 1st axis is in contact with the mech...

Page 56: ...rection software motion limit 0 RANG value obtained in Checking the set RANG value 2 When the positive direction mechanical ends are the permanent mechanical ends and the negative direction mechanical...

Page 57: ...ositive direction software motion limits PLIMs and RANG values according to steps 1 through 23 described below Changing Positive Direction Software Motion Limits PLIMs STEP 1 Turn the power switch of...

Page 58: ...elect the Software motion limit J1 deg field STEP 7 Press F5 Change The numeric keypad appears STEP 8 Using the numeric keys enter the positive direction software motion limit value then press OK The...

Page 59: ...alues STEP 10 Press F2 RANG The RANG window appears as shown below F5 STEP 11 Press F5 Change The numeric keypad appears STEP 12 Using the numeric keys enter RANG values then press OK The screen retur...

Page 60: ...bot controller to OFF STEP 15 Turn the power switch of the robot controller to ON STEP 16 Press F2 Arm on the top screen CALSET of the 1st Axis STEP 17 Press SHIFT Press F12 Maint The Maintenance Func...

Page 61: ...6 CALSET on the window in Step 18 The Set CALSET window appears STEP 20 Touch the J1 field and confirm that the mark turns green STEP 21 Press OK The message window appears asking you whether you want...

Page 62: ...mits to the original settings and repeat the procedure from the beginning 1 The software motion limits do not function when the axis is near a mechanical end and another error 6111 6121 or 6171 occurs...

Page 63: ...ed Change the set negative direction software motion limits PLIMs according to steps 1 through 10 described below STEP 1 Turn the power switch of the robot controller to ON STEP 2 Set the mode selecto...

Page 64: ...g dial or cursor keys select the Software motion limit J1 deg field STEP 7 Press F5 Change The numeric keypad appears STEP 8 Using the numeric keys enter a negative direction software motion limit val...

Page 65: ...stops just before the mechanical end and ERROR6071 appears In the following cases reset the bolt positions the positive direction software motion limits the RANG values and the negative direction soft...

Page 66: ...al ends change the software motion limits to the positions inside the mechanical end positions And also if you change the RANG values required after a mechanical end change the CALSET must also be per...

Page 67: ...3rd axis Mechanical Stops 2 1 Fixing plates for the 2nd axis and 3rd axis mechanical stoppers The VM 6083G VM 60B1G series of robots has fixing plates to mount the 2nd and 3rd axis mechanical stopper...

Page 68: ...shown in the figure below 2nd axis mechanical stopper 3rd axis mechanical stopper External appearance External appearance Reference drawing Reference drawing Fixing Bolt Hex Socket head 4pcs Specifica...

Page 69: ...position of mechanical stopper Positive direction Negative direction Original A0 Original mechanical end position 137 13 Original software motion limit 135 B0 Original mechanical end position 92 13 O...

Page 70: ...osition VM 6083G 167 46 VM 60B1G 170 37 Original software motion limit VM 6083G 165 VM 6083G 168 B0 Original mechanical end position 82 36 Original software motion limit 80 1 A1 25 inside from A0 2 A2...

Page 71: ...Remove the 2nd axis and 3rd axis cover Install the mechanical stopper to the fixing position of the robot using four bolts according to 2 3 Tightening torque 3 9 Nm 20 Note Pay attention to the direct...

Page 72: ...d in the floppy disks that come with the robot unit Therefore even if the memory backup battery in the robot controller dies so that the CALSET data is lost you do not need to CALSET the robot Just re...

Page 73: ...1 of the second arm comes to the upper side and the internal wiring is not caught in the crank at this time Checking the 4th axis position for VM 6083G VM 60B1G Internal wiring at normal position wher...

Page 74: ...unt a CALSET jig to set a temporary mechanical end for CALSET Then press the 6th axis against this mechanical end and get the position When CALSETing the 6th axis you need to press also the 5th axis a...

Page 75: ...re coming into contact with the mechanical end 4 In automatic operation start to run the robot at low speed Ensuring safety gradually increase the speed It makes adjustment easy 5 Position related dat...

Page 76: ...a stopper pin in the CALSET jig STEP 2 Release the brake of the 6th axis STEP 3 Install the CALSET jig on the flange of the 6th axis as shown in the figure below and the figure on the next page TIP T...

Page 77: ...robot unit STEP 1 Remove the 3rd axis motor cover and unscrew the CALSET bolt NOTE After CALSETing be sure to set the bolt back into place and torque it to 1 0 Nm 20 Removing the CALSET Bolt VM 6083G...

Page 78: ...LSET jig Using any other bolt will result in a positional error in CALSET TIP The CALSET position of the 4th axis refers to the point where the notch of the second arm comes into contact with the head...

Page 79: ...on the 4th axis Turning end in the positive direction which is set by a CALSET jig See Section 2 4 4 counterclockwise end when viewed from the arm end 5th axis Turning end in the positive direction u...

Page 80: ...ALSETing the 6th axis When CALSETing any other axes skip to Step 3 STEP 1 Required for CALSETing the 4th and 6th axes Mount the CALSET jig according to Section 2 4 2 1 Mounting the CALSET Jig STEP 2 R...

Page 81: ...63 STEP 7 Press the MOTOR key on the teach pendant to turn OFF the power to the motor STEP 8 Press F2 Arm on the teach pendant STEP 9 Press the SHIFT key and F12 Maint F12 STEP 10 Press F3 Brake F3...

Page 82: ...ed green display STEP 12 Confirm that there is no danger even if the arm falls as a result of released brakes CAUTION The brake of the specified axis has been released STEP 13 Press OK The system mess...

