Horizontal Articulated Robot – IX Series Tabletop Type, Clean-room Specification Arm Length 250/350 IX-NNC-2515, IX-NNC-3515 Operation Manual Fourth Eition
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. The CD or DVD that comes with the product contains operation manuals for IAI products.
CE Marking If a compliance with the CE Marking is required, please follow Overseas Standards Compliance Manual (ME0287) that is provided separately.
Table of Contents Safety Guide ······················································································································1 Caution in Handling ···········································································································8 1. Names of Robot Parts ································································································9 1.1 1.2 1.3 2.
8. Warranty ·················································································································· 66 8.1 8.2 8.3 8.4 8.5 8.
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No. 2 2 Operation Description Transportation 3 Storage and Preservation 4 Installation and Start Description Ɣ When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. Ɣ 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.
No. 4 Operation Description Installation and Start Description (2) Cable Wiring Ɣ 8VH RXU FRPSDQ\¶V JHQXLQH FDEOHV for connecting between the actuator and controller, and for the teaching tool. Ɣ Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around. Do not insert it. Do not put any heavy thing on it. Failure to do so may cause a fire, electric shock or malfunction due to leakage or continuity error.
No. 4 4 Operation Description Installation and Start 7HDFKLQJ Description (4) Safety Measures Ɣ 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.
No. 6 7 Operation Description Trial Operation Automatic Operation Description Ɣ 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. Ɣ After the teaching or programming operation, perform the check operation one step by one step and then shift to the automatic operation.
No. 8 9 6 Operation Description Maintenance and Inspection 10 Modification and Dismantle Disposal 11 Other Description Ɣ 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. Ɣ Perform the work out of the safety protection fence, if possible.
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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.
1 Names of Robot Parts Clean-room Specification ALM (indicator) 1. Change History 1.
1. Change History 1.2 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.
1.3 Label Positions Warning on handling of the vertical axis 1.
2 Transportation and Handling 2. Transportation and Handling 2.1 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. x Place the carton on a level surface if it is to be left there for a while. x Do not climb upon the carton.
2.3 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 pairings with the controllers. 2.4 2. Transportation and Handling The robot will not stand on its own after being unloaded from the carton pallet. Hold it by hand, or place a cushioning material on the floor and place the robot on its side upon the cushion.
2.5 Transporting the Robot 2. Transportation and Handling When transporting the robot, affix the arms using the supplied arm fixing plate. Additionally, wrap the cables around the base and secure them with gummed tape or other means. Use a dolly, forklift, crane, or other appropriate equipment for transportation. When transporting the robot, move it slowly so that it maintains its balance. Also, safeguard the robot against vibration or impact.
3 Installation Environment and Storage Environment 3.1 Installation Environment Install the robot in an environment that satisfies the following conditions: Generally, the robot must be installed where the operator need not wear protective gear in order to work. 3.2 Installation Platform The platform on which to install the robot receives a significant reactive force. Be certain the platform has sufficient rigidity to withstand the anticipated force.
4. How to Install Shown below is how to install SCARA Robot. 4.1 Installation Posture ż : Available s : Not available Wall-Mount Ceiling-Mount ż s s 4.
4.2 4.1 Installing the Robot Install the robot on a level surface. Secure the robot using M8 hex bolts and washers (tightening torque: 3.2 kgfm). For the hex bolts, use high-tension bolts with an ISO rating of 10.9 or higher. 4. How to Install 33333333 Warning Caution z Always insert a washer below each bolt. Without a washer, the bolt-bearing surface may sink. z Tighten the hex bolts securely to the correct torque.
4.3 4.3 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. 4.
Output voltage: 24 VDC r 10% Current capacity: 20 to 30 W 24 VDC power supply for brake (provided by user) PG cable (outside robot) 4. How to Install M cable (outside robot) Tool, control unit, etc. (provided by user) U cable (outside robot) (cable for user wiring) BK power cable (outside robot) Standard cable length: 5 m 150 mm I4, quick joint (3 pcs.) To air tube (provided by user) Warning z Before connecting or disconnecting a cable, always turn off the power to the controller.
5 Precautions for Use 5.1 Reference Acceleration/Deceleration Settings Use the robot based on appropriate acceleration/deceleration settings by referring to the following graph: (1) PTP operation (Set using the SEL language commands ACCS and DCLS.) Acceleration/deceleration (%) 5.
(2) CP operation (Set using the SEL language commands ACC and DCL.) Arm length 350 Arm length 250 Reference acceleration/deceleration settings for CP operation Reference acceleration/deceleration settings for CP operation Acceleration/deceleration (G) 1.6 1.2 0.8 Reference range of maximum setting 0.4 Reference range for continuous operation setting 0 1.2 5. Precautions for Use Acceleration/deceleration (G) 1.6 Reference range of maximum setting 0.
5.2 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. 5. Precautions for Use If the tool diameter exceeds 40 mm, the tool will interfere with the robot within the robot’s operation area.
5.3 Carrying Load Load capacity Rated load capacity: 1 kg Maximum load capacity: 3 kg Load’s permissible moment of inertia 0.015 kgm (both rated and maximum) Load offset (from the center of axis 4 (rotational axis)) 40 mm or less 5. Precautions for Use Center of axis 4 (rotational axis) Load’s center of gravity 40 mm or less Caution z Set appropriate acceleration/deceleration according to the mass of the tip and moment of inertia.
5.4 User Wiring and Piping The robot comes with standard cables and tubes that the user can use in a desired wiring/piping configuration. Quick joint I4 (red) Quick joint I4 (white) ALM (indicator) BK SW Brake-release switch Air tubes (I4 x 3 pcs.
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 I11 or less. To turn on the ALM (indicator), the user must configure a dedicated circuit that uses the controller I/O output signal, etc.
5.5 Suction Rate The robot will conform to cleanliness class 10 when air is sucked at a specified rate from the quick suction joint provided on the rear panel of the base. x The user must provide the suction device and suction air tube (I12). 5.
6 Inspection/Maintenance 6.1 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.
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 Safety cage Robot Cables 6. Inspection/Maintenance Emergency-stop switch 6.1.2 Description Correct the deformation or positional shift of the cage. Confirm that the interlock mechanism is operating properly. Check the robot mounting bolts for looseness.
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 Ball-screw spline * Harmonic speed reducer Description Check the shaft for looseness. (Contact IAI if an abnormality is found.) Change the grease. (Contact IAI.) * Based on 24-hour operation. Change the grease every three years or so if the robot is operated eight hours a day.
6.2.2 Removing the Cover (1) With arms 1 and 2 extended as illustrated below, remove the six countersunk head screws [1]. (2) Lift the panel and remove the connectors (M, PG, BK) from the back of the panel. (Do not cause the wires to be pulled with excessive force when lifting the panel.) (3) Next, remove the bellows. Loosen the bellows clamp using a Phillips screwdriver. 6. Inspection/Maintenance Panel Rotary joint [1] 6 - M3 x 4 (countersunk head screw) Remove the connectors (M, PG, BK).
(4) Remove the two cap screws (M4 x 8) [2] on the cap, and remove the cap. (5) Loosen the cap screw (M5 x 15) [3] on the stopper, and remove the stopper, gasket and bearing case in this order. (6) Remove the four cap screws (M3 x 15) [4] affixing the bellows, and remove the bellows. (7) Lift the cover and remove upward. [2] CAP 2 - M4 x 8 Cap Gasket Stopper [3] Loosen CAP M5 x 15 6. Inspection/Maintenance Bearing case [4] CAP 4 - M3 x 15 Lift the cover and remove upward.
6.2.3 Checking the Belt Tension 6. Inspection/Maintenance 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. If the deflection is 2.4 mm, the belt tension is normal. If the deflection is not 2.4 mm, adjust the tension by referring to 6.2.6, “Adjusting the Belt Tension for the Vertical Axis.
6.2.5 Checking the Belt Tension for the Rotational Axis Using a push-pull gauge, push the timing belt for rotational 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.” Push-pull gauge 6. Inspection/Maintenance Deflection (0.
6.2.6 Loosen the four M5 bolts [1] slightly, making sure the fastened points do not become overly loose. Loosen the lock nut [2], and then turn the adjuster bolt [3] to tension the belt. Check the belt tension by referring to 6.2.4 “Checking the Belt Tension for the Vertical Axis.” Tighten the M5 bolts [1] loosened in step 1 (tightening torque: 7.6 Nm) and tighten the lock nut [2]. Check the belt tension again by referring to 6.2.4 “Checking the Belt Tension for the Vertical Axis.