Page 83: ...stem message appears informing that the brake is released and warning against drop of arms STEP 15 Press the axis to be CALSET against the mechanical stop by hand STEP 16 Press F6 CALSET The Set CALSE...

Page 84: ...display for the other axes that are not required to be CALSET STEP 18 Press OK The system message appears asking whether you want to carry out CALSET and showing a caution that the robot reference po...

Page 85: ...tle in the opposite direction of the mechanical end and turn ON the power again STEP 23 Move the CALSETed axis in the opposite direction from the mechanical end by the manual operation of the teach pe...

Page 86: ...Control Set of Motion Optimization The payload center of gravity is represented by the TOOL0 coordinate system see this figure below in the unit of mm The origin of the TOOL0 coordinate system is the...

Page 87: ...it is set for floor mount If you overhead mount your robot you need to change the installation settings For the setting procedure refer to the SETTING UP MANUAL Section 2 10 Setting the Robot Installa...

Page 88: ...vals Purposes 1 Daily Perform inspection jobs specified in Section 3 2 every day before starting operations To use your robot safely 2 Quarterly Perform inspection jobs specified in Section 3 3 every...

Page 89: ...ng inside Jobs requiring special care CALSET Cleaning of cooling fan filters in the robot controller Replacement of encoder backup batteries Replacement of controller memory backup batteries Inspectio...

Page 90: ...erly displayed Repair or replace 4 Pilot lamps on the robot controller ON Visually Should light Repair or replace 5 Cooling fan in the robot controller ON Visually Note 2 Should work properly Repair o...

Page 91: ...ghtening torque with a torque wrench No looseness Specified torque 128 26 Nm Tighten the bolts to the specified torque 2 Cooling fan filters in the robot controller OFF Visually No dust or dirt Clean...

Page 92: ...memory of the encoder Programs parameters CAL data etc are stored in the internal memory of the robot controller The backup battery for each memory retains the above data while the power to the robot...

Page 93: ...the encoder backup battery according to the procedure below Replacing procedure STEP 1 Prepare a new set of 3 backup batteries for replacement Note Be sure to replace all of three batteries with new...

Page 94: ...76 STEP 3 Remove the hexagon socket head bolts from the battery support plate Standard type VM 6083G VM 60B1G Dust splash proof type VM 6083G W VM 60B1G W...

Page 95: ...ll out the battery support plate from the robot unit Note If the robot is the dust splash proof type replace the O ring to the new ones Standard type VM 6083G VM 60B1G Dust splash proof type VM 6083G...

Page 96: ...new battery 1st one to the pin from which you have disconnected the dummy connector cap in Step 5 Note Do not disconnect old backup batteries before connecting a new one to the pin from which the dum...

Page 97: ...and then connect a new battery 2nd one STEP 8 Disconnect the old backup battery that is left next to the new battery connected in Step 7 and then connect a new battery 3rd one Note Be sure to replace...

Page 98: ...tery and connect the dummy connector cap disconnected in Step 5 STEP 10 Secure the battery support plate to the connector plate Tightening torque 1 6 0 3 Nm Standard type VM 6083D VM 60B1D Dust splash...

Page 99: ...nt date will also become incorrect STEP 1 On the top screen of the teach pendant press F6 Set The Settings Main window appears STEP 2 Press F6 Maint in the Settings Main window The Maintenance menu ap...

Page 100: ...7M controller 3 Fuse 1 3A 410054 0230 For LM13 for controller I O 4 Fuse 3 2A 410054 0270 For LM32 for controller I O 5 IC for output NPN 410077 0010 IC M54522P for controller output 6 IC for output P...

Page 101: ...the robot leaves the factory You cannot reset the odometer Trip meter Shows the distance of each axis traversed after you reset the trip meter to zero You can reset the trip meter by pressing F6 Reset...

Page 102: ...own below F5 Press F5 Odometer STEP 5 The Odometer window appears as shown below F6 In the above Odometer window the J1 through J6 are expressed in rpm If the Trip meter count exceeds the Interval val...

Page 103: ...ter to Zero STEP 1 Display the Odometer window as shown below Access F6 Set F6 Maint F5 Odometer from the top screen F6 Press F6 Reset STEP 2 The following message appears Press the OK button The trip...

Page 104: ...time counted after the robot leaves the factory Cumu operation Shows the total of the robot controller ON time counted after you reset the user counter to zero Cumu running Shows the total of the robo...

Page 105: ...after the robot leaves the factory Cumu operation Shows the total of the robot controller ON time counted after you reset the user counter to zero Cumu running Shows the total of the robot running tim...

Page 106: ...nning Time STEP 1 Display the Total hours window as shown below Access F6 Set F6 Maint F1 Total h from the top screen F4 To reset the user counter of the controller ON time Cumu operation for example...

Page 107: ...89 The user counter of the controller ON time has been reset to zero as shown below...

Page 108: ...n encoder backup batteries or Error 677 occurs due to a great impact applied to the robot when the power is off is any of 1 to 6 denoting the object axis This section describes how to reset encoders F...

Page 109: ...backup battery for instance use the arm data held in the initialization floppy disk for recovery STEP 1 Loading the arm data held in the initialization floppy disk into the WINCAPSIII project Start W...

Page 110: ...ted If it is selected creating a new project and transferring arm parameters overwrites the CALSET related data in the robot controller with the transferred data causing errors in teaching positions S...

Page 111: ...l is to provide accurate information in the handling and operating of the robot Please feel free to send your comments regarding any errors or omissions you may have found or any suggestions you may h...

Page 112: ......

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