6.2.7 (1) (2) (3) (4) (5) Adjusting the Belt Tension for the Rotational Axis Loosen the two M4 bolts [1] slightly, making sure the fastened points do not become overly loose. Move the rotational-axis motor [2] to tension the belt. Check the belt tension by referring to 6.2.5 “Checking the Belt Tension for the Rotational Axis.” Tighten the bolts [1] loosened in step 1 (tightening torque: [1] 3.7 Nm). Check the belt tension again by referring to 6.2.5 “Checking the Belt Tension for the Rotational Axis.
6.2.8 Installing the Cover 6. Inspection/Maintenance (1) Install the cover and connect the motor connectors (M, PG, BK) 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. Do not forcibly tighten the screws with the panel still floating.
(5) Tighten the two cap screws (M4 x 8) [4] to affix the cap. (6) Tighten the bellows clamp using a Phillips screwdriver. (7) Turn the cap to confirm that the bellows rotate smoothly. [4] Turn the cap to check if the bellows are not twisted. Cap Phillips screwdriver 6. Inspection/Maintenance Caution z z z z Check the marking tubes to prevent improper connections. Be careful not to bend the air tubes. Be careful not to pinch the cables.
6.3 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 (4 pieces) Model: AB-3 6. Inspection/Maintenance 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 a serious accident.
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 batteries from the extension cables from the battery connectors, and connect new batteries. x After removing the old batteries, quickly connect new batteries (roughly within 5 minutes x number of batteries).
6.4 Absolute Reset Procedure 6.4.1 Preparation for Absolute Reset The following jig is required when performing an absolute reset: 6. Inspection/Maintenance 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.
6.4.2 Starting the Absolute Reset Menu (1) Open the absolute reset window from the PC software. 6. Inspection/Maintenance (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.
6.4.3 Absolute Reset Procedure for Arm 1 or 2 6. Inspection/Maintenance (1) Click the “Encoder Rotation Data Reset1” button. (2) Click the “Reset Controller Error” button.
(3) Click the “Servo ON” button. 6. Inspection/Maintenance (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.
(6) Press the emergency-stop switch. Arm 1 Positioning mark label for arm 1 Insertion depth: Approx. 60 mm 6. Inspection/Maintenance (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.
(8) Click the “OK” button. 6. Inspection/Maintenance (9) Click the “Encoder Rotation Data Reset2” button.
(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. 6. Inspection/Maintenance 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).
6.4.4 Absolute Reset Procedure for the Rotational Axis + Vertical Axis (1) Click “Encoder Rotation Data Reset1” button. 6. Inspection/Maintenance (2) Click the “Reset Controller Error” button.
6. Inspection/Maintenance (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” button.
(6) Click the “Servo-OFF” button. 6. Inspection/Maintenance (7) Press the emergency-stop switch.
(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. 1) Confirm that the rotational axis is roughly in the reference position. (Vertical positioning marks should align. The D-cut surface should be on the right side when viewed from the front.) 2) Set a plate jig on the rotational axis by causing its side labeled “UPPER (ARM SIDE)” to face up.
(9) Click the “OK” button. 6. Inspection/Maintenance (10) Click the “Encoder Rotation Data Reset2” button.
6. Inspection/Maintenance (11) Click the “Home pos. automatic update” button. (12) Remove the adjustment jig. (13) Release the emergency-stop switch. (14) Click the “OK” button.
(15) Click the “Servo ON” button. 6. Inspection/Maintenance (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.
6. Inspection/Maintenance (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.
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. 6. Inspection/Maintenance (2) When the writing of flash ROM is complete, the following screen is displayed. Click the “Yes” button.
6.4.6 Resetting the Controller 6. Inspection/Maintenance (1) Select “Software Reset” from the Controller menu on the tool bar. (2) Click the “Yes” button. The controller is reset and restarted.
7 7.1 Specifications Specification Table IX-NNC2515 (Arm Length 250, Clean-room Specification) Item Specifications Type IX-NNC2515- L-T1 Degree of freedom Four degrees of freedom Overall arm length 250 mm Arm 1 length 125 Arm 2 length Drive method 125 Axis 1 (arm 1) AC servo motor + Speed reducer Axis 2 (arm 2) AC servo motor + Speed reducer Axis 3 (vertical axis) AC servo motor with brake + Belt + Ball-screw spline Motor capacity 7.
Item Specifications User wiring D-sub 15-pin connector with 15-core AWG26 shielded cable (socket) Alarm indicator (*9) One small, red LED indicator (rated voltage: 24 V) Suction pipe joint Applicable tube: Outer diameter 12 (inner diameter 8) Three air tubes (outer diameter: 4, inner diameter: 2.5) (normal service pressure: 0.
IX-NNC3515 (Arm Length 350, Clean-room Specification) Item Specifications Type IX-NNC3515- L-T1 Degree of freedom Four degrees of freedom Overall arm length 350 mm Arm 1 length Arm 2 length Drive method 125 Axis 1 (arm 1) AC servo motor + Speed reducer Axis 2 (arm 2) AC servo motor + Speed reducer Axis 3 (vertical axis) AC servo motor with brake + Belt + Ball-screw spline Axis 4 (rotational axis) Motor capacity 225 AC servo motor + Belt + Reduction gear + Spline Axis 1 (arm 1) 200 Axis
Item Specifications Three air tubes (outer diameter: 4, inner diameter: 2.5) (normal service pressure: 0.8 MPa) User piping Operating environment Ambient temperature/humidity Temperature: 0 to 40 C, humidity: 20 to 85%RH or less (non-condensing) Altitude m 1,000 or less Noise dB 71 Robot weight kg 20 Brake power source for main unit W 24V DC ±10% Cleanliness class Class 10 (0.
7.2 External Dimensions IX NNC 2515 (Arm Length 250, Clean-room Specification) Reference surface 140 Arm 1 stopper User connector (D-sub 15-pin connector) BK SW (Brake-release switch) Arm 2 stopper 160 ALM (indicator) I4 quick air-tube joint (black, red, white; 3 locations) Tapped hole for peripheral installation (M4, 4 locations) 7. Specifications (Mechanical end) I16, counterbore depth 0.
IX NNC 3515 (Arm Length 350, Clean-room Specification) ALM (indicator) Reference surface Arm 1 stopper I4 quick air-tube joint (black, red, white; 3 locations) User connector (D-sub 15-pin connector) BK SW (Brake-release switch) Arm 2 stopper 7. Specifications (Mechanical end) I16, counterbore depth 0.
7.3 Robot Operation Area IX NNC 2515 (Arm Length 250, Clean-room Specification) Area of prohibited entry Movement range Mechanical stopper position 7.
64 U cable (outside robot) BK power cable (outside robot) Dedicated batteries for IX: AB-3 PG cable (outside robot) M cable (outside robot) Cable fix cap (Capcon) Air joint, white (I4) Air joint, red (I4) Air joint, black (I4) FG (To base) Board Servo motor for axis 1 (arm 1) Inside base Quick suction joint Flexible cable U cable (inside robot) M cable (inside robot) FG (to D-sub housing) Electromagnetic brake for axis 4 (R-axis) Servo motor for axis 4 (R-axis) Servo motor with brake for
Axis 1 servo motor Axis 2 servo motor Axis 3 servo motor w/ brake Axis 4 servo motor M cable (inside robot) M cable (outside robot) 2 3 4 5 6 Code name 1 No. TS4602 N2032 E200 TS4606 N7032 E200 IAI IAI Wire: Wire: 40, 50 W, key groove, CE certified 60, 100 W, w/ brake, round shaft, CE certified 60, 100 W, key groove, CE certified 60, 200 W, key groove, CE certified Remarks 300 V, 105qC (rated), AWG18 (0.84 mm2), flexible cable, UL VW-1, c-UL FT-1 2 300 V, 80qC (rated), AWG18 (0.
8. Warranty 8.1 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 8.2 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. 8.
8.5 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.
Change History Revision Date Change History April 2011 68 Description of Revision Second edition A page for CE Marking added March 2012 Third edition Introduction, Safety Symbols and Safety Precautions are deleted Pg. 1 to 7 Safety Guide added Pg. 8 Caution in Handling added Pg. 17 Brake voltage source capacity from 20W to 30W ĺ changed to 10W Pg. 27 Caution notes added telling to go to see the doctor to have an appropriate treatment when the grease got into an eye Pg.
Manual No.: ME3629-4A (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.